A compact material yard automatic stacking method and system based on three-dimensional scanning

Abstract

The present invention discloses an automatic stacking method and system for a compact material yard based on three-dimensional scanning, comprising: scanning the material yard to obtain point cloud data of the material yard; judging whether to load point cloud data of the raw material yard to obtain point cloud data to be solved; parsing the point cloud data to be solved; inputting the parsed point cloud data to be solved into a preset stacker control instruction set solution model to obtain control instructions; using the control instructions to control the operation of the stacker to realize automatic stacking; wherein, in the stacker control instruction set solution model, the size of the circumscribed circle of the stacker bucket wheel is taken into consideration; the present invention realizes the automatic stacking process of new stacking and supplementary stacking, and for a compact material yard, the space of the material yard can be maximized.

Description

Technical Field

[0001] The present invention belongs to the technical field of industrial automation control material stacking, and in particular, relates to a compact material yard automatic material stacking method and system based on three-dimensional scanning. Background Art

[0002] The statements in this section merely provide background information related to the present disclosure and do not necessarily constitute prior art.

[0003] In steel production, the raw material yard is used to store, transfer and transport raw materials and fuels, which is the guarantee of steel production. The area where raw materials and fuels are piled is called a pile. The pile process is the process of stacking raw materials and fuels from train unloading, car unloading and dock unloading systems to the designated material position through belt transmission and stacking machines.

[0004] At present, the stacking operation process is mainly manual, and the operator sits in the cab of the stacker-reclaimer to complete the stacking operation; during the stacking process, the operator needs to observe the on-site material pile conditions and select the entry point for the stacking according to the material pile conditions; the material shed is dusty, which seriously affects the operator's line of sight, and production accidents often occur due to lack of concentration or obstructed vision, resulting in collisions between the stacker-reclaimer and the material pile or other on-site equipment; and the on-site working environment is poor, which is not conducive to the physical and mental health of the operators and is very likely to cause occupational diseases.

[0005] In the existing automatic material taking method, the control parameters are established only on the basis of judging whether it is new material, but the influence of the material pile on the raw material position on the control is not considered when the material pile is a supplementary pile (that is, there is material on the material position, and the stacker-reclaimer piles the material conveyed on the belt on the raw material position); the influence of the bucket wheel size of the stacker-reclaimer on the control parameters is not considered either; the control accuracy is low and the automatic stacking effect is poor. Summary of the invention

[0006] In order to solve the above problems, the present disclosure proposes a method and system for automatic stacking in a compact material yard based on three-dimensional scanning; the present disclosure realizes the automatic stacking process of new stacking and supplementary stacking, and for a compact material yard, can maximize the utilization of the material yard space.

[0007] In order to achieve the above objectives, in a first aspect, the present disclosure provides a compact material yard automatic stacking method based on three-dimensional scanning, which adopts the following technical solutions:

[0008] A compact material yard automatic stacking method based on three-dimensional scanning, comprising:

[0009] Scan the pile of materials and obtain the point cloud data of the pile of materials;

[0010] Determine whether to load the point cloud data of the raw material pile, and obtain the point cloud data to be solved;

[0011] Analyzing the point cloud data to be solved;

[0012] The parsed point cloud data to be solved is input into the preset stacker control instruction set solving model to obtain the control instruction;

[0013] The control instructions are used to control the operation of the stacking machine to achieve automatic stacking;

[0014] Among them, in the stacker control instruction set solution model, the size of the circumscribed circle of the stacker bucket wheel is taken into consideration.

[0015] Furthermore, when determining whether to load the point cloud data of the raw material pile, determine whether the scanned material pile is a new pile or a supplementary pile; if it is a supplementary pile, first load the point cloud data of the original material pile, and then parse the point cloud data; if it is a new pile, directly parse the point cloud data.

[0016] Furthermore, the analysis of the point cloud data to be solved includes the calculation of the stockpile entry boundary and the real-time update of the stockpile.

[0017] Furthermore, when calculating the cut-in boundary of the stockpile, if it is a supplementary pile, the original stockpile information is first preprocessed, including denoising, segmentation and surface reconstruction; then the stockpile is cut into layers according to the stockpile process parameters and the stockpile information; based on the cut-in layers, the envelope boundary of the current layer of the stockpile is obtained, and the cut-in parameters are inversely solved from the envelope boundary of the current layer of the stockpile.

