Gantry crane grab bucket and cabin hatch anti-collision system and method

Abstract

The invention relates to the technical field of anti-collision of gantry cranes, in particular to an anti-collision system and method for a grab bucket and a cabin hatch of a gantry crane. Cabin hatch contour data and grab bucket contour data acquired by the laser radar I, the laser radar II and the camera, cabin hatch position data acquired by the camera in real time and cabin height data acquired by the laser radar III are respectively transmitted to the industrial personal computer; the industrial personal computer preprocesses the transmitted data and extracts the position and the size of a cabin hatch; encoder data of each mechanism of the gantry crane and grab bucket operation type data are respectively transmitted to the industrial personal computer through the PLC, and the position of the grab bucket is calculated; the industrial personal computer compares the relative positions of the grab bucket and the cabin hatch and judges the collision risk of the grab bucket and the cabin hatch, and the anti-collision system and method for the grab bucket and the cabin hatch of the gantry crane are good in stability and high in accuracy.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of portal crane anti-collision technology, and particularly relates to a portal crane grab and ship hatch anti-collision system and method. BACKGROUND

[0002] Portal cranes occupy a dominant position in most bulk cargo terminals. Under the current manual unloading mode, production efficiency and safety depend on the experience and proficiency of the driver. In the case of limited operating field of view and long-term high-intensity labor, the probability of collision between the grab and the ship body is significantly increased. Handling collision accidents is usually accompanied by problems such as shutdown and repair compensation, which greatly affects the production operation of the terminal. SUMMARY

[0003] The present application aims to provide a portal crane grab and ship hatch anti-collision system and method to solve the technical problems in the background.

[0004] To achieve the above-mentioned purpose, the technical solution of the present application is as follows:

[0005] A portal crane grab and ship hatch anti-collision system, comprising: a portal crane, a laser radar one, a laser radar two, a laser radar three, a camera, a PLC controller and an industrial computer, the laser radar one, the laser radar two and the camera are used to scan and collect the ship hatch profile data and the portal crane grab profile data in real time, the camera also collects the position data of the ship hatch in real time, the laser radar three is used to collect the height data of the ship hatch, the ship hatch profile data collected by the laser radar one, the laser radar two and the camera, the position data of the ship hatch collected by the camera in real time and the height data of the ship hatch collected by the laser radar three are transmitted to the industrial computer, the industrial computer pre-processes the transmitted data and extracts the position and size of the ship hatch, the encoder data of the hoisting mechanism, the encoder data of the luffing mechanism, the encoder data of the slewing mechanism, the encoder data of the traveling mechanism and the grab operation type data of the portal crane are transmitted to the industrial computer through the PLC controller and the position of the portal crane grab is calculated through the industrial computer, the industrial computer compares the relative position of the portal crane grab and the ship hatch and judges the collision risk of the portal crane grab and the ship hatch.

[0006] Further, the laser radar one and the camera are respectively installed below the driver's room of the portal crane, the laser radar two is installed below the elephant trunk beam of the portal crane, the laser radar three is installed in the middle of the sea survey beam of the portal crane, and the PLC controller and the industrial computer are respectively installed in the driver's room of the portal crane.

[0007] Further, the PLC controller is used to control the lifting, luffing, slewing, traveling and grab opening and closing of the portal crane.

[0008] Further, the grab operation type data includes: empty load or full load.

[0009] A portal crane grab and ship hatch anti-collision method applies a portal crane grab and ship hatch anti-collision system, which specifically includes the following steps:

[0010] Step one, start the anti-collision system;

[0011] Step two, the industrial computer calculates the center position of the portal crane grab according to the lifting mechanism encoder data, luffing mechanism encoder data, slewing mechanism encoder data and traveling mechanism encoder data of the portal crane;

[0012] Step three, the industrial computer processes the portal crane grab contour data collected by laser radar one, laser radar two and camera, and obtains the grab contour point set P grap ;

[0013] Step four, the 3D point cloud data of the ship hatch contour of the transport ship is obtained by scanning and collecting the transport ship hatch contour of the lower working area by laser radar one and laser radar two, then the industrial computer pre-processes the 3D point cloud data, and obtains the ship hatch boundary point set P hatch ;

[0014] Step five, the industrial computer divides the portal crane grab boundary point and the transport ship hatch boundary point by deep learning algorithm, and calculates the shortest distance D min from the portal crane grab boundary point to the transport ship hatch boundary point.

[0015] Step six, set the safety distance threshold d safe and the collision threshold d collsion , compare the shortest distance D min calculated in step five with the safety distance threshold d safe and the collision threshold d collsion , and make state judgment and response.

