Intelligent unloading system and method based on automatic unloading machine for aluminum anode carbon blocks

Abstract

The invention relates to the technical field of intelligent unloading, and discloses an intelligent unloading system and method based on an automatic unloading machine for aluminum anode carbon blocks, and the intelligent unloading system comprises a movable carbon block tray system which is used for receiving and separating carbon block columns in a stacking warehouse area; an intelligent double-force clamp system comprises a lifting mechanism, a clamp and a safety detection module. The 3D scanning intelligent modeling system comprises an intelligent modeling module and a plurality of laser radars. The laser radar is used for scanning vehicles and carbon blocks in real time; the intelligent modeling module is used for identifying a vehicle contour and a carbon block contour and outputting a three-dimensional coordinate matrix and a three-dimensional scanning graph; the central centralized control system comprises a central control module; and the central control module is used for receiving a control instruction and positioning and controlling the movable carbon block tray system or the intelligent dual-force clamp system to operate according to the control instruction. Full-automatic unloading of the vehicle carbon blocks can be achieved, unloading control is accurate, and the unloading efficiency and the unloading quality can be improved.

Description

Technical Field

[0001] The present invention relates to the technical field of intelligent unloading, and in particular to an intelligent unloading system and method based on an automatic unloading machine for aluminum anode carbon blocks. Background Art

[0002] Aluminum anode carbon blocks are key raw materials for electrolytic aluminum production. Their unloading and warehousing efficiency and operational safety directly affect the production continuity and personnel safety of the roasting workshop.

[0003] The current mainstream process relies on manual prying and the coordinated operation of an overhead crane. After the transport vehicle enters the warehouse, a worker must climb to the top of the vehicle and use a crowbar to physically separate the charcoal blocks and create a clearance. The overhead crane operator then operates a clamp to lift and stack the blocks. This process suffers from multiple systemic flaws. First, the manual labor is extremely intensive, requiring workers to frequently pry and lift the blocks within the cramped vehicle compartment, which is filled with charcoal blocks weighing over a ton. The surface temperature, oil contamination, and dust exacerbate operational risks. Second, visual coordination is inefficient. Due to the height restriction of the overhead crane operator's cab (typically 8-12 meters above the ground), it is difficult for the crane operator to accurately determine the location of the gaps between the charcoal blocks and the stacking status on the ground. Repeated communication and adjustments with ground personnel must be made through gestures or voice commands. Third, during transportation, the charcoal blocks can shift, tilt, or even partially collapse due to vehicle jigs, leading to dynamic changes in the gripping point. Manual handling can easily cause clamp collisions or charcoal blocks to fall. According to industry safety statistics, unloading charcoal blocks from trucks accounts for over 37% of all accidents in roasting plants. Therefore, the development of a fully automatic intelligent unloading system is a rigid demand to resolve the risks of manual operations, improve logistics efficiency and realize the transformation to intelligent manufacturing.

[0004] Although some automated coal block handling technologies are currently in use, most are focused on fixed-scene applications within storage areas. Furthermore, while these unmanned overhead crane systems can automatically transfer coal blocks between preset stacks, their operation presupposes that the coal blocks are already in a stable stack and that the gripping position is standardized. These systems rely on preset programs and fixed scanning points, and can only grasp coal blocks on the warehouse floor or on conveyors with known spatial coordinates. They are unable to adapt to the dynamic uncertainty of the transport vehicle's loading platform (stacked coal blocks can shift due to bumpy roads during transport, and different drivers have varying skills and parking positions, resulting in slight deviations). Furthermore, they have a low tolerance for vehicle positioning deviations. Furthermore, existing unmanned overhead crane systems only support standalone operation. Actual unloading requires simultaneous coordination of actions such as fine-tuning the transport vehicle, intervention in the coal block separation mechanism, and obstacle avoidance path planning for the fixture. This makes it impossible for existing systems to truly achieve fully automated unloading.

[0005] In summary, there is an urgent need for a new intelligent unloading system to solve the above problems. Summary of the Invention

[0006] The present invention aims to provide an intelligent unloading system and method based on an automatic unloading machine for aluminum anode carbon blocks, which can realize fully automatic unloading of vehicle carbon blocks, and the unloading control is precise, which helps to improve unloading efficiency and unloading quality.

