Tank car loading and unloading safety training and checking system and control method

Abstract

The invention discloses a tank truck loading and unloading safety training and checking system and a control method. The system comprises a hardware simulation module, a software control platform, a control unit module, a fault simulation module and an intelligent scoring module. The hardware simulation module comprises a tank car model, a sensor assembly, a valve assembly, an electrostatic grounding device and a practical training operation box. The software control platform is used for visually displaying a loading and unloading process, triggering a fault scene and feeding back a state; the control unit module executes an operation instruction based on the PLC and is linked with the software control platform to feed back an operation state; the fault simulation module comprises an electrostatic grounding failure simulation unit, a filling pipeline fracture fault simulation unit and a safety valve abnormal fault simulation unit; and the intelligent scoring module is used for recording the operation behavior data and generating an evaluation report. By establishing an actual tank car operation scene and a simulation model of a matched software platform, operation assessment can be performed on a typical fault scene in tank car loading and unloading, and a safe, real and comprehensive training assessment effect is achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of tank truck loading and unloading safety training and assessment, and in particular to a tank truck loading and unloading safety training and assessment system and a control method. Background Art

[0002] Currently, the transportation of hazardous chemicals, such as liquefied gases, is primarily accomplished by tanker trucks. Loading and unloading processes are highly risky, involving multiple hazards such as high voltage, flammability, and static electricity. Therefore, loading and unloading personnel must possess solid theoretical knowledge and emergency response skills. However, existing training methods rely on theoretical instruction and on-site practical training. These methods suffer from limitations such as limited training scenarios, high practical risks, fixed training modules, a lack of troubleshooting exercises, and subjective assessments, making it difficult to comprehensively and rapidly improve trainees' practical and emergency response capabilities.

[0003] At present, the training and assessment of tank truck loading and unloading safety have the following deficiencies: 1. Actual operations are difficult and dangerous: Practical operations such as tanker filling and unloading need to be carried out in a real environment, which has high training costs and poses safety risks such as leakage and explosion.

[0004] 2. Insufficient scenario simulation: Traditional training makes it difficult to simulate various complex fault scenarios in a controlled environment, such as filling pipeline rupture, electrostatic grounding failure, etc., and the opportunities for emergency response drills are limited.

[0005] 3. Outdated assessment methods: Existing assessments mostly rely on manual observation or simple paper tests, and lack a comprehensive and real-time assessment of students’ practical operation capabilities and emergency response capabilities. Summary of the Invention

[0006] The present invention aims to address at least one of the technical problems existing in the prior art. To this end, it proposes a tank truck loading and unloading safety training and assessment system and control method. By establishing a simulation model of actual tank truck operation scenarios and a supporting software platform, it can conduct operational assessments for typical failure scenarios in tank truck loading and unloading, achieving safe, realistic, and comprehensive training and assessment results.

[0007] In one aspect, an embodiment of the present invention provides a tank truck loading and unloading safety training and assessment system, comprising: A hardware simulation module, comprising a tank truck model, a sensor assembly, a valve assembly, an electrostatic grounding device, and a training operation box, wherein the training operation box is connected to the tank truck model, the sensor assembly, the valve assembly, and the electrostatic grounding device, respectively; A software control platform, which is used to visualize the loading and unloading process, trigger fault scenarios, and provide status feedback; A control unit module, the control unit module is connected to the hardware simulation module and the software control platform respectively, the control unit module executes operation instructions based on the PLC controller, and cooperates with the software control platform to feedback the operation status, so as to realize two-way interaction between hardware operation instructions and software simulation; A fault simulation module, comprising an electrostatic grounding failure simulation unit, a filling pipeline rupture fault simulation unit, and a safety valve abnormality fault simulation unit; An intelligent scoring module is used to record operational behavior data and generate an evaluation report.

[0008] According to some embodiments of the present invention, the sensor assembly includes a pressure sensor, a liquid level sensor, and a temperature sensor, and the pressure sensor, the liquid level sensor, and the temperature sensor are all installed inside the tank truck model.

[0009] According to some embodiments of the present invention, the software control platform is also used for cloud-based remote control and monitoring, including operation monitoring, task issuance, video interaction, and hierarchical authority management.

[0010] According to some embodiments of the present invention, the software control platform displays the medium flow state, temperature change and pressure distribution process in the tank truck through three-dimensional dynamic simulation.

