A freight train eccentric load detection and automatic correction system

Abstract

The present invention discloses a freight train overload detection and automatic correction system, comprising a gantry frame spanning rails, with a discharge chute provided on the frame, a loaded carriage passing under the frame, and the discharge chute unloading the cargo into the carriage during the passing process, a first three-dimensional laser radar, a material leveling device, and a second three-dimensional laser radar sequentially provided on the frame after the discharge chute, the material leveling device comprising a cylinder with a hydraulic telescopic arm, the cylinder being fixed on the frame, a material leveling scraper being provided at the front end of the telescopic arm extended from the cylinder, a controller connecting the discharge chute, the first and second three-dimensional laser radars, and a cylinder control circuit; the controller detects the loading status of the carriage material in real time through the first and second three-dimensional laser radars, and controls the extended length of the cylinder telescopic arm and the status of the material leveling scraper according to the loading status of the carriage material, thereby balancing the overload of the forward loaded carriage after passing through the material leveling scraper when overload occurs during loading.

Description

Technical Field

[0001] The invention relates to a freight train eccentric load detection and automatic correction system. Background Art

[0002] In recent years, with the increase in the amount of goods transported by rail, the safety of rail transportation has received more and more attention. Ore transportation is an important area of ​​train freight. 90% of the iron ore imported to ocean ports needs to be transported inland by rail. As a transportation management unit, the relevant railway departments require that the materials in the carriage are evenly distributed horizontally and the longitudinal load difference does not exceed the allowable value. Because when the train passes through a curve during driving, due to the effect of centrifugal force, the sharp-angled material piles in the carriage will be thrown to one side of the carriage, causing the material loading on both sides of the carriage to be unbalanced, which is not only easy to cause the material to fall, but also the unstable center of gravity is also a cause of the train rollover.

[0003] Due to the stacking characteristics of bulk materials, when loading bulk materials into train carriages by means of loading buildings or forklifts, the materials will form a pile with a sharp top in the middle of the carriage. Affected by factors such as humidity, viscosity, and density, the materials in the carriage are uneven and overloaded. Especially for high-density ore materials, their bulk density is large, and the material loading height is only about 1 / 2 of the height of the carriage, which is more than 1 meter lower than the upper edge of the side of the car. The loading chute cannot approach the surface for scraping, not only because of its own insufficient length, but also to avoid collision with the carriage. The material falls by its own weight, forming an irregular sharp pile, and the overload phenomenon is particularly prominent. If the above-mentioned overload phenomena are not discovered and handled in time, when the train is running at high speed, due to the centrifugal force of the curve, the sharp pile in the carriage will be thrown to one side, which may cause the carriage to tilt, and even in severe cases, it may cause the carriage to overturn, causing danger to personnel and goods, not only affecting transportation efficiency, but also causing road damage, vehicle damage, and safety hazards.

[0004] However, the existing freight train overload detection and correction and leveling mainly rely on manual labor, usually requiring three to five workers to work together with the help of shovels and climb into the carriages when the freight train passes. It takes about 3 to 10 minutes per carriage on average, and the total time for the entire train is about 3 to 10 hours (calculated based on 60 carriages). This production method is not only labor-intensive and time-consuming, but also the workers' frequent climbing, entering and exiting, and jumping from the carriages are high-altitude operations, which poses a great safety hazard.

[0005] In a few areas, mechanical assistance is used, and the control method is basically manual operation, relying on human observation experience to evaluate whether the carriage material is overloaded, and manually adjusting the overload height. This production method cannot detect overload in real time and quickly and accurately control the overload height. Moreover, loading operations and overload detection belong to different functional departments, which are usually far away and cannot be operated synchronously. They need to occupy lanes and stop and wait separately, which is inefficient and affects the railway transportation time. Summary of the invention

[0006] In view of the above problems, the purpose of the present invention is to provide a freight train overload detection and automatic correction system, which can detect the material stacking pattern distribution in the carriage in real time, discover the overload situation in time and take corrective measures simultaneously.

[0007] In order to achieve the above object, the scheme of the present invention is: A freight train overload detection and automatic correction system comprises a gantry frame across rails, a discharge chute is arranged on the frame, a loaded carriage passes under the frame, and the discharge chute discharges the cargo into the carriage during the passing process, wherein: a first three-dimensional laser radar, a material leveling device and a second three-dimensional laser radar are sequentially arranged on the frame after the discharge chute, the material leveling device comprises a cylinder with a hydraulic telescopic arm, the cylinder is fixed on the frame, a material leveling scraper is arranged at the front end of the telescopic arm extended from the cylinder, a controller connects the discharge chute, the first and second three-dimensional laser radars and the cylinder control circuit; the controller detects the loading status of the carriage material in real time through the first and second three-dimensional laser radars, and controls the extension length of the cylinder telescopic arm and the status of the material leveling scraper according to the loading status of the carriage material, thereby making the overload of the forward loaded carriage tend to be balanced after passing through the material leveling scraper when overload occurs during loading.

