Method for automatic loading of bulk material into a vehicle

Abstract

The application discloses a kind of bulk material automatic loading method, solve the problem of guiding after opening bulk truck bulk material automatic loading in the scene of intelligent loading and unloading robot, obtain laser point cloud data by rotating two-dimensional laser radar sensor driven by platform, process laser point cloud data, guide vehicle positioning to discharge port, detect hopper size, detect material level and guide vehicle forward, detect end stop and discharge.The application has high integration, strong applicability, optimizes dust scene, can measure material level at multiple points, meets the needs of vehicle full load, optimizes rotation strategy, increases the real-time nature of material level detection, specifically processes special vehicles, algorithm does not need training data, does not need complex algorithm, and has strong real-time nature.

Description

Technical Field

[0001] This invention relates to a method for automatically loading bulk materials onto trucks. Background Technology

[0002] Weighing and loading involves using a weighbridge to measure the empty weight of the truck, setting a pre-load weight, and loading while weighing, stopping when full. However, this method cannot accurately and evenly fill the entire truck bed. The pre-load weight is affected by material density, moisture content, and particle size, and does not accurately reflect the material volume, making it prone to spillage or incomplete filling.

[0003] Manual loading involves an operator guiding the vehicle to a designated location, manually opening the unloading port, observing changes in material level, and notifying the driver via verbal communication or a bell to move the vehicle forward or backward, thus completing the loading process. Manual loading requires a high degree of concentration from both the driver and operator, is highly susceptible to human error, and is prone to misjudging material spillage. Furthermore, the loading process is quite noisy, and the driver may either fail to move forward enough to spill material or move the vehicle too far forward, resulting in insufficient loading and requiring subsequent replenishment, thus impacting loading efficiency.

[0004] The system uses a video method, with a camera mounted above the feeding port to inspect the vehicles. However, the measurement of vehicle dimensions is subject to some error due to calibration limitations, and inaccurate measurements are not possible in low-light conditions at night. It is also susceptible to interference from dust. Furthermore, it is difficult to accurately detect small objects such as vehicle ropes and reinforcing bars, affecting vehicle dimension measurement. The system also requires processing large amounts of data, which impacts real-time performance.

[0005] A standalone microwave radar is typically installed behind the feed inlet. After the hopper is manually aligned with the feed inlet, a fixed material height threshold is set, the material height is measured, and the vehicle is guided forward. This solution cannot complete vehicle positioning and can only perform semi-automatic loading.

[0006] Therefore, finding an automated loading method that is highly integrated, widely applicable, has good real-time performance, and can be used on a variety of complex vehicles has become an urgent technical problem to be solved. Summary of the Invention

[0007] The purpose of this invention is to provide a method for automatically loading bulk materials onto trucks, thereby solving the aforementioned problems.

[0008] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0009] The present invention discloses an automatic loading method for bulk materials, characterized by comprising the following steps:

[0010] (1) Equipment installation: The two-dimensional laser radar sensor is installed 2-4 meters behind the feed port via a swing table, and the computer is connected to the swing table and the laser radar sensor.

[0011] (2), the guiding positioning stage: this stage does not need to swing, the laser radar sensor is at 0 ° of the swing table, scans the vehicle long high section directly below, establishes the coordinate system, the laser radar sensor directly below is the coordinate system origin, the X axis points to the rear of the carriage, the Y axis points to the directly above, the X axis detection range is (-17000mm, 17000mm), the Y axis detection range (400mm, the laser radar sensor installation height-100mm);

[0012] 2.1), judgment when starting detection: if the vehicle is in front of the laser radar sensor when starting detection, the vehicle is completely on the list, the detection signal is triggered by starting detection through card swiping, the vehicle is guided to retreat, whether the characteristics of judging the length of the hopper are met is judged, until the hopper is not blocked by the material port, the laser radar sensor can completely scan the front fender of the vehicle, if the characteristics of judging the length of the hopper are met, then the next step is entered;

[0013] If the vehicle is directly below or behind the laser when starting detection, then the vehicle is guided to advance at the entrance to identify the license plate to trigger the start of detection, until the tail of the hopper is less than 4 meters directly below the equipment, the length is detected after the condition is met;

[0014] 2.2), measure the length of the hopper: the point cloud in the positive and negative directions of the X axis is segmented by X coordinate interval 500mm, save the point cloud to the corresponding array, each positive direction array saves the X coordinate greater than 0 and meets the corresponding segment of the X coordinate range divided by the above X coordinate interval 500mm, the negative direction array is the same as the positive direction, saves the X coordinate less than 0 and meets the corresponding segment of the X coordinate range divided by the above X coordinate interval 500mm, calculates the minimum value of Y coordinate of each segment data point, finds along the X axis positive direction segment, if the minimum Y value difference between adjacent segments is greater than 300mm, stop, find the rear fender in the previous segment, the negative direction is the same as the positive direction, find the front fender in the corresponding segment, find the maximum X value in the above segment, which is the position of the rear fender, find the maximum Y value in the X axis range (maximum X-200mm, maximum X) in the segment, which is the height of the fender, the algorithm for finding the front fender is the same as that for finding the rear fender, the minimum X in the corresponding segment is the position of the front fender, this algorithm is a dynamic iterative search, which can prevent the influence caused by more than 0.5 meters of following vehicle;

[0015] 2.3) Guide the vehicle positioning: Real-time judge the position of the current point cloud data of the vehicle front baffle Xi, assuming that the coordinates of the front edge of the discharge port are Xj, and the vehicle parking range is (Xj-1000mm, Xj-200mm), if XiXj-1000mm, then send a forward command to guide the vehicle forward, if Xi>Xj-200mm, then send a forward command to guide the vehicle forward, if Xi>Xj-1000mm and XiXj-200mm, then send a stop command, and if the vehicle front baffle is in the range for 10s, the vehicle is notified to park in place for the next step;

[0016] (3) Bin size detection stage: The table starts to swing, and three-dimensional point cloud data of the vehicle is obtained. The coordinate system is established, the origin of the coordinate system is directly below the device, X points to the left side of the carriage, Y axis points to the rear of the carriage, and Z axis points to the top. Four parameters are detected, which are bin length, bin bottom distance from ground height, bin width and bin height. The four parameters are used to assist in calculating how much bulk material needs to be loaded and as a bulk material level height reference;

[0017] 3.1) Measure the length of the vehicle: This data is obtained in step 2.2) above;

[0018] 3.2) Measure the height of the vehicle bottom from the ground: Take the minimum Z value of the data points in the X coordinate range (-200mm, 200mm) and Y coordinate range (-200mm, 200mm) as the height of the vehicle bottom from the ground;

[0019] 3.3) Measure the width of the vehicle: Take the point cloud of the vehicle bottom height ±100mm, that is, the data points with Z coordinate in the range (bin bottom height-100mm, bin bottom height+100mm) and Y coordinate in the range (vehicle front baffle coordinates, vehicle rear baffle coordinates). Segment with Y coordinate interval of 500mm, calculate the maximum X coordinate and minimum X coordinate in each segment, and the maximum X-coordinate minus the minimum X-coordinate is the width of each segment. The final average value of the cumulative width of each segment divided by the number of segments is the final width of the vehicle;

[0020] 3.4) Measure the height of the vehicle: Take the data points with Y coordinate in the range (vehicle front baffle coordinates+200mm, vehicle rear baffle coordinates), segment with Y coordinate interval of 500mm, calculate the maximum Z coordinate in each segment, compare the maximum Z coordinate values in each segment, and take the minimum value as the final vehicle height;

[0021] (4) Level detection stage: Detect the level height in this stage to determine whether it is full load:

[0022] 4.1) Calculate the height of the center material level: Assume that the Y coordinate of the rear of the discharge port is Yi. Take all data points within the X coordinate range (-200mm, 200mm) and the Y coordinate range (Yi-200mm, Yi). Calculate the minimum Z value of the data points, which is the height of the material level. Dust will drift to a certain height, so the maximum Z value cannot be taken. Take the minimum Z value in a small area in the middle of the vehicle. This can both filter the dust and find the height of the material level that is closest to the actual height.

[0023] 4.2) Calculate the material level height on both sides: Assume that the Y coordinate of the rear of the discharge port is Yi. Take all data points within the Y coordinate range (Yi-200mm, Yi+200mm) and calculate the maximum X and minimum X. The maximum X is the left side of the bucket, and the minimum X is the right side of the bucket. Take the point with the minimum Z axis within the range of (minimum X, minimum X+200mm) of the existing data points as the material level height on the right side of the bucket, and take the point with the minimum Z axis within the range of (maximum X-200mm, maximum X) of the existing data points as the material level height on the left side of the bucket.

[0024] 4.3) Full load judgment: When the difference between the material level height and the truck bed height is greater than a certain threshold, it is considered that the loose material at the corresponding position of the discharge port is full, and the vehicle is guided to move forward. The standard load measurement is mainly based on the center material level height, and the material level heights on both sides are used as an auxiliary to judge whether the material is spilled. The full load is mainly based on the material level heights on both sides.

[0025] (5) End detection stage: In this stage, the position of the tail of the truck bed is detected. The maximum Y coordinate Ym within the detection range is the position of the tail of the truck bed. The low-bucket truck bed is lower and the material pile is easier to fill. The high-bucket truck bed is higher and the material pile is not easy to fill. Assuming the coordinate of the rear of the discharge port is Yi, the end condition of the low-bucket truck bed is Ym < Yi+400mm, and the end condition of the high-bucket truck bed is Ym < Yi+200mm. If the conditions are met, the end signal is given.

[0026] Furthermore, at the start of the detection, if the vehicle is in front of the lidar sensor, it will continuously determine whether it meets the characteristics of the truck bed length during the reversing process. In order to identify the vehicle length as soon as possible, it will enter the measurement guidance and positioning stage to avoid unnecessary vehicle movement.

[0027] Furthermore, when starting the inspection, if the vehicle is directly below or behind the laser, in order to avoid the influence of the vehicle's connecting rod, the vehicle should be driven to a more forward position, where the connecting rod and the noise under the front of the vehicle can be blocked by the front fender.

[0028] Furthermore, iteratively querying the minimum value of the Y-axis when measuring the length of the truck bed can prevent the effects of bracing and truck bed tilt.

[0029] Furthermore, during the truck bed size detection stage, if the truck is a flip-top truck with two automatically opening covers on the roof, these covers will flip to the sides of the truck bed during loading. The laser radar sensor's scanning beam will pass through the gaps and scan the flip-top section, affecting the vehicle width scan. Therefore, data points with Y-coordinates within the range of (front and rear truck bed covers) are taken, and segmented at 300mm intervals. Within each segment, data points with X-coordinates within the range of (-300mm) are selected. Calculate the maximum height Z from the data points within the range of m, 300mm. Segments with a maximum height Z greater than the bottom height of the truck bed + 200mm are marked as segments with bracing. For the segments without bracing, find the first data point with a Z coordinate greater than the bottom height of the truck bed + 200mm along the positive and negative half axes from the origin of the X coordinate system. These points are the coordinates of the two side panels. Subtract the coordinates of the two side panels to get the width of the segment. Accumulate the width of the truck bed for each segment without bracing, divide by the number of segments, and take the average of the final widths as the final truck bed width.

[0030] Furthermore, during the truck bed size detection stage, if there is a pull rope on the truck, the height of the pull rope needs to be filtered to identify the height of the truck bed. This can be achieved by using the feature that there is a certain distance between the pull rope and the truck bed to filter the height of the pull rope. For data points with Y coordinates in the range of (coordinates of the front baffle of the truck bed +200mm, coordinates of the rear baffle of the truck bed -200mm) and Z coordinates in the range of (height of the bottom of the truck bed -100mm, 5000mm), create an array of size 500. The array is spaced at 1cm intervals, and size 500 represents 0-5 meters. Traverse the data points and project all data points into this array, that is, set the array data with the Z coordinate value of each data point as the subscript of 10 to 1. Assuming that the maximum subscript value of the array value is Idx, and the values ​​in the subscript range (Idx-20, Idx), if there are 5 consecutive values ​​of 0, then the height corresponding to the subscript of the first consecutive 0 value in the array -1 is taken as the final height.

[0031] Furthermore, during the material level detection stage, the real-time performance of material level detection is optimized. During the loading of bulk materials, the stockpiles are symmetrically distributed. The current material level can be output by rotating half an angle. When detecting the material level, the swing table rotates ±45°, the motor angular resolution is 1°, the motor speed is 30r / min, that is, 180° / s, and the material level output can be completed in 0.25s. If full load is not required, the rotation angle can be reduced, and only the height of the center material level can be measured. The swing table is ±10°, and the material level output can be completed in 0.05s, which greatly improves the real-time performance of material level detection.

[0032] Further, in the tail detection stage, if the discharged granular material is fine, dust will be discharged outside the car during the discharging process, and the rear of the tail will detect point cloud data, and the maximum Y value cannot be used to determine the end condition, under the condition of dust, the laser can pass through the dust and return to the ground data point, at this time, the data of the swing table angle of ±5° is extracted, the data of the ground data point and the Z coordinate value <400mm is obtained, the smallest Y value in the detection range is detected, the angle of the laser in the swing table angle of ±5° range and the ground data point detected above the original point is calculated, , the bottom of the tail is between 1500m and 1600mm from the ground, assuming that the height of the bottom of the vehicle is 1550mm, at this time , the positioning of the tail at this time can be estimated, and the positioning is used for end logic judgment.

