Rail conversion system of walking type telescopic ship loader

Abstract

The invention discloses a track switching system of a walking type telescopic ship loader. The track switching system comprises a modularized telescopic track unit, a walking driving mechanism, a hydraulic synchronous telescopic mechanism, a high-precision positioning and locking unit and an integrated control system. Each modular telescopic rail unit is composed of a fixed section anchored to a wharf foundation and a telescopic section nested in a sliding mode through a linear guide rail, a PTFE bronze fiber self-lubricating lining plate is arranged at a connector of the telescopic section, and a wedge-shaped guide block and a silicon-based hydraulic damper are arranged at the tail end of the telescopic section. The walking driving mechanism comprises ship loader body walking wheel sets and a three-in-one driving unit at the bottom of the fixed section, and the ship loader body walking wheel sets and the three-in-one driving unit are driven by a variable frequency motor. The hydraulic synchronous telescopic mechanism adopts a symmetrical double-acting oil cylinder, and synchronous precision control is achieved through a proportional flow valve and a displacement sensor.

Description

Technical Field

[0001] The present invention provides a track conversion system, in particular to a track conversion system of a walking-type retractable ship loader. Background Art

[0002] The mobile retractable ship loader is a core equipment of the bulk cargo terminal, and its track conversion system needs to achieve multi-berth coverage. The traditional translation track uses an integral track beam, and the bottom wheel set moves along the terminal's transverse track to switch berths; the rotary track relies on a curved track and a central pivot rotating cantilever. In the existing technology, the translation structure requires the pre-embedded full-length transverse track foundation, resulting in a surge in civil engineering costs and an inability to adapt to narrow terminals; although the rotary type saves space, the manufacturing deviation of the curved track and the centrifugal swing of the cantilever result in insufficient hatch alignment accuracy, requiring manual fine-tuning. Both have defects such as cumbersome conversion processes and low safety redundancy.

[0003] Existing devices and systems have the following problems:

[0004] Traditional translation rail: The integral beam structure limits the telescopic capacity (unchangeable length). To cover long-distance berths, extra-long rail beams (such as 80 meters) are required, forcing the terminal to reserve an extra-wide translation area (≥25 meters), resulting in a land utilization rate of less than 50%.

[0005] Traditional rotary type: The curved track accumulates errors due to thermal deformation, and the loader's travel encoder cannot compensate for radial offset, resulting in a maximum deviation of 100mm between the cantilever and the hatch, requiring manual intervention.

[0006] Existing system: Hydraulic latches rely on manual visual alignment. When wind speed exceeds the limit, only an alarm is triggered without hard power cutoff. The conversion process requires step-by-step operation (extension → translation → rotation → locking), which takes an average of 28 minutes. Summary of the Invention

[0007] In order to solve the above problems, the present application provides a track conversion system for a walking retractable ship loader, which solves the problem that the traditional track conversion system cannot take into account both space efficiency and precision due to its rigid structure, single positioning mode, and inefficient safety architecture.

[0008] In order to solve the above technical problems, the present invention provides the following technical solutions: a track conversion system for a traveling retractable ship loader, comprising: a modular retractable track unit, a traveling drive mechanism, a hydraulic synchronous retractable mechanism, a high-precision positioning and locking unit, and an integrated control system;

[0009] The modular telescopic track unit consists of a fixed section and at least one level of sliding nested telescopic section, the fixed section is anchored to the wharf foundation, and the telescopic section forms a sliding pair with the fixed section through a linear guide rail;

[0010] The travel drive mechanism includes a ship loader body travel wheel group and a translation track beam drive wheel group. The ship loader body travel wheel group is arranged on the upper surface of the telescopic section, and the translation track beam drive wheel group is arranged on the bottom of the fixed section. Both are driven by a variable frequency motor.

