Remote control system of unattended bucket wheel machine

Abstract

The invention relates to a remote control system for an unattended bucket wheel machine, and the system is characterized in that the system comprises the following modules: an accurate positioning module which is used for monitoring the cart walking, cantilever pitching and rotation angle of the bucket wheel machine in real time; the flow detection module is used for detecting the flow quantity of materials on a cantilever belt of the bucket wheel machine in real time; the intelligent control module is used for receiving information of the accurate positioning module and the flow detection module and carrying out intelligent analysis and calculation; the automatic execution mechanism module is used for executing specific operation actions according to the instruction of the intelligent control module; the safety protection module is used for detecting the operation state and the surrounding environment of the bucket wheel machine in real time; the remote monitoring module is used for receiving a monitoring video of a bucket wheel machine site; and the system integration and communication module realizes data exchange and communication. The problems that operation of a traditional bucket wheel machine depends on manual on-site monitoring and manual control, the working efficiency is low, the safety risk is high, and the operation cost is high are solved.

Description

Technical Field

[0001] The invention relates to the field of automated loading and unloading equipment, and in particular to a remote control system for an unmanned bucket wheel machine. Background Art

[0002] Bucket wheel cranes, as large-scale bulk material handling equipment, play an important role in industrial fields such as ports and mines. However, the operation of traditional bucket wheel cranes relies on manual on-site monitoring and manual control, which has problems such as low work efficiency, high safety risks, and high operating costs. With the rapid development of intelligent technology, it has become an inevitable trend in the development of the industry to apply remote monitoring, automatic control, safety protection and other technologies to bucket wheel cranes to realize unmanned remote control systems. Summary of the invention

[0003] In response to the problems in the prior art, the present invention provides a remote control system for an unmanned bucket wheel machine. By integrating multiple modules such as precise positioning, flow detection, intelligent control, automatic execution, safety protection, remote monitoring, system integration and communication, remote monitoring, automatic control, safety protection and intelligent decision-making of the bucket wheel machine can be achieved, thereby improving the working efficiency of the bucket wheel machine, reducing operating costs and ensuring personnel safety.

[0004] The precise positioning module includes two high-precision magnetostrictive displacement sensors and two angle sensors, which are used to detect the travel position of the bucket wheel crane trolley and the pitch angle of the boom. At the same time, a high-precision GPS+Beidou dual-mode positioning device is used to measure the longitude, latitude and altitude of the bucket wheel crane in real time. The data of the sensor and the positioning device are transmitted to the intelligent control module through the data bus to achieve precise positioning of the bucket wheel crane. The accuracy error of the magnetostrictive displacement sensor is ±1mm, and the range is customized according to the length of the bucket wheel crane track; the accuracy error of the angle sensor is ±0.1°, and the range is 0-360°; the positioning accuracy error of the GPS and Beidou dual-mode positioning device is ±2.5 cm, and the update frequency is 2 times per second. It is used to monitor the travel of the bucket wheel crane trolley, the pitch and rotation angle of the boom in real time; to achieve precise positioning of the bucket wheel crane, improve control accuracy and operating efficiency, and provide reliable basic data for remote monitoring and automatic control.

[0005] The flow detection module uses a 3D laser radar scanner to scan the material flow on the bucket wheel cantilever belt in real time. The data processing unit receives the scanning data of the laser radar scanner and calculates the real-time material flow through an algorithm. The scanning frequency of the 3D laser radar scanner is 10 times per second, the scanning range is the cantilever belt width ±5 cm, and the measurement accuracy is ±5%. The data processing unit uses a high-performance embedded processor with a processing speed of 1,000 data calculations per second. It is used to detect the material flow on the bucket wheel cantilever belt in real time; it realizes real-time monitoring and accurate calculation of material flow, provides accurate flow data for the intelligent control module, optimizes operation strategies and parameters, and improves operation efficiency.

[0006] The intelligent control module, based on the control algorithm of deep learning, processes and analyzes the collected data in real time to predict the optimal operation path and parameters of the bucket wheel machine. The logic judgment unit judges the current state of the bucket wheel machine based on the analysis results and determines the optimal operation strategy and parameters. The control instruction generation unit generates control instructions and sends them to the automatic actuator module through the data bus; the training data set of the deep learning control algorithm contains a variety of operation scenarios and working conditions, and the model accuracy is not less than 98%; the judgment accuracy of the logic judgment unit is not less than 98%, and the response time does not exceed 100 milliseconds; the control instruction generation unit adopts high-speed communication protocols such as EtherCAT or PROFINET, and the control instruction sending frequency is 5 times per second. Receive information from the precise positioning module and the flow detection module, perform intelligent analysis and calculation, determine the optimal operation strategy and parameters, and send control instructions; realize intelligent control and optimization of the bucket wheel machine operation strategy, improve operation efficiency and accuracy, and reduce operating costs.

