Grab ship unloader cabin bottom anti-collision system and method based on image recognition technology

Abstract

The invention discloses a grab ship unloader cabin bottom anti-collision system and method based on an image recognition technology, and the system comprises an image recognition unit which comprises a high-definition camera installed in the middle of a cantilever crane and an image processing server installed in a PLC room, a PLC control unit which comprises a PLC module and a switch which are installed in the PLC room, and an image processing unit which is installed in the PLC room. The PLC module receives the data information of the exposure condition of the bottom plate at the bottom of the cabin transmitted by the image processing server, and outputs a control instruction; and the mechanism driving unit comprises a lifting frequency converter and an opening and closing frequency converter which are arranged in the electrical room, and a lifting opening and closing motor which is arranged in the machine room. According to the system, the risk that the grab bucket hits the bottom of a cabin in the operation process of the grab bucket ship unloader, especially in the cabin cleaning operation stage, is reduced, the cost needed for maintaining a cabin bottom plate is saved, and the overall operation efficiency of a bulk cargo wharf is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of grab unloader control, and particularly relates to a system and method for preventing grab from hitting and colliding with the bottom of the cabin of a grab unloader based on image recognition technology. Background Art

[0002] As an important ship unloading equipment in bulk cargo terminals, the demand for intelligent and digital grab unloaders has been increasing in recent years. At present, intelligent grab unloaders generally use laser scanning to detect the distribution of materials in the cabin. Due to the limitations of the technical characteristics of laser scanning, only the morphology of the solid structure on the working surface in the cabin can be recognized, and it is impossible to judge whether the recognized solid structure on the working surface is materials or the bottom plate of the cabin. At the same time, the unloading of ships in bulk cargo terminals is complex, and it is often impossible to obtain the hatch depth data of the ship. Therefore, when automatically unloading to the bottom area of the cabin, there is often a situation where the grab hits and collides with the bottom plate of the cabin, which may cause damage to the bottom plate of the cabin in severe cases, resulting in economic losses to the operation of the bulk cargo terminal. Therefore, it is urgent to develop a reliable bottom recognition function to judge and locate the area and position where the bottom plate of the cabin is exposed on the working surface in the cabin. The grab unloader can realize the anti-hitting and anti-collision protection of the bottom of the cabin based on this data. Summary of the Invention

[0003] According to the problems existing in the prior art, the present invention discloses a system for preventing grab from hitting and colliding with the bottom of the cabin of a grab unloader based on image recognition technology, which specifically includes:

[0004] An image recognition unit, including a high-definition camera installed in the middle of the boom and an image processing server installed in the PLC room. The high-definition camera is used to collect image information of the working material surface in the cabin and transmit it to the image processing server. The image processing server processes the received image information to judge whether the bottom plate of the cabin is exposed and obtain the working position information of the exposed bottom plate of the cabin.

[0005] A PLC control unit, including a PLC module and a switch installed in the PLC room. The PLC module receives the data information of the exposure situation of the bottom plate of the cabin transmitted by the image processing server and outputs a control instruction.

[0006] A mechanism driving unit, including a hoisting frequency converter and an opening and closing frequency converter installed in the electrical room and a hoisting and opening and closing motor installed in the machine room. The hoisting frequency converter and the opening and closing frequency converter control the operation of the hoisting and opening and closing motor by receiving the control instruction transmitted by the PLC control unit. The hoisting and opening and closing motor drives the grab mechanism to perform corresponding ascending and descending actions.

[0007] Furthermore, the high-definition camera transmits the image data of the working material surface in the cabin collected through the TCP / IP protocol to the image processing server.

[0008] Further, the switch is used for data transmission between the PLC module, the image recognition unit, and the mechanism drive unit; when the image processing server detects the exposure of the bottom cabin floor, it analyzes the position of the exposed area of the bottom cabin floor, calculates the area value, and transmits it to the PLC module through the switch using the TCP / IP protocol.

[0009] Further, when the PLC module receives the data on the exposure of the bottom cabin floor and the position of the exposed area of the bottom cabin floor, it controls the actions of the docking and grasping points during the ship unloading operation, avoiding the impact of the falling materials in the exposed area of the bottom cabin floor. In the form of the Profinet protocol, it is transmitted through the switch to the hoisting frequency converter and the opening and closing frequency converter in the mechanism drive unit, and then drives the operation of the hoisting and opening and closing motors to avoid the impact on the bottom cabin floor of the grab ship unloader.

[0010] A control method for the anti-collision system at the bottom of the cabin of a grab ship unloader based on image recognition technology includes:

[0011] S1: The high-definition camera samples the image data of the material operation area in the cabin in real time and records the initial color card value of the material pixels in the material operation area in the cabin.

[0012] S2: The image processing server processes the image data of the material operation area in the cabin, judges the exposure situation of the bottom cabin floor, and obtains whether the bottom cabin floor at the current grasping point is exposed and the degree of exposure.

[0013] When there is a deviation area between the actual pixel color card value of the image data of the material operation surface in the cabin and the initial color card value in S1, it is determined that the bottom cabin floor has been exposed on the material operation surface in the cabin.

[0014] When K 目标位 = P 异常 / P 整体 > 100%, it is judged that the bottom cabin floor at the current grasping point is not exposed.

[0015] When K 目标位 = P 异常 / P 整体 < 100% and K 目标位 = P 异常 / P 整体 > 50%, it is judged that the bottom cabin floor at the current grasping point is slightly exposed.

[0016] When K 目标位 = P 异常 / P 整体 < 50%, it is judged that the bottom cabin floor at the current grasping point is severely exposed.

[0017] Where K 目标位 is the abnormal proportion of the pixel color card value in the target grasping point area, and P异常 The number of pixel points with abnormal color card values in the target grabbing point area is P 整体 is the total number of pixel points in the target grabbing point area.

[0018] S3: If it is determined that the bottom plate of the cabin is not exposed at the current grabbing position, the PLC module issues control instructions to the hoisting frequency converter and the opening / closing frequency converter, driving the normal speed of the hoisting and opening / closing motors to decrease, and controlling the grab to discharge and pick up materials;

[0019] S4: If it is determined that the bottom plate of the cabin is slightly exposed at the current grabbing position, the PLC module issues control instructions to the hoisting frequency converter and the opening / closing frequency converter, driving the hoisting and opening / closing motors to decrease speed limit, and controlling the grab to discharge and pick up materials. The calculation method of speed limit decrease is as follows:

[0020] V = V max ×K 露出 ;

[0021] where V is the speed limit value for hoisting and opening / closing descent, V max is the maximum speed for hoisting and opening / closing descent, and K 露出 is the proportion of the exposed bottom plate of the cabin at the current grabbing point.

[0022] S5: If it is determined that the bottom plate of the cabin is severely exposed at the current grabbing position, the PLC module automatically bans this grabbing position and prohibits grabbing materials at this grabbing position, continuously activating the anti-collision system function at the bottom of the grab ship unloader cabin until the ship unloading operation is completed.

[0023] Due to the adoption of the above technical solution, a grab ship unloader cabin bottom anti-collision system and method based on image recognition technology provided by the present invention. The system is based on image recognition technology and accurately judges the exposure of the cabin bottom plate during the ship unloading operation. The grab ship unloader can automatically control the given speed during the descent of the grab at the corresponding grabbing position according to the detected exposure position and exposure situation of the cabin bottom plate, effectively reducing the impact on the cabin bottom plate during the descent of the grab and realizing the anti-collision protection of the cabin bottom plate. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments recorded in the present application. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0025] Figure 1 is the structural block diagram of the system of the present invention

[0026] Figure 2Layout diagram of the anti-collision and anti-smashing system at the bottom of the cabin of a grab unloader based on image recognition technology of the present invention

[0027] Figure 3 Wiring diagram of the image recognition unit in the present invention

[0028] Figure 4 Wiring diagram of the PLC control unit in the present invention

[0029] Figure 5 Wiring diagram of the mechanism drive unit in the present invention

[0030] Figure 6 Illustration diagram for image acquisition of the material working surface at the bottom of the cabin in the present invention

[0031] Figure 7 Control flow chart of the anti-collision and anti-smashing system at the bottom of the cabin of a grab unloader based on image recognition technology of the present invention Detailed implementation manners

[0032] To make the technical solutions and advantages of the present invention clearer, the following clearly and completely describes the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention:

