Bucket wheel excavator-truck cooperative loading alignment device and method

Abstract

A bucket wheel excavator-truck coordinated loading alignment device and method, relating to the field of open pit mines. The coordinated loading method first uses a high-precision GNSS positioning sensor to collect the position information of the bucket wheel excavator and the truck, and judges whether the bucket wheel excavator is unloading by the positions of the two, and judges whether the truck is full by the height of the truck material. The method does not require repeated communication between the bucket wheel driver and the truck, and can directly complete the bucket wheel excavator and truck coordinated loading process, which is highly efficient and conducive to reducing environmental pollution.

Description

Technical Field

[0001] The invention relates to the field of open-pit mines, and in particular to a bucket wheel excavator-truck cooperative loading alignment device and method. Background Art

[0002] As open-pit mines are developing in the direction of intelligence, the single-bucket-truck intermittent process in open-pit mines is subject to a series of problems such as small equipment capacity and large number, high personnel and equipment density, poor production and operation safety, and severe environmental pollution. The application of bucket wheel excavators in open-pit mines has gradually adapted to the trend of the times. However, the current semi-continuous process of bucket wheel-front loader-truck results in raw coal falling directly to the ground during the mining process, and the front loader then loads the truck. This process directly results in low process production efficiency, large height difference between the bucket wheel discharge arm and the ground, and high height difference between the front loader and the front loader, which cause secondary dust and serious pollution to the mining environment. It can no longer meet the needs of safe, green, intelligent, and efficient mining in open-pit mines. Summary of the invention

[0003] In view of the deficiencies in the prior art, an object of the present invention is to provide a bucket wheel excavator-truck cooperative loading alignment device.

[0004] The technical solution adopted by the invention is: a bucket wheel excavator-truck coordinated loading alignment device, the technical points of which include:

[0005] Bucket wheel excavator positioning sensor, installed on the left and right sides of the discharge port of the bucket wheel excavator, and connected to the field controller through a wireless data transmission radio to collect the discharge port position information;

[0006] Radar level meter: The radar level meter is installed on the front and rear sides of the discharge port under the discharge arm of the bucket wheel excavator, and is connected to the field controller through a wireless data transmission radio to monitor the current material loading height in real time;

[0007] The mining truck positioning sensor is installed on the left and right sides of the mining truck driver's cab and is wirelessly connected to the dispatch room server through the truck's onboard terminal 4G network to collect the truck's own bucket position information;

[0008] The field controller is installed in the field electric control cabinet and connected to the dispatching room service end through optical fiber. It is used to receive the collected signals of the bucket wheel excavator positioning sensor and radar level meter, and transmit the information to the dispatching room service end.

[0009] The dispatch room service end is connected to the terminal equipment in the bucket wheel excavator and the terminal equipment in the mining truck through the 4G network. It is used to calculate the position relationship between the radar level meter and the bucket wheel excavator, calculate the height of the material in the mining truck compartment, and output control signals to control whether the bucket wheel excavator unloads the material, and control the terminal in the truck to display the current material loading status.

[0010] A bucket wheel excavator-truck coordinated loading alignment method, the technical key points of which are as follows:

[0011] The step of determining the positional relationship between the mining truck and the bucket wheel excavator is to draw a top view of the mining truck compartment contour using the collected mining truck compartment position information and the known compartment length and width information of the mining truck; and to draw a top view of the bucket wheel excavator compartment contour using the collected bucket wheel excavator discharge port position information; and the above two top views of the contours are simultaneously displayed on the display screen of the terminal device;

[0012] The step of unloading the bucket wheel excavator is to prompt the bucket wheel excavator driver to control the bucket wheel excavator to start unloading into the mining truck when the outline of the bucket wheel excavator's discharge port and the outline of the truck compartment are in an inscribed relationship for the first time;

[0013] The steps of loading the mining truck: when loading materials, the material level of the mining truck is monitored online in real time. When the material level reaches the upper boundary of the truck compartment, the truck driver moves the truck to the next loading position to continue loading. Repeat the above loading steps until the discharge port of the bucket wheel excavator and the outline of the truck compartment are inscribed for the second time, and then the bucket wheel excavator driver is prompted to control the bucket wheel excavator to stop unloading the bucket, and the mining truck driver is prompted that the material is full and the loading task is completed.