[0008] The solution is further that: the distance between the first three-dimensional laser radar and the unloading chute is not less than 2m, and the distance between the second three-dimensional laser radar and the flat material scraper is not more than 1m.

[0009] The solution is further as follows: the flat material scraper is divided into two scraper sections from the middle, and the two scraper sections are horizontally rotatably connected by a hinge. A rearward-extending bracket is provided between the two scraper sections, and there are two electric telescopic arms. One end of the two electric telescopic arms is connected to the bracket through a rotating shaft, and the other ends of the two electric telescopic arms are respectively hinged with the two scraper sections for transverse sliding. The horizontal rotation of the two scraper sections is controlled by the two electric telescopic arms, thereby changing the horizontal angles of the two scraper sections to different states with the axis of the carriage.

[0010] The solution is further that the two scraper sections are horizontally at different horizontal angles with the axis of the carriage, including: the two scraper sections are horizontally vertical at 90 degrees to the axis of the carriage and the middle of the two scraper sections protrudes forward to form an arrow shape.

[0011] The solution is further that when the two scraper sections are in a horizontal and vertical state of 90 degrees with the axis of the carriage, the rotation angle of the two scraper sections rotating horizontally forward or backward is not greater than 20 degrees.

[0012] The solution is further that: the controller also controls the opening of the discharge chute outlet gate according to the loading status, and sends a speed control signal to control the forward speed of the loading compartment.

[0013] The scheme further includes: the process of controlling the extension length of the oil cylinder telescopic arm and the state of the flat material scraper according to the loading state of the carriage material, so as to make the unbalanced load in the forward loading carriage tend to be balanced after passing through the flat material scraper, includes: Step 1: Adjust the two scrapers to be 90 degrees horizontally and vertically with the axis of the carriage; Step 2: Obtain laser point cloud data of the first 3D laser radar; Step 3: Based on the laser point cloud data of the first 3D laser radar and the known geometric dimension data of the loading compartment, a loading state model of the bulk material in the compartment is established. The loading state model includes the height distribution state of the bulk material in the width direction of the compartment, and then the unbalanced loading state of the bulk material is obtained from the height distribution state and the weight per unit volume of the bulk material; Step 4: Adjust the height of the flat material scraper at the front end of the cylinder telescopic arm in the car according to the height distribution of the bulk material and the eccentric load of the bulk material; Step 5: Obtain laser point cloud data of the second 3D laser radar; Step 6: Based on the laser point cloud data of the second 3D laser radar and the known geometric dimension data of the loading compartment, a loading state model of the bulk material in the compartment after passing through the flat material scraper is established. The loading state model includes the height distribution state of the bulk material in the width direction of the compartment, and then the unbalanced load state of the bulk material after passing through the flat material scraper is obtained from the height distribution state and the weight per unit volume of the bulk material; Step 7: Based on the eccentric load state of the bulk material after passing through the flat material scraper, if it has tended to be balanced, maintain the flat material scraper state; if it is still unbalanced, adjust the flat material scraper state again to make the eccentric load tend to be balanced.

[0014] The solution is further that: the adjusting the flat material scraper according to the obtained eccentric load state of the bulk material after passing through the flat material scraper comprises: When the weight is concentrated along the center axis of the carriage: lower the height of the flat material scraper in the carriage, and adjust the middle of the two scrapers to bulge forward in the shape of an arrow; When one side along the center axis of the car is heavier: lower the height of the flat material scraper in the car, adjust the scraper on the heavier side of the car to rotate forward, keep the scraper on the lighter side of the car at a 90-degree horizontal vertical state with the axis of the car, or adjust the scraper on the lighter side of the car to rotate backward.

[0015] A further solution is that the eccentric load tends to balance when the eccentric load deviation is less than a set safety value.