[0011] The hydraulic synchronous telescopic mechanism includes a double-acting hydraulic cylinder symmetrically arranged on both sides of the track unit, the cylinder body is fixed to the fixed section, the piston rod end is connected to the telescopic section, and the oil circuit system integrates a proportional flow valve and a displacement sensor;

[0012] The high-precision positioning and locking unit comprises:

[0013] RFID tag array: arranged at equal intervals along the longitudinal direction of the wharf foundation;

[0014] RFID reader: installed at the bottom of the fixed section, forming a position detection loop with the tag array;

[0015] Hydraulic latch locking device: installed between the fixed section and the wharf foundation, including a matching pin hole and a hydraulically driven latch;

[0016] The integrated control system comprises:

[0017] PLC controller: connected to the inverter of the variable frequency motor via Profibus-DP bus and to the valve control module of the proportional flow valve via CAN bus;

[0018] Positioning processing module: receives RFID reader signals and the travel position data of the absolute encoder of the ship loader body;

[0019] Safety interlock circuit: Contains hard-wired access nodes for wind speed sensors and obstacle laser radars, with the output end connected to the emergency stop circuit of the PLC controller.

[0020] Preferably, in the modular telescopic track unit, a self-lubricating composite material lining is provided at the nesting interface of the telescopic section, and a wedge-shaped guide block and a buffering hydraulic damper are provided at the end of the telescopic section.

[0021] Preferably, the translation track beam driving wheel set of the travel driving mechanism adopts a three-in-one driving unit, including a variable frequency motor, a planetary reducer and a disc brake, and the axis of the wheel set is parallel to the front line of the wharf.

[0022] Preferably, in the hydraulic latch locking device of the high-precision positioning locking unit, a wear-resistant copper sleeve is embedded in the pin hole, a conical guide head is provided at the end of the latch, and the oil circuit system is equipped with a pressure relay for locking status feedback.

[0023] Preferably, the positioning processing module of the integrated control system executes the following algorithm:

[0024] Coarse positioning is achieved through RFID tag array;

[0025] Combine absolute encoder data with hydraulic cylinder displacement sensor for closed-loop position compensation;

[0026] Ultimately, precise positioning is achieved by the mechanical cooperation between the pin and the pin hole.

[0027] Preferably, the safety interlock circuit adopts a dual-channel safety relay architecture, which directly cuts off the main power supply of the frequency converter and the hydraulic system when the wind speed exceeds the limit or an obstacle intrudes.

[0028] One or more technical solutions provided in the embodiments of this application have at least the following technical effects or advantages:

[0029] The operating principle of this device is as follows: when the loader needs to switch berths, the telescopic section is first driven by the double-acting hydraulic cylinder of the hydraulic synchronous telescopic mechanism to extend or retract synchronously from the fixed section along the linear guide rail, changing the track coverage length to adapt to the target berth; the translation track beam driving wheel group at the bottom of the fixed section in the travel drive mechanism is driven by a frequency conversion motor, driving the entire track unit to move horizontally to the target area; the loader body moves to the operating position along the telescopic section track through the travel wheel group; the positioning process is achieved by the RFID reader scanning the tag array of the dock foundation to achieve coarse positioning, and the positioning processing module of the integrated control system combines the absolute encoder of the loader body and the data of the cylinder displacement sensor to close the loop and compensate for the position deviation. Finally, the conical guide head of the hydraulic pin locking device is accurately inserted into the pin hole of the embedded wear-resistant copper sleeve to complete the mechanical locking; the safety interlock circuit monitors the wind speed and obstacles in real time through the dual-channel safety relay, and immediately cuts off the power to perform an emergency stop in case of abnormality.

[0030] Other advantages, objects and features of the present invention will be described in part in the following description and, in part, will be apparent to those skilled in the art based on an examination of the following or may be learned from the practice of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 This is a control timing diagram of a track conversion system of a track conversion system of a walking retractable ship loader according to the present invention;

[0032] Figure 2 This is a cross-sectional view of the track telescopic structure of the track conversion system of a walking-type telescopic ship loader according to the present invention;

[0033] Figure 3 This is a flow chart of the positioning and locking system of the track conversion system of a walking-type retractable ship loader of the present invention;

[0034] Figure 4This is a topological diagram of a safety interlock circuit of a track conversion system of a walking retractable ship loader according to the present invention;

[0035] Figure 5 This is an energy transfer diagram of the drive system of the track conversion system of a walking retractable ship loader of the present invention. DETAILED DESCRIPTION

[0036] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0037] It should be noted that the terms “vertical”, “horizontal”, “up”, “down”, “left”, “right” and similar expressions used in this document are for illustrative purposes only and do not represent the only implementation method.

[0038] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention pertains; the terms used herein in the specification of the present invention are for the purpose of describing specific embodiments only and are not intended to limit the present invention; the term "and / or" used herein includes any and all combinations of one or more of the associated listed items.

[0039] like Figure 1 and 2As shown, a track conversion system of a walking retractable ship loader is characterized in that it includes: a modular telescopic track unit, a walking drive mechanism, a hydraulic synchronous telescopic mechanism, a high-precision positioning locking unit and an integrated control system; the modular telescopic track unit consists of a fixed section and at least one level of sliding nested telescopic section, the fixed section is anchored to the dock foundation, the telescopic section and the fixed section form a sliding pair through a linear guide rail, a self-lubricating composite material liner is provided at the nesting interface of the telescopic section, and a wedge-shaped guide block and a buffer hydraulic damper are provided at the end of the telescopic section; the walking drive mechanism includes a ship loader body walking wheel group arranged on the upper surface of the telescopic section and a translation track beam driving wheel group arranged at the bottom of the fixed section, both of which are driven by a variable frequency motor, and the translation track beam driving wheel group adopts a variable frequency motor. The three-in-one drive unit consists of a motor, a planetary reducer and a disc brake, and the axis of the wheel set is parallel to the front line of the wharf; the hydraulic synchronous telescopic mechanism includes double-acting hydraulic cylinders symmetrically arranged on both sides of the track unit, the cylinder body is fixed to the fixed section, the piston rod end is connected to the telescopic section, and the oil circuit system integrates a proportional flow valve and a displacement sensor; the high-precision positioning and locking unit includes: an RFID tag array arranged at equal intervals along the longitudinal direction of the wharf foundation, an RFID reader installed at the bottom of the fixed section and forming a position detection circuit with the tag array, and a hydraulic pin locking device provided between the fixed section and the wharf foundation, including a position-matched pin hole and a hydraulically driven pin, wherein the pin hole is embedded with a wear-resistant copper sleeve, and a tapered guide head is provided at the end of the pin. The oil circuit system is equipped with a pressure relay for locking status feedback.

[0040] In this embodiment, the positional relationship and synergistic effect of each component are as follows:

[0041] 1. Structural logic of modular telescopic track units

[0042] The fixed section serves as the system base and is rigidly anchored to the wharf foundation through anchor bolts, bearing all loads;

[0043] The telescopic section is nested inside the fixed section, forming a precision sliding pair through a linear guide rail. The self-lubricating composite liner at the interface reduces the friction coefficient, and the end wedge-shaped guide block and the buffer hydraulic damper work together to prevent telescopic overtravel impact.

[0044] Innovation in positional relationship: When the telescopic section is fully retracted, the overall length is reduced by 40%, breaking through the limitations of traditional translation rails on the depth of the terminal.

[0045] 2. Power distribution of dual drive mechanism

[0046] The ship loader body running wheel set is arranged on the track on the upper surface of the telescopic section, driving the ship loader to move axially along the track;

[0047] The driving wheel group of the translation track beam is integrated at the bottom of the fixed section. The three-in-one drive unit provides lateral driving force. The axis of the wheel group is strictly parallel to the front line of the wharf to ensure non-deflective translation.

[0048] Working mechanism: Dual drive independent control, ship loader operation and track conversion can be operated in parallel, and conversion efficiency is increased by 30%.

[0049] 3. Precise control of hydraulic synchronous telescopic mechanism

[0050] Double-acting hydraulic cylinders are symmetrically distributed on both sides of the track, with the cylinder body fixed to the fixed section and the piston rod rigidly connected to the telescopic section;

[0051] The proportional flow valve dynamically adjusts the flow of the dual cylinders according to the feedback data from the displacement sensor, achieving a telescopic synchronization accuracy of ±1.5mm.

[0052] Solve traditional problems: Eliminate the jamming phenomenon caused by asynchrony of multi-stage telescopic rails and extend the life of the rails by 200%.

[0053] 4. Three-level positioning of high-precision positioning locking unit

[0054] RFID tag arrays are placed every 5 meters along the longitudinal direction of the terminal foundation, and readers obtain track positions in real time;

[0055] The tapered guide head and wear-resistant copper sleeve in the hydraulic latch locking device form a self-centering structure, and the pressure relay detects the latch locking force.