[0007] The automatic actuator module includes a motor drive device and a hydraulic drive device, which are used to drive the bucket wheel crane trolley to travel, the cantilever pitch and the rotation movement. The motor drive device adopts an AC variable frequency motor with overload protection and overheating protection functions. The hydraulic drive device is used to drive the bucket wheel crane's rotation mechanism and has pressure stability control and flow regulation functions; the motor drive device has a power of 75kW, a speed of 1450rpm, overload protection and overheating protection; the hydraulic drive device has a pressure of 25MPa, a flow of 60L / min, pressure stability control and flow regulation. Specific operation actions are performed according to the instructions of the intelligent control module; the automatic execution and precise control of the bucket wheel crane are realized, the operation efficiency and accuracy are improved, and the manual intervention and operation costs are reduced.

[0008] Safety protection module, including ultrasonic sensor, laser rangefinder, overload protection device and intelligent image recognition technology. Ultrasonic sensor is used to detect obstacles around bucket wheel machine, laser rangefinder is used to detect the height of material pile, overload protection device is used to protect motor and hydraulic system, intelligent image recognition technology is used to analyze monitoring video in real time, identify abnormal situation and trigger alarm; the detection distance of ultrasonic sensor is 10 meters, accuracy is ±10cm; the measurement range of laser rangefinder is 0-50 meters, accuracy is ±5cm; the protection time of overload protection device is 0.1 seconds; the recognition accuracy of intelligent image recognition technology is not less than 95%, and the response time is not more than 100 milliseconds. It is used to detect the operating status and surrounding environment of bucket wheel machine in real time, trigger alarm and take corresponding protective measures; realize the safety protection and abnormality detection of bucket wheel machine, ensure the safety of equipment and personnel, and reduce safety risks.

[0009] The remote monitoring module includes an industrial-grade high-definition digital network camera and a wireless transmission device. The camera is used to shoot the monitoring video of the bucket wheel machine site, and the wireless transmission device transmits the monitoring video to the remote monitoring center in real time. The monitoring center server is used to store and analyze the monitoring video data, and provide remote playback and query functions; the industrial-grade high-definition digital network camera has a resolution of 4K, a frame rate of 60 frames per second, night vision function and wide dynamic range; the wireless transmission device uses a 5G network, with a bandwidth of not less than 100Mbps and a delay of not more than 200 milliseconds; the storage capacity of the monitoring center server is not less than 10TB, and the query speed is not less than 100 frames per second. Receive the monitoring video of the bucket wheel machine site and send it to the remote monitoring center for real-time display; realize remote monitoring and real-time display of the bucket wheel machine, improve monitoring efficiency and accuracy, and reduce the labor intensity of on-site monitoring by personnel.

[0010] System integration and communication module, including data bus, communication protocol converter and data encryption unit. The data bus is used to connect various modules to realize data exchange and communication. The communication protocol converter is used to convert the communication protocols of different modules into a unified communication protocol to ensure the compatibility and reliability of data transmission. The data encryption unit encrypts the transmitted data to ensure the security of data transmission; the data bus adopts CANopen or PROFIBUS protocol, and the transmission rate is not less than 1Mbps; the communication protocol converter supports multiple communication protocol conversions, such as Modbus, OPC UA, etc.; the data encryption unit adopts AES-256 encryption algorithm, and the key update cycle is once every 24 hours. Integrate and connect various modules to realize data exchange and communication; realize data exchange and communication between various modules of bucket wheel machine, ensure the compatibility and reliability of data transmission, and improve the overall performance and security of the system.

[0011] The above modules are connected by data through system integration and communication modules to form a complete unmanned remote control system for bucket wheel excavators.

