Automatic positioning system of ship unloader and data processing method thereof

Abstract

The invention relates to a ship unloader automatic positioning system and a data processing method thereof. The ship unloader automatic positioning system specifically comprises a positioning module, a data processing module, a control module, a communication module, a man-machine interaction module and a safety monitoring module. The positioning module is in data connection with the data processing module through the communication module and used for collecting the position and posture data of the ship unloader in real time. The data processing module is in two-way communication with the control module through an industrial bus, and is used for filtering, fusing and path planning of the positioning data; the control module is connected with an executing mechanism of the ship unloader through the communication module and used for generating a control instruction and driving the executing mechanism to act. And the man-machine interaction module is connected with the data processing module and is used for displaying a system state and receiving a manual input instruction. The problems that traditional ship unloader operation mainly depends on manual work, positioning precision is low, operation efficiency is low, and labor intensity is high are solved.

Description

Technical Field

[0001] The present invention relates to the field of automation control technology, and particularly to a ship unloader automatic positioning system and its data processing method. Background Art

[0002] In the bulk cargo loading and unloading operations at ports, as a key equipment, the operation efficiency and safety of ship unloaders are of crucial importance. The traditional operation of ship unloaders mainly relies on manual labor, which has problems such as low positioning accuracy, low operation efficiency, and high labor intensity. With the continuous increase in port throughput and the development of automation technology, higher requirements are put forward for the automation level of ship unloaders.

[0003] At present, although there are already some ship unloader automatic positioning technologies, there are many deficiencies. For example, some systems only use a single sensor for positioning, and the positioning accuracy is greatly affected by environmental factors, making it difficult to meet the requirements of high-precision operations; the data processing ability is limited, and it is unable to process a large amount of sensor data in real time and perform effective path planning; the response speed of the control module is slow, resulting in a lag in the actions of the ship unloader and affecting the operation efficiency; the stability of the communication module is poor, and data transmission delays or losses are likely to occur, affecting the reliability and safety of the system; the human-machine interaction interface is not user-friendly, and it is difficult for operators to grasp the system status in real time; the safety monitoring mechanism is imperfect, and potential safety hazards cannot be detected and processed in time. Therefore, it is of great practical significance to develop a ship unloader automatic positioning system with high precision, high efficiency, and high safety. Summary of the Invention

[0004] Aiming at the problems in the prior art, the present invention provides a ship unloader automatic positioning system and its data processing method, including the following modules: a positioning module, a data processing module, a control module, a communication module, a human-machine interaction module, and a safety monitoring module. Each module is interconnected through a specific communication method and works together to achieve the automatic positioning, control, and safety monitoring of the ship unloader.

[0005] The present invention provides a ship unloader automatic positioning system, which specifically includes the following modules: a positioning module, a data processing module, a control module, a communication module, a human-machine interaction module, and a safety monitoring module; the positioning module is data-connected to the data processing module through the communication module and is used to collect the position and attitude data of the ship unloader in real time; the data processing module communicates bidirectionally with the control module through an industrial bus and is used to filter, fuse, and perform path planning on the positioning data; the control module is connected to the actuating mechanism of the ship unloader through the communication module and is used to generate control instructions and drive the actuating mechanism to act; the human-machine interaction module is connected to the data processing module and is used to display the system status and receive manual input instructions; the safety monitoring module is connected to the data processing module through a sensor network and is used to detect the safety status of the ship unloader operating environment and trigger an emergency braking signal.