[0018] Furthermore, the real-time update of the stockpile includes:

[0019] Obtain material pile point cloud data in real time;

[0020] Real-time point cloud data segmentation of the material pile, removing noise data according to the location of the material pile stacking area, and obtaining the area data to which the material pile belongs;

[0021] Grid processing of point cloud data of the area where the stockpile belongs;

[0022] Gridding updates in real time.

[0023] Furthermore, the control instructions include a pitch angle, a yaw angle and a stocker position.

[0024] Furthermore, the pitch angle is defined as zero when horizontal, the upward pitch angle is positive, and the downward pitch angle is negative; when solving the pitch angle of the stacker, the lowest point of the circumscribed circle of the stacker bucket wheel is tangent to the bottom surface of the current working layer, and the height of the pile is compared with the height of the stacker boom when it is horizontal:

[0025] If the height of the stacker's boom rotation point from the ground is less than the sum of the height of the pile and the radius of the circumscribed circle of the stacker's bucket wheel, the stacker's pitch angle is an elevation angle, and the pitch angle is positive;

[0026] If the height of the stacker boom rotation point from the ground is greater than the sum of the pile height and the radius of the circumscribed circle of the stacker bucket wheel, the stacker pitch angle is a depression angle, and the pitch angle is negative.

[0027] Furthermore, when solving the swing angle, the minimum swing angle and the maximum swing angle are solved according to the transformation relationship between the stacker position and the working trajectory of the stacker when it intersects the boundaries of the two ends of the stockpile.

[0028] Furthermore, the position of the stacker is determined based on the current pitch angle, yaw angle and boom length information, combined with the current operating material pile data coordinate information, to solve the real-time position of the current stacker.

[0029] In order to achieve the above-mentioned purpose, in a second aspect, the present disclosure also provides a compact material yard automatic stacking system based on three-dimensional scanning, which adopts the following technical solutions:

[0030] A compact material yard automatic stacking system based on three-dimensional scanning, comprising a scanning module, a judgment module, a processing module, a stacking machine control instruction set solving module and a control module;

[0031] The scanning module is configured to: scan the pile of materials to obtain point cloud data of the pile of materials;

[0032] The judgment module is configured to: judge whether to load the point cloud data of the raw material pile to obtain the point cloud data to be solved;

[0033] The processing module is configured to: parse the point cloud data to be solved;

[0034] The stacker control instruction set solving module is configured to: input the parsed point cloud data to be solved into a preset stacker control instruction set solving model to obtain control instructions;

[0035] The control module is configured to: use the control instructions to control the operation of the stacking machine to achieve automatic stacking;

[0036] Among them, in the stacker control instruction set solution model, the size of the circumscribed circle of the stacker bucket wheel is taken into consideration.

[0037] Compared with the prior art, the present invention has the following beneficial effects:

[0038] 1. The present invention realizes the automatic stacking process of new stacking and supplementary stacking, and for compact stockyards, can maximize the use of stockyard space;

[0039] 2. When solving the pitch angle of the stacker, the present invention takes into account the size of the circumscribed circle of the bucket wheel of the stacker, thereby improving the accuracy of the control parameters and ensuring the stacking effect;

[0040] 3. The present invention controls the stacking machine according to the control parameters, realizes automatic stacking, does not require manual on-site operation, reduces manual labor intensity, and improves work efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] The drawings in the specification that constitute a part of this embodiment are used to provide a further understanding of this embodiment. The schematic embodiments of this embodiment and their descriptions are used to explain this embodiment and do not constitute improper limitations on this embodiment.

[0042] Figure 1 This is a flowchart of the automatic flow pile material taking method of Example 1 of the present disclosure;

[0043] Figure 2 This is a model diagram for solving the stockpile boundary conditions of Example 1 of the present disclosure;

[0044] Figure 3 This is a model diagram for solving the elevation angle of Embodiment 1 of the present disclosure;

[0045] Figure 4 This is a model diagram for solving the pitch angle of embodiment 1 of the present disclosure;

[0046] Figure 5 It is a coordinate definition diagram of the moving direction of the stacker in Example 1 of the present disclosure;

[0047] Figure 6 This is a model diagram for solving the roll angle of embodiment 1 of the present disclosure. DETAILED DESCRIPTION

[0048] The present disclosure is further described below in conjunction with the accompanying drawings and embodiments.

[0049] It should be noted that the following detailed descriptions are illustrative and are intended to provide further explanation of the present application. Unless otherwise specified, all technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art to which the present application belongs.

[0050] Embodiment 1:

[0051] like Figure 1 As shown, the present disclosure provides a compact material yard automatic stacking method based on three-dimensional scanning, comprising:

[0052] Scan the pile of materials and obtain the point cloud data of the pile of materials;

[0053] Determine whether to load the point cloud data of the raw material pile, and obtain the point cloud data to be solved;

[0054] Analyzing the point cloud data to be solved;

[0055] The parsed point cloud data to be solved is input into the preset stacker control instruction set solving model to obtain the control instruction;

[0056] The control instructions are used to control the operation of the stacking machine to achieve automatic stacking;

[0057] Among them, in the stacker control instruction set solution model, the size of the circumscribed circle of the stacker bucket wheel is taken into consideration.

[0058] In this embodiment, automatic scanning and imaging devices are installed on both sides of the stacker arm to scan the material pile and transmit the point cloud data to the image processing unit. The image processing unit parses the point cloud image data, determines the stacker operation motion parameters according to the stacking process requirements, obtains the parameters such as the pitch angle, yaw angle and travel position of the stacker operation on each layer, and transmits them to the stacker PLC to realize automatic operation. The automatic stacking method provided in this embodiment realizes the automatic stacking process of new stacking and supplementary stacking, and for compact material yards, it can maximize the use of material yard space and free human operation from complicated and harsh working conditions.

[0059] It should be noted that automatic stacking can be mainly divided into two categories: new stacking and supplementary stacking. Among them, the new stacking means that there is no material on the raw material position, and the stacker stacks the material on the belt at this material position according to certain rules; the supplementary stacking means that there is material on the material position, and the stacker stacks the material conveyed by the belt on the raw material position. At this time, the shape of the material pile on the raw material position needs to be considered.

[0060] In this embodiment, when determining whether to load the point cloud data of the raw material pile, it is determined whether the scanned material pile is a new pile or a supplementary pile; if it is a supplementary pile, the point cloud data of the original material pile is loaded first, and then the point cloud data is parsed; if it is a new pile, the point cloud data is directly parsed; specifically, Figure 1 As shown, when stacking materials, it is necessary to determine whether the stacking process is a new stacking or a supplementary stacking; if it is a supplementary stacking, the original material pile point cloud data file needs to be loaded, and the information of the original material pile is solved through the material pile point cloud data processing module, so as to be input into the stacker control instruction set solving module to solve the stacker control instruction set; if it is a new stacking, the new stack instruction information can be directly input into the stacker control instruction set solving module; after the stacker control instruction set is obtained, the control instruction is sent to the stacker, and in the process of stacking materials, the scanner (scanning imaging device) is controlled to scan in real time, and the scanning information is transmitted to the material pile point cloud data processing module, the material pile information is updated in real time, and the stacking process is corrected in real time in combination with the material pile information until the operation is completed.

[0061] In this embodiment, the analysis of the point cloud data to be solved includes the calculation of the stockpile cut-in boundary and the real-time update of the stockpile. It can be understood that the stockpile point cloud data processing module mainly includes two parts, one is the stockpile cut-in boundary calculation of the stockpile machine, and the other is the real-time update of the stockpile.

[0062] Calculation of the stacking cut-in boundary of the stacker: The calculation of the stacking cut-in boundary is to solve the boundary conditions of the stockpile. For the case of supplementary stacking, it is necessary to preprocess the original stockpile information (denoising, segmentation, and surface reconstruction), and then perform cut-layering on it according to the stacking process parameters and the stockpile information. After cut-layering, the stockpile information of the current layer is obtained; as Figure 1 shown, the B1 area is the area to be stacked, and the B2 area is the area of the existing stockpile. The task of the stacking operation is to fill the B1 area, that is, start stacking from the critical stacking point until the cut-in starting point start position, and at the same time, the boundary angles a1 and a2 need to be known; the solution of both depends on the stockpile boundary conditions; according to the cut-layering, the envelope boundary of the stockpile is obtained, and the cut-in parameters are inversely solved from the envelope boundary of the current layer of the stockpile.

[0063] Real-time update of the stockpile: The real-time update of the stockpile involves the problem of large data volume update, and the real-time performance must be guaranteed; the process of stockpile update is as follows:

[0064] Real-time acquisition of the stockpile point cloud data;

[0065] Segmentation of the real-time point cloud data of the stockpile. It is necessary to remove the noise data according to the position of the stockpile stacking area to obtain the data belonging to the stockpile;

[0066] Grid processing of the point cloud data in the area belonging to the stockpile. The processing accuracy can be set to reduce the stockpile data volume, and at the same time, the key feature information of the stockpile data is not lost, improving the real-time processing speed;

[0067] Grid real-time update.