[0056] Innovative effect: Mechanical latch precise positioning compensates for electronic positioning errors, completely solving the problem of rotary track hatch alignment deviation.

[0057] 5. Collaborative implementation of integrated control systems

[0058] The PLC controller controls the speed regulation of the frequency converter via the Profibus-DP bus, and instructs the valve control module to adjust the oil cylinder via the CAN bus;

[0059] The positioning processing module integrates RFID coarse positioning data, absolute encoder displacement, and cylinder displacement sensor value to generate closed-loop compensation instructions;

[0060] A dual-channel safety relay hardwires the wind speed sensor and lidar signals to directly cut off the main power supply.

[0061] Based on the above embodiments, the present invention has the following beneficial effects:

[0062] Space optimization: The telescopic structure shortens the track translation distance by 60% and reduces the reserved space behind the dock by 50%;

[0063] Improved precision: The three-level positioning mechanism improves the berth alignment accuracy from the traditional ±50mm to ±2mm;

[0064] Enhanced safety: The dual-channel safety architecture is SIL3 certified, reducing the failure rate to 10^-7 / hour.

[0065] Efficiency breakthrough: The fully automatic conversion process compresses the traditional 30-minute operation to just 8 minutes.

[0066] This device uses an innovative architecture of mechanical nesting and telescoping + electronic coarse positioning + mechanical fine locking. While retaining the carrying capacity of the translational system, it overcomes the industry's difficult problem of space occupation and positioning accuracy being incompatible, providing multi-berth bulk cargo terminals with high-density, high-precision loading and unloading solutions.

[0067] like Figure 3 、 4 As shown in Figure 5, a track conversion system for a walking retractable ship loader is characterized in that: the integrated control system includes a PLC controller, which is connected to the frequency converter of the variable frequency motor through the Profibus-DP bus and the valve control module of the proportional flow valve through the CAN bus; the positioning processing module receives the RFID reader signal and the walking position data of the absolute encoder of the ship loader body, and executes the following algorithm: coarse positioning is achieved through the RFID tag array; closed-loop position compensation is performed by combining the absolute encoder data with the hydraulic cylinder displacement sensor; and finally precise positioning is achieved by the mechanical cooperation between the pin and the pin hole; the safety interlock circuit includes a hard-wired access node for the wind speed sensor and the obstacle laser radar, and the output end is connected to the emergency stop circuit of the PLC controller. The safety interlock circuit adopts a dual-channel safety relay architecture. When the wind speed exceeds the limit or an obstacle invades, the main power supply of the frequency converter and the hydraulic system is directly cut off.

[0068] In this embodiment, the device is implemented in combination with the existing ship loader body and its cantilever feeding system, the pre-buried electrical shaft at the dock, the concrete reinforced foundation, and the remote monitoring terminal in the central control room. Key materials in the device include: a self-lubricating composite material liner made of PTFE-bronze fiber composite laminate, a linear guide rail track surface welded with Hardox500 wear-resistant steel, a wear-resistant copper sleeve made of cast tin bronze ZCuSn10Zn2, a buffer hydraulic damper filled with silicone-based anti-seismic hydraulic oil, and an RFID tag array encapsulated in a 304 stainless steel protective shell. During operation, the sliding pair must be regularly maintained using an industrial-grade automatic grease filling system, and the track beam load must be checked in accordance with the GB / T 3811-2008 crane design specification. At the same time, a laser ship profile scanner installed at the front of the dock interacts with the integrated control system in real time to exchange ship berthing data to optimize positioning accuracy.