[0006] Furthermore, as a key part of the system for obtaining the position and attitude information of the ship unloader, the positioning module realizes data connection with the data processing module through the communication module, and collects and transmits relevant data in real time. This module adopts multi-sensor fusion technology, specifically including lidar, differential GPS unit, and inertial measurement unit, to give full play to the advantages of each sensor and improve the accuracy and reliability of positioning. Among them, the working wavelength of the lidar is 905 nanometers. This wavelength has good performance in lidar applications, can reduce ambient light interference while ensuring a certain detection distance, the scanning field of view angle is not less than 270 degrees, can cover a wider area, ensure a comprehensive perception of the environment around the ship unloader, the angular resolution is not greater than 0.1 degree, can accurately capture the detailed information of objects, improve the accuracy of positioning, the ranging accuracy error does not exceed plus or minus 2 centimeters, ensures the high precision of distance measurement, provides reliable data for subsequent pose calculation, the maximum detection distance is not less than 150 meters, meets the positioning requirements of the ship unloader in a large working range, and the scanning frequency is not less than 20 hertz, can obtain the change information of the surrounding environment in real time, and ensure the timeliness of positioning data. The differential GPS unit supports carrier-phase differential positioning technology. This technology can eliminate most errors through the differential of carrier-phase observations between the reference station and the rover station, and achieve centimeter-level high-precision positioning. The horizontal positioning accuracy does not exceed 1 centimeter, and the vertical positioning accuracy does not exceed 2 centimeters, which can provide accurate global position information for the ship unloader. It supports the reception of L1 and L2 dual-band satellite signals, increases the number of satellite signals that can be received, and improves the reliability and stability of positioning. The data update rate is not less than 10 hertz, ensuring the real-time update of position information and meeting the system's requirements for dynamic positioning. The inertial measurement unit includes a three-axis microelectromechanical system gyroscope and accelerometer, and can measure the angular velocity and acceleration information of an object at the same time. The range of the gyroscope is ±2000 degrees per second, which can adapt to the large angular velocity changes during the operation of the ship unloader. The zero-bias stability does not exceed 10 degrees per hour, ensuring the measurement accuracy of the gyroscope during long-term operation. The range of the accelerometer is ±16 times the acceleration of gravity, which can meet the acceleration measurement requirements of the ship unloader under different working conditions. The sampling frequency is not less than 200 hertz, which can capture the dynamic changes of the object in real time and provide rich data for attitude calculation. The dynamic attitude angle measurement accuracy does not exceed 0.1 degree, ensuring the accuracy of attitude information.

[0007] Furthermore, the data processing module is the core computing unit of the system. It communicates bidirectionally with the control module via an industrial bus and is responsible for key processing tasks such as filtering, fusing, and path planning of positioning data. Among them, the multi-core processor has a main frequency of not less than 2.5 gigahertz, with powerful computing capabilities, capable of quickly processing a large amount of sensor data. It supports the floating-point operation instruction set, which can effectively improve the speed and accuracy of data processing, especially when performing complex mathematical operations. The memory bandwidth is not less than 50 gigabytes per second, ensuring high-speed data transmission between the processor and memory and avoiding data bottlenecks. It is built with a real-time operating system that can respond to various task requests of the system in real time, ensuring the real-time performance and stability of the system.

[0008] The parallel computing unit is implemented based on a programmable logic device. The number of logic units is not less than 50 thousand, with powerful parallel computing capabilities, which can accelerate the execution of data processing algorithms. It supports the hardware-accelerated Kalman filtering algorithm, with an iteration period of no more than 10 milliseconds, capable of quickly filtering sensor data and improving the accuracy and stability of the data.

[0009] The data fusion algorithm uses the extended Kalman filter to fuse lidar, GPS, and IMU data, making full use of the advantages of each sensor and outputting six-degree-of-freedom pose information. The pose update frequency is not less than 100 hertz, ensuring the real-time update of pose information and providing accurate pose data for the control module. The noise covariance matrix of the data fusion algorithm is dynamically adjusted according to the measured errors of the sensors. The lidar noise variance does not exceed 0.0004 square meters, the GPS horizontal noise variance does not exceed 0.0001 square meters, and the IMU angular velocity noise density does not exceed 0.01 degrees per square root hour, improving the accuracy and adaptability of data fusion. The path planning algorithm is based on the combination of the A* algorithm and the dynamic window method. The A* algorithm can quickly search for the optimal path, and the dynamic window method takes into account the dynamic constraints of the ship unloader, ensuring the feasibility of the path. The planning period does not exceed 50 milliseconds, capable of quickly responding to system changes and real-time planning of the optimal path. The path tracking error does not exceed 5 centimeters, ensuring that the ship unloader can accurately track the planned path and improving the operation accuracy.

[0010] Furthermore, the control module is the core part of the system for realizing the action control of the ship unloader. It is connected to the actuators of the ship unloader through the communication module, generates and sends control instructions, and drives the actuators to complete various actions. Among them, the industrial programmable logic controller supports the EtherCAT bus communication protocol, which has the characteristics of high speed, real time, and synchronization, enabling high-speed data transmission between the PLC and the servo drive. The minimum control period does not exceed 1 millisecond, capable of quickly responding to system changes and generating control instructions in a timely manner. The isolation voltage of the input and output channels is not less than 2500 volts, effectively preventing electrical interference and improving the reliability and safety of the system.

