Loader remote intelligent control system based on multi-network fusion and modular design

Abstract

The invention discloses a loader remote intelligent control system based on multi-network fusion and modular design, and relates to the technical field of loader remote control, and the loader remote intelligent control system comprises an equipment end, a remote control end and a cloud server end; the equipment end comprises the following hardware modules: a hardware sensing module which comprises a multi-type sensor array and a data acquisition unit and realizes real-time acquisition of mechanical parameters, environmental parameters and attitude data; and the main control processing module integrates a CPU (Central Processing Unit) and an FPGA (Field Programmable Gate Array) acceleration unit, is internally provided with a QNX real-time operating system, and is used for data preprocessing, control logic execution and hardware drive management. Through a remote intelligent control scheme, an operator can operate and control equipment in a safe area, the operation safety is improved, the operability and flexibility of the equipment are enhanced, modular design is adopted to facilitate installation, maintenance and rapid deployment, and a multi-network fusion architecture ensures stable data transmission in different environments; the low-delay and accurate control technology realizes the undifferentiated response speed of remote control and field operation.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of loader remote control, in particular to a loader remote intelligent control system based on multi-network fusion and modular design. BACKGROUND

[0002] As engineering machinery widely used in mine, port, factory and other scenes, the traditional operation mode of loader relies on the operator to control the equipment action through mechanical handle, foot pedal and other devices in the cab, and the control system is mainly divided into mechanical type, electrical type and protocol type.

[0003] In the traditional operation of the loader, the operator needs to work in the field under dangerous working conditions, which has safety risks, and the lack of operation flexibility due to space limitations, and the traditional mechanical, electrical or protocol control system faces problems such as signal transmission delay and poor stability when remotely controlled, making it difficult to achieve efficient and accurate remote control. To solve the above problems, the following scheme is proposed. SUMMARY

[0004] The purpose of the present application is to provide a loader remote intelligent control system based on multi-network fusion and modular design, which improves the operation safety through a remote intelligent control scheme, adopts modular design for easy installation, maintenance and rapid deployment, and ensures low-delay stable transmission of data in different environments through a multi-network fusion architecture, solving the problem that the existing loader needs to be operated by the operator in the field under dangerous working conditions.

[0005] To solve the above technical problems, the present application is realized by the following technical scheme: The present application is a loader remote intelligent control system based on multi-network fusion and modular design, which includes a device end, a remote control end, a cloud server end and a network transmission layer, forming an "end-edge-cloud" collaborative architecture. The device end includes the following hardware modules: The hardware perception module includes a multi-type sensor array (inertial measurement unit / pressure sensor / camera / ultrasonic radar) and a data acquisition unit, which realizes real-time acquisition of mechanical parameters, environmental parameters and attitude data. The main control processing module integrates CPU and FPGA acceleration unit, and is built-in QNX real-time operating system, which is used for data preprocessing (moving average filtering / CRC checking), control logic execution and hardware driver management. The communication transmission module supports 5G / 4G / Wi-Fi / satellite communication multi-network fusion, including a link quality monitoring unit (real-time calculation of RSSI / SNR / packet loss rate) and an automatic switching module. The power management module has three levels of protection (surge protection / filter circuit / power monitoring) and a backup battery, and supports wide temperature operation. Security encryption module, integrated ECDSA digital signature, AES-256 data encryption and HMAC-SHA256 verification, to realize the security verification of instructions.

[0006] Further, the device end includes the following four software modules: Control execution module, including hydraulic / motor drive unit, inverse kinematics algorithm and anti-collision logic (multi-sensor fusion detection, distance <1m forced shutdown); State feedback module, supporting video stream, data frame and tactile feedback (handle vibration); Mode switching module, using hardware relay interlocking (switching time <50ms) and software state machine (four-state model: S0-S3), supporting parameter adaptive adjustment (speed / acceleration compensation) Maintenance and upgrade module, supporting modular hot plug and OTA upgrade, recording full life cycle data through black box; The remote control end includes the following two modules: Remote operation module, including human-computer interaction interface (three-screen display / force feedback handle), emergency shutdown unit (hardware interrupt response <20ms) and operation instruction generation unit (64-byte fixed format instruction package, including CRC-32 verification); Server management module, including deployment message queue (Kafka), edge computing node (data filtering / exception marking), cluster management (multi-device cooperative scheduling / task allocation algorithm) and data storage, supporting OTA online upgrade (difference file <1MB, upgrade time <2 minutes); The cloud server end includes a cooperative work module, which realizes multi-device networking through server clusters, allocates work tasks based on task scheduling algorithms, and realizes multi-device action cooperative control through precise time synchronization and positioning; The network transmission layer uses 5G-TSN fusion technology (IEEE802.1Qbv time slot scheduling, time delay jitter ±50μs), combined with SRv6 optimized routing (hop count 3-5), to realize end-to-end delay ≤130ms.