[0033] As Figure 1 shown, an anti-collision and anti-smashing system at the bottom of the cabin of a grab unloader based on image recognition technology includes three parts: an image recognition unit, a PLC control unit, and a mechanism drive unit. The image recognition unit consists of a high-definition camera installed in the middle of the boom and an image processing server installed in the PLC room. The high-definition camera is used to sample the image of the working material surface in the cabin; the image processing server performs algorithm processing on the sampled image of the working material surface in the cabin, detects whether the cabin bottom plate is exposed and the working position where the cabin bottom plate is exposed, and transmits the detection result to the PLC control unit. The PLC control unit consists of a PLC module and a switch installed in the PLC room. The PLC module controls the mechanism drive unit by receiving the data of the exposure of the cabin bottom plate detected by the image recognition unit to avoid the grab mechanism from hitting and smashing the cabin bottom plate; the switch is used for data transmission between the PLC module, the image recognition unit, and the mechanism drive unit. The mechanism drive unit consists of a hoisting frequency converter and an opening and closing frequency converter installed in the electrical room, and a hoisting and opening and closing motor installed in the machine room. The hoisting and opening and closing frequency converters control the operation of the hoisting and opening and closing motors by receiving the control instructions of the PLC control unit; the hoisting and opening and closing motors drive the grab mechanism to perform corresponding rising and falling actions. The layout diagram of the anti-collision and anti-smashing system at the bottom of the cabin of a grab unloader based on image recognition technology is as Figure 2 shown.

[0034] The anti-collision and anti-smashing system at the bottom of the cabin of a grab ship unloader based on image recognition technology consists of three parts: an image recognition unit U1, a PLC control unit U2, and a mechanism drive unit U3. The system architecture diagram is as shown in Figure 2 shown below.

[0035] As shown in Figure 3 shown below, the image recognition unit U1 consists of a high-definition camera and an image processing server. The high-definition camera is used to collect the image data of the material working surface in the cabin and transmit the collected image data of the material working surface in the cabin to the image processing server through the TCP / IP protocol. The image processing server processes the received image data of the material working surface in the cabin through algorithms, judges whether the bottom plate of the cabin bottom is exposed on the material working surface. If the bottom plate of the cabin bottom is exposed, the position of the exposed area of the bottom plate of the cabin bottom can be calculated and transmitted to the PLC module through the switch in the PLC control unit U2 in the form of the TCP / IP protocol.

[0036] As shown in Figure 4 shown below, the PLC control unit U2 consists of a PLC module and a switch. After the PLC module obtains the exposed condition of the bottom plate of the cabin bottom and the position data of the exposed area of the bottom plate of the cabin bottom transmitted by the image recognition unit U1, it controls the actions of the grabbing points for ship unloading operation, avoids the falling, collision and impact of the materials in the exposed area of the bottom plate of the cabin bottom, and transmits them to the hoisting frequency converter and the opening and closing frequency converter in the mechanism drive unit U3 in the form of the Profinet protocol through the switch, and then drives the hoisting and opening and closing motors to realize the anti-collision and anti-smashing of the bottom plate of the cabin of the grab ship unloader. The switch is used for data transmission between the PLC module and the hoisting frequency converter, the opening and closing frequency converter in the mechanism drive unit U3 and the image processing server in the image recognition unit U1.

[0037] As shown in Figure 5 shown below, the mechanism drive unit U3 consists of a hoisting frequency converter, an opening and closing frequency converter, and hoisting and opening and closing motors. After the hoisting frequency converter and the opening and closing frequency converter obtain the hoisting and opening and closing control instructions in the PLC control unit U2, they drive the hoisting and opening and closing motors to perform corresponding operating actions in the form of hard wiring, realizing the anti-collision and anti-smashing of the bottom plate of the cabin of the grab ship unloader.

[0038] The specific control method of an anti-collision and anti-smashing system at the bottom of the cabin of a grab ship unloader based on image recognition technology is as follows:

[0039] Step 1: When the ship unloading operation starts, the anti-collision and anti-smashing system function at the bottom of the cabin of the grab ship unloader based on image recognition technology is activated;

[0040] Step 2: The high-definition camera samples the image data of the material working area in the cabin in real time and records the initial color card value of the pixels of the materials in the material working area in the cabin;

[0041] Step 3: The image processing server processes the image data of the in-cabin material operation area, judges the exposure of the bottom cabin floor, and obtains whether the bottom cabin floor at the current grasping point is exposed and the degree of exposure. Refer to Figure 6 Illustration of image acquisition of the material operation surface at the bottom of the cabin to explain the specific data processing method:

[0042] When there is a deviation area between the actual pixel color card value of the in-cabin material operation surface image data and the initial color card value in Step 2, it is determined that the bottom cabin floor has appeared in the in-cabin material operation surface.