[0016] Further, in step one, after starting the anti-collision system, the system performs self-checking, and if the self-checking is abnormal, the system issues a fault alarm.

[0017] Further, in step five, the shortest distance D minThe steps are as follows:

[0018] Portal crane grab bucket boundary point p=(x p ,y p ,z p ) and the boundary point of the transport ship's hatch q=(x q ,y q ,z q The Euclidean distance D(q,p) between two nodes is calculated as follows:

[0019]

[0020] Among them, LiDAR 1, LiDAR 2 and LiDAR 3 scan the cabin of the transport ship and establish the world coordinate system, x p 、y p and z p are the coordinate values ​​of the boundary point p of the gantry crane grab bucket in the world coordinate system; q 、y q and z q are the coordinate values ​​of the boundary point q of the transport ship's hatch in the world coordinate system;

[0021]

[0022] Here, |pq| represents the minimum distance between any boundary point p of the portal crane grab bucket and any boundary point q of the transport ship's hatch.

[0023] Furthermore, in step six, the shortest distance D calculated in step five is min and the safety distance threshold d safe and collision threshold d collsion The specific status judgment and response are as follows:

[0024] If D min ≤d collsion , the state judgment is: collision; the response is: system alarm, driver observe carefully;

[0025] If d collsion <D min ≤d safe ,Status judgment is: warning; Response is: system issues a warning, driver observes;

[0026] If D min >d safe , the status is judged as: safe; the response is: continue normal operation.

[0027] Compared with the prior art, the present invention has the following beneficial effects:

[0028] The present application is aimed at the gantry crane which occupies the main loading and unloading position in most bulk cargo terminals, determines the grab state by combining the PLC controller and the camera, determines the grab position by using the lifting mechanism encoder data, the luffing mechanism encoder data, the slewing mechanism encoder data and the traveling mechanism encoder data in the gantry crane, determines the outline and position of the ship hatch by three laser radars, and combines the camera to determine the grab boundary point set and the ship hatch boundary point set, the two detection data are checked with each other, are corrected in real time, and the stability and accuracy of the anti-collision system are improved. BRIEF DESCRIPTION OF DRAWINGS

[0029] Figure 1 is the system block diagram of the gantry crane grab and ship hatch anti-collision system provided by the present application;

[0030] Figure 2 is the installation position schematic diagram of the laser radar one and the camera in the present application;

[0031] Figure 3 is the installation position schematic diagram of the laser radar two in the present application;

[0032] Figure 4 is the installation position schematic diagram of the laser radar three in the present application Figure 1 ;

[0033] Figure 5 is the installation position schematic diagram of the laser radar three in the present application Figure 2 ;

[0034] Figure 6 is the anti-collision system working flow chart in the present application.

[0035] The labels in the drawings are: LA-01-laser radar one, LA-02-laser radar two, LA-03-laser radar three, CA-01-camera. DETAILED DESCRIPTION

[0036] The present application will be further described in detail below in combination with the drawings and examples.

[0037] Reference Figures 1-6As shown, a gantry crane grab and cabin hatch anti-collision system includes: a gantry crane, a laser radar 1, a laser radar 2, a laser radar 3, a camera, a PLC controller and an industrial control computer. The laser radar 1, the laser radar 2 and the camera are used to scan and collect the contour data of the transport ship cabin hatch and the contour data of the gantry crane grab in real time. The camera also collects the position data of the transport ship cabin hatch in real time. The laser radar 3 is used to collect the height data of the transport ship cabin. The transport ship cabin hatch contour data and the gantry crane grab contour data collected by the laser radar 1, the laser radar 2 and the camera, the transport ship cabin hatch position data collected by the camera in real time and the transport ship cabin height data collected by the laser radar 3 are respectively transmitted to the industrial control computer. The industrial control computer preprocesses the transmitted data and extracts the position and size of the transport ship cabin hatch; the purpose of the preprocessing is to as much as possible The PLC controller is used to control the lifting, luffing, slewing, traveling, and grab bucket opening and closing of the gantry crane. The PLC controller transmits the encoder data of the lifting mechanism, luffing mechanism, slewing mechanism, traveling mechanism, and grab bucket operation type data (empty or fully loaded) to the industrial computer via the PLC controller, and the position of the gantry crane grab bucket is calculated by the industrial computer. The anti-collision distance varies depending on whether the grab bucket is empty or fully loaded. The open contour of the grab bucket is the largest when empty, and the closed contour of the grab bucket is the smallest when fully loaded. Therefore, the safe landing range of the grab bucket is calculated according to the different states of the grab bucket. The industrial computer compares the relative position of the gantry crane grab bucket and the hatch of the transport ship's hold and determines the collision risk between the gantry crane grab bucket and the hatch of the transport ship's hold.

