Gondola car parameter acquisition through-type dumper unloading system and working method

Abstract

This invention discloses a through-type tippler unloading system and its operating method that utilizes sensing technology to acquire parameters of open wagons. The system includes: an OCR system, a laser imaging radar device, a wheel clamp, a loaded wagon shunting machine, a tippler, and a backstop, arranged sequentially according to the direction of vehicle entry. The laser radar system, through the movement of a radar trolley, performs a complete scan of the open wagon. By calculating the laser flight time, it obtains the distance information of all pixels and combines this with the relative position information between the radar and the open wagon to obtain three-dimensional imaging data of the open wagon. Analysis of the three-dimensional imaging data yields an image of the open wagon, and based on this image, the system obtains the dimensional parameters of the open wagon, outputting its length, width, and height. This system utilizes a sensing technology that integrates OCR and laser radar scanning imaging technologies to acquire parameters such as the length, width, and height of the open wagon to be tipped in advance, enabling precise control of the operation of individual equipment, ensuring equipment stability, and improving the operating efficiency of the tippler system.

Description

Technical Field

[0001] This invention relates to the field of tippler unloading system control, and more particularly to a through tippler unloading system and its working method that utilizes sensing technology to acquire open wagon parameters. Background Technology

[0002] Optical Character Recognition (OCR) is a technology that analyzes and recognizes textual information from image files containing text, and is an important component of artificial intelligence within the field of computer vision. With the rapid development of computer technology in recent years, OCR technology has made leaps and bounds in recognition speed and accuracy, leading to its increasingly wide range of applications.

[0003] LiDAR is a product of the combination of traditional radar technology and laser technology. Compared with microwave radar, it has extremely strong anti-jamming capabilities, high-resolution range detection, extremely high angular resolution, extremely high velocity resolution, and can obtain a variety of image information of the target. It is also small in size and lightweight. Laser scanning imaging radar is one type of it. With the development of technology, its applications have expanded from military to civilian fields, and in recent years, it has been widely used in intelligent industrial scenarios.

[0004] A tippler unloading system is a highly specialized bulk material unloading system that can unload bulk materials loaded on existing railway open wagons. The system generally consists of individual units such as tipplers, loaded shunting locomotives, empty shunting locomotives, transfer platforms, and wheel clamps.

[0005] Currently, conventional through-type tippler unloading systems are designed and operated based on the limit dimensions of open wagon formations arriving from the railway. Radio frequency identification (RFID) technology is used to identify open wagon numbers. This technology uses ground-based AEI (Air-Aspect Identification) equipment to read the tags on the bottom of the open wagons, thereby obtaining their technical parameters. In practical applications, due to the harsh operating environment of open wagons, tags are prone to loss, contamination, and damage, resulting in low accuracy for ground-based AEI equipment in reading these tags. Currently, this function is limited to collecting open wagon information and obtaining information about incoming railway materials, but it is not involved in the operation and control of the tippler system. Summary of the Invention

[0006] To address the problems existing in the prior art, this invention discloses a through-type tippler unloading system that utilizes sensing technology to acquire parameters of open wagons, including...

[0007] The following components are installed sequentially according to the direction of vehicle entry: OCR system, laser imaging radar device, wheel clamp, heavy car shunting machine tipper and backstop;

[0008] The OCR system includes an image reading device, a self-built database, and an analysis module. The image reading device is installed on both sides of the wheel clamp and set parallel to the railway track to acquire image information of open wagons. The self-built database stores the dimensions and various parameters of various open wagon models. The analysis module receives the image information transmitted by the image reading device, extracts the text information of the open wagon model and verifies it with the parameters in the self-built database, and transmits the length, width, and height parameters of the corresponding open wagons to the tippler system PLC to accurately control the unloading process.

[0009] The laser imaging radar device includes a trolley track, a radar trolley, and a laser radar system. The trolley track is installed next to the wheel clamp in the tipper system and is set parallel to the railway track. The radar trolley, as the carrier of the laser radar system, moves back and forth on the trolley track. The laser radar system achieves a complete scan of the open wagon by moving the radar trolley. By calculating the laser flight time, the distance information of all pixels is obtained, and combined with the relative position information between the radar and the open wagon, three-dimensional imaging data of the open wagon is obtained. The three-dimensional imaging data of the open wagon is analyzed to obtain an image of the open wagon, and the size parameters of the open wagon are obtained from the image. The length, width, and height information of the open wagon are then output.

