Material detection system and method for unattended bulk material ship loader

Abstract

The application discloses an unmanned bulk loading machine material detection system, which comprises a material detection module, a ship posture monitoring module, a collision prevention and state detection module, a communication module, a central processing unit and a PLC control system. The modules are connected through a preset data interface and a communication protocol to form a complete material detection system. The material detection system has the advantages of improving work efficiency and precision, enhancing work safety and stability, improving the reliability and stability of the communication system, and being easy to integrate and optimize. These advantages make the system important for promoting the intelligent and efficient development of the port logistics industry.

Description

Technical Field

[0001] This invention relates to the field of material detection technology for bulk cargo loaders, and more particularly to a material detection system and method for unattended bulk cargo loaders. Background Technology

[0002] In the port logistics industry, bulk cargo loaders are crucial loading and unloading equipment, and their operational efficiency and safety directly impact the efficiency and cost of the entire logistics chain. Traditional loading operations rely on manual labor, resulting in low efficiency, low accuracy, and numerous safety hazards. With the development of automation technology, unattended bulk cargo loaders are gradually becoming the industry trend. However, existing unattended loaders still face some technical bottlenecks in material detection, such as insufficient detection accuracy, room for improvement in operational safety, and inadequate reliability of communication systems.

[0003] The information disclosed in this background section is intended only to enhance the understanding of the general background of the invention and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0004] To address the problems existing in the prior art, the present invention aims to provide a material detection system and method for an unattended bulk material loader. This system integrates a high-precision 3D laser scanner and millimeter-wave radar to achieve full coverage and high-precision scanning of materials inside the ship's hold, generating a 3D distribution model of the materials, including detailed information such as shape, height, and volume.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A material detection system for an unattended bulk cargo loader, the material detection system comprising:

[0007] Material detection module: Used to detect the shape, height and distribution of materials in the cabin in real time. This 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 via optical fiber.

[0008] Ship attitude monitoring module: used to monitor the ship's attitude changes in real time, including tilt angle and roll amplitude. It uses a laser scanner to detect the ship's position and attitude in real time, and combines Beidou satellite positioning to form a coordinate system to provide coordinate calculation basis. The data is then transmitted to the central processing unit through a wireless communication module.

[0009] Anti-collision and state detection module: used for detecting the distance between the ship loader and the ship, other equipment and obstacles, preventing collision, and monitoring the equipment operating state, including vibration, noise, temperature and current parameters. This module is realized through ultrasonic sensors, temperature sensors and current sensors, and is connected with the PLC control system;

[0010] Communication module: including optical fiber communication line and 5G wireless network, used for realizing high-speed data transmission and real-time control between devices, ensuring real-time transmission of module data to the central processing unit;

[0011] Central processing unit: located in the central control room, configured with a server and an operation interface developed based on industrial control software, used for receiving module data, performing data analysis and processing, and issuing control instructions to the PLC control system;

[0012] PLC control system: connected with the central processing unit, controls the operation of the ship loader according to the received control instructions, including the running speed of the chute, the depth adjustment and the movement of the trolley;

[0013] Among them, the above-mentioned modules are connected through pre-set data interface and communication protocol to form a complete material detection system.

[0014] Further, the laser scanner in the material detection module specifically adopts a high-precision three-dimensional laser scanner, with scanning accuracy of ±3mm and scanning range covering the entire internal space of the ship cabin, ensuring that the material shape and distribution information are captured without omission.

[0015] Further, the coordinate system in the ship attitude monitoring module includes: a coordinate system with a specified location on the wharf as the origin, a coordinate system with a specific location of the ship unloader as the origin, and a coordinate system with a specific location of the ship body as the origin.

[0016] Further, the ultrasonic sensor in the anti-collision and state detection module adopts a wideband design, with a detection distance range of 0.5m to 10m to adapt to different distance safety detection requirements; the temperature sensor selects an industrial-grade thermistor probe, with a measurement range of -40°C to +100°C, ensuring accurate readings under various environmental temperatures; the current sensor has a high-precision A / D conversion circuit, with a measurement accuracy of not less than ±0.5%, realizing accurate monitoring of the equipment operating state.

[0017] Further, the optical fiber communication line in the communication module selects low-loss single-mode optical fiber, the transmission wavelength is 1310nm or 1550nm, the transmission rate is stably maintained at 10Gbps or more, ensuring high-speed transmission of large data volume; the 5G wireless network part adopts a non-independent networking architecture, combined with a 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.

