Unattended port remote control system for clinker screw conveyor

Abstract

The application discloses an unattended clinker screw conveyor port remote control system, which comprises a conveyor, wherein the conveyor comprises a base column, a vertical screw conveying pipe and a material taking head; a detection device is arranged at the end position of the vertical screw conveying pipe; the detection device comprises a visual detection device and a laser ranging device matched with the visual detection device; the base column, the horizontal screw conveying pipe, the vertical screw conveying pipe and the material taking head are respectively provided with position sensors; the horizontal swing driving device, the horizontal rotation driving device, the vertical rotation driving device and the material taking swing driving device are respectively provided with first rotary encoders; the cloud platform is provided with a three-dimensional model corresponding to the base column, the horizontal screw conveying pipe, the vertical screw conveying pipe and the material taking head; the deformation change of the material three-dimensional virtual model is generated according to the material three-dimensional virtual model and the conveying efficiency of the material taking head, so as to adjust the three-dimensional pose of the material taking head.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of automated port equipment, in particular to a remote control system for unmanned clinker screw conveyor port. BACKGROUND

[0002] The port clinker conveyor is generally mainly used to realize the conveying of bulk materials, but with the development of automated equipment, it is also applied to large-volume equipment. The key to unmanned operation lies in the real-time of the machine and the stable feeding of the clinker screw conveyor during the conveying process. The key point is:

[0003] 1. How to remotely identify and control the material when unmanned;

[0004] 2. How to ensure safe transportation and control when the machine is delayed;

[0005] 3. How to realize remote control between the clinker conveyor and the cloud platform, and realize the precise control of the operator;

[0006] 4. The material is mainly clinker, so it is in granular form (such as cement, sand, etc.), so the change of the material pile is in arc shape (flowing sand change), which is a non-standard change. Therefore, how to realize automatic material searching is also one of the key points of the design. The existing method generally uses a position sensor to realize the relative distance between the material taking head and the material, and then the material taking head is inserted into the material pile. However, when the depth of the material taking head is greater than the predetermined value, it is easy to cause the material to be unable to be conveyed (too much resistance) or the material to be conveyed to be clumped (resulting in idling), thereby affecting the conveying efficiency;

[0007] Therefore, how to detect the material pile and then adjust the position of the material taking head in time is the key point of automatic feeding. SUMMARY

[0008] The main purpose of the present application is to provide a remote control system for unmanned clinker screw conveyor port, which can realize unmanned clinker screw conveying through limited machine permissions, reduce human operation during conveying, and improve work efficiency.

[0009] The unmanned operation is limited to unmanned operation during conveying, reduces the redundant time of monitoring, and ensures the work efficiency.

[0010] In the actual operation initial segment and the control of the permission is mainly by manual operation, and the unmanned operation mainly plans the path automatically through the change of the material of the screw conveyor.

[0011] To achieve the above purpose, the present application provides a remote control system for unmanned clinker screw conveyor port, which comprises a conveyor,

[0012] The conveyor comprises:

[0013] a base column, a horizontal spiral conveying pipe is pivotally installed at the top end of the base column, the top end of the base column is provided with a horizontal swing driving device for driving the horizontal spiral conveying pipe to horizontally rotate,

[0014] a horizontal spiral conveying pipe is pivotally installed at the top end of the base column, the top end of the base column is provided with a horizontal swing driving device for driving the horizontal spiral conveying pipe to horizontally rotate,

[0015] a vertical spiral conveying pipe, the top end of the vertical spiral conveying pipe is swingably installed at the end of the horizontal spiral conveying pipe, the base column and the horizontal spiral conveying pipe are provided with a vertical swing driving device for driving the vertical spiral conveying pipe to swing,

[0016] the vertical spiral conveying pipe is provided with a spiral conveying shaft arranged in rotation, and the rear end of the vertical spiral conveying pipe is provided with a vertical rotation driving device for driving the spiral conveying shaft to rotate;

[0017] a material taking head, the material taking head is swingably arranged at the end of the vertical spiral conveying pipe, the vertical spiral conveying pipe is provided with a material taking swing driving device for driving the material taking head to swing, and the material taking head is provided with a material taking rotation driving device for driving a material taking shaft to rotate;

[0018] a detection device, the detection device is arranged at the end of the vertical spiral conveying pipe, the detection device comprises a visual detection device and a laser ranging device matched with the visual detection device,

[0019] the base column, the horizontal spiral conveying pipe, the vertical spiral conveying pipe and the material taking head are respectively provided with a position sensor,

[0020] the horizontal swing driving device, the horizontal rotation driving device, the vertical rotation driving device and the material taking swing driving device are respectively provided with a first rotary encoder;

[0021] a cloud platform, the cloud platform is provided with a three-dimensional model corresponding to the base column, the horizontal spiral conveying pipe, the vertical spiral conveying pipe and the material taking head,

[0022] the three-dimensional model acquires the three-dimensional pose of the conveyor through the position sensor and the first rotary encoder;

[0023] a fitting three-dimensional surface, the fitting three-dimensional surface firstly acquires image data within a predetermined range of the material taking head through the visual detection device, and then marks convex and concave images through the image data,

[0024] Then the laser ranging device respectively measures the convex surface and the concave surface and obtains the first position and the second position, and generates a three-dimensional virtual model of the material through image data and the relative distance between the first position and the second position,

[0025] And through the conveying efficiency of the material by the material taking head, the deformation change of the three-dimensional virtual model of the material is generated, and the three-dimensional pose of the material taking head is adjusted.

[0026] The present application has the following advantages:

[0027] 1. The first rotary encoder and position sensor are arranged on each mechanism of the conveyor, so that the relative positions of the horizontal spiral conveying pipe, the vertical spiral conveying pipe and the material taking head can be accurately obtained,

[0028] The three-dimensional pose (Xn, Yn, Zn) of the material taking head is adjusted by adjusting the relative positions of the mechanisms, and at least two sets of relative position monitoring devices are used in the other mechanisms to reduce the problem of collision of the material taking head, improve the safety of the conveyor, and improve the use safety,

[0029] At the same time, when a fault occurs, the pose can be accurately adjusted or the work can be stopped, thereby improving the stability of automatic work;

[0030] 2. A proportional three-dimensional model is arranged on the cloud platform, so that the virtual position of the conveyor can be clearly obtained in the computer operation room,

[0031] Among them, in order to save the load of calculation power, the operation of the conveyor can be manually operated, and the main material conveying is selected by the three-dimensional virtual model of the material on the cloud platform, so as to reduce the real-time operation of manual operation and reduce the problem of manual monitoring, and realize unattended material taking;

[0032] 3. Unlike existing designs, existing single laser ranging generation models require the collection of more data, so the corresponding calculation amount of the cloud platform is large, which has a large hysteresis for industrial production, affects the production stability, and the data cannot be changed according to the actual demand;

[0033] 4. The cloud platform can obtain the best material taking position according to the change of the three-dimensional virtual model of the material, thereby improving the efficiency and reducing the manual intervention, and realizing unattended material taking;

[0034] 5. Compared with the three-dimensional scanning device, the equipment cost is lower, and the fault tolerance is lower. The existing three-dimensional scanning device has a high cost, and its damage rate is high in industrial application, mainly using high-precision lenses,

[0035] The laser ranging device and the visual detection device can be selected according to the volume of the material pile, and compared with the three-dimensional scanning device, the laser ranging device and the visual detection device are more power-saving, and the stability of the material change can be improved by monitoring the material change through the rotation network. BRIEF DESCRIPTION OF DRAWINGS

[0036] Figure 1 is a schematic diagram of a conveyor;

[0037] Figure 2 is a schematic diagram of a material planar image;

[0038] Figure 3 is a sectional view of a fitted material three-dimensional virtual model;

[0039] Figure 4 is a schematic diagram of a virtual fence;

[0040] Figure 5 is a block diagram of the present application.

[0041] In the drawings,

[0042] 1 is a base column, 11 is a horizontal spiral conveying pipe, 12 is a vertical spiral conveying pipe, and 13 is a material taking head.

