Remote automatic control system of ship loader

Abstract

A remote automatic control system of a ship loader comprises a laser scanning modeling module, a dynamic data monitoring module, a digital twin simulation module, a safety anti-collision module, an automatic control module, a remote operation module, a video module, a voice module and a material level height detection module. The laser scanning modeling module and the dynamic data monitoring module comprise a plurality of peripheral sensing devices, and the peripheral sensing devices obtain data signals for a first recognition target, a second recognition target and a third recognition target and upload the data signals to the digital twin simulation module; by performing remote automatic system integration on the ship loader, continuity and high efficiency of ship loading operation can be realized, loading and unloading time can be greatly shortened, the throughput of a port can be improved, the ship loader can autonomously complete the ship loading operation at the automatic operation rate of 80%-85% through remote automatic research, the links of manual operation are greatly reduced, and the working efficiency of the ship loader is improved. And the manual intervention rate is lower than 15%, so that the working efficiency is improved.

Description

Technical Field

[0001] The invention relates to the technical field of port loading and unloading, and more specifically to a remote automatic control system for a ship loader. Background Art

[0002] Ports are transport hubs located along the coasts of seas, rivers, lakes and reservoirs, with water-land transport equipment and conditions for ships to enter, exit and berth safely. Ports are the gathering points and hubs of water and land transportation, the distribution centers of industrial and agricultural products and foreign trade import and export materials, and the places where ships berth, load and unload goods, get on and off passengers, and replenish supplies. The construction and development of ports requires certain natural conditions. Superior geographical location, vast water and land areas, necessary berth depth, good weather and other conditions are necessary guarantees for the long-term filling of modern docks. The development of ports also requires developed economic hinterland conditions to provide ports with a stable source of goods.

[0003] At present, most of the bulk cargo loading and unloading in domestic and foreign ports adopts loading and unloading equipment that relies on manual operation. The operating range of the loading and unloading equipment and the movement of each mechanism of the loading and unloading equipment are controlled by the driver through the operating console. The belt conveyor is inspected manually along the belt line. The working environment is harsh and the labor intensity is high. There is only simple interlocking protection between each device, and there is a lack of full-process collaborative operation capabilities. The operation efficiency and safety are entirely dependent on the proficiency and tacit cooperation of the driver and the commander. Summary of the invention

[0004] In order to solve the above problems and overcome the shortcomings of the prior art, the present invention provides a remote automatic control system for a ship loader.

[0005] To achieve the above-mentioned purpose, the present invention provides a remote automation control system for a ship loader, a laser scanning modeling module, a dynamic data monitoring module, a digital twin simulation module, a safety anti-collision module, an automation control module, a remote operation module, a video module, a voice module and a material level height detection module;

[0006] The laser scanning modeling module includes a plurality of peripheral sensing devices, which acquire data signals for the first recognition target, the second recognition target, and the third recognition target and upload them to the digital twin simulation module;

[0007] The dynamic data monitoring module includes a plurality of peripheral sensing devices, which acquire dynamic signals for the first identification target, the second identification target and the third identification target and upload them to the digital twin simulation module;

[0008] The digital twin simulation module obtains data signals and dynamic signals from the laser scanning modeling module and the dynamic data monitoring module for simulation, and performs operation analysis, fault prediction and fault location;

[0009] The safety anti-collision module includes an anti-collision warning unit, an anti-collision analysis unit and a parameter verification unit. It combines the dynamic data obtained by the dynamic data monitoring module and the data signal obtained by the laser scanning modeling module to realize collision warning analysis and rapid positioning of the collision position through online simulation, and feeds back the collision analysis results to the automation control module.

[0010] The automation control module obtains the collision analysis results, issues interactive operation instructions to multiple ship loaders based on the collision warning analysis and collision position rapid positioning results, adjusts the working status of the ship loaders in real time, and realizes one-to-many production scheduling, task distribution, coordinated full-automatic operation of multiple ship loaders, and safe collision avoidance strategies for multiple ship loaders. The working status includes the travel speed, travel path, chute position, and belt conveyor running speed of multiple ship loaders.

