An unattended positioning system for bucket wheel excavator

Abstract

The present invention relates to an unmanned positioning system for a bucket wheel machine, which is characterized by comprising the following modules: a laser scanning module for real-time scanning of a coal yard and generating a three-dimensional image of a coal pile; a bucket wheel machine positioning module, which specifically comprises a trolley positioning unit, a slewing positioning unit and a pitching positioning unit, which are respectively used to determine the trolley position, slewing angle and pitching angle of the bucket wheel machine; an anti-collision warning and safety protection module, which performs anti-collision pre-alarm according to the bucket wheel machine position information and the three-dimensional position information of the coal pile; a coal flow real-time module, which is used to feedback the belt coal flow in real time; a PLC control module, which receives data from each module and controls the operation of the bucket wheel machine; a video monitoring module, which is used to monitor the operating environment of the bucket wheel machine; and all systems are connected via a communication network. The present invention solves the problems of insufficient positioning accuracy, slow anti-collision warning response, inaccurate coal flow monitoring, etc. in most existing unmanned systems.

Description

Technical Field

[0001] The invention relates to the technical field of unmanned bucket wheel machines, and in particular to an unmanned positioning system for bucket wheel machines. Background Art

[0002] Traditional bucket wheel machines require manual operation or monitoring during coal yard operations, which has problems such as high labor costs, low operating accuracy, and great safety hazards. With the development of industrial automation technology, unmanned technology has gradually been applied to coal yard management, but most of the existing unmanned systems have problems such as insufficient positioning accuracy, slow anti-collision warning response, and inaccurate coal flow monitoring, which affect the operating efficiency and safety of bucket wheel machines. Therefore, the development of a high-precision, high-security, and highly intelligent unmanned bucket wheel machine positioning system is of great significance for improving coal yard operating efficiency, reducing labor costs, and ensuring operating safety. Summary of the invention

[0003] In response to the problems in the prior art, the present invention provides an unmanned positioning system for a bucket wheel excavator. The system realizes unmanned, efficient and safe operation of the bucket wheel excavator by integrating technologies such as high-precision laser scanning, precise positioning, anti-collision warning, coal flow monitoring, PLC control and video monitoring.

[0004] The technical solution adopted by the present invention to solve the technical problem is as follows: specifically comprising the following modules: The laser scanning module is used to scan the coal yard in real time and generate a three-dimensional image of the coal pile. Through high-precision laser scanning, a three-dimensional image of the coal pile is generated in real time, providing an accurate basis for the precise positioning of the bucket wheel machine and the material retrieving / stacking operations, thus improving the operation accuracy and efficiency. ; The bucket wheel positioning module specifically includes a trolley positioning unit, a rotation positioning unit and a pitch positioning unit, which are used to determine the trolley position, rotation angle and pitch angle of the bucket wheel respectively. Through the precise positioning module, the precise measurement and redundant positioning of the trolley position, rotation angle and pitch angle of the bucket wheel are realized, which improves the positioning accuracy and reliability, and provides a strong guarantee for the precise operation of the bucket wheel; The anti-collision warning and safety protection module performs anti-collision pre-alarm according to the bucket wheel machine position information and the three-dimensional position information of the coal pile. It monitors the distance between the bucket wheel machine and surrounding objects in real time through an ultrasonic rangefinder and issues a warning signal when the distance is less than the preset value. It is also equipped with an emergency stop button and an overload protection device, which improves the safety of the bucket wheel machine and avoids equipment damage and casualties caused by collision. The coal flow real-time module is used to provide real-time feedback on the belt coal flow. The coal flow on the belt is monitored in real time through the coal flow detection equipment, and the data is transmitted to the PLC control module, realizing accurate measurement and real-time feedback of the coal flow, providing an accurate basis for the bucket wheel excavator's material handling / stacking operations, and improving the operation efficiency and accuracy. The PLC control module receives data from each module and controls the operation of the bucket wheel machine. The PLC control module realizes the real-time collection, processing and transmission of data from each module, and controls the operation of the bucket wheel machine according to the preset control logic. At the same time, the real-time data transmission is realized through the communication network and the remote monitoring center, which improves the communication speed and reliability of the system and provides strong support for the unattended operation of the bucket wheel machine. The video monitoring module is used to monitor the operating environment of the bucket wheel machine. It monitors the operating environment of the bucket wheel machine in real time through a high-definition camera and transmits the monitoring data to the PLC control module or the remote monitoring center, realizing remote monitoring and fault warning. At the same time, the real-time transmission and remote access of the monitoring data are realized through the communication network, which improves the real-time performance and reliability of the monitoring module; All systems are connected through a communication network to achieve real-time data transmission and processing, forming a complete unmanned bucket wheel excavator positioning system; Among them, the laser scanning module, bucket wheel positioning module, anti-collision warning and safety protection module, and coal flow real-time module respectively transmit data to the PLC control module through the communication network. The PLC control module controls the operation of the bucket wheel according to the received data. At the same time, the video monitoring module monitors the operating environment of the bucket wheel in real time, and transmits the monitoring data to the PLC control module and the external remote monitoring center.

[0005] Furthermore, the laser scanning module uses two high-precision two-dimensional laser scanners installed on the left and right sides of the front of the bucket wheel machine cantilever. The scanning range is 0° to 360°, the scanning frequency is 20Hz, the scanning accuracy is ±5mm, the maximum scanning distance can reach 100m, the scanning repetition error is no more than 5‰, the laser wavelength is 650nm, the scanning angle resolution is 0.1°, and it has the function of transmitting data via Gigabit Ethernet optical fiber. After data collection, it is transmitted to the PLC control module via Cat6a Ethernet optical fiber.

[0006] Furthermore, the bucket wheel machine positioning module includes: The trolley positioning unit adopts an absolute encoder device, with an overall positioning accuracy of ±5mm, and is equipped with a radio frequency correction device for correction. The carrier frequency of the radio frequency correction device is 13.56 MHz, the output power is 200 mW, the working distance is 0.5m to 10m, and the communication protocol is ISO / IEC 14443 Type A; The rotary positioning unit adopts an absolute encoder device with a positioning accuracy of ≤0.1° and is equipped with a radio frequency correction device for redundant positioning. The carrier frequency of the radio frequency correction device is 13.56 MHz, the output power is 200 mW, the working distance is 0.5m to 10m, and the communication protocol is ISO / IEC 14443 Type A; The pitch positioning unit uses an absolute encoder device and an inclinometer for redundant positioning, with a positioning accuracy of ≤0.1°, an inclinometer measurement range of ≥±15°, a measurement accuracy of 0.05°, a protection grade of IP67, an operating temperature range of -40°C to +85°C, and a response time of less than 1ms.

[0007] Furthermore, the anti-collision warning and safety protection module includes four ultrasonic rangefinders, which are installed in the front, rear, left and right directions of the bucket wheel excavator respectively. The detection range is 0.05m to 10m, the detection accuracy is ±1mm, and the operating frequency is 40kHz. When the distance is less than the preset value, a warning signal is issued. It is also equipped with an equipment safety protection system, including an emergency stop button and an overload protection device, to provide timely feedback on the equipment operating status.

[0008] Furthermore, the coal flow real-time module includes a belt coal flow microwave detection radar installed on the belt conveyor, with a measurement range of 0 to 2000t / h, a measurement accuracy of ±1%, an operating frequency of 24GHz, an output signal of 4-20mA, and transmits data to the PLC control module. The PLC control module adjusts the bucket wheel excavator's material taking or stacking speed according to the coal flow data.

[0009] Furthermore, the video surveillance module includes four high-definition cameras with face recognition and FaceID functions, a resolution of 1920x1080 pixels, a frame rate of 30fps, a field of view of 69.4°, and a lens focal length of 2.8mm to 12mm. It can accurately identify people entering the field of view and issue corresponding alarms. The camera is equipped with a 5G communication device, supports NSA and SA dual-mode, with a downlink rate of up to 2Gbps and an uplink rate of up to 1Gbps.