[0007] Further, the communication transmission module specifically includes: the main link (5G) adopts dynamic beamforming (6dBi antenna / MIMO2x2), supports 256QAM modulation (35Mbps stable transmission under 20MHz bandwidth); the standby link (4G / Wi-Fi / satellite) is dynamically switched through a link quality scoring algorithm (weight: RSSIx2+SNRx3+(1-packet loss rate)x5), and the switching delay is less than 200ms; the transmission protocol is designed in layers: the control instruction goes through TCP (to ensure reliability), the video stream goes through UDP+RTP (to reduce delay), and the application layer defines a remote control protocol (instruction packet 64 bytes, analysis delay less than 5ms); The multi-sensor fusion mechanism of the hardware perception module specifically includes: An inertial measurement unit (MPU9250, 100Hz update rate) and a dual-axis tilt sensor (SCA100T, 0.01° precision) are fused through a Kalman filtering algorithm, and output the attitude angle (pitch / roll precision ±0.1°); A multi-spectral camera (1920x1080, 30fps) and an ultrasonic radar (8 channels, 0.1-10m ranging) are fused, a 360° environment perception network is constructed, obstacle detection (precision ±2cm) and anti-collision warning (speed reduction at a distance of less than 2m, and shutdown at a distance of less than 1m) are supported.

[0008] Further, the precise control strategy of the control execution module includes: The walking system adopts double-motor independent driving, and the rotation speed is controlled through a PID algorithm (proportion coefficient 0.8 / integration time 0.2s / differentiation time 0.05s), and the speed tracking error is less than 2%; The working device (boom / dipper / shovel) adopts three-cylinder linkage control, and realizes smooth action based on a trajectory planning algorithm (cubic spline interpolation), and the synchronization error is less than 5ms; The hydraulic system driving signal is generated through a 16-bit DAC (resolution 0.001V), simulates the original vehicle operating mechanism electric signal (0-5V corresponds to 0-100% throttle), and the linearity is greater than 99.5%.

[0009] Further, the three-verification mechanism of the security encryption module includes: Digital signature verification: ECDSA algorithm (P-256 curve) is adopted, and the verification time is less than 2ms; Device ID binding verification: comparison of instruction source IP and device registration IP (allowing ±5% geographical deviation); Operation permission check: based on operator level restriction function (such as speed limit 80% / inhibition of dangerous action), the permission query response time is less than 1ms.

[0010] Further, the modular design includes: Hardware modularization: drawer architecture (main control / communication / IO / power module), hot plug through PCIe interface (replacement time <5 minutes), sensor interface supports multiple protocols (analog / digital / CANopen); Software modularization: microservice architecture (data acquisition / communication management / control algorithm independent service), communication through MQTT message queue (coupling degree <0.2), support for custom driver development (templated interface, cycle <1 week); The state feedback and fault handling mechanism comprises: Black box function: 128GB SSD cyclically records 10 hours of data (sampling rate 100Hz), supports fault tracing (CRC check ensures data integrity); Multi-level alarm system: first level alarm (yellow, limit action), second level alarm (red, prohibited action), third level response (safety shutdown, 20ms ultra-fast response), alarm information priority display; Force feedback mechanism: built-in vibration module in handle (amplitude 0-2mm), real-time generation of tactile feedback according to hydraulic resistance (delay <20ms).

[0011] Further, the workflow of the intelligent control system is as follows: Step S1, signal acquisition and preprocessing: sensor array acquires data at 10ms cycle, 24-bit ADC conversion, sliding average filtering (window 16) and CRC-16 check, packaged as JSON format (LZO compression, compression ratio 1.8:1); Step S2, multi-network fusion transmission: dynamically select 5G main link or backup link according to link quality score, control instructions are transmitted through TCP (TLS1.3 encryption, key 10 minutes update), video stream is transmitted through UDP+RTP (H.265 encoding, ROI technology saves bandwidth by 50%); Step S3, instruction processing and execution: remote end instructions are parsed into drive signals (PWM / CANopen) by the main control processing module after threefold security verification, control hydraulic / motor actuators, and execute anti-collision logic (multi-sensor fusion detection) synchronously; Step S4, state feedback and monitoring: device status is returned at 100Hz frequency, video stream is displayed with low latency (end-to-end delay ≤140ms), fault diagnosis module (200+ rules) analyzes sensor data in real time, triggering multi-level alarm or safety shutdown; Step S5, modular maintenance and upgrade: support hot plug replacement module (completed within 30s) and OTA online upgrade (dual partition design, upgrade process does not affect emergency stop function).