[0038] Taking into full consideration the size and swing of the grab bucket, the hatch area is divided into an "U" shape, with the entire hatch range being divided into an internal safety area, an edge deceleration area, and a boundary danger area. Combined with the grab bucket's operation type data, it is determined in real time whether there is a risk of collision between the grab bucket and the cabin hatch during the current operation. If the cabin hatch anti-collision function detects a collision risk between the grab bucket's current position and the cabin hatch position, an alarm signal is transmitted to the PLC controller, which then transmits the alarm signal to the driver's cab touch screen display. The driver checks the current position of the boom based on the alarm information to determine whether there is a collision risk at the current position. If there is a collision risk, the driver controls the boom to a safe position and continues operation to avoid a collision accident.

[0039] Laser radar 1 and camera are respectively installed under the operator's cab of the gantry crane, laser radar 2 is installed under the trunk beam of the gantry crane, laser radar 3 is installed in the middle of the sea survey beam of the gantry crane, and the PLC controller and industrial computer are respectively installed in the operator's cab of the gantry crane.

[0040] A portal crane grab and ship hatch anti-collision method, specifically comprising the following steps:

[0041] Step one, start the anti-collision system; the system performs self-checking, and if the self-checking is abnormal, the system issues a fault alarm;

[0042] Step two, the industrial computer calculates the center position of the portal crane grab according to the lifting mechanism encoder data, the luffing mechanism encoder data, the slewing mechanism encoder data and the traveling mechanism encoder data of the portal crane;

[0043] Step three, the industrial computer processes the portal crane grab contour data collected by the laser radar one, the laser radar two and the camera, and combines the grab operation type data transmitted by the PLC controller to obtain the grab contour point set P grap ;

[0044] Step four, the laser radar one and the laser radar two scan and collect the transport ship hatch contour of the lower working area, obtain the 3D point cloud data of the transport ship hatch, and then the industrial computer pre-processes the 3D point cloud data, and combines the transport ship hatch contour data and position data collected by the camera to obtain the transport ship hatch boundary point set P hatch ;

[0045] Step five, the industrial computer divides the portal crane grab boundary point and the transport ship hatch boundary point by a deep learning algorithm, and calculates the shortest distance D min ;

[0046] The Euclidean distance D(q, p) between the portal crane grab boundary point p=(x p ,y p ,z p ) and the transport ship hatch boundary point q=(x q ,y q ,z q ) is calculated as follows:

[0047]

[0048] Wherein, the laser radar one, the laser radar two and the laser radar three scan the transport ship hatch and establish a world coordinate system, x p , y p and z p are the coordinate values of the portal crane grab boundary point p in the world coordinate system; x q , y q and z q are the coordinate values of the transport ship hatch boundary point q in the world coordinate system;

[0049]

[0050] Wherein, |p-q| represents the minimum distance between any one boundary point p of the grab bucket of the portal crane and any one boundary point q of the hatch of the transport ship.

[0051] Step six, setting a safety distance threshold d safe and a collision threshold d collsion , comparing the shortest distance D min calculated in step five with the safety distance threshold d safe and the collision threshold d collsion , making a state judgment and response:

[0052] If D min ≤ d collsion , the state judgment is collision; the response is that the system alarms and the driver carefully observes.

[0053] If d collsion <D min ≤ d safe , the state judgment is warning; the response is that the system issues a warning and the driver observes.

[0054] If D min >d safe , the state judgment is safe; the response is to continue normal operation.

[0055] In the description of the present application, it should be noted that the terms "upper", "lower", "left", "right", "inner", "outer", "top / bottom end" and the like indicate the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0056] The above is only the preferred embodiment of the present application, and does not limit the present application in any form. Any skilled person in the art, without departing from the scope of the technical solution of the present application, can make any simple modification, equivalent replacement and improvement to the above embodiment according to the technical essence of the present application, and all of the above still belong to the protection scope of the technical solution of the present application.

Claims

1. A portal crane grab bucket and cabin hatch anti-collision system, characterized in that: include: Portal crane, laser radar 1, laser radar 2, laser radar 3, camera, PLC controller and industrial computer, the laser radar 1, laser radar 2 and camera are used to scan and collect the contour data of the transport ship's cabin hatch and the contour data of the portal crane bucket in real time, the camera also collects the position data of the transport ship's cabin hatch in real time, the laser radar 3 is used to collect the height data of the transport ship's cabin, the contour data of the transport ship's cabin hatch and the contour data of the portal crane bucket collected by the laser radar 1, laser radar 2 and camera, the position data of the transