A self-adaptive loading method for rotary three-bin quantitative loading station
By using an adaptive loading method at a rotary three-compartment quantitative loading station, and utilizing belt conveyors and sensor systems to dynamically adjust the loading volume and rotation speed, the problem of loading accuracy and efficiency for multiple vehicle types at existing loading stations has been solved, achieving precise loading and efficient loading of vehicles ranging from 20t to 150t.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- ZHONGMEI KEGONG INTELLIGENT STORAGE TECH CO LTD
- Filing Date
- 2023-12-21
- Publication Date
- 2026-05-19
AI Technical Summary
Existing railway loading stations are unable to simultaneously adapt to changes in vehicle type from 20t to 150t, and it is difficult to achieve precise loading accuracy. Especially in the case of multimodal transport, the quantitative storage capacity of conventional loading stations is insufficient or too small, resulting in poor loading accuracy.
The rotating three-compartment quantitative loading station, combined with belt conveyors, weighing sensors and unloading gates, achieves adaptive loading through calculation and controller, dynamically adjusting the loading capacity and rotation speed of each compartment to meet the loading needs of different vehicle types.
It achieves precise loading within the 20t-150t vehicle range, improves the loading efficiency and adaptability of loading stations, and enables continuous automated loading tasks to be completed under unmanned conditions.
Smart Images
Figure CN117645170B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to an adaptive loading method for a rotary three-compartment quantitative loading station, which is a loading process method for automated loading machinery, and is a loading process method specifically for a rotary three-compartment quantitative loading station. Background Technology
[0002] With the increasing diversification of railway transportation, smaller loading stations, capable of rapidly adjusting to changes in loading volume for bulk container loading in multimodal transport scenarios, are better suited to container loading modes. Simultaneously, the capacity of open wagons is constantly increasing, making it challenging for existing loading stations to simultaneously accommodate heavy-load loading and multimodal container loading. Currently, conventional railway loading stations typically have a maximum capacity of only 100 tons for fixed-quantity silos, making it difficult to control the precision of 20-ton batching. Conversely, smaller fixed-quantity silos designed to improve loading precision struggle to handle batching exceeding 100 tons. Therefore, achieving a wide loading range for all wagon types from 20-150 tons at a single loading station is a problem that needs to be solved. Summary of the Invention
[0003] To overcome the problems of existing technologies, this invention proposes an adaptive loading method for a rotary three-compartment quantitative loading station. The method utilizes a rotary three-compartment quantitative loading station, taking advantage of the ability of the three compartments to continuously adjust the loading capacity and the fact that each compartment has a loading capacity of only 20t, facilitating accurate weighing. This invention proposes a loading method that can accommodate all types of open wagons (20t-150t) and containers, while also ensuring accurate weighing.
[0004] The objective of this invention is achieved as follows: an adaptive loading method for a rotary three-compartment quantitative loading station, wherein the rotary three-compartment quantitative loading station used in the method comprises: a belt conveyor capable of adjusting the conveying capacity and a belt scale installed on the belt conveyor, three compartments capable of rotating slowly together, and a speed sensor, wherein each of the three compartments is equipped with its own weighing sensor and unloading gate; a loading station controller connected to a host computer, wherein the loading station controller is connected to the vehicle speed sensor, the belt scale, the compartment speed sensor, the weighing sensor of the three compartments, and is also connected to the belt conveyor controller, the three unloading gates, and the speed controller;
[0005] The loading method of the method includes the following steps:
[0006] Step 1, Obtain Train Information: Before the train enters the loading station, the controller obtains train information from the host computer, including: the total number of carriages N, the sequence number n of each carriage, and the loading capacity S of each carriage. i ;
[0007] Step 2, Calculate the compartment code: Based on the serial number of each car and the loading capacity of each car, calculate the number of compartments and the compartment code for each car.
[0008]
[0009] L is the code for the assigned warehouse, L≤3 and L∈N * n is the current carriage number, n∈N * ;
[0010] M is the volume of a single compartment;
[0011] i is the carriage number, i≤N, and i∈N * ;
[0012] S i Let j represent the load capacity of each car, and j represent the current car's compartment allocation number. And j∈N * ;
[0013] Step 3: Calculate the target value V for each carriage. j :
[0014]
[0015]
[0016] Step 4: Calculate the preset value P for starting rotation. j :
[0017]
[0018] Among them: W j This represents the real-time weighing value displayed in each compartment; k is a constant related to the rotation speed of the three compartments; v belt The instantaneous flow rate or weight of material fed by the belt scale;
[0019] Step 5: Loading operation according to the calculated parameters: Start the conveyor belt, allowing the material on the conveyor belt to begin falling into a sector-shaped bin; the weighing sensor of the sector-shaped bin detecting the material entering notifies the loading station controller, which designates the sector-shaped bin into bin A, and designates the other two bins as bins B and C according to the rotation direction. Simultaneously, adjust the position of bin A relative to the conveyor head chute discharge port, aligning the conveyor head chute discharge port with the starting side of bin A's rotation direction; according to the calculated L, P... j V j The values are used to feed materials to each silo in the order of A, B, and C, and to load materials into each car; according to the calculated L and P values... j V jThe values are fed to each silo in the order of A, B, C, and each car is loaded with materials.