[0011] The remote operation module includes a remote operation console and a PLC remote station installed in the central control room, which are used to send control instructions from each operation console to the automation control module, which then forwards the instructions to the control center of each ship loader to execute the relevant control instructions, thereby realizing remote operation;

[0012] The material level detection module includes at least two radar level meters, which are installed at the chute position to detect the material height in the cabin and transmit the data signal to the digital twin simulation module for real-time simulation.

[0013] Furthermore, the first recognition target includes the ship window position, the ship side height, the hatch cover height and the material, and the scanning coverage area of ​​the 3D laser scanner includes the hatch and the material operation area.

[0014] Furthermore, the second identification target includes the position of the chute and the position of the trolley traveling mechanism.

[0015] Furthermore, the third identification target includes solid obstacles in the site other than the first identification target or the second identification target. When a solid obstacle is detected, the loader stops the current action until the safety anti-collision module detects that the obstacle disappears and issues instructions through the automation control module, and the loader automatically continues to perform the previous operation task.

[0016] Furthermore, it also includes a data storage module. The data signals and action signals of the laser scanning modeling module, the dynamic data monitoring module and the material level height detection module are synchronously sampled and stored, and the data storage module stores the data signals and action signals in real time.

[0017] Furthermore, the anti-collision warning unit compares the dynamic data collected by the dynamic data monitoring module with the simulation model established by the digital twin simulation module through real-time simulation, and sends warning information to the anti-collision analysis unit when the comparison result exceeds the preset threshold range;

[0018] After receiving the warning information from the anti-collision warning unit, the anti-collision analysis unit performs analysis according to the preset anti-collision analysis strategy to quickly locate the collision position;

[0019] Among them, the preset anti-collision analysis strategies include soft anti-collision strategy, trolley anti-collision strategy, communication abnormality protection strategy and hull balance detection strategy. The soft anti-collision strategy is to return the position information of the ship loader in real time and compare it with the limit position of the track. When the ship loader reaches the limit position, the trolley automatically stops and generates a warning message; the trolley anti-collision strategy is to automatically slow down and stop when an obstacle is detected, and display the fault and alarm in the central control room to achieve regional protection in the direction of the trolley's movement. The detection range of the trolley anti-collision strategy is 2 meters on both sides of the track and an effective distance of 14 meters in the forward direction. When the distance is 6 meters, it starts to slow down and stop, and emergency stop when the distance is less than 2 meters. After the trolley slows down and stops, the PLC remote station is self-locked and will not reset automatically. When it stops completely, the fault display screen in the remote control room has a fault and an alarm; the communication abnormality strategy is to establish a network heartbeat detection. When the communication network between the ship loader and the central control room is abnormal, an alarm is issued and the system operation is stopped; the hull balance detection strategy is to detect the changes in the ship's loading posture in real time, analyze the ship's front and rear tilt angles and left and right tilt angles by extracting feature points, and provide real-time feedback and warning through the tilt angle.

[0020] Furthermore, the voice module includes a desktop intercom terminal installed in the central control room and a power amplifier and a loudspeaker installed in the ship loader, which are used to enable the central control room to shout instructions to the site.

[0021] Furthermore, the video module includes no less than 20 cameras for transmitting video signals to the central control room for centralized display. The video signals include the trolley track, belt operation, cargo conditions in the cabin and operation of key mechanisms of the loader.

[0022] Furthermore, the peripheral sensing devices include a multi-turn absolute encoder, an RFID magnetic nail device, a 3D laser scanner, a radar level meter and an inclination sensor.