[0033] Compared with the prior art, the beneficial technical effects of the present application are:

[0034] The present application has high integration and strong applicability, optimizes the dust scene, can measure the material level at multiple points, meets the demand of full load of the vehicle, optimizes the rotation strategy, increases the real-time performance of the material level detection, and specially processes special vehicles, the algorithm does not need training data and complex algorithm, and has strong real-time performance. BRIEF DESCRIPTION OF DRAWINGS

[0035] The present application will be further described below in combination with the drawings.

[0036] Figure 1 is a whole flow chart;

[0037] Figure 2 is an equipment installation diagram;

[0038] Figure 3 is a guide process coordinate system;

[0039] Figure 4 is a guide positioning stage point cloud diagram;

[0040] Figure 5 is a swing process coordinate system;

[0041] Figure 6 is a car hop size detection stage point cloud diagram;

[0042] Figure 7 is a flip car point cloud diagram;

[0043] Figure 8 is a pull rope point cloud diagram;

[0044] Figure 9 is a discharging point cloud diagram;

[0045] Figure 10 is a dust-free point cloud diagram;

[0046] Figure 11 for dust point cloud map; DETAILED DESCRIPTION

[0047] As Figures 1-11 shown, a bulk material automatic loading method is characterized in that it comprises the following steps:

[0048] (1) Install the equipment: install the two-dimensional laser radar sensor on the position 2-4 meters behind the discharge port through the swing table, and connect the swing table and the laser radar sensor with the computer;

[0049] (2) Guiding positioning stage: the swing table does not need to swing in this stage, the laser radar sensor is at 0° of the swing table, scans the vehicle length and height section directly below, establishes the coordinate system, the coordinate system origin is directly below the laser radar sensor, the X axis points to the rear of the vehicle, the Y axis points to the directly above, the X axis detection range is (-17000mm, 17000mm), and the Y axis detection range is (400mm, laser radar sensor installation height-100mm);

[0050] 2.1) Judgment when starting detection: if the vehicle is in front of the laser radar sensor when starting detection, the vehicle is completely on the list, the detection signal is triggered by card swiping to start detection, the vehicle is guided to retreat, and the characteristics of meeting the vehicle hopper length are continuously judged during the retreat process. In order to identify the vehicle length as soon as possible, enter the measurement guiding positioning stage, avoid unnecessary vehicle movement, judge whether the characteristics of meeting the vehicle hopper length are met, until the vehicle hopper is not blocked by the discharge port, the laser radar sensor can completely scan the front fender of the vehicle, if the characteristics of meeting the vehicle hopper length are met, then enter the next step;

[0051] If the vehicle is directly below or behind the laser when starting detection, the vehicle is guided to advance until the tail of the vehicle hopper is less than 4 meters directly below the equipment, the length is detected after the condition is met, in order to avoid the influence of the vehicle connecting rod part, the vehicle is driven to a relatively forward position, and the miscellaneous points below the connecting rod and the vehicle head can be blocked by the front fender;

[0052] 2.2) Measure the length of the car: the point cloud in the positive and negative direction of the X axis is segmented by 500mm X coordinate interval, and the point cloud is saved to the corresponding array. Each positive direction array saves the data points with X coordinate greater than 0 and meeting the X coordinate range of the corresponding segment divided by 500mm X coordinate interval. The negative direction array is the same as the positive direction, which saves the data with X coordinate less than 0 and meeting the X coordinate range of the corresponding segment divided by 500mm X coordinate interval. The minimum Y coordinate of each segment data point is calculated, and the minimum Y value is searched along the X axis positive direction segment. If the difference between adjacent segments is greater than 300mm, stop. The front baffle is searched in the previous segment. The negative direction is the same as the positive direction. The front baffle is searched in the corresponding segment. Iterative query of the minimum value of Y axis during the measurement of the length of the car can prevent the influence of the reinforcing rib and the inclination of the car. The maximum X value in the above segment is the position of the rear baffle. The maximum Y value in the X axis range (maximum X-200mm, maximum X) in the segment is the height of the baffle. The algorithm for searching the front baffle is the same as that for searching the rear baffle. The minimum X in the corresponding segment is the position of the front baffle. This algorithm is a dynamic iterative search, which can prevent the influence of the vehicle greater than 0.5 meters;

