Material detection system and method for unattended bulk cargo ship loader

Abstract

The invention discloses a material detection system of an unattended bulk cargo ship loader. The material detection system comprises a material detection module, a ship attitude monitoring module, an anti-collision and state detection module, a communication module, a central processing unit and a PLC control system. All the modules are connected through a preset data interface and a communication protocol to form a complete material detection system; compared with the prior art, the material detection system has the remarkable beneficial effects that the operation efficiency and precision are remarkably improved, the operation safety and stability are enhanced, the reliability and stability of a communication system are improved, and integration and optimization are easy. Due to the advantages, the system has important significance for promoting intelligent and efficient development of the port logistics industry.

Description

Technical Field

[0001] The invention relates to the technical field of material detection of bulk material ship loader, and in particular to a material detection system and method of an unattended bulk material ship loader. Background Art

[0002] In the port logistics industry, bulk ship loaders are important loading and unloading equipment, and their operating efficiency and safety directly affect the efficiency and cost of the entire logistics chain. Traditional loading operations rely on manual operations, which have problems such as low efficiency, low precision, and many safety hazards. With the development of automation technology, unmanned bulk ship loaders have gradually become a trend in the industry. However, the existing unmanned ship loaders still have some technical bottlenecks in material detection, such as insufficient detection accuracy, need to improve operating safety, and insufficient reliability of the communication system.

[0003] The information disclosed in this background technology section is only intended to deepen the understanding of the overall background technology of the present invention, and should not be regarded as acknowledging or suggesting in any form that the information constitutes the prior art already known to those skilled in the art. Summary of the invention

[0004] In view of the problems existing in the prior art, the purpose of the present invention is to provide a material detection system and method for an unmanned bulk material loader. The system integrates a high-precision three-dimensional laser scanner and a millimeter-wave radar to achieve full coverage and high-precision scanning of materials in the cabin, and generate a three-dimensional distribution model of the material, including detailed information such as shape, height, and volume.

[0005] In order to achieve the above object, the present invention adopts the following technical solutions: A material detection system for an unattended bulk material ship loader, the material detection system comprising: Material detection module: used to detect the shape, height and distribution of materials in the cabin in real time. The module includes at least one laser scanner and one millimeter wave radar. The laser scanner and millimeter wave radar are connected to the central processing unit through optical fiber; Ship attitude monitoring module: used to monitor the changes in the ship's attitude in real time, including the tilt angle and shaking amplitude. It uses a laser scanner to detect the position and attitude of the ship in real time, combines Beidou satellite positioning to form a coordinate system, provides a basis for coordinate calculation, and transmits data to the central processing unit through a wireless communication module; Anti-collision and status detection module: used to detect the distance between the ship loader and the ship, other equipment and obstacles, prevent collisions, and monitor the equipment operation status, including vibration, noise, temperature and current parameters. This module is implemented through ultrasonic sensors, temperature sensors and current sensors, and is connected to the PLC control system; Communication module: including optical fiber communication lines and 5G wireless networks, used to achieve high-speed data transmission and real-time control between devices, ensuring real-time transmission of data from each module to the central processing unit; Central processing unit: located in the central control room, equipped with a server and an operation interface developed based on industrial control software, used to receive data from each module, perform data analysis and processing, and issue control instructions to the PLC control system; PLC control system: connected to the central processing unit, controls various operations of the ship loader according to the received control instructions, including the running speed of the chute, depth adjustment and carriage movement; Among them, the above modules are connected through preset data interfaces and communication protocols to form a complete material detection system.

[0006] Furthermore, the laser scanner in the material detection module specifically adopts a high-precision three-dimensional laser scanner, whose scanning accuracy is accurate to ±3mm, and the scanning range fully covers the internal space of the cabin, ensuring that the material shape and distribution information is captured without omission.

[0007] Furthermore, the coordinate system constructed in the ship posture monitoring module includes: a coordinate system with a designated position on the dock shore as the origin, a coordinate system with a specific position of the ship unloader as the origin, and a coordinate system with a specific position of the hull as the origin.

