Full-automatic control system, method and equipment for car loader

Abstract

The invention discloses a car loader full-automatic control system, method and device, and relates to the technical field of car loaders, and the system comprises a user interface module, a sensor module, a car number identification module, an overload and unbalanced load detection module, a PLC control module, a historical record module, an alarm processing module and a communication module. Through cooperation of the user interface module, the sensor module, the vehicle number recognition module, the overload and unbalanced load detection module, the PLC control module, the historical record module, the alarm processing module and the communication module, automatic control over the loading process is achieved, the requirement for manual operation is reduced, and the efficiency, safety and controllability of loading operation are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of loading machines, and specifically to a full-automatic control system, method, and device for a loading machine. Background Art

[0002] A loading machine is a mechanical device used for automatically loading or unloading goods, and is usually used in scenarios such as logistics, warehousing, production lines, etc. They usually have a mobile platform and a loading / unloading device, and can independently or according to preset instructions perform tasks such as loading, handling, and unloading of goods.

[0003] With the continuous growth of global trade, port operations are facing greater challenges and opportunities. One of the core issues is how to achieve efficient loading and unloading of goods, which is directly related to the transportation throughput capacity and service level of the port. Traditional loading machine operations have various problems, including low operation efficiency, errors caused by human factors, and long operation time. These problems not only affect the speed and efficiency of goods flow, but also increase the costs and management pressure of port operations. Summary of the Invention

[0004] In view of this, the purpose of the present invention is to provide a full-automatic control system, method, and device for a loading machine to solve the problems of low efficiency and long manual operation time in traditional loading machine operations.

[0005] Based on the above purpose, the present invention provides the following technical solution: A full-automatic control system for a loading machine, including a user interface module provided for operators to use;

[0006] A sensor module for real-time monitoring of the status of the loading machine;

[0007] A vehicle number recognition module for identifying the vehicle number of the loading vehicle on the main side;

[0008] An overloading and offloading detection module for detecting whether the loading machine is overloaded or offloaded;

[0009] A PLC control module for controlling each execution component of the loading machine. The PLC control module controls the operations of the loading machine according to the instructions sent by the user interface module, adjusts the operations of the loading machine according to the status information of the loading machine transmitted by the sensor module, identifies and records the vehicle number information of the loading vehicle transmitted by the vehicle number recognition module, and monitors whether the loading machine is overloaded or offloaded according to the data transmitted by the overloading and offloading detection module and takes corresponding measures;

[0010] A historical record module for recording the operation historical data of the loading machine;

[0011] An alarm processing module for monitoring various conditions on one side of the loading machine and giving alarms. The alarm processing module monitors the operating states of the above-mentioned various modules and provides corresponding processing suggestions or automatically executes emergency procedures according to the situations;

[0012] A communication module for data exchange and communication between various modules.

[0013] A full-automatic control method for a loading machine. This method is applied to the full-automatic control system of the loading machine. The user interface module specifically includes the following steps:

[0014] S11. Provide a user login function, including the input of username and password;

[0015] S12. Select the loading machine to be controlled on the login interface and then input the account password to log in;

[0016] S13. Display the real-time state of the loading machine and provide operation buttons and a control panel;

[0017] S14. Allow the user to set loading parameters, including loading direction, track selection, loading speed, and loading volume;

[0018] S15. Allow the user to input a loading operation plan, including train number information, loading sequence, and loading volume;

[0019] S16. Provide functions for saving and loading parameters and operation plans;

[0020] S17. Provide a history record interface;

[0021] S18. Provide a system setting interface.

[0022] Preferably, the sensor module specifically includes the following steps:

[0023] S21. Install the sensors at appropriate parts of the loading machine;

[0024] S22. Obtain the state data of the loading machine;

[0025] S23. Transmit the sensor data through a communication network.

[0026] Preferably, the vehicle number identification module specifically includes the following steps:

[0027] S31. Obtain the image of the loading area of the loading machine;

[0028] S32. Preprocess the collected image;

[0029] S33. Use an image processing algorithm to locate the vehicle position in the image of the loading area;

[0030] S34. Identify the vehicle number based on image processing and recognition algorithms;

[0031] S35. Output the identified vehicle number information to the loading machine control system.

[0032] Preferably, the overloading and offloading detection module specifically includes the following steps:

[0033] S41. Obtain the cargo weight data;

[0034] S42. Apply an algorithm to identify abnormal weight data and determine whether there is an overloading and offloading situation;

[0035] S43. Output the overloading and offloading detection result to the loading machine control system.

[0036] Preferably, the PLC control module specifically includes the following steps:

[0037] S51. Define the input and output logic according to the system design to ensure correct control logic and operation process;

[0038] S52. Integrate the PLC control module with other system components, including sensors, actuators, control panels, etc., to ensure communication and coordination between components;

[0039] S53. Analyze the operation data of the loading machine and perform corresponding operations.

[0040] Preferably, the historical record module specifically includes the following steps:

[0041] S61. Determine the data types and fields to be recorded;

[0042] S62. Specify the data recording format and structure;

[0043] S63. Obtain the historical data of the loading machine operation;

[0044] S64. Record the collected data into the historical record database or file.

[0045] Preferably, the alarm handling module specifically includes the following steps:

[0046] S71. Determine various abnormal situations to be monitored in the system and classify them as alarm types;

[0047] S72. Set the conditions and thresholds for alarm triggering;

[0048] S73. Determine the alarm notification method;

[0049] S75. Obtain the device operation status and data in real time to detect whether the alarm triggering conditions are met;

[0050] When the alarm condition is triggered, immediately issue a corresponding alarm notification.

[0051] Preferably, the communication module specifically includes the following steps:

[0052] S81. Establish a communication connection with an external device or system in the system;

[0053] S82. Transmit the data generated in the system to an external system or device through the communication module.

[0054] A fully automatic control device for a loading machine, which is applied to a control method. The device includes:

[0055] A sensor for sensing the surrounding environment and the state of the loading machine itself;

[0056] An actuator for performing specific operations;

[0057] A controller for controlling the overall operation of the system;

[0058] A human-machine interface device for human-machine interaction.