[0010] Furthermore, the PLC control module is equipped with Ethernet communication, the CPU main frequency is 1.5GHz, the memory is 2GBDDR4, the storage is 32GB SSD, it supports multiple communication protocols, and IO cards are added according to the newly added sensor points. The number of cards meets the usage and reserves 20% spare points. At the same time, the PLC control module and the remote monitoring center realize real-time data transmission through the 5G private network. The frequency band of the 5G private network is n78, the bandwidth is 100MHz, the uplink rate can reach up to 1Gbps, and the downlink rate can reach up to 2Gbps.

[0011] The beneficial effects of the present invention are: improving the operating accuracy and efficiency of the bucket wheel machine, through high-precision laser scanning and precise positioning systems, the precise operation of the bucket wheel machine is realized, and the operating accuracy and efficiency are improved; the safety of the bucket wheel machine is improved, through the anti-collision warning and safety protection system, the coal flow real-time system and the video monitoring system, the all-round safety monitoring and protection of the bucket wheel machine is realized, and equipment damage and casualties caused by collision, overload, etc. are avoided; the labor cost is reduced, through unmanned technology, the automatic operation and remote monitoring of the bucket wheel machine are realized, and the labor cost is reduced; the reliability and stability of the system are improved, through the PLC control system and 5G private network technology, the real-time collection, processing and transmission of data of each system are realized, and the reliability and stability of the system are improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0013] Figure 1 It is a system structure framework diagram of the present invention.

[0014] Figure 2 It is the work flow chart of the present invention.

[0015] In the figure: 100, laser scanning module; 200, bucket wheel excavator positioning module; 201, trolley positioning unit; 202, rotation positioning unit; 203, pitch positioning unit; 300, anti-collision warning and safety protection module; 400, coal flow real-time module; 500, PLC control module; 600, video monitoring module; 700, communication network; 701, remote monitoring center. DETAILED DESCRIPTION

[0016] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further explained below in conjunction with specific implementation methods.

[0017] like Figure 1-Figure 2 As shown, the unmanned positioning system for a bucket wheel machine described in the present invention is characterized in that it specifically includes the following modules: The laser scanning module 100 is used to scan the coal yard in real time and generate a three-dimensional image of the coal pile; The bucket wheel positioning module 200 specifically includes a trolley positioning unit 201, a rotation positioning unit 202 and a pitch positioning unit 203, which are used to determine the trolley position, rotation angle and pitch angle of the bucket wheel respectively; The anti-collision warning and safety protection module 300 performs anti-collision warning according to the bucket wheel machine position information and the three-dimensional position information of the coal pile; A coal flow real-time module 400 is used to provide real-time feedback of the belt coal flow rate; PLC control module 500, receiving data from each module and controlling the operation of the bucket wheel machine; A video monitoring module 600 is used to monitor the operating environment of the bucket wheel machine; All systems are connected through the communication network 700 to achieve real-time data transmission and processing, forming a complete unmanned bucket wheel machine positioning system; Among them, the laser scanning module 100, the bucket wheel positioning module 200, the anti-collision warning and safety protection module 300, and the coal flow real-time module 400 respectively transmit data to the PLC control module 500 through the communication network 700. The PLC control module 500 controls the operation of the bucket wheel according to the received data. At the same time, the video monitoring module 600 monitors the operating environment of the bucket wheel in real time, and transmits the monitoring data to the PLC control module 500 and the external remote monitoring center 701.

[0018] The laser scanning module 100 uses two high-precision two-dimensional laser scanners, which are installed on the left and right sides of the front of the bucket wheel machine cantilever. The scanning range is 0° to 360°, the scanning frequency is 20Hz, the scanning accuracy is ±5mm, the maximum scanning distance can reach 100m, the scanning repetition error is no more than 5‰, the laser wavelength is 650nm, the scanning angle resolution is 0.1°, and it has the function of transmitting data via Gigabit Ethernet optical fiber. After data collection, it is transmitted to the PLC control module 500 via Cat6a Ethernet optical fiber.