[0012] Further, the multi-device collaborative work process comprises: Device networking: connect servers through star topology, support device ID mapping and logical pairing (such as loader-truck cooperation); Task scheduling: the server optimizes task allocation based on genetic algorithm (objective function: total operation time is shortest), considers device load / position / working condition, and the scheduling period is less than 10s; Action synchronization: through Beidou+GPS fusion positioning (accuracy 10cm) and NTP time synchronization (error ±1ms), realize multi-device action cooperation (synchronization error <50ms).

[0013] Further, the mode switching process comprises: Hardware interlocking: 16-way SPDT relay switching control loop, disconnects local operating mechanism connection (contact resistance <50mΩ), connects intelligent control box driving circuit, and the switching time is less than 50ms; Software state machine: four-state conversion (S0-S3) needs to meet the link connectivity / device self-check / permission verification conditions, and automatically loads corresponding mode control parameters (such as remote mode speed limit 80%) when switching.

[0014] Further, the remote operation module is connected with the service management module, the service management module is connected with the cooperative operation module, the cooperative operation module is connected with the main control processing module, the server management module is connected with the communication transmission module, the communication transmission module is connected with the main control processing module, the power management module is connected with the main control processing module, the security encryption module is connected with the main control processing module, the hardware sensing module is connected with the main control processing module, and the main control processing module is connected with the state feedback module, the maintenance and upgrade module, the mode switching module and the control execution module respectively. The state feedback module is connected with the server management module.

[0015] The application has the following beneficial effects: The application enables the operator to operate the device in a safe area, improves the operation safety, avoids the space limitation of on-site operation, enhances the operability and flexibility of the device, adopts modular design to facilitate installation, maintenance and rapid deployment, ensures stable data transmission in different environments through multi-network fusion architecture, realizes the same response speed of remote operation and on-site operation through low delay and precise control technology, and guarantees the stable operation of the system in complex environment through multiple security protection, intelligent fault diagnosis and other functions, and brings safe, efficient and flexible operation experience to the purchaser.

[0016] Of course, any product implementing the application does not necessarily need to achieve all the advantages described above at the same time. BRIEF DESCRIPTION OF DRAWINGS

[0017] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following will briefly introduce the drawings needed to be used in the description of the embodiments, obviously, the drawings in the following description are only some of the embodiments of the present application, and for the ordinary skilled in the art, other drawings can also be obtained without creative labor based on these drawings.

[0018] Figure 1 The structure schematic diagram of the loader remote intelligent control system based on multi-network fusion and modular design of the present application. DETAILED DESCRIPTION

[0019] The technical solutions in the embodiments of the present application will be described clearly and completely in the following with reference to the drawings in the embodiments of the present application, obviously, the described embodiments are only some of the embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by the ordinary skilled in the art without creative labor are within the protection scope of the present application.

[0020] Please refer to Figure 1 The present application is a loader remote intelligent control system based on multi-network fusion and modular design, including the following processes: 1. System initialization and self-checking process 1) Hardware module initialization Power module activation: The vehicle-mounted power supply is connected to the intelligent control box, which first triggers the power module self-checking: the surge protection circuit starts, responds to overvoltage impact within 1ns; the three-stage filter circuit suppresses EMI, and outputs 5V / 12V stable voltage to each module; the standby battery enters the floating state, and the voltage monitoring module confirms that the main and standby power supply voltage difference is <0.5V.

[0021] Main control module starts: ARMCortex-A9 main control chip loads QNX real-time operating system: partition memory initialization, divides 1MB emergency task area, 4MB sensor data buffer area, and 8MB control algorithm running area; hardware abstraction layer enumerates PCIe interface devices, identifies main control module, communication module, and IO module.

[0022] Sensor array self-checking: multi-sensor network enters initialization sequence, inertial measurement unit performs zero offset calibration, idles for 3s after power-on, collects 1000 groups of data to calculate static deviation; camera module automatically focuses, double-shaft motor drives lens, determines the best focal length through image sharpness evaluation function, and the focusing time is <200ms; the pressure sensor injects calibration voltage, verifies the linearity of the output signal, and triggers the sensor fault code when abnormal.

[0023] 2) Software system starts: Protocol stack initialization: The MQTT client connects to the server and sends a device registration message with a registration response time of <50ms. The CAN bus controller is initialized with a master channel baud rate of 500Kbps and a slave channel baud rate of 1Mbps. Bus activity detection frames are periodically sent.

[0024] Modular self-test: Communication module: 5GCPE scans the 3.5GHz frequency band, detects base stations with signal strength > -85dBm, establishes a primary link, and simultaneously scans 2.4G / 5G Wi-Fi hotspots to add to the backup link list; IO module: The analog channel injects calibration current, and the digital channel outputs high and low levels and reads back to verify the consistency of IO port response; Security module: The ECDSA private key is loaded from the hardware security chip to generate a device digital signature, which completes two-way authentication with the server's pre-stored public key.

[0025] Mode selection and interlock: Local operator console rotary switch selection mode: Local mode: The relay matrix closes the local control mechanism circuit (such as handle potentiometer → original vehicle ECU), and the intelligent control box enters data monitoring mode (only collection but not control); Remote mode: The relay disconnects the local control link, connects to the intelligent control box drive circuit, and sends a mode switching request to the server, waiting for confirmation from the remote end.

[0026] 2. Signal acquisition and preprocessing process 1) Multi-dimensional data collection Mechanical system parameters: Hydraulic system: Six pressure sensors collect the main pump / pilot oil line pressure. The signals are converted by a 24-bit Σ-Δ ADC and filtered through a sliding average filter to eliminate high-frequency noise. The boom / arm angle encoder measures the angle in real time through a rack and pinion mechanism, and the data is calculated by a hardware differentiator to calculate the angular velocity. The travel half-axle speed sensor (pulse counting type) accumulates the number of pulses and converts it into real-time vehicle speed.

[0027] Electrical and Environmental Data: Vehicle ECU data: Engine speed, oil temperature, and battery voltage are read via the CAN bus, with one extended data frame containing a 29-bit ID received every 20ms. The multispectral camera switches to the operating area, and the infrared mode automatically compensates for low light conditions. The ultrasonic radar cyclically scans blind spots, achieving a ranging error of <2cm.

[0028] Attitude and positioning data: The IMU outputs three-axis angular velocity and acceleration. The raw data is fused with the dual-axis tilt sensor through complementary filtering to output the pitch / roll angle of the device. Beidou + GPS dual-mode positioning module analyzes NMEA-0183 protocol, obtains latitude and longitude, elevation, and combines with odometer data (wheel radius calibration) to perform position fusion.

[0029] 2) Data encoding and packaging: Signal conditioning and verification: Analog signal: 4-20mA current signal is converted to 0-5V voltage through I / V conversion, and a second-order Butterworth low-pass filter is used to suppress high-frequency vibration interference of the hydraulic system; Digital signal: CAN message extracts valid data segment (such as PGN parameter group of J1939 protocol), adds CRC-16 check code, and discards the frame if the verification fails.

[0030] Data compression and protocol packaging: Structured data (sensor parameters) are packaged into JSON format and compressed using LZO algorithm, for example, 128 bytes of original data are compressed to 71 bytes; Video stream processing: work camera video is encoded by H.265, using ROI encoding technology, encoding delay <30ms, transmitted through RTP protocol; Unified packaging: all data add MQTT header (fixed header 2 bytes + variable header 4 bytes), including timestamp, device ID, QoS level.

[0031] 3. Multi-network fusion transmission process 1) Main link (5G network) transmission Physical layer optimization: 5GCPE uses dynamic beamforming: 6dBi high-gain antenna generates 4 spatial streams through MIMO technology, and the base station side adjusts the beam direction according to SRS signal measurement, signal strength is improved by 3dB, and downlink rate is stable at 100Mbps; Air interface resource scheduling: the base station allocates dedicated RB (resource block) for remote control business, uses semi-static scheduling, and maps control messages to low-latency subframes, end-to-end delay ≤130ms.