[0010] The wheel clamp clamps the first pair of heavy cars to be unloaded, thereby preventing the train from slipping.

[0011] The shunting locomotive is used to pull loaded cars into the tippler and push empty cars out of the tippler to the backstop.

[0012] The tipper is used to unload materials from open wagons.

[0013] The backstop is used to prevent the car body at the outgoing end from slipping into the tipper.

[0014] A method for operating a through-type tippler unloading system that utilizes sensing technology to acquire parameters of open wagons includes:

[0015] While the loaded wagon is waiting, the tippler system PLC obtains accurate length, width, and height parameters of the open wagon through the OCR system and laser imaging radar device. The empty wagon from the previous cycle is unloaded inside the tippler and the empty wagon stops at the backstop at the exit end.

[0016] After the shunting locomotive reverses and engages the car coupler, it pulls the car train to be unloaded forward. When the car reaches the wheel clamp, it stops, disconnects the coupler between the car and the car, and continues to pull the car into the tippler for positioning. The empty car that has been unloaded is pushed out of the tippler to the backstop. The coupler between the shunting locomotive and the empty car is automatically disconnected. After reversing a safe distance and stopping, the boom is raised and returned to its original position, and the boom is lowered to wait for the next cycle.

[0017] After confirming that the loaded car has left the shunting locomotive, the tipper performs the pressing and siding actions, pressing and siding the open car, flipping it to the specified angle, and then returning to 0 degrees. The siding and pressing actions then return to wait for the next cycle.

[0018] By adopting the above technical solution, the present invention provides a through-type tippler unloading system and working method that uses sensing technology to obtain open wagon parameters. The system obtains parameters such as the length, width and height of the open wagon to be tipped in advance through sensing technology that combines OCR technology and lidar scanning imaging technology, so as to accurately control the operation of individual equipment, ensure the stability of equipment operation and improve the operating efficiency of the tippler system. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a structural block diagram of the system of the present invention.

[0021] Figure 2 This is a flowchart of the system of the present invention. Detailed Implementation

[0022] To make the technical solutions and advantages of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention:

[0023] like Figure 1 The system shown is a through-type tippler unloading system that uses sensing technology to obtain parameters of open wagons. It includes an OCR system 1, a laser imaging radar device 2, a wheel clamp 3, a loaded wagon shunting machine 4, a tippler 5, and a backstop 6.

[0024] OCR system 1 includes image reading devices, a self-built database, and an analysis module. The image reading devices are installed on both sides of the wheel clamp 3, parallel to the railway track. They are used to take pictures of the open wagons. The analysis module receives the image information transmitted by the image reading devices, extracts the wagon model and text information, compares it with parameters in the self-built database, and transmits the corresponding length, width, and height parameters of the wagons to the tippler system PLC for precise control of the unloading process.

[0025] The laser imaging radar device 2 includes a radar trolley, a trolley track, and a laser radar system. The trolley track is installed next to the wheel clamp 3 in the tipper system, parallel to the railway track. The radar trolley is the carrier of the laser radar system and can move back and forth on the track. The laser radar system consists of a laser emitting unit, a scanning unit, a receiving antenna, a photodetector, a magnification and shaping system, and a three-dimensional imaging system. Its imaging principle is that the laser radar device achieves a complete scan of the open wagon by moving the radar trolley. During scanning, the distance information of all pixels is obtained by calculating the laser flight time. Combined with the relative position information of the radar and the open wagon, three-dimensional imaging data information about the open wagon can be obtained. The analysis module analyzes the three-dimensional imaging data information to obtain an accurate imaging image, and derives the size parameters of the open wagon based on the imaging image, outputting the length, width, and height of the open wagon.

[0026] The wheel clamp 3 clamps the first pair of heavy cars to be unloaded, thereby preventing the train from slipping.

[0027] The backstop 6 is used to prevent the car body at the exit end from slipping into the tipper 6.

