A remote control system for a bucket wheel excavator with automatic digging function

Abstract

This application discloses a remote control system for a bucket wheel excavator with automatic digging function, relating to the field of excavator control technology. The system includes: Step S1, using surveying technology to accurately survey the material yard, obtaining the geographic coordinates and terrain data of the material yard, generating a material yard coordinate system, and establishing a three-dimensional material yard coordinate system on a remote control server based on the surveying data, and modeling the data; Step S2, acquiring the position data of the bucket wheel excavator in real time, mapping the bucket wheel excavator to the material yard coordinate system, and calculating the current position of the bucket wheel excavator in the material yard coordinate system; Step S3, acquiring the corresponding slewing angle of the bucket wheel excavator when its position changes, and identifying the target working area corresponding to the slewing angle; Step S4, acquiring the state of the bucket wheel excavator in the target working area, identifying the current forward distance and slewing angle, and determining the control mode of the bucket wheel excavator; this system can improve the operating efficiency and accuracy of the excavator.

Description

Technical Field

[0001] This invention relates to the field of excavator control technology, and in particular to a remote control system for a bucket wheel excavator with automatic digging function. Background Technology

[0002] Bucket wheel excavators are key equipment in continuous and semi-continuous open-pit mining processes. A bucket wheel excavator is a multi-bucket excavator that uses multiple buckets mounted on the front wheel of the boom for continuous digging. It is used for large-scale earthmoving, stripping and excavation in mines, and loading and unloading operations in large material yards. It boasts high productivity, significant digging force, and can directly excavate relatively hard soil. It is an ideal multi-bucket excavator for continuous mining operations and is one of the largest complete excavation systems in the world.

[0003] Bucket wheel excavators require precise positioning of the material pick-up point during operation. However, due to their complex structure, which includes multiple mechanisms that require positioning such as the transfer machine, connecting bridge, tracked walking mechanism, slewing mechanism, and pitching mechanism, precise positioning of the material pick-up point has become a technical challenge. Summary of the Invention

[0004] This application provides a remote control system for a bucket wheel excavator with automatic digging function, which solves the technical problem of difficulty in locating the material picking point in the prior art and improves the accuracy of positioning.

[0005] This application provides a remote control system for a bucket wheel excavator with automatic digging function, including:

[0006] Step S1: Use surveying technology to accurately survey the material yard, obtain the geographic coordinates and terrain data of the material yard, generate the material yard coordinate system, and establish a three-dimensional material yard coordinate system on the remote control server based on the surveying data, and perform data modeling on it.

[0007] Step S2: Obtain the position data of the bucket wheel excavator in real time, match the bucket wheel excavator with the material yard coordinate system, and calculate the current position of the bucket wheel excavator in the material yard coordinate system;

[0008] Step S3: Obtain the slewing angle of the bucket wheel excavator when its position changes, and identify the target working area corresponding to the slewing angle;

[0009] Step S4: Obtain the status of the bucket wheel excavator in the target working area, identify the current forward distance and slewing angle, and determine the control mode of the bucket wheel excavator.

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

[0011] By acquiring the status of the bucket wheel excavator in the target working area, identifying the forward distance and slewing angle, and determining the excavator's control mode, and simultaneously determining the priority of the control mode based on the priority of the flag positions, intelligent control and mode optimization of the excavator are achieved. The excavator's direction of movement can be identified, and the rotatable angle in that direction and the movable angle of the second flag position relative to the first flag position can be determined. This provides a basis for precise angle adjustment and path planning of the excavator, enabling efficient work path planning and workload management. Attached Figure Description

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

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

[0014] To facilitate understanding of the present invention, a more complete description of this application will be given below with reference to the accompanying drawings, which illustrate preferred embodiments of the invention. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to enable a more thorough and complete understanding of the disclosure of the present invention.