[0011] The servo drive adopts the vector control mode, supports the three-loop closed-loop control of position, speed, and torque, and can accurately control the motion state of the motor; the encoder feedback resolution is not less than 20 bits, providing high-precision position feedback information and ensuring the positioning accuracy of the motor; the control bandwidth is not less than 500 Hz, which can quickly respond to control commands and achieve fast and accurate control of the motor; the overload capacity is not less than 150% of the rated load, ensuring the reliable operation of the servo drive under overload conditions; the steady-state tracking error does not exceed 0.01 degrees, ensuring that the motor can accurately track the command signal and improving the accuracy of the ship unloader's operation; The proportional-integral-derivative parameters of the servo drive are optimized by the self-tuning algorithm. The proportional gain range covers 0.1 to 1000, the integral time constant range covers 0.001 s to 10 s, the derivative time constant range covers 0 to 1 s, and the feedback signal sampling frequency is not less than 10 kHz. It can automatically adjust the PID parameters according to the actual situation of the system and improve the control performance; the servo drive is connected to the grab motor and the traveling motor of the ship unloader. The rated power of the motor is not less than 30 kW, the rated torque is not less than 200 N•M, and the speed range covers 0 to 3000 revolutions per minute, which can meet the power requirements of the ship unloader during operation.

[0012] Furthermore, the communication module is responsible for data transmission between various modules within the system and between the system and the remote monitoring center, ensuring the real-time and reliability of data; among them, the industrial Ethernet switch supports the IEEE 802.3 standard, ensuring compatibility with other Ethernet devices; the transmission rate is not less than 1 gigabit per second, which can meet the fast transmission requirements of a large amount of data; the port delay does not exceed 1 microsecond, reducing the data transmission delay and improving the real-time performance of the system; it supports the IEEE1588 precise clock synchronization protocol, and the clock synchronization accuracy does not exceed 100 nanoseconds, ensuring the time consistency between devices, which is crucial for applications that require precise time synchronization; The working frequency band of the wireless communication unit covers 3.5 GHz to 5 GHz. This frequency band has a wide bandwidth and low interference, suitable for high-speed data transmission; it supports the 5G new air interface protocol, and the uplink and downlink rates are both not less than 1 gigabit per second, the transmission delay does not exceed 10 milliseconds, and the bit error rate does not exceed one in a million, which can provide high-speed, low-latency, and high-reliability wireless data transmission services; the communication protocol stack supports Modbus TCP, OPC UA, and custom data encapsulation, meeting the communication requirements between different devices and applications; the data packet check uses the 32-bit cyclic redundancy check algorithm, which can effectively detect errors during data transmission and ensure the integrity of data.

[0013] Furthermore, the human-machine interaction module provides an interface for operators to interact with the system, facilitating the operators to grasp the system status in real time, perform parameter settings, and conduct manual intervention. Among them, the industrial touch screen has a screen size of no less than 10.1 inches, providing a large display area for operators to view system information conveniently. The resolution is not lower than 1920 by 1080 pixels, with clear display, capable of accurately presenting various graphic and text information. It supports multi-touch, with convenient and flexible operation, improving the operation efficiency. The brightness is not lower than 500 candela per square meter, enabling clear display under different lighting conditions. The protection level reaches IP65, adapting to harsh industrial environments and ensuring the reliability and service life of the touch screen.

[0014] The LED light source brightness of the audible and visual alarm device is not lower than 2000 candela, and the color temperature range is from 5000 to 6000 Kelvin, capable of providing visual alarm signals. The sound pressure level is not lower than 85 decibels, and the alarm sound frequency band covers 500 Hertz to 4 kilohertz, effectively attracting the attention of operators. It supports voice broadcast and stroboscopic warning, providing multiple alarm methods and improving the reliability of alarms. The interactive software supports a three-dimensional visualization interface, which can display the pose of the ship unloader, the grab trajectory, and the safety warning area in real time, enabling operators to intuitively understand the working status of the system. The interface refresh rate is not lower than 30 frames per second, ensuring the smoothness of the interface and avoiding screen jamming.

[0015] Furthermore, the safety monitoring module is used to monitor the environment around the ship unloader in real time, timely detect and handle potential safety hazards, and ensure the safe operation of the ship unloader. Among them, the detection angle of the multi-beam infrared obstacle avoidance sensor is not lower than 120 degrees, capable of covering a wide monitoring area. The detection distance covers 0.1 meter to 15 meters, meeting the safety monitoring requirements at different distances. The response time does not exceed 10 milliseconds, enabling quick detection of the presence of obstacles. The anti-environmental light interference ability is not lower than 100,000 lux, and it can work normally in strong light environments.

[0016] The resolution of the stereo vision camera is not lower than 3840 by 2160 pixels, capable of providing high-definition image information. The frame rate is not lower than 60 frames per second, ensuring the real-time nature of the images. The size of the photosensitive element is not less than 1 / 1.8 inches, the low-light sensitivity is not higher than 0.01 lux, and it supports high dynamic range (HDR) imaging, capable of obtaining clear images under different lighting conditions. The target detection algorithm is based on a deep learning framework, with powerful feature extraction and classification capabilities. The detection delay does not exceed 30 milliseconds, enabling quick and accurate target recognition. It supports the classification and recognition of personnel and obstacles, and the detection accuracy is not lower than 99.5%, providing a reliable basis for safety warning and emergency braking.

