Intelligent scheduling management and control system for grab ship unloader

Abstract

The invention discloses an intelligent scheduling management and control system for a grab ship unloader. The intelligent scheduling management and control system comprises a grab ship unloader operation execution unit and a control unit, wherein the grab ship unloader operation execution unit comprises a driving device used for executing corresponding actions of ship unloading operation of the grab ship unloader; the PLC control device is used for sending a control instruction to the driving device, and the metal structure is used for building a metal frame for the grab ship unloader, providing a carrier for grabbing, transporting and unloading materials and providing a room body for assembly for the PLC control device and the driving device; the grab ship unloader dispatching management and control unit comprises an HMI dispatching management and control server and a second switch; the HMI scheduling management and control server is used for operating an HMI scheduling management and control interface so as to realize distribution, distribution, execution and scheduling functions of unloading tasks of materials loaded in each hatch of an operation ship when a plurality of grab ship unloaders work cooperatively; and a Profinet data transmission link is constructed between the HMI scheduling management and control server and the grab ship unloader operation execution unit. The system is high in intelligent degree, and the labor cost is saved; and the scheduling control function is complete.

Description

Technical Field

[0001] The invention belongs to the technical field of grab ship unloaders and relates to an intelligent dispatching and control system for grab ship unloaders. Background Art

[0002] Grab ship unloaders, as important ship unloading equipment at bulk material terminals, currently still generally adopt a combination of semi-automatic and manual operation modes, with a low degree of intelligence and unmanned operation. In today's era of global advocacy for the development of artificial intelligence and intelligent manufacturing, the development of unmanned grab ship unloaders has become a development trend in the industry. At present, the existing intelligent control systems of grab ship unloaders in the industry are basically only aimed at realizing intelligent ship unloading operations for a single machine and a single cabin, and cannot realize the coordinated scheduling function of multiple machines. To this end, we have developed an intelligent scheduling and control system for grab ship unloaders, which is used to realize the allocation, dispatching, execution, and scheduling functions of unloading tasks of materials loaded in each hatch of the operating ship when multiple grab ship unloaders work together. Summary of the Invention

[0003] In order to solve the above problems, the technical solution adopted by the present invention is: an intelligent dispatching and control system for a grab ship unloader, comprising: a grab ship unloader operation execution unit and a grab ship unloader dispatching and control unit;

[0004] The grab ship unloader operation execution unit includes:

[0005] Driving device: used to execute the corresponding actions of the grab ship unloader's ship unloading operation;

[0006] PLC control device: used to issue control instructions to the drive device and establish a data transmission link with the grab ship unloader scheduling and control unit;

[0007] The grab ship unloader scheduling and control unit includes an HMI scheduling and control server and a first switch;

[0008] The HMI scheduling and control server is used to run the HMI scheduling and control interface to realize the allocation, dispatching, execution and scheduling functions of unloading tasks of materials loaded in various hatches of the operating ship when multiple grab ship unloaders work in coordination;

[0009] A data transmission link is established between the HMI scheduling and control server and the grab ship unloader operation execution unit;

[0010] The first switch is used to establish a data transmission link between the HMI scheduling and control server and the grab ship unloader operation execution unit.

[0011] Further: the PLC control device includes a PLC master station, a second switch and a PLC slave station;

[0012] The PLC master and slave stations use the Profinet communication protocol for data transmission. Furthermore, the PLC master sends control instructions to the inverter in the drive unit via the Profinet protocol via the second switch, thereby controlling the movement of the grab ship unloader.

[0013] The PLC master station uses the Profinet protocol to transmit data with the grab ship unloader dispatching and control unit via the second switch.

[0014] Furthermore: the driving device includes:

[0015] Hoisting motor: used to drive the grab bucket mechanism to rise and fall;

[0016] Opening and closing motor: used to drive the grab mechanism to rise, fall, open and close the grab;

[0017] Trolley motor: used to drive the grab mechanism to move horizontally in the seaward and landward directions;

[0018] Trolley motor: used to drive the grab ship unloader to move forward and backward along the dock track;

[0019] Hoisting inverter: used to control the forward and reverse operation of the hoisting motor;

[0020] Switching frequency converter: used to control the forward and reverse operation of the switching motor;

[0021] Trolley frequency converter: used to control the forward and reverse operation of the trolley motor;

[0022] Trolley inverter: used to control the forward and reverse operation of the trolley motor;

[0023] Hoisting reducer: used to convert the forward and reverse operation of the hoisting motor into the rising and falling movement of the grab mechanism through the retraction and extension of the wire rope;

[0024] Opening and closing reducer: used to convert the forward and reverse operation of the opening and closing motor into the rising, falling, grab opening and closing actions of the grab mechanism through the retraction and extension of the wire rope.

[0025] According to any one of the above-mentioned methods, a control method of an intelligent dispatching and controlling system for a grab ship unloader comprises the following steps:

[0026] Step 1: Before the ship berths, the grab ship unloader intelligent scheduling and control system is activated based on the ship's stowage plan provided to the terminal management;

[0027] Step 2: Use the ship loading function on the HMI scheduling and control interface to enter the ship stowage diagram information into the grab ship unloader intelligent scheduling and control system;

[0028] Step 3: Use the ship unloading task work order entry function on the HMI scheduling and control interface to automatically start allocating the ship unloading task work orders to the two grab ship unloaders;

[0029] Step 4: The HMI scheduling and control server receives the status information of the 1# and 2# grab ship unloaders. If both the 1# and 2# grab ship unloaders are in a healthy standby state, the two grab ship unloaders will execute the unloading task work order;

[0030] Step 5: The HMI scheduling and control server dispatches the respective unloading task work orders to the two grab ship unloaders, and the two grab ship unloaders begin unloading operations according to the task execution order of the assigned unloading task work orders;

[0031] Step 6: The grab ship unloader performs hatch alignment according to the first task of the ship unloading task work order. The grab ship unloader automatically moves to the target hatch to be operated and performs alignment judgment;

[0032] Step 7: After the hatch alignment is completed, the grab ship unloader starts the ship unloading operation at the current hatch;

[0033] Step 8: During the operation, the HMI scheduling and control server counts the unloading operations of the two grab ship unloaders in real time;

[0034] Step 9: When the HMI scheduling and control server detects that the unloading operation volume of the 1# or 2# grab ship unloader at the hatch corresponding to the current unloading task work order reaches the unloading task volume allocated by the unloading task work order, it is determined that the work order task process of the current hatch is completed, and the grab ship unloader will perform the unloading task of the next hatch in the unloading task work order. For the execution method of the hatch alignment and unloading task, please refer to Step 6 to Step 8;

[0035] Step 10: Execute the assigned hatch work order tasks in sequence according to the unloading task work order until the unloading operation is completed.

[0036] Furthermore: the alignment determination method is as follows:

[0037] When S 卸船机 目标舱右 And S 卸船机 >S 目标舱左 When the grab ship unloader is positioned to the target hatch;

[0038] When S 卸船机 >S 目标舱右 When the grab ship unloader is on the right side of the target hatch, it needs to move to the left. The calculation method of the left movement speed V1 is as follows:

[0039] V1=-(2*a*((S 目标舱右 +S 目标舱左 ) / 2-S 卸船机 ))​0.5 ;

[0040] When S 卸船机 目标舱左 When , the grab ship unloader is on the left side of the target hatch and needs to move to the right. The calculation method of the right movement speed V2 is as follows:

[0041] V2=(2*a*((S 目标舱右 +S 目标舱左 ) / 2-S 卸船机 )) 0.5 ;

[0042] Among them S 卸船机 is the real-time position of the grab ship unloader; S 目标舱右 is the right edge position of the target hatch; S 目标舱左 is the left edge position of the target hatch; a is the acceleration of the grab ship unloader trolley mechanism.

[0043] Furthermore: the statistical method is as follows:

[0044] W=W 前 +(W 当HO +W 当TR ) / 2;

[0045] Where: W is the current operating volume statistics of the grab ship unloader; W 前 is the statistical value of the previous cycle operation of the grab ship unloader; W 当HO W is the grab bucket weight value when the current operation cycle is in the closed bucket lifting uniform speed state; 当TR It is the grab bucket weight value when the current operation cycle is in the closed bucket trolley uniform speed state.

[0046] Furthermore, the intelligent dispatching and control system for grab ship unloaders also includes the following control processes: when a single grab ship unloader needs to undergo maintenance, it exits the ship unloading operation, and when the maintenance is completed, it resumes the ship unloading operation:

[0047] Step 1: During the ship unloading operation, the HMI scheduling and control server receives real-time status information of the 1# and 2# grab ship unloaders. When it receives a notification that a grab ship unloader needs to be repaired, the system interrupts the execution of the current work order.

[0048] Step 2: The grab ship unloader in a faulty state exits the ship unloading operation;

[0049] Step 3: The HMI scheduling and control server reallocates the unloading tasks of the grab ship unloaders in a healthy state to reallocate the unloading work order tasks;

[0050] Step 4: The grab ship unloader in a healthy state performs the unloading operation according to the new unloading task order; ​

[0051] Step 5: When the HMI scheduling and control server receives the information that the grab ship unloader has completed the fault repair and can be put into unloading operation again, the system interrupts the execution of the current work order;

[0052] Step 6: The HMI scheduling and control server reallocates the unloading tasks of the two grab ship unloaders based on the execution status of the previous unloading tasks;

[0053] Step 7: The two grab ship unloaders carry out the unloading operation according to the reallocated unloading task order until the unloading task is completed.

[0054] The present invention provides an intelligent dispatching and control system for grab ship unloaders, which enables the allocation, dispatching, execution, and scheduling of unloading tasks for materials loaded into various hatches of operating vessels when multiple grab ship unloaders are working in coordination. The application of this intelligent dispatching and control system technology for grab ship unloaders can significantly reduce the number of operators and lower labor costs; it has the following advantages:

[0055] High degree of intelligence, saving labor costs;

[0056] Strong adaptability and perfect dispatching and control functions;

[0057] Higher safety, high efficiency and reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0058] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative labor.

[0059] Figure 1 This is the architecture diagram of the intelligent dispatching and control system for grab ship unloaders;

[0060] Figure 2 This is the layout diagram of the grab ship unloader operation execution unit;

[0061] Figure 3 This is the wiring diagram of the grab ship unloader operation execution unit;

[0062] Figure 4 This is the wiring diagram of the grab ship unloader dispatching and control unit;

[0063] Figure 5 This is a diagram of the HMI scheduling and control interface;

[0064] Figure 6 This is the control flow chart of the intelligent dispatching and control system of grab ship unloader;

[0065] Figure 7 This is a control flow chart of the grab ship unloader intelligent dispatching and control system when a single grab ship unloader needs to be repaired;

[0066] Figure 8 It is the ship's stowage plan.

[0067] Figure numerals: 1. Grab ship unloader operation execution unit, 2. Grab ship unloader scheduling and control unit, 3. Door leg structure, 4. Hopper structure, 5. Room structure, 6. Trolley structure, 7. Main beam structure, 8. Boom structure, 9. Cart structure, 10. Tower structure, 11. Grab mechanism, 12. Driver's cab PLC communication component, 13. Feeding room PLC communication component, 14. Pitching room PLC communication component, 15. Lifting inverter, 16. Opening and closing inverter, 17. Cart inverter, 18. Cart inverter, 19. Lifting motor, 20. Opening and closing motor, 21. Cart motor, 22. Cart motor, 23. Reducer assembly, 24. Inverter assembly, 25. PLC master station communication component, 26. HMI scheduling and control server. DETAILED DESCRIPTION

[0068] It should be noted that, unless there is any conflict, the embodiments of the present invention and the features in the embodiments may be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0069] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is in no way intended to limit the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0070] An intelligent dispatching and control system for a grab ship unloader includes a grab ship unloader operation execution unit 1 and a grab ship unloader dispatching and control unit 2;

[0071] The grab ship unloader operation execution unit 1 includes a PLC control device, a drive device and a metal structure;

[0072] The PLC control device is used to issue control instructions to the drive device, and at the same time establish a Profinet data transmission link with the grab ship unloader scheduling and control unit 2.

[0073] The PLC control device includes:

[0074] PLC master station, PLC slave station and second switch;

[0075] The driving device executes corresponding actions of the grab ship unloader's ship unloading operation by receiving control instructions from the PLC control device;

[0076] The drive device includes: a frequency converter assembly 24, a motor assembly and a reducer assembly 23. The frequency converter assembly 24 includes a lifting frequency converter 15, an opening and closing frequency converter 16, a trolley frequency converter 17, and a carriage frequency converter 18.

[0077] The motor assembly includes a lifting motor 19, an opening and closing motor 20, a trolley motor 21 and a carriage motor 22;

[0078] The speed reducer assembly 23 includes a lifting speed reducer and an opening and closing speed reducer;

[0079] Hoisting motor 19: used to drive the grab bucket mechanism to rise and fall;

[0080] Opening and closing motor 20: used to drive the grab bucket mechanism to rise, fall, open and close the grab bucket;

[0081] Trolley motor 21: used to drive the grab mechanism to move horizontally in the seaward and landward directions;

[0082] Trolley motor 22: used to drive the grab ship unloader to move forward and backward along the dock track;

[0083] Hoisting inverter 15: used to control the forward and reverse operation of the hoisting motor 19;

[0084] Open / close frequency converter 16: used to control the forward and reverse operation of the open / close motor 20;

[0085] Trolley inverter 17: used to control the forward and reverse operation of the trolley motor 21;

[0086] Carriage inverter 18: used to control the forward and reverse operation of the carriage motor 22;

[0087] Hoisting reducer: used to convert the forward and reverse operation of the hoisting motor 19 into the rising and falling movement of the grab mechanism through the retraction and extension of the wire rope;

[0088] Opening and closing reducer: used to convert the forward and reverse operation of the opening and closing motor 20 into the rising, falling, grab opening and grab closing actions of the grab mechanism through the retraction and extension of the wire rope.

[0089] The output end of the PLC master station is connected to the input end of the second switch, and the output end of the second switch is connected to the input ends of the lifting inverter 15, the opening and closing inverter 16, the trolley inverter 17, and the carriage inverter 18;

[0090] The output end of the lifting frequency converter 15 is connected to the input end of the lifting motor 19;

[0091] The output end of the switching frequency converter 16 is connected to the input end of the switching motor 20;

[0092] The output end of the trolley frequency converter 17 is connected to the input end of the trolley motor 21;

[0093] The output end of the trolley frequency converter 18 is connected to the input end of the trolley motor 22 .

[0094] The metal structure consists of a door leg structure 3, a hopper structure 4, a housing structure 5, a trolley structure 6, a main beam structure 7, an arm structure 8, a trolley structure 9, a tower structure 10, and a grab mechanism 11. It forms the metal framework for the grab ship unloader, provides a carrier for grabbing, transporting, and unloading materials, and provides an assembly room for the PLC control device and drive device.

[0095] The grab ship unloader scheduling and control unit 2 includes an HMI scheduling and control server 26 and a first switch.

[0096] The HMI scheduling and control server 26 is installed at the remote control console in the remote control room and is used to run the HMI scheduling and control interface to realize the allocation, dispatching, execution and scheduling functions of the unloading tasks of the materials loaded in each hatch of the operating ship when multiple grab ship unloaders work in coordination;

[0097] A Profinet data transmission link is established between the HMI scheduling and control server 26 and the grab ship unloader operation execution unit 1;

[0098] The first switch is installed in the central communication cabinet of the remote control room, supports the Profinet protocol, and builds a data transmission link between the HMI scheduling and control server 26 and the grab ship unloader operation execution unit 1.

[0099] The grab ship unloader operation execution unit 1 includes a PLC control device, a drive device, and a metal structure. The specific layout is as follows: Figure 2 shown.

[0100] The PLC control device includes a PLC master station communication component 25, a driver's cab PLC communication component 12, a feeding room PLC communication component 13, and a pitching room PLC communication component 14;

[0101] The PLC master station communication component 25 includes a PLC master station and a second switch installed in the PLC room.

[0102] The driver's cab PLC communication component 12, the feeding room PLC communication component 13, and the pitching room PLC communication component 14 are respectively installed with PLC substations and switches in the driver's cab, the feeding room, and the pitching room, including the driver's cab PLC substation and switch, the feeding room PLC substation and switch, and the pitching room PLC substation and switch;

[0103] Specific wiring such as Figure 3 As shown in the figure, the PLC master station and the PLC slave station use the Profinet communication protocol for data transmission. In addition, the PLC master station sends control instructions to the inverter in the drive device through the switch via the Profinet protocol, thereby realizing the motion control of the grab ship unloader.

[0104] The PLC master station realizes data transmission between the grab ship unloader dispatching and control unit 2 through the second switch using the Profinet protocol.

[0105] The drive device consists of a lifting inverter 15, a switching inverter 16, a trolley inverter 17, and a carriage inverter 18 installed in the electrical room, a lifting motor 19, a switching motor 20, a trolley motor 21 installed in the machine room, a lifting reduction box, a switching reduction box, and a carriage motor 22 installed on the trolley;

[0106] The lifting inverter 15, the opening and closing inverter 16, the trolley inverter 17, and the carriage inverter 18 receive control instructions from the PLC control device and drive the lifting motor 19, the opening and closing motor 20, the trolley motor 21, and the carriage motor 22 to operate respectively in the form of hard wiring;

[0107] The lifting motor 19, the opening and closing motor 20, and the trolley motor 21 rotate to drive the lifting reduction box and the opening and closing reduction box to rotate, thereby realizing the grab bucket lifting, opening and closing, and translation movement of the grab bucket unloader;

[0108] The trolley motor 22 is driven by rotation to realize the forward and backward movement of the grab ship unloader along the trolley track direction.

[0109] The metal structure includes a door leg structure 3, a hopper structure 4, a room structure 5, a trolley structure 6, a main beam structure 7, an arm structure 8, a trolley structure 9, a tower structure 10, and a grab mechanism 11;

[0110] The door leg structure 3, hopper structure 4, trolley structure 6, main beam structure 7, boom structure 8 and tower structure 10 constitute the metal frame of the grab ship unloader;

[0111] The room structure 5 includes a machine room with a built-in PLC room and an electrical room, a driver's room distributed under the main beam structure 7 and the arm structure 8, a pitch room distributed on the tower structure 10, and a feeding room distributed on the hopper structure 4, providing assembly space for the PLC control device and the drive device.

[0112] The trolley structure 9 consists of a main trolley and two driving trolleys, located above the boom structure 8 and the main beam structure 7. It is connected to the lifting and opening and closing reduction box in the drive device through a steel wire rope and is controlled by it to achieve translational movement along the boom structure 8 and the main beam structure 7.

[0113] The grab bucket structure is suspended below the main trolley of the trolley structure 9 by a steel wire rope, and is controlled by the steel wire rope to realize actions such as closing the bucket to take materials, rising operation, and opening the bucket to throw materials.

[0114] Grab ship unloader dispatching control unit 2 Figure 4 As shown, it includes an HMI scheduling and control server 26 and a first switch; wherein the HMI scheduling and control server 26 is located at the remote control console in the remote control room and is used to run the HMI scheduling and control interface. The scheduling and control server realizes data transmission between the grab ship unloader operation execution unit 1 through the Profinet protocol via the first switch.

[0115] The first switch is located in the central communication cabinet of the remote control room, supports the Profinet protocol, and establishes a data transmission link between the HMI scheduling and control server 26 and the grab ship unloader operation execution unit 1.