[0007] To achieve the above objectives, the present invention provides the following basic solutions.

[0008] Option 1

[0009] The intelligent unloading system based on the automatic unloading machine for aluminum anode carbon blocks includes:

[0010] A movable carbon block pallet system, comprising several rows of movable sub-pallets, for receiving and separating the carbon block rows in the stacking area;

[0011] The intelligent dual-force clamp system includes a lifting mechanism, a clamp, and a safety detection module. The lifting mechanism has two sets of clamps independently arranged longitudinally on the overhead traveling crane trolley, each controlling a set of clamps to support clamp misalignment operations. The lifting mechanism includes a front lifting mechanism for operating the carbon blocks at the front of the vehicle and a rear lifting mechanism for operating the carbon blocks at the rear of the vehicle. The safety detection module is used to detect the distance between the clamps and the carbon blocks in real time.

[0012] The 3D scanning intelligent modeling system includes an intelligent modeling module and multiple laser radars; the laser radars are used to scan the vehicle and the carbon block in real time; the intelligent modeling module is used to identify the vehicle outline and the carbon block outline based on the scanned data of the vehicle and the carbon block, and output a three-dimensional coordinate matrix and a three-dimensional scanned image;

[0013] The central control system is used to collaboratively control the movable carbon block tray system, the intelligent dual-force clamp system and the 3D scanning intelligent modeling system through PLC, including a central control module; the central control module is used to receive control instructions and, in accordance with the control instructions, refer to the three-dimensional coordinate matrix to locate and control the operation of the movable carbon block tray system or the intelligent dual-force clamp system.

[0014] Furthermore, the movable carbon block tray system includes: a wireless control module and three movable sub-trays; the bottom of each sub-tray is provided with an electric control moving component for driving the sub-tray to move, so as to realize the merging and separation of the three sub-trays;

[0015] The wireless control module establishes communication connections with the electric-controlled mobile component and the central control system, and is used to control the electric-controlled mobile component so that the three columns of pallets are merged or separated at specified intervals; the separation includes unilateral separation and bilateral separation.

[0016] Furthermore, the clamp is a mechanical linkage clamp, comprising: a clamp beam and a clamp bracket; the clamp beam and the clamp bracket are connected by a pull plate and a transition pull plate; the pull plate and the transition pull plate are connected by a pin shaft;

[0017] The clamp bracket is connected to the clamp frame through an adapter, and the bottom of the transition pull plate is connected to the clamp frame through a pin; the pull plate, transition pull plate and clamp frame are symmetrically provided with two; the bottom inner side of each clamp frame is provided with a clamp; the clamp is provided with a grab nail;

[0018] The clamp beam is provided with a hoisting mechanism and a pulley mechanism; the steel wire rope of the hoisting mechanism is connected with the clamp bracket; and a heavy hammer is also provided on the steel wire rope.

[0019] Furthermore, the clamp is provided with a self-locking structure to achieve automatic locking after clamping and self-unlocking and decoupling after placement.

[0020] Furthermore, the intelligent dual-force clamp system also includes an anti-sway control module; the anti-sway control module is used to adjust control parameters to suppress the swing of the carbon block during lifting.

[0021] Furthermore, the intelligent dual-force clamp system also includes a clamping force detection module; the clamping force detection module is used to monitor the contact status between the clamp and the carbon block in real time.

[0022] Furthermore, the intelligent dual-force clamp system also includes a weight monitor, an overload limiter, a block missing detector and a block-loosening prevention timing controller;

[0023] The weight monitor is used to collect the load weight of the clamp in real time;

[0024] The overload limiter performs graded load limit according to the load weight - when the load weight is greater than 90% of the rated load, it triggers an audible and visual warning and limits the acceleration of the lifting mechanism to ≤ 0.2m / s 2 When the load weight is greater than 105% of the rated load, an emergency alarm is triggered and the lifting mechanism's ascending function is mechanically locked, allowing only descending operations.