[0011] According to some embodiments of the present invention, the fault simulation module also includes a valve stuck fault simulation unit, a sensor failure simulation unit and an emergency shut-off valve unable to close fault simulation unit. The fault simulation module is provided with a random trigger mechanism and manual control logic, and supports multi-fault linkage simulation.

[0012] According to some embodiments of the present invention, the intelligent scoring module includes an event stream analysis unit, a rule engine, a machine learning corrector and a real-time feedback unit, and also has a built-in multi-level risk quantification model.

[0013] According to some embodiments of the present invention, the scoring dimensions of the intelligent scoring module include operational process integrity, operational timeliness, fault handling correctness, safety awareness, and operational fluency.

[0014] In another aspect, an embodiment of the present invention provides a tank truck loading and unloading safety training and assessment control method, comprising: Trainees log in to the tank truck loading and unloading safety training and assessment system and select the tank truck filling task or unloading task training type on the software control platform; The software control platform guides the training task steps according to the selected training task type, simulating the filling process or unloading process; Conduct multi-dimensional fault simulation and emergency response based on preset fault trigger logic and response rules; The control unit module executes the operating instructions sent by the software control platform, controls the hardware simulation module to interact and feedback the operating status. The software control platform dynamically displays the medium flow, pressure changes and alarm prompts on the operation interface; The assessment score is calculated based on the operation step weight, error level, response time and rule engine, and an evaluation report is generated.

[0015] According to some embodiments of the present invention, performing multi-dimensional fault simulation and emergency response according to preset fault triggering logic and response rules includes: Collect students' current operation speed and step skipping frequency; Calculate the probability of misoperation P = k1 × V + k2 × F, where V is the current operation speed, F is the step skip frequency, k1 is the first weight coefficient, and k2 is the second weight coefficient; If P>preset threshold, the complexity of the next stage fault is reduced.

[0016] According to some embodiments of the present invention, calculating the assessment score based on the operation step weight, error level, response time, and rule engine includes: Collect and label operation events in real time; The original score is calculated based on a multi-dimensional weighted model of process completeness, timeliness, fault handling correctness, safety awareness, and operational fluency; The original score is converted into the final score based on the level of the trainee, the complexity of the fault, the historical accuracy characteristics and the correction coefficient. The final score is calculated as S = S0×(1+δ), where S0 is the original score and δ is the correction coefficient. The scoring results are converted into acoustic, optical and vibration signals of the hardware model.

[0017] The embodiments of the present invention have at least the following beneficial effects: By establishing a simulation model of actual tanker operation scenarios and a supporting software platform, typical fault scenarios during tanker loading and unloading can be assessed, achieving safe, realistic, and comprehensive training. The model represents the tanker's internal structure and control devices, including the tank, valves, piping, safety valve, pressure gauge, and static grounding device. The software control platform integrates the loading and unloading process steps and typical fault handling triggers, such as a ruptured filling line causing a leak, an abnormal tripping of a safety valve, or a failure of a static grounding device, into the loading and unloading workflow, providing real-time feedback on the fault status. The in-depth integration of the physical simulation model with dynamic fault injection hardware and software creates a closed "operation-feedback-evaluation" loop, addressing long-standing industry safety risks and incomplete assessment challenges. The system achieves the triple goals of safety training, multi-fault drills, and intelligent assessment, significantly outperforming traditional training and assessment methods. The system combines practical training with software simulation assessment, allowing trainees to practice tanker loading and unloading and emergency response operations in a safe, simulated environment. The system automatically records and evaluates operational data. Through the linkage of software and hardware, the intercommunication between operating instructions and simulation feedback is achieved during the training process, which not only ensures the realism of the training, but also reduces safety risks and provides comprehensive training assessment results.

[0018] Additional aspects and advantages of the present invention will be set forth in part in the description which follows and, in part, will be obvious from the description which follows, or may be learned by practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the following description of the embodiments with reference to the accompanying drawings, in which: Figure 1 This is a module diagram of a tank truck loading and unloading safety training and assessment system according to an embodiment of the present invention; Figure 2 This is a flow chart of a tank truck loading and unloading safety training and assessment control method according to an embodiment of the present invention; Figure 3 This is a flowchart of multi-dimensional fault simulation and emergency response in the tank truck loading and unloading safety training and assessment control method according to an embodiment of the present invention; Figure 4 The present invention is a flowchart of calculating the assessment score in the tank truck loading and unloading safety training assessment control method according to an embodiment of the present invention.