[0053] 2.3) Guide the positioning of the vehicle: real-time judge the position Xi of the front baffle of the car in the current point cloud data. Assume that the coordinate of the front edge of the discharge port is Xj, and the vehicle parking range is (Xj-1000mm, Xj-200mm). If Xi < Xj-1000mm, send a backward command to guide the vehicle to move backward. If Xi > Xj-200mm, send a forward command to guide the vehicle to move forward. If Xi > Xj-1000mm and Xi < Xj-200mm, send a stop command. If the vehicle front baffle is always within the range within 10s, the vehicle is notified to park in place for the next step.

[0054] (3) Car size detection stage: the table starts to swing, three-dimensional point cloud data of the vehicle is obtained, a coordinate system is established, the origin of the coordinate system is directly below the equipment, X points to the left side of the car, Y axis points to the rear of the car, and Z axis points to the upper side. Four parameters are detected, which are car length, car bottom distance from ground height, car width and car height. The four parameters are used to assist in calculating how much bulk material needs to be loaded and as a bulk material level height reference.

[0055] 3.1) Measure the length of the car: the data is obtained in step 2.2) above;

[0056] 3.2) Measure the distance from the bottom of the car to the ground: the minimum Z value of the data points in the X coordinate range (-200mm, 200mm) and Y coordinate range (-200mm, 200mm) is the distance from the bottom of the car to the ground;

[0057] 3.3) Measurement of the width of the car body: Take the point cloud at the height of the bottom of the car body ±100mm, that is, the data points with Z coordinates in the range of (the height of the bottom of the car body -100mm, the height of the bottom of the car body +100mm) and Y coordinates in the range of (the front baffle coordinate of the car body, the rear baffle coordinate of the car body), segment them at intervals of 500mm in Y coordinates, calculate the maximum X coordinate and the minimum X coordinate in each segment, and the difference between the maximum X coordinate and the minimum X coordinate is the width of each segment, then accumulate the width of each segment and divide by the number of segments to obtain the final average value as the final width of the car body;

[0058] If the vehicle is a flip cover vehicle, two automatic flip covers are installed on the roof of the flip cover vehicle, and the two flip covers will be flipped to the two sides of the car body during loading. The light beam of the laser radar sensor will pass through the gap and scan the flip cover part, which will affect the scanning of the width of the vehicle. Therefore, the data points with Y coordinates in the range of (the front baffle coordinate of the car body, the rear baffle coordinate of the car body) are segmented at intervals of 300mm in Y coordinates, the data points with X coordinates in the range of (-300mm, 300mm) in each segment are taken to calculate the maximum height Z, and the data segments with maximum height Z greater than the height of the bottom of the car body +200mm are marked as segments with ribs. The first data point with Z coordinate greater than the height of the bottom of the car body +200mm along the X coordinate origin to the positive and negative half axes is taken as the coordinate of the baffle on the two sides, and the difference between the coordinates of the baffles on the two sides is the width of the segment. Accumulate the width of each rib-free segment and divide by the number of segments to obtain the final average value as the final width of the car body.

[0059] 3.4) Measurement of the height of the car body: Take the data points with Y coordinates in the range of (the front baffle coordinate of the car body +200mm, the rear baffle coordinate of the car body), segment them at intervals of 500mm in Y coordinates, calculate the maximum Z coordinate in each segment, compare the maximum Z coordinate values in each segment, and take the minimum value as the final height of the car body.

[0060] If there is a pull rope on the vehicle, the height of the pull rope needs to be filtered, and the height of the car body needs to be identified. The height of the pull rope can be filtered by the feature that there is a certain gap between the pull rope and the car body. The data points with Y coordinates in the range of (the front baffle coordinate of the car body +200mm, the rear baffle coordinate of the car body -200mm) and Z coordinates in the range of (the height of the bottom of the car body -100mm, 5000mm) are created into an array with a size of 500, which is an interval of 1cm, and the size 500 is 0-5m. Project all data points into the array, that is, set the array data at the index of the Z coordinate value / 10 of each data point to 1. Assuming that the maximum index value of the array value 1 is Idx, and the values in the index range (Idx-20, Idx) are all 0, then the height value corresponding to the starting value index -1 of the array with consecutive 0 is the final height.