[0116] like Figure 5 As shown in the figure, the grab ship unloader scheduling and control interface is divided into a three-dimensional presentation area, an operation data display area, and an operation task scheduling and control area.

[0117] The three-dimensional presentation area is used to dynamically present real-time data such as the position, posture, and material distribution of the grab ship unloader;

[0118] The operation data display area is used to display the current operation status information of the grab ship unloader in real time;

[0119] The operation task scheduling and control area is used to realize the compilation and import of operation tasks, the dispatch of operation tasks, the start and stop control of operation tasks, and the manual change of material operation points.

[0120] A control method for an intelligent dispatching and control system of a grab ship unloader comprises the following steps:

[0121] Step 1: Before the ship berths, the grab ship unloader intelligent scheduling and control system is activated based on the ship's stowage plan provided to the terminal management;

[0122] Step 2: Use the ship loading function on the HMI scheduling and control interface to enter the ship stowage diagram information into the grab ship unloader intelligent scheduling and control system;

[0123] Step 3: Use the ship unloading task work order entry function on the HMI scheduling and control interface to automatically start allocating the ship unloading task work orders to the two grab ship unloaders;

[0124] Step 4: The HMI scheduling and control server 26 receives the status information of the 1# and 2# grab ship unloaders. If both the 1# grab ship unloader and the 2# grab ship unloader are in a healthy standby state, the two grab ship unloaders will execute the unloading task work order;

[0125] Step 5: The HMI scheduling and control server 26 dispatches the respective unloading task work orders to the two grab ship unloaders, and the two grab ship unloaders start the unloading operation according to the task execution order of the assigned unloading task work orders;

[0126] Step 6: The grab ship unloader performs hatch alignment according to the first task of the ship unloading task work order. The grab ship unloader automatically moves to the target hatch to be operated and performs alignment judgment;

[0127] Step 7: After the hatch alignment is completed, the grab ship unloader starts the ship unloading operation at the current hatch;

[0128] Step 8: During the operation, the HMI scheduling and control server 26 respectively counts the unloading operation volume of the two grab ship unloaders in real time;

[0129] Step 9: When the HMI scheduling and control server 26 detects that the unloading operation volume of the 1# or 2# grab ship unloader at the hatch corresponding to the current unloading task work order reaches the unloading task volume allocated by the unloading task work order, it is determined that the work order task process of the current hatch is completed, and the grab ship unloader will perform the unloading task of the next hatch in the unloading task work order. The hatch alignment and unloading task execution method refer to steps 6 to 8;

[0130] Step 10: Execute the assigned hatch work order tasks in sequence according to the unloading task work order until the unloading operation is completed.

[0131] Furthermore: the alignment determination method is as follows:

[0132] When S 卸船机 目标舱右 And S 卸船机 >S 目标舱左 When the grab ship unloader is positioned to the target hatch;

[0133] When S 卸船机 >S 目标舱右 When the grab ship unloader is on the right side of the target hatch, it needs to move to the left. The calculation method of the left movement speed V1 is as follows:​

[0134] V1=-(2*a*((S 目标舱右 +S 目标舱左 ) / 2-S 卸船机 )) 0.5 ;

[0135] When S 卸船机 目标舱左 When , the grab ship unloader is on the left side of the target hatch and needs to move to the right. The calculation method of the right movement speed V2 is as follows:

[0136] V2=(2*a*((S 目标舱右 +S 目标舱左 ) / 2-S 卸船机 )) 0.5 ;

[0137] Among them S 卸船机 is the real-time position of the grab ship unloader; S 目标舱右 is the right edge position of the target hatch; S 目标舱左 is the left edge position of the target hatch; a is the acceleration of the grab ship unloader trolley mechanism.

[0138] Furthermore: the statistical method is as follows:

[0139] W=W 前 +(W 当HO +W 当TR ) / 2;

[0140] Where: W is the current operating volume statistics of the grab ship unloader; W 前 is the statistical value of the previous cycle operation of the grab ship unloader; W 当HO W is the grab bucket weight value when the current operation cycle is in the closed bucket lifting uniform speed state; 当TR It is the grab bucket weight value when the current operation cycle is in the closed bucket trolley uniform speed state.

[0141] Furthermore, the intelligent dispatching and control system for grab ship unloaders also includes the following control processes: when a single grab ship unloader needs to undergo maintenance, it exits the ship unloading operation, and when the maintenance is completed, it resumes the ship unloading operation:

[0142] Step 1: During the ship unloading operation, the HMI scheduling and control server 26 receives the status information of the 1# and 2# grab ship unloaders in real time. When receiving a message that a grab ship unloader needs to be repaired, the system interrupts the execution of the current work order;

[0143] Step 2: The grab ship unloader in a faulty state exits the ship unloading operation;

[0144] ​Step 3: The HMI scheduling and control server 26 reallocates the unloading tasks of the grab ship unloaders in a healthy state to reallocate the unloading work order tasks;

[0145] Step 4: The grab ship unloader in a healthy state performs the unloading operation according to the new unloading task order;

[0146] Step 5: When the HMI scheduling and control server 26 receives the information that the grab ship unloader in the fault state has been repaired and can be put into ship unloading operation again, the system interrupts the execution of the current work order;

[0147] Step 6: The HMI scheduling and control server 26 reallocates the unloading tasks of the two grab ship unloaders based on the execution status of the previous unloading tasks;

[0148] Step 7: The two grab ship unloaders carry out the unloading operation according to the reallocated unloading task order until the unloading task is completed.