[0023] The beneficial effects of the present invention are

[0024] It realizes the construction of 1 control 3 functions, that is, it can control three ship loaders at the same time without adjusting the operating table. It has multiple modes of 1 control 2, 1 control 3, 2 control 3, and 3 control 3. The functions of 1 control 2 and 2 control 3 are mainly used during use. When one person operates remotely, multiple devices can be monitored on one operating table at the same time; when one person operates remotely, the reminder alarm function is realized when 60%-80% of the loading is completed, and the time interval between the time requiring manual intervention and the automatic operation is intelligently pushed, realizing one control and multiple functions. When one or two devices both issue instructions that require operation, they are controlled in sequence. Real-time update of laser scanning of the hull is realized, and the accuracy of the hull coordinate position is high. If the hull is offset or tilted, an alarm prompt function is issued. After manual access, automatic loading is restored, with the aim of improving loading quality and reducing the risk of spillage.

[0025] Improve loading and unloading efficiency: By integrating the remote automation system of the loader, the continuity and efficiency of the loading operation can be achieved, the loading and unloading time can be greatly shortened, and the port's throughput can be increased. Through remote automation research, the loader can independently complete the loading operation with an automation rate of 80%-85%, which greatly reduces the manual operation links and the manual intervention rate is less than 15%, thereby improving work efficiency.

[0026] Reduce operating costs: Automation technology can reduce dependence on human resources and reduce labor costs. At the same time, by precisely controlling the operation of the ship loader, it can reduce energy consumption and equipment wear, further reducing operating costs.

[0027] Enhanced safety: The automated control system has higher accuracy and reliability, which can reduce the safety risks caused by human operating errors. Through remote monitoring and fault diagnosis systems, potential safety hazards can be discovered and dealt with in a timely manner to ensure the safety and stability of loading operations.

[0028] Promoting intelligent development: This project is an important part of the intelligent development of ports. By studying automation technology and intelligent management systems, it can promote the development of ports towards a higher level of intelligence and automation. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Attached Figure 1 It is a system structure diagram of the present invention; DETAILED DESCRIPTION

[0030] In order to make the purpose, technical scheme and advantages of the present invention more clear, the following will be combined with the appended claims of the present invention. Figure 1 , the present invention is described in more detail.

[0031] The present invention provides a remote automation control system for a ship loader, comprising a laser scanning modeling module, a dynamic data monitoring module, a digital twin simulation module, a safety anti-collision module, an automation control module, a remote operation module, a video module, a voice module and a material level detection module; the laser scanning modeling module comprises a plurality of peripheral sensing devices, which acquire data signals for a first recognition target, a second recognition target and a third recognition target and upload the data signals to the digital twin simulation module; the dynamic data monitoring module comprises a plurality of peripheral sensing devices, which acquire dynamic signals for the first recognition target, the second recognition target and the third recognition target and upload the data signals to the digital twin simulation module; the digital twin simulation module acquires data from the laser The data signals and dynamic signals of the scanning modeling module and the dynamic data monitoring module are simulated, and operation analysis, fault prediction and fault location are performed; the safety anti-collision module includes an anti-collision warning unit, an anti-collision analysis unit and a parameter verification unit. Combined with the dynamic data obtained by the dynamic data monitoring module and the data signal obtained by the laser scanning modeling module, collision warning analysis and rapid positioning of the collision position are realized through online simulation, and the collision analysis results are fed back to the automatic control module; the automatic control module obtains the collision analysis results, and according to the collision warning analysis and the rapid positioning results of the collision position, interactive operation instructions are issued to multiple ship loaders, and the working status of the ship loaders is adjusted in real time, realizing one-to-many production scheduling, operation task issuance, and multiple The ship loader cooperates with fully automatic operation and multiple ship loaders with safe anti-collision strategies. The working status includes the travel speed, travel path, chute position and belt conveyor running speed of multiple ship loaders. The remote operation module includes a remote operation console and a PLC remote station installed in the central control room, which is used to send the control instructions of each operation console to the automation control module, and the automation control module forwards the instructions to the control center of each ship loader to execute the relevant control instructions to achieve remote operation. The material level detection module includes at least two radar level meters, which are installed at the chute position to detect the height of the cabin material and transmit the data signal to the digital twin simulation module for real-time simulation. The first identification target includes the ship window position and the ship side height. , hatch cover height and materials. The scanning coverage area of ​​the 3D laser scanner includes the hatch and material operation area; the second identification target includes the chute position and the trolley travel mechanism position; the third identification target includes solid obstacles in the site other than the first identification target or the second identification target. When a solid obstacle is detected, the loader stops the current action until the safety anti-collision module detects that the obstacle disappears and issues instructions through the automation control module, and the loader automatically continues to perform the previous operation task; it also includes a data storage module. The data signals and action signals of the laser scanning modeling module, the dynamic data monitoring module and the material level height detection module are synchronously sampled and stored. The data storage module stores the data signals and action signals in real time;The anti-collision warning unit compares the dynamic data collected by the dynamic data monitoring module with the simulation model established by the digital twin simulation module through real-time simulation. When the comparison result exceeds the preset threshold range, a warning message is sent to the anti-collision analysis unit. After receiving the warning message sent by the anti-collision warning unit, the anti-collision analysis unit performs analysis according to the preset anti-collision analysis strategy to quickly locate the collision position. Among them, the preset anti-collision analysis strategy includes soft anti-collision strategy, trolley anti-collision strategy, communication abnormality protection strategy and hull balance detection strategy. The soft anti-collision strategy returns the position information of the loader in real time and compares it with the limit position of the track. When the loader reaches the limit position, the trolley automatically stops and generates a warning message. The trolley anti-collision strategy is to automatically slow down and stop when an obstacle is detected, and display the fault and alarm in the central control room to achieve regional protection in the direction of the trolley's travel. The detection range of the trolley anti-collision strategy is 2 meters on both sides of the track and an effective distance of 14 meters in the forward direction. When the distance is 6 meters, it starts to slow down and stop, and the distance is less than 2 meters When the vehicle is in emergency stop mode, the PLC remote station will be self-locked after the trolley decelerates and stops, and will not automatically reset. When the vehicle stops completely, the fault display screen in the remote control room will have a fault and alarm. The communication abnormality strategy is to establish a network heartbeat detection. When the communication network between the loader and the central control room is abnormal, an alarm will be issued and the system will be stopped. The hull balance detection strategy is to detect the changes in the ship loading posture in real time, analyze the ship's front and rear tilt angles and left and right tilt angles by extracting feature points, and provide real-time feedback and warning through the tilt angle. The voice module includes a desktop intercom terminal installed in the central control room and an amplifier and speaker installed in the loader, which are used to realize the central control room's command shouting to the site. The video module includes no less than 20 cameras, which are used to transmit video signals to the central control room for centralized display. The video signals include the trolley running track, the belt running status, the cargo status in the cabin, and the operation status of the key mechanisms of the loader. The peripheral sensing equipment includes a multi-turn absolute encoder, an RFID magnetic nail device, a 3D laser scanner, a radar level meter, and an inclination sensor. ;

[0032] Embodiment 1 is as follows:

[0033] A remote automation control system for a ship loader, laser scanning modeling module, dynamic data monitoring module, digital twin simulation module, safety anti-collision module, automation control module, remote operation module, video module, voice module and material level height detection module, the main working forms include:

[0034] 1. Condition monitoring and anti-collision identification: collect equipment operating parameters in real time through various peripheral sensing devices, and input them into the digital twin model to evaluate the working status.

[0035] 2. Collision simulation: simulate potential collision risks in real time in the digital twin simulation model, observe, record and intelligently learn the response of each parameter, establish a collision risk database for deep intelligent learning, and optimize the accuracy and intelligence of collision risk warning.

[0036] 3. Digital twin system integration: multiple ship loaders are in the same digital twin simulation model, so that one operator can achieve "one-to-many" and "many-to-many" operation modes with the assistance of the automation control module, thereby improving overall operational efficiency.