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

[0016] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains; the terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to limit the invention; the term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0017] Example 1

[0018] like Figure 1 , Figure 2 As shown, this application discloses a remote control system for a bucket wheel excavator with automatic digging function, comprising:

[0019] Step S1: Use surveying technology to accurately survey the material yard, obtain the geographic coordinates and terrain data of the material yard, generate the material yard coordinate system, and establish a three-dimensional material yard coordinate system on the remote control server based on the surveying data, and perform data modeling on it.

[0020] Step S2: Obtain the position data of the bucket wheel excavator in real time, match the bucket wheel excavator with the coordinate system of the material yard, and calculate the current position of the bucket wheel excavator in the coordinate system of the material yard.

[0021] Step S3: Obtain the slewing angle of the bucket wheel excavator when its position changes, and identify the target working area corresponding to the slewing angle;

[0022] Step S4: Obtain the status of the bucket wheel excavator in the target working area, identify the current forward distance and slewing angle, and determine the control mode of the bucket wheel excavator.

[0023] First, surveyors use drones or ground surveying equipment to survey the material yard, obtaining high-precision terrain data and boundary coordinates. Then, using professional 3D modeling software on a remote server, a virtual model of the material yard is constructed based on the survey data. The remote server calculates the current position (e.g., X and Y coordinates) of the bucket wheel excavator based on the material yard coordinate system and BeiDou positioning data. At this point, the bucket wheel excavator is controlled by installing electronic compass sensors at appropriate positions along the centerline of the cantilever boom and connecting bridge's slewing platform. Using the horizontal direction of the system belt as a reference, the zero-degree slewing angle is determined, and the electronic compass sensors acquire the slewing angles of the cantilever boom and connecting bridge in real time. The sensors then transmit the slewing angle data of the cantilever boom and connecting bridge to the PLC and remote server in real time.

[0024] The operator selects the work location on the remote server. Based on the operator's selected location and the current position of the bucket wheel excavator, the system calculates parameters such as forward distance and slewing angle. According to the received instructions, the system automatically controls the bucket wheel excavator to perform operations such as addressing and material handling, including 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 work.

[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. It conveys materials to the subsequent system via the cantilever conveyor belt. The tracked 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. The receiving conveyor belt, unloading conveyor belt, and transfer mechanism ensure smooth material transfer inside the excavator and between it and other equipment through mechanical connections and adhesives.

[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 a bucket wheel excavator is working, it mainly controls the current processing method based on the distance between the current working position and the target position through multiple sets of structures. If multiple sets of movement coordinates are obtained, the bucket wheel excavator can control the corresponding rotating and moving components according to the position of the corresponding coordinates. By working together, the most suitable coordinate position for working can be found.

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

[0029] The control modes for bucket wheel excavators include:

[0030] Obtain the values ​​of the corresponding flag positions under each control mode, obtain the image data of the first flag position, where the image data of the first flag position is used to determine the current initial rotation position coordinates, and obtain the image data of the second flag position, where the second flag position is used to determine the position that can be reached after movement.

[0031] Determine the relative position of the bucket wheel excavator on the first marker position, determine the movement trajectory of the bucket wheel excavator on the adjacent first marker positions, determine the corresponding position change when the bucket wheel excavator moves, determine the priority of the first marker position based on the corresponding position change, and determine the priority of the control mode based on the priority of the first marker position.

[0032] Specific feature points on the marker are identified using image processing techniques (such as edge detection and feature extraction). Based on the coordinates of the feature points in the image, combined with the camera's intrinsic and extrinsic parameters, the image coordinates are converted into actual three-dimensional world coordinates using camera calibration techniques, thereby determining the current initial rotation position coordinates (X1, Y1). Similarly, the image of the second marker is captured. Feature points are identified, and the image coordinates are converted into three-dimensional world coordinates to determine the position coordinates (X2, Y2) that can be reached after movement.

[0033] Let θ be the angle between the forward direction of the bucket wheel excavator and the positive X-axis. Then θ can be calculated using the following formula:

[0034]

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

[0036] Determine the initial opening angle and the change of the opening angle after advancing. Calculate the average value of the initial opening angle and the opening angle after advancing when working in each target area, and use the difference between the current initial opening angle, the opening angle after advancing and the corresponding average value as the identified change value.

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

[0038] The working angle is determined by the change between 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 layer opening angle of the excavator at (X1,Y1); α1 is the target layer opening angle of the excavator at (X2,Y2) (or at a certain point during the movement).

[0041] If 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 be used normally. If the working angle is greater than the preset angle value, it means that the current working angle changes significantly and is prone to working errors.

[0042] The priority of the first flag can be determined based on the change in the coordinates of the slewing center, which determines the position change of the bucket wheel excavator during travel.

[0043] The priority of the first flag can be defined based on the magnitude of the position change. For example, if the absolute values ​​of ΔX2 and ΔY2 are larger, indicating a greater movement distance, they may be given a higher priority.

[0044] The priority of the first flag bit is represented as follows:

[0045]

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

[0047] The control mode priority is determined based on the flag priority:

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

[0049] The priority of the control mode associated with the first flag can be determined based on its priority. For example, if the first flag has a high priority, then the control mode associated with it will also have a high priority.

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

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

[0052] If the current control mode is available, it is identified as the highest priority available control mode, and traversal stops.

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

[0054] If no highest priority available control mode is determined, the second flag is set to the default value, and no control mode is executed at present.

[0055] Based on the on / off status or other conditions of each control mode, the value of the first flag bit of each control mode is updated in real time; based on 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 pseudocode for determining the highest priority available control mode can be represented 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 scheme primarily uses logical judgments and loops to select the optimal control mode. In practical applications, these steps may be implemented using programming languages ​​and corresponding algorithms.

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

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

[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 current work and the shortest travel path in the current work state are identified. The travel path is calculated by calculating the distance between the first marker and the current first target position, and the current rotatable angle is determined according to the relative coordinates of the adjacent work objects at the first target position. Based on the rotatable angle, the current work plan is determined.

[0072] Once the work plan is determined, for each part to be worked, statistical calculations are used to determine the angle that appears most frequently during overall control, and the image of working at that angle is obtained to acquire the second target position. The second target position is used to determine the frequently selected working position in the current direction during the current work. Based on the angle corresponding to the second working face 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] Based on the change in the current angle, calculate the position in the working area that is closest to the current angle and use it as the first target position.

[0074] For example, if the work 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 work done each time from the current angle, and by identifying the current working posture and the actual volume of the target relative to the first target position.

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

[0077] Based on the reduction amount, calculate the remaining volume of the current working objective.

[0078] Based on the remaining volume, identify the current working status (e.g., completed, in progress, to be started).

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

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

[0081] Considering the relative coordinates of adjacent workpieces at the first target position, determine the rotatable angle.

[0082] For example, if the distance from the first marker to the first target position is 5 meters in a straight line and the rotatable angle is 90 degrees, then 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 remaining volume, determine the current working scheme.

[0085] For example, if the rotatable angle is 90 degrees and the remaining volume is 5 cubic centimeters, the working procedure might be to first move along a straight line and cut the material, and then rotate 90 degrees to continue working.

[0086] Comprehensive statistical calculations and strategy adjustments:

[0087] For each part to be worked on, statistical methods were used to calculate the angle that appeared most frequently when controlling the overall situation.

[0088] Determine the image when working at this angle, and obtain the position of the second target.

[0089] Adjust the working path at the first working position based on the angle corresponding to the second target position.

[0090] For example, if statistics show that the most frequently occurring angle is 60 degrees, and the image display efficiency is highest at this angle, then the first working position may be adjusted to a position at 60 degrees, 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, a strategy might be to prioritize working along the most efficient path and adjust the angle as necessary.

[0093] Suppose there is a circular work area where material needs to be cut to achieve a specific shape and volume. The current angle is 45 degrees, and statistically, 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] The reduction is calculated as the amount of material that can be cut each time (e.g., 1 cubic centimeter).

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

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

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

[0099] Based on statistical results and the work efficiency graph at a 60-degree angle, the first working position is adjusted to a highly efficient position in the 60-degree direction.

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

[0101] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. For those skilled in the art, the present invention can have various modifications and variations. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A remote control system for a bucket wheel excavator with automatic digging function, characterized in that, include: Step S1: Use surveying technology to accurately survey the material yard, obtain the geographic coordinates and terrain data of the material yard, generate the material yard coordinate system, and establish a three-dimensional material yard coordinate system on the remote control server based on the surveying data, and perform data modeling on it. Step S2: Obtain the position data of the bucket wheel excavator in real time, match the bucket wheel excavator with the material yard coordinate system, and calculate the current position of the bucket wheel excavator in the material yard coordinate system; Step S3: Obtain the slewing angle of the bucket wheel excavator when its position changes, and identify the target working area corresponding to the slewing angle; Step S4: Obtain the status of the bucket wheel excavator in the target working area, identify the current forward distance and slewing angle, and determine the control mode of the bucket wheel excavator; The control modes of the bucket wheel excavator include: Obtain the value of the corresponding flag position under each control mode, obtain the image data of the first flag position, where the image data of the first flag position is used to determine the current initial rotation position coordinates, and obtain the image data of the second flag position, where the second flag position is used to determine the position that can be reached after movement; Determine the relative position of the bucket wheel excavator on the first marker position, determine the movement trajectory of the bucket wheel excavator on the adjacent first marker positions, determine the corresponding position change when the bucket wheel excavator moves, and determine the priority of the first marker position based on the corresponding position change. Based on the priority of the first marker position, determine the priority of the control mode. The priority of the first flag is determined by the change in the coordinates of the slewing center, which determines the position change of the bucket wheel excavator during travel. The priority of the first flag bit is represented as follows: ； Where k is a weighting coefficient. This represents the change in the horizontal direction of the coordinates of the center of rotation. This represents the change in the vertical direction of the coordinates of the center of rotation. This indicates the priority of the first flag bit.

2. The remote control system for a bucket wheel excavator with automatic digging function as described in claim 1, characterized in that, For each control mode, check if its first flag indicates that it is available; If the currently processed control mode is available, then it is identified as the highest priority available control mode, and traversal is stopped; If all control modes are unavailable, the highest priority available control mode is set, the second flag is set to the value of the first flag of that control mode, and the control mode corresponding to the second flag is set to the current control mode. If no highest priority available control mode is determined, the second flag is set to the default value, and no control mode is executed at present.

3. The remote control system for a bucket wheel excavator with automatic digging function as described in claim 1, characterized in that, Based on the acquired first marker, the direction of movement of the bucket wheel excavator is identified, and the rotatable angle in that direction is determined. The movable angle of the second marker relative to the first marker is determined. Based on the angle between the first and second markers, the relative distance to the target position during movement is determined. Based on the relative distance to the target position, the angle change of movement in that direction is determined.

4. The remote control system for a bucket wheel excavator with automatic digging function as described in claim 3, characterized in that, Based on the change in the current angle, determine the first target position corresponding to the angle change. The first target position represents the nearest position on the currently selected work area. Determine the reduction amount of the work target at the current first target position. The reduction amount is determined by calculating the amount of work done at the current angle and identifying the current work posture and the actual volume of the target relative to the first target position. 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 current work and the shortest travel path in the current work state are identified. The travel path is calculated by calculating the distance between the first marker and the current first target position, and the current rotatable angle is determined according to the relative coordinates of the adjacent work objects at the first target position. Based on the rotatable angle, the current work plan is determined.

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