[0018] Further, the core of the central processing unit is a server configured with a high-performance Intel Xeon series CPU, matched with large-capacity DDR4 ECC memory with ECC verification, to ensure that the system can operate efficiently and stably when processing massive data from various modules.

[0019] Further, the central processing unit integrates a database system, and the operating personnel input and save ship parameters and bulk material characteristics; after the material detection module monitors the volume and distribution of bulk materials, the CPU calls relevant material and ship parameters; the CPU uses the golden section algorithm based on the golden ratio optimization technology to iteratively narrow the search interval to find the optimal solution that meets the stacking flatness and safety.

[0020] Further, the central processing unit integrates the Hertz-Mindlin contact model for simulating the mechanical behavior of particle contact; through the API, the user defines the bulk material plant, simulates the required material group; in the simulation, the particles can be assigned initial kinetic parameters; after the material is detected, the CPU calls the physical information to simulate the loading behavior, and the built-in ANN uses the SPSS MLP structure to process 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 to optimize the loading process and ensure the stability and safety of the ship.

[0021] Further, the PLC control system adopts a dual-machine hot standby architecture, and the main PLC and the standby PLC are connected through a high-speed redundant communication link; when the main PLC cannot work normally due to failure, the standby PLC can automatically take over the control task within milliseconds, seamlessly switching to standby mode, ensuring the continuous, stable and safe operation of the ship loader in an unattended state.

[0022] A material detection method of an unattended bulk material ship loader, comprising the following steps:

[0023] S1: Each module collects data and transmits it to the central processing unit through the communication module;

[0024] S2: After receiving the data, the central processing unit performs real-time data analysis to generate a material distribution model and a ship attitude report;

[0025] S3: According to the analysis result, the central processing unit sends control instructions to the ship loader through the PLC control system to adjust the running speed, depth and movement path of the car;

[0026] S4: The anti-collision and state detection module monitors the equipment running state and the surrounding environment in real time, and immediately sends an alarm to the central processing unit when an abnormal situation is found, and starts the safety protection measures;

[0027] S5: The steps S1 to S4 are executed in a cycle to realize the full-automatic material detection and loading operation of the unattended bulk material ship loader.

[0028] By adopting the above technical scheme, the present application has the following beneficial effects:

[0029] The present application provides a material detection system for an unattended bulk material 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 the materials in the ship cabin, generating a three-dimensional distribution model of the materials, including detailed information such as shape, height, volume, etc. In addition, the system also monitors the running state of the ship loader and the surrounding environment in real time through ultrasonic sensors, temperature sensors, current sensors, etc. to enhance the safety and stability of the operation. In terms of communication, the system uses low-loss single-mode optical fiber and 5G communication technology to ensure the reliability and speed of data transmission.

[0030] The material detection system of the present application has significant advantages over the prior art, including significantly improving the efficiency and accuracy of the operation, enhancing the safety and stability of the operation, improving the reliability and stability of the communication system, and being easy to integrate and optimize. These advantages make the system important for promoting the intelligent and efficient development of the port logistics industry. BRIEF DESCRIPTION OF DRAWINGS

[0031] In order to more clearly illustrate the technical solutions in the specific embodiments or prior art, the following will briefly introduce the drawings needed to be used in the specific embodiments or prior art description. Obviously, the drawings described below are some embodiments of the present application, and those skilled in the art can obtain other drawings according to these drawings without creative labor.

[0032] Figure 1 It is a system framework diagram of the present application.

[0033] Figure 2 It is a system flowchart of the present application. DETAILED DESCRIPTION

[0034] The technical solutions of the present application will be clearly and completely described below with reference to the drawings. Obviously, the described embodiments are part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor fall within the scope of protection of the present application.

[0035] The specific embodiments of the present application will be described in detail below with reference to the drawings. It should be understood that the specific embodiments described herein are only used to illustrate and explain the present application, and are not used to limit the present application.

[0036] In combination with Figure 1 As shown in the drawings, the material detection system of the unattended bulk loading machine provided by the present application comprises:

[0037] The material detection module: a high-precision three-dimensional laser scanner is selected as the main detection device and is installed at a proper position of the loading machine (such as the chute arm) to realize full-coverage scanning of the materials in the ship cabin. At the same time, a millimeter wave radar is equipped as an auxiliary detection device and is installed near the laser scanner to supplement the depth information and enhance the robustness of detection. The laser scanner and the millimeter wave radar are connected to the central processing unit through an optical fiber, and the high-speed transmission characteristics and anti-interference ability of the optical fiber are utilized 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 by a dedicated image processing software and algorithm to generate a three-dimensional distribution model of the materials, including the shape, height, volume and other information of the materials.