[0017] The beneficial effects of the present invention are as follows: Through the fusion of multiple sensors and data fusion algorithms, high-precision positioning of the ship unloader is achieved, improving the operation accuracy and efficiency; The high-performance control module and optimized control algorithms ensure the rapid response and precise execution of the ship unloader's actions, improving the operation efficiency; The high-speed and stable communication module guarantees the real-time and reliable data transmission between the internal modules of the system and between the system and the remote monitoring center; The friendly human-machine interaction interface facilitates the operator to grasp the system status in real time, perform parameter settings and manual intervention; The perfect safety monitoring mechanism can timely detect and handle potential safety hazards, ensuring the safe operation of the ship unloader. Brief Description of the Drawings

[0018] The present invention will be further described below in conjunction with the drawings and embodiments.

[0019] Figure 1 It is the system framework diagram of the present invention.

[0020] Figure 2 It is the working flow chart of the present invention.

[0021] In the figure: 100, positioning module; 200, data processing module; 300, control module; 400, communication module; 500, human-machine interaction module; 600, safety monitoring module; 101, lidar; 102, differential GPS unit; 103, inertial measurement unit; 201, multi-core processor; 202, parallel computing unit; 203, data fusion algorithm; 301, programmable logic controller; 302, servo driver; 401, Ethernet switch; 402, wireless communication unit; 501, industrial touch screen; 502, audible and visual alarm device; 601, multi-beam infrared obstacle avoidance sensor; 602, stereo vision camera. Detailed Embodiments

[0022] In order to make the technical means, creative features, achieved purposes and effects of the present invention easy to understand, the present invention will be further described below in conjunction with specific embodiments.

[0023] As Figure 1 - Figure 2As shown in the figure, an automatic positioning system for a ship unloader and its data processing method according to the present invention specifically include the following modules: a positioning module 100, a data processing module 200, a control module 300, a communication module 400, a human-machine interaction module 500, and a safety monitoring module 600; the positioning module 100 is data-connected to the data processing module 200 through the communication module 400, and is used to collect the position and attitude data of the ship unloader in real time; the data processing module 200 and the control module 300 communicate bidirectionally through an industrial bus, and are used to filter, fuse, and plan paths for the positioning data; the control module 300 is connected to the actuating mechanism of the ship unloader through the communication module 400, and is used to generate control instructions and drive the actuating mechanism to act; the human-machine interaction module 500 is connected to the data processing module 200, and is used to display the system status and receive manual input instructions; the safety monitoring module 600 is connected to the data processing module 200 through a sensor network, and is used to detect the safety status of the operating environment of the ship unloader and trigger an emergency braking signal.

[0024] The positioning module 100 includes a lidar 101, whose operating wavelength is 905 nanometers, the scanning field of view angle is not less than 270 degrees, the angular resolution is not greater than 0.1 degree, the ranging accuracy error does not exceed plus or minus 2 centimeters, the maximum detection distance is not less than 150 meters, and the scanning frequency is not less than 20 hertz; the positioning module 100 further includes a differential GPS unit 102, which supports carrier phase differential positioning technology, the horizontal positioning accuracy does not exceed 1 centimeter, the vertical positioning accuracy does not exceed 2 centimeters, supports L1 and L2 dual-band satellite signal reception, and the data update rate is not less than 10 hertz; the positioning module 100 further includes an inertial measurement unit 103, which includes a three-axis microelectromechanical system gyroscope and an accelerometer, the gyroscope range is ±2000 degrees per second, the zero-bias stability does not exceed 10 degrees per hour, the accelerometer range is ±16 times the acceleration of gravity, the sampling frequency is not less than 200 hertz, and the dynamic attitude angle measurement accuracy does not exceed 0.1 degree; The lidar is installed on the top of the ship unloader to ensure that its scanning field of view angle can cover the main operating area around the ship unloader. The lidar is fixed through a special mounting bracket, and the mounting bracket has shock absorption and anti-vibration functions to ensure the stable operation of the lidar; the antenna of the differential GPS unit is installed at the highest point of the ship unloader to obtain the best satellite signal reception effect. The differential GPS receiver is installed in the electrical control cabinet of the ship unloader and is connected to the antenna through a low-loss coaxial cable; the IMU is installed at the center of gravity of the ship unloader to reduce the influence of vibration on the measurement accuracy. The IMU is fixed to the structure of the ship unloader through bolts and ensures that its installation direction is correct The data processing module 200 includes a multi-core processor 201 with a main frequency of not less than 2.5 GHz, supporting a floating-point instruction set, a memory bandwidth of not less than 50 GB per second, and a built-in real-time operating system; the data processing module 200 also includes a parallel computing unit 202 implemented based on a programmable logic device, with the number of logic units not less than 50,000, supporting a hardware-accelerated Kalman filtering algorithm, and an iteration period of not more than 10 milliseconds; the data processing module 200 also includes a data fusion algorithm 203 that uses an extended Kalman filter to fuse lidar, GPS, and IMU data, outputs six-degree-of-freedom pose information, with a pose update frequency of not less than 100 Hz, a built-in path planning algorithm based on the combination of the A* algorithm and the dynamic window method, a planning period of not more than 50 milliseconds, and a path tracking error of not more than 5 cm. The multi-core processor and the parallel computing unit are installed in an industrial control computer, which is placed in the electrical control room of the ship unloader and has good heat dissipation and dust-proof conditions; a real-time operating system and data processing software are installed in the industrial control computer, including a multi-core processor driver program, a configuration software for the parallel computing unit, and implementation programs for the data fusion algorithm and the path planning algorithm.