[0020] Step 6, End of loading: When it is determined that the current loading car is the last car, the belt conveyor stops running after the last compartment is finished dispensing material. When the last compartment is finished unloading material, the rotation of the three compartments stops, and the loading process ends.
[0021] The advantages and beneficial effects of this invention are as follows: This invention utilizes a miniaturized rotating multi-compartment quantitative loading station for continuous automated loading operations, which calculates the number of bins required for each car and the loading capacity of each bin by designing and adjusting the loading capacity of each car through algorithms. The loading method can adapt to all car models of open wagons from 20t to 150t, effectively improving the loading technology level and application range of bulk materials, and its loading efficiency is on par with that of standard car model trains. Attached Figure Description
[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments.
[0023] Figure 1 This is a schematic diagram of the three compartments of the loading station described in an embodiment of the present invention;
[0024] Figure 2 This is a block diagram illustrating the control principle of the loading station as described in an embodiment of the present invention;
[0025] Figure 3 This is a flowchart of the loading method described in an embodiment of the present invention. Detailed Implementation
[0026] Example 1:
[0027] This embodiment is an adaptive loading method for a rotary three-compartment quantitative loading station, such as... Figure 1 , 2 As shown. The rotary three-compartment quantitative loading station used in the method includes: a belt conveyor 1 capable of adjusting the conveying capacity and a belt scale mounted on the belt conveyor, and three compartments 2 capable of rotating slowly together (e.g., Figure 1 As shown, there are three compartments (A, B, and C, rotating in the direction of the arrow) and speed sensors. Each of the three compartments is equipped with its own load cell and unloading gate. A loading station controller is connected to the host computer. This loading station controller is connected to the vehicle speed sensor, belt scale, compartment speed sensor, and the load cells of the three compartments (compartment A, B, and C load cells). It is also connected to the belt conveyor controller, the three unloading gates (compartment A, B, and C unloading gates), and the speed controller. Figure 2 As shown.
[0028] The three-compartment quantitative loading station described in this embodiment is a type of loading station that differs from traditional loading stations. This type of loading station has three compartments arranged at 120-degree angles on a plane, forming a circular cross-section. The compartments are continuously loaded, weighed, and unloaded while rotating slowly. Through optimized loading and unloading times, the loading operations can be carried out continuously on each car of the train without stopping.
[0029] The main components of this loading method are the three compartments, belt conveyor, and loading station controller. Other components include the steel structure frame of the loading station, chutes, hydraulic system, and a series of sensors.
[0030] The rotation speed of the three rotating chambers is adjustable, with a rotation adjustment system consisting of a rotation sensor and a variable frequency motor. The belt conveyor also has a speed adjustment system, which can adjust the material output of the belt conveyor.
[0031] The aforementioned host computer is a business system connected to the material supply or sales system of the loading station, used for external business matters related to loading. The host computer typically provides information about the trains to be loaded, including information on various types of carriages and the loading capacity of each carriage. Various sensors aggregate information before and during loading, and control the system according to calculated parameters to achieve information feedback and automatic adjustment.
[0032] Each railway freight train consists of dozens of open wagons. The composition of the wagons is not necessarily uniform. When the wagon types are not uniform, it means that the loading weight of the wagons is also not necessarily uniform. In the rotating three-compartment loading mode, the application of the three compartments is random. Because the capacity of the weighing compartment is limited, the number of times it is used for weighing is determined by the load weight of the wagon. At the same time, because the multiple compartments always rotate in one direction, the use of the three compartments is sequential.
[0033] The loading process is a continuous process, and the loading system needs to automate the entire loading process for the train in one go. When the previous car is loaded, the sequence number and number of compartments used by the next car are not fixed or regular. Therefore, the sequence number and order of the compartments used by each car, as well as the reading of the weighing instruments and the control of the unloading gates for each compartment, are all adaptively adjusted and allocated using this algorithm.
[0034] Let the capacity of a single warehouse be M tons. When encountering a wagon with a standard load of S tons, the number of weighings n = [S / M], that is, the number of weighings is rounded up. The actual set value for each weighing is m = S / n tons. For example, if the warehouse capacity is 22 tons, when encountering a 20-ton container, the weighing count is 1. When encountering an 80-ton open wagon, the weighing count is 4, with each weighing count set at 20 tons.
[0035] Because the rotary three-compartment loading system operates on a three-compartment cycle for feeding, weighing, and loading, it is essential to dynamically allocate and apply the actual compartments, along with their associated weighing systems and gate devices, based on previous calculations to achieve adaptive loading. Let the compartments, their associated weighing systems, and the gates be designated A, B, and C. Loading is performed in a clockwise direction, see... Figure 1 Since the conveyor belt aligns with a random compartment when loading begins, it is necessary to first define this current compartment as compartment A, and then determine compartments B and C according to the rotation sequence.
[0036] To meet diverse loading needs (i.e., a mix of various car body types), it controls the number of compartment allocations and automatically adjusts the compartments, weighing system, and unloading gates to meet the loading requirements.
[0037] The specific process of the method described in this embodiment consists of five steps: calculating the compartment code; calculating the target value for each car; calculating the preset value for starting rotation; performing loading operations according to the calculated parameters; and ending the loading process. Figure 3 As shown.
[0038] The table below shows an application example. Each of the three compartments has a capacity of 22 tons. When the first car has a standard load of 70 tons, the system automatically calculates four weighing operations, each weighing 17.5 tons, and automatically allocates the required compartments and equipment as A, B, C, and A, completing four full feeding, weighing, and unloading processes. Next, for a standard load of 61 tons, the system calculates three weighing operations are needed. After the first car is loaded, the system sequentially cycles through the compartments, allocating the corresponding compartments and equipment as B, C, and A. This process continues for the third, fourth, and so on, until the loading cycle is complete.
[0039]
[0040] The entire train's information, including the order of the carriages and the serial number of each carriage, is obtained from the host computer before loading. Based on the above analysis, the following algorithm and formula are derived:
[0041]
[0042] This formula is the algorithm for allocating bins, instruments, and gates, calculating the bin corresponding to the j-th batching of the n-th car. L is the bin code for allocation, L≤3 and L∈N. * n is the current carriage number, n∈N * ;
[0043] M is the volume of a single compartment; i is the carriage number, i≤N, and i∈N *S represents the load capacity of each car, and j represents the current car allocation sequence number. And j∈N * ;
[0044] According to this formula, the system can calculate the compartment number L corresponding to the number of times the materials are dispensed in the wagon at any time during the automated loading process.
[0045] This formula can allocate cargo compartments for the entire train. It first calculates the cargo compartments that have been used and their order, and then derives the number of compartments and unloadings for the current car based on this calculation, thus obtaining the cargo compartment code corresponding to each loading of the current car.
[0046] This process is crucial in fully automated, unmanned loading operations. During the execution of the automated program, the weighing value and execution unit of each compartment in each batching process are actually dynamic variables. This process involves assigning values to the actual compartment parameters, which is done automatically by the system using the aforementioned algorithms and formulas. For example, when the nth car is batched for the jth time and parameter 2 is obtained, the weighing value of compartment #2 will be assigned to the calculation process for this batching, driving the control unit of compartment #2 to complete the gate operation. Furthermore, because these three compartments are always in operation, their sequence must be highly consistent with the batching sequence of the car. Only after a compartment has completed receiving, weighing, and unloading can it be assigned a new weighing and loading process. If the sequence is disordered, it will cause malfunctions in the sensors and controlled units, leading to production accidents.
[0047] The aforementioned formulas and algorithms ensure that the system can automatically analyze the bin code of each car's sub-batch, guaranteeing the realization of key aspects of fully automated production and forming the core of achieving continuous, unmanned, and intelligent loading.
[0048] For special cases, optimizations are made. When n=1, the gate closes step by step as the amount of material falling increases, ensuring that the amount of material falling eventually approaches the target value and passes through the gate, thus guaranteeing the accuracy of the weight of the loaded material.
[0049] During the adaptive operation, when n>1, the first n-1 compartments use coarse batching and unloading to ensure loading speed, resulting in relatively large errors between the actual loading value and the set value in each compartment. The weighing set value of each compartment is dynamically adjusted in real time according to changes in actual loading. Assuming n=4, after weighing and unloading of the 2 compartments, the difference between the actual weighing value and the set value of the first 2 compartments (because n=4, the set value of the 2 compartments in this car = set loading amount / 2) will be added to the weighing set value of the last 2 compartments.
[0050] When n>1, the weighing setpoint of the nth compartment needs to be calculated after the weighing and unloading of the first n-1 compartments to ensure that the material in the compartment is sufficient and to guarantee accuracy. Weighing values for each bin. To ensure loading accuracy, the nth bin uses fine batching. As the amount of material falling increases, the gate closes in stages to ensure that the final amount of material falling approaches the target value and the accuracy of the loading weight.
