Remote control system with automatic excavating function for bucket-wheel excavator

Abstract

The invention discloses a remote control system with an automatic excavation function for a bucket-wheel excavator, and relates to the technical field of excavator control, which comprises the following steps of: S1, accurately surveying and mapping a stock ground by using a surveying and mapping technology, acquiring geographic coordinates and topographic data of the stock ground, generating a stock ground coordinate system, and performing remote control on a remote control server; establishing a three-dimensional stockyard coordinate system according to the surveying and mapping data, and performing data modeling on the three-dimensional stockyard coordinate system; s2, position data of the bucket-wheel excavator are obtained in real time, the bucket-wheel excavator corresponds to the stock ground coordinate system, and the current position of the bucket-wheel excavator in the stock ground coordinate system is calculated; s3, acquiring a corresponding rotation angle when the position of the bucket-wheel excavator changes, and identifying a target working area corresponding to the rotation angle; s4, the state of the bucket-wheel excavator in the target working area is obtained, the current advancing distance and the current rotation angle are recognized, and the control mode of the bucket-wheel excavator is determined; the working efficiency and accuracy of the excavator can be improved.

Description

Technical Field

[0001] The invention relates to the technical field of excavator control, and in particular to a remote control system with an automatic excavation function for a bucket wheel excavator. Background Art

[0002] Bucket wheel excavator is a key equipment for continuous mining and semi-continuous mining in open pit mines. Bucket wheel excavator is a multi-bucket excavator that uses multiple buckets installed on the rotating wheel at the front end of the boom for continuous excavation. It is used for excavation of large amounts of earth, stripping and mining in mines, and loading and unloading operations in large material yards. It has high productivity and large excavation force. It can directly excavate harder soil. It is an ideal multi-bucket excavation equipment in continuous operation equipment and one of the largest complete excavation equipment in the world.

[0003] Bucket-wheel excavators need to accurately locate the material-retrieving point during operation. However, due to their complex structure, including the transfer machine, connecting bridge, crawler walking mechanism, slewing mechanism and pitch mechanism, etc., multiple mechanisms that need to be positioned make the accurate positioning of the material-retrieving point a technical challenge. Summary of the invention

[0004] The embodiment of the present application solves the technical problem of difficulty in locating the material taking point in the prior art by providing a remote control system for a bucket wheel excavator with an automatic excavation function, thereby improving the accuracy of positioning.

[0005] The embodiment of the present application provides a remote control system for a bucket wheel excavator with an automatic excavation function, comprising:

[0006] Step S1, using surveying and mapping technology to accurately survey the material yard, obtain the geographical coordinates and terrain data of the material yard, generate a material yard coordinate system, establish a three-dimensional material yard coordinate system on the remote control server according to the surveying and mapping data, and perform data modeling on it;

[0007] Step S2, acquiring the position data of the bucket wheel excavator in real time, matching the bucket wheel excavator with the material yard coordinate system, and calculating the current position of the bucket wheel excavator in the material yard coordinate system;

[0008] Step S3, obtaining the corresponding rotation angle of the bucket wheel excavator when the position changes, and identifying the target working area corresponding to the rotation angle;

[0009] Step S4, obtaining the state of the bucket wheel excavator in the target working area, identifying the current forward distance and rotation angle, and determining the control mode of the bucket wheel excavator.

[0010] One or more technical solutions provided in the embodiments of the present application have at least the following technical effects or advantages:

[0011] By acquiring the state of the bucket wheel excavator in the target working area, identifying the forward distance and the rotation angle, and determining the control mode of the excavator; at the same time, determining the priority of the control mode based on the priority of the flag position, the intelligent control and mode optimization of the excavator are realized; it is able to identify the direction of the excavator's movement, and determine the rotatable angle in this direction and the movable angle on the second flag position relative to the first flag position; this provides a basis for realizing precise angle adjustment and path planning of the excavator; and realizes efficient work path planning and workload management of the excavator. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 A system schematic diagram of a remote control system for a bucket wheel excavator with an automatic excavation function according to the present invention;

[0013] Figure 2 This is an example schematic diagram of a remote control system for a bucket wheel excavator with an automatic excavation function according to the present invention. DETAILED DESCRIPTION

[0014] To facilitate the understanding of the present invention, the present application will be described more comprehensively below with reference to the relevant drawings; the drawings show preferred embodiments of the present invention, but the present invention can be implemented in many different forms and is not limited to the embodiments described herein; on the contrary, the purpose of providing these embodiments is to enable a more thorough and comprehensive understanding of the disclosed content of the present invention.