[0061] (4) Material level detection stage: In this stage, the material level height is detected to determine whether it is full load:

[0062] 4.1) Calculate the center material level height: Assuming that the Y coordinate of the rear of the discharge port is Yi, take the X coordinate range (-200mm, 200mm) and the Y coordinate range (Yi-200mm, Yi) of all data points, calculate the minimum Z value of the data points, which is the material level height. Dust will float to a certain height, so the maximum Z value cannot be taken. Taking the minimum Z value of a small range in the middle of the vehicle can filter dust and also calculate the height of the closest real material level.

[0063] 4.2) Calculate the material level height on both sides: Assuming that the Y coordinate of the rear of the discharge port is Yi, take all data points in the Y coordinate range (Yi-200mm, Yi+200mm), calculate the maximum X and minimum X. The maximum X is on the left side of the vehicle, and the minimum X is on the right side of the vehicle. Take the minimum Z value of the existing data points in the range (Xmin, Xmin+200mm) as the material level height on the right side of the vehicle, and take the minimum Z value of the existing data points in the range (Xmax-200mm, Xmax) as the material level height on the left side of the vehicle.

[0064] 4.3) Full load judgment: When the difference between the material level height and the vehicle height is greater than a certain threshold, it is considered that the bulk material at the corresponding position of the discharge port is full, and the vehicle is guided to advance. The center material level height is the main measurement, and the material level height on both sides is used to assist in determining whether to scatter material. The material level height on both sides is the main full load.

[0065] (5) End detection stage: In this stage, the vehicle tail position is detected, and the vehicle tail is detected. The maximum Y coordinate Ym in the detection range is the positioning of the vehicle tail. The low vehicle has a lower vehicle, and the material pile is easy to fill. The high vehicle has a higher vehicle, and the material pile is not easy to fill. Assuming that the coordinate of the rear of the discharge port is Yi, the end condition of the low vehicle is Ym < Yi+400mm, and the end condition of the high vehicle is Ym < Yi+200mm. If the conditions are met, an end signal is given.

[0066] If the discharged bulk material particles are fine, dust will float out of the vehicle during the discharging process, and point cloud data will be detected at the rear of the vehicle tail. The maximum Y value cannot be used to determine the end condition. In the presence of dust, the laser can pass through the dust and return to the ground data point. At this time, the data of the ground data point and the Z coordinate value < 400mm are extracted at the angle of ±5°, the angle of the laser detected on the ground data point in the above extracted angle of ±5° range and the positive original point is calculated, , the distance between the vehicle tail bottom and the ground is between 1500m and 1600mm, assuming that the vehicle bottom height is 1550mm, at this time That is, the positioning of the vehicle tail at this time can be estimated, and the positioning is used for tailing logic judgment.

[0067] In the material level detection stage, the material level detection real-time optimization, bulk loading process in the material is symmetrical distribution, rotation half angle can output current material level, material level detection when the table rotates ± 45 ° motor angle resolution 1 °, motor speed 30 r / min, namely 180 ° / s, 0.25 s can complete a material level output, if not need full load can reduce the rotation angle, only measure the center material level height, table ± 10 °, 0.05 s can complete a material level output, greatly improve the real-time of material level detection.

[0068] The above-described embodiments are only to describe the preferred modes of the present application, and not to limit the scope of the present application, and various modifications and improvements of the technical solutions of the present application made by those skilled in the art without departing from the design spirit of the present application shall fall within the protection scope determined by the claims of the present application.

