Material accumulation angle real-time detection device and method based on laser sensor

Abstract

The invention discloses a material accumulation angle real-time detection device and method based on a laser sensor, and relates to the field of automatic material spading, the material accumulation angle real-time detection device comprises a laser ranging module, a double-shaft holder, an anti-shake device and a control operation system.The anti-shake device comprises an upper platform, an anti-shake spring and a lower platform, the lower platform is arranged at the top end of a loading machine cockpit, and the upper platform is connected with the anti-shake spring; the upper platform is arranged over the lower platform through the anti-shake spring, the double-shaft holder is arranged on the upper platform, the laser ranging module is arranged at the top end of the double-shaft holder, and the laser ranging module and the double-shaft holder are both electrically connected with the control operation system. According to the invention, real-time accumulation angle measurement can be carried out on operation materials of the loading machine, whether the materials are to-be-shoveled materials or not is judged, real-time accumulation angle detection is carried out every time operation is carried out, the real-time accumulation angle detection can be used as parameter input for operation track planning and operation pose adjustment of the loading machine, and the method is more suitable for practical engineering application.

Description

Technical Field

[0001] The present invention belongs to the field of automatic material shoveling, and particularly relates to a device and method for real-time detection of the material accumulation angle based on a laser sensor. Background Art

[0002] As a multi-purpose construction machinery, the wheel loader plays a significant role in the field of engineering construction. During the entire shoveling operation cycle, the operation posture of the bucket during the material shoveling operation is the most complex, the operation resistance is the greatest, and the energy consumption accounts for the largest proportion. Since the operation objects of the wheel loader are various geotechnical media with large differences in characteristics, different operation objects correspond to different optimal shoveling methods. Currently, the common method of the wheel loader shoveling operation in China is that the operator inserts the bucket into the material at one time by relying on the traction force of the whole machine, and then manipulates the boom handle and the bucket handle to realize the rotation and lifting of the bucket to complete the shoveling operation, which completely depends on the operator's experience and has problems of low operation efficiency and high energy consumption.

[0003] The Chinese invention patent with the patent number CN112144592B discloses an intelligent shoveling control system, method and wheel loader for a wheel loader, which measures and analyzes the particle size characteristics and density characteristics of the material through a screening and weighing device, calculates the left and right distances and relative deviations of the bucket relative to the material pile and the material accumulation angle and relative deviations in real time, and controls the steering system, the forward system and the shoveling system according to the material pile characteristics and relative position relationships, adjusts the bucket insertion posture, automatically judges the conditions for the bucket to start inserting into the material, and compares in real time in the shoveling operation posture library to match and call the optimal automatic shoveling control parameters to improve the full bucket rate of shoveling. However, this wheel loader still needs to perform screening, weighing and analysis on the material before excavation, the equipment setting is complex, the measurement takes a long time, the operation process is cumbersome, and multiple sensors are arranged on the swing arm of the loader, the cost of the sensors is high, the cost is high, and it is easy to cause wear and damage during use, and the use and maintenance costs are expensive.

[0004] Therefore, how to provide a device and method for rapid real-time detection of the material accumulation angle based on a laser sensor with a simple structure has become a problem that needs to be solved by those skilled in the art. Summary of the Invention

[0005] In view of this, the present invention provides a device and method for real-time detection of the material accumulation angle based on a laser sensor. The structure of the present invention is simple, and it can measure the real-time accumulation angle of the material during the operation of the loader, determine the interval of the material, and match the optimal shoveling trajectory.

[0006] In order to achieve the above object, the present invention adopts the following technical solutions:

[0007] A real-time detection device for the material accumulation angle based on a laser sensor, comprising: a laser ranging module, a two-axis pan-tilt head, an anti-shake device and a control operation system. The anti-shake device includes an upper platform, anti-shake springs and a lower platform. The lower platform is arranged at the top of the loader cab. The upper platform is arranged directly above the lower platform through the anti-shake springs. The two-axis pan-tilt head is arranged on the upper platform. The laser ranging module is arranged at the top of the two-axis pan-tilt head. The laser ranging module and the two-axis pan-tilt head are both electrically connected to the control operation system.

[0008] Further, the two-axis pan-tilt head includes a pitch rotation axis and a horizontal rotation axis. The pitch rotation axis is rotatably arranged on the horizontal rotation axis and is used to control the detection orientation of the laser ranging module.