[0025] The control module 300 includes a programmable logic controller  301 that supports the EtherCAT bus communication protocol, with a minimum control period of not more than 1 millisecond and an isolation voltage of not less than 2500 volts for the input and output channels; the control module 300 also includes a servo driver 302 that uses a vector control mode, supports three-loop closed-loop control of position, speed, and torque, has an encoder feedback resolution of not less than 20 bits, a control bandwidth of not less than 500 Hz, an overload capacity of not less than 150% of the rated load, and a steady-state tracking error of not more than 0.01 degrees; the servo driver is connected to the grab motor and the travel motor of the ship unloader, and the rated power of the motor is not less than 30 kW, the rated torque is not less than 200 N·m, and the speed range covers 0 to 3000 revolutions per minute. The industrial-grade programmable logic controller is installed in the electrical control cabinet of the ship unloader and is closely connected to the electrical system of the ship unloader; the servo driver is installed near the actuator, the grab motor, and the travel motor to reduce cable transmission loss and interference; a control program is written in the PLC of the control module 300 to implement a feedforward-feedback composite control strategy.

[0026] The communication module 400 includes an Ethernet switch 401 that supports the IEEE 802.3 standard, has a transmission rate of no less than 1 gigabit per second, a port delay of no more than 1 microsecond, supports the IEEE 1588 Precision Clock Synchronization Protocol, and a clock synchronization accuracy of no more than 100 nanoseconds. The communication module 400 also includes a wireless communication unit 402 with a working frequency band covering 3.5 GHz to 5 GHz, supporting the 5G New Radio protocol, with both uplink and downlink rates of no less than 1 gigabit per second, a transmission delay of no more than 10 milliseconds, and a bit error rate of no more than one in a million. The communication protocol stack supports Modbus TCP, OPC UA, and custom data encapsulation, and the packet checksum uses a 32-bit cyclic redundancy check algorithm. The industrial Ethernet switch is installed in the electrical control cabinet of the ship unloader and is connected to each module through network cables. The antenna of the wireless communication unit is installed on the top of the ship unloader, and the wireless communication device is installed in the electrical control cabinet.

[0027] The human-machine interaction module 500 includes an industrial touch screen 501 with a screen size of no less than 10.1 inches, a resolution of no less than 1920 by 1080 pixels, supporting multi-touch, a brightness of no less than 500 candelas per square meter, and an IP65 protection level. The human-machine interaction module 500 also includes an audible and visual alarm device 502 with an LED light source brightness of no less than 2000 candelas, a color temperature range of 5000 to 6000 Kelvin, a sound pressure level of no less than 85 decibels, an alarm sound frequency band covering 500 Hz to 4 kHz, and supporting voice broadcast and stroboscopic warning. The interaction software supports a three-dimensional visualization interface, which can display the pose of the ship unloader, the grab trajectory, and the safety warning area in real time, with an interface refresh rate of no less than 30 frames per second. The industrial touch screen is installed in the operation room of the ship unloader for convenient operation by the operator. The audible and visual alarm device is installed in prominent positions in the operation room and around the ship unloader to ensure that the operator and surrounding personnel can receive alarm information in a timely manner. The interaction software is installed in the industrial touch screen to implement the three-dimensional visualization interface and parameter setting functions.