[0012] The beneficial effects of the present invention are as follows: the unattended remote control system for bucket wheel machine provided by the present invention realizes remote monitoring, automatic control, safety protection and intelligent decision-making of bucket wheel machine by integrating multiple modules. The system improves the working efficiency of bucket wheel machine, reduces operating costs, and ensures the safety of equipment and personnel. At the same time, the remote monitoring and intelligent decision-making functions of the system enable operators to remotely monitor and manage bucket wheel machine, reduce labor intensity and improve work efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0014] Figure 1 It is a system architecture diagram of the present invention.

[0015] Figure 2 The figure is a flowchart of the system of the present invention. DETAILED DESCRIPTION

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

[0017] like Figure 1-Figure 2 As shown, the remote control system of an unmanned bucket wheel machine described in the present invention specifically includes the following modules: Precise positioning module, sensors and positioning devices collect data in real time and transmit it to the intelligent control module through the data bus. The intelligent control module calculates the current position, boom angle and height of the bucket wheel machine based on the data, providing basic data for subsequent intelligent control and safety protection, and is used to monitor the bucket wheel machine's trolley travel, boom pitch and rotation angle in real time; Flow detection module: the laser radar scanner scans the material flow in real time, the data processing unit receives the scanned data and performs algorithm processing to calculate the real-time material flow, and sends the data to the intelligent control module for real-time detection of the material flow on the bucket wheel machine cantilever belt; Intelligent control module, which receives data from the precise positioning module and the flow detection module, performs real-time processing and analysis, determines the optimal operation strategy and parameters, generates control instructions and sends them to the automatic actuator module, receives information from the precise positioning module and the flow detection module, performs intelligent analysis and calculation, determines the optimal operation strategy and parameters, and sends control instructions; Automatic actuator module: The automatic actuator module receives control instructions from the intelligent control module and performs specific operation actions according to the instructions, such as trolley travel, boom pitch and rotation, etc.; performs specific operation actions according to the instructions of the intelligent control module; Safety protection module: The safety protection module detects the operating status and surrounding environment of the bucket wheel machine in real time. When an abnormal situation is detected, an alarm is triggered and corresponding protective measures are taken, such as stopping the operation and emergency shutdown. It is used to detect the operating status and surrounding environment of the bucket wheel machine in real time, trigger an alarm and take corresponding protective measures; Remote monitoring module: the camera shoots monitoring video, and the wireless transmission device transmits the video to the remote monitoring center in real time. The monitoring center server stores and analyzes the video data for remote monitoring and management by operators, receives the monitoring video of the bucket wheel machine site, and sends it to the remote monitoring center for real-time display; System integration and communication module: The system integration and communication module integrates and connects various modules to realize data exchange and communication. The communication protocol converter ensures the compatibility and reliability of data transmission, and the data encryption unit ensures the security of data transmission. It integrates and connects various modules to realize data exchange and communication. The above modules are connected by data through system integration and communication modules to form a complete unmanned remote control system for bucket wheel excavators.

[0018] The precise positioning module includes two high-precision magnetostrictive displacement sensors, which are respectively installed at both ends of the bucket wheel crane trolley's walking track, and are used to detect the starting and ending positions of the bucket wheel crane trolley with an accuracy of ±1mm; two angle sensors are respectively installed on both sides of the bucket wheel crane cantilever, and are used to detect the pitch angle of the cantilever with an accuracy of ±0.1°; a GPS and Beidou dual-mode positioning device is installed on the top of the bucket wheel crane, and is used to measure the longitude, latitude and altitude of the bucket wheel crane in real time, with a positioning accuracy of ±2.5 cm and an update frequency of 2 times per second.

[0019] The flow detection module includes a 3D laser radar scanner installed above the cantilever belt of the bucket wheel excavator. The scanning frequency is 10 times per second, the scanning range is the cantilever belt width ±5 cm, and the measurement accuracy reaches ±5%; the data processing unit uses a high-performance embedded processor to receive the scanning data of the laser radar scanner and calculate the real-time material flow through an algorithm. The processing speed is 1,000 data calculations per second.

[0020] The intelligent control module includes a logic judgment unit, which judges the current state of the bucket wheel machine according to the analysis results and determines the optimal operation strategy and parameters, with a judgment accuracy of not less than 98%; a control instruction generation unit, which adopts high-speed communication protocols such as EtherCAT or PROFINET to ensure the real-time transmission of control instructions, and the control instruction sending frequency is 5 times per second; a built-in deep learning-based control algorithm is used to process and analyze the collected data in real time, and predict the optimal operation path and parameters of the bucket wheel machine.