[0008] Furthermore, the ultrasonic sensor in the anti-collision and status detection module adopts a wide-band design, and the detection distance range is controlled between 0.5 meters and 10 meters to meet the safety detection requirements of different distances; the temperature sensor uses an industrial-grade thermistor probe with a measurement range of -40°C to +100°C, ensuring accurate readings under various ambient temperatures; the current sensor is equipped with a high-precision A / D conversion circuit with a measurement accuracy of not less than ±0.5%, realizing accurate monitoring of the equipment's operating status.

[0009] Furthermore, the optical fiber communication line in the communication module uses low-loss single-mode optical fiber with a transmission wavelength of 1310nm or 1550nm. The transmission rate is stably maintained at above 10Gbps, ensuring high-speed transmission of large amounts of data; the 5G wireless network part adopts a non-independent networking architecture, combined with the Sub-6GHz frequency band, to achieve a downlink rate of not less than 1Gbps and an uplink rate of not less than 300Mbps, ensuring the real-time and stability of remote monitoring and command transmission.

[0010] Furthermore, the core of the central processing unit is a server equipped with a high-performance Intel Xeon series CPU, combined with a large-capacity DDR4 ECC memory with ECC verification, to ensure that the system can run efficiently and stably when processing massive data from each module.

[0011] Furthermore, the central processing unit is integrated with a database system, and the operator customizes the input and saves the ship parameters and bulk material characteristics; after the material detection module monitors the volume and distribution of the bulk material, the CPU calls the relevant material and ship parameters; the CPU uses the golden section algorithm, based on the golden ratio optimization technology, to iteratively narrow the search range and find the optimal solution that meets the stacking flatness and safety.

[0012] Furthermore, the central processing unit integrates the Hertz-Mindlin contact model to simulate the mechanical behavior of contact between particles. Through the API, the user defines a bulk material factory to simulate the required material group. During the simulation, the particles can be given initial kinetic parameters. After material detection, the CPU calls physical information to simulate loading behavior, and the built-in ANN uses the SPSS MLP structure to handle nonlinear problems. The neural network input includes state parameters, and the output is a real-time three-dimensional space model and a prediction model, which are compared with the standard model to evaluate the loading process. The system automatically adjusts the loading parameters according to the differences, optimizes the loading process, and ensures the stability and safety of the ship.

[0013] Furthermore, the PLC control system adopts a dual-machine hot standby architecture, and the main PLC and the backup PLC are connected by a high-speed redundant communication link; when the main PLC cannot work normally due to a fault, the backup PLC can automatically take over the control task within milliseconds and seamlessly switch to the backup working mode, ensuring the continuous, stable and safe operation of the loader in an unattended state.

[0014] A material detection method for an unattended bulk material ship loader comprises the following steps: S1: Each module collects data separately and transmits it to the central processing unit through the communication module; S2: After receiving the data, the central processing unit performs real-time data analysis and generates a material distribution model and a ship attitude report; S3: Based on the analysis results, the central processing unit sends control instructions to the ship loader through the PLC control system to adjust the running speed, depth of the chute and the moving path of the trolley; S4: The anti-collision and status detection module monitors the equipment operation status and surrounding environment in real time. If any abnormality is found, it will immediately send an alarm to the central processing unit and initiate safety protection measures. S5: Execute steps S1 to S4 cyclically to realize the fully automated material detection and loading operation of the unmanned bulk material ship loader.

[0015] By adopting the above technical solution, the present invention has the following beneficial effects: The present invention proposes a material detection system for an unmanned bulk ship loader. The system integrates a high-precision three-dimensional laser scanner and a millimeter-wave radar to achieve full coverage and high-precision scanning of materials in the cabin, and generates a three-dimensional distribution model of the materials, including detailed information such as shape, height, and volume. In addition, the system also monitors the operating status and surrounding environment of the ship loader in real time through ultrasonic sensors, temperature sensors, and current sensors to enhance operational safety and stability. In terms of communication, the system uses low-loss single-mode optical fiber and 5G communication technology to ensure the reliability and high speed of data transmission.