[0015] It should be noted that the terms “vertical”, “horizontal”, “up”, “down”, “left”, “right” and similar expressions used in this document are only for illustrative purposes and do not represent the only implementation method.

[0016] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by technicians in the technical field to which the present invention belongs; the terms used in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention; the term "and / or" used herein includes any and all combinations of one or more related listed items.

[0017] Embodiment 1

[0018] like Figure 1 , Figure 2 As shown, the present application provides a remote control system for a bucket wheel excavator with an automatic excavation function, comprising:

[0019] Step S1, use surveying and mapping technology to accurately map the material yard, obtain the geographical coordinates and terrain data of the material yard, generate the material yard coordinate system, establish a three-dimensional material yard coordinate system on the remote control server according to the surveying and mapping data, and perform data modeling on it.

[0020] Step S2, acquiring the position data of the bucket wheel excavator in real time, matching the bucket wheel excavator with the material yard coordinate system, and calculating the current position of the bucket wheel excavator in the material yard coordinate system.

[0021] Step S3, obtaining the corresponding rotation angle of the bucket wheel excavator when the position changes, and identifying the target working area corresponding to the rotation angle;

[0022] Step S4, obtaining the state of the bucket wheel excavator in the target working area, identifying the current forward distance and rotation angle, and determining the control mode of the bucket wheel excavator.

[0023] First, surveying personnel use drones or ground surveying equipment to survey the material yard to obtain high-precision terrain data and boundary coordinates; use professional 3D modeling software on the remote server to build a virtual model of the material yard based on the surveying data, and the remote server calculates the current specific position of the bucket wheel excavator (such as X, Y coordinates) based on the material yard coordinate system and Beidou positioning data; at this time, the bucket wheel excavator is controlled by installing electronic compass sensors at appropriate positions on the center line of the slewing platform of the cantilever boom and the connecting bridge; with the horizontal direction of the system belt as the reference, locate the zero degree of rotation, and obtain the rotation angle of the cantilever boom and the connecting bridge in real time through the electronic compass sensor; the sensor sends the rotation angle data of the cantilever boom and the connecting bridge to the PLC and the remote server in real time.

[0024] The operator selects the location to be operated on the remote server. The system calculates parameters such as the forward distance and the rotation angle according to the location selected by the operator and the current location of the bucket-wheel excavator. According to the received instructions, the bucket-wheel excavator is automatically controlled to perform operations such as addressing and material taking. This includes the rotation of the cantilever boom and the raising and lowering of the pitch mechanism, to determine the movement mode and working status of the bucket-wheel excavator during the current operation.

[0025] The bucket wheel mechanism is installed at the front end of the cantilever boom, and the rear end of the cantilever boom is hinged to the excavator body, and the material is conveyed to the subsequent system through the cantilever conveyor belt; the crawler walking mechanism supports the entire excavator and provides mobility; the turntable mechanism is connected to the base through a slewing bearing to achieve 360-degree rotation; the wire rope winch mechanism controls the lifting of components; and the receiving belt conveyor, unloading belt conveyor and transfer mechanism are mechanically connected, bonded, etc. to ensure the smooth transmission of materials inside the excavator and between other equipment.

[0026] The bucket wheel mechanism consists of a hydraulic motor, a bucket wheel reducer, a bucket wheel shaft, a bucket wheel body and a bucket, and is driven by a hydraulic system and a mechanical transmission system.

[0027] When the bucket wheel excavator is working, it mainly controls the current processing method according to the current working position and the distance to the target position through multiple groups of structures. If multiple groups of moving coordinates are obtained, the bucket wheel excavator can control the corresponding rotating and moving components according to the positions of the corresponding coordinates, and find the most suitable coordinate position for the work according to the joint operation of these components.

[0028] Preferably, the initial rotation center coordinates (X1, Y1) of the bucket wheel excavator, the rotation center coordinates (X2, Y2) of the bucket wheel excavator after moving forward, the mine boundary coordinates (X0, Y0), the initial layer opening angle α, and the layer opening angle β after moving forward are obtained; the corresponding working angles are set to determine the forward distance of the bucket wheel excavator.

[0029] Then the control mode of bucket wheel excavator includes:

[0030] Obtain the value of the corresponding mark position under each control mode, obtain the image data of the first mark position, wherein the image data of the first mark position is used to determine the current initial rotation position coordinates, and obtain the image data of the second mark position, wherein the second mark position is used to determine the position that can be reached after moving.