[0043] 21 is a first position, and 22 is a second position. DETAILED DESCRIPTION

[0044] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0045] It should be noted that if the embodiments of the present application involve directional indications (such as up, down, left, right, front, back, top, bottom, inside, outside, vertical, horizontal, longitudinal, counterclockwise, clockwise, circumferential, radial, axial, etc.), the directional indications are only used to explain the relative positional relationship, movement condition, etc. between the components in a certain posture (as shown in the drawings), and if the certain posture changes, the directional indications also change accordingly.

[0046] In addition, if the description of "first" or "second" and the like is involved in the embodiments of the present application, the description of "first" or "second" and the like is only for the purpose of description, and cannot be understood as indicating or implying the relative importance of the indicated technical features or implicitly indicating the number of the indicated technical features. Therefore, the features limited by "first", "second" can be explicitly or implicitly included at least one of the features. In addition, the technical solutions of various embodiments can be combined with each other, but it must be based on the realization of ordinary skilled in the art, when the combination of technical solutions appears contradictory or unachievable, it should be considered that the combination of technical solutions does not exist, also not within the protection scope required by the present application.

[0047] As shown in Figures 1 to 5 A kind of unattended clinker screw conveyor port remote control system, including conveyor,

[0048] The conveyor includes:

[0049] Base column 1, the top end of the base column 1 is pivotally installed with horizontal spiral conveying pipe 11, the top end of the base column 1 is equipped with horizontal swing drive device driving horizontal spiral conveying pipe 11 horizontal rotation,

[0050] Horizontal spiral conveying pipe 11 is equipped with horizontally arranged horizontal spiral blade shaft, the rear end of horizontal spiral conveying pipe 11 is equipped with horizontal rotation drive device driving horizontal spiral blade shaft rotation;

[0051] Vertical spiral conveying pipe, the top end of the vertical spiral conveying pipe is swingly installed at the end of horizontal spiral conveying pipe 11, the base column 1 and horizontal spiral conveying pipe 11 are equipped with vertical swing drive device driving vertical spiral conveying pipe swing,

[0052] The vertical spiral conveying pipe is equipped with rotationally arranged spiral conveying shaft, and the rear end of the vertical spiral conveying pipe is equipped with vertical rotation drive device driving the spiral conveying shaft rotation;

[0053] Material taking head, the material taking head is swingly arranged at the end of the vertical spiral conveying pipe, the vertical spiral conveying pipe is equipped with material taking swing drive device driving the material taking head swing, and the material taking head is equipped with material taking rotation drive device driving the material taking shaft rotation;

[0054] Detection device, the detection device is arranged at the end of the vertical spiral conveying pipe, and the detection device includes visual detection device and laser ranging device matched with the visual detection device,

[0055] The base column 1, the horizontal spiral conveying pipe 11, the vertical spiral conveying pipe and the material taking head are respectively equipped with position sensor,

[0056] The horizontal swing driving device, the horizontal rotation driving device, the vertical rotation driving device and the material taking swing driving device are respectively provided with a first rotary encoder;

[0057] The cloud platform is provided with a three-dimensional model corresponding to the base column 1, the horizontal spiral conveying pipe 11, the vertical spiral conveying pipe and the material taking head,

[0058] The three-dimensional model obtains the three-dimensional pose of the conveyor through the position sensor and the first rotary encoder;

[0059] The fitting three-dimensional surface firstly obtains image data in a predetermined range of the material taking head through the visual detection device, and then marks the convex surface and the concave surface image through the image data,

[0060] Then the laser ranging device ranges the convex surface and the concave surface respectively and obtains the first position and the second position, and generates a material three-dimensional virtual model through the image data and the relative distance between the first position and the second position,

[0061] And through the conveying efficiency of the material taking head to the material three-dimensional virtual model, the deformation change of the material three-dimensional virtual model is generated, and the three-dimensional pose of the material taking head is adjusted.