[0025] The missing block detector is used to determine whether there is a carbon block falling off according to the load weight, and when it is determined that there is a carbon block falling off, control the lifting function of the locking lifting mechanism;

[0026] The anti-blocking timing controller is used to perform the following steps:

[0027] S1, after the clamp is closed, control the lifting mechanism to rise 5cm;

[0028] S2, maintain high altitude for 3 seconds, during which the leakage detector continuously monitors;

[0029] S3: If there is no shedding signal during the stagnation period, continue to ascend to the target altitude;

[0030] S4: If a fall-off is detected, an emergency stop will be immediately executed and the clamp will reset automatically.

[0031] Furthermore, the central control system also includes a bionic operation module; the bionic operation module includes a remote control operation unit and an automatic operation unit; the remote control operation unit is used to provide manual remote control functions, including remote control of the overhead crane trolley, lifting mechanism or clamp movement; the automatic operation unit is used to provide automatic control functions, including automatically linking the control module to perform intelligent unloading after the carbon block transport vehicle arrives at the designated location.

[0032] Furthermore, the control instructions include: unloading instructions, start-stop instructions and pause instructions; the unloading instructions include: designated charcoal block transport vehicles, designated unloading ranges, and designated charcoal block placement targets.

[0033] Option 2

[0034] An intelligent unloading method based on an automatic unloading machine for aluminum anode carbon blocks uses an intelligent unloading system based on an automatic unloading machine for aluminum anode carbon blocks as described in Solution 1 to achieve automatic unloading of carbon blocks; the method comprises the following steps:

[0035] Step 1: The 3D scanning intelligent modeling system performs real-time modeling of the briquette transport vehicle parked at the unloading area, generating a 3D coordinate matrix and a 3D scan map showing the distribution of the briquette. The central control system then plans the gripping path.

[0036] Step 2: The front lifting mechanism positions the carbon block at the front of the vehicle, and the rear lifting mechanism positions the carbon block at the rear of the vehicle; and automatically selects a single-block clamping mode or a double-block clamping mode based on the carbon block gap threshold;

[0037] Step 3: The intelligent dual-force clamp system transfers the carbon blocks to the movable carbon block tray system, and the clamp releases the carbon blocks when it contacts the tray;

[0038] Step 4: Use a stacking crane to grab the carbon blocks and put them into the warehouse.

[0039] The working principle and advantages of the present invention are:

[0040] The present invention is based on an intelligent unloading system and method for an automatic unloading machine for aluminum anode carbon blocks, which can achieve fully automated unloading of vehicle carbon blocks with precise unloading control, helping to improve unloading efficiency and quality. The key points are:

[0041] First, this solution achieves dynamic coupling of multiple systems, enabling fully automated unloading and strong adaptability to complex scenarios. The movable charcoal block tray system utilizes an electronically controlled split tray design, directly addressing the randomly varying spacing between charcoal blocks on transport vehicles and significantly reducing manual adjustments compared to fixed receiving platforms. The intelligent dual-force clamp system features a specially designed dual lifting mechanism with independent longitudinal control, enabling the front and rear clamps to operate in a staggered manner along the vehicle's longitudinal axis. This overcomes the limitations of traditional single clamps, which must operate in a fixed sequence, and can adapt to the different postures of charcoal blocks at the front and rear of the vehicle due to bumpy transportation. The 3D scanning intelligent modeling system, through the fusion of multiple LiDAR point clouds and an intelligent modeling module, generates a three-dimensional coordinate matrix containing the vehicle's outline, providing a spatial reference for dynamic gripping. Furthermore, a central control system, via PLC, coordinates the various systems. As the clamps locate the charcoal blocks based on 3D coordinates, the split trays simultaneously adjust their spacing, further improving unloading efficiency.

[0042] Second, the unloading safety of this solution is relatively high. This solution sets up multiple auxiliary modules to control the unloading process. Among them, the clamping force detection module can identify abnormal contact status, the weight monitor is linked with the leakage detector (such as S2 stage stagnation monitoring), and the overload limiter implements a graded response (90% warning speed limit / 105% mechanical lock), which can form a closed loop from risk warning to hard intervention, ensuring perfect supervision of the carbon block transfer process. Secondly, during the transfer process, the anti-block falling-off timing controller can completely eliminate the hidden dangers of carbon blocks falling off due to instantaneous acceleration in traditional operations through the process operation of micro-lifting-stagnation monitoring-continued lifting / emergency stop.