[0037] The laser scanning modeling module includes a plurality of peripheral sensing devices, which acquire data signals for the first recognition target, the second recognition target, and the third recognition target and upload them to the digital twin simulation module;

[0038] The dynamic data monitoring module includes a plurality of peripheral sensing devices, which acquire dynamic signals for the first identification target, the second identification target and the third identification target and upload them to the digital twin simulation module;

[0039] The peripheral sensing equipment includes multi-turn absolute encoders, RFID magnetic nail devices, 3D laser scanners, radar level meters and inclination sensors. The multi-turn absolute encoders are used in a single mechanism positioning detection system, which includes three parts: positioning detection of the chute telescopic mechanism, which uses a multi-turn absolute encoder to calculate the running distance of the chute telescopic mechanism, and the positioning error is not greater than ±30mm; positioning detection of the boom telescopic mechanism, which uses a multi-turn absolute encoder to calculate the running distance of the boom telescopic mechanism, and the absolute encoder is calibrated through the proximity switch, and the positioning error is not greater than ±30mm; positioning detection of the walking mechanism, which uses a multi-turn absolute encoder to calculate the walking position of the trolley, and the absolute encoder is calibrated through the RFID magnetic nail device, and the positioning error is not greater than ±30mm.

[0040] The RFID magnetic nail device is used for numerical calibration in the positioning detection of the walking mechanism. A multi-turn absolute encoder is used to calculate the walking position of the trolley, and then the absolute encoder is calibrated through the RFID magnetic nail device. The positioning error is no more than ±30mm.

[0041] 3D laser scanners are used for the soft collision avoidance function and large vehicle collision avoidance function of the laser scanning modeling system and the safety collision avoidance system. For the laser scanning modeling system, at least two laser scanning devices are installed on the machine to identify the targets to be identified. The targets to be identified include: ship hatch position, ship side height, hatch cover height, and material identification. The scanning area covers the hatch and the materials in the operation area. To ensure the integrity of the data collection of the identified targets, the data is connected to the digital twin simulation module for modeling.

[0042] The soft anti-collision function of the safety anti-collision system obtains information about the cabin, materials, warehouse partitions, and hull through 3D laser scanning, that is, the dynamic signal obtained by the dynamic data monitoring module, to avoid collision between the chute and them. The position information of the loader is returned in real time through the positioning detection of the loader, and compared with the limit position of the track. When the loader reaches the limit position, the trolley automatically stops and generates a warning message, making the limit position protection of the loader safer and more reliable.

[0043] In order to realize the trolley anti-collision function of the safety anti-collision system, no less than 4 laser scanners are installed on the traveling mechanism, and their signals are connected to the automation control module. When an obstacle is detected, the vehicle will automatically slow down and stop, and the fault will be displayed and an alarm will be issued in the central control room to realize regional protection in the traveling direction of the trolley. The detection range of the trolley anti-collision strategy is 2 meters on both sides of the track and an effective distance of 14 meters in the forward direction. When the distance is 6 meters, it will start to slow down and stop, and emergency stop will be made when the distance is less than 2 meters. After the trolley decelerates and the stop signal is actuated, the PLC remote station will be self-locked and will not reset automatically. When it stops completely, the fault display screen in the remote control room will show a fault and an alarm will be issued.

[0044] Radar level meter is used in material level height detection system. No less than 2 high-frequency radar level meters are installed at appropriate positions near the chute to detect the height of materials in the cabin. The range of radar level meter is not less than 50m.

[0045] The inclination sensor is used for hull balance detection. The inclination sensor can detect the changes in the ship's loading posture in real time, analyze the ship's front and rear inclination angles and left and right inclination angles by extracting feature points, provide real-time feedback and early warning through the inclination angle, and ensure safe production by adjusting the loading position.

[0046] The first recognition targets include the position of ship windows, ship side height, hatch cover height and materials. The scanning coverage area of ​​the 3D laser scanner includes hatches and material operation areas, which can cover the port operation area, complete simulation modeling, and improve the integrity of the simulation model.

[0047] The second identification target includes the position of the chute and the trolley walking mechanism, mainly targeting the operating equipment, collecting information such as the position, walking path, height, length, etc. of the operating equipment, collecting dynamic information, and complete real-time simulation modeling. The coordination and synchronization of the simulation model and the actual situation have been determined.