[0009] Further, it further includes an anti-interference ceiling. The anti-interference ceiling is arranged at the top of the loader cab and wraps the entire detection device.

[0010] Further, the control operation system includes a main controller, a laser sensor module, a data operation module, a pan-tilt head motor controller, an excavation trajectory database, an electric control system and a serial communication bus. The laser sensor module, the data operation module, the pan-tilt head motor controller, the excavation trajectory database and the electric control system are all electrically connected to the main controller through the serial communication bus.

[0011] A real-time detection method for the material accumulation angle based on a laser sensor, comprising the following steps:

[0012] S01. The pan-tilt head is placed in the horizontal forward direction. The loader moves forward into the range of the laser ranging module, and the horizontal distance l between the sensor and the surface of the material pile is measured. AB ;

[0013] S02. If l AB is within the set standard value, then l AB is a valid value, and the measured material pile is a large material pile; otherwise, it is a small material pile. The pan-tilt head remains in the forward direction, and the pitch axis rotates downward by an angle σ until the collected l AB is a valid value.

[0014] S03. The distance l BC at the bottom of the material pile is collected, and the data operation module calculates where λ1 is the ratio of l AB to l BC when the pan-tilt head remains in the forward direction.

[0015] S04. The pan-tilt head is offset 30° to the left and right respectively, and steps S01 - S03 are repeated to obtain λ2 and λ3. λ2 is the ratio of l AB to l BC when offset 30° to the left.The ratio, where λ3 is l when offset 30° to the right AB and l BC the ratio;

[0016] S05. When the stockpile is a large stockpile, the calculated formula for the stacking angle β obtained through analysis is:

[0017]

[0018] where i = 1, 2, 3;

[0019] When the stockpile is a small stockpile, the calculated formula for the stacking angle β is:

[0020]

[0021] where β′ i is the angle between the stockpiled material and l AB and i = 1, 2, 3;

[0022] The real-time stacking angles β1, β2, and β3 are obtained through formula calculation, where β1 is the positive stacking angle, β2 is the left stacking angle, and β3 is the right stacking angle. The difference ratio of the left and right stacking angles is used as the basis for adjusting the loading machine pose, and the calculated stacking angle difference ratio is used as the input m.

[0023] Further, the excavation trajectory database is called. The excavation trajectory database inputs the physical property information of different materials and obtains the corresponding stacking angles according to the theoretical experimental method. Let be the preset value, n be different material piles. Because the materials are affected by temperature and humidity environments and there are certain errors, the preset stacking angle range is used as the basis for matching with the actual situation. The stacking range for a single material is set as: -a ≤ x n ≤ b. It is judged whether m is within the range of x1 - a ≤ m ≤ x1 + b, where x1 is the first material pile; if not within this range, it is determined that it is not this material, and then it is transferred to before other materials, and the next range determination of x2 - a ≤ m ≤ x2 + b is entered, where x2 is the second material pile, and so on for x n -a ≤ m ≤ x n + b until m appears in the material interval to be excavated.

[0024] Further, the material to be excavated is determined according to the input m, and the optimal excavation trajectory route corresponding to this material is transmitted back to the main controller. The main controller schedules the bucket and boom cylinder through the electric control system connecting to control the loader, and adjusts the position for excavation operation.

[0025] The beneficial effects of the present invention are:

[0026] 1. The present invention adopts a solution of a high-precision pan-tilt combined with a high-precision laser ranging module, realizing the rapid detection of the material stacking angle. According to the different stacking angles presented by different materials, it can automatically determine whether the material is the material to be shoveled. Compared with other non-contact devices, the detection principle is simple, the cost is low, the speed is fast and the precision is high, and there is almost no limitation on the measured material, realizing the universality of the measuring device;

[0027] 2. The present invention can perform real-time stacking angle measurement on the materials during the operation of the loader. Each time an operation is performed, a real-time stacking angle detection is carried out, which can be used as the parameter input for the operation trajectory planning of the loader and the adjustment of the operation pose of the loader, and is more applicable to engineering practical applications;

[0028] 3. The present invention adopts a solution of a high-precision two-axis pan-tilt combined with a high-precision laser ranging module. Compared with the contact measurement method, the detection speed is fast, the practicability is stronger, and the anti-interference ability is stronger;