[0019] The bucket wheel machine positioning module 200 comprises: The trolley positioning unit 201 adopts an absolute encoder device, with an overall positioning accuracy of ±5mm, and is equipped with a radio frequency correction device for correction. The radio frequency correction device has a carrier frequency of 13.56 MHz, an output power of 200 mW, a working distance of 0.5m to 10m, and a communication protocol of ISO / IEC 14443 Type A; The rotary positioning unit 202 uses an absolute encoder device with a positioning accuracy of ≤0.1° and is provided with a radio frequency correction device for redundant positioning. The radio frequency correction device has a carrier frequency of 13.56 MHz, an output power of 200 mW, a working distance of 0.5m to 10m, and a communication protocol of ISO / IEC 14443 Type A; The pitch positioning unit 203 uses an absolute encoder device and an inclinometer for redundant positioning, with a positioning accuracy of ≤0.1°, an inclinometer measurement range of ≥±15°, a measurement accuracy of 0.05°, a protection level of IP67, an operating temperature range of -40°C to +85°C, and a response time of less than 1ms.

[0020] The anti-collision warning and safety protection module 300 includes four ultrasonic rangefinders, which are installed in the front, rear, left and right directions of the bucket wheel excavator respectively. The detection range is 0.05m to 10m, the detection accuracy is ±1mm, and the operating frequency is 40kHz. When the distance is less than the preset value, a warning signal is issued. It is also equipped with an equipment safety protection system, including an emergency stop button and an overload protection device, to provide timely feedback on the equipment operating status.

[0021] The coal flow real-time module 400 includes a belt coal flow microwave detection radar, which is installed on the belt conveyor, has a measurement range of 0 to 2000t / h, a measurement accuracy of ±1%, an operating frequency of 24GHz, an output signal of 4-20mA, and transmits data to the PLC control module 500. The PLC control module 500 adjusts the bucket wheel excavator's material taking or stacking speed according to the coal flow data.

[0022] The video surveillance module 600 includes four high-definition cameras, with face recognition and FaceID functions, a resolution of 1920x1080 pixels, a frame rate of 30fps, a field of view of 69.4°, and a lens focal length of 2.8mm to 12mm. It can accurately identify people entering the field of view and issue corresponding alarms. The camera is equipped with a 5G communication device, supports NSA and SA dual modes, and has a downlink rate of up to 2Gbps and an uplink rate of up to 1Gbps.

[0023] The PLC control module 500 is equipped with Ethernet communication, the CPU main frequency is 1.5GHz, the memory is 2GB DDR4, the storage is 32GB SSD, it supports multiple communication protocols, and IO cards are added according to the newly added sensor points. The number of cards meets the usage and reserves 20% spare points. At the same time, the PLC control module 500 and the remote monitoring center realize real-time data transmission through the 5G private network. The 5G private network frequency band is n78, the bandwidth is 100MHz, the uplink rate can reach up to 1Gbps, and the downlink rate can reach up to 2Gbps.

[0024] The specific workflow of the system is as follows: System self-check: Before startup, the unmanned bucket wheel excavator positioning system will perform a series of self-check procedures, including checking the connection status and working status of the laser scanner, positioning encoder, ultrasonic rangefinder, coal flow detection equipment, PLC control module and video monitoring module to ensure that all equipment is in normal condition.

[0025] Parameter setting: According to the actual needs of coal yard operations, the bucket wheel machine's operating parameters are set through the remote monitoring center or on-site operation panel, including the location of reclaiming / stacking, operating depth, belt speed, etc.

[0026] Start command: When all equipment self-checks pass and parameter settings are completed, a start command is issued through the remote monitoring center or the on-site operation panel, and the bucket wheel positioning system starts working.

[0027] Laser scanning and 3D imaging, the laser scanner starts to scan the coal yard in real time, and transmits the scan data to the PLC control module through Ethernet optical fiber. The PLC control module processes the scan data and generates a 3D image of the coal pile, providing an accurate basis for the precise positioning and operation of the bucket wheel machine.