[0051] Based on the above reasoning, we can derive the formula:
[0052]
[0053]
[0054] When the number of times a material allocation needs to be completed exceeds one, the subsequent estimated allocation value cannot be exactly the same as the initial estimate. It is necessary to continuously adjust the subsequent estimated allocation value based on the results of previous allocations. This formula adjusts the target allocation value in real time based on the loading status of the current wagon. Where V is the target allocation value, j is the current allocation sequence number, S is the standard load of the current wagon, R is the actual value of materials that have been allocated and unloaded, the subscript i of R is the sequence number of the previous allocation, and M is the wagon volume.
[0055] Because the material receiving process is continuous, with the belt constantly conveying material, the feed rate of each bin is adjusted by the timing of the bin's rotation. Therefore, the timing of the bin's rotation away from the receiving area is crucial. This is generally achieved through a certain lead time. For example, if the bin requires 22 tons, the bin should start rotating at 21.5 tons. During the process of leaving the receiving area, an additional 0.5 tons will be added, ensuring the received material is as close as possible to the target value. For the final receiving operation, to ensure sufficient material is received, the bin will wait until the target value is reached before leaving the receiving area. Combining the previous formula with this requirement, we obtain the piecewise function:
[0056]
[0057] Where P represents the preset value of the starting rotation state, W represents the real-time value of the weighing display of the bin, k is a constant related to the speed of equipment rotation, and v belt This represents the instantaneous flow rate or weight of material being fed as detected by the belt scale.
[0058] Throughout the loading process, the weighing value of each compartment in each car is calculated using a high-low weighing mode, and the sum of the weighing values from all weighing processes is the actual loading value of the car.
[0059] Clearly, this method can handle trains of the same or mixed train models simultaneously.
[0060] Finally, it should be noted that the above is only used to illustrate the technical solution of the present invention and not to limit it. Although the present invention has been described in detail with reference to the preferred arrangement, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solution of the present invention (such as the form of the three-compartment loading station, the application of various formulas, the order of steps, etc.) without departing from the spirit and scope of the technical solution of the present invention.
Claims
1. An adaptive loading method for a rotary three-compartment quantitative loading station, wherein the rotary three-compartment quantitative loading station used in the method comprises: The system includes an adjustable conveyor belt, a belt scale mounted on the conveyor belt, three hoppers that can rotate slowly together, and a speed sensor. Each of the three hoppers is equipped with its own weighing sensor and unloading gate. The system also includes a loading station controller connected to a host computer. The loading station controller is connected to the vehicle speed sensor, the belt scale, the hopper speed sensor, the weighing sensor of the three hoppers, and the conveyor belt controller, the three unloading gates, and the speed controller. The method is characterized in that the loading method includes the following steps: Step 1, Obtain Train Information: Before the train enters the loading station, the controller obtains train information from the host computer, including: the total number of carriages N, the sequence number n of each carriage, and the loading capacity S of each carriage. i ; Step 2, Calculate the compartment code: Based on the serial number of each car and the loading capacity of each car, calculate the number of compartments and the compartment code for each car. L is the code for the assigned warehouse, L ≤ 3 and n is the current carriage number. ; M is the volume of a single compartment; i is the carriage number, i ≤ N, and ; S represents the load capacity of each car, and j represents the current car allocation sequence number. ,and ; Step 3: Calculate the target value V for each carriage. j : Where: R i This represents the actual value of the material in the i-th preceding warehouse that has already completed the allocation and unloading process; Step 4: Calculate the preset value P for starting rotation. j : Among them: W j This represents the real-time weighing value displayed in each compartment; k is a constant related to the rotation speed of the three compartments; v belt The instantaneous flow rate or weight of material fed by the belt scale; Step 5: Loading operation according to the calculated parameters: Start the conveyor belt, allowing the material on the conveyor belt to begin falling into a sector-shaped bin; the weighing sensor of the sector-shaped bin detecting the material entering notifies the loading station controller, which designates the sector-shaped bin into bin A, and designates the other two bins as bins B and C according to the rotation direction. Simultaneously, adjust the position of bin A relative to the conveyor head chute discharge port, aligning the conveyor head chute discharge port with the starting side of bin A's rotation direction for material discharge; according to the calculated L, P... j V j The values are fed to each silo in the order of A, B, C, and each car is loaded with materials. Step 6, End of loading: When it is determined that the current loading car is the last car, the belt conveyor stops running after the last compartment is finished dispensing material. When the last compartment is finished unloading material, the rotation of the three compartments stops, and the loading process ends.