[0068] In this embodiment, the control instructions include the pitch angle, yaw angle, and the position of the stacker; the stacker control instruction set calculation module needs to solve the key control parameters of the stacker according to the stockpile boundary information and the stacking and reclaiming process parameters. The solution process is as follows:

[0069] As Figure 3 and Figure 4 shown, the solution of the pitch angle of the stacker is:

[0070] Convention on the positive and negative signs of the pitch angle of the stacker: The pitch angle is zero when the stacker is horizontal, positive for upward pitch, and negative for downward pitch.

[0071] When solving the pitch angle of the stacker, the lowest point of the circumscribed circle of the stacker bucket wheel is exactly tangent to the bottom surface of the current working layer. According to the comparison between the stockpile height and the height of the stacker boom when it is horizontal, there are two cases.

[0072] If H < CurPileHeight + R, the pitch angle of the stacker is the elevation angle, and the pitch angle is positive. The pitch angle solution formula is:

[0073]

[0074] If H>CurPileHeight+R, the pitch angle of the stacker is the pitch angle, and the pitch angle is negative. The formula for solving the pitch angle is:

[0075]

[0076] Among them, H is the height of the stacker boom rotation point from the ground, CurPileHeight is the height of the pile, R is the radius of the circumscribed circle of the stacker bucket wheel, and L is the length of the stacker boom.

[0077] like Figure 5 and Figure 6 As shown, the solution for the deflection angle is:

[0078] During the stacking process, the movement direction of the stacker is the positive direction of the Y axis. The arc line in the figure is the operating path of the stacker during the material picking process.

[0079] The relationship between the stacker's operating trajectory and the stacker's position transformation when it intersects the left and right boundaries of the pile is:

[0080] The coordinate difference between BO and B2 on the Y axis:

[0081] The coordinate difference between BO and B3 on the Y axis:

[0082] Solution for the yaw angle:

[0083] Minimum deflection angle

[0084] Maximum deflection angle:

[0085] Among them, BO is the center point of the stacker-reclaimer body, B2 is the right boundary point of the stacker-reclaimer when stacking materials, and B3 is the left boundary point of the stacker-reclaimer when stacking materials.

[0086] The stacker position is solved as:

[0087] The position of the stacker can be determined based on the current pitch angle, yaw angle and boom length information, combined with the current operating material pile data coordinate information, to determine the real-time position of the current stacker.

[0088] Embodiment 2:

[0089] This embodiment provides a compact material yard automatic stacking system based on three-dimensional scanning, including a scanning module, a judgment module, a processing module, a stacking machine control instruction set solving module and a control module;

[0090] The scanning module is configured to: scan the pile of materials to obtain point cloud data of the pile of materials;

[0091] The judgment module is configured to: judge whether to load the point cloud data of the raw material pile to obtain the point cloud data to be solved;

[0092] The processing module is configured to: parse the point cloud data to be solved;

[0093] The stacker control instruction set solving module is configured to: input the parsed point cloud data to be solved into a preset stacker control instruction set solving model to obtain control instructions;

[0094] The control module is configured to: use the control instructions to control the operation of the stacking machine to achieve automatic stacking;

[0095] Among them, in the stacker control instruction set solution model, the size of the circumscribed circle of the stacker bucket wheel is taken into consideration.

[0096] The above description is only a preferred embodiment of the present embodiment and is not intended to limit the present embodiment. For those skilled in the art, the present embodiment may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present embodiment shall be included in the protection scope of the present embodiment.