[0059] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0060] A fully automatic control system, method, and device for a loading machine provided by the present invention realize the automatic control of the loading process through the cooperation of a user interface module, a sensor module, a vehicle number identification module, an over-offset load detection module, a PLC control module, a historical record module, an alarm processing module, and a communication module, reduce the need for manual operation, and improve the efficiency, safety, and controllability of the loading operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0061] In order to more clearly illustrate the technical solutions in the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the drawings in the following description are only those of the present invention. For those of ordinary skill in the art, other drawings can also be obtained based on these drawings without creative efforts.

[0062] Figure 1 It is a frame diagram of a fully automatic control system for a loading machine of the present invention;

[0063] Figure 2 It is a schematic diagram of the installation position of the sensor of the present invention Figure 1 ;

[0064] Figure 3 It is a schematic diagram of the installation position of the sensor of the present invention Figure 2 .

[0065] Figure 4Schematic diagram of 3D scanning for carriage identification of the present invention Figure 1 。

[0066] Figure 5 Schematic diagram of 3D scanning for carriage identification of the present invention Figure 2 。 Detailed implementation manners

[0067] To make the objectives, technical solutions and advantages of the present invention clearer and more understandable, the following further elaborates on the present invention in conjunction with specific embodiments.

[0068] It should be noted that unless otherwise defined, the technical terms or scientific terms used in the present invention should have the ordinary meanings understood by those with ordinary skills in the field to which the present invention belongs. The "first", "second" and similar terms used in the present invention do not indicate any order, quantity or importance, but are only used to distinguish different components. Words such as "including" or "comprising" mean that the elements or objects appearing before this word cover the elements or objects listed after this word and their equivalents, without excluding other elements or objects. Words such as "connected" or "coupled" are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect. "Upper", "lower", "left", "right", etc. are only used to represent relative position relationships, and when the absolute position of the object being described changes, the relative position relationship may also change accordingly.

[0069] The following further describes the present invention in conjunction with embodiments.

[0070] Combined with Figure 1 , a fully automatic control system for a loading machine of the present invention includes a user interface module, a sensor module, a vehicle number identification module, an overloading and offloading detection module, a PLC control module, a historical record module, an alarm processing module, and a communication module;

[0071] The user interface module is used to provide operations. Specifically, in a browser, enter the website to enter the login interface. In the login interface, first select the loading machine to be controlled, and then enter the account password to log in. After entering the operation interface, it is mainly divided into 7 major interfaces, namely: main interface, preloaded vehicle, operation console, vehicle number identification, overloading and offloading detection, historical report, and alarm history.

[0072] The main interface can be roughly divided into eight major areas. In Area 1, it is possible to view the control right of the large machine, the current operation mode, the track to be operated currently, the loading direction, the carriage direction, the signal lights for the operation permission of the large vehicle, and the signal lights for single-machine communication. Finally, there are two buttons for emergency stop and fault reset. If the track, loading direction, and carriage direction are not displayed, they will be shown after the carriage information is sent. Area 2 shows the position information of the large vehicle, the anti-collision information of the boom and the traveling, and the distance between the two large machines. Area 3 shows the status of each mechanism. Area 4 shows the operation mode of the large machine in the remote manual mode. Area 5 shows various information during the loading operation and allows for the modification of correction values. Area 6 shows the operation steps for remote automatic loading, which can be automatically transferred to the next step or can be single-pointed. Area 7 shows the real-time curve graph of the instantaneous flow rate and the traveling speed. The last area, Area 8, shows the real-time alarm information.

[0073] The pre-installed vehicle interface is an interface for displaying the carriage information sent by the PLC control module.

[0074] The operation console interface has the same functions as the operation console in the loading machine room driver's cab. Click the button to send a command. If the execution is successful, the button light will be on constantly. When clicking the walking direction button for the first time, it will be at low speed to the left, and the button light will be on. The loading machine is walking at 1500 Hz. Click again to cancel the low speed. Other buttons are similar. The speed gears are low speed 1500 HZ, medium speed 3500 HZ, and high speed 7000 HZ. The operation console interface also has an auxiliary function interface for viewing the status of the 3D radar, the status of the walking GPS, and the status indicator lights of the boom GPS. There are three types of turntable displays: green for normal, yellow for warning, and red for error review. When the yellow or red light appears, it is necessary to check for problems and solve the fault points before the operation can be carried out.

[0075] The vehicle number identification interface is used to view the historical records of whether the vehicle number identification is consistent during remote operations within 30 days.

[0076] The overloading and offloading detection interface is used to view the historical records of overloading and offloading detection during remote operations within 30 days.

[0077] The historical report interface is used to view the historical records of alarms during remote operations within 30 days.

[0078] The alarm history interface is used to view the historical records of alarms during remote operations within 30 days.

[0079] During operation, the remote operation mode is divided into three types: remote operation console, remote manual, and remote automatic. The operation method of the remote operation console is similar to that of the cab operation. In the remote manual mode, the car number can be input to automatically position the machine above the input car; or the target value can be input, and the machine can travel to the target value; the same principle applies to the boom extension. In the remote automatic mode, the machine loads automatically. Before switching the control right to remote, the central control personnel need to perform the following checks. After passing the checks, the personnel on the machine can give the control right to the central control. Check whether the operation permission light is green; check whether the single machine communication light is flashing; check whether the target positions and the mechanism positions of each mechanism in the status display are consistent; check whether there is a fault alarm message; check whether the machine is in the loading mode or the return material mode.

[0080] The operation process in the automatic mode is as follows: Align the boom of the trolley to the middle of the first car, click the start button for automatic loading control (in the automatic mode, the start button needs to be turned on first before sending the car information). In the pre-loading vehicle interface, first select the track, loading direction, car direction, and type of the car to be loaded, then select the operation sequence, and finally send the car information to the PLC control module. In the last step, click the automatic car alignment program to start, and the machine will start automatic operation. After the operation is completed, put the automatic loading control to stop.

[0081] Combined with Figure 1 , a fully automatic control method for a loading machine, which is applied to the fully automatic control system of the loading machine. The user interface module specifically includes the following steps:

[0082] S11. Provide a user login function, including the input of username and password;

[0083] S12. Select the loading machine to be controlled on the login interface and then input the account password to log in;

[0084] S13. Display the real-time status of the loading machine and provide operation buttons and a control panel;

[0085] S14. Allow the user to set the loading parameters, including the loading direction, track selection, loading speed, and loading volume;

[0086] S15. Allow the user to input the loading operation plan, including train number information, loading sequence, and loading volume;

[0087] S16. Provide functions for saving and loading parameters and operation plans;

[0088] S17. Provide a historical record interface;

[0089] S18. Provide a system setting interface.