[0043] Third, this solution specifically transplants the concept of movable pallets in warehousing and logistics to the coal block unloading scenario, and innovatively adds an electronically controlled mobile component and a bilateral separation mode, allowing it to dynamically adapt to the uneven distribution of coal blocks in the car. Unlike the known fixed coal block receiving device, it can adapt to more diverse and more disordered actual coal block transportation scenarios. Secondly, the staggered operation mechanism of the double lifting clamps allows the operating range to cover the entire length of the car; the clamps use a mechanical linkage mechanism with a simple structure that is easy to maintain and operate; and the transition design of the transition pull plate and the clamp frame can provide a certain degree of tilt angle adaptability, making the clamps more adaptable to clamping. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 This is a schematic diagram of the system structure of an embodiment of an intelligent unloading system and method based on an automatic unloading machine for aluminum anode carbon blocks according to the present invention;

[0045] Figure 2 This is a schematic diagram of the clamp structure of an embodiment of the intelligent unloading system and method based on an automatic unloading machine for aluminum anode carbon blocks of the present invention;

[0046] Figure 3 This is a structural schematic diagram of an intelligent double-force clamp system according to an embodiment of the intelligent unloading system and method of the present invention based on an automatic unloading machine for aluminum anode carbon blocks.

[0047] The symbols in the drawings of the specification include: clamp beam 1, pull plate 2, transition pull plate 3, clamp bracket 4, pin 5, adapter 6, clamp frame 7, clamp 8, grab nail 9, winch mechanism 10, heavy hammer 11, pulley mechanism 12, clamp 13, lifting mechanism 14. DETAILED DESCRIPTION

[0048] The following is a further detailed description through specific implementation methods:

[0049] The embodiment is basically as shown in the attached Figure 1 Shown: Intelligent unloading system based on automatic unloading machine for aluminum anode carbon blocks, including:

[0050] The movable carbon block pallet system includes several rows of movable sub-pallets for receiving and separating carbon block rows in the stacking storage area.

[0051] Specifically, the movable charcoal block tray system includes a wireless control module and three movable columns of trays. Each column of the tray can hold up to 10 charcoal blocks. Each tray is equipped with an electrically controlled motion assembly at the bottom to drive the trays' movement, enabling the three columns to merge and separate. In this embodiment, the electrically controlled motion assembly can utilize existing electrically controlled wheels or slideways.

[0052] The wireless control module establishes communication connections with both the electronically controlled mobile assembly and the centralized control system, controlling the electronically controlled mobile assembly to merge the three columns of pallets or separate them at specified intervals. Separation can include single-sided or double-sided separation. In this embodiment, the specified interval is set to 40 cm. In actual application, this interval can be adjusted based on actual unloading requirements.

[0053] In specific applications, after 8-10 groups of carbon blocks are placed on two or three columns of pallets, the two or three columns of pallets in the pallet system are separated by a 40cm gap, thereby separating the carbon blocks from one column to another. The stacking crane then grabs the carbon blocks and puts them into storage, eliminating process limitations.

[0054] like Figure 3 As shown, the intelligent dual-force clamp 13 system includes a lifting mechanism 14, a clamp 13 and a safety detection module.

[0055] The lifting mechanism 14 is provided with two groups and is independently arranged longitudinally on the overhead crane trolley and controls a group of clamps 13 respectively to support the dislocation operation of the clamps 13, including a front lifting mechanism 14 for operating the carbon blocks at the front of the vehicle and a rear lifting mechanism 14 for operating the carbon blocks at the rear of the vehicle; the safety detection module is used to detect the distance between the clamp 13 and the carbon block in real time, and when the distance between the clamp 13 and the carbon block is 0 (that is, the clamp 13 is in contact with the carbon block), the safety detection module also links the central control module to prohibit the clamp 13 from continuing to descend.

[0056] like Figure 2 As shown, the clamp 13 is a mechanical linkage type clamp 13, including: a clamp beam 1 and a clamp bracket 4; the clamp beam 1 and the clamp bracket 4 are connected by a pull plate 2 and a transition pull plate 3; the pull plate 2 and the transition pull plate 3 are connected by a pin shaft 5.

[0057] The clamp bracket 4 is connected to the splint frame 7 through an adapter 6, and the bottom of the transition pull plate 3 is connected to the splint frame 7 through a pin 5; the pull plate 2, transition pull plate 3 and splint frame 7 are symmetrically provided with two; a splint 8 is provided on the inner side of the bottom of each splint frame 7; and a grabbing nail 9 is provided on the splint 8.

[0058] The clamp beam 1 is provided with a hoisting mechanism 10 and a pulley mechanism 12 ; the steel wire rope of the hoisting mechanism 10 is connected to the clamp bracket 4 ; and a weight 11 is also provided on the steel wire rope.

[0059] The clamp 13 is provided with a self-locking structure to realize automatic locking after clamping and self-unlocking and decoupling after placement.

[0060] The intelligent double-force clamp 13 system also includes an anti-sway control module, a clamping force detection module, a weight monitor, an overload limiter, a missing block detector and an anti-block-dropping timing controller.

[0061] The anti-sway control module is used to adjust control parameters to suppress the carbon block from swinging during lifting. The clamping force detection module is used to monitor the contact status between the clamp 13 and the carbon block in real time and confirm whether the carbon block is clamped tightly. In this embodiment, the clamping force detection module uses a force sensor to detect the clamping force between the clamp 13 and the carbon block to confirm whether the carbon block is clamped tightly.

[0062] The weight monitor is used to collect the load weight of the clamp 13 in real time.

[0063] The overload limiter performs graded load limit according to the load weight - when the load weight is greater than 90% of the rated load, it triggers an audible and visual warning and limits the acceleration of the lifting mechanism 14 to ≤ 0.2m / s 2 When the load weight is greater than 105% of the rated load, an emergency alarm is triggered and the lifting function of the lifting mechanism 14 is mechanically locked, and only the descending operation is allowed.

[0064] The missing block detector is used to determine whether there is a carbon block falling off according to the load weight, and when it is determined that there is a carbon block falling off, control the lifting function of the locking lifting mechanism 14.

[0065] The anti-blocking timing controller is used to perform the following steps:

[0066] S1, after the clamp 13 is closed, the lifting mechanism 14 is controlled to rise 5 cm;

[0067] S2, maintain high altitude for 3 seconds, during which the leakage detector continuously monitors;

[0068] S3: If there is no shedding signal during the stagnation period, continue to ascend to the target altitude;

[0069] S4: If the detachment is detected, the emergency stop is immediately performed and the clamp 13 is reset automatically.

[0070] The 3D scanning intelligent modeling system includes an intelligent modeling module and multiple laser radars; the laser radars are used to scan vehicles and carbon blocks in real time; the intelligent modeling module is used to identify the vehicle outline and the carbon block outline based on the scanning data of the vehicle and the carbon block, and output a three-dimensional coordinate matrix and a three-dimensional scanning image.

[0071] Specifically, in this embodiment, the LiDAR is deployed in the unloading area, ensuring that its scanning range covers the entire transport vehicle (e.g., truck) and the stack of charcoal briquettes it carries. The LiDAR collects point cloud scan data of the vehicle (specifically, the charcoal briquette transport vehicle) and the charcoal briquettes.

[0072] The intelligent modeling module then processes and analyzes the point cloud scanning data:

[0073] First, point cloud preprocessing is performed, including: noise reduction filtering - applying algorithms such as statistical outlier removal and radius filtering to eliminate interference points caused by environmental dust, light reflections, moving objects (such as people), etc.

[0074] Next, point cloud registration is performed: point cloud data from different viewpoints (different radars) is accurately fused into a complete scene point cloud model in a unified coordinate system through feature matching (such as the ICP algorithm) or preset calibration parameters. Scene segmentation is then performed, including ground / background segmentation. In this example, the RANSAC algorithm is used to fit the ground plane, remove the ground and fixed background point clouds (such as warehouse walls and fixed equipment), and focus on the vehicle and coal blocks.

[0075] Next, vehicle outline recognition is performed: Based on geometric features, point cloud clusters with regular rectangular shapes (truck cabins) are identified. Combined with prior knowledge such as the cabin's size and location (typically above ground and near the unloading area), the vehicle's point cloud outline is accurately segmented. The vehicle's 3D bounding box (position, length, width, height, and posture) is then output.