[0048] The third identification target includes solid obstacles in the site other than the first identification target or the second identification target. When a solid obstacle is detected, the loader stops the current action until the safety anti-collision module detects that the obstacle disappears and issues instructions through the automation control module, and the loader automatically continues to perform the previous operation task.

[0049] The digital twin simulation module obtains the data signals and dynamic signals from the laser scanning modeling module and the dynamic data monitoring module for simulation, and performs operation analysis, fault prediction and fault location. The modeling tool can use MATLAB and Simulink tools to pre-process the collected data signals and dynamic signals by removing outliers and filling missing values.

[0050] The safety anti-collision module includes an anti-collision warning unit, an anti-collision analysis unit and a parameter verification unit. It combines the dynamic data obtained by the dynamic data monitoring module and the data signal obtained by the laser scanning modeling module to realize collision warning analysis and rapid positioning of the collision position through online simulation, and feeds back the collision analysis results to the automation control module.

[0051] The anti-collision warning unit compares the dynamic data collected by the dynamic data monitoring module with the simulation model established by the digital twin simulation module through real-time simulation. When the comparison result exceeds the preset threshold range, the warning information is sent to the anti-collision analysis unit;

[0052] After receiving the warning information from the anti-collision warning unit, the anti-collision analysis unit performs analysis according to the preset anti-collision analysis strategy to quickly locate the collision position;

[0053] Among them, the preset anti-collision analysis strategies include soft anti-collision strategy, trolley anti-collision strategy, communication abnormality protection strategy and hull balance detection strategy. The soft anti-collision strategy is to return the position information of the ship loader in real time and compare it with the limit position of the track. When the ship loader reaches the limit position, the trolley automatically stops and generates a warning message; the trolley anti-collision strategy is to automatically slow down and stop when an obstacle is detected, and display the fault and alarm in the central control room to achieve regional protection in the direction of the trolley's movement. The detection range of the trolley anti-collision strategy is 2 meters on both sides of the track and an effective distance of 14 meters in the forward direction. When the distance is 6 meters, it starts to slow down and stop, and emergency stop when the distance is less than 2 meters. After the trolley slows down and stops, the PLC remote station is self-locked and will not reset automatically. When it stops completely, the fault display screen in the remote control room has a fault and an alarm; the communication abnormality strategy is to establish a network heartbeat detection. When the communication network between the ship loader and the central control room is abnormal, an alarm is issued and the system operation is stopped; the hull balance detection strategy is to detect the changes in the ship's loading posture in real time, analyze the ship's front and rear tilt angles and left and right tilt angles by extracting feature points, and provide real-time feedback and warning through the tilt angle.

[0054] An onboard automatic control system is added to the ship loader to realize functions such as location information acquisition and automatic control of each mechanism, and is connected to the original control system of the ship loader. When a fault occurs, it will not affect the operation of the original control system of the ship loader. The automatic control module obtains the collision analysis results, and issues interactive operation instructions to multiple ship loaders based on the collision warning analysis and the rapid positioning results of the collision position, and adjusts the working status of the ship loaders in real time, realizing one-to-many production scheduling, operation task issuance, coordinated full-automatic operation of multiple ship loaders, and safe collision avoidance strategies for multiple ship loaders. The working status includes the walking speed, walking path, chute position, and belt conveyor running speed of multiple ship loaders.

[0055] The remote operation module includes a remote operation console and a PLC remote station installed in the central control room, which are used to send control instructions from each operation console to the automation control module, which then forwards the instructions to the control center of each ship loader to execute the relevant control instructions, thereby realizing remote operation;

[0056] Three new remote control consoles have been added to the central control room, which can be integrated with the existing remote control consoles of automated ship loaders to achieve one-to-many and many-to-many operation functions. Any console can be used alone and can control other ship loaders outside the console. If one console fails, it will not affect the normal operation of other consoles. Any console can be offline when idle and out of working state.

[0057] The remote operation console also has the following basic functions:

[0058] ①The handles, buttons, and indicator lights used in the remote control console meet the grade requirements of industrial control. The layout of the operating components and displays is compact, and the height of the table can be adjusted according to needs, which is convenient for the driver to operate and meets the needs of long-term continuous operation.