[0090] In this embodiment, in the browser, enter the website to enter the login interface. On the login interface, first select the loading machine to be controlled, and then enter the account password to log in. After logging in, click the preloaded vehicle button to enter the preloaded vehicle page. The following are respectively displayed: Current track: Select the track corresponding to the current loading machine; Loading direction: Select left / right; Carriage direction: Select left / right; Loading type: Select ordinary box / container; Distance between the vehicle head and the stop sign: The distance is in meters; Reload the list: Retrieve the current list again; Reset and send: Reset the list to the initial state;

[0091] When the preloaded vehicle is sent to the PLC: In the first step, fill in the operation sequence, write in the starting and ending numbers of the loading, and click OK. The list of tick numbers will appear, and the operation carriage numbers will be automatically ticked on the leftmost side of the list. Click the button to send to the PLC, and a prompt box will pop up. The basic information of this PLC sending will be in the prompt box. Click Confirm to send to the PLC to complete. For the data successfully sent to the PLC, the function of overall adjusting the preloaded vehicle weight will appear. After ticking a certain item, it will turn green. After setting the loading weight value and clicking the OK button, the weight will be added or subtracted simultaneously in the preloaded vehicle weights of the ticked data. Separate setting of the preloaded vehicle weight: Click on a certain preloaded vehicle weight, and a modification box for the preloaded vehicle weight will pop up. The input box requires entering the value you want after modification. Click the Confirm button to complete the modification. After the preloaded vehicle is successfully sent to the PLC, the data enters the main interface. On the left side of the main page, there are loading control and basic loading information; operating permission and single-machine communication working indicator lights, emergency stop and reset buttons, and the position information of the large machine. In the middle is the full-automatic loading control, the starting and ending serial numbers of the loading are prompted, the automatic vehicle alignment function, the large machine walking function, and the boom telescoping function; and page information similar to HMI information; The automatic loading control start module, the button can be clicked to display the current working state of the large machine. The buttons of this module must be operated under the condition that the automatic loading control is started. At the same time, the automatic vehicle alignment function, the large machine walking function, and the boom telescoping function will be prohibited from being operated. On the right side is the status display of the large machine; The relative curve graph of the instantaneous flow rate and the traveling speed of the large machine during loading; The real-time fault list function;

[0092] The operating console includes an operating console part and an auxiliary function part. The circular icons on the page are signal lights or buzzers; the square icons are buttons; the drop-down box is a knob function. The left side of the page is the operating console part, and the overall layout is the layout of the operating console in the large machine driver's cab:

[0093] The auxiliary function part is: Buttons: Light on; Light off; Raise the large vehicle anchor; Lower the large vehicle anchor; Signals: Large vehicle anchor raised in place; Large vehicle anchor lowered in place; Boom in place signal for track 18; Boom in place signal for track 17; Three-dimensional radar status; Traveling GPS status; Boom GPS status;

[0094] The display list of vehicle number recognition interface can be filtered by time period and consistency status, and has a data export function. Clicking on the view icon will pop up the function of viewing large pictures. If the data status in the list is unconfirmed, it means that the staff has not viewed and confirmed this piece of data. Clicking the confirmation button will pop up a confirmation box. Clicking the OK button completes the confirmation;

[0095] The over - offset and overweight monitoring list has functions for filtering by operation number and track number. Each piece of data shows the basic situation of the operation. At the same time, it has a list export function. Clicking on "View": all carriages under the corresponding operation number will be displayed. Clicking on the model of a certain item: the basic information of the corresponding carriage will be displayed, as well as the specific situation of over - offset monitoring reflected by the 3D model drawn by scanning the 3D radar of the corresponding carriage;

[0096] The historical report page shows the data statistically after each operation. Each piece of data represents the basic situation of each operation, including time, track, loading machine number, train number, loading direction, carriage direction, loading type, and total weight;

[0097] The alarm record page records historical alarm information, which shows different colors according to the alarm information level. Each piece of data has a corresponding status. The data can be filtered by time period and alarm level, and has a data export function.

[0098] Combined with Figures 1 - 3 , the sensor module specifically includes the following steps:

[0099] S21. Install the sensor at a suitable position on the loading machine;

[0100] S22. Obtain the status data of the loading machine;

[0101] S23. Transmit the sensor data through the communication network.

[0102] In this embodiment, various types of sensors are installed at suitable positions on the loading machine, and the status data of each part of the loading machine is obtained through the sensors, and the data is transmitted to the operation console auxiliary interface for viewing. The installation positions and sensors are shown in the following table:

[0103]

[0104] Combined with Figures 1 - 3 , the vehicle number recognition module specifically includes the following steps: S31. Obtain the image of the loading area of the loading machine;

[0105] S32. Pre - process the collected image;

[0106] S33. Use image - processing algorithms to locate the vehicle position in the image of the loading area;

[0107] S34. Identify the vehicle number based on image processing and recognition algorithms;

[0108] S35. Output the recognized vehicle number information to the loading machine control system.

[0109] In this embodiment, a real-time image of the loading area, including the carriage, license plate, and load, is obtained through a camera or sensor on the loading machine. The collected image is preprocessed, including image denoising, grayscale conversion, contrast adjustment, and edge detection, etc., to improve the image clarity. Image processing algorithms are used to locate the vehicle position in the image. Based on the located vehicle position, the license plate is recognized, the license plate information is extracted, and OCR is performed. The recognized vehicle number information is output to the control system of the loading machine and can be displayed on the vehicle number recognition interface.

[0110] Combined with Figures 1 - 3 , the overloading and offloading detection module specifically includes the following steps:

[0111] S41. Obtain the cargo weight data;

[0112] S42. Apply an algorithm to identify abnormal weight data and determine whether there is an overloading and offloading situation;

[0113] S43. Output the overloading and offloading detection result to the loading machine control system.

[0114] In this embodiment, the weight data of the cargo is obtained through a sensor or, and an algorithm is applied to analyze and process the obtained weight data to identify abnormal weight situations. The overloading and offloading detection result is output to the control system of the loading machine.