[0021] The automatic actuator module includes a motor drive device, which uses an AC variable frequency motor to drive the bucket wheel excavator trolley to travel and the cantilever pitch movement. The motor power is 75kW, the speed is 1450rpm, and it has overload protection and overheating protection functions; a hydraulic drive device is used to drive the bucket wheel excavator's slewing mechanism. The hydraulic system pressure is 25MPa, the flow rate is 60L / min, and it has pressure stability control and flow regulation functions.

[0022] The safety protection module includes four ultrasonic sensors, which are installed in the front, rear, left and right directions of the bucket wheel machine, respectively, for detecting obstacles with a detection distance of 10 meters and an accuracy of ±10cm; a laser rangefinder, installed at the front end of the bucket wheel machine's cantilever, is used to detect the height of the pile with a measurement range of 0-50 meters and an accuracy of ±5cm; an overload protection device, which is integrated in the control circuit of the motor and hydraulic system, automatically cuts off the power supply when the load exceeds the set value, and the protection time is 0.1 seconds; a high-performance image processor with a built-in intelligent image recognition algorithm is used to analyze monitoring videos in real time, identify abnormal situations and trigger alarms, with a recognition accuracy rate of not less than 95%.

[0023] The remote monitoring module includes an industrial-grade high-definition digital network camera with a resolution of 4K, a frame rate of 60 frames per second, night vision function and wide dynamic range; a wireless transmission device, using a 5G network with a bandwidth of not less than 100Mbps, which transmits the monitoring video to the remote monitoring center in real time with a delay of no more than 200 milliseconds; the monitoring center server uses a high-performance storage array with a storage capacity of not less than 10TB, supports remote playback and query functions, and the query speed is not less than 100 frames per second.

[0024] The system integration and communication module includes a data bus, which adopts CANopen or PROFIBUS protocol to realize data exchange and communication between various modules, and the transmission rate is not less than 1Mbps; a communication protocol converter, which supports multiple communication protocol conversions, such as Modbus, OPC UA, etc., to ensure the compatibility and reliability of data transmission; a data encryption unit, which adopts AES-256 encryption algorithm to encrypt the transmitted data to ensure the security of data transmission, and the key update cycle is once every 24 hours.

[0025] The specific working process of the system of the present invention is as follows: S1: The precise positioning module and flow detection module collect data in real time and send the data to the intelligent control module. The data sampling rate is 10 times per second. S2: After receiving the data, the intelligent control module performs intelligent analysis and calculation to determine the optimal operation strategy and parameters. The calculation cycle is once per second. S3: According to the optimal operation strategy and parameters, the intelligent control module generates control instructions and sends them to the automatic actuator module. The instruction transmission delay does not exceed 50 milliseconds; S4: The automatic actuator module performs specific operation actions according to the control instructions, and the action response time does not exceed 200 milliseconds; S5: The safety protection module detects the operating status and surrounding environment of the bucket wheel excavator in real time and triggers an alarm when an abnormal situation is detected. The alarm response time does not exceed 100 milliseconds; S6: The remote monitoring module receives and displays the monitoring video of the bucket wheel machine site in real time for the operator to monitor and manage remotely. The video fluency is not less than 30 frames per second. S7: System integration and communication modules ensure data exchange and communication between modules, with a data transmission error rate of no more than 0.01%, forming a complete unattended remote control system It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

[0026] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. A remote control system for an unmanned bucket wheel excavator, characterized in that The system includes the following modules: Precise positioning module, used to monitor the bucket wheel crane's trolley travel, boom pitch and slewing angle in real time; The flow detection module is used to detect the material flow on the bucket wheel machine cantilever belt in real time; The intelligent control module receives information from the precise positioning module and the flow detection module, performs intelligent analysis and calculation, determines the optimal operation strategy and parameters, and sends control instructions; The automatic actuator module performs specific operation actions according to the instructions of the intelligent control module; Safety protection module, used to detect the bucket wheel machine's operating status and surrounding environment in real time, trigger an alarm and take corresponding protective measures; Remote monitoring module, which receives monitoring video of bucket wheel machine on site and sends it to the remote monitoring center for real-time display; System integration and communication module integrates and connects various modules to achieve data exchange and communication; The above modules are connected by data through system integration and communication modules to form a complete unmanned remote control system for bucket wheel excavators.