[0059] ②An emergency stop button is set on the remote operating console. When a special situation occurs, all actions of the ship loader can be stopped immediately and the machine will enter a locked state waiting for manual intervention.

[0060] ③The power supply of the remote operation console comes from UPS to ensure AC power supply. When the power supply is suddenly cut off, it can store the current data and allow the operator to stop the operation of all ship loaders.

[0061] A server cabinet is installed in the central control room, which contains the core switch, fiber distribution frame, remote control server and other types of servers. The power supply of the server cabinet comes from UPS, which provides power for the switch and each server. When the power supply system fails, UPS can continuously supply power to the central control room, allowing the operator to complete the current operation instructions and shut down, save the current data, and shut down the server. UPS can provide the central control room console and server cabinet with a battery life of no less than 30 minutes. Multiple ship loaders can share one server cabinet.

[0062] The material level detection module includes at least two radar level meters, which are installed at the chute position to detect the height of the cabin materials and transmit the data signals to the digital twin simulation module for real-time simulation. The range of the radar level meter is not less than 50m.

[0063] In order to meet the needs of remote control and enable the central control room to speak to the site, a voice module needs to be installed. The voice module includes a desktop intercom terminal installed in the central control room and an amplifier and speaker installed on the ship loader. The voice system includes a desktop intercom terminal installed in the central control room and an amplifier and speaker installed on the host. The speaker power is not less than 80W to meet the needs of the on-site environment.

[0064] The video module includes no less than 20 cameras, which are used to transmit video signals to the central control room for centralized display. The video signals include the running track of the trolley, the running status of the belt, the cargo situation in the cabin, and the running status of the key mechanism of the loader. The video monitoring system, as an auxiliary monitoring system of the automatic control system, also plays a very important role. When the remote control operator is operating manually, he relies on the video monitoring screen to monitor the on-site situation. Therefore, the video system should ensure the reliability and stability of the video monitoring and ensure the clarity and smoothness of the video monitoring screen in the remote control room. The video system needs to display the running track of the trolley, the running status of the belt, the cargo situation in the cabin, the running status of the key mechanism of the loader, etc. at the front of the console in the central control room, and install no less than 20 cameras. The pixel of the camera is not less than 200W, the pixel of the ball camera is not less than 400W, and the image delay value is less than 250ms. The video system is stored in the hard disk recorder, and the video monitoring image is stored in H.264 or H.265 code stream, and the storage time is not less than 30 days.

[0065] It also includes a data storage module. The data signals and action signals of the laser scanning modeling module, the dynamic data monitoring module and the material level height detection module are sampled and stored synchronously. The data storage module stores the data signals and action signals in real time.

[0066] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A remote automatic control system for a ship loader, characterized in that: Laser scanning modeling module, dynamic data monitoring module, digital twin simulation module, safety anti-collision module, automation control module, remote operation module, video module, voice module and material level height detection module; The laser scanning modeling module includes a plurality of peripheral sensing devices, which acquire data signals for the first recognition target, the second recognition target, and the third recognition target and upload them to the digital twin simulation module; The dynamic data monitoring module includes a plurality of peripheral sensing devices, which acquire dynamic signals for the first identification target, the second identification target and the third identification target and upload them to the digital twin simulation module; The digital twin simulation module acquires data signals and dynamic signals from the laser scanning modeling module and the dynamic data monitoring module for simulation, and performs operation analysis, fault prediction and fault location; The safety anti-collision module includes an anti-collision warning unit, an anti-collision analysis unit and a parameter verification unit. It combines the dynamic data obtained by the dynamic data monitoring module and the data signal obtained by the laser scanning modeling module to realize collision warning analysis and rapid positioning of the collision position through online simulation, and feeds back the collision analysis results to the automatic control module; The automatic control module obtains the collision analysis results, issues interactive operation instructions to multiple ship loaders based on the collision warning analysis and the rapid positioning results of the collision position, adjusts the working status of the ship loaders in real time, and realizes one-to-many production scheduling, operation task issuance, multiple ship loaders coordinated fully automatic operation and multiple ship loaders safe collision avoidance strategy. The working status includes the travel speed, travel path, chute position and belt conveyor running speed of multiple ship loaders; The remote operation module includes a remote operation console and a PLC remote station installed in the central control room, which are used to send control instructions from each operation console to the automation control module, which then forwards the instructions to the control center of each ship loader to execute the relevant control instructions, thereby realizing remote operation; The material level detection module includes at least two radar level meters, which are installed at the chute position to detect the height of the cabin material and transmit the data signal to the digital twin simulation module for real-time simulation.