[0076] Then the contours of the charcoal blocks are identified and separated, including: separation of charcoal block clusters - after identifying the point cloud area belonging to the charcoal block stack, the clustering algorithm is used to cluster the points close to each other into a cluster according to the point cloud density. Since there are usually physical gaps between charcoal blocks, the density of their point clouds will drop significantly at the gaps, and thus they are identified as different clusters by the algorithm. Each cluster corresponds to an individual charcoal block. For each separated point cloud cluster, its geometric features (size, shape, orientation) are analyzed, and its precise center point coordinates, length, width, height dimensions, and rotation angles (yaw, pitch, roll) relative to the global coordinate system are calculated to identify whether the charcoal blocks are tilted, collapsed, or irregularly placed.

[0077] Preferably, the carbon block stacking rules (such as the number of layers, the number of blocks per layer, and the staggered method) can be combined with the graphical model to assist in verifying the clustering results and handle complex stacking situations or partial occlusions.

[0078] Finally, a three-dimensional coordinate matrix and a three-dimensional scanned image are output. The three-dimensional coordinate matrix is a structured data table (matrix), in which each row represents an identified individual charcoal block. Each row contains at least the following key fields: a unique identifier, the three-dimensional coordinates of the geometric center of the charcoal block in the global coordinate system, the size of the charcoal block, the rotation angle of the charcoal block relative to the horizontal plane, the placement of the charcoal block, a status flag (such as: unclamped, clamped, abnormal), and the associated vehicle identification. The three-dimensional scanned image is a rendered point cloud image or mesh model image, and is highlighted in different colors: the outline of the identified vehicle (such as a blue wireframe); the outline of each individual charcoal block (such as each charcoal block represented by a different colored bounding box or a transparent solid model); key feature points (such as the center point of the charcoal block), and a schematic diagram of the planned clamping points. This image can be used for monitoring, debugging, and manual review of the charcoal block unloading process.

[0079] The central control system is used to collaboratively control the movable carbon block tray system, the intelligent dual-force clamp 13 system and the 3D scanning intelligent modeling system through PLC, including a central control module and a bionic operation module.

[0080] The central control module is used to receive control instructions and, in accordance with the control instructions, reference the three-dimensional coordinate matrix to locate and control the operation of the movable charcoal pallet system or the intelligent dual-force clamp 13 system. The control instructions include: unloading instructions, start / stop instructions, and pause instructions; unloading instructions include specifying a charcoal transport vehicle, a designated unloading area, and a designated charcoal placement target.

[0081] Specifically, the central control module first determines the target vehicle and the range of carbon blocks that need to be unloaded based on the control instructions (such as "unloading instructions") and the three-dimensional coordinate matrix. And according to the posture and size of the carbon block, combined with the geometric structure of the clamp 13 (claw length, opening and closing range, clamping surface shape), the optimal clamping point is calculated, and the position that enables the clamp 13 to stably and symmetrically clamp the two sides of the carbon block is selected as the optimal clamping point. Then a spatial trajectory from the current position to the target carbon block clamping point is planned for each clamp 13. After confirming that the clamp 13 is accurately positioned at the predetermined clamping point, an instruction is sent to control the clamp 13 to perform the clamping action. And the clamping force detection module can be used to ensure that the clamping force is moderate (it is clamped firmly without slipping, and does not damage the carbon block). Then plan and control the clamp 13 (with the carbon block) to move to the placement point above the target sub-pallet; after precise positioning, control the clamp 13 to release the carbon block.

[0082] The bionic operation module includes a remote control operation unit and an automatic operation unit; the remote control operation unit is used to provide manual remote control functions, including remote control of the movement of the overhead crane trolley, the lifting mechanism 14 or the clamp 13; the automatic operation unit is used to provide automatic control functions, including automatically linking the control module to perform intelligent unloading after the carbon block transport vehicle arrives at the designated location.

[0083] This embodiment also provides an intelligent unloading method based on an automatic unloading machine for aluminum anode carbon blocks, which uses the intelligent unloading system based on the automatic unloading machine for aluminum anode carbon blocks as described above to achieve automatic unloading of carbon blocks; the method includes the following steps:

[0084] Step 1: The 3D scanning intelligent modeling system performs real-time modeling of the briquette transport vehicle parked at the unloading area, generating a 3D coordinate matrix and a 3D scan map showing the distribution of the briquette. The central control system then plans the gripping path.