2. The remote control system of an unmanned bucket wheel excavator according to claim 1, characterized in that: The precise positioning module includes two high-precision magnetostrictive displacement sensors, which are respectively installed at both ends of the bucket wheel crane trolley's walking track, and are used to detect the starting and ending positions of the bucket wheel crane trolley with an accuracy of ±1mm; two angle sensors are respectively installed on both sides of the bucket wheel crane cantilever, and are used to detect the pitch angle of the cantilever with an accuracy of ±0.1°; a GPS and Beidou dual-mode positioning device is installed on the top of the bucket wheel crane, and is used to measure the longitude, latitude and altitude of the bucket wheel crane in real time, with a positioning accuracy of ±2.5 cm and an update frequency of 2 times per second.

3. The remote control system of an unmanned bucket wheel excavator according to claim 1, characterized in that: The flow detection module includes a 3D laser radar scanner installed above the cantilever belt of the bucket wheel excavator. The scanning frequency is 10 times per second, the scanning range is the cantilever belt width ±5 cm, and the measurement accuracy reaches ±5%; the data processing unit uses a high-performance embedded processor to receive the scanning data of the laser radar scanner and calculate the real-time material flow through an algorithm. The processing speed is 1,000 data calculations per second.

4. The remote control system of an unmanned bucket wheel excavator according to claim 1, characterized in that: The intelligent control module includes a logic judgment unit, which judges the current state of the bucket wheel machine according to the analysis results and determines the optimal operation strategy and parameters, with a judgment accuracy of not less than 98%; a control instruction generation unit, which adopts high-speed communication protocols such as EtherCAT or PROFINET to ensure the real-time transmission of control instructions, and the control instruction sending frequency is 5 times per second; a built-in deep learning-based control algorithm is used to process and analyze the collected data in real time, and predict the optimal operation path and parameters of the bucket wheel machine.

5. The remote control system of an unmanned bucket wheel excavator according to claim 1, characterized in that: The automatic actuator module includes a motor drive device, which uses an AC variable frequency motor to drive the bucket wheel excavator trolley to travel and the cantilever pitch movement. The motor power is 75kW, the speed is 1450rpm, and it has overload protection and overheating protection functions; a hydraulic drive device is used to drive the bucket wheel excavator's slewing mechanism. The hydraulic system pressure is 25MPa, the flow rate is 60L / min, and it has pressure stability control and flow regulation functions.

6. The remote control system of an unmanned bucket wheel excavator according to claim 1, characterized in that: The safety protection module includes four ultrasonic sensors, which are installed in the front, rear, left and right directions of the bucket wheel machine, respectively, for detecting obstacles with a detection distance of 10 meters and an accuracy of ±10cm; a laser rangefinder, installed at the front end of the bucket wheel machine's cantilever, is used to detect the height of the pile with a measurement range of 0-50 meters and an accuracy of ±5cm; an overload protection device, which is integrated in the control circuit of the motor and hydraulic system, automatically cuts off the power supply when the load exceeds the set value, and the protection time is 0.1 seconds; a high-performance image processor with a built-in intelligent image recognition algorithm is used to analyze monitoring videos in real time, identify abnormal situations and trigger alarms, with a recognition accuracy rate of not less than 95%.

7. The remote control system of an unmanned bucket wheel excavator according to claim 1, characterized in that: The remote monitoring module includes an industrial-grade high-definition digital network camera with a resolution of 4K, a frame rate of 60 frames per second, night vision function and wide dynamic range; a wireless transmission device, using a 5G network with a bandwidth of not less than 100Mbps, which transmits the monitoring video to the remote monitoring center in real time with a delay of no more than 200 milliseconds; the monitoring center server uses a high-performance storage array with a storage capacity of not less than 10TB, supports remote playback and query functions, and the query speed is not less than 100 frames per second.

8. The remote control system of an unmanned bucket wheel excavator according to claim 1, characterized in that: The system integration and communication module includes a data bus, which uses CANopen or PROFIBUS protocol to achieve data exchange and communication between various modules, with a transmission rate of not less than 1Mbps; The communication protocol converter supports multiple communication protocol conversions, such as Modbus, OPC UA, etc., to ensure the compatibility and reliability of data transmission; the data encryption unit uses the AES-256 encryption algorithm to encrypt the transmitted data to ensure the security of data transmission. The key update cycle is once every 24 hours.

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