Claims

1. A method of automatic bulk loading of a truck, characterized in that, Comprising the following steps: (1) Install the equipment: install the two-dimensional laser radar sensor on the position 2-4 meters behind the discharge port through the swing table, and connect the computer with the swing table and the laser radar sensor; (2) Guiding positioning stage: the swing table does not need to swing in this stage, the laser radar sensor is at 0° of the swing table, scans the vehicle long and high section directly below, establishes the coordinate system, the coordinate system origin is directly below the laser radar sensor, the X axis points to the rear of the vehicle, the Y axis points to the directly above, the X axis detection range is (-17000mm, 17000mm), and the Y axis detection range is (400mm, laser radar sensor installation height-100mm); 2.1) Judgment when starting detection: if the vehicle is in front of the laser radar sensor when starting detection, the vehicle is completely on the list, a start detection signal is triggered through card swiping, the vehicle is guided to retreat, whether the characteristics of judging the length of the hopper is met is judged, until the hopper is not blocked by the discharge port, the laser radar sensor completely scans the front apron of the vehicle, if the characteristics of judging the length of the hopper are met, the next step is entered; If the vehicle is directly below or behind the laser when starting detection, the start detection is triggered by identifying the license plate at the entrance, the vehicle is guided to advance, until the tail of the hopper is less than 4 meters directly below the equipment, the length starts to be detected after the condition is met; 2.2) Measuring the length of the hopper: the point cloud in the positive and negative directions of the X axis is segmented by taking 500mm as an interval, the point cloud is saved to the corresponding array, each positive direction array saves the data points with X coordinates greater than 0 and meeting the X coordinate range of the corresponding segment divided by taking 500mm as an interval, the negative direction array is the same as the positive direction, saves the data with X coordinates less than 0 and meeting the X coordinate range of the corresponding segment divided by taking 500mm as an interval, the minimum value of the Y coordinates of the data points in each segment is calculated, the segmentation along the positive direction of the X axis is found, if the minimum Y values of adjacent segments are different by more than 300mm, stop, find the rear apron in the previous segment, the negative direction is the same as the positive direction, find the front apron in the corresponding segment, find the maximum X value in the above segment, which is the position of the rear apron, find the maximum Y value in the X axis range (maximum X-200mm, maximum X) in the segment, which is the height of the apron, the algorithm for finding the front apron is the same as that for finding the rear apron, the minimum X in the corresponding segment is the position of the front apron, and the algorithm is a dynamic iterative finding; 2.3) Guiding the vehicle positioning: the position Xi of the hopper front apron in the current point cloud data is judged in real time, the coordinate of the front edge of the discharge port is Xj, the vehicle parking range is (Xj-1000mm, Xj-200mm), XiXj-1000mm and XiXj-200mm, the stop command is sent, the vehicle is guided to advance, XiXj-1000mm and XiXj-200mm, the stop command is sent, and the vehicle is guided to advance. (3) The hopper size detection stage: the swing table starts to swing, three-dimensional point cloud data of the vehicle is obtained, a coordinate system is established, the original point of the coordinate system is directly below the equipment, X points to the left side of the vehicle compartment, Y axis points to the rear of the vehicle compartment, Z axis points to the top, four parameters are detected, which are hopper length, hopper bottom distance from ground height, hopper width and hopper height, the four parameters are used to assist in calculating how much bulk material needs to be loaded and as a bulk material level height reference; 3.1) Measure the hopper length: this data is obtained in step 2.2) above; 3.2) Measure the hopper bottom distance from the ground height: take the minimum Z value of the data points in the X coordinate range (-200mm, 200mm) and Y coordinate range (-200mm, 200mm) as the hopper bottom distance from the ground height; 3.3) Measure the hopper width: take the point cloud of the hopper bottom height ±100mm, that is, the data points with Z coordinate in the range of (hopper bottom height-100mm, hopper bottom height+100mm) and Y coordinate in the range of (vehicle compartment front baffle coordinate, vehicle compartment rear baffle coordinate), segment the data points with Y coordinate interval of 500mm, calculate the maximum X coordinate and the minimum X coordinate in each segment, the maximum X - the minimum X is the hopper width of each segment, accumulate the hopper width of each segment divided by the number of segments, and take the final average value as the final hopper width; 3.4) Measure the hopper height: take the data points with Y coordinate in the range of (vehicle compartment front baffle coordinate+200mm, vehicle compartment rear baffle coordinate), segment the data points with Y coordinate interval of 500mm, calculate the maximum Z coordinate in each segment, compare the maximum Z coordinate values in the segments, and take the minimum value as the final hopper height; (4) The level detection stage: the level height is detected in this stage to determine whether it is fully loaded: 4.1) Calculate the center level height: the Y coordinate of the rear part of the discharge port is Yi, take all data points in the X coordinate range (-200mm, 200mm) and Y coordinate range (Yi-200mm, Yi), calculate the minimum Z value of the data points, which is the level height; 4.2) Calculate the level height on both sides: take all data points in the Y coordinate range (Yi-200mm, Yi+200mm), calculate the maximum X and the minimum X, the maximum X is the left side of the hopper, the minimum X is the right side of the hopper, take the minimum Z point in the range of (X minimum, X minimum+200mm) in the existing data points as the level height on the right side of the hopper, and take the minimum Z point in the range of (X maximum-200mm, X maximum) in the existing data points as the level height on the left side of the hopper; 4.3) Fully loaded judgment: when the difference between the level height and the hopper height is greater than the threshold value, it is considered that the bulk material at the position corresponding to the discharge port is full, the vehicle is guided to advance, the center level height is mainly used for load measurement, and the level height on both sides is used to assist in judging whether to spread the material, and the fully loaded is mainly based on the level height on both sides; (5) Tail detection phase: In this phase, the tail position of the car hopper is detected, and the maximum Y coordinate Ym in the detection range is the positioning of the tail. The tail of the low hopper car is lower, and the material pile is easy to fill. The tail of the high hopper car is higher, and the material pile is not easy to fill. The tail condition of the low hopper car is Ym < Yi+400mm, and the tail condition of the high hopper car is Ym < Yi+200mm. If the condition is met, a tail signal is given.