[0115] Combined with Figures 1 - 3 , the PLC control module specifically includes the following steps:

[0116] S51. Define the input and output logic according to the system design to ensure the correct control logic and operation process;

[0117] S52. Integrate the PLC control module with other system components, including sensors, actuators, control panels, etc., to ensure the communication and coordination between each component;

[0118] S53. Analyze the operation data of the loading machine and perform corresponding operations.

[0119] In this embodiment, first, according to the system design, the input and output logics are defined to ensure correct control logic and operation processes. Second, the PLC control module is integrated with other system components, including sensors, actuators, control panels, etc., to ensure communication and coordination among components. Finally, the operation data of the loading machine is analyzed, and corresponding operations are performed, such as adjusting the loading speed or sending an alarm to notify the operator. These steps are aimed at ensuring the efficiency and safety of the loading system so that it can operate and function according to the design requirements.

[0120] Combined with Figures 1 - 3 , the historical record module specifically includes the following steps:

[0121] S61. Determine the data types and fields to be recorded;

[0122] S62. Specify the data recording format and structure;

[0123] S63. Obtain the historical data of the loading machine operations;

[0124] S64. Record the collected data into the historical record database or file.

[0125] In this embodiment, first, determine the data types and fields to be recorded, including the operating status of the loading machine, operator information, loading volume, etc. After determining the data to be recorded, specify the format and structure of data recording for subsequent data storage and retrieval. By monitoring the operation process of the loading machine, obtain relevant historical data and record the collected data into the historical record database or file for display on the historical report page.

[0126] Combined with Figures 1 - 3 , the alarm handling module specifically includes the following steps:

[0127] S71. Determine various abnormal conditions to be monitored in the system and classify them as alarm types;

[0128] S72. Set the conditions and thresholds for alarm triggering;

[0129] S73. Determine the alarm notification method;

[0130] S75. Obtain the device operating status and data in real time to detect whether the alarm triggering conditions are met;

[0131] S76. When the alarm triggering conditions are met, immediately send the corresponding alarm notification.

[0132] In this embodiment, first, the abnormal conditions in the system and the corresponding alarm types are determined, the conditions and thresholds for triggering an alarm are set, the alarm notification method is determined, the device status and data are monitored in real time to detect the triggering conditions, and corresponding alarm notifications are immediately sent when the conditions are triggered, and the real-time information is displayed on the main interface.

[0133] Combined with Figures 1 - 3 , the communication module specifically includes the following steps:

[0134] S81. Establish a communication connection with an external device or system in the system;

[0135] S82. Transmit the data generated in the system to an external system or device through the communication module.

[0136] In this embodiment, first, a communication connection with an external device or system is established in the system, and the data generated in the system is transmitted to an external system or device through the communication module, ensuring that the system can effectively exchange data and communicate with external devices, realizing information sharing and the integrity of system functions.

[0137] Combined with Figures 1 - 3 , a fully automatic control device for a loading machine, the device includes:

[0138] Sensors for sensing the surrounding environment and the status of the loading machine itself;

[0139] Actuators for performing specific operations;

[0140] A controller for controlling the overall operation of the system;

[0141] A human-machine interface device for human-machine interaction.

[0142] In this embodiment, first, the sensors are responsible for sensing the surrounding environment and the status of the loading machine itself. They can collect information about position, speed, pressure, temperature, etc. to ensure the safety and accuracy of the loading process. Secondly, the actuators are the parts that actually perform the loading operations, including various mechanical and electronic components such as motors, cylinders, and valves. The actuators complete specific mechanical actions according to the instructions of the controller. Then, the controller is the core of the entire system, responsible for managing and coordinating the operation of each part. It decides the operations of the actuators based on the data from the sensors and ensures the efficiency and accuracy of the loading process. Finally, the human-machine interface device provides an interface for the operator to interact with the control system. It includes a display screen, buttons, a touch screen, etc., allowing the operator to monitor the system status, input instructions, or adjust parameters. Through the coordinated work of these components, precise control of the loading process can be achieved, ensuring efficient and safe loading operations.

[0143] In summary, the automatic control system of the loading machine includes functions such as the walking and positioning of the loading machine, the telescopic positioning of the boom, the 3D scanning of the carriage for material monitoring, the automatic walking and loading system of the loading machine, the automatic control system of the loading machine PLC, and the safety protection system. It can realize the intelligent control of the whole process of loading operation and reserve the interface function for process interlocking. The automatic loading changes the previous method of manual control of loading operation, improves the working environment of employees, reduces the labor intensity and loading pressure of drivers, and improves the loading quality and operation efficiency. At the same time, the operator can monitor the loading operation process of the loading machine through the remote control console and perform manual intervention and manual control when necessary.

[0144] 1. Automatic loading operation

[0145] The function of automatic loading operation can be realized both locally and at the remote control console:

[0146] Before the operation starts, when the operator determines that there is no safety risk on site, an operation instruction is input to make the loading machine enter the automatic operation mode. The loading machine operates in a fully automatic mode. The scope of fully automatic operation includes functions such as automatically walking to the position of the first section of the train to be loaded and aligning, automatically telescoping the boom to the corresponding carriage, automatically walking for loading, automatically passing empty (faulty) cars, automatically flipping the plate, one-key anchoring, and automatically turning on the lighting at night. That is, all operations in each train car operation cycle are completed by automatic control without manual intervention; when equipment failures or other safety risks occur, the loading machine operates with manual remote intervention.

[0147] Through functions such as the positioning of the loading machine, the telescopic positioning of the boom, the 3D scanning of the carriage for material monitoring, the automatic walking and loading system of the loading machine, and the automatic control system of the loading machine PLC, the intelligent control of the whole process of loading operation can be realized, and the interface function for process interlocking is reserved. The intelligent automatic loading changes the previous method of manual control of loading operation, improves the working environment of employees, reduces the labor intensity and loading pressure of drivers, and improves the loading quality and operation efficiency.

[0148] Transformation of the walking positioning system of the loading machine:

[0149] 1) The original walking positioning system of the loading machine has failed. Two different positioning methods based on measurement principles should be added to position the walking of the loading machine, which can achieve mutual redundancy and verification. One is coding positioning and the other is GNSS positioning.