[0020] Reference numerals: Hardware simulation module 100, tank truck model 110, sensor assembly 120, valve assembly 130, electrostatic grounding device 140, training operation box 150, software control platform 200, control unit module 300, fault simulation module 400, intelligent scoring module 500. DETAILED DESCRIPTION

[0021] The following describes embodiments of the present invention in detail. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended only to explain the present invention and are not to be construed as limiting the present invention.

[0022] In the description of the present invention, it should be understood that descriptions involving orientations, such as up, down, front, back, left, right, etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they cannot be understood as limitations on the present invention.

[0023] In the description of the present invention, "several" means one or more, "multiple" means more than two, "greater than," "less than," and "exceed" are understood to exclude the number itself, and "above," "below," and "within" are understood to include the number itself. The use of terms such as "first" and "second" is solely for the purpose of distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly specifying the number of the indicated technical features, or implicitly specifying the order of the indicated technical features.

[0024] In the description of the present invention, unless otherwise clearly defined, words such as “set,” “install,” “connect,” and “connected” should be understood in a broad sense, and technicians in the relevant technical field can reasonably determine the specific meanings of the above words in the present invention based on the specific content of the technical solution.

[0025] The technical solution of the present invention is described in detail below through the accompanying drawings and specific embodiments.

[0026] See Figure 1This embodiment discloses a tank truck loading and unloading safety training and assessment system, comprising a hardware simulation module 100, a software control platform 200, a control unit module 300, a fault simulation module 400, and an intelligent scoring module 500. The hardware simulation module 100 includes a tank truck model 110, a sensor assembly 120, a valve assembly 130, an electrostatic grounding device 140, and a training operation box 150. The training operation box 150 is connected to the tank truck model 110, the sensor assembly 120, the valve assembly 130, and the electrostatic grounding device 140, respectively. The software control platform 200 is used to visualize the loading and unloading process, trigger fault scenarios, and provide status feedback. The control unit module 300 is connected to the hardware simulation module 100 and the software control platform 200, respectively. The control unit module 400 executes operating instructions based on a PLC controller and, in conjunction with the software control platform 200, provides operational status feedback, enabling bidirectional interaction between hardware operating instructions and software simulation. The fault simulation module 400 includes an electrostatic grounding failure simulation unit, a filling pipeline rupture fault simulation unit, and a safety valve abnormality fault simulation unit. The intelligent scoring module 500 is used to record operational behavior data and generate an evaluation report.

[0027] The tank truck model 110 simulates a real tank truck in terms of dimensions and structure. The tank is equipped with compartments, a stirring device, and pressure, temperature, and level sensors to collect oil status data. Hazardous materials safety signs and operating instructions are affixed to the exterior of the tank, and the body features an integrated electrostatic grounding connector. The tank truck model 110 is equipped with operating devices such as a filling valve, a discharge valve, a safety valve, and an electrostatic grounding switch, allowing trainees to simulate their operation. The electrostatic grounding device 140 incorporates an electromagnetic simulated disabler, which receives commands from the software control platform to disconnect the magnetic circuit and physically simulate a grounding failure. The training operation box 150 integrates a PLC controller, multiple relays, a power supply regulator, and various indicator lights and pushbutton switches. Trainees operate the pushbuttons and switches to send control commands to the PLC controller, which then controls the operating status of the tank truck model's components. The training operation box 150 features a touchscreen display, with a human-machine interface displaying real-time data and an operator interface, including information such as pump operating status, valve opening, and fault alerts. The power supply adopts a voltage stabilization protection system and uses industrial-grade sensors and components to ensure long-term stable operation of the system.