[0028] Positioning encoder data acquisition: The trolley positioning unit, slewing positioning unit and pitch positioning unit collect the trolley position, slewing angle and pitch angle data of the bucket wheel in real time through the absolute encoder, and transmit the data to the PLC control module. The PLC control module processes the positioning data to achieve accurate positioning of the bucket wheel.

[0029] Ultrasonic ranging and anti-collision warning, the ultrasonic rangefinder detects the distance between the bucket wheel excavator and surrounding objects in real time. When the distance is less than the preset value, a warning signal is issued and the emergency stop button or overload protection device is triggered through the PLC control module to avoid collision accidents.

[0030] Coal flow detection, belt coal flow detection equipment detects the coal flow on the belt in real time and transmits the data to the PLC control module. The PLC control module adjusts the bucket wheel excavator's material reclaiming or stacking speed and the belt speed according to the coal flow data to ensure the stability and accuracy of the coal flow.

[0031] Video monitoring: high-definition cameras monitor the operating environment of the bucket wheel machine in real time, including the working status of the bucket wheel machine, environmental changes in the coal yard, etc., and transmit the monitoring data to the PLC control module or remote monitoring center.

[0032] Data processing: The PLC control module processes and analyzes the real-time collected data, including laser scanning data, positioning data, ultrasonic ranging data, coal flow data, and video monitoring data. The PLC control module processes and analyzes the data according to the preset control logic and algorithm and generates control instructions.

[0033] Decision-making and control: The PLC control module controls the operation of the bucket wheel machine according to the processed data and control instructions. This includes adjusting the position of the bucket wheel machine's trolley, the rotation angle and the pitch angle, controlling the speed of retrieving or stacking materials and the belt speed, etc. At the same time, the PLC control module will also monitor and adjust the operating status of the bucket wheel machine according to real-time data to ensure the stable operation and operating efficiency of the bucket wheel machine.

[0034] Remote monitoring: The remote monitoring center realizes real-time data transmission and remote access through the communication network and PLC control module. The remote monitoring center can monitor the bucket wheel machine's operating status, operating parameters, fault information, etc. in real time, and can remotely control and adjust the bucket wheel machine.

[0035] Fault warning: When an abnormal situation or fault occurs in the bucket wheel machine, the PLC control module will immediately send out a warning signal and transmit the fault information to the remote monitoring center. The remote monitoring center can take timely measures to deal with the fault information to avoid the impact of the fault on the operation and operation of the bucket wheel machine.

[0036] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

[0037] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. An unmanned positioning system for a bucket wheel excavator, characterized in that Specifically includes the following modules: A laser scanning module (100) is used to scan the coal yard in real time and generate a three-dimensional image of the coal pile; The bucket wheel machine positioning module (200) specifically comprises a trolley positioning unit (201), a rotation positioning unit (202) and a pitch positioning unit (203), which are used to determine the trolley position, rotation angle and pitch angle of the bucket wheel machine respectively; The anti-collision warning and safety protection module (300) performs anti-collision warning according to the bucket wheel machine position information and the coal pile three-dimensional position information; A coal flow real-time module (400) is used to provide real-time feedback of the belt coal flow rate; A PLC control module (500) receives data from each module and controls the operation of the bucket wheel machine; A video monitoring module (600) is used to monitor the operating environment of the bucket wheel machine; All systems are connected via a communication network (700) to achieve real-time data transmission and processing, forming a complete unmanned bucket wheel machine positioning system; The laser scanning module (100), the bucket wheel machine positioning module (200), the anti-collision warning and safety protection module (300), and the coal flow real-time module (400) respectively transmit data to the PLC control module (500) through the communication network (700); the PLC control module (500) controls the operation of the bucket wheel machine according to the received data; meanwhile, the video monitoring module (600) monitors the operating environment of the bucket wheel machine in real time, and transmits the monitoring data to the PLC control module (500) and an external remote monitoring center (701).