[0029] 4. The present invention only needs one laser sensor, and the stacking angle detection can be completed by combining with the pan-tilt. Compared with the original multiple sensors, it greatly saves the high sensor cost, and has a simple structure. Installing it on the top of the loader cab not only saves space, but also avoids the contact between the sensor and the material. It can be directly installed and disassembled on-site, and the detection speed is fast. This detection pan-tilt can realize the detection of the stacking angle and the optimal trajectory, achieving the energy-saving effect of the loader. And this pan-tilt is detachable and can be connected to various types of loaders, with strong universality and flexible and convenient installation. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 is a schematic diagram of the main structure of the detection device of the present invention;

[0031] Figure 2 is a schematic diagram of the circuit connection of the control operation system of the present invention;

[0032] Figure 3 is a schematic diagram of the installation position of the detection device of the present invention;

[0033] Figure 4 is Figure 3 the front view of;

[0034] Figure 5 is a schematic diagram of the determination of a large material pile of the present invention;

[0035] Figure 6 is a schematic diagram of the determination of a small material pile of the present invention;

[0036] Figure 7 is a flow chart of the determination of the stacking angle of the material pile of the present invention;

[0037] Figure 8 is a schematic diagram of the determination of different types of materials of the present invention.

[0038] In the figure: 1. Laser ranging module; 201. Pitch rotation axis; 202. Horizontal rotation axis; 301. Upper platform; 302. Anti-vibration spring; 303. Lower platform; 4. Loader cockpit; 501. Main controller; 502. Laser sensor module; 503. Data operation module; 504. Pan-tilt motor controller; 505. Excavation trajectory database; 506. Electric control system; 507. Serial communication bus; 6. Stockpile. Specific implementation mode

[0039] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention.

[0040] In the description of the present invention, it should be noted that the orientation or positional relationship indicated by the terms "center", "upper", "lower", "left", "right", "horizontal", "inner", "outer", "one side", etc. is based on the orientation or positional relationship shown in the accompanying drawings. It is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation to the present invention; the terms "first", "second", "third" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0041] Embodiment 1

[0042] As Figures 1-4 shown, a real-time detection device for the material stacking angle based on a laser sensor proposed in this embodiment includes: a laser ranging module 1, a two-axis pan-tilt, an anti-vibration device, a control operation system, and an anti-interference ceiling. The anti-vibration device includes an upper platform 301, an anti-vibration spring 302, and a lower platform 303. The lower platform 303 is connected to the top of the loader cockpit 4 by bolts. The upper platform 301 is arranged directly above the lower platform 303 through the anti-vibration spring 302. The two-axis pan-tilt is arranged on the upper platform 301. The two-axis pan-tilt includes a pitch rotation axis 201 and a horizontal rotation axis 202. The pitch rotation axis 201 is rotatably arranged on the horizontal rotation axis 202 for controlling the detection direction of the laser ranging module 1. The laser ranging module 1 is arranged at the top of the pitch rotation axis 201. The laser ranging module 1 is electrically connected to the control operation system. The anti-interference ceiling is arranged at the top of the loader cockpit 4 to wrap the entire detection device.

[0043] The control operation system includes a main controller 501, a laser sensor module 502, a data operation module 503, a pan-tilt motor controller 504, an excavation trajectory database 505, an electric control system 506, and a serial communication bus 507. The laser sensor module 502, the data operation module 503, the pan-tilt motor controller 504, the excavation trajectory database 505, and the electric control system 506 are all electrically connected to the main controller 501 through the serial communication bus 507.