[0031] Determine the relative position of the bucket-wheel excavator on the first mark position, determine the moving trajectory of the bucket-wheel excavator on the adjacent first mark position, determine the corresponding position change when the bucket-wheel excavator moves, and determine the priority of the first mark position based on the corresponding position change, and determine the priority of the control mode according to the priority of the first mark position.

[0032] Identify specific feature points on the marker through image processing techniques (such as edge detection, feature extraction, etc.); based on the coordinates of the feature points in the image and in combination with the internal and external parameters of the camera, use camera calibration technology to convert the image coordinates into actual three-dimensional world coordinates to determine the current initial rotation position coordinates (X1, Y1); similarly, capture the image of the second marker; identify the feature points, and convert the image coordinates into three-dimensional world coordinates to determine the position coordinates (X2, Y2) that can be reached after the move.

[0033] Assuming that the angle between the forward direction of the bucket wheel excavator and the positive direction of the X axis is θ, θ can be calculated by the following formula:

[0034]

[0035] After obtaining the moving distance of the bucket wheel excavator, the relative position and moving trajectory of the bucket wheel excavator are determined according to the initial layer opening angle, the change of the layer opening angle after moving forward, and the change of the corresponding working axis direction.

[0036] Determine the changes in the initial layer opening angle and the layer opening angle after advancement by calculating the average values ​​of the initial layer opening angle and the layer opening angle after advancement when working in each target area, and use the difference between the current initial layer opening angle, the layer opening angle after advancement and the corresponding average values ​​as the identified change value.

[0037] Using the known marker coordinates (X1, Y1) and (X2, Y2), calculate the position of the bucket wheel excavator relative to these markers; assuming that the bucket wheel excavator moves in a straight line on the adjacent first marker, the movement trajectory can be represented by the line segment connecting (X1, Y1) and (X2, Y2). If the movement trajectory is not a straight line, adjust the forward movement trajectory based on the working angle required by the bucket wheel excavator when working.

[0038] The working angle is determined by the change in the initial layer opening angle and the layer opening angle after advancing; the working angle is expressed as:

[0039] Δα=α1-α0;

[0040] α0 is the initial opening angle of the excavator at (X1, Y1); α1 is the target opening angle of the excavator at (X2, Y2) (or a certain point during the movement).

[0041] When the obtained working angle is less than the preset angle value, it means that the current working angle is at a normal level and can work normally. If the working angle is greater than the preset angle value, it means that the current working angle changes greatly and working errors are prone to occur.

[0042] Regarding the method for determining the priority of the first flag position, the position change of the bucket wheel excavator during movement can be determined based on the change in the coordinates of the rotation center.

[0043] Based on the size of the position change, the priority of the first flag can be defined. For example, if the absolute values ​​of ΔX2 and ΔY2 are large, indicating a long moving distance, a higher priority may be given.

[0044] The priority of the first flag is expressed as:

[0045]

[0046] Where k is a weight coefficient, ΔX represents the change in the horizontal direction of the rotation center coordinate, ΔY represents the change in the vertical direction of the rotation center coordinate, and Priority represents the priority of the first flag.

[0047] Determine the control mode priority based on the flag priority:

[0048] Assume that there are different control modes to choose from, each mode corresponds to one or more flag bits.

[0049] According to the priority of the first flag bit, the priority of the control mode associated therewith can be determined. For example, if the first flag bit has a high priority, the control mode associated therewith will also have a high priority.

[0050] All control modes are traversed in descending order of priority.

[0051] For each control mode, check whether its first flag bit indicates that it is available.

[0052] If the control mode currently being processed is available, it is determined as the available control mode with the highest priority, and the traversal is stopped.

[0053] If all control modes are unavailable, the available control mode with the highest priority is set, the second flag bit is set to the value of the first flag bit of the control mode, and the control mode corresponding to the second flag bit is set to the current control mode.

[0054] If the available control mode with the highest priority is not determined, the second flag bit is set to a preset value, and no control mode is currently executed.

[0055] According to the switch status or other conditions of each control mode, the value of the first flag bit of each control mode is updated in real time; according to the value of the second flag bit, the corresponding control mode is executed.

[0056] Let Flag1[i] be the first flag of the i-th control mode, Priority[i] be the priority of the i-th control mode, CurrentMode be the current control mode, and Flag2 be the second flag.

[0057] The pseudo code for determining the highest priority available control mode can be expressed as:

[0058] CurrentMode=None

[0059] max_priority=-1

[0060] foriinrange(num_modes):

[0061] if Flag1[i]indicates available and Priority[i]>max_priority:

[0062] max_priority = Priority[i]

[0063] CurrentMode=Mode[i]

[0064] if CurrentMode is not None:

[0065] Flag2 = Flag1 [CurrentMode]

[0066] else:

[0067] Flag2 = preset_value (eg, 0)

[0068] This solution mainly selects the optimal control mode through logical judgment and loop. In practical applications, these steps may be implemented through programming languages ​​and corresponding algorithms.

[0069] Based on the acquired first marker, the direction of the bucket wheel excavator during movement is identified, and the rotatable angle in the direction is determined, the movable angle on the second marker relative to the first marker is determined, the relative distance from the target position during movement is determined based on the angles of the first marker and the second marker, and based on the relative distance from the target position, the angular change in the direction is determined.

[0070] According to the change of the current angle, the first target position corresponding to the angle change is determined. The first target position represents the nearest position on the currently selected working area. The reduction amount of the working target at the current first target position is determined. The reduction amount is determined by calculating the amount of each work at the current angle and identifying the current working posture and the actual volume of the relative target at the first target position to determine the reduction amount of the corresponding angle during the current work.

[0071] Based on the obtained reduction, the remaining volume of the current work target is determined, and based on the remaining volume of the current work target, the state of the corresponding work during the current work and the shortest travel path under the work state are identified. The travel path is calculated by calculating the distance between the first mark position and the current first target position, and the current rotatable angle is determined according to the relative coordinates of the adjacent objects to be worked on the first target position, and based on the rotatable angle, the current work plan is determined.

[0072] After the work plan is determined, for each part to be worked on, statistics are used for comprehensive calculations to determine the angle that appears most frequently during overall control, and the image when working at that angle is determined, and the second target position is obtained. The second target position is used to determine the work position that is frequently selected in the current direction during the current work, and according to the angle corresponding to the second working surface position, the working path at the first working position is adjusted, and the control mode strategy for the final adjustment is determined based on the adjusted path.

[0073] According to the change of the current angle, the position closest to the current angle on the working area is calculated as the first target position.

[0074] For example, if the working area is a circle and the current angle is 45 degrees, the first target position may be the position corresponding to 45 degrees on the circle.

[0075] The reduction amount is calculated based on the amount of each work at the current angle and the actual volume of the relative target at the first target position and the posture of the current work.

[0076] For example, if 1 cubic centimeter of material can be cut each time at the current angle, and the target volume is 10 cubic centimeters, the reduction is 1 cubic centimeter.

[0077] Based on the reduction, the remaining volume of the current working target is calculated.

[0078] Based on the remaining volume, identify the current work status (such as completed, in progress, to be started).

[0079] For example, if the remaining volume is 0, the job status is completed.

[0080] The shortest travel path is obtained by calculating the distance between the first marker position and the current first target position.

[0081] The rotatable angle is determined by considering the relative coordinates of the adjacent objects to be worked on the first target position.

[0082] For example, if the distance from the first mark position to the first target position is 5 meters in a straight line, and the rotatable angle is 90 degrees, the travel path is to travel 5 meters in a straight line and then rotate 90 degrees.

[0083] Determine the work plan:

[0084] Based on the rotatable angle and the remaining volume, the current working plan is determined.

[0085] For example, if the rotation angle is 90 degrees and the residual volume is 5 cubic centimeters, the working plan may be to go in a straight line and cut the material, then rotate 90 degrees and continue working.

[0086] Comprehensive statistical calculation and strategy adjustment:

[0087] For each part to be worked on, a statistical method is used to calculate the angle that occurs most frequently during overall control.

[0088] The image when the angle is working is determined, and the second target position is obtained.

[0089] According to the angle corresponding to the second target position, the working path at the first working position is adjusted.

[0090] For example, if statistics show that the most common angle is 60 degrees, and the image display efficiency is highest at this angle, the first working position may be adjusted to a position in the 60-degree direction, and the travel path may be optimized.

[0091] Based on the adjusted path and statistical results, the final control mode strategy is determined.

[0092] For example, the strategy might be to work along the most efficient paths first, making angle adjustments when necessary.

[0093] Suppose there is a circular work area on which material needs to be cut to achieve a specific shape and volume. The current angle is 45 degrees, and according to statistical calculations, the most common angle is 60 degrees.

[0094] The first target position is determined to be the position corresponding to 45 degrees on the circle.

[0095] Calculate the reduction as the amount of material that can be cut each time (e.g. 1 cubic centimeter).

[0096] Determine the remaining volume and identify the operating status based on it.

[0097] The shortest travel path is calculated as traveling in a straight line to the first target position and then rotating to a 60 degree direction.

[0098] The work plan was determined to first cut the material in a straight line and then rotate it to 60 degrees to continue working.

[0099] According to the statistical results and the working efficiency image at an angle of 60 degrees, the first working position is adjusted to a high-efficiency position in the direction of 60 degrees.

[0100] The final control mode strategy was determined to prioritize working along the efficient path in the 60-degree direction and make angle adjustments when necessary to optimize efficiency.

[0101] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A remote control system for a bucket wheel excavator with automatic excavation function, characterized in that: include: Step S1, using surveying and mapping technology to accurately survey the material yard, obtain the geographical coordinates and terrain data of the material yard, generate a material yard coordinate system, establish a three-dimensional material yard coordinate system on the remote control server according to the surveying and mapping data, and perform data modeling on it; Step S2, acquiring the position data of the bucket wheel excavator in real time, matching the bucket wheel excavator with the material yard coordinate system, and calculating the current position of the bucket wheel excavator in the material yard coordinate system; Step S3, obtaining the corresponding rotation angle of the bucket wheel excavator when the position changes, and identifying the target working area corresponding to the rotation angle; Step S4, obtaining the state of the bucket wheel excavator in the target working area, identifying the current forward distance and rotation angle, and determining the control mode of the bucket wheel excavator.

2. A remote control system for a bucket wheel excavator with automatic excavation function as claimed in claim 1, characterized in that: The control mode of the bucket wheel excavator includes: Obtain the value of the corresponding mark position in each control mode, obtain the image data of the first mark position, wherein the image data of the first mark position is used to determine the current initial rotation position coordinates, and obtain the image data of the second mark position, wherein the second mark position is used to determine the position that can be reached after the movement; Determine the relative position of the bucket-wheel excavator on the first mark position, determine the moving trajectory of the bucket-wheel excavator on the adjacent first mark position, determine the corresponding position change when the bucket-wheel excavator moves, and determine the priority of the first mark position based on the corresponding position change, and determine the priority of the control mode according to the priority of the first mark position.

3. A remote control system for a bucket wheel excavator with automatic excavation function as claimed in claim 2, characterized in that: The method for determining the priority of the first flag position determines the position change of the bucket wheel excavator during movement based on the change in the coordinates of the rotation center.

4. A remote control system for a bucket wheel excavator with automatic excavation function as claimed in claim 2, characterized in that: The priority of the first flag bit is expressed as: Where k is a weight coefficient, ΔX represents the change in the horizontal direction of the rotation center coordinate, ΔY represents the change in the vertical direction of the rotation center coordinate, and Priority represents the priority of the first flag.

5. A remote control system for a bucket wheel excavator with automatic excavation function as claimed in claim 2, characterized in that: For each control mode, check whether its first flag bit indicates that it is available; If the currently processed control mode is available, it is determined as the available control mode with the highest priority and the traversal is stopped; If all control modes are unavailable, set the available control mode with the highest priority, set the second flag bit to the value of the first flag bit of the control mode, and set the control mode corresponding to the second flag bit to the current control mode; If the available control mode with the highest priority is not determined, the second flag bit is set to a preset value, and no control mode is currently executed.

6. A remote control system for a bucket wheel excavator with automatic excavation function as claimed in claim 2, characterized in that: Based on the acquired first marker, the direction of the bucket wheel excavator during movement is identified, and the rotatable angle in the direction is determined, the movable angle on the second marker relative to the first marker is determined, the relative distance from the target position during movement is determined based on the angles of the first marker and the second marker, and based on the relative distance from the target position, the angular change in the direction is determined.

7. A remote control system for a bucket wheel excavator with automatic excavation function as claimed in claim 6, characterized in that: According to the change of the current angle, the first target position corresponding to the angle change is determined, the first target position represents the nearest position on the currently selected working area, and the reduction amount of the working target at the current first target position is determined. The reduction amount is determined by calculating the amount of each work at the current angle and identifying the current working posture and the actual volume of the relative target at the first target position, and determining the reduction amount of the corresponding angle during the current work; Based on the obtained reduction, the remaining volume of the current work target is determined, and based on the remaining volume of the current work target, the state of the corresponding work during the current work and the shortest travel path under the work state are identified. The travel path is calculated by calculating the distance between the first mark position and the current first target position, and the current rotatable angle is determined according to the relative coordinates of the adjacent objects to be worked on the first target position, and based on the rotatable angle, the current work plan is determined.

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