[0016] Compared with the prior art, the material detection system of the present invention has significant beneficial effects, including significantly improving operation efficiency and accuracy, enhancing operation safety and stability, improving the reliability and stability of the communication system, and facilitating integration and optimization, etc. These advantages make the system of great significance for promoting the intelligent and efficient development of the port logistics industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0018] Figure 1 Schematic diagram of the system framework of the present invention.

[0019] Figure 2 It is a flow chart of the system operation of the present invention. DETAILED DESCRIPTION

[0020] The technical solution of the present invention will be described clearly and completely below in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0021] The specific implementation of the present invention is described in detail below in conjunction with the accompanying drawings. It should be understood that the specific implementation described here is only used to illustrate and explain the present invention, and is not used to limit the present invention.

[0022] Combination Figure 1 As shown, the material detection system of the unattended bulk material ship loader proposed by the present invention comprises: Material detection module: A high-precision 3D laser scanner is selected as the main detection equipment and installed at an appropriate position of the ship loader (such as on the chute arm) to achieve full coverage scanning of the materials in the cabin. At the same time, a millimeter-wave radar is equipped as an auxiliary detection device and installed near the laser scanner to supplement the depth information and enhance the robustness of the detection. The laser scanner and millimeter-wave radar are connected to the central processing unit through optical fiber. The high-speed transmission characteristics and anti-interference ability of the optical fiber are used to ensure that the scanning data can be transmitted to the processing unit in real time and accurately. In the central processing unit, the received laser scanning data and millimeter-wave radar data are processed through dedicated image processing software and algorithms to generate a three-dimensional distribution model of the material, including the shape, height, volume and other information of the material.

[0023] Ship attitude monitoring module: shore, machine, and ship three-body positioning, using laser material detection, ship loader position data comprehensive analysis to establish the control system space coordinate system, track along the ship loader running direction as X axis, vertical to the shore direction as Y axis, height direction as Z axis, accurately measure the distance parameters between the shore, ship, and ship loader to establish shore, machine, and ship three-dimensional positioning. Through 3D laser scanning of the three-dimensional model of the ship, combined with the installation position of the laser scanner, a ship-machine coordinate system is formed, and then combined with the position of the ship loader, a machine-ship-shore overall three-dimensional coordinate system is formed, and laser data is obtained for data processing. The laser scan is fan-shaped, and the polar coordinate value (L, β) with the laser emission center as the origin is obtained. L is the distance from the measuring point to the laser scanner; β is the angle between the laser light and the horizontal axis of the laser scanning plane. According to the above obtained (L, β) and the model parameters of the overall mechanical structure of the loader, the three-dimensional coordinates of the imaging model obtained by coordinate transformation are the three-dimensional coordinates obtained by direct calculation based on geometric space.

[0024] Anti-collision and status detection module: Ultrasonic sensor layout: Multiple ultrasonic sensors are installed around the ship loader and at key locations (such as the front end of the chute arm and both sides of the moving track) to form an all-round detection network. Ultrasonic sensors measure the distance to surrounding objects by emitting ultrasonic waves and receiving echoes. Temperature sensors and current sensors are installed on key components of the ship loader, such as motors, reducers, and bearings. The temperature sensor uses an industrial-grade thermistor probe, and the current sensor obtains the current value through non-invasive measurement. The data of the ultrasonic sensor, temperature sensor, and current sensor are transmitted to the PLC control system via wired or wireless methods. The PLC control system collects this data in real time and conducts preliminary analysis and judgment to monitor the operating status of the equipment and the safety status of the surrounding environment. When an abnormal equipment status (such as excessive temperature, excessive current) or a collision risk is detected, the PLC control system immediately sends an alarm signal to the central processing unit and initiates corresponding safety protection measures (such as shutdown, deceleration, obstacle avoidance, etc.).

[0025] Communication module: Lay low-loss single-mode optical fiber as the main communication line between the ship loader and the central control room. The optical fiber line should have good anti-interference ability and stability to ensure the reliability and high speed of data transmission. Deploy 5G base stations in the port area to provide high-speed wireless network access capabilities for the ship loader. Install a 5G communication module on the ship loader, access the 5G network through the non-independent networking (NSA) architecture, realize real-time communication with the remote monitoring system, formulate a unified communication protocol and data interface standard, and ensure that data between modules and between modules and the central processing unit can be smoothly transmitted and exchanged. At the same time, design redundant communication links and fault switching mechanisms to improve the reliability and stability of the communication system.