[0085] Step 2: The front lifting mechanism 14 positions the carbon block at the front of the vehicle, and the rear lifting mechanism 14 positions the carbon block at the rear of the vehicle; and automatically selects a single block clamping mode or a double block clamping mode based on the carbon block gap threshold;

[0086] Step 3: The intelligent dual-force clamp 13 system transfers the carbon blocks to the movable carbon block tray system, and the clamp 13 releases the carbon blocks when it contacts the tray;

[0087] Step 4: Use a stacking crane to grab the carbon blocks and put them into the warehouse.

[0088] The present embodiment provides an intelligent unloading system and method based on an automatic unloading machine for aluminum anode carbon blocks, which can realize fully automatic unloading of vehicle carbon blocks, and the unloading control is precise, which helps to improve unloading efficiency and unloading quality.

[0089] The above is only an embodiment of the present invention. Common knowledge such as the specific structure and characteristics of the scheme is not described in detail here. Ordinary technicians in the relevant field are aware of all common technical knowledge in the technical field of the invention before the application date or priority date, can obtain all existing technologies in the field, and have the ability to apply conventional experimental means before that date. Ordinary technicians in the relevant field can improve and implement this scheme in combination with their own abilities under the guidance of this application. Some typical well-known structures or well-known methods should not become obstacles for ordinary technicians in the relevant field to implement this application. It should be pointed out that for those skilled in the art, without departing from the structure of the present invention, several variations and improvements can be made, which should also be regarded as the scope of protection of the present invention. These will not affect the effect of the implementation of the present invention and the practicality of the patent.

Claims

1. The intelligent unloading system based on the automatic unloading machine for aluminum anode carbon blocks is characterized by: include: A movable carbon block pallet system, comprising several rows of movable sub-pallets, for receiving and separating the carbon block rows in the stacking area; The intelligent dual-force clamp system includes a lifting mechanism, a clamp, and a safety detection module. The lifting mechanism has two sets of clamps independently arranged longitudinally on the overhead traveling crane trolley, each controlling a set of clamps to support clamp misalignment operations. The lifting mechanism includes a front lifting mechanism for operating the carbon blocks at the front of the vehicle and a rear lifting mechanism for operating the carbon blocks at the rear of the vehicle. The safety detection module is used to detect the distance between the clamps and the carbon blocks in real time. The 3D scanning intelligent modeling system includes an intelligent modeling module and multiple laser radars; the laser radars are used to scan the vehicle and the carbon block in real time; the intelligent modeling module is used to identify the vehicle outline and the carbon block outline based on the scanned data of the vehicle and the carbon block, and output a three-dimensional coordinate matrix and a three-dimensional scanned image; The central control system is used to collaboratively control the movable carbon block tray system, the intelligent dual-force clamp system and the 3D scanning intelligent modeling system through PLC, including a central control module; the central control module is used to receive control instructions and, in accordance with the control instructions, refer to the three-dimensional coordinate matrix to locate and control the operation of the movable carbon block tray system or the intelligent dual-force clamp system.

2. The intelligent unloading system based on the automatic unloading machine for aluminum anode carbon blocks according to claim 1 is characterized in that: The movable carbon block tray system includes: a wireless control module and three movable sub-trays; the bottom of each sub-tray is provided with an electric control moving component for driving the sub-tray to move, so as to realize the merging and separation of the three sub-trays; The wireless control module establishes communication connections with the electric-controlled mobile component and the central control system, and is used to control the electric-controlled mobile component so that the three columns of pallets are merged or separated at specified intervals; the separation includes unilateral separation and bilateral separation.

3. The intelligent unloading system based on the automatic unloading machine for aluminum anode carbon blocks according to claim 1 is characterized in that: The clamp is a mechanical linkage type clamp, comprising: a clamp beam and a clamp bracket; the clamp beam and the clamp bracket are connected by a pull plate and a transition pull plate; the pull plate and the transition pull plate are connected by a pin shaft; The clamp bracket is connected to the clamp frame through an adapter, and the bottom of the transition pull plate is connected to the clamp frame through a pin; the pull plate, transition pull plate and clamp frame are symmetrically provided with two; the bottom inner side of each clamp frame is provided with a clamp; the clamp is provided with a grab nail; The clamp beam is provided with a hoisting mechanism and a pulley mechanism; the steel wire rope of the hoisting mechanism is connected with the clamp bracket; and a heavy hammer is also provided on the steel wire rope.