[0028] like Figure 2 As shown, a working method for a through-type tippler unloading system that utilizes sensing technology to acquire parameters of open wagons includes the following steps:

[0029] S1: While the loaded car C2 is waiting, the tipper system PLC obtains accurate length, width, and height parameters of the open car through the OCR system 1 and the laser imaging radar device 2. The empty car C2 from the previous cycle is unloaded inside the tipper 5, and the empty car C1 remains at the outgoing end backstop 7.

[0030] S2: After the shunting locomotive 4 reverses and couples the loaded car C2, it pulls the train of loaded cars to be unloaded forward. When the loaded car C3 reaches the wheel clamp 3, it stops. The coupler between the loaded car C2 and the loaded car C3 is manually disconnected. The loaded car C2 continues to be pulled into the tippler 5 and positioned. The empty car C1, which has been unloaded from the tippler 5, is pushed out of the tippler 5 and passes through the exit stop 6. The coupler between the shunting locomotive 4 and the empty car C1 is automatically disconnected. After reversing a safe distance and stopping, the boom is raised and returned to its original position. The boom is lowered and the train waits for the next cycle.

[0031] During the operation of the shunting locomotive 4, the shunting locomotive 4 achieves precise control of the acceleration and deceleration positions of the shunting locomotive C3 in the wheel clamp 3, the empty car C1 in the tippler 5, and the shunting locomotive C2 in the tippler, based on the length of the shunting locomotive C2.

[0032] S3: After the tipper 5 confirms that the loaded car shunting machine 4 has left, it performs the pressing and siding actions to press and sidle the open car, then flips it to the specified angle and returns to 0 degrees. The siding and pressing actions then return to the previous cycle.

[0033] Example:

[0034] Conventional tippler systems use mixed trains with dozens to hundreds of cars, ranging in length from 11938 to 13976 mm, height from 2993 to 3793 mm, and width from 3100 to 3243 mm. During system operation, they operate according to the maximum dimensions of open wagons. The tippler system PLC of this invention acquires accurate length, width, and height parameters of the open wagons through an OCR system 1 and a laser imaging radar device 2, for precise control of the following operational processes.

[0035] 1. The tipper 5 presses down on and approaches the vehicle.

[0036] 1) In conventional tipper systems, the lifting height of the weighing arm is designed based on the maximum height of the wagon train (3793mm) plus a safety distance. For other open wagons with lower heights, the lifting arm's movement time is long. This invention, after knowing the actual height of the wagon C2 to be tipped in advance, controls the lifting height of the weighing arm according to the actual height of the open wagon plus a safety distance upon completion of the previous cycle. This reduces the running time of the weighing arm's descent and weighing action.

[0037] 2) In a conventional system, the tipper 5 is positioned relative to the car, designed according to the maximum width of the car train (3243mm) plus a safety distance. For other narrower open wagons, the tipper's contact time is long. This invention, after knowing the actual width of the wagon C2 to be tipped in advance, controls the tipper's contact position according to the actual width of the open wagon plus a safety distance upon completion of the previous cycle. This reduces the tipper's contact time.

[0038] 2. The shunting locomotive 4 is in operation.

[0039] 1) The shunting locomotive 4 pulls the loaded car C2 through the wheel clamp 3 and onto the wheel clamp 3. In conventional systems, the deceleration position is designed based on the shortest length of the open wagon (11938mm). For longer open wagons, the shunting locomotive 4 operates at low speed for a considerable time to pull the loaded car C3 onto the wheel clamp 3. This invention, by knowing the length of the open wagon in advance, can decelerate according to the actual length of the open wagon during operation, reducing the low-speed operation time of the shunting locomotive and improving operational efficiency.

[0040] 2) The shunting locomotive 4 is used to couple empty wagon C1 to the tippler. In conventional systems, the deceleration position is designed based on the maximum length of the open wagon (13976mm). For shorter open wagons, the shunting locomotive 4 requires a longer low-speed operation time to couple the empty wagon C1. This invention, by knowing the open wagon length in advance, can decelerate according to the actual length of the open wagon during operation, reducing the low-speed operation time of the shunting locomotive and improving operational efficiency.

[0041] The above-mentioned precise control procedures improve the operating efficiency of the tippler system. It features precise and efficient technology.

[0042] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A through-type tippler unloading system that utilizes sensing technology to acquire parameters of open wagons, characterized in that... include: The following components are installed in sequence according to the direction of vehicle entry: OCR system (1), laser imaging radar device (2), wheel clamp (3), heavy vehicle shunting machine (4), tipper (5) and backstop (6). The OCR system (1) includes an image reading device, a self-built database and an analysis module. The image reading device is installed on both sides of the wheel clamp (3) and set parallel to the railway track to obtain image information of open wagons. The self-built database stores the size and various parameter information of various open wagon models. The analysis module receives the image information transmitted by the image reading device, extracts the text information of the open wagon model and checks it against the parameters in the self-built database, and transmits the length, width and height parameter information of the corresponding open wagon to the tippler system PLC, so as to accurately control the lifting height of the tippler (5) itself, the position of the car-side plate and the acceleration and deceleration position of the heavy car shunting machine (4) during the unloading process. The laser imaging radar device (2) includes a trolley track, a radar trolley, and a laser radar system. The trolley track is installed next to the wheel clamp (3) in the tipper system and is set parallel to the railway track. The radar trolley is the carrier of the laser radar system and moves back and forth on the trolley track. The laser radar system realizes a complete scan of the open wagon by moving the radar trolley. The distance information of all pixels is obtained by calculating the laser flight time, and the three-dimensional imaging data of the open wagon is obtained by combining the relative position information of the radar and the open wagon. The three-dimensional imaging data of the open wagon is analyzed to obtain the imaging image of the open wagon, and the size parameters of the open wagon are obtained according to the imaging image. The length, width and height information of the open wagon are output. The heavy car shunting locomotive (4) is used to pull heavy cars into the tippler (5) and push empty cars out of the tippler (5) to the backstop (6); The backstop (6) is used to prevent the car body at the outgoing end from slipping into the tipper (5).

2. The through-type tippler unloading system for acquiring open wagon parameters using sensing technology according to claim 1, characterized in that: The wheel clamp (3) clamps the first section of the heavy car train wheelset to be unloaded, thereby preventing the train from slipping.

3. The through-type tippler unloading system for acquiring open wagon parameters using sensing technology according to claim 1, characterized in that: The tipper (5) is used to unload materials from open wagons.

4. A working method for a through-type tippler unloading system that utilizes sensing technology to acquire open wagon parameters as described in claim 1, characterized in that... include: While the loaded car (C2) is waiting, the tippler system PLC obtains accurate length, width and height parameters of the open car through the OCR system (1) and laser imaging radar device (2). The empty car (C1) of the previous cycle is unloaded in the tippler (5), and the empty car (C1) stays at the exit stop (6). After the shunting locomotive (4) reverses and couples with the first loaded car (C2), it pulls the train of loaded cars to be unloaded forward. When the second loaded car (C3) reaches the wheel clamp (3), it stops, disconnects the coupler between the first loaded car (C2) and the second loaded car (C3), and continues to pull the first loaded car (C2) into the tippler (5) for positioning. Then, it pushes the empty car (C1) that has been unloaded from the tippler (5) out of the tippler (5) to the backstop (6), and automatically disconnects the shunting locomotive. (4) After the coupler with the empty car (C1) moves back a safe distance and stops, raise the boom and return to the original position, lower the boom and wait for the next cycle; during the operation of the shunting locomotive (4) pulling the first car (C2) through the wheel clamp (3) to the second car (C3) onto the wheel clamp (3), reduce the speed according to the actual length of the open car; during the operation of the shunting locomotive (4) connecting the empty car (C1) in the tippler, reduce the speed according to the actual length of the open car; After the shunting machine (4) leaves the car, the tipper (5) presses down on the car and approaches the car, presses down on the open car, flips it to the specified angle and returns to 0 degrees. The approaching and pressing actions return to wait for the next cycle. The height of the pressing arm is controlled according to the actual height of the open car + safety distance, and the position of the approaching plate is controlled according to the actual width of the open car + safety distance.

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