[0016] The beneficial effects of the present invention are: The present invention uses laser point cloud technology to accurately measure the internal shape of the carriage through the three-dimensional laser radars set before and after the scraper. By processing and analyzing the laser point cloud data, the unbalanced load of the carriage can be detected in real time and accurately. The fully automatic operation does not require manual intervention or climbing the carriage, which is safe and efficient. Its advantages include: 1. Real-time monitoring: The system can detect the material accumulation distribution in the carriage in real time, detect the unbalanced loading situation in time and take corrective measures simultaneously.

[0017] 2. Accurate ranging: LiDAR has accurate ranging capabilities and can measure the load conditions at different positions in the car with high precision.

[0018] 3. High degree of automation: The system adopts automation technology, which can automatically identify and analyze the unbalanced load of the carriage. Through computer analysis and processing, combined with PLC drive control actuator, it can completely replace manual work.

[0019] 4. Safe and reliable: The system has complete safety protection measures and fault monitoring functions to ensure the stable operation of the system and the safety of operation.

[0020] 5. Remote monitoring: The system can realize remote monitoring and management of data through network connection function, which is convenient for users to view and analyze anytime and anywhere The present invention provides a freight compartment overload detection and full-automatic correction based on three-dimensional laser scanning, which can realize real-time detection and correction, thereby improving transportation efficiency and safety. At the same time, the system has a simple structure, is easy to operate, and has good practicality and broad application prospects.

[0021] The present invention is described in detail below with reference to the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of the system structure of the present invention; Figure 2 It is a schematic diagram of the flat material scraper structure of the system of the present invention; Figure 3 It is a schematic diagram of the flat material scraper of the system of the present invention in the arrow state. DETAILED DESCRIPTION

[0023] A freight train eccentric load detection and automatic correction system, such as Figure 1 and Figure 2As shown, the system includes a gantry frame 1 across the rails, a discharge chute 2 and a storage bin 3 are arranged on the frame, the upper port of the discharge chute 2 is connected to the storage bin 3, a regulating valve 201 is arranged on the lower port side of the discharge chute 2, and the regulating valve 201 is used to adjust and control the discharge flow rate of the lower port of the discharge chute 2, the upper port of the storage bin 3 is connected to the feeding belt conveyor 4, a parking space recognition sensor 5 is arranged on one end of the frame 1, and a loading carriage 6 passes under the frame 1 after passing through the parking space recognition sensor 5, and the discharge chute 2 discharges the cargo into the carriage 6 during the passing process, wherein: the frame 1 is sequentially provided with a first three-dimensional laser radar 7, a flat material device 8 and a second three-dimensional laser radar 9 after the discharge chute. 3D laser radar 9, the flattening device 8 includes a cylinder 802 with a hydraulic telescopic arm 801, the cylinder 802 is fixed on the frame 1, and a flattening scraper 803 is arranged at the front end of the telescopic arm 801 extended by the hydraulic cylinder. A controller (not shown in the figure) is connected to the unloading chute 2, the first 3D laser radar 7 and the second 3D laser radar 9 and the cylinder control circuit; the controller detects the loading status of the carriage material in real time through the first and second 3D laser radars 7 and 9, and controls the extended length of the cylinder telescopic arm and the state of the flattening scraper according to the loading status of the carriage material, so that when the front loading carriage is overloaded, the overload can be balanced after passing through the flattening scraper.

[0024] The system also has a network connection function: the system can share data and link equipment with the previous loading system through wireless or wired communication to reduce unnecessary operating losses, and transmit monitoring data and correction results to the dispatching center or train control system to facilitate remote monitoring and management of the train.

[0025] Among them, the hydraulic cylinder can also be replaced by a servo motor, and the three-dimensional laser radar is installed at a height of 5 meters to 6 meters directly above the freight car to obtain a three-dimensional model of the loading status of the freight car in real time. The overload detection module in the controller analyzes the three-dimensional model, calculates the overload situation of the freight car, and feeds back the result to the fully automatic correction module in the controller. The fully automatic correction module drives the servo motor or hydraulic actuator to act according to the overload situation, adjusts the lifting height and lifting time of the flattening device in the vertical direction, and scrapes the material in the horizontal direction with the help of the relative speed of the train to achieve fully automatic correction. In order to achieve the best flattening effect: the interval between the first three-dimensional laser radar and the unloading chute is not less than 2m, and the distance between the second three-dimensional laser radar and the flattening scraper is not more than 1m.