[0043] When K 目标位 = P 异常 / P 整体 > 100%, it is judged that the bottom cabin floor at the current grasping point is not exposed;

[0044] When K 目标位 = P 异常 / P 整体 < 100% and K 目标位 = P 异常 / P 整体 > 50%, it is judged that the bottom cabin floor at the current grasping point is slightly exposed;

[0045] When K 目标位 = P 异常 / P 整体 < 50%, it is judged that the bottom cabin floor at the current grasping point is severely exposed;

[0046] Among them, K 目标位 is the abnormal proportion of pixel color card values in the target grasping point area, P 异常 is the number of pixel points with abnormal color card values in the target grasping point area, P 整体 is the total number of pixel points in the target grasping point area.

[0047] Step 4: If it is judged that the bottom cabin floor at the current grasping point is not exposed, the PLC module issues control commands to the hoisting frequency converter and the opening and closing frequency converter, drives the hoisting and opening and closing motors to decrease at normal speed, and controls the grab to discharge and pick up materials;

[0048] Step 5: If it is judged that the bottom cabin floor at the current grasping point is slightly exposed, the PLC module issues control commands to the hoisting frequency converter and the opening and closing frequency converter, drives the hoisting and opening and closing motors to decrease speed limit, and controls the grab to discharge and pick up materials. The calculation method of speed limit decrease is as follows:

[0049] V = V max × K 露出 ;

[0050] Among them, V is the speed limit value of hoisting and opening and closing descent, V max is the maximum speed of hoisting and opening and closing descent, K露出 It is the exposed proportion of the bottom plate of the cabin at the current grabbing point.

[0051] Step 6: If it is judged that the bottom plate of the cabin at the current grabbing point is severely exposed, the PLC module automatically bans this grabbing point and prohibits grabbing materials at this grabbing point.

[0052] Step 7: Continuously activate the anti-collision system function at the bottom of the grab unloader's cabin until the ship unloading operation is completed.

[0053] Embodiment:

[0054] Taking an 1800t / h grab unloader and a 50,000-ton bulk carrier as examples, the control process of the anti-collision system at the bottom of the grab unloader's cabin based on image recognition technology is described. As Figure 7 shown: When the ship unloading operation starts, the anti-collision system function at the bottom of the grab unloader's cabin based on image recognition technology is activated; then the high-definition camera samples the image data of the material operation area in the cabin in real time; after the image sampling is completed, the image processing server processes the image data of the material operation area in the cabin, judges the exposed situation of the bottom plate of the cabin, and obtains whether the bottom plate of the cabin at the current grabbing point is exposed and the degree of exposure; if it is judged that the bottom plate of the cabin at the current grabbing point is not exposed, the PLC module issues control instructions to the hoist frequency converter and the opening and closing frequency converter, drives the hoist and opening and closing motors to descend at normal speed, and controls the grab to discharge and pick up materials; if it is judged that the bottom plate of the cabin at the current grabbing point is slightly exposed, the PLC module issues control instructions to the hoist frequency converter and the opening and closing frequency converter, drives the hoist and opening and closing motors to descend at medium speed, and controls the grab to discharge and pick up materials; if it is judged that the bottom plate of the cabin at the current grabbing point is severely exposed, the PLC module automatically bans this grabbing point and prohibits grabbing materials at this grabbing point; continuously activate the anti-collision system function at the bottom of the grab unloader's cabin until the ship unloading operation is completed.

[0055] An anti-collision system at the bottom of a grab unloader's cabin based on image recognition technology disclosed by the present invention provides users with a reliable anti-collision protection function at the bottom of the cabin, reduces the risk of the grab hitting the bottom of the cabin during the operation of the grab unloader, especially during the cabin cleaning operation stage, saves the cost required for repairing the cabin bottom plate, and improves the overall operation efficiency of the bulk cargo terminal. The development of the anti-collision system at the bottom of the grab unloader's cabin based on image recognition technology greatly increases the market core competitiveness of the grab unloader product.

[0056] The above is only a preferred specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention, according to the technical solution and inventive concept of the present invention, makes equivalent replacements or changes, and all should be covered within the protection scope of the present invention.

Claims

1. A grab unloader cabin bottom anti-collision system based on image recognition technology, characterized in that Including: An image recognition unit, including a high-definition camera installed in the middle of the boom and an image processing server installed in the PLC room. The high-definition camera is used to collect image information of the working material surface in the cabin and transmit it to the image processing server. The image processing server processes the received image information to judge whether the cabin bottom plate is exposed and obtain the working position information of the exposed cabin bottom plate; A PLC control unit, including a PLC module and a switch installed in the PLC room. The PLC module receives the data information of the exposure condition of the cabin bottom plate transmitted by the image processing server and outputs a control instruction; A mechanism driving unit, including a hoisting frequency converter and an opening / closing frequency converter installed in the electrical room and a hoisting / opening / closing motor installed in the machine room. The hoisting frequency converter and the opening / closing frequency converter control the operation of the hoisting / opening / closing motor by receiving the control instruction transmitted by the PLC control unit. The hoisting / opening / closing motor drives the grab mechanism to perform corresponding rising and falling actions.

2. The anti-collision and anti-smashing system for the bottom of the cabin of a grab ship unloader based on image recognition technology according to claim 1, wherein: The high-definition camera transmits the image data of the material working surface in the cabin collected through the TCP / IP protocol to the image processing server.

3. The anti-collision and anti-smashing system for the bottom of the cabin of a grab ship unloader based on image recognition technology according to claim 1, characterized in that: The switch is used for data transmission between the PLC module, the image recognition unit and the mechanism driving unit; when the image processing server detects the exposure of the cabin bottom plate, it analyzes the position of the exposed area of the cabin bottom plate and calculates the area value, and transmits it to the PLC module through the switch using the TCP / IP protocol.

4. The anti-collision and anti-smashing system for the bottom of the cabin of a grab unloader based on image recognition technology according to claim 3, characterized in that: When the PLC module receives the data of the exposure condition of the cabin bottom plate and the position of the exposed area of the cabin bottom plate, it controls the action of the docking and grabbing point during the ship unloading operation, avoiding the material falling and hitting impact in the exposed area of the cabin bottom plate. In the form of the Profinet protocol, it is transmitted through the switch to the hoisting frequency converter and the opening / closing frequency converter in the mechanism driving unit, and then drives the operation of the hoisting / opening / closing motor to avoid hitting the cabin bottom plate of the grab ship unloader.

5. A control method for the anti-collision and anti-smashing system at the bottom of the cabin of a grab unloader based on image recognition technology, using the anti-collision and anti-smashing system at the bottom of the cabin of a grab unloader described in any one of claims 1-4, characterized in that Including: S1: The high-definition camera samples the image data of the material working area in the cabin in real time and records the initial color card value of the pixels of the materials in the material working area in the cabin; S2: The image processing server processes the image data of the material working area in the cabin, judges the exposure condition of the cabin bottom plate, and obtains whether the cabin bottom plate at the current grabbing point is exposed and the degree of exposure; When there is a deviation area between the actual pixel color card value of the image data of the material working surface in the cabin and the initial color card value in S1, it is determined that the cabin bottom plate has been exposed on the material working surface in the cabin; When K 目标位 = P 异常 / P 整体 > 100%, it is determined that the bottom plate of the cabin floor at the current grasping point is not exposed; When K 目标位 = P 异常 / P 整体 < 100% and K 目标位 = P 异常 / P 整体 > 50%, it is determined that the bottom plate of the current grasping point is slightly exposed; When K 目标位 = P 异常 / P 整体 < 50%, it is determined that the bottom plate of the current grasping point is severely exposed; where K 目标位 is the abnormal proportion of pixel color card values in the target grasping point area, and P 异常 is the number of pixel points with abnormal color card values in the target grasping point area, and P 整体 is the total number of all pixel points in the target grasping point area; S3: If it is judged that the cabin bottom plate at the current grabbing point is not exposed, the PLC module issues control instructions to the hoisting frequency converter and the opening / closing frequency converter, drives the hoisting / opening / closing motor to descend at a normal speed, and controls the grab to drop and pick up materials; S4: If it is judged that the cabin bottom plate at the current grabbing point is slightly exposed, the PLC module issues control instructions to the hoisting frequency converter and the opening / closing frequency converter, drives the hoisting / opening / closing motor to descend at a speed limit, and controls the grab to drop and pick up materials. The speed limit descent calculation method is as follows: V = V max × K 露出 ; Among them, V is the speed limit value for hoisting and closing and lowering, and V max is the maximum speed for hoisting and closing and lowering, and K 露出 is the exposed proportion of the bottom plate of the hold at the current grasping point; S5: If it is judged that the bottom plate of the current grabbing point is seriously exposed, the PLC module automatically bans this grabbing point and prohibits grabbing materials at this grabbing point, continuously activating the anti-collision system function at the bottom of the grab unloader's cabin until the ship unloading operation is completed.

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