[0150] 2) A communication card is newly added to the large vehicle walking frequency converter of the loading machine to realize the bus communication function between the frequency converter and the PLC;

[0151] 3) A high-precision absolute encoder is installed on the output shaft of the walking wheel of the loading machine, and the encoder readings are reflected into the PLC program through communication for positioning.

[0152] 4) Add a GNSS positioning device to the loading machine to achieve the positioning of the loading machine's trolley position. The encoder positioning and GNSS positioning methods rely on each other and are compared with each other, facilitating timely adjustment and avoiding errors. The GNSS device uses a four-star multi-frequency RTK mobile station and adopts a network communication mode instead of a radio communication mode. The differential base station can be built independently or utilize the existing high-standard GNSS reference station system. When using the existing base station, a firewall or network gateway device needs to be configured to ensure network security between the control network and the office network.

[0153] 5) Add an RFID positioning and calibration device to the walking mechanism of the loading machine, and install 1 calibration point every 200 meters along the loading machine track. The RFID calibration device is connected to the PLC control system.

[0154] Encoder device parameters:

[0155] Resolution: The resolution of the encoder is 16 bits (65535 counts / revolution)

[0156] Operating temperature: -40°C to +85°C

[0157] Signal output mode: Ethernet or Profibus-DP output

[0158] Protection level: IP65

[0159] Supply voltage: DC24V

[0160] RFID measurement device parameter requirements:

[0161] Normal detection distance: >50mm

[0162] Measurement speed: Maximum 3m / s

[0163] Signal output mode: Ethernet output

[0164] Protection level: IP67

[0165] Reform of the telescopic position system of the cantilever boom:

[0166] 1) The original boom telescopic system does not have a positioning sensor, and 1 kind of cantilever boom telescopic positioning device should be added. It is recommended to use the absolute encoder positioning method.

[0167] 2) Add a communication card to the telescopic frequency converter to achieve the bus communication function between the frequency converter and the PLC;

[0168] 3) Install an absolute encoder at the gears or bearings of the telescopic reduction gearbox, and use communication to reflect the encoder degrees into the PLC program for positioning. The cantilever telescopic encoder has a zero setting function.

[0169] Encoder device parameters:

[0170] Resolution: The resolution of the encoder is 16 bits (65535 counts / revolution)

[0171] Operating temperature: -40°C to +85°C

[0172] Signal output mode: Ethernet or Profibus-DP output

[0173] Degree of protection: IP65

[0174] Supply voltage: DC24V

[0175] Carriage identification 3D scanning and material height monitoring device:

[0176] 1) The 3D scanning system is mainly used to pre-detect the relative position between the chute mechanism of the loading machine and the carriage. It can accurately tell the PLC the specific position of the next carriage. Two 3D scanners are installed on one loading machine, facing the left and right sides of the loading machine cantilever respectively. When the loading machine loads to the right, the right scanner is used for detection, and vice versa for the left scanner. The 3D scanner can scan the current working carriage in real time and clearly, quickly and accurately collect and organize the scanning data of the working carriage, and visually present the train layout in a three-dimensional image. The 3D scanner is equipped with protection devices such as anti-collision, dust-proof and waterproof. The measurement accuracy and resolution of the scanner need to meet the requirements of timely and accurate measurement of the offloading situation of the loading machine.

[0177] a) The starting loading position of the first carriage is automatically set and reached by the system. After arriving, the scanning system detects the outline of the next carriage.

[0178] b) The system calculates the starting loading position of the next carriage.

[0179] c) As Figure 4 shown, when the loading machine loads to the right, when loading the 2# carriage, the scanner calculates in advance the starting loading coordinates X3 of the next carriage 1#.

[0180] d) As Figure 5 shown, when the loading machine loads to the left, when loading the 1# carriage, the scanner calculates in advance the starting loading coordinates X3 of the next carriage 2#.

[0181] During the carriage replacement, the loading machine runs automatically, stopping the chute at the accurate starting loading position of the carriage, eliminating the need for manual operation by the driver.

[0182] 2) To prevent the impact of shaking during the loading process on the scanner, an inertial navigation measurement system is added, which is required to measure the inertial motion parameters of the cantilever during the movement of the loading machine and apply these parameters to the deviation correction process of the laser three-dimensional modeling, thereby ensuring the accuracy of the three-dimensional modeling system.

[0183] 3) During the loading process, real-time material level detection is achieved through a radar level gauge installed below the material dropping opening, which is used to control the loading speed.

[0184] Requirements for laser scanner parameters:

[0185] Number of lines: not less than 16 lines

[0186] Single-line transceiver optical component

[0187] Detection distance: 280 m (10% reflectivity), 400 m (20% reflectivity)

[0188] Farthest detection distance: 500 m

[0189] Range measurement accuracy: ±2 cm (typical value)

[0190] Horizontal field of view: 360°

[0191] Horizontal field of view angular resolution: 0.09° - 0.36°, rotation rate: 5 Hz - 20 Hz

[0192] Class1 eye-safe wavelength: 905 nm

[0193] Power consumption: 12 W (typical value), working voltage: 9 - 32 V

[0194] Safety level: IP67

[0195] Operating environment temperature: -20°C - +60°C, storage temperature: -40°C - +85°C

[0196] Supports editable digital output

[0197] Supports low-power mode

[0198] Single echo mode: ~20K

[0199] Communication: 100M Ethernet

[0200] Synchronization time tag supports GPS interface

[0201] 1) During the loading process, real-time material level detection is achieved through the radar level gauge installed below the blanking port to control the loading speed. Radar level gauge equipment parameters:

[0202] Power supply and signal mode: 24VDC, two-wire system;

[0203] Antenna frequency: ≥79GHz;

[0204] Output signal: 4 - 20mA;

[0205] Protection level: IP68;

[0206] Measurement range: 120 meters;

[0207] Antenna transmitting beam angle: less than 4°;

[0208] Operating temperature: -20°C ---- +80°C;

[0209] Installation method: with angle adjustment device °;

[0210] Anti-collision and other security systems for the loading machine:

[0211] Necessary sensors, limit switches, laser detection technologies, etc. are set for each mechanism of the loading machine to ensure that during the operation of the equipment, collisions between each mechanism of the loading machine and surrounding objects and objects on the track surface cannot occur. A two-level alarm for the pre-alarm area and the emergency stop alarm area is set. To ensure the safety of the loading machine during the operation process, especially the safety of remote fully automatic intelligent operation, the loading machine must be equipped with functions such as avoiding pedestrians on the railway track, mechanical obstacle avoidance, avoiding the train head and the tarpaulin box, and avoiding adjacent large machines.