4. The intelligent unloading system based on the automatic unloading machine for aluminum anode carbon blocks according to claim 1 is characterized in that: The clamp is provided with a self-locking structure to realize automatic locking after clamping and self-unlocking and decoupling after placement.

5. The intelligent unloading system based on the automatic unloading machine for aluminum anode carbon blocks according to claim 1 is characterized in that: The intelligent dual-force clamp system further includes an anti-sway control module; the anti-sway control module is used to adjust control parameters to suppress the swing of the carbon block during lifting.

6. The intelligent unloading system based on the automatic unloading machine for aluminum anode carbon blocks according to claim 1 is characterized in that: The intelligent dual-force clamp system further includes a clamping force detection module; the clamping force detection module is used to monitor the contact state between the clamp and the carbon block in real time.

7. The intelligent unloading system based on the automatic unloading machine for aluminum anode carbon blocks according to claim 1 is characterized in that: The intelligent dual-force clamp system also includes a weight monitor, an overload limiter, a block missing detector and a block-loosening prevention timing controller; The weight monitor is used to collect the load weight of the clamp in real time; The overload limiter performs graded load limit according to the load weight - when the load weight is greater than 90% of the rated load, it triggers an audible and visual warning and limits the acceleration of the lifting mechanism to ≤ 0.2m / s 2 When the load weight is greater than 105% of the rated load, an emergency alarm is triggered and the lifting mechanism's ascending function is mechanically locked, allowing only descending operations. The missing block detector is used to determine whether there is a carbon block falling off according to the load weight, and when it is determined that there is a carbon block falling off, control the lifting function of the locking lifting mechanism; The anti-blocking timing controller is used to perform the following steps: S1, after the clamp is closed, control the lifting mechanism to rise 5cm; S2, maintain high altitude for 3 seconds, during which the leakage detector continuously monitors; S3: If there is no shedding signal during the stagnation period, continue to ascend to the target altitude; S4: If a fall-off is detected, an emergency stop will be immediately executed and the clamp will reset automatically.

8. The intelligent unloading system based on the automatic unloading machine for aluminum anode carbon blocks according to claim 1 is characterized in that: The central control system also includes a bionic operation module; the bionic operation module includes a remote control operation unit and an automatic operation unit; the remote control operation unit is used to provide manual remote control functions, including remote control of the movement of the overhead crane trolley, lifting mechanism or clamp; the automatic operation unit is used to provide automatic control functions, including automatically linking the control module to perform intelligent unloading after the coal block transport vehicle arrives at the designated location.

9. The intelligent unloading system based on the automatic unloading machine for aluminum anode carbon blocks according to claim 1 is characterized in that: The control instructions include: unloading instructions, start-stop instructions and pause instructions; the unloading instructions include: designated coal block transport vehicles, designated unloading ranges, and designated coal block placement targets.

10. An intelligent unloading method based on an automatic unloading machine for aluminum anode carbon blocks, characterized in that: The intelligent unloading system based on the automatic unloading machine for aluminum anode carbon blocks according to any one of claims 1 to 9 is used to realize the automatic unloading of carbon blocks; the system comprises the following steps: Step 1: The 3D scanning intelligent modeling system performs real-time modeling of the briquette transport vehicle parked at the unloading area, generating a 3D coordinate matrix and a 3D scan map showing the distribution of the briquette. The central control system then plans the gripping path. Step 2: The front lifting mechanism positions the carbon block at the front of the vehicle, and the rear lifting mechanism positions the carbon block at the rear of the vehicle; and automatically selects a single-block clamping mode or a double-block clamping mode based on the carbon block gap threshold; Step 3: The intelligent dual-force clamp system transfers the carbon blocks to the movable carbon block tray system, and the clamp releases the carbon blocks when it contacts the tray; Step 4: Use a stacking crane to grab the carbon blocks and put them into the warehouse.

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