2. The unmanned positioning system for a bucket wheel excavator according to claim 1, characterized in that: The laser scanning module (100) uses two high-precision two-dimensional laser scanners installed on the left and right sides of the front of the bucket wheel machine boom, with a scanning range of 0° to 360°, a scanning frequency of 20 Hz, a scanning accuracy of ±5 mm, a maximum scanning distance of 100 m, a scanning repetition error of no more than 5‰, a laser wavelength of 650 nm, a scanning angle resolution of 0.1°, and a function of transmitting data via Gigabit Ethernet optical fiber. After data collection, the data is transmitted to the PLC control module (500) via Cat6a Ethernet optical fiber.

3. The unmanned positioning system for a bucket wheel excavator according to claim 1, characterized in that: The bucket wheel machine positioning module (200) comprises: The trolley positioning unit (201) adopts an absolute encoder device, and the overall positioning accuracy reaches ±5mm. It is also equipped with a radio frequency correction device for correction. The radio frequency correction device has a carrier frequency of 13.56 MHz, an output power of 200 mW, a working distance of 0.5m to 10m, and a communication protocol of ISO / IEC 14443 Type A.

4. The unmanned positioning system for a bucket wheel excavator according to claim 1, characterized in that: The bucket wheel machine positioning module (200) comprises: The rotary positioning unit (202) adopts an absolute value encoder device, has a positioning accuracy of ≤0.1°, and is provided with a radio frequency correction device for redundant positioning, wherein the radio frequency correction device has a carrier frequency of 13.56 MHz, an output power of 200 mW, a working distance of 0.5 m to 10 m, and a communication protocol of ISO / IEC 14443 Type A.

5. The unmanned positioning system for a bucket wheel excavator according to claim 1, characterized in that: The bucket wheel machine positioning module (200) comprises: The pitch positioning unit (203) uses an absolute encoder device and an inclinometer for redundant positioning, with a positioning accuracy of ≤0.1°, an inclinometer measurement range of ≥±15°, a measurement accuracy of 0.05°, a protection level of IP67, an operating temperature range of -40°C to +85°C, and a response time of less than 1ms.

6. The unmanned positioning system for a bucket wheel excavator according to claim 1, characterized in that: The anti-collision warning and safety protection module (300) includes four ultrasonic rangefinders, which are installed in the front, rear, left and right directions of the bucket wheel machine respectively. The detection range is 0.05m to 10m, the detection accuracy is ±1mm, and the working frequency is 40kHz. When the distance is less than the preset value, a warning signal is issued. The equipment safety protection system is also equipped, including an emergency stop button and an overload protection device, to timely feedback the equipment operation status.

7. The unmanned positioning system for a bucket wheel excavator according to claim 1, characterized in that: The coal flow real-time module (400) comprises a belt coal flow microwave detection radar, which is installed on the belt conveyor, has a measurement range of 0 to 2000 t / h, a measurement accuracy of ±1%, an operating frequency of 24 GHz, an output signal of 4-20 mA, and transmits data to a PLC control module (500). The PLC control module (500) adjusts the material taking or stacking speed of the bucket wheel excavator according to the coal flow data.

8. The unmanned positioning system for a bucket wheel excavator according to claim 1, characterized in that: The video surveillance module (600) includes four high-definition cameras, has face recognition function and FaceID function, has a resolution of 1920x1080 pixels, a frame rate of 30fps, a field of view of 69.4°, and a lens focal length of 2.8mm to 12mm. It can accurately identify people entering the field of view and issue corresponding alarms. The camera is equipped with a 5G communication device, supports NSA and SA dual modes, and has a downlink rate of up to 2Gbps and an uplink rate of up to 1Gbps.

9. The unmanned positioning system for a bucket wheel excavator according to claim 1, characterized in that: The PLC control module (500) is equipped with Ethernet communication, a CPU main frequency of 1.5 GHz, a memory of 2 GB DDR4, a storage of 32 GB SSD, supports multiple communication protocols, and increases IO cards according to the newly added sensor points. The number of cards meets the usage and reserves 20% spare points. At the same time, the PLC control module (500) and the remote monitoring center realize real-time data transmission through a 5G private network. The 5G private network frequency band is n78, the bandwidth is 100 MHz, the uplink rate can reach up to 1 Gbps, and the downlink rate can reach up to 2 Gbps.

Images