[0038] The ship attitude monitoring module: the shore, machine and ship positioning, the data of laser material detection and loading machine position are comprehensively analyzed to establish a control system space coordinate system, the track along the running direction of the loading machine is the X axis, the vertical direction to the shore is the Y axis, and the height direction is the Z axis. The distance parameters between the shore, the ship and the loading machine are accurately measured to establish the three-dimensional positioning of the shore, the machine and the ship. By 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 loading machine, a whole three-dimensional coordinate system of machine-ship-land is formed. The laser data is processed, the scanning of the laser presents a fan-shaped distribution, and the polar coordinate values (L, β) with the laser emission center as the origin are obtained. L is the distance from the measurement point to the laser scanner; β is the included angle between the laser light and the horizontal axis of the laser scanning plane. According to the (L, β) obtained above and the model parameters of the overall mechanical structure of the loading machine, the three-dimensional coordinates of the imaging model are obtained through coordinate transformation. The three-dimensional coordinates are directly obtained by geometric space operation.

[0039] Anti-collision and state detection module: Ultrasonic sensor layout: Install multiple ultrasonic sensors around the ship loader and at key locations (such as the front end of the chute arm, both sides of the moving track) to form a comprehensive 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 critical components of the ship loader, such as motors, reducers, and bearings. Temperature sensors use industrial-grade thermistor probes, and current sensors use non-invasive measurement methods to obtain current values. The data from ultrasonic sensors, temperature sensors, and current sensors are transmitted to the PLC control system via wired or wireless methods. The PLC control system collects these data in real time and performs preliminary analysis and judgment to monitor the operating status of the equipment and the safety of the surrounding environment. When detecting abnormal equipment status (such as high temperature or excessive current) or collision risk, the PLC control system immediately sends an alarm signal to the central processing unit and initiates appropriate safety protection measures (such as stopping, slowing down, and avoiding obstacles).

[0040] Communication module: Low-loss single-mode optical fiber is laid between the ship loader and the central control room as the main communication line. The optical fiber line should have good anti-interference ability and stability to ensure the reliability and speed of data transmission. 5G base stations are deployed in the port area to provide high-speed wireless network access capabilities for the ship loader. A 5G communication module is installed on the ship loader to access the 5G network through the non-standalone (NSA) architecture, enabling real-time communication with the remote monitoring system. A unified communication protocol and data interface standard are established to ensure smooth data transmission and exchange between modules and between modules and the central processing unit. Redundant communication links and fault switching mechanisms are designed to improve the reliability and stability of the communication system.

[0041] Central processing unit: A server 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 large-capacity ECC-verified DDR4 ECC memory and high-speed SSD hard drives or RAID arrays to improve data processing and storage capabilities. An industrial control software-based operation interface and data processing algorithm are developed. The operation interface should have a friendly human-machine interface and rich function options to facilitate operators to monitor and control the system. The data processing algorithm should be efficient and accurate, capable of processing massive data from various modules in real time and generating control instructions. The modules and the central processing unit are integrated into a system, and comprehensive functional and performance tests are conducted. During testing, focus on real-time, accuracy, stability, and reliability, and optimize and adjust the system based on test results.

[0042] In the central processing unit (CPU), the integrated database system allows the operator to customize the input and save the detailed parameters of the common ship and the physical properties of the bulk material. These data include but are not limited to the density, particle size distribution, friction coefficient, angle of repose, etc. of the material. After the material detection module completes the real-time monitoring of the volume and distribution of the bulk material, the central processing unit will call the corresponding material physical parameters in the database and the corresponding ship parameters.

[0043] 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. Based on the golden ratio, this algorithm gradually narrows the search interval through an iterative process until the optimal solution that meets the material pile flatness and ship safety requirements is found. Mathematically, the search process for the pile volume can be described as a single-peak function optimization problem under no constraints, with the goal of finding the pile volume parameters that minimize the objective function value. The change curve of the pile volume is established as a three-dimensional space model, serving as a standard pile mathematical model that can provide a theoretical basis for subsequent loading processes. This model can reflect the pile shape of different materials under different loading conditions, providing guidance for efficient and safe loading.