[0026] Central processing unit: A server equipped with a high-performance Intel Xeon series CPU is selected as the core device of the central processing unit. The server should be equipped with a large-capacity ECC-checked DDR4 ECC memory and a high-speed SSD hard disk or RAID array to improve data processing and storage capabilities, and the operation interface and data processing algorithm should be developed based on industrial control software. The operation interface should have a friendly human-computer interaction interface and rich functional options to facilitate operators to monitor and control the system. The data processing algorithm should be efficient and accurate, able to process massive data from each module in real time and generate control instructions, integrate each module with the central processing unit, and conduct comprehensive functional and performance tests. During the test process, the focus should be on issues such as the real-time, accuracy, stability and reliability of the system, and the system should be optimized and adjusted according to the test results.

[0027] In the central processing unit (CPU), the integrated database system allows operators to customize and save detailed parameters of common ships and physical properties of bulk materials. These data include but are not limited to material density, particle size distribution, friction coefficient, stacking angle, etc. After the material detection module completes the real-time monitoring of the volume and distribution of bulk materials, the central processing unit will call the corresponding material physical parameters and corresponding ship parameters in the database.

[0028] The central processing unit uses the golden section algorithm, which is an optimization technique for finding the minimum value of a function within a given interval. The algorithm is based on the golden ratio and gradually narrows the search interval through an iterative process until the optimal solution that meets the material stacking flatness and ship safety requirements is found. Mathematically, the search process for the pile volume can be expressed as a single valley function optimization problem under unconstrained conditions. Its goal is to solve the pile volume parameters that minimize the objective function value, and establish the change curve of the pile volume as a three-dimensional space model. As a standard stacking mathematical model, it can provide a theoretical basis for the subsequent loading process. This model can reflect the stacking morphology of different materials under different loading conditions, and provide guidance for efficient and safe loading.

[0029] The central processing unit also integrates the Hertz-Mindlin contact model, which is a model for simulating the mechanical behavior of inter-particle contact. Through the application programming interface (API), the operator can define the bulk material factory (UDL) and realize the simulation of the bulk material group required by the individual. During the simulation, each particle can be given initial dynamic parameters such as velocity and acceleration. After the material detection module is completed, the central processing unit will call the corresponding physical information in the bulk material factory to simulate the material behavior during the actual loading process. The built-in artificial neural network (ANN) adopts the SPSS multi-layer perceptron (MLP) structure and can handle nonlinear problems. In this system, the input of the neural network includes the state parameters collected by the material detection module, the ship attitude monitoring module, and the anti-collision and state detection module. These parameters are input into the neural network as variable dependent variables, while other continuous variables are used as covariates. The architecture of the neural network usually includes at least one hidden layer, and this system is set to 2 layers to enhance the nonlinear fitting ability of the model. If the neural network has no hidden layer, it can only solve linear problems. By increasing the number of hidden layers, a multi-layer neural network structure is formed, which can solve nonlinear samples.

[0030] The neural network forms a real-time 3D spatial model and a predicted 3D spatial model through transformation algorithms. These models are compared with the standard stacking mathematical model to evaluate whether the current loading process is close to the ideal material stacking and flat loading process. According to the difference between the models, the system can automatically adjust the loading parameters to optimize the loading process and ensure the stability and safety of the ship.

[0031] Combination Figure 2 As shown, the material detection method of the unattended bulk material ship loader proposed by the present invention comprises the following steps: S1: Each module collects data separately and transmits it to the central processing unit through the communication module; S2: After receiving the data, the central processing unit performs real-time data analysis and generates a material distribution model and a ship attitude report; S3: Based on the analysis results, the central processing unit sends control instructions to the ship loader through the PLC control system to adjust the running speed, depth of the chute and the moving path of the trolley; S4: The anti-collision and status detection module monitors the equipment operation status and surrounding environment in real time. If any abnormality is found, it will immediately send an alarm to the central processing unit and initiate safety protection measures. S5: Execute steps S1 to S4 cyclically to realize the fully automated material detection and loading operation of the unmanned bulk material ship loader.