2. The ship loader remote automation control system according to claim 1, characterized in that: The first recognition targets include the ship window position, the ship side height, the hatch cover height and the materials, and the scanning coverage area of ​​the three-dimensional laser scanner includes the hatch and the material operation area.

3. The ship loader remote automation control system according to claim 1, characterized in that: The second identification target includes the position of the chute and the position of the trolley traveling mechanism.

4. The ship loader remote automation control system according to claim 1, characterized in that: The third identification target includes solid obstacles in the site other than the first identification target or the second identification target. When a solid obstacle is detected, the loader stops the current action until the safety anti-collision module detects that the obstacle disappears and issues instructions through the automation control module, and the loader automatically continues to perform the previous operation task.

5. The ship loader remote automation control system according to claim 1, characterized in that: It also includes a data storage module. The data signals and action signals of the laser scanning modeling module, the dynamic data monitoring module and the material level height detection module are sampled and stored synchronously. The data storage module stores the data signals and action signals in real time.

6. The ship loader remote automation control system according to claim 1, characterized in that: The anti-collision warning unit compares the dynamic data collected by the dynamic data monitoring module with the simulation model established by the digital twin simulation module through real-time simulation, and sends warning information to the anti-collision analysis unit when the comparison result exceeds a preset threshold range; After receiving the warning information sent by the anti-collision warning unit, the anti-collision analysis unit performs analysis according to the preset anti-collision analysis strategy to quickly locate the collision position; Among them, the preset anti-collision analysis strategy includes soft anti-collision strategy, trolley anti-collision strategy, communication abnormality protection strategy and hull balance detection strategy. The soft anti-collision strategy is to return the position information of the ship loader in real time and compare it with the limit position of the track. When the ship loader reaches the limit position, the trolley automatically stops and generates a warning message; the trolley anti-collision strategy is to automatically slow down and stop when an obstacle is detected, and display the fault and alarm in the central control room to achieve regional protection in the direction of the trolley's movement. The detection range of the trolley anti-collision strategy is 2 meters on both sides of the track and 14 meters in the forward direction. When the distance is 6 meters, it starts to slow down and stop. When the distance is less than 2 meters, it stops urgently. After the trolley slows down and stops, the PLC remote station is self-locked and will not reset automatically. When it stops completely, the fault display screen in the remote control room has a fault and an alarm; the communication abnormality strategy is to establish a network heartbeat detection. When the communication network between the ship loader and the central control room is abnormal, an alarm is issued and the system stops running; the hull balance detection strategy is to detect the changes in the loading posture of the ship in real time, analyze the front and rear tilt angles and left and right tilt angles of the ship by extracting feature points, and give real-time feedback and warning through the tilt angle.

7. The ship loader remote automation control system according to claim 1, characterized in that: The voice module includes a desktop intercom terminal installed in the central control room and a power amplifier and a loudspeaker installed in the ship loader, which are used to enable the central control room to shout instructions to the site.

8. The ship loader remote automation control system according to claim 1, characterized in that: The video module includes no less than 20 cameras, which are used to transmit video signals to the central control room for centralized display. The video signals include the trolley running track, belt running status, cargo status in the cabin and the operation status of key mechanisms of the loader.

9. The ship loader remote automation control system according to claim 1, characterized in that: The peripheral sensing equipment includes a multi-turn absolute encoder, an RFID magnetic nail device, a 3D laser scanner, a radar level meter and an inclination sensor.

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