[0062] The application has the following advantages:

[0063] 1. The first rotary encoder and the position sensor are arranged on each mechanism of the conveyor, so that the relative positions of the horizontal spiral conveying pipe 11, the vertical spiral conveying pipe and the material taking head can be accurately obtained,

[0064] The three-dimensional pose (Xn, Yn, Zn) of the material taking head is adjusted by adjusting the relative positions of the mechanisms, and at least two sets of relative position monitoring devices are used in the other mechanisms to reduce the problem of collision of the material taking head, improve the safety of the conveyor and improve the use safety,

[0065] At the same time, when a fault occurs, the pose can be accurately adjusted or the work can be stopped, thereby improving the stability of automatic work;

[0066] 2. A proportional three-dimensional model is arranged on the cloud platform, so that the virtual position of the conveyor can be clearly obtained in the computer operation room,

[0067] In order to save the load of calculation, the operation of the conveyor can be manually operated, the main material conveying is selected through the material three-dimensional virtual model of the cloud platform, the predetermined material taking position is selected, the real-time operation of the manual operation is reduced, the problem of manual monitoring is reduced, and the material taking is realized without manual operation;

[0068] 3. Unlike existing designs, which use a single laser ranging generation model and require the collection of a large amount of data, the corresponding cloud platform has a large computational load, which will cause a significant lag in industrial production and affect production stability. At the same time, the data cannot be changed according to actual needs.

[0069] 4. The cloud platform can obtain the optimal material picking position based on the changes in the three-dimensional virtual model of the material, thereby improving efficiency, reducing manual intervention, and realizing unattended material picking.

[0070] 5. Compared to 3D scanning devices, it has lower equipment costs but also lower fault tolerance. Existing 3D scanning devices are expensive and have a high failure rate in industrial applications, primarily due to the use of high-precision lenses.

[0071] Laser rangefinders and vision inspection devices can be selected based on the volume of the material pile. They are also more energy-efficient than 3D scanning devices, and the stability of material changes can be improved by monitoring material changes through rotation nets.

[0072] The additional visual inspection device and laser inspection device are set on the horizontal spiral conveyor pipe 11 to reduce interference from external objects and improve the stability of inspection. It is a good reference model for this type of large machinery, which can realize both position detection and material detection, while minimizing interference from external objects.

[0073] In an embodiment of the invention,

[0074] The material is granular or powdered.

[0075] The transition between the convex and concave surfaces, which is defined by an arc shape, is called an inclined surface.

[0076] During the image data forming process, the inclined plane directly fits the three-dimensional model with the shortest distance between the convex and concave surfaces, thereby reducing the complexity of calculations. Furthermore, by monitoring changes in the material in real time, the relative position of the material receiving head can be adjusted in real time.

[0077] In the embodiments of the invention, the cloud platform obtains the material range through a visual inspection device and a laser rangefinder or through a position sensor before picking up the material.

[0078] The cloud platform generates a virtual location fence based on the material range. The virtual location fence is used to limit the maximum range of movement of the horizontal spiral conveyor pipe 11, the vertical spiral conveyor pipe, and the material picker head.

[0079] In an embodiment of the invention, the process of generating the three-dimensional virtual model of the material includes:

[0080] Step one: the visual detection device obtains image data within a predetermined range, which is pixelated and generates a coordinate system (Xi, Yi);

[0081] Step two: filter the color of the image data through a filter, then label the convex and concave surfaces respectively,

[0082] Mark the first and second positions one by one through the image contrast data filtered by the filter,

[0083] Wherein the second position of the concave surface is annularly arranged, and the second position of the convex surface is distributed in a dot or block shape;

[0084] Step three: the laser ranging device measures the distance of the first position to obtain the first distance Z1i, and obtains multiple positions of the second position and the second distance Z2i,

[0085] Step four, generate a fitting modeling three-dimensional model by rotation network (rotationnet) from the coordinate system (Xi, Yi), the first distance Z1i and the second distance Z2i.

[0086] Wherein the rotation network (rotationnet) is a prior art, in addition to extracting view features, the viewpoint label is also taken as a latent variable, and its pose and object category are jointly estimated, thereby improving the recognition ability of the 3D model to a certain extent, and the change of the material can be obtained through simple operation.

[0087] In the embodiment of the application, when the color of the material or the particles of the material are different, the visual detection device applies a filter to the image data,

[0088] The filter is a color filter, and the convex and concave surfaces are developed after filtering by the filter. In different materials, the reflectivity and density are different, so the presentation of the product in the image data is also different.