[0014] The material level height refers to the distance between the center of the bucket discharge port contour line and the material in the carriage obtained in real time; the distance specifically includes: the distance between the center of the bucket discharge port contour line and the bottom of the carriage before unloading; during the unloading process, the distance between the center of the bucket discharge port contour line and the upper surface of the material in the carriage calculated using the natural repose angle of the material.

[0015] The beneficial effects of the present invention are as follows: the bucket wheel excavator-truck cooperative loading alignment device and method first utilizes a high-precision GNSS positioning sensor to collect the position information of the bucket wheel excavator and the mining truck, and determines whether the bucket wheel excavator is unloading based on the positions of the two. The radar level meter monitors the height of the truck material in real time online to determine whether the truck is full. This method does not require repeated communication between the bucket wheel driver and the truck, and can directly complete the bucket wheel excavator and truck cooperative loading process, which is highly efficient and helps reduce environmental pollution. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] 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 will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0017] Figure 1 It is a front view of the installation state of the bucket wheel excavator-mining truck cooperative loading alignment device in an embodiment of the present invention;

[0018] Figure 2 It is a side view of the installation state of the bucket wheel excavator-mining truck cooperative loading alignment device in an embodiment of the present invention;

[0019] Figure 3 It is a top view of the installation state of the discharge port-mining truck position coordinated loading alignment device in an embodiment of the present invention;

[0020] Figure 4 Schematic diagram of the general position of the discharge port-mining truck in the embodiment of the present invention;

[0021] Figure 5 This is a first internal diagram of the position of the discharge port-mining truck in an embodiment of the present invention;

[0022] Figure 6 This is a second inscribed schematic diagram of the discharge port-mining truck position in an embodiment of the present invention;

[0023] Figure 7 It is a schematic diagram of the material level height measurement principle in the initial state of a mining truck compartment in an embodiment of the present invention;

[0024] Figure 8 Schematic diagram of the material level height measurement principle at the front end of a mining truck compartment in the initial state in an embodiment of the present invention;

[0025] Fig. 9 Schematic diagram of the principle of measuring the material level height at the rear end of a mining truck compartment in the initial state in an embodiment of the present invention;

[0026] The serial numbers in the figure are explained as follows: 1 the first high-precision GNSS positioning sensor, 2 the first radar level meter, 3 the second radar level meter, 4 the second high-precision GNSS positioning sensor, 5 the third high-precision GNSS positioning sensor, 6 the fourth high-precision GNSS positioning sensor. DETAILED DESCRIPTION

[0027] To make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the following is a brief description of the present invention in conjunction with the attached Figures 1 to 9 The present invention is further described in detail with reference to the accompanying drawings and specific embodiments.

[0028] The bucket wheel excavator-truck cooperative loading alignment device used in this embodiment includes four high-precision GNSS positioning sensors, each of which has an accuracy of at least centimeter level, two of which are used as bucket wheel excavator discharge port positioning sensors, and the other two are used as mining truck positioning sensors. The first high-precision GNSS positioning sensor 1 and the second high-precision GNSS positioning sensor 4 are respectively installed on both sides of the longitudinal direction above the end of the bucket wheel excavator discharge port. A horizontal safety distance △g should be reserved between the first high-precision GNSS positioning sensor 1 (or the second high-precision GNSS positioning sensor 4) and the bucket wheel excavator discharge port. In this embodiment, the first radar level meter 2 and the second radar level meter 3 are respectively installed on both sides of the transverse direction below the end of the bucket wheel excavator discharge port. A horizontal safety distance △d is reserved between the first radar level meter 2 (or the second radar level meter 3) and the bucket wheel excavator discharge port. The third high-precision GNSS positioning sensor 5 and the fourth high-precision GNSS positioning sensor 6 are respectively installed on both sides of the longitudinal direction of the driver's cab of the mining truck. A safety distance △c is reserved between the third high-precision GNSS positioning sensor 5 (or the fourth high-precision GNSS positioning sensor 6) and the boundary of the mining truck compartment. The △g, △d and △c reserved in this embodiment are set to meet the distances set within the allowable range of the high-precision GNSS positioning sensor error, improve the safety of the bucket wheel excavator-truck coordinated loading and alignment loading and the allowable monitoring data accuracy value, and avoid the occurrence of material spillage during the loading process due to inaccurate sensor monitoring values.