[0044] The central processing unit also integrates the Hertz-Mindlin contact model, which is a model used to simulate the mechanical behavior of particle contact. Through the application programming interface (API), the operator can define the discrete element method (DEM) and implement the simulation of the discrete element method (DEM) required by the individual. During the simulation process, each particle can be assigned initial velocity, acceleration, and other dynamic parameters. After the material detection module is completed, the central processing unit will call the corresponding physical information in the discrete element method (DEM) to simulate the behavior of the material during the actual loading process. The built-in artificial neural network (ANN) uses 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 as variables into the neural network, while other continuous variables are used as covariants. The architecture of the neural network usually includes at least one hidden layer, and this system is set to two 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.

[0045] The neural network forms real-time three-dimensional space models and predictive three-dimensional space models through transformation algorithms. These models are compared with the standard pile mathematical model to evaluate whether the current loading process is approaching the ideal state of material pile flatness 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.

[0046] In combination Figure 2 As shown in the figure, the material detection method of the unattended bulk loading machine provided by the present application comprises the following steps:

[0047] S1: Each module collects data and transmits it to the central processing unit through the communication module;

[0048] S2: After receiving the data, the central processing unit performs real-time data analysis to generate a material distribution model and a ship attitude report;

[0049] S3: According to the analysis results, the central processing unit sends control instructions to the loading machine through the PLC control system to adjust the running speed, depth and cart moving path of the chute;

[0050] S4: The anti-collision and state detection module monitors the equipment running state and the surrounding environment in real time, and immediately sends an alarm to the central processing unit and starts safety protection measures when an abnormal situation is found;

[0051] S5: Circulate S1 to S4 steps to realize the full automation of the unattended bulk loading machine for material detection and loading operation.

[0052] Compared with the prior art, the present application has the following main beneficial technical effects:

[0053] Significantly improve the operation efficiency and accuracy: by integrating high-precision three-dimensional laser scanners and millimeter wave radars, the system can realize full coverage and high-precision scanning of the materials in the ship cabin, generating a three-dimensional distribution model of the materials, including detailed information such as shape, height, volume, etc. This not only improves the accuracy and efficiency of material detection, but also provides accurate data support for subsequent loading operations, significantly improving the overall operation efficiency.

[0054] Enhance the safety and stability of the operation: through three-dimensional imaging, the analysis system separates, filters and constructs the three-dimensional model to obtain the relative position of the material to the cabin and the relative position of the cabin and the loading machine, thereby unifying the system coordinate system. The loading machine can always perceive the relative position of the cabin during operation, ensuring the safety of system production and operation.

[0055] 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 application realizes high-speed and stable network communication. At the same time, the design of redundant communication links and fault switching mechanism further improves the reliability and stability of the communication system, ensuring the real-time and accuracy of data transmission.

[0056] Easy to integrate and optimize: the detection system of the application adopts unified communication protocol and data interface standard between each module and between the module and the central processing unit, which is easy to integrate and expand the function. At the same time, the operation interface and data processing algorithm developed based on high-performance server and industrial control software make the system have high efficient and accurate data processing ability, which can be flexibly configured and optimized according to the actual demand.

[0057] In summary, the material detection system of the unmanned bulk loading machine proposed by the application has significant beneficial effects in improving the efficiency and accuracy of the lifting operation, enhancing the safety and stability of the operation, reducing the labor cost and improving the management efficiency, improving the reliability and stability of the communication system, and being easy to integrate and optimize, which has important significance for promoting the intelligent and efficient development of the port logistics industry.

[0058] Finally, it should be pointed out that: the above embodiments are only used to illustrate the technical solutions of the application, but not to limit them; although the application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that: it can still modify the technical solutions recorded in the foregoing embodiments, or make equivalent replacement for part or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the application.