[0089] In the embodiment of the application, the horizontal rotation driving device, the vertical rotation driving device and the material taking rotation device are respectively provided with a second rotary encoder,

[0090] When the second rotary encoder detects that the number of rotations of the predetermined rotation driving device is less than the predetermined number of rotations,

[0091] The predetermined material is blocked or the load is less than the predetermined value;

[0092] When the second rotary encoder detects that the number of rotations of the predetermined rotation driving device is greater than the predetermined number of rotations, the predetermined shaft is idling or the conveying amount of the material is less than the predetermined value,

[0093] Then the cloud platform control monitoring device monitors the position of the material pile,

[0094] Then adjust the relative position of the material taking port.

[0095] In the embodiment of the application, the cloud platform is provided with a material viscosity compensation module, which is used for applying to materials with different densities and feeding back to the second rotary encoder. In the actual material viscosity compensation module, after the conveyor runs for a predetermined time, the predetermined number of rotations of the second rotary encoder is obtained, and the predetermined number of rotations is taken as a predetermined reference value, and a range of the predetermined reference value is set,

[0096] The material viscosity compensation module can be stored.

[0097] In the embodiment of the application, the horizontal rotation driving device, the vertical rotation driving device and the material taking rotation device are respectively provided with vibration sensors, the vibration sensors judge the conveying condition of the material according to the rotation vibration frequency of the conveying shaft, and the data of the vibration sensors and the data of the second rotary encoder are combined to further judge the material condition of the conveying pipeline, thereby improving the working monitoring stability of the conveyor.

[0098] In the embodiment of the application, the path of the material taking head is based on historical data to train a clinker fluidity prediction model, and the material taking path is optimized.

[0099] The prediction model includes a rotation network and a training model, and the prediction model is used to obtain the predetermined material taking position of the inclined plane and the depth of the material taking head.

[0100] In the embodiment of the application, the training model is a decision tree model, and of course, an existing AI model can also be used to select an optimal route, and the clinker fluidity is obtained in combination with the rotation network.

[0101] Specifically, in the actual laser ranging detection, the detection speed can be set according to the density and supportability of the material, and the flow change of the clinker pile can also be obtained through the model.

[0102] The adjustment of the pose is prior art.

[0103] Specifically, the base column 1 can also be provided with a lifting shaft.

[0104] Although the system is unattended, due to industry regulations and safety standards, unattended personnel still serve as instructors,

[0105] In the design, an anti-collision system, an emergency avoidance system and an emergency treatment system are also designed, so as to realize automatic production of the system while ensuring basic safety.

[0106] The above merely describes the preferred embodiments of the present application, and is not intended to limit the patent scope of the present application. Any equivalent structural changes made according to the content of the present application specification and drawings, or direct / indirect application in other related technical fields, are included in the patent protection scope of the present application.

Claims

1. An unmanned port remote control system for a clinker screw conveyor, characterized in that, The conveying machine comprises a base column, a horizontal spiral conveying pipe pivotally mounted at the top end of the base column, a horizontal swing driving device provided at the top end of the base column for driving the horizontal spiral conveying pipe to swing horizontally, a horizontal spiral blade shaft rotatably arranged in the horizontal spiral conveying pipe, a horizontal rotation driving device provided at the rear end of the horizontal spiral conveying pipe for driving the horizontal spiral blade shaft to rotate, a vertical spiral conveying pipe swingably mounted at the end of the horizontal spiral conveying pipe, a vertical swing driving device provided at the base column and the horizontal spiral conveying pipe for driving the vertical spiral conveying pipe to swing, a spiral conveying shaft rotatably arranged in the vertical spiral conveying pipe, a vertical rotation driving device provided at the rear end of the vertical spiral conveying pipe for driving the spiral conveying shaft to rotate, a material taking head swingably arranged at the end of the vertical spiral conveying pipe, a material taking swing driving device provided at the vertical spiral conveying pipe for driving the material taking head to swing, a material taking rotation driving device provided at the material taking head for driving a material taking shaft to rotate, a detection device provided at the end of the vertical spiral conveying pipe, the detection device comprising a visual detection device and a laser ranging device matched with the visual detection device, position sensors respectively provided at the base column, the horizontal spiral conveying pipe, the vertical spiral conveying pipe and the material taking head, first rotary encoders respectively provided at the horizontal swing driving device, the horizontal rotation driving device, the vertical rotation driving device and the material taking swing driving device, a cloud platform provided with a three-dimensional model corresponding to the base column, the horizontal spiral conveying pipe, the vertical spiral conveying pipe and the material taking head, the three-dimensional model acquiring a three-dimensional pose of the conveying machine through the position sensors and the first rotary encoders, a fitting three-dimensional surface firstly acquiring image data within a predetermined range of the material taking head through the visual detection device, then marking a convex surface and a concave surface image through the image data, then the laser ranging device respectively ranging the convex surface and the concave surface to obtain a first position and a second position, and generating a material three-dimensional virtual model through the image data and the relative distance between the first position and the second position, and generating a deformation change of the material three-dimensional virtual model through the material three-dimensional virtual model and the conveying efficiency of the material taking head, and further adjusting the three-dimensional pose of the material taking head.