[0029] The bucket wheel excavator positioning sensor and radar level meter communicate with the on-site Siemens PLC controller installed in the on-site control cabinet through wireless data transmission radio, respectively, and transmit the position information and material level height to the on-site Siemens PLC controller in real time, and then transmit it to the dispatch room service end through optical fiber, realizing real-time collection of the bucket wheel excavator position and material level height.

[0030] The mining truck positioning sensor is connected through the on-board terminal equipment installed in the vehicle. Using the 4G signal network, the positioning information is transmitted to the dispatch room server through the mining truck on-board terminal and TCP / IP to complete the data collection of the real-time location of the mining truck.

[0031] In this embodiment, the method of loading and aligning by using bucket wheel excavator and truck cooperation includes the following steps:

[0032] Step 1, determining the positional relationship between the bucket wheel excavator and the mining truck.

[0033] Acquire the position coordinates of the discharge port of the mining truck and bucket wheel excavator in real time, use the first high-precision GNSS positioning sensor 1 and the second high-precision GNSS positioning sensor 4 to collect the position coordinates of the discharge port of the bucket wheel excavator in real time, and draw a top view of the outline of the discharge port of the bucket wheel excavator in combination with the known discharge port diameter data, use the third high-precision GNSS positioning sensor 5 and the fourth high-precision GNSS positioning sensor 6 to collect the position coordinates of the mining truck in real time, and draw the outline of the mining truck compartment in combination with the known length and width of the mining truck compartment, and display the top view of the compartment outline on the system terminal interface of the mining truck and bucket wheel excavator respectively. In this embodiment, the outline of the discharge port of the bucket wheel excavator collected in real time by the wireless data transmission radio is circular, while the outline of the mining truck compartment is rectangular. Through the display interface, the user can clearly see the positional relationship between the discharge ports of the mining truck and the bucket wheel excavator, which solves the problem that the truck driver must stop the car multiple times to determine the material loading position in the existing method. Figure 5 It can be seen that only when the circle representing the discharge port of the bucket wheel excavator is inscribed with the rectangle representing the outline of the mining truck compartment, it means that the mining truck is ready.

[0034] Step 2: The bucket wheel excavator starts unloading.

[0035] Step 2.1: When the mining truck approaches the bucket wheel excavator, the vehicle terminal interface displays the following Figure 4 As shown, when the mining truck and the discharging port of the bucket wheel excavator are far apart or gradually intersect but do not form an inscribed relationship, the mining truck driver should drive the vehicle to move, and the discharging port of the bucket wheel excavator will not discharge materials.

[0036] Step 2.2: When the bucket wheel excavator discharge opening contour forms an inscribed relationship with the mining truck for the first time, the bucket wheel excavator driver is prompted to operate the bucket wheel excavator for unloading operations, such as Figure 5 When the bucket wheel excavator discharge port contour line is within the mining truck contour line, the bucket wheel excavator will perform unloading operations. However, as the material is loaded, after the front of the compartment is full, the truck needs to be moved to continue loading the rear of the compartment. Therefore, it is also necessary to determine the height of the material in the truck compartment in real time online. The specific method is as follows:

[0037] (1) In the initial state, the height of the material in the truck compartment is 0. At this time, the radar level meter monitors the distance between the center of the front wheel bucket discharge port contour and the bottom of the compartment.

[0038] (2) When the position relationship between the mining truck compartment and the discharge port radar level meter is as follows Figure 8As shown in the figure, the heights of the first and second radar level meters monitored online in real time are L1 and L2 respectively. Because the positions of the two radar level meters are based on the axisymmetric position relationship of the center position of the discharge port, in order to accurately obtain the height of the material falling from the center of the discharge port, it can be obtained based on the natural repose angle α of the material. Figure 8 As shown, angle ∠BAC = α. According to the mining manual, the natural repose angle of materials in open-pit coal mines can be taken as 33°, which can be obtained according to the formula:

[0039]

[0040] The intersection point of the material drop height obtained by the first radar level meter and the material is A, and the intersection point of the material drop height at the discharge port center and the material is C. A straight line AD parallel to the line where the first radar level meter and the second radar level meter are located is drawn along point A, and the midpoint of the straight line where the first radar level meter and the second radar level meter are located is connected to point C. The intersection point of the extended line and AD is B. BC can be used to accurately obtain the height L of the material drop at the discharge port center, and then prompt the truck compartment is not full and should continue to load. This method can achieve the maximum efficiency of mining truck loading.