Claims

1. A compact material yard automatic stacking method based on three-dimensional scanning, characterized in that: include: Scan the pile of materials and obtain the point cloud data of the pile of materials; Determine whether to load the point cloud data of the raw material pile, and obtain the point cloud data to be solved; Analyzing the point cloud data to be solved; The parsed point cloud data to be solved is input into the preset stacker control instruction set solving model to obtain the control instruction; The control instructions are used to control the operation of the stacking machine to achieve automatic stacking; Wherein, in the stacker control instruction set solution model, the size of the circumscribed circle of the stacker bucket wheel is taken into consideration; The control instructions include pitch angle, yaw angle and stacker position; The pitch angle is defined as zero when horizontal, the upward pitch angle is positive, and the downward pitch angle is negative; when solving the pitch angle of the stacker, the lowest point of the circumscribed circle of the stacker bucket wheel is tangent to the bottom surface of the current working layer, and the height of the pile is compared with the height of the stacker boom when it is horizontal: If the height of the stacker's boom rotation point from the ground is less than the sum of the stockpile height and the radius of the circumscribed circle of the stacker's bucket wheel, the stacker's pitch angle is an elevation angle, and the pitch angle is positive; If the height of the stacker's boom rotation point from the ground is greater than the sum of the stockpile height and the radius of the circumscribed circle of the stacker's bucket wheel, the stacker's pitch angle is a depression angle, and the pitch angle is negative; When solving the deflection angle, the minimum deflection angle and the maximum deflection angle are solved according to the transformation relationship between the stacker's operating trajectory and the position of the stacker when it intersects the boundaries of the two ends of the pile; The position of the stacker is determined based on the current pitch angle, yaw angle and boom length information, combined with the current operating material pile data coordinate information to solve the current real-time position of the stacker.

2. A compact material yard automatic stacking method based on three-dimensional scanning as described in claim 1, characterized in that: When determining whether to load the point cloud data of the raw material pile, determine whether the scanned material pile is a new pile or a supplementary pile; if it is a supplementary pile, first load the original material pile point cloud data, and then parse the point cloud data; if it is a new pile, directly parse the point cloud data.

3. A compact material yard automatic stacking method based on three-dimensional scanning as described in claim 1, characterized in that: The analysis of the point cloud data to be solved includes the calculation of the stockpile cut-in boundary and the real-time update of the stockpile.

4. A compact material yard automatic stacking method based on three-dimensional scanning as shown in claim 3, characterized in that: When calculating the stockpile cut-in boundary, if it is a supplementary stockpile, the original stockpile information is preprocessed first, including denoising, segmentation and surface reconstruction; then the stockpile is divided into layers according to the stockpile process parameters and the stockpile information; According to the cutting layer, the envelope boundary of the current layer of the pile is obtained, and the cutting parameters are inversely solved from the envelope boundary of the current layer of the pile.

5. A compact material yard automatic stacking method based on three-dimensional scanning as shown in claim 3, characterized in that: The real-time update of the stockpile includes: Obtain material pile point cloud data in real time; Real-time point cloud data segmentation of the material pile, removing noise data according to the location of the material pile stacking area, and obtaining point cloud data of the area to which the material pile belongs; Grid processing of point cloud data of the area where the stockpile belongs; Gridding updates in real time.

6. A compact material yard automatic stacking system based on three-dimensional scanning, characterized in that: It includes a scanning module, a judgment module, a processing module, a stacker control instruction set solving module and a control module; The scanning module is configured to: scan the pile of materials to obtain point cloud data of the pile of materials; The judgment module is configured to: judge whether to load the point cloud data of the raw material pile to obtain the point cloud data to be solved; The processing module is configured to: parse the point cloud data to be solved; The stacker control instruction set solving module is configured to: input the parsed point cloud data to be solved into a preset stacker control instruction set solving model to obtain control instructions; The control module is configured to: use the control instructions to control the operation of the stacking machine to achieve automatic stacking; Wherein, in the stacker control instruction set solution model, the size of the circumscribed circle of the stacker bucket wheel is taken into consideration; The control instructions include pitch angle, yaw angle and stacker position; The pitch angle is defined as zero when horizontal, the upward pitch angle is positive, and the downward pitch angle is negative; when solving the pitch angle of the stacker, the lowest point of the circumscribed circle of the stacker bucket wheel is tangent to the bottom surface of the current working layer, and the height of the pile is compared with the height of the stacker boom when it is horizontal: If the height of the stacker's boom rotation point from the ground is less than the sum of the stockpile height and the radius of the circumscribed circle of the stacker's bucket wheel, the stacker's pitch angle is an elevation angle, and the pitch angle is positive; If the height of the stacker's boom rotation point from the ground is greater than the sum of the stockpile height and the radius of the circumscribed circle of the stacker's bucket wheel, the stacker's pitch angle is a depression angle, and the pitch angle is negative; When solving the deflection angle, the minimum deflection angle and the maximum deflection angle are solved according to the transformation relationship between the stacker's operating trajectory and the position of the stacker when it intersects the boundaries of the two ends of the pile; The position of the stacker is determined based on the current pitch angle, yaw angle and boom length information, combined with the current operating material pile data coordinate information to solve the current real-time position of the stacker.

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