2. The unmanned clinker spiral conveying machine port remote control system according to claim 1, wherein the material is granular or powdery, the convex surface and the concave surface are defined as an inclined surface through an arc-shaped transition, the inclined surface is directly fitted into a three-dimensional model with the shortest distance between the convex surface and the concave surface during the image data shaping process, the cloud platform acquires a material range through the visual detection device and the laser ranging device before taking the material, or acquires the material range through the position sensor, and the cloud platform generates a virtual position fence through the material range, the virtual position fence being used to limit the maximum activity range of the horizontal spiral conveying pipe, the vertical spiral conveying pipe and the material taking head.

4. The unmanned clinker spiral conveying machine port remote control system according to claim 2, wherein the material three-dimensional virtual model generation process comprises: ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ 3. The unattended port remote control system for a clinker screw conveyor, according to claim 1, characterized in that: ​ ​ ​ ​ Step one: the visual detection device obtains image data within a predetermined range, which is pixelated and generates a coordinate system (Xi, Yi); Step two: filter the color of the image data through a filter, then label the convex and concave surfaces respectively, Through the image contrast data of the filter, the first and second positions are labeled one by one, Wherein the second position of the concave surface is annularly arranged, and the second position of the convex surface is distributed in a dot or block shape; Step three: the laser ranging device measures the distance of the first position to obtain the first distance Z1i, and obtains multiple positions of the second position and the second distance Z2i, Step four: generate a fitting three-dimensional model by rotating the network of the coordinate system (Xi, Yi), the first distance Z1i and the second distance Z2i.

5. The unattended port remote control system for a clinker screw conveyor as claimed in claim 1, characterized in that: When the color of the material or the particles of the material are different, the visual detection device applies a filter to the image data, The filter is a color filter, and the convex and concave surfaces are developed after the filter.

6. The unattended port remote control system for a clinker screw conveyor as claimed in claim 1, characterized in that: The horizontal rotation driving device, the vertical rotation driving device and the material taking rotating device are respectively provided with a second rotary encoder, When the second rotary encoder detects that the number of rotations of the predetermined rotation driving device is less than the predetermined number of rotations, The predetermined material is blocked or loaded; When the second rotary encoder detects that the number of rotations of the predetermined rotation driving device is greater than the predetermined number of rotations, the predetermined shaft is idling or the conveying amount of the material is less than the predetermined value, Then the cloud platform control detection device monitors the position of the material pile, Then adjust the relative material taking position of the material taking port.

7. The unattended port remote control system for a clinker screw conveyor as claimed in claim 1, characterized in that: The cloud platform is provided with a material viscosity compensation module, which is used for different density materials and feedback to the second rotary encoder.

8. The unattended port remote control system for a clinker screw conveyor as claimed in claim 1, characterized in that: The horizontal rotation driving device, the vertical rotation driving device and the material taking rotating device are respectively provided with a vibration sensor, which judges the conveying condition of the material according to the rotation vibration frequency of the conveying shaft.

9. The unattended port remote control system for a clinker screw conveyor, according to claim 4, characterized in that: The path of the material taking head is based on historical data to train a clinker fluidity prediction model to optimize the material taking path, The prediction model includes a rotating network and a training model, which is used to obtain the predetermined material taking position of the inclined surface and the depth of the material taking head.

10. The unattended port remote control system for a clinker screw conveyor, according to claim 9, characterized in that: The training model is a decision tree model.

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