[0149] Example:

[0150] Taking the berthing of a 50,000-ton ship with 5 hatches and two 1800t / h grab ship unloaders operating simultaneously as an example, the control process of the grab ship unloader intelligent scheduling and control system is explained. Figure 6 shown.

[0151] Description of the control process of the grab ship unloader intelligent scheduling and control system:

[0152] Step 1: Before the ship berths, the shipowner provides the ship's stowage plan to the terminal controller, who then activates the grab ship unloader intelligent dispatching and control system, and the system functions are activated;

[0153] like Figure 8 As shown in the figure, the material stowage information of a 50,000-ton operating vessel is as follows:

[0154] The ship has a total of 5 hatches, and the material quantities loaded in hold 1# to hold 5# are 9000t, 10000t, 9000t, 10000t and 9232t respectively.

[0155] During the unloading operation, each hatch was emptied in two rounds. The amount of material unloaded in the first round from 1# to 5# holds was 5,000t. The amount of material unloaded in the first round from 1# to 5# holds was 4,000t, 5,000t, 4,000t, 5,000t and 4,232t respectively.

[0156] The hatch operation order for each round is two machines: 2 / 4-1 / 5-3.

[0157] Step 2: Use the ship loading function on the HMI scheduling and control interface to enter the ship stowage diagram information into the grab ship unloader intelligent scheduling and control system;

[0158] Step 3: Use the ship unloading task work order entry function on the HMI scheduling and control interface to automatically start allocating the ship unloading task work orders to the two grab ship unloaders;

[0159] Step 4: The HMI scheduling and control server 26 receives the status information of the 1# and 2# grab ship unloaders. If both the 1# grab ship unloader and the 2# grab ship unloader are in a healthy standby state, the unloading task work orders to be executed by the two grab ship unloaders are as follows:

[0160] The unloading task order to be executed by the 1# grab ship unloader is: 2# hatch 5000t - 1# hatch 5000t - 3# hatch 5000t - 2# hatch 5000t - 1# hatch 4000t;

[0161] The unloading task order to be executed by the 2# grab ship unloader is: 4# hatch 5000t-5# hatch 5000t-4# hatch 5000t-5# hatch 4232t-3# hatch 4000t;

[0162] Step 5: The HMI scheduling and control server 26 dispatches the respective unloading task work orders to the two grab ship unloaders, and the two grab ship unloaders start the unloading operation according to the task execution order of the assigned unloading task work orders;

[0163] Step 6: The grab ship unloader performs hatch alignment according to the first task of the ship unloading task work order. The grab ship unloader automatically moves to the target hatch to be operated. The alignment determination method is as follows:

[0164] When S 卸船机 目标舱右 And S 卸船机 >S 目标舱左 When the grab ship unloader is positioned to the target hatch;

[0165] When S 卸船机 >S 目标舱右 When the grab ship unloader is on the right side of the target hatch, it needs to move to the left. The calculation method of the moving speed V1 is as follows:

[0166] V1=-(2*a*((S 目标舱右 +S 目标舱左 ) / 2-S 卸船机 )) 0.5 ;

[0167] When S 卸船机 目标舱左 When the grab ship unloader is on the left side of the target hatch, it needs to move to the right. The calculation method of the moving speed V2 is as follows:

[0168] V2=(2*a*((S 目标舱右 +S 目标舱左 ) / 2-S 卸船机 ))​​0.5 ;

[0169] Among them S 卸船机 is the real-time position of the grab ship unloader; S 目标舱右 is the right edge position of the target hatch; S 目标舱左 is the left edge position of the target hatch; a is the acceleration of the grab ship unloader trolley mechanism.

[0170] Step 7: After the hatch alignment is completed, the grab ship unloader starts the ship unloading operation at the current hatch;

[0171] Step 8: During the operation, the HMI scheduling and control server 26 respectively counts the unloading operation volume of the two grab ship unloaders in real time. The statistical method is as follows:

[0172] W=W 前 +(W 当HO +W 当TR ) / 2;

[0173] Where W is the current operating volume statistics of the grab ship unloader; W 前 is the statistical value of the previous cycle operation of the grab ship unloader; W 当HO W is the grab bucket weight value when the current operation cycle is in the closed bucket lifting uniform speed state; 当TR It is the grab bucket weight value when the current operation cycle is in the closed bucket trolley uniform speed state.