[0028] In some embodiments of the present invention, the sensor assembly includes a pressure sensor, a liquid level sensor, and a temperature sensor, all of which are installed inside the tank truck model. The pressure sensor is a diaphragm pressure sensor with redundant outputs; the liquid level sensor is a capacitive type; and the temperature sensor is, for example, a PT100. An industrial-grade PLC controller is used to support long-term operation. The power supply design uses a surge protection isolation module, switching to a UPS backup power source in the event of voltage instability. In some embodiments of the present invention, the software control platform also enables remote cloud-based control and monitoring, including operation monitoring, task issuance, video interaction, and hierarchical permission management. The host computer and PLC controller are connected to the local area network via a gateway; the interface is accessible via VPN or WebSocket. Teachers can remotely log in to the control backend to view real-time operation video streams and status data; remotely issue training tasks and fault simulation instructions; and provide voice intercom and text guidance.

[0029] In some embodiments of the present invention, the software control platform displays the medium flow state, temperature change and pressure distribution process in the tank truck through three-dimensional dynamic simulation.

[0030] In some embodiments of the present invention, the fault simulation module also includes a valve stuck fault simulation unit, a sensor failure simulation unit, and an emergency shut-off valve failure simulation unit. The fault simulation module features a random trigger mechanism and manual control logic, and supports multi-fault linkage simulation. Each unit is designed with independent PLC control logic and software interfaces, using a unified bus protocol (such as Modbus / TCP) for communication. It supports hot swapping and automatic software module identification, for example, automatically identifying newly added nitrogen leak units and fire alarm units.

[0031] In some embodiments of the present invention, the intelligent scoring module includes an event stream analysis unit, a rules engine, a machine learning corrector, and a real-time feedback unit, along with a built-in multi-level risk quantification model. The event stream analysis unit collects and labels operational events in real time; the rules engine calculates the raw score based on a multi-dimensional weighting model that considers process integrity, timeliness, fault handling accuracy, safety awareness, and operational fluency; the machine learning corrector converts the raw score into a final score based on the student level, fault complexity, historical accuracy characteristics, and a correction factor; and the real-time feedback unit converts the scoring results into acoustic, optical, and vibration signals for the hardware model.

[0032] In some embodiments of the present invention, the scoring dimensions of the intelligent scoring module include operational process integrity, operational timeliness, fault handling correctness, safety awareness, and operational fluency. A multi-dimensional scoring weight model is established, and weight factors are set for each scoring dimension. For example, the weight factor W1 for operational process integrity is 0.3, and its calculation rule is the number of missed key steps / total number of steps × 100%; the weight factor W2 for operational timeliness is 0.2, and its calculation rule is the response time score = 1 - actual time / reference time; the weight factor W3 for fault handling correctness is 0.25, and its calculation rule is the number of incorrect actions × deduction coefficient (for example, 5 points for accidentally touching the emergency stop); the weight factor W4 for safety awareness is 0.15, and its calculation rule is the safety item completion score (for example, 10 points for ungrounded operation; 15 points for not stopping the pump due to overpressure); and the weight factor W for operational fluency is 0.1, and its calculation rule is the number of redundant actions × 0.5 + the number of accidentally touching non-critical equipment × 0.3.

[0033] See Figure 2 This embodiment also provides a control method for performing tank truck loading and unloading safety assessment based on the above tank truck loading and unloading safety training and assessment system, which mainly includes steps S101 to S105: S101. The trainee logs in to the tank truck loading and unloading safety training and assessment system and selects the training task type of tank truck filling task or tank truck unloading task on the software control platform.

[0034] S102: The software control platform guides students through the training steps based on the selected training task type, simulating the filling or unloading process. The system simulates a normal fuel loading and unloading process. Trainees complete the following steps on the interface: login, task selection, valve opening, pump startup, and filling / unloading. The system then prompts the trainees with the steps.

[0035] S103. Perform multi-dimensional fault simulation and emergency response according to the preset fault trigger logic and response rules. Typical faults can be triggered according to preset conditions or randomly during the loading and unloading process. For example, when a filling pipeline rupture fault is triggered, the system simulates oil leakage and issues an alarm. The trainee needs to stop the pump and close the valve in time. When a safety valve fault is triggered, the system simulates excessive pressure, causing the safety valve to pop open and back pressure. The trainee needs to adjust the pressure. When the electrostatic conductive device fails, the system prompts a grounding fault warning on the touch screen. The trainee needs to reconnect the electrostatic grounding device. All fault simulations send signals from the software to the PLC controller, which controls the hardware model to respond accordingly, such as emitting a light alarm or simulating a leak.