[0032] Protocol stack processing: MAC layer: control instruction data (64 bytes fixed length) is packaged into RLC AM mode (acknowledgment mode), the initial value of the retransmission timer is 50ms, and the exponential backoff is used after timeout; IP layer: SRv6 segment routing (SID list contains access network / core network / data center nodes), route hop number is controlled within 3-5 hops, TTL value is set to 64 to prevent loops; Transport layer: control instructions go through TCP channel, establish 3-way handshake connection, and sliding window size is 16KB; video stream goes through UDP channel, RTP payload type is set to 96, and timestamp reference is 90kHz.

[0033] 2) Backup link (4G / Wi-Fi / Satellite) coordination Link quality monitoring: Intelligent control box calculates link score (0-100) in real time: 5G score = 2xRSSI + 3xSNR (dB) + 5x(1-packet loss rate), trigger backup link scanning when threshold <60; Wi-Fi prefers 5GHz frequency band, switches to 2.4GHz when detecting same frequency interference, uses 802.11k / v protocol for fast roaming; Satellite communication as the ultimate backup, sends short burst data to confirm link connectivity when starting, delay compensation algorithm adjusts control command sending time.

[0034] Seamless switching mechanism: Link switching trigger condition: 3 consecutive heartbeat packet loss or score <40 on main link; Switch execution: communication module generates link switching event, suspends data transmission, disconnects main link TCP connection, activates backup link, re-establishes MQTT connection (session preservation flag bit 1), ensures control does not interrupt; Bandwidth dynamic allocation: when using 5G+Wi-Fi simultaneously, use load balancing algorithm (round robin + bandwidth weight), control commands go through 5G (priority 1), video stream goes through Wi-Fi (priority 2), non-critical data (such as logs) is cached to local SSD.

[0035] 4, Remote terminal instruction processing and control execution flow 1) Operator human-computer interaction Operation signal acquisition: dual joystick (Hall effect sensor) collects X / Y axis displacement, built-in force feedback motor simulates hydraulic resistance, force feedback delay <20ms; Key matrix (including 12 function keys) scanning period 10ms, emergency stop button uses normally closed contact, hardware interrupt trigger (priority 255), interrupts all current tasks within 3ms.

[0036] Instruction generation and encoding: Operation analysis: call corresponding control strategy according to operation mode (excavation / walking / loading), such as calculating bucket arm / shovel cooperation angle when excavating; Instruction packaging: generate 64-byte fixed format instruction packet, including operation code, parameters, CRC-32 check code, send to server through TCP protocol.

[0037] 2) Server transit and security verification Data transit and edge computing: Message queue (Kafka) processing: device-side data is written to the topic "device / [id] / data", and the remote side subscribes to the topic "remote / control / [id]", with a message throughput of 1000 msg / s and a delay of <10 ms; Edge node preprocessing: data filtering is performed on the MEC server closest to the device, repeated data is discarded, abnormal data is marked, and cloud-side load is reduced.

[0038] Triple security verification: Digital signature verification: verify the instruction signature using the device public key, with a verification time of <2 ms, and trigger a warning if the signature is incorrect; Permission check: query the operator permission table (stored in Redis cache) to limit dangerous operations such as overspeed and overangle; Device binding verification: compare the instruction source IP with the device registration IP (allow a ±5% geographical location deviation, verified by GPS positioning), to prevent cross-device misoperation.

[0039] 3) Device-side control execution Instruction unpacking and distribution: After the intelligent control box receives the TCP packet, it is first decrypted using TLS1.3, then the operation code is parsed according to the protocol, and it is distributed to the corresponding control module: Walking control: sent to the drive box to generate a 0-5V voltage signal (corresponding to 0-100% throttle), and control the double motor speed through a proportional valve (PID algorithm, proportional coefficient 0.8, integral time 0.2s); Work device: send PDO message through CANopen protocol to control the electromagnetic valve group PWM signal, with a hydraulic action delay of ≤50 ms.

[0040] Precise control of the actuator: Inverse kinematics: calculate the hydraulic cylinder extension based on the target angle and the current attitude angle, and send it to the hydraulic control system; Anti-collision logic: combine laser radar and camera data, when the obstacle distance is <2m, the operation instruction is first sent to the speed planning module, and when the distance is <1m, trigger a hardware interrupt to stop.

[0041] 5、State feedback and closed-loop monitoring process 1) Multi-modal information feedback Data feedback channel: Basic parameters: 56 operating parameters (such as engine speed, hydraulic oil temperature) are packaged into a 128-byte UDP message and sent to the server, and the remote side is updated in real time through WebSocket; Attitude data: fused pitch / roll angle, heading angle dynamically rendered in the operating console 3D model, rendering frame rate 60fps, view angle automatically adjusted following the bucket position.

[0042] Video and haptic feedback: Video stream processing: H.265 stream decoded by GPU hardware (CUDA accelerated), main screen displays first-person view, secondary screen displays rear / side camera view, supports picture-in-picture switching; Force feedback mechanism: when the bucket touches the ground, the operating handle simulates soil resistance, the resistance size is linearly related to the pressure sensor data.

[0043] 2) Fault diagnosis and safety response Multi-level fault handling: First-level alarm (yellow): if the hydraulic oil temperature > 80℃, the intelligent control box sends a warning message (priority 3), the operating console displays a flashing warning, and the maximum speed of the working device is limited; Second-level alarm (red): when the inclination angle > 15°, the boom / dipper arm action is prohibited, the control lock command is sent, and the sound alarm is triggered; Third-level response (safety shutdown): communication interruption > 50ms or emergency stop button triggered, immediately cut off the power supply of the electromagnetic valve, send shutdown message, enable parking brake.

[0044] Data recording and traceability: Black box function: SSD cyclically records the last 10 hours of data, including operation instructions, sensor data, fault logs, and automatically overwrites the oldest data when the storage space is full (CRC check is performed before overwriting to ensure data integrity); Remote log query: server storage device stores full life cycle data, supports time / fault code retrieval, log compression ratio 3:1, query response time < 5s.

[0045] 6, mode switching and system maintenance process 1) Local / remote mode non-disturbance switching Hardware interlock execution: Switching request: remote end clicks "take control" button, sends mode switching command, device end confirms link quality; Relay action: 16-way SPDT relay switches control loop, disconnects local handle potentiometer connection, connects intelligent control box drive signal output, switching time < 50ms, during which sends empty command to maintain hydraulic system pressure stability.

[0046] Software state machine conversion: State transition: from "native running S1" to "remote running S3" requires passing through "remote standby S2", during which the control parameter switching is performed (such as remote mode walking speed limit 80% of rated value, acceleration reduction 30%); Data synchronization: after switching, the intelligent control box sends the current device state (position, attitude, hydraulic parameters) to the remote end, and the remote end synchronizes the operation interface display to ensure that the man-machine state is consistent.

[0047] 2) Modular maintenance and upgrade Hardware hot plug replacement: Module fault detection: the intelligent control box detects that the communication module temperature > 70°C (threshold 65°C) or 5G signal interruption, generates fault code 0x0401, and triggers module replacement prompt; Replacement process: power off (not necessary, support hot plug) → open drawer type case → pull out faulty module (PCIe card buckle release) → insert new module (version number automatically matched) → system re-enumerate device; OTA online upgrade: Upgrade trigger: server pushes upgrade package, device end verifies signature, and when the remaining storage space > 20MB, starts downloading; Dual partition switching: download to standby partition → verify CRC32 → restart and load new firmware, emergency stop function runs independently during upgrade, overall time < 2 minutes.

[0048] 7, Multi-device collaborative work extension process 1) Collaborative networking and task allocation Device registration and pairing: Cluster server (4 load balancing) maintains device list, loader (device A) and transport vehicle (device B) establish logical pairing through UUID, and bind work area (such as mine area A coordinate range); Time synchronization: all devices access NTP server to ensure consistent timestamp for collaborative action, and differential GPS corrects positioning accuracy to 10cm.

[0049] Task scheduling algorithm: Server optimizes task allocation through genetic algorithm based on device load, position, and working conditions, with the target function being the shortest total work time; Collaborative instruction: after the loader completes loading, it sends material weight and position information to the transport vehicle, which automatically plans the driving path.

[0050] 2) Multi-device linkage control Action synchronization mechanism: Master-slave mode: loader as master device sends collaborative instruction, transport vehicle as slave device executes positioning action, guided by laser radar to align with the center of the bucket; Synchronization error compensation: When the deviation of the two vehicle attitude angles is detected to be > 2°, the device automatically adjusts the driving direction to ensure a smooth receiving process.

[0051] Cluster monitoring and scheduling: Visual interface: 3D map showing all device locations, operation status (color coding: green = running, red = fault), click on device icon to pop up real-time parameters; Statistical analysis: Generate daily reports (production, fuel consumption, device utilization), predict device failures through machine learning (such as bearing wear prediction), and push maintenance plans in advance.

[0052] 8. Abnormal scenario processing flow 1) Extreme environment adaptation High temperature working condition (> 60℃): Intelligent control box fan speed increases to 100%, heat sink temperature sensor real-time monitoring, more than 70℃ when sending frequency reduction command, to ensure that the chip temperature < 85℃; Camera enables automatic cooling mode: lens module fan starts, internal circulation cooling, to avoid CMOS sensor overheating noise.

[0053] Low temperature start-up (-30℃): Backup battery preheating: 5 minutes before starting to activate the heating film, the battery temperature rises above -20℃, to ensure that the internal resistance < 100mΩ; Software preheating: main control module executes empty cycle instructions, raises chip temperature, until reaches working temperature.

[0054] 2) Network congestion and attack response Traffic burst processing: Local cache: 1MB FIFO buffer area built-in intelligent control box, when network throughput > 40Mbps, non-critical data (such as debug logs) are temporarily stored in the buffer area, control instructions are sent according to QoS level (oldest data is discarded before buffer overflow); Dynamic code rate adjustment: video stream automatically switches resolution according to network bandwidth, ensuring that control instruction bandwidth ≥ 30Mbps.

[0055] Network security response: Intrusion detection: server-side WAF identifies SYN Flood attacks, triggers IP blacklist, and updates ACL rules on the device side (blocks attack source IP); Data encryption enhancement: detects abnormal login attempts, automatically switches to AES-256-GCM encryption, encryption delay increases by 5ms, ensuring data transmission security.

[0056] In the description of the specification, reference to "one embodiment", "an example", "a specific example" or the like means that a particular feature, structure, material or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the application. The appearances of the phrases "in one embodiment", "an example", "a specific example" or the like in various places in the specification are not necessarily referring to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics can be combined in any suitable manner in one or more embodiments or examples.

[0057] The preferred embodiments of the application disclosed above are only to help explain the application. The preferred embodiments do not describe all the details of the application and limit the application to the specific embodiments described. Obviously, many modifications and variations can be made in light of the contents of the specification. The specification selects and specifically describes these embodiments in order to better explain the principles and practical application of the application, so that those skilled in the art can well understand and utilize the application. The application is limited only by the claims and their full scope and equivalents.

Claims

1. The loader remote intelligent control system based on multi-network integration and modular design is characterized by: Including device side, remote control side, and cloud server side; The device side includes the following hardware modules: Hardware perception module, including multi-type sensor arrays and data acquisition units, to achieve real-time collection of mechanical parameters, environmental parameters, and posture data; The main control processing module integrates CPU and FPGA acceleration units, and has a built-in QNX real-time operating system for data preprocessing, control logic execution, and hardware driver management; Communication transmission module, supporting 5G / 4G / Wi-Fi / satellite communication multi-network integration, including link quality monitoring unit and automatic switching module; Power management module, with three levels of protection and backup battery, supports wide temperature operation; The security encryption module integrates ECDSA digital signature, AES-256 data encryption and HMAC-SHA256 verification to achieve command security verification.

2. The loader remote intelligent control system based on multi-network integration and modular design according to claim 1 is characterized in that: The device side includes the following four software modules: Control execution module, including hydraulic / motor drive unit, kinematic inverse algorithm and anti-collision logic; State feedback module, supporting video stream, data frame and tactile feedback; The mode switching module uses hardware relay interlocking and software state machine to support parameter adaptive adjustment; Maintenance and upgrade module, supports modular hot-swap and OTA upgrade, and records full life cycle data through a black box; The remote control terminal includes the following two modules: Remote operation module, including human-computer interaction interface, emergency stop unit and operation instruction generation unit; Server management module, including deployment of message queues, edge computing nodes, cluster management and data storage, and support for OTA online upgrades; The cloud server includes a collaborative operation module, which realizes multi-device networking through a server cluster, allocates operation tasks based on a task scheduling algorithm, and realizes multi-device action collaborative control through precise time synchronization and positioning; The network transport layer adopts 5G-TSN fusion technology and combines SRv6 optimized routing to achieve end-to-end delay ≤ 130ms.