[0028] The safety monitoring module 600 includes a multi-beam infrared obstacle avoidance sensor 601 with a detection angle of no less than 120 degrees, a detection distance covering 0.1 m to 15 m, a response time of no more than 10 milliseconds, and an anti-environmental light interference ability of no less than 100,000 lux. The safety monitoring module 600 also includes a stereo vision camera 602 with a resolution of no less than 3840 by 2160 pixels, a frame rate of no less than 60 frames per second, a photosensitive element size of no less than 1 / 1.8 inches, a low-light sensitivity of no higher than 0.01 lux, and supporting high dynamic range imaging. The target detection algorithm is based on a deep learning framework, with a detection delay of no more than 30 milliseconds, supporting the classification and recognition of personnel and obstacles, and a detection accuracy of no less than 99.5%. Multi-beam infrared obstacle avoidance sensors are installed at the front end and both sides of the ship unloader to cover the main areas around the ship unloader; a stereo vision camera is installed on the top of the ship unloader to ensure that a panoramic image around the ship unloader can be obtained. The target detection algorithm software is installed in the safety monitoring module to process the images collected by the stereo vision camera.

[0029] The noise covariance matrix of the data fusion algorithm 203 is dynamically adjusted according to the actual measurement errors of the sensors. The variance of the lidar noise does not exceed 0.0004 square meters, the horizontal variance of the GPS noise does not exceed 0.0001 square meters, and the angular velocity noise density of the IMU does not exceed 0.01 degrees per square root hour.

[0030] The proportional-integral-derivative parameters of the servo drive 302 are optimized by a self-tuning algorithm. The proportional gain range covers 0.1 to 1000, the integral time constant range covers 0.001 seconds to 10 seconds, the derivative time constant range covers 0 to 1 second, and the feedback signal sampling frequency is not less than 10 kHz.

[0031] Use a professional calibration tool to calibrate the lidar, adjust its scanning angle and ranging accuracy to ensure the accuracy of the point cloud data; perform calibration at a reference point with a known precise position to obtain the error correction parameters of the differential GPS unit and improve the positioning accuracy; place the IMU in a stationary state for zero-bias calibration and scale factor calibration to eliminate the sensor errors; use a network tester to test the industrial Ethernet switch and wireless communication unit to check the connectivity and transmission rate of the communication link to ensure normal data transmission between modules; perform self-tuning on the PID parameters of the servo drive, and adjust the proportional gain, integral time constant, and derivative time constant according to the actual operating conditions of the ship unloader so that the motor can accurately track the command signal.

[0032] The lidar starts to scan the surrounding environment, obtains point cloud data at a set scanning frequency, and transmits it to the data processing module 200 through the communication module 400; the differential GPS unit receives satellite signals in real time, calculates the longitude and latitude coordinates of the ship unloader, and sends the data to the data processing module 200; the IMU measures the angular velocity and acceleration information of the ship unloader and transmits the data to the data processing module 200 at a sampling frequency not less than 200 Hz.

[0033] After the data processing module 200 receives the data from each sensor, it first performs filtering processing. The hardware-accelerated Kalman filtering algorithm is used to perform preliminary filtering on the data of the lidar, GPS, and IMU to remove noise interference; then the extended Kalman filtering algorithm is used to fuse the filtered data to calculate the six-degree-of-freedom pose information of the ship unloader. At the same time, an environment map is constructed through the simultaneous localization and mapping algorithm, and the map resolution is 5 cm.

[0034] The control module 300 generates motor commands according to the pose information provided by the data processing module 200 and the preset unloading path. The feedforward control calculates the control quantity in advance according to the preset path and the dynamic model of the ship unloader, and the feedback control adjusts the control quantity according to the real-time pose error. The control period is 5 milliseconds to ensure the real-time performance and accuracy of the control commands.

[0035] The communication module 400 uploads the system status information, including pose information, sensor data, control commands, etc., to the remote monitoring center in real time through the industrial Ethernet and the wireless communication network; the remote monitoring center can view the working status of the ship unloader in real time and send external control commands, such as start, stop, path modification, etc. The 256-bit Advanced Encryption Standard algorithm is used for encryption during the data transmission process to ensure the security of the data.

[0036] The multi-beam infrared obstacle avoidance sensors and the stereo vision cameras in the safety monitoring module 600 monitor the surrounding environment of the ship unloader in real time; the multi-beam infrared obstacle avoidance sensors detect the distance of the surrounding obstacles at a detection frequency of not less than 10 Hz. When the detected distance of the obstacle does not exceed 2 meters, an alarm is triggered; the stereo vision cameras collect images at a frame rate of not less than 60 frames per second, and the target detection algorithm classifies and identifies the targets in the images. When it is detected that a person or an obstacle invades the safety area or the system status is abnormal, the audible and visual alarm device is immediately triggered to give an alarm; at the same time, an emergency braking command is sent to the control module 300 through the communication module 400. After receiving the command, the control module 300 immediately controls the actuators of the ship unloader to stop operating.