[0036] S104: The control unit module executes the operational instructions sent by the software control platform, controls the hardware simulation module to interact, and provides operational status feedback. The software control platform dynamically displays medium flow, pressure changes, and alarm prompts on the operation interface. The system collects sensor data (pressure, temperature, liquid level, etc.) on the tank truck model 110 and the trainee's operational information in real time. The touch screen and host computer interface display the current status in real time. For each operational step, the system provides feedback based on preset safety thresholds and operating specifications. If an anomaly occurs, the interface will alarm and record the fault information. Each step must be completed as required before proceeding to the next step. Otherwise, a warning will be issued to ensure that the preparation and finishing work before filling and after unloading are also completed.

[0037] S105: Calculate the assessment score based on the weight of the operation steps, error level, response time, and the rule engine, and generate an evaluation report. The system automatically scores the trainee based on the standardization of the operation, time efficiency, and emergency response effectiveness. The scoring includes step completion, fault response timing, operation error rate, etc., and ultimately generates a comprehensive score and provides a training results report as the basis for assessment and evaluation.

[0038] The multi-dimensional fault simulation and emergency response in step S103 above are performed according to the preset fault trigger logic and response rules, including: (1) Simulation of electrostatic grounding failure Set up a grounding status sensor or simulation switch. Once the grounding loop is simulated to be disconnected, a "grounding fault" warning will pop up on the system interface; at the same time, the "grounding alarm indicator light" will light up, accompanied by a buzzer alarm; the trainee needs to manually reconnect the ground wire simulator and press the "reset" button to cancel the alarm.

[0039] (2) Valve stuck fault simulation Set a specific probability in the control logic or manually trigger the valve to become stuck. After the valve is triggered, the PLC controller simulates the valve being in an "unable to open or close" state. The screen prompts "valve abnormality" and the trainee needs to select "manual emergency closure" or change the operation path (bypass discharge).

[0040] (3) Sensor failure simulation The system sends a signal by interrupting sensor data (e.g., a pressure sensor constantly outputs 0 or 999); the software identifies abnormal data and outputs a "pressure sensor failure" prompt; students need to make emergency decisions based on redundant display values ​​(or a comprehensive judgment of liquid level and temperature); the system records reaction time and decision path as a basis for scoring.

[0041] (4) Filling pipeline rupture failure simulation The filling pipeline area is equipped with an audible and visual leak alarm or a flashing LED to simulate the effect of a ruptured filling pipeline. Trigger conditions include an abnormal flow rate or a sudden drop in pressure. The system software triggers a "leak fault" and sends a signal to the PLC controller. A simulated leak alarm (sound and light effects) is displayed; the interface prompts "Filling pipeline leak, please stop the pump immediately." The corresponding valve light on the control panel flashes to guide the trainee in correct operation. If the trainee fails to stop the pump and close the valve within the specified time, the system will record the incorrect operation and generate an incident report.

[0042] (5) Safety valve abnormal tripping fault simulation The software adjusts the simulated tank pressure to cause the safety valve to trip at an abnormal pressure point. A pop-up window prompts, "Safety valve tripped abnormally, current pressure X MPa." A warning light flashes on the physical model of the safety valve. If equipped with a pressure gauge, a pulsating animation can be added. The PLC controller receives abnormal pressure feedback or triggers a fault directly using a software-defined fault value. Two abnormal conditions, overpressure and underpressure, are set to verify the trainee's identification and judgment skills. Trainees are prompted to address the fault by reducing pressure, closing the inlet valve, or verifying the valve status. The system provides feedback based on the operational process and timeliness.

[0043] (6) Fault simulation of emergency shut-off valve failing to close After the trainee operates the "emergency shut-off" button, the valve status is still displayed as "open"; the simulation system uses animation + prompt sound to inform "shut-off failure"; the emergency shut-off valve is set with a status indicator light, and the valve position is simulated to be stuck through the PLC controller; the "signal not closed" feedback mechanism is implemented in the software; if the trainee does not check the valve position status and proceeds to the next operation, the system will warn and deduct points; points will be awarded after the correct power-off / manual isolation / remote control method is adopted; the fault mode can be set to periodic, controllable or random trigger to increase training diversity; the module provides "replay of the process" for teaching review.