[0174] Step 9: When the HMI scheduling and control server 26 detects that the unloading operation volume of the 1# or 2# grab ship unloader at the hatch corresponding to the current unloading task work order reaches the unloading task volume allocated by the unloading task work order, it is determined that the work order task process of the current hatch is completed, and the grab ship unloader will perform the unloading task of the next hatch in the unloading task work order. The hatch alignment and unloading task execution method refer to steps 6-8;

[0175] Step 10: Execute the assigned hatch work order tasks in sequence according to the unloading task work order until the unloading operation is completed.

[0176] Figure 7 This is a control flow chart of the grab ship unloader intelligent dispatching and control system when a single grab ship unloader needs to be repaired;

[0177] During the operation of the grab ship unloader intelligent dispatching and control system, when a single grab ship unloader needs to be repaired, the control process of exiting the ship unloading operation and re-entering the ship unloading operation after the repair is completed is described as follows:

[0178] Step 1: During the ship unloading operation, the HMI scheduling and control server 26 receives the status information of the 1# and 2# grab ship unloaders in real time. When receiving a message that a grab ship unloader needs to be repaired, the system interrupts the execution of the current work order;

[0179] Step 2: The grab ship unloader in a faulty state exits the ship unloading operation;

[0180] Step 3: The HMI scheduling and control server 26 reallocates the unloading tasks of the grab ship unloaders in a healthy state. The allocation method is similar to the above method. The reallocation of the unloading work order task is explained when both grab ship unloaders are in the first unloading task execution:

[0181] New unloading task work order for grab ship unloader in healthy state: 2# hatch 5000 remaining tons - 4# hatch 5000 remaining tons - 1# hatch 5000t - 5# hatch 5000t - 3# hatch 5000t - 2# hatch 5000t - 4# hatch 5000t - 1# hatch 4000t - 5# hatch 4232t - 3# hatch 4000t;

[0182] Step 4: The grab ship unloader in a healthy state performs the unloading operation according to the new unloading task order;

[0183] Step 5: When the HMI scheduling and control server 26 receives the information that the grab ship unloader in the fault state has been repaired and can be put into ship unloading operation again, the system interrupts the execution of the current work order;

[0184] Step 6: The HMI scheduling and control server 26 reallocates the unloading tasks of the two grab ship unloaders based on the execution status of the previous unloading tasks, and the allocation method is similar to the above method;

[0185] Step 7: The two grab ship unloaders carry out the unloading operation according to the reallocated unloading task order until the unloading task is completed.

[0186] It will be used in the intelligent grab ship unloader project produced by the Port Machinery Division of Dalian Huarui Heavy Industries Group Co., Ltd.

[0187] The development of the intelligent dispatching and control system for grab ship unloaders has greatly increased the core market competitiveness of grab ship unloader products.

[0188] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An intelligent dispatching and control system for grab ship unloaders, characterized by: include: Grab ship unloader operation execution unit and grab ship unloader scheduling and control unit; The grab ship unloader operation execution unit includes: Driving device: used to execute the corresponding actions of the grab ship unloader's ship unloading operation; PLC control device: used to issue control instructions to the drive device and establish a data transmission link with the grab ship unloader scheduling and control unit; The grab ship unloader scheduling and control unit includes an HMI scheduling and control server and a first switch; The HMI scheduling and control server is used to run the HMI scheduling and control interface to realize the allocation, dispatching, execution and scheduling functions of unloading tasks of materials loaded in various hatches of the operating ship when multiple grab ship unloaders work in coordination; A data transmission link is established between the HMI scheduling and control server and the grab ship unloader operation execution unit; The first switch is used to establish a data transmission link between the HMI scheduling and control server and the grab ship unloader operation execution unit.

2. The intelligent dispatching and control system for grab ship unloader according to claim 1 is characterized by: The PLC control device includes a PLC master station, a second switch and a PLC slave station; The PLC master and slave stations use the Profinet communication protocol for data transmission. Furthermore, the PLC master sends control instructions to the inverter in the drive unit via the Profinet protocol via the second switch, thereby controlling the movement of the grab ship unloader. The PLC master station uses the Profinet protocol to transmit data with the grab ship unloader dispatching and control unit via the second switch.

3. The intelligent dispatching and control system for grab ship unloader according to claim 1 is characterized by: The driving device comprises: Hoisting motor: used to drive the grab bucket mechanism to rise and fall; Opening and closing motor: used to drive the grab mechanism to rise, fall, open and close the grab; Trolley motor: used to drive the grab mechanism to move horizontally in the seaward and landward directions; Trolley motor: used to drive the grab ship unloader to move forward and backward along the dock track; Hoisting inverter: used to control the forward and reverse operation of the hoisting motor; Switching frequency converter: used to control the forward and reverse operation of the switching motor; Trolley frequency converter: used to control the forward and reverse operation of the trolley motor; Trolley inverter: used to control the forward and reverse operation of the trolley motor; Hoisting reducer: used to convert the forward and reverse operation of the hoisting motor into the rising and falling movement of the grab mechanism through the retraction and extension of the wire rope; Opening and closing reducer: used to convert the forward and reverse operation of the opening and closing motor into the rising, falling, grab opening and closing actions of the grab mechanism through the retraction and extension of the wire rope.