[0212] (1) Pedestrian obstacle avoidance for the loading machine

[0213] Install one set of pedestrian obstacle avoidance devices at the head and tail of the loading machine respectively. Through the walking safety obstacle avoidance device of the loading machine, the area within 5m in front of and behind the loading machine is monitored in real time. Once a person or an obstacle is detected in the monitored area, it can give graded alarms according to the distance and perform actions such as alarming and stopping walking. The central control can view, make decisions and issue obstacle removal instructions through relevant video cameras. After the alarm is lifted, the system continues to run.

[0214] (2) Obstacle avoidance between adjacent large machines

[0215] Establish an obstacle avoidance mechanism and a space anti-collision system for adjacent large machines. The loading machine to be renovated this time should fully consider dividing the safe working areas of two adjacent large machines on different or the same tracks. When the minimum distance between the two large machines is less than the preset value (for example, 10 - 20 meters), the space anti-collision system sends a collision alarm to the corresponding large machine and issues a stop command to protect the corresponding large machine. Remote monitoring personnel can set the protection area and bypass control through the anti-collision monitoring interface.

[0216] Set up a two-level alarm for the pre-alarm area and the emergency stop alarm area. After encountering an obstacle, the system issues an alarm. The central control can view, make decisions and issue obstacle removal instructions through relevant video cameras to prevent collisions between large machines. It is required that when adjacent large machines are in a stopped state or lose communication, the machine can also prevent itself from actively colliding with adjacent large machines.

[0217] (3) Emergency control device

[0218] The emergency control device is used for the emergency stop of the loading machine. One end is connected to the console in the central control room, and the other end is connected to the emergency stop input terminal (dry contact input) of the loading machine body.

[0219] (4) Access control device

[0220] The main vehicle of the loading machine is equipped with 2 sets of access control devices, and the tail vehicle is equipped with 2 sets of access control devices. The whole set of system consists of access protection devices, access control equipment, access image monitoring, etc. The signals and data of all the safety protection equipment of the loading machine are uniformly transmitted to the system control server, and all personnel access permissions are authorized in the central control room. The operating personnel can query the real-time data of the personnel entering and leaving the loading machine on the server and can remotely control the opening of each door point of the loading machine. The access control related data needs to have a general interface for docking with the background security platform of the tenderer.

[0221] (5) Video monitoring system

[0222] Utilize some of the monitoring cameras on the existing loading machine, and add more if necessary. Write the construction process plan according to the site requirements. There are 12 cameras already installed on the loading machine, which are respectively installed at 1 on the tail car belt, 1 on the boom belt, 2 at the bifurcated funnel, 1 on the cable reel device, 2 for the loading machine to move, 2 for left and right loading monitoring, 1 in each of the high and low voltage electrical rooms, and 2 in the driver's cab; the video monitoring camera image information is saved for 45 days.

[0223] (6) One-key anchoring device

[0224] The original anchoring device on the loading machine was manually operated. After the automatic control transformation of the loading machine, there are no operators on the equipment, so the original anchoring device needs to be automated. By adding limit switches and modifying mechanical devices, the automatic control of the anchoring function is achieved by connecting to the PLC control system.

[0225] (7) Integrated control device for on-machine lights

[0226] Modify the original on-machine light control system to achieve functions such as one-key switching.

[0227] (8) Video monitoring device

[0228] The captured images are displayed on the liquid crystal color display on the remote console, which can be displayed in multiple screens or one by one; the system should have earthquake resistance, and the images should be clear and stable. The installation position of the display should be designed reasonably and conveniently observable, and high-quality products of well-known brands should be selected. After the signal video is distributed, it is sent to the central control through the optical cable.

[0229] There are no less than 8 newly added vehicle number recognition cameras (4 dome cameras and 4 bullet cameras). The video monitoring system is required to be able to monitor the loading situation of the carriage and recognize the vehicle number. The video monitoring of the carriage loading situation is immediately carried out after the laser scanning is completed to jointly save and compare the three-dimensional contour and the video photo. The carriage video is required to be able to save the carriage video information for later comparison with the carriage contour graph. The high-precision video camera for the carriage video is required to have the function of cooperating with the laser scanning system to process the noise points of the carriage contour and perform the position calibration function. The vehicle number recognition system is used to record the current scanned loading carriage number and compare it with the vehicle number given by the production management system to prevent the situation of incorrect correspondence between the vehicle number and the loading content. The vehicle number recognition uses a high-precision video camera and is equipped with a corresponding supplementary lighting function, which can realize the function of clearly recognizing the carriage vehicle number under any working conditions of the vehicle. Since the loading vehicle has the function of loading in both the front and rear directions and there are two tracks below, in order to avoid the occlusion of the camera by the boom and another set of carriages during loading, it is necessary to install vehicle number recognition cameras on the two tracks on both sides of the boom respectively. The vehicle number recognition cameras are installed above the guardrail, which can avoid the damage of the camera by the lower guardrail during the telescopic process of the boom.

[0230] All video signals are connected to the newly added video recorder installed in the low-voltage control room, and the bidder shall provide relevant video decoding equipment and monitoring access authorization and other supporting facilities in the central control room.

[0231] Reform of the on-board PLC control system:

[0232] 1) In order to reduce the modification of the original main control PLC program and ensure the integrity and stability of the main control PLC program, a new automation control PLC is added near the original PLC module to implement all automation-related task process control, equipment safety protection and other functions. The automation control PLC uses a world-renowned brand series PLC and communicates with the original main PLC as a slave station via Ethernet or Profi bus. While the automation control PLC transmits instructions to the main control PLC, it receives the device status information feedback by the main control PLC. The automation program should be completely open for users' daily use and maintenance. In the original main control PLC program, only an automation control interface needs to be added.