[0032] Compared with the prior art, the main beneficial technical effects of the present invention include: Significantly improve operational efficiency and accuracy: By integrating high-precision 3D laser scanners and millimeter-wave radars, the system can achieve full coverage and high-precision scanning of materials in the cabin, and generate a 3D distribution model of the materials, including detailed information such as shape, height, and volume. This not only improves the accuracy and efficiency of material detection, but also provides accurate data support for subsequent loading operations, significantly improving overall operational efficiency.

[0033] Enhance operational safety and stability: Through 3D imaging, the analysis system separates, filters, and constructs 3D models to obtain the relative position of the material to the cabin, and the relative position of the cabin and the ship loader, thereby unifying the system coordinate system. This enables the ship loader to always sense the relative position of the cabin during operation, ensuring the safety of system production and operation.

[0034] Improve the reliability and stability of the communication system: By laying low-loss single-mode optical fiber as the main communication line and deploying 5G base stations in the port area, the detection system of the present invention achieves high-speed and stable network communication. At the same time, the design of redundant communication links and fault switching mechanisms further improves the reliability and stability of the communication system and ensures the real-time and accuracy of data transmission.

[0035] Easy to integrate and optimize: The detection system of the present invention adopts a unified communication protocol and data interface standard between the modules and between the modules and the central processing unit, which is easy to integrate the system and expand its functions. At the same time, the operating interface and data processing algorithm developed based on high-performance servers and industrial control software enable the system to have efficient and accurate data processing capabilities, and can be flexibly configured and optimized according to actual needs.

[0036] In summary, the material detection system for an unmanned bulk loader proposed in the present invention shows significant beneficial effects in improving operating efficiency and accuracy, enhancing operating safety and stability, reducing labor costs and improving management efficiency, improving communication system reliability and stability, and facilitating integration and optimization, which is of great significance for promoting the intelligent and efficient development of the port logistics industry.

[0037] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A material detection system for an unattended bulk material ship loader, characterized in that: The material detection system comprises: Material detection module: used to detect the shape, height and distribution of materials in the cabin in real time. The module includes at least one laser scanner and one millimeter wave radar. The laser scanner and millimeter wave radar are connected to the central processing unit through optical fiber; Ship attitude monitoring module: used to monitor the changes in the ship's attitude in real time, including the tilt angle and shaking amplitude. It uses a laser scanner to detect the position and attitude of the ship in real time, combines Beidou satellite positioning to form a coordinate system, provides a basis for coordinate calculation, and transmits data to the central processing unit through a wireless communication module; Anti-collision and status detection module: used to detect the distance between the ship loader and the ship, other equipment and obstacles, prevent collisions, and monitor the equipment operation status, including vibration, noise, temperature and current parameters. This module is implemented through ultrasonic sensors, temperature sensors and current sensors, and is connected to the PLC control system; Communication module: including optical fiber communication lines and 5G wireless networks, used to achieve high-speed data transmission and real-time control between devices, ensuring real-time transmission of data from each module to the central processing unit; Central processing unit: located in the central control room, equipped with a server and an operation interface developed based on industrial control software, used to receive data from each module, perform data analysis and processing, and issue control instructions to the PLC control system; PLC control system: connected to the central processing unit, controls various operations of the ship loader according to the received control instructions, including the running speed of the chute, depth adjustment and carriage movement; Among them, the above modules are connected through preset data interfaces and communication protocols to form a complete material detection system.

2. The material detection system for an unmanned bulk material ship loader according to claim 1, characterized in that: The laser scanner in the material detection module specifically adopts a high-precision three-dimensional laser scanner, whose scanning accuracy is accurate to ±3mm, and the scanning range fully covers the internal space of the cabin, ensuring that the material shape and distribution information are captured without omission.