3. The loader remote intelligent control system based on multi-network integration and modular design according to claim 1 is characterized in that: The communication transmission module further includes: The main link uses dynamic beamforming and supports 256QAM modulation; Backup links are dynamically switched using a link quality scoring algorithm; Layered transmission protocol design: control commands use TCP, video streams use UDP+RTP, and the application layer uses a custom remote control protocol; The multi-sensor fusion mechanism of the hardware perception module is as follows: the inertial measurement unit and the dual-axis tilt sensor are fused through the Kalman filter algorithm to output the attitude angle; the multi-spectral camera and ultrasonic radar data are fused to build a 360-degree environmental perception network to support obstacle detection and anti-collision warning.

4. The loader remote intelligent control system based on multi-network integration and modular design according to claim 2 is characterized in that: The control strategy of the control execution module includes: The walking system adopts dual-motor independent drive, and the speed is controlled by PID algorithm, with a speed tracking error of <2%; The working device adopts three-cylinder linkage control and realizes smooth movement based on trajectory planning algorithm, with synchronization error <5ms; The hydraulic system drive signal is generated by a 16-bit DAC to simulate the electrical signal of the original vehicle's control mechanism.

5. The loader remote intelligent control system based on multi-network integration and modular design according to claim 1 is characterized in that: The security encryption module contains a triple verification mechanism, specifically: Digital signature verification: using ECDSA algorithm; Device ID binding verification: compare the command source IP with the device registration IP; Operation permission check: Based on operator level restriction function, permission query response time is <1ms.

6. The loader remote intelligent control system based on multi-network integration and modular design according to claim 2 is characterized in that: The modular design includes: Hardware modularity: The intelligent control box adopts a drawer-type architecture, is hot-swappable via the PCIe interface, and the sensor interface supports multiple protocols; Software modularity: Based on microservice architecture, it communicates through MQTT message queues and supports custom driver development; The state feedback module includes the following mechanisms: Black box function: 128GB SSD records 10 hours of data in a loop and supports fault tracing; Multi-level alarm system: first-level alarm, second-level alarm, third-level response, alarm information priority sorting and display; Force feedback mechanism: The handle has a built-in vibration module that generates tactile feedback in real time based on the hydraulic resistance.

7. The loader remote intelligent control system based on multi-network integration and modular design according to claim 2 is characterized in that: The working method of the intelligent control system is as follows: Step S1, signal acquisition and preprocessing: The sensor array periodically collects data, converts it into 24-bit ADC, performs sliding average filtering and CRC-16 checksum, and then encapsulates it into JSON format; Step S2, multi-network integrated transmission: Dynamically select the 5G primary link or backup link based on the link quality score, control instructions are transmitted via TCP, and video streams are transmitted via UDP+RTP; Step S3, command processing and execution: After the remote end command undergoes triple safety verification, the main control processing module interprets it as a drive signal, controls the hydraulic / motor actuator, and synchronously executes the anti-collision logic; Step S4, status feedback and monitoring: The device status is transmitted back at a fixed frequency, the video stream is displayed with low latency, and the fault diagnosis module analyzes the sensor data in real time, triggering multi-level alarms or safety shutdowns; Step S5: Modular maintenance and upgrade: supports hot-swappable module replacement and OTA online upgrade.

8. The loader remote intelligent control system based on multi-network integration and modular design according to claim 7 is characterized in that: The multi-device collaborative operation process of the intelligent control system includes: Device networking: Connect to the server through a star topology, supporting device ID mapping and logical pairing; Task scheduling: The server optimizes task allocation based on genetic algorithms, taking into account equipment load / location / operating conditions; Action synchronization: Through Beidou + GPS integrated positioning and NTP time synchronization, multi-device action coordination is achieved.

9. The loader remote intelligent control system based on multi-network integration and modular design according to claim 7 is characterized in that: The process of mode switching includes: Hardware interlock: 16-way SPDT relay switches the control circuit, disconnects the local control mechanism, and connects the intelligent control box drive circuit; Software state machine: The four-state transition must meet the link connectivity / device self-test / authorization verification conditions, and the corresponding mode control parameters are automatically loaded during switching.

10. The loader remote intelligent control system based on multi-network integration and modular design according to claim 2 is characterized in that: The remote operation module is connected to the service management module, the service management module is connected to the collaborative operation module, the collaborative operation module is connected to the main control processing module, the server management module is connected to the communication transmission module, the communication transmission module is connected to the main control processing module, the power management module is connected to the main control processing module, the security encryption module is connected to the main control processing module, the hardware perception module is connected to the main control processing module, the main control processing module is respectively connected to the status feedback module, the maintenance and upgrade module, the mode switching module, and the control execution module, and the status feedback module is connected to the server management module.

Images