[0044] See Figure 3 The above-mentioned step S103 performs multi-dimensional fault simulation and emergency response according to the preset fault trigger logic and response rules, and further includes: S201, collecting the student's current operation speed and step skipping frequency; S202, calculate the probability of incorrect operation P = k1 × V + k2 × F, where V is the current operation speed, F is the step skip frequency, k1 is the first weight coefficient, and k2 is the second weight coefficient; S203: If P>preset threshold, reduce the complexity of the next stage fault.

[0045] It should be noted that the preset threshold is generally set to 0.7. For example, if the novice trainee's operating speed V is 2 steps / second, the first weight coefficient k1 is 0.3, the jump frequency F is 4 times / process, and the second weight coefficient k2 is 0.1, then P=1.0>0.7, only a single fault is triggered.

[0046] The calculation of the risk factor in step S105 based on the operation step weight, error level, response time, and rule engine includes: The risk coefficient is calculated using the risk coefficient calculation formula, which is: Where R is the risk factor, W i is the weight factor of the i-th step operation, E i is the error level of the i-th step operation, T is the actual response time (seconds), T0 is the dynamic reference time (seconds), M is the frequency of wrong operation, M max is the maximum allowed number of incorrect operations, α is the time penalty coefficient (default is 0.8), and β is the incorrect operation penalty coefficient (default is 0.5).

[0047] Risk classification and handling are performed based on the calculated risk factor. When the risk factor R ≤ 1.0, a standard assessment report is generated for low risk, and the green light is always on. When the risk factor R is 1.0 < R ≤ 2.0, the risk is medium, the current faulty module is locked, and re-operation is required, and the yellow light flashes. When the risk factor R is greater than 2.0, the risk is high, the operation is forcibly terminated, and a customized training course is pushed, and the red light flashes and the vibration alarm continues.

[0048] For example, when dealing with an abnormal tripping fault of a safety valve, a trainee failed to close the upstream valve in time (W1=0.3, E1=3) and accidentally pressed the pressure relief button twice (M=2, M max =5), the actual response time T = 150s, and the risk coefficient calculation formula is R = 1.892, which is judged as medium risk. The system response: the yellow light flashes, the safety valve is locked, and the student is required to re-learn the "Valve Emergency Operation" course.

[0049] See Figure 4 The calculation of the assessment score in the above step S105 based on the operation step weight, error level, response time and rule engine includes: S301, collect operation events in real time and tag them; S302. Calculate the original score based on a multi-dimensional weighted model of process integrity, timeliness, fault handling accuracy, safety awareness, and operational fluency; S303. Convert the original score to a final score based on the student level, fault complexity, historical accuracy characteristics, and correction coefficient. The final score is calculated as S = S0 × (1 + δ), where S0 is the original score and δ is the correction coefficient. S304: Convert the scoring result into an acoustic, optical, and vibration signal of the hardware model.

[0050] Among them, the operational fluency is quantified by the following methods: Number of redundant actions = number of actual operation steps - number of standard steps; Number of times non-critical devices are accidentally touched = number of times undefined operations are triggered in the operation event flow; Fluency score = 100 - (number of redundant actions × 0.5 + number of false touches × 0.3).

[0051] It should be noted that the calculation formula of the correction coefficient δ is: Where δ is the correction coefficient, X is the eigenvector [x1, x2, x3, x4, x5], x1 is the original score deviation, x2 is the student grade coefficient, x3 is the fault complexity, x4 is the historical accuracy, and x5 is the operation volatility; ω j is the model weight, b is the bias term, g j is the basis function. The correction coefficient δ is generated by the radial basis function neural network. j Satisfies the following formula: Where, γ The default value for the bandwidth parameter is 0.5, μ j are the cluster centers extracted from the training data.

[0052] For example, a novice trainee handles a scenario where a filling pipe ruptures. The input features are: X=[0.25, 0.32, 0.7, 0.65, 0.4] (low raw score / novice / medium to high complexity / average history / large operational fluctuations).

[0053] Basis function calculation: g1 = exp(-0.5*||X-[0.1,0.3,0.2,0.6,0.1]||^2) = 0.82 g2 = exp(-0.5*||X-[0.3,0.4,0.6,0.7,0.3]||^2) = 0.93 g3 = exp(-0.5*||X-[0.2,0.3,0.5,0.5,0.5]||^2) = 0.21 Correction coefficient δ = ω1g1 + ω2g2 + ω3g3 + b =(0.6×0.82)+(0.3×0.93)+(-0.2×0.21)+0.05 = 0.779 The original score S0=65, then the final score S=65×(1+0.779)=115.6.