3. The material detection system for an unmanned bulk ship loader according to claim 1, characterized in that: The coordinate systems in the ship attitude monitoring module include: a coordinate system with a designated position on the dock shore as the origin, a coordinate system with a specific position of the ship unloader as the origin, and a coordinate system with a specific position of the hull as the origin.

4. The material detection system for an unmanned bulk ship loader according to claim 1, characterized in that: The ultrasonic sensor in the anti-collision and status detection module adopts a wide-band design, and the detection distance range is controlled between 0.5 meters and 10 meters to meet the safety detection requirements of different distances; the temperature sensor uses an industrial-grade thermistor probe with a measurement range of -40°C to +100°C to ensure accurate readings under various ambient temperatures; the current sensor is equipped with a high-precision A / D conversion circuit with a measurement accuracy of not less than ±0.5%, realizing accurate monitoring of the equipment's operating status.

5. The material detection system for an unmanned bulk material ship loader according to claim 1, characterized in that: The optical fiber communication line in the communication module uses low-loss single-mode optical fiber with a transmission wavelength of 1310nm or 1550nm. The transmission rate is stably maintained at above 10Gbps, ensuring high-speed transmission of large amounts of data; the 5G wireless network part adopts a non-independent networking architecture, combined with the Sub-6GHz frequency band, to achieve a downlink rate of not less than 1Gbps and an uplink rate of not less than 300Mbps, ensuring the real-time and stability of remote monitoring and command transmission.

6. The material detection system for an unmanned bulk material ship loader according to claim 1, characterized in that: The core of the central processing unit is a server equipped with a high-performance Intel Xeon series CPU, coupled with a large-capacity DDR4ECC memory with ECC verification, to ensure that the system can run efficiently and stably when processing massive data from each module.

7. The material detection system for an unmanned bulk material ship loader according to claim 1, characterized in that: The central processing unit is integrated with a database system, and the operator customizes the input and saves the ship parameters and bulk material characteristics; after the material detection module monitors the volume and distribution of the bulk material, the CPU calls the relevant material and ship parameters; the CPU uses the golden section algorithm, based on the golden ratio optimization technology, to iteratively narrow the search range and find the optimal solution that meets the stacking flatness and safety.

8. The material detection system for an unattended bulk material ship loader according to claim 1, characterized in that: The central processing unit integrates the Hertz-Mindlin contact model to simulate the mechanical behavior of contact between particles. Through the API, users define bulk material factories to simulate the required material groups. During the simulation, particles can be given initial kinetic parameters. After material detection, the CPU calls physical information to simulate loading behavior, and the built-in ANN uses the SPSS MLP structure to handle nonlinear problems. The neural network input includes state parameters, and the output is a real-time three-dimensional space model and a prediction model, which are compared with the standard model to evaluate the loading process. The system automatically adjusts the loading parameters according to the differences, optimizes the loading process, and ensures the stability and safety of the ship.

9. The material detection system for an unmanned bulk material ship loader according to claim 1, characterized in that: The PLC control system adopts a dual-machine hot standby architecture, and the main PLC and the backup PLC are connected by a high-speed redundant communication link; when the main PLC cannot work normally due to a fault, the backup PLC can automatically take over the control task within milliseconds and seamlessly switch to the backup working mode, ensuring the continuous, stable and safe operation of the ship loader in an unattended state.

10. A method for material detection using the material detection system of an unattended bulk ship loader according to any one of claims 1 to 9, characterized in that: The following steps are involved: S1: Each module collects data separately and transmits it to the central processing unit through the communication module; S2: After receiving the data, the central processing unit performs real-time data analysis and generates a material distribution model and a ship attitude report; S3: Based on the analysis results, the central processing unit sends control instructions to the ship loader through the PLC control system to adjust the running speed, depth of the chute and the moving path of the trolley; S4: The anti-collision and status detection module monitors the equipment operation status and surrounding environment in real time. If any abnormality is found, it will immediately send an alarm to the central processing unit and initiate safety protection measures. S5: Execute steps S1 to S4 cyclically to realize the fully automated material detection and loading operation of the unmanned bulk material ship loader.

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