[0044] The present invention can realize automatic measurement of the real-time accumulation angle of materials, real-time display and transmission to the excavation trajectory database 505, and provide the main controller 501 with a key planning parameter - the accumulation angle. This device only needs one laser sensor and can complete the detection of the accumulation angle with a two-axis pan-tilt. Compared with the original setting of multiple sensors, it greatly saves the high cost of sensors, and has a simple structure. Installed on the top of the loader cab 4, it saves space, can be directly installed and disassembled on-site, and has a fast detection speed. The laser sensor has strong anti-interference ability, and the ranging accuracy can be guaranteed in a harsh engineering environment, which is beneficial to improving the recognition accuracy of the accumulation angle of the material pile 6. During the whole detection process, only need to place the detector on the top of the loader cab 4, and the laser sensor module 502 is controlled by the two-axis pan-tilt to realize the switching of the measurement pose. The main controller 501 receives the horizontal distance information collected by the laser sensor. If the distance is within the preset standard value, it starts to measure the distance at the bottom of the material pile 6, and sends an instruction to the pan-tilt motor controller 504 to adjust the angle of the two-axis pan-tilt, make the pitch angle rotate, and then through data operation, obtain the final accumulation angle, realizing the real-time measurement of the accumulation angle of the working material of the device. The main controller 501 calculates the accumulation angle difference based on the obtained accumulation angle, and uses this as the basis for adjusting the loader's attitude. Then, the excavation trajectory database 505 is called through the main controller 501. The accumulation angle is a physical property of the material, and different materials have corresponding accumulation angle ranges. Therefore, according to different accumulation angle differences, the optimal excavation trajectory is matched by the excavation trajectory database 505 in the main controller 501, and then the electric control system 506 of the loader is connected through the main controller 501 to control the boom and bucket cylinders, realizing a reasonable and energy-saving loading trajectory.

[0045] Embodiment 2

[0046] As Figures 5-8 shown, this embodiment discloses a method for real-time detection of the material accumulation angle based on a laser sensor, including the following steps:

[0047] S01. Place the pan-tilt in the horizontal forward direction, and the loader moves forward to within the range of the laser ranging module (generally 2 - 5m), and measure the horizontal distance l between the sensor and the surface of the material pile AB ;

[0048] S02. If lAB Within the set standard value, then l AB is a valid value, then the measured material pile is a large material pile, and enter step S03; otherwise, it is determined to be a small material pile, the pan-tilt head remains facing forward, and the pitch axis rotates downward by an angle σ until the collected l AB becomes a valid value;

[0049] S03. Collect the distance l from the bottom end of the material pile BC , and the data operation module calculates When the input 1 is l when the pan-tilt head remains facing forward AB and l BC ratio;

[0050] S04. The pan-tilt head is offset 30° to the left and right respectively, and steps S01 - S03 are repeated to obtain λ2 and λ3. λ2 is the ratio of l AB and l BC when offset 30° to the left, and λ3 is the ratio of l AB and l BC when offset 30° to the right;

[0051] S05. When the material pile is a large material pile, the calculation formula for the angle of repose β obtained through analysis is:

[0052]

[0053] where i = 1, 2, 3;

[0054] When the material pile is a small material pile, the calculation formula for the angle of repose β is:

[0055]

[0056] where β′ i is the angle between the stacked material and l AB , i = 1, 2, 3;

[0057] The real-time angles of repose β1, β2, and β3 are calculated through the formula, where β1 is the positive angle of repose, β2 is the left angle of repose, and β3 is the right angle of repose. The difference ratio of the left and right angles of repose is used as the basis for adjusting the loading machine pose, and the data operation module uses the calculated difference ratio of the angles of repose as the input m;

[0058] S06. The main controller calls the excavation trajectory database. The excavation trajectory database inputs various physical property information and obtains the corresponding angle of repose according to the theoretical experimental method. Let be the preset value, n be different material piles. Because the material is affected by environmental factors such as temperature and humidity, there is a certain error. Therefore, the preset angle of repose range is used as the basis for matching with the actual situation, and the stacking range of a single material is set as -a ≤ x ≤ b;

[0059] S07. Determine whether m is within the range of x1 - a ≤ m ≤ x1 + b, where x1 is the first material pile. If it is not within this range, it is determined that it is not this material, and then it is transferred to before other materials, and the next range determination of x2 - a ≤ m ≤ x2 + b is entered, where x2 is the second material pile, and so on for x n - a ≤ m ≤ x n + b until m appears in the material range to be excavated;

[0060] S08. Determine the material to be excavated according to the input m, and then the optimal excavation trajectory route corresponding to the material is transmitted back to the main controller through the serial communication bus by the excavation trajectory database;

[0061] S09. The main controller schedules the bucket and boom cylinder by connecting to the electronic control system of the loader, and adjusts the position to perform the excavation operation.

[0062] Although the specific implementation manner of the present invention has been described above in conjunction with the accompanying drawings, it is not a limitation to the protection scope of the present invention. Those skilled in the art should understand that based on the technical solution of the present invention, various modifications or deformations that can be made by those skilled in the art without creative labor are still within the protection scope of the present invention.