[0054] The system utilizes a dual-engine scoring architecture. The rules engine ensures transparent and explainable scoring, while machine learning corrections address individual differences and dynamic scenario adaptation, breaking through the "one-size-fits-all" flaw of traditional scoring models. A cross-modal feedback mechanism converts digital scores into physical signals such as sound, light, and vibration. This deeply integrates with the hardware simulation module 100 to form a closed "operation-scoring-perception" loop. Operational fluency (redundant actions / number of false touches) is incorporated into the hazardous materials handling training scoring system, achieving innovation in quantitative dimensions. After each training assessment, the system automatically generates a report that includes a step-by-step execution flowchart, exception handling statistics, score composition and reasons for loss of points, and improvement suggestions, such as recommendations for specialized training modules based on past performance.

[0055] The system allows teachers to initiate exams with a single click, and students can enter the exam through the interface. After completion, the system automatically scores students and synchronizes the data to their student profile. Teachers can view all exam records and error comments and export PDF reports. The system automatically scores students based on their standardized operation, time efficiency, and emergency response effectiveness. Scoring factors include step completion, fault response timing, and operational error rate. A comprehensive score is generated and a training results report is provided as a basis for assessment evaluation. A "critical item veto" mechanism has been introduced. Operations that seriously violate safety red lines and could lead to major accidents (such as loading and unloading without grounding or failing to shut down a pump immediately after a leak) will result in a failure, even if otherwise performed well. This reinforces safety bottom-line thinking. A segmented assessment mechanism has also been introduced, allowing the entire tank truck loading and unloading process to be broken down into several stages (such as pre-operation inspection, normal loading and unloading, and emergency response) for independent assessment. The final assessment report includes not only the overall score and scores for each module, but also highlights the core competencies most relevant to the trainee's role and provides improvement recommendations tailored to their job requirements. For example, the operator's report will analyze in detail the valve operation and fault handling details; the safety supervisor's report will focus on analyzing the hidden danger detection rate and the effectiveness of emergency command.

[0056] By deeply integrating physical simulation models with dynamic fault injection software and hardware, a closed "operation-feedback-evaluation" loop is achieved, resolving long-standing industry safety risks and incomplete assessment challenges. This approach achieves the triple goals of safety training, multi-fault drills, and intelligent assessment, significantly outperforming traditional training and assessment methods. A highly realistic tank truck emergency drill and assessment system has been constructed. Trainees can conduct near-realistic operational training while receiving systematic fault assessment and evaluation, reducing training costs and improving training effectiveness and safety.

[0057] The embodiments of the present invention have the following beneficial effects: 1. All-round realistic simulation: Combining physical simulation models with software simulation, the tanker structure and operation process are simulated to achieve dual visual and tactile simulation, enhancing the immersiveness of training.

[0058] 2. The control unit module can be expanded independently: The control unit module adopts a modular design, and each control unit (such as valve control, fault simulation) operates independently, which facilitates the subsequent function expansion and maintenance of the system.

[0059] 3. Software and hardware linkage feedback: The operation box communicates with the host computer software in real time. The trainee's operation instructions are executed by the PLC controller and fed back to the software. The system can immediately feedback the operation results (such as indicator lights, alarm prompts and screen displays) to achieve interactive training effects.

[0060] 4. Pressure data simulation output: Software and hardware work together to collect actual data in real time through sensors, and also simulate and output corresponding pressure signals through software algorithms, making fault simulation more realistic.

[0061] 5. High-stability hardware design: The system uses industrial-grade sensors, relays, stabilized power supplies and other components, and adopts multiple power protection and signal isolation measures to ensure the stability and reliability of the equipment under long-term and high-frequency use.

[0062] 6. Integration of automated assessment and teaching: Through the data collection and scoring module, the student's operation process can be automatically recorded and analyzed, making the assessment more objective. At the same time, the training and assessment processes are integrated to improve teaching efficiency.

[0063] The embodiments of the present invention are described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Various changes can be made within the knowledge of ordinary technicians in the relevant technical field without departing from the scope of the present invention.