[0233] 2) To meet the processing requirements of the on-board scanner, a new on-board data processing system is added to be responsible for completing the data acquisition of laser scanning equipment, video equipment, GNSS equipment, and inertial navigation equipment, and the realization of three-dimensional graphics, video shooting, positioning data parsing, and vehicle number recognition functions. At the same time, it realizes the data communication functions with the on-board PLC control system and the production management system. The performance configuration requirements of the newly added on-board data processing system are as follows: I9 / 64G DDR / 1T SSD + 1T / independent display with 8G video memory / keyboard / mouse, which needs to meet the use in the on-board dust, humidity, and bumpy environment.

[0234] 3) The equipment is installed in the cabinet in the existing low-voltage control room. Add 1 video switch and 1 control switch to realize the access of on-site Ethernet equipment. The control switch is configured with no less than 2 1000M optical ports and 24 100M network ports, and the video switch supports POE power supply for cameras.

[0235] 4) The on-board communication is mainly based on the existing optical fiber communication, and at the same time, 2 sets of redundant wireless communication network equipment are added to realize the remote wireless communication function. The 2 sets of wireless communication functions are respectively video redundant wireless communication and control redundant wireless communication, and wireless redundant switching modules and wireless communication modules are respectively configured. At the same time, the future 5G communication function is reserved.

[0236] Remote manual operation function of the loader:

[0237] (1) Set 2 automatic control system servers in the program control room to realize the automatic control algorithm of the loader and the three-dimensional scan image formation function. The server configuration parameters are as follows: rack server, Silver medal: 41142.2GHz dual CPUs (64 cores), 64G memory, 1.2T 10k SAS hard disks * 5 pieces (4 pieces form a RAID5, 1 piece for backup), dual power supply redundant configuration for processor and memory expansion; including 27-inch monitors, genuine operating system, genuine database, etc.

[0238] (2) Specific requirements for the remote operation console: The design dimensions, appearance color, and device layout of the operation console are unified, and the concealed layout of devices such as industrial control computers and controllers is considered.

[0239] (3) The operation handle is selected from S+B or equivalent brands to meet the functional requirements of remote intervention control for the train loading machine.

[0240] (4) The operation console is configured with 6 monitors, 4 for video monitoring and 2 for RCMS screen monitoring; the video monitor screens need to be associated with the production operation status and automatically jump to the screens required by the production scenario. A remote operation console is set up to be managed and scheduled through the remote operating system to achieve remote operation of on-site equipment and control of automated loading operations.

[0241] (5) The remote operating system has functions such as task management, remote control, operation console permission allocation, operation console switching, working status monitoring of the loading machine, and CCTV video monitoring.

[0242] (6) One set of new network broadcast calling system is added to achieve the function of remotely calling the in-situ loading machine, realize remote call and alarm functions, and there are no less than 4 on-site loudspeakers.

[0243] (7) The driver can select operation tasks through the remote operation console for remote operations. During the operation process, the driver can observe and intervene in the operation status of the current equipment through the current operation console, or can also select other equipment through the current operation console for observation and intervention. When selecting to jump to other equipment, the monitoring screen can automatically follow and jump.

[0244] (8) The loading machine operation console and the engineer station are set up in the central control room. The central control remote operation console should at least have a seamless switching switch for operation modes, control on / off buttons, start / stop buttons for the boom belt and hydraulic station, loading machine fault reset button, emergency stop button, travel operation handle, front and rear flap, boom telescoping operation handle, etc.

[0245] (9) Each loading machine operation console displays in real time the relevant information required by the automated system, carriage graphics and parameters, loading machine status parameters, and loading machine video monitoring screens. The screens can be switched, adjusted, and displayed according to the preset settings for different operations of the driver. The operation panel is arranged in front of the monitor and mainly consists of handles, buttons, indicator lights, emergency stop buttons, etc.

[0246] Functions achieved by the transformation of the automated loading machine:

[0247] (1) Realize the automatic operation of the loading machine's travel: Use a 3D scanning system to pre-detect the relative position between the chute mechanism of the train loading machine and the train carriage. Through the received belt scale data and the precise positioning of the carriage position, automatically control the travel speed mode of the loading machine to meet the stable loading quality of the loading machine in the automatic loading mode. In any case of automatic travel operation, manual intervention can be carried out at any time to control the travel of the loading machine or make an emergency stop. By online real-time monitoring of the relevant parameters of the loading mechanism, if the load is overloaded, the loading machine should be able to take corresponding actions in time in the automatic loading mode to avoid damage to the loading machine due to overloading caused by travel failures.

[0248] (2) High-precision, short-response-time, and stable positioning and detection devices should be adopted to achieve precise measurement of the positions of the loading machine's travel, telescoping, and each mechanism, as well as precise positioning of the carriage position. All equipment should be ensured to be firmly installed, fully considering issues such as mechanical vibration, dust prevention, and salt spray corrosion.

[0249] (3) Realize remote monitoring of the operating parameters, status, and on-site images of the loading machine equipment.

[0250] (4) The loading machine has a remote manual control function: Install a remote control console in the centralized control room to perform actions such as the travel, telescoping, and tipping of the loading machine, as well as emergency stop and fault reset operations. Retain the local manual operation function of the loading machine, with a manual-automatic switching function to ensure that it can be switched to the manual mode regardless of the operating situation. Set remote and local switching switches in the driver's cab and the central control room of the loading machine.

[0251] (5) Anti-collision and distance alarm reminders for two devices on the same track of the loading machine to achieve safe operation.

[0252] (6) The efficiency of automatic loading is not lower than the effect of normal driver operation: Manual intervention ≤ 5% (the ratio of manual intervention time to the total operation time, and situations that do not support automatic operation such as loading operations higher than the standard height requirement are not included).

[0253] (7) The system needs to implement the function of synchronous display of three-dimensional space solid vector graphics and video images. The scanning data of the laser scanner and the image acquisition data of the camera are automatically uploaded to the monitoring center. After being processed by the computer software system, the captured pictures of each carriage and the three-dimensional space solid vector graphics are presented in front of the user duty officer on the computer screen at the same time, and the duty officer can intuitively view the status of each carriage.

[0254] (8) The system needs to implement the function of automatic vehicle number recognition. The system uses the railway automatic vehicle number recognition device to read information such as the vehicle type and vehicle number of each carriage, and uploads it to the monitoring terminal for display. At the same time, the vehicle type and vehicle number information can be corresponding to the three-dimensional stereoscopic vector graphics and captured images of the carriage one by one.