[0026] In order to flexibly adjust the eccentric load, different structures are proposed for the flat material scraper: Figure 2 and Figure 3As shown, the flat material scraper is divided into two scraper sections from the middle, namely a left scraper 803-1 and a right scraper 803-2, and the two scraper sections are horizontally rotatably connected by a hinge 803-3. A rearward-extending bracket 803-4 is arranged between the two scraper sections 803-1 and 803-2, and two electric telescopic arms 804 are connected to the bracket 803-4 at one end through a rotating shaft, and the other ends of the two electric telescopic arms 804 are respectively connected to the two The scraper segments are laterally slidably hinged, as shown in the figure, a transverse groove 803-5 is set on the two scraper segments, a sliding shaft 803-6 is set in the groove 803-5, and the other ends of the two electric telescopic arms 804 are rotatably connected to the sliding shaft 803-6. The two electric telescopic arms 804 are used to control the horizontal rotation of the two scraper segments 803-1 and 803-2, thereby changing the horizontal state of the two scraper segments 803-1 and 803-2 to form different horizontal angles with the car body axis 601.

[0027] Wherein: the two scraper sections are horizontally at different angles to the carriage axis, including: Figure 3 As shown, the two scraper sections are in a horizontal and vertical state at 90 degrees to the axis of the carriage, and the middle of the two scraper sections protrudes forward in an arrow-like state.

[0028] Furthermore, when the two scraper sections are in a horizontal and vertical state with the axis of the carriage at 90 degrees, the rotation angle of the two scraper sections when rotating horizontally forward or backward is not greater than 20 degrees.

[0029] In the embodiment: the controller further controls the opening of the discharge chute outlet gate according to the loading state, and sends a speed control signal to control the forward speed of the loading compartment.

[0030] In the embodiment: the process of controlling the extension length of the telescopic arm of the oil cylinder and the state of the flat material scraper according to the loading state of the carriage material, so as to make the unbalanced load in the forward loading carriage tend to be balanced after passing through the flat material scraper, includes: Step 1: Adjust the two scrapers to be 90 degrees horizontally and vertically with the axis of the carriage; Step 2: Obtain laser point cloud data of the first 3D laser radar; Step 3: Based on the laser point cloud data of the first 3D laser radar and the known geometric dimension data of the loading compartment, a loading state model of the bulk material in the compartment is established. The loading state model includes the height distribution state of the bulk material in the width direction of the compartment, and then the unbalanced loading state of the bulk material is obtained from the height distribution state and the weight per unit volume of the bulk material; Step 4: Adjust the height of the flat material scraper at the front end of the cylinder telescopic arm in the car according to the height distribution of the bulk material and the eccentric load of the bulk material; Step 5: Obtain laser point cloud data of the second 3D laser radar; Step 6: Based on the laser point cloud data of the second 3D laser radar and the known geometric dimension data of the loading compartment, a loading state model of the bulk material in the compartment after passing through the flat material scraper is established. The loading state model includes the height distribution state of the bulk material in the width direction of the compartment, and then the unbalanced load state of the bulk material after passing through the flat material scraper is obtained from the height distribution state and the weight per unit volume of the bulk material; Step 7: Based on the eccentric load state of the bulk material after passing through the flat material scraper, if it has tended to be balanced, maintain the flat material scraper state; if it is still unbalanced, adjust the flat material scraper state again to make the eccentric load tend to be balanced.

[0031] Wherein: the step of adjusting the flat material scraper according to the unbalanced load state of the bulk material after passing through the flat material scraper comprises: When the weight is concentrated along the center axis of the carriage: lower the height of the flat material scraper in the carriage, and adjust the middle of the two scrapers to bulge forward in the shape of an arrow; When one side along the center axis of the car is heavier: lower the height of the flat material scraper in the car, adjust the scraper on the heavier side of the car to rotate forward, keep the scraper on the lighter side of the car at a 90-degree horizontal vertical state with the axis of the car, or adjust the scraper on the lighter side of the car to rotate backward.

[0032] Wherein: the eccentric load tending to balance means that the eccentric load deviation is less than a set safety value.

[0033] The above-mentioned freight train overload detection and automatic correction system embodiment can realize the accurate measurement of the internal shape of the carriage through the three-dimensional laser radars arranged before and after the scraper; through the processing and analysis of the laser point cloud data, the overload situation of the carriage can be detected in real time and accurately; it is fully automatic in operation, without the need for manual intervention or climbing the carriage, and is safe and efficient.