Claims

1. A bulk material detection system for an unattended bulk ship loader, characterised in that, The material detection system comprises: A material detection module: for real-time detection of the shape, height and distribution of the material in the cabin, which comprises at least one laser scanner and one millimeter wave radar, and the laser scanner and the millimeter wave radar are connected with the central processing unit through an optical fiber; A ship attitude monitoring module: for real-time monitoring of the attitude change of the ship, including the inclination angle and the shaking amplitude, the laser scanner is used to detect the position and attitude of the ship body in real time, combined with the Beidou satellite positioning, a coordinate system is formed to provide the basis for coordinate calculation, and the data is transmitted to the central processing unit through the wireless communication module; A collision prevention and state detection module: for detecting the distance between the ship unloader and the ship, other equipment and obstacles, preventing collision, and monitoring the equipment running state, including vibration, noise, temperature and current parameters, which is realized by ultrasonic sensors, temperature sensors and current sensors, and connected with the PLC control system; A communication module: including optical fiber communication line and 5G wireless network, for realizing high-speed data transmission and real-time control between devices, ensuring real-time transmission of module data to the central processing unit; A central processing unit: located in the central control room, configured with a server and an operation interface developed based on industrial control software, for receiving module data, data analysis and processing, and issuing control instructions to the PLC control system; A PLC control system: connected with the central processing unit, controlling the operation of the ship unloader according to the received control instructions, including the running speed of the chute, the depth adjustment and the movement of the cart; Wherein, the above modules are connected through pre-set data interface and communication protocol to form a complete material detection system; The central processing unit integrates a database system, and the operator inputs and saves the ship parameters and bulk material characteristics; after the material detection module monitors the bulk material volume and distribution, the CPU calls the relevant material and ship parameters; the CPU uses the golden section algorithm to iteratively narrow the search interval to find the optimal solution that meets the stacking flatness and safety; The central processing unit integrates the Hertz-Mindlin contact model for simulating the mechanical behavior of particle contact; through API, the user defines the bulk material factory to simulate the required material group; in the simulation, the particles can be assigned initial kinetic parameters; after the material detection, the CPU calls the physical information to simulate the loading behavior, and the built-in ANN uses the SPSS MLP structure to process 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 to optimize the loading process and ensure the stability and safety of the ship; The PLC control system adopts a dual-machine hot standby architecture, and the main PLC and the standby PLC are connected through a high-speed redundant communication link; when the main PLC fails to work normally, the standby PLC can automatically take over the control task within milliseconds, seamlessly switching to the standby working mode, ensuring the continuous, stable and safe operation of the ship unloader in the unattended state.

2. The unattended bulk material ship loader material detection system of claim 1, wherein, The laser scanner in the material detection module specifically adopts a high-precision three-dimensional laser scanner, which has a scanning accuracy of ±3 mm and a scanning range that fully covers the internal space of the cabin, ensuring that the material form and distribution information is captured without omission.

3. The unattended bulk material ship loader material detection system of claim 1, wherein, The ultrasonic sensor in the anti-collision and state detection module adopts a wideband design, with a detection distance range controlled between 0.5 meters and 10 meters to adapt to different distance safety detection needs; the temperature sensor selects an industrial-grade thermistor probe with a measurement range covering -40°C to +100°C, ensuring accurate readings under various environmental temperatures; the current sensor has a high-precision A / D conversion circuit with a measurement accuracy of not less than ±0.5%, achieving accurate monitoring of the equipment operating state.

4. The unattended bulk material ship loader material detection system of claim 1, wherein, The optical fiber communication line in the communication module selects a low-loss single-mode optical fiber with a transmission wavelength of 1310 nm or 1550 nm, a transmission rate stably maintained above 10 Gbps, ensuring high-speed transmission of large data volumes; the 5G wireless network part adopts a non-standalone networking architecture combined with a Sub-6GHz frequency band, achieving a downlink rate of not less than 1 Gbps and an uplink rate of not less than 300 Mbps, ensuring the real-time and stability of remote monitoring and command transmission.

5. The unattended bulk material ship loader material detection system of claim 1, wherein, The core of the central processing unit is a server configured with a high-performance Intel Xeon series CPU, paired with large-capacity DDR4 ECC memory with ECC verification, ensuring that the system can efficiently and stably operate when processing massive data from various modules.

6. A method for material detection using a material detection system of the unattended bulk material ship loader according to any one of claims 1 to 5, characterized in that, The method comprises the following steps: S1: Each module collects data 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 to generate a material distribution model and a ship attitude report; S3: According to 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, and cart movement path of the spout; S4: The anti-collision and state detection module monitors the equipment operating state and the surrounding environment in real time and immediately sends an alarm to the central processing unit if an abnormality is found; S5: Steps S1 to S4 are executed in a loop to achieve full automation of material detection and ship loading operations for unmanned bulk material loaders.

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