[0255] (9) The system is responsible for data docking with the existing production management software related to train operations in the port to meet two-way data interaction.

[0256] Precision loading measurement transformation of the automatic loading machine:

[0257] (1) Realize automatic comparison of loading volume: Connect with the production management system, and automatically input the required loading volume of each carriage according to the tare weight and standard weight of the empty car. By comparing the profit and loss situation of the previous train, automatically fine-tune the loading volume of the next train to ensure the accuracy of the loading volume of each section, and achieve a full load rate of more than 99.9% for ordinary carriages and more than 99.5% for open-top containers of containers.

[0258] (2) Realize automatic input of the correction value number of the loading machine: Install a scanning system or obtain the track scale data through the production management system, identify the load weight of the empty carriage of this train, the tare weight of the empty car, and compare the profit and loss situation of the previous train, and automatically adjust the loading volume of each section to reduce manual intervention and realize automatic input of the correction value number of the loading machine. At the same time, under any circumstances, manual intervention can be carried out at any time to adjust the loading correction value.

[0259] (3) Realize that the loading quality meets the standards in the front, back, left and right directions: Through the scanning system, according to the loading situation of the previous section, automatically adjust the material dropping point of the next train in a timely manner to ensure that the front and back deviation of each train is controlled within 7T and the left and right deviation is controlled within 30mm.

[0260] (8) Those of ordinary skill in the art should understand that the discussion of any of the above embodiments is only exemplary and is not intended to imply that the scope of the present invention (including the claims) is limited to these examples; under the concept of the present invention, the technical features in the above embodiments or different embodiments can also be combined, and the steps can be implemented in any order, and there are many other variations in different aspects of the present invention as described above, and they are not provided in detail for the sake of brevity.

[0261] The present invention is intended to cover all such substitutions, modifications, and variations that fall within the broad scope of the appended claims. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention shall be included within the protection scope of the present invention.

Claims

1. An automatic control system for a loading machine, characterized in that: Comprising: A user interface module for providing to the operator for use; A sensor module for real-time monitoring of the loading machine status; A vehicle number identification module for identifying the vehicle number of the loading vehicle on the specified side; An overloading and offloading detection module for detecting whether there is overloading or offloading of the loading machine; A PLC control module for controlling each execution component of the loading machine. The PLC control module controls the operations of the loading machine according to the instructions sent by the user interface module, adjusts the operations of the loading machine according to the loading machine status information transmitted by the sensor module, identifies and records the vehicle number information of the loading vehicle transmitted by the vehicle number identification module information, and monitors whether there is overloading or offloading of the loading machine according to the data transmitted by the overloading and offloading detection module and takes corresponding measures; A historical record module for recording the operation historical data of the loading machine; An alarm processing module for monitoring various abnormal situations of the loading machine and giving alarms. The alarm processing module monitors the running status of each of the above modules and provides corresponding processing suggestions or automatically executes emergency procedures according to the situation; A communication module for data exchange and communication between each module.

2. A fully automatic control method for a loading machine, which is applied to the fully automatic control system of the loading machine according to claim 1, and is characterized in that: The user interface module specifically includes the following steps: S11. Provide a user login function, including user name and password input; S12. Select the loading machine to be controlled on the login interface and then input the account password to log in; S13. Display the real-time status of the loading machine and provide operation buttons and a control panel; S14. Allow the user to set loading parameters, including loading direction, track selection, loading speed, loading quantity; S15. Allow the user to input a loading operation plan, including train number information, loading sequence, loading quantity; S16. Provide functions for saving and loading parameters and operation plans; S17. Provide a historical record interface; S18. Provide a system setting interface.

3. The full-automatic control method of a loading machine according to claim 2, characterized in that: The sensor module specifically includes the following steps: S21. Install the sensor at a suitable part of the loading machine; S22. Obtain the loading machine status data; S23. Transmit the sensor data through a communication network.

4. A fully automatic control method for a loading machine according to claim 3, characterized in that: The vehicle number identification module specifically includes the following steps: S31. Obtain the image of the loading area of the loading machine; S32. Preprocess the collected image; S33. Use an image processing algorithm to locate the vehicle position in the loading area image; S34. Based on image processing and recognition algorithms, identify the vehicle number of the vehicle; S35. Output the identified vehicle number information to the loading machine control system.

5. A fully automatic control method for a loading machine according to claim 4, characterized in that: The overloading and offloading detection module specifically includes the following steps: S41. Obtain the cargo weight data; S42. Apply an algorithm to identify abnormal weight data and judge whether there is overloading or offloading; S43. Output the overloading and offloading detection result to the loading machine control system.

6. The fully automatic control method of a loading machine according to claim 5, wherein: The PLC control module specifically includes the following steps: S51. According to the system design, define the input and output logic to ensure correct control logic and operation process; S52. Integrate the PLC control module with other system components, including sensors, actuators, control panels, etc., to ensure communication and coordination between each component; S53. Analyze the running data of the loading machine and execute corresponding operations.

7. A fully automatic control method for a loading machine according to claim 6, characterized in that: The historical record module specifically includes the following steps: S61. Determine the data types and fields to be recorded; S62. Specify the data recording format and structure; S63. Obtain the operation history data of the loading machine; S64. Record the collected data into the historical record database or file.

8. The fully automatic control method of a loading machine according to claim 7, characterized in that: The alarm handling module specifically includes the following steps: S71. Determine various abnormal conditions to be monitored in the system and classify them as alarm types; S72. Set the conditions and thresholds for alarm triggering; S73. Determine the alarm notification method; S75. Obtain the device operation status and data in real time to detect whether the alarm triggering conditions are met; S76. When the alarm triggering conditions are met, immediately issue the corresponding alarm notification.

9. The full-automatic control method of a loading machine according to claim 8, characterized in that: The communication module specifically includes the following steps: S81. Establish a communication connection with external devices or systems in the system; S82. Transmit the data generated in the system to external systems or devices through the communication module.

10. A fully automatic control device for a loading machine, which is applied to the control method described in any one of claims 2-9, and is characterized in that: The device includes: Sensors for perceiving the surrounding environment and the status of the loading machine itself; Actuators for performing specific operations; Controllers for controlling the overall operation of the system; Human-machine interface devices for human-machine interaction.

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