4. The control method of the intelligent dispatching and control system of a grab ship unloader according to any one of claims 1 to 3, characterized in that: The following steps are involved: Step 1: Before the ship berths, the grab ship unloader intelligent scheduling and control system is activated based on the ship's stowage plan provided to the terminal management; Step 2: Use the ship loading function on the HMI scheduling and control interface to enter the ship stowage diagram information into the grab ship unloader intelligent scheduling and control system; Step 3: Use the unloading task work order entry function on the HMI scheduling and control interface to automatically start allocating the unloading task work orders to the two grab ship unloaders; Step 4: The HMI scheduling and control server receives the status information of the 1# and 2# grab ship unloaders. If both the 1# and 2# grab ship unloaders are in a healthy standby state, the two grab ship unloaders will execute the unloading task work order; Step 5: The HMI scheduling and control server dispatches the respective unloading task work orders to the two grab ship unloaders, and the two grab ship unloaders begin unloading operations according to the task execution order of the assigned unloading task work orders; Step 6: The grab ship unloader performs hatch alignment according to the first task of the ship unloading task work order. The grab ship unloader automatically moves to the target hatch to be operated and performs alignment judgment; Step 7: After the hatch alignment is completed, the grab ship unloader starts the ship unloading operation at the current hatch; Step 8: During the operation, the HMI scheduling and control server counts the unloading operations of the two grab ship unloaders in real time; Step 9: When the HMI scheduling and control server detects that the unloading operation volume of the 1# or 2# grab ship unloader at the hatch corresponding to the current unloading task work order reaches the unloading task volume allocated by the unloading task work order, it is determined that the work order task process of the current hatch is completed, and the grab ship unloader will perform the unloading task of the next hatch in the unloading task work order. For the execution method of the hatch alignment and unloading task, please refer to Step 6 to Step 8; Step 10: Execute the assigned hatch work order tasks in sequence according to the unloading task work order until the unloading operation is completed.

5. The control method of the intelligent dispatching and control system of grab ship unloader according to claim 4 is characterized in that: The alignment determination method is as follows: When S 卸船机 目标舱右 And S 卸船机 >S 目标舱左 When the grab ship unloader is positioned to the target hatch;​ When S 卸船机 >S 目标舱右 When the grab ship unloader is on the right side of the target hatch, it needs to move to the left. The calculation method of the left movement speed V1 is as follows: V1=-(2*a*((S 目标舱右 +S 目标舱左 ) / 2-S 卸船机 )) 0.5 ; When S 卸船机 目标舱左 When , the grab ship unloader is on the left side of the target hatch and needs to move to the right. The calculation method of the right movement speed V2 is as follows:​ V2=(2*a*((S 目标舱右 +S 目标舱左 ) / 2-S 卸船机 )) 0.5 ; Among them S 卸船机 is the real-time position of the grab ship unloader; S 目标舱右 is the right edge position of the target hatch; S 目标舱左 is the left edge position of the target hatch; a is the acceleration of the grab ship unloader trolley mechanism.

6. The control method of the intelligent dispatching and control system of a grab ship unloader according to claim 4 is characterized in that: The statistical method is as follows: W=W 前 +(W 当HO +W 当TR ) / 2; Where: W is the current operating volume statistics of the grab ship unloader; W 前 is the statistical value of the previous cycle operation of the grab ship unloader; W 当HO W is the grab bucket weight value when the current operation cycle is in the closed bucket lifting uniform speed state; 当TR It is the grab bucket weight value when the current operation cycle is in the closed bucket trolley uniform speed state.

7. The control method of the intelligent dispatching and control system of a grab ship unloader according to claim 4 is characterized in that: It also includes the control process of the grab ship unloader intelligent dispatching and control system during operation, when a single grab ship unloader needs to be repaired, exiting the ship unloading operation, and re-entering the ship unloading operation after the repair is completed. Step 1: During the ship unloading operation, the HMI scheduling and control server receives real-time status information of the 1# and 2# grab ship unloaders. When it receives a notification that a grab ship unloader needs to be repaired, the system interrupts the execution of the current work order. Step 2: The grab ship unloader in a faulty state exits the ship unloading operation; Step 3: The HMI scheduling and control server reallocates the unloading tasks of the grab ship unloaders in a healthy state to reallocate the unloading work order tasks; Step 4: The grab ship unloader in a healthy state performs the unloading operation according to the new unloading task order; Step 5: When the HMI scheduling and control server receives the information that the grab ship unloader has completed the fault repair and can be put into unloading operation again, the system interrupts the execution of the current work order; Step 6: The HMI scheduling and control server reallocates the unloading tasks of the two grab ship unloaders based on the execution status of the previous unloading tasks; Step 7: The two grab ship unloaders carry out the unloading operation according to the reallocated unloading task order until the unloading task is completed.

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