[0041] (3) When the position relationship between the mining truck compartment and the discharge port radar level meter is as follows Fig. 9 As shown, when the second radar level meter monitors a height beyond the limit of the mining truck compartment, the wheel bucket excavator driver is promptly prompted to stop the wheel bucket operation signal. Thus, a loading task is completed, and the mining truck driver should move the mining truck position, load the rear of the compartment, and repeat step 2.2.

[0042] Step 3: When the discharge opening contour of the bucket wheel excavator forms an inscribed relationship with the mining truck for the second time, the bucket wheel driver should be prompted to stop the bucket wheel operation to unload, and the mining truck driver should be prompted to complete the loading operation and go to the next location to complete the work, such as Fig. 9 shown.

[0043] The above process allows mining truck drivers and bucket wheel excavator drivers to perform their work independently without having to communicate with each other repeatedly to confirm the height of the materials in the car, when the truck needs to leave when loading the rear of the truck car, and when the truck is judged to be full and leaving. These situations are completed through the visualization system, which improves the overall work process and transforms the entire process from the original manual communication method to the automated processing method, greatly improving work efficiency.

[0044] The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art can easily think of changes or substitutions within the technical scope disclosed by the present invention, which should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims

1. A bucket wheel excavator-truck cooperative loading alignment device, characterized in that ,include: Bucket wheel excavator positioning sensor, installed on the left and right sides of the discharge port of the bucket wheel excavator, and connected to the field controller through a wireless data transmission radio to collect the discharge port position information; Radar level meter: The radar level meter is installed on the front and rear sides of the discharge port under the discharge arm of the bucket wheel excavator, and is connected to the field controller through a wireless data transmission radio to monitor the current material loading height in real time; The mining truck positioning sensor is installed on the left and right sides of the mining truck driver's cab and is wirelessly connected to the dispatch room server through the truck's onboard terminal 4G network to collect the truck's own bucket position information; The field controller is installed in the field electric control cabinet and connected to the dispatching room service end through optical fiber. It is used to receive the collected signals of the bucket wheel excavator positioning sensor and radar level meter, and transmit the information to the dispatching room service end. The dispatch room service end is connected to the terminal equipment in the bucket wheel excavator and the terminal equipment in the mining truck through the 4G network. It is used to calculate the position relationship between the radar level meter and the bucket wheel excavator, calculate the height of the material in the mining truck compartment, and output control signals to control whether the bucket wheel excavator unloads the material, and control the terminal in the truck to display the current material loading status.

2. A bucket wheel excavator-truck coordinated loading alignment method, using the bucket wheel excavator-truck coordinated loading alignment device according to claim 1, characterized in that: The following steps are involved: The step of determining the positional relationship between the mining truck and the bucket wheel excavator is to use the collected position information of the dual high-precision GNSS positioning sensor of the mining truck and the known length and width of the mining truck compartment to draw a top view of the contour of the mining truck compartment; and to use the collected position information of the discharge port of the bucket wheel excavator to draw a top view of the contour of the discharge port of the bucket wheel excavator; and the above two top views of the contours are simultaneously displayed on the display screen of the terminal device; The step of unloading the bucket wheel excavator is to prompt the bucket wheel excavator driver to unload the material into the mining truck when the profile of the discharge port of the bucket wheel excavator and the profile of the truck compartment are inscribed for the first time; The steps of loading the mining truck: when loading materials, the material level of the mining truck is monitored online in real time. When the material level reaches the upper boundary of the truck compartment, the truck driver moves the truck to the next loading position to continue loading. Repeat the above loading steps until the discharge port of the bucket wheel excavator and the outline of the truck compartment are inscribed for the second time, and then the bucket wheel excavator driver is prompted to control the bucket wheel excavator to stop unloading the bucket, and the mining truck driver is prompted that the vehicle is full and the loading task is completed. The material level height refers to the distance between the center of the wheel bucket discharge port contour line obtained in real time and the material in the carriage; the distance specifically includes: the distance between the center of the wheel bucket discharge port contour line and the bottom of the carriage before unloading; During the unloading process, the distance between the center of the bucket discharge opening contour and the upper surface of the material in the carriage is calculated using the natural repose angle of the material.

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