Claims

1. A real-time detection device for the material accumulation angle based on a laser sensor, characterized in that Comprising: A laser ranging module, a two-axis pan-tilt, an anti-shake device and a control operation system. The anti-shake device includes an upper platform, anti-shake springs and a lower platform. The lower platform is arranged at the top of the loader cab. The upper platform is arranged directly above the lower platform through the anti-shake springs. The two-axis pan-tilt is arranged on the upper platform. The laser ranging module is arranged at the top of the two-axis pan-tilt. The laser ranging module and the two-axis pan-tilt are both electrically connected to the control operation system.

2. The real-time detection device for the material accumulation angle based on a laser sensor according to claim 1, wherein The two-axis pan-tilt includes a pitch rotation axis and a horizontal rotation axis. The pitch rotation axis is rotatably arranged on the horizontal rotation axis for controlling the detection orientation of the laser ranging module.

3. The real-time detection device for the material accumulation angle based on a laser sensor according to claim 1, characterized in that, It further includes an anti-interference ceiling arranged at the top of the loader cab.

4. A real-time detection device and method for the material accumulation angle based on a laser sensor according to claim 1, characterized in that, The control operation system includes a main controller, a laser sensor module, a data operation module, a pan-tilt motor controller, an excavation trajectory database, an electric control system and a serial communication bus. The laser sensor module, the data operation module, the pan-tilt motor controller, the excavation trajectory database and the electric control system are all electrically connected to the main controller through the serial communication bus.

5. A real-time detection method for the material stacking angle based on a laser sensor, characterized in that, Including the following steps: S01. The pan-tilt is placed in the horizontal forward direction. The loader moves forward into the range of the laser ranging module to measure the horizontal distance l between the sensor and the surface of the stockpile AB ; S02. If l AB is within the set standard value, then l AB is a valid value, and the measured material pile is a large material pile; otherwise, it is a small material pile. The pan-tilt head remains facing forward, and the pitch axis rotates downward by an angle σ until the collected l AB becomes a valid value; S03. Collect the distance l at the bottom end of the material pile BC , the data operation module calculates When input 1 is the value of l when the pan-tilt head keeps moving forward AB and l BC The ratio of; S04. The pan-tilt is offset 30° to the left and right respectively, and steps S01 - S03 are repeated to obtain λ2 and λ3. λ2 is the ratio of l AB to l BC when offset 30° to the left, and λ3 is the ratio of l AB to l BC when offset 30° to the right; S05. When the material pile is a large material pile, the calculation formula for the stacking angle β obtained through analysis is: where i = 1, 2, 3; When the material pile is a small material pile, the calculation formula for the stacking angle β is: where β′ i is the angle between the stockpile and l AB , and i = 1, 2, 3; The real-time accumulation angles β1, β2, and β3 are calculated through formulas, where β1 is the positive accumulation angle, β2 is the left accumulation angle, and β3 is the right accumulation angle, and the difference ratio of the left and right accumulation angles As the basis for adjusting the loading machine pose, the calculated difference ratio of the accumulation angles is used as the input m.

6. The real-time detection method for the material stacking angle based on a laser sensor according to claim 5, characterized in that, Call the excavation trajectory database. The excavation trajectory database inputs the physical property information of different materials and obtains the corresponding angle of repose according to the theoretical experimental method. Let be the preset value, and n be different material piles. Since the materials are affected by temperature and humidity environments and there is a certain error, the preset angle-of-repose range is used as the basis for matching with the actual situation. The stacking range for a single material is set as: -a ≤ x n ≤ b. Determine whether m is within the range of x1 - a ≤ m ≤ x1 + b, where x1 is the first material pile; if it is not within this range, it is determined that it is not this material, and then it is transferred to other materials. Before that, enter the next range determination of x2 - a ≤ m ≤ x2 + b, where x2 is the second material pile, and so on for x n - a ≤ m ≤ x n + b until m appears in the material interval to be excavated.

7. A real-time detection method for the material accumulation angle based on a laser sensor according to claim 6, characterized in that, Determine the material to be excavated according to the input m, and transmit the optimal excavation trajectory route corresponding to the material back to the main controller. The main controller schedules the bucket and the boom cylinder by connecting and controlling the electric control system of the loader, and adjusts the position for excavation operation.

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