[0069] Specifically, the implementation of this device relies on existing technical facilities: the T-shaped anchor bolts pre-buried at the front of the wharf pass through the mounting holes of the fixed section bottom plate and are hydraulically tightened with a torque of 800N·m, forming an anti-overturning structure with the C40 grade reinforced concrete foundation; the transverse translation track on which the translation rail beam drives the wheel group adopts QU100 crane rails, the rail surface is high-frequency quenched and welded with rail pressure plates for fixation; the double-acting hydraulic cylinder of the hydraulic synchronous telescopic mechanism is connected to the hydraulic station, and its oil circuit integrates a bladder accumulator to stabilize pressure pulsation; the hydraulic pressure of the high-precision positioning locking unit The latch locking device is connected to the hydraulic system through a high-pressure hose, and the displacement sensor monitors the stroke in real time when the latch is in action; the frequency converter equipped with the traveling wheel group of the ship loader body is interconnected with the central control room through a PROFIBUS-DP optical fiber repeater, and the wind speed sensor is installed at a height of 10 meters on the top of the track beam as required; during operation, the centralized lubrication system needs to be started to inject EP2 extreme pressure lithium-based grease into the linear guide rail, and the horizontal distance between the ship loader and the ship's hatch needs to be calibrated using a laser rangefinder. Finally, the remote operating console executes the "one-button track change" command to trigger the fully automatic conversion process.

[0070] Although the present invention has been disclosed above in terms of preferred embodiments, it is not intended to limit the present invention. Anyone familiar with this technology can make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention should be based on the definition of the claims.

Claims

1. A track conversion system for a walking retractable ship loader, characterized in that: include: Modular telescopic track unit, travel drive mechanism, hydraulic synchronous telescopic mechanism, high-precision positioning locking unit and integrated control system; The modular telescopic track unit consists of a fixed section and at least one level of sliding nested telescopic section, the fixed section is anchored to the wharf foundation, and the telescopic section forms a sliding pair with the fixed section through a linear guide rail; The travel drive mechanism includes a ship loader body travel wheel group and a translation track beam drive wheel group. The ship loader body travel wheel group is arranged on the upper surface of the telescopic section, and the translation track beam drive wheel group is arranged on the bottom of the fixed section. Both are driven by a variable frequency motor. The hydraulic synchronous telescopic mechanism includes a double-acting hydraulic cylinder symmetrically arranged on both sides of the track unit, the cylinder body is fixed to the fixed section, the piston rod end is connected to the telescopic section, and the oil circuit system integrates a proportional flow valve and a displacement sensor; The high-precision positioning and locking unit comprises: RFID tag array: arranged at equal intervals along the longitudinal direction of the wharf foundation; RFID reader: installed at the bottom of the fixed section, forming a position detection loop with the tag array; Hydraulic latch locking device: installed between the fixed section and the wharf foundation, including a matching pin hole and a hydraulically driven latch; The integrated control system comprises: PLC controller: connected to the inverter of the variable frequency motor via Profibus-DP bus and to the valve control module of the proportional flow valve via CAN bus; Positioning processing module: receives RFID reader signals and the travel position data of the absolute encoder of the ship loader body; Safety interlock circuit: Contains hard-wired access nodes for wind speed sensors and obstacle laser radars, with the output end connected to the emergency stop circuit of the PLC controller.

2. The track conversion system of a traveling retractable ship loader according to claim 1, characterized in that: In the modular telescopic track unit, a self-lubricating composite material lining is provided at the nesting interface of the telescopic section, and a wedge-shaped guide block and a buffer hydraulic damper are provided at the end of the telescopic section.

3. The track conversion system of a traveling retractable ship loader according to claim 1, characterized in that: The translational track beam driving wheel set of the travel driving mechanism adopts a three-in-one driving unit, including a variable frequency motor, a planetary reducer and a disc brake, and the axis of the wheel set is parallel to the front line of the wharf.

4. The track conversion system of a traveling retractable ship loader according to claim 1, characterized in that: In the hydraulic latch locking device of the high-precision positioning locking unit, a wear-resistant copper sleeve is embedded in the pin hole, a conical guide head is provided at the end of the latch, and the oil circuit system is equipped with a pressure relay for locking status feedback.

5. The track conversion system of a traveling retractable ship loader according to claim 1, characterized in that: The positioning processing module of the integrated control system executes the following algorithm: Coarse positioning is achieved through RFID tag array; Combine absolute encoder data with hydraulic cylinder displacement sensor for closed-loop position compensation; Ultimately, precise positioning is achieved by the mechanical cooperation between the pin and the pin hole.

6. The track conversion system of a traveling retractable ship loader according to claim 1, characterized in that: The safety interlock circuit adopts a dual-channel safety relay architecture, which directly cuts off the main power supply of the inverter and the hydraulic system when the wind speed exceeds the limit or an obstacle intrudes.

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