Claims

1. A tank truck loading and unloading safety training and assessment system, characterized by: include: A hardware simulation module, comprising a tank truck model, a sensor assembly, a valve assembly, an electrostatic grounding device, and a training operation box, wherein the training operation box is connected to the tank truck model, the sensor assembly, the valve assembly, and the electrostatic grounding device, respectively; A software control platform, which is used to visualize the loading and unloading process, trigger fault scenarios, and provide status feedback; A control unit module, the control unit module is connected to the hardware simulation module and the software control platform respectively, the control unit module executes operation instructions based on the PLC controller, and cooperates with the software control platform to feedback the operation status, so as to realize two-way interaction between hardware operation instructions and software simulation; A fault simulation module, comprising an electrostatic grounding failure simulation unit, a filling pipeline rupture fault simulation unit, and a safety valve abnormality fault simulation unit; An intelligent scoring module is used to record operational behavior data and generate an evaluation report.

2. The tank truck loading and unloading safety training and assessment system according to claim 1 is characterized in that: The sensor assembly includes a pressure sensor, a liquid level sensor and a temperature sensor, and the pressure sensor, the liquid level sensor and the temperature sensor are all installed inside the tank truck model.

3. The tank truck loading and unloading safety training and assessment system according to claim 1 is characterized in that: The software control platform is also used for cloud-based remote control and monitoring, including operation monitoring, task issuance, video interaction, and hierarchical authority management.

4. The tank truck loading and unloading safety training and assessment system according to claim 1 is characterized in that: The software control platform displays the medium flow state, temperature change and pressure distribution process in the tank truck through three-dimensional dynamic simulation.

5. The tank truck loading and unloading safety training and assessment system according to claim 1 is characterized in that: The fault simulation module also includes a valve stuck fault simulation unit, a sensor failure simulation unit and an emergency shut-off valve unable to close fault simulation unit. The fault simulation module is provided with a random trigger mechanism and manual control logic, and supports multi-fault linkage simulation.

6. The tank truck loading and unloading safety training and assessment system according to claim 1 is characterized in that: The intelligent scoring module includes an event stream analysis unit, a rule engine, a machine learning corrector and a real-time feedback unit, and also has a built-in multi-level risk quantification model.

7. The tank truck loading and unloading safety training and assessment system according to claim 6 is characterized in that: The scoring dimensions of the intelligent scoring module include operational process integrity, operational timeliness, fault handling correctness, safety awareness and operational fluency.

8. A tank truck loading and unloading safety training assessment control method, characterized in that: The tank truck loading and unloading safety training and assessment system according to any one of claims 1 to 7 comprises: Trainees log in to the tank truck loading and unloading safety training and assessment system and select the tank truck filling task or unloading task training type on the software control platform; The software control platform guides the training task steps according to the selected training task type, simulating the filling process or unloading process; Conduct multi-dimensional fault simulation and emergency response based on preset fault trigger logic and response rules; The control unit module executes the operating instructions sent by the software control platform, controls the hardware simulation module to link and feedback the operating status. The software control platform dynamically displays the medium flow, pressure changes and alarm prompts on the operation interface; The assessment score is calculated based on the operation step weight, error level, response time and rule engine, and an evaluation report is generated.

9. The tank truck loading and unloading safety training assessment control method according to claim 8 is characterized in that: The multi-dimensional fault simulation and emergency response are performed according to the preset fault trigger logic and response rules, including: Collect students' current operation speed and step skipping frequency; Calculate the probability of misoperation P = k1 × V + k2 × F, where V is the current operation speed, F is the step skip frequency, k1 is the first weight coefficient, and k2 is the second weight coefficient; If P>preset threshold, the complexity of the next stage fault is reduced.

10. The tank truck loading and unloading safety training assessment control method according to claim 8, characterized in that: The assessment score is calculated based on the operation step weight, error level, response time and rule engine, including: Collect and label operation events in real time; The original score is calculated based on a multi-dimensional weighted model of process completeness, timeliness, correctness of fault handling, safety awareness, and operational fluency; The original score is converted into the final score based on the level of the trainee, the complexity of the fault, the historical accuracy characteristics and the correction coefficient. The final score is calculated as S = S0×(1+δ), where S0 is the original score and δ is the correction coefficient. The real-time feedback unit converts the scoring results into sound, light and vibration signals of the hardware model.

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