Claims

1. A freight train overload detection and automatic correction system, comprising a gantry frame across the rails, with a discharge chute provided on the frame, and a loaded carriage passing under the frame, and the discharge chute discharges the cargo into the carriage during the passing process, characterized in that: A first three-dimensional laser radar, a material leveling device and a second three-dimensional laser radar are sequentially arranged on the frame after the unloading chute. The material leveling device includes a cylinder with a hydraulic telescopic arm. The cylinder is fixed on the frame. A material leveling scraper is arranged at the front end of the telescopic arm extended from the cylinder. A controller connects the unloading chute, the first and second three-dimensional laser radars and the cylinder control circuit. The controller detects the loading status of the carriage material in real time through the first and second three-dimensional laser radars, and controls the extended length of the cylinder telescopic arm and the state of the material leveling scraper according to the loading status of the carriage material, so that when the front loading carriage is unevenly loaded, the uneven load can be balanced after passing through the material leveling scraper.

2. The system according to claim 1, characterized in that The distance between the first three-dimensional laser radar and the unloading chute is not less than 2m, and the distance between the second three-dimensional laser radar and the flat material scraper is not more than 1m.

3. The system according to claim 1, characterized in that The flat material scraper is divided into two scraper sections from the middle, and the two scraper sections are horizontally rotatably connected by a hinge. A rearward-extending bracket is arranged between the two scraper sections, and there are two electric telescopic arms. One end of the two electric telescopic arms is connected to the bracket through a rotating shaft, and the other ends of the two electric telescopic arms are respectively hinged with the two scraper sections for transverse sliding. The horizontal rotation of the two scraper sections is controlled by the two electric telescopic arms, thereby changing the horizontal state of the two scraper sections to form different horizontal angles with the axis of the carriage.

4. The system according to claim 3, characterized in that The two scraper sections are horizontally at different angles to the carriage axis, including: the two scraper sections are horizontally vertical at 90 degrees to the carriage axis and the middle of the two scraper sections protrudes forward to form an arrow.

5. The system according to claim 3, characterized in that When the two scraper sections are in a horizontal and vertical state with the axis of the carriage at 90 degrees, the rotation angle of the two scraper sections when rotating horizontally forward or backward is no more than 20 degrees.

6. The system according to claim 1, characterized in that The controller also controls the opening of the discharge chute outlet gate according to the loading status, and sends a speed control signal to control the forward speed of the loading carriage.

7. The system according to claim 3, characterized in that The process of controlling the extension length of the oil cylinder telescopic arm and the state of the flat material scraper according to the loading state of the carriage material, so as to make the eccentric load of the forward loading carriage tend to be balanced after passing through the flat material scraper, includes: Step 1: Adjust the two scrapers to be 90 degrees horizontally and vertically with the axis of the carriage; Step 2: Obtain laser point cloud data of the first 3D laser radar; Step 3: Based on the laser point cloud data of the first 3D laser radar and the known geometric dimension data of the loading compartment, a loading state model of the bulk material in the compartment is established. The loading state model includes the height distribution state of the bulk material in the width direction of the compartment, and then the unbalanced loading state of the bulk material is obtained from the height distribution state and the weight per unit volume of the bulk material; Step 4: Adjust the height of the flat material scraper at the front end of the cylinder telescopic arm in the car according to the height distribution of the bulk material and the eccentric load of the bulk material; Step 5: Obtain laser point cloud data of the second 3D laser radar; Step 6: Based on the laser point cloud data of the second 3D laser radar and the known geometric dimension data of the loading compartment, a loading state model of the bulk material in the compartment after passing through the flat material scraper is established. The loading state model includes the height distribution state of the bulk material in the width direction of the compartment, and then the unbalanced load state of the bulk material after passing through the flat material scraper is obtained from the height distribution state and the weight per unit volume of the bulk material; Step 7: Based on the eccentric load state of the bulk material after passing through the flat material scraper, if it has tended to be balanced, maintain the flat material scraper state; if it is still unbalanced, adjust the flat material scraper state again to make the eccentric load tend to be balanced.

8. The system according to claim 7, characterized in that The method of adjusting the flat material scraper according to the unbalanced load state of the bulk material after passing through the flat material scraper comprises: When the weight is concentrated along the center axis of the carriage: lower the height of the flat material scraper in the carriage, and adjust the middle of the two scrapers to bulge forward in the shape of an arrow; When one side along the center axis of the car is heavier: lower the height of the flat material scraper in the car, adjust the scraper on the heavier side of the car to rotate forward, keep the scraper on the lighter side of the car at a 90-degree horizontal vertical state with the axis of the car, or adjust the scraper on the lighter side of the car to rotate backward.

9. The system according to claim 1 or 7, characterized in that: The eccentric load tending to balance means that the eccentric load deviation is less than a set safety value.

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