[0037] For those skilled in the art, it is obvious that the present invention is not limited to the details of the above exemplary embodiments, and the present invention can be implemented in other specific forms without departing from the spirit or basic characteristics of the present invention. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be encompassed by the present invention. Any reference signs in the claims should not be regarded as limiting the claimed invention.

[0038] In addition, it should be understood that although this specification is described according to the embodiments, not every embodiment only contains an independent technical solution. This narrative way of the specification is only for clarity. Those skilled in the art should regard the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. An automatic positioning system for a ship unloader and its data processing method, characterized in that , specifically including the following modules: a positioning module (100), a data processing module (200), a control module (300), a communication module (400), a human-machine interaction module (500), and a safety monitoring module (600); The positioning module (100) is data-connected to the data processing module (200) through the communication module (400), and is used for real-time acquisition of the position and attitude data of the ship unloader; The data processing module (200) communicates bidirectionally with the control module (300) through an industrial bus, and is used for filtering, fusing, and path planning of the positioning data; The control module (300) is connected to the actuating mechanism of the ship unloader through the communication module (400), and is used for generating control instructions and driving the actuating mechanism to act; The human-machine interaction module (500) is connected to the data processing module (200), and is used for displaying the system status and receiving manual input instructions; The safety monitoring module (600) is connected to the data processing module (200) through a sensor network, and is used for detecting the safety status of the operating environment of the ship unloader and triggering an emergency braking signal.

2. The automatic positioning system for a ship unloader and its data processing method according to claim 1, characterized in that: The positioning module (100) includes a lidar (101) with a working wavelength of 905 nanometers, a scanning field of view of not less than 270 degrees, an angular resolution of not more than 0.1 degree, a ranging accuracy error of not exceeding plus or minus 2 centimeters, a maximum detection distance of not less than 150 meters, and a scanning frequency of not less than 20 hertz; the positioning module (100) also includes a differential GPS unit (102) that supports carrier-phase differential positioning technology, with a horizontal positioning accuracy of not more than 1 centimeter, a vertical positioning accuracy of not more than 2 centimeters, supports L1 and L2 dual-band satellite signal reception, and a data update rate of not less than 10 hertz; the positioning module (100) also includes an inertial measurement unit (103) that includes a three-axis microelectromechanical system gyroscope and accelerometer, with a gyroscope range of ±2000 degrees per second, a zero-bias stability of not more than 10 degrees per hour, an accelerometer range of ±16 times the acceleration of gravity, a sampling frequency of not less than 200 hertz, and a dynamic attitude angle measurement accuracy of not more than 0.1 degree.

3. The automatic positioning system of a ship unloader and its data processing method according to claim 1, characterized in that: The data processing module (200) includes a multi-core processor (201) with a main frequency of not less than 2.5 gigahertz, supporting a floating-point instruction set, a memory bandwidth of not less than 50 gigabytes per second, and an embedded real-time operating system; the data processing module (200) also includes a parallel computing unit (202) implemented based on a programmable logic device, with a number of logic units of not less than 50,000, supporting a hardware-accelerated Kalman filtering algorithm, and an iteration period of not more than 10 milliseconds; the data processing module (200) also includes a data fusion algorithm (203) that uses an extended Kalman filter to fuse lidar, GPS, and IMU data, outputs six-degree-of-freedom pose information, with a pose update frequency of not less than 100 hertz, an embedded path planning algorithm based on a combination of the A* algorithm and the dynamic window method, a planning period of not more than 50 milliseconds, and a path tracking error of not more than 5 centimeters.

4. The automatic positioning system of a ship unloader and its data processing method according to claim 1, characterized in that: The control module (300) includes a programmable logic controller (301) that supports the EtherCAT bus communication protocol, with a minimum control cycle of no more than 1 millisecond and an isolation voltage between input and output channels of no less than 2500 volts; the control module (300) also includes a servo drive (302) that adopts a vector control mode, supports closed-loop control of position, speed, and torque in three loops, has an encoder feedback resolution of no less than 20 bits, a control bandwidth of no less than 500 hertz, an overload capacity of no less than 150% of the rated load, and a steady-state tracking error of no more than 0.01 degrees; the servo drive is connected to the grab motor and the traveling motor of the ship unloader, and the rated power of the motor is no less than 30 kilowatts, the rated torque is no less than 200 N·m, and the speed range covers 0 to 3000 revolutions per minute.

5. The automatic positioning system of a ship unloader and its data processing method according to claim 1, characterized in that: The communication module (400) includes an Ethernet switch (401) that supports the IEEE 802.3 standard, with a transmission rate of no less than 1 gigabit per second, a port delay of no more than 1 microsecond, supports the IEEE 1588 precise clock synchronization protocol, and a clock synchronization accuracy of no more than 100 nanoseconds; the communication module (400) also includes a wireless communication unit (402) that operates in the frequency band covering 3.5 gigahertz to 5 gigahertz, supports the 5G new air interface protocol, with both uplink and downlink rates of no less than 1 gigabit per second, a transmission delay of no more than 10 milliseconds, and a bit error rate of no more than one in a million; the communication protocol stack supports Modbus TCP, OPC UA, and custom data encapsulation, and the packet checksum uses a 32-bit cyclic redundancy check algorithm.

6. The automatic positioning system of a ship unloader and its data processing method according to claim 1, characterized in that: The human-machine interaction module (500) includes an industrial touch screen (501) with a screen size of no less than 10.1 inches, a resolution of no less than 1920 by 1080 pixels, supports multi-touch, a brightness of no less than 500 candela per square meter, and an IP65 protection level; the human-machine interaction module (500) also includes an audible and visual alarm device (502) with an LED light source brightness of no less than 2000 candela, a color temperature range of 5000 to 6000 Kelvin, a sound pressure level of no less than 85 decibels, an alarm sound frequency band covering 500 hertz to 4 kilohertz, and supports voice broadcast and stroboscopic warning; the interactive software supports a three-dimensional visualization interface, and can display the pose of the ship unloader, the grab trajectory, and the safety warning area in real time, with an interface refresh rate of no less than 30 frames per second.

7. The automatic positioning system of a ship unloader and its data processing method according to claim 1, characterized in that: The safety monitoring module (600) includes a multi-beam infrared obstacle avoidance sensor (601) with a detection angle of not less than 120 degrees, a detection distance covering 0.1 meter to 15 meters, a response time of not more than 10 milliseconds, and an anti-environmental light interference ability of not less than 100,000 lux; the safety monitoring module (600) further includes a stereo vision camera (602) with a resolution of not less than 3840 by 2160 pixels, a frame rate of not less than 60 frames per second, a photosensitive element size of not less than 1 / 1.8 inches, a low-light sensitivity of not more than 0.01 lux, and support for high dynamic range imaging; the target detection algorithm is based on a deep learning framework, with a detection delay of not more than 30 milliseconds, support for classification and recognition of personnel and obstacles, and a detection accuracy of not less than 99.5%.

8. The automatic positioning system for a ship unloader and its data processing method according to claim 1, characterized in that: The noise covariance matrix of the data fusion algorithm (203) is dynamically adjusted according to the actual measurement errors of the sensors. The variance of the lidar noise does not exceed 0.0004 square meters, the variance of the GPS horizontal noise does not exceed 0.0001 square meters, and the angular velocity noise density of the IMU does not exceed 0.01 degrees per square root hour.

9. The automatic positioning system of a ship unloader and its data processing method according to claim 1, characterized in that: The proportional-integral-derivative parameters of the servo driver (302) are optimized by a self-tuning algorithm. The proportional gain range covers 0.1 to 1000, the integral time constant range covers 0.001 seconds to 10 seconds, the derivative time constant range covers 0 to 1 second, and the feedback signal sampling frequency is not less than 10 kHz.

10. A data processing method for an automatic positioning system of a ship unloader according to claims 1-9, characterized in that, The specific steps of the data processing method of the system are as follows: S1. The positioning module (100) synchronously collects lidar point cloud data, GPS longitude and latitude coordinates, and IMU angular velocity and acceleration data. S2. The data processing module (200) fuses multi-source data through an extended Kalman filter to generate six-degree-of-freedom pose information, and constructs an environmental map through a simultaneous localization and mapping algorithm, with a map resolution of not more than 5 centimeters. S3. The control module (300) generates motor commands based on the pose information and the preset unloading path, using a feedforward-feedback composite control strategy, with a control period of not more than 5 milliseconds. S4. The communication module (400) uploads the system status to the remote monitoring center in real time and receives external control commands. Data encryption uses the 256-bit Advanced Encryption Standard algorithm. S5. The safety monitoring module (600) detects obstacles through infrared and vision fusion. If an intrusion into the safety area or an abnormal system state is detected, it immediately triggers an audible and visual alarm and sends an emergency braking command to the control module (300).

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