2. The method of automatic bulk loading of wagons as claimed in claim 1, wherein: When starting detection, if the vehicle is in front of the laser radar sensor, continuously judge the characteristics of the car hopper length during the backward process, in order to identify the vehicle length as soon as possible, enter the measurement guide positioning phase, and avoid vehicle movement.

3. The method of automatic bulk loading of railcars as claimed in claim 1, wherein: When starting detection, if the vehicle is directly below or behind the laser, in order to avoid the influence of the vehicle connecting rod part, let the vehicle drive into a relatively forward position.

4. The method of automatic bulk loading of railcars as claimed in claim 1, wherein: Iterative query Y axis minimum value when measuring hopper length.

5. The method of automatic bulk loading of railcars as claimed in claim 1, wherein: When the car hopper size detection phase, if the car is a flip cover car, two automatic opening covers are installed on the top of the flip cover car, and the two covers will be turned to the two sides of the car hopper during loading. The laser radar sensor beam will scan through the gap to the flip cover part, which will affect the vehicle width scanning. Then take the data points with Y coordinates in the range of (car hopper front baffle coordinates, car hopper rear baffle coordinates), and segment every 300mm interval of Y coordinates. Take the data points with X coordinates in (-300mm, 300mm) in each segment to calculate the maximum height Z. If the maximum height Z is greater than the hopper bottom height+200mm, mark the data segment as a segment with reinforcement. Take the data points of the non-reinforced segment along the X coordinate origin to the positive and negative half axes to find the first data point with Z coordinate greater than the hopper bottom height+200mm, which is the coordinate of the two side baffles. The difference between the coordinates of the two side baffles is the width of the segment. Add the hopper width of each non-reinforced segment to the segment number, and take the final average value as the final hopper width.

6. The method of automatic bulk loading of railcars as claimed in claim 1, wherein: When the car hopper size detection phase, if there is a pull rope on the car, the height of the pull rope needs to be filtered, and the height of the car hopper is identified. The height of the pull rope is filtered through the gap between the pull rope and the car hopper. The data points with Y coordinates in the range of (car hopper front baffle coordinates+200mm, car hopper rear baffle coordinates-200mm) and Z coordinates in the range of (hopper bottom height-100mm, 5000mm) are created. An array with a size of 500 is created, with an interval of 1cm. The size 500 is 0-5 meters. Iterate the data points, project all data points into the array, that is, set the array data with each data point Z coordinate value / 10 as the subscript to 1. The maximum subscript value of the array value 1 is Idx. The value in the subscript range (Idx-20, Idx) is 0 if there are 5 consecutive values. The starting value subscript-1 of the continuous 0 in the array corresponds to the final height.

7. The method of automatic bulk loading of railcars as claimed in claim 1, wherein: In the material level detection stage, the material level detection real-time optimization, bulk loading process in the pile material distribution symmetry, half angle output current material level, material level detection when the table rotates ± 45 ° motor angle resolution 1 °, motor speed 30 r / min, 0.25 s to complete a material level output, if not full load to reduce the rotation angle, only measure the center material level height, table ± 10 °, 0.05 s to complete a material level output.

8. The method of automatic bulk loading of railcars as claimed in claim 1, wherein: In the tail detection phase, if the particles of the falling material are fine, dust will float out of the car during the discharging process. The rear of the car tail will detect point cloud data, and the maximum Y value cannot be used to determine the end condition. Under the condition of dust, the laser returns to the ground data point through the dust. At this time, the data of the swing table angle of ± 5° is extracted, the ground data point is obtained, and the Z coordinate value < 400mm data is obtained. Through the smallest Y value in the detection range, the angle of the laser detected in the swing table angle of ± 5° range and the positive lower origin is calculated, , the distance between the bottom of the car tail and the ground is between 1500m and 1600mm, assuming that the height of the bottom of the vehicle is 1550mm, at this time , the positioning of the car tail at this time can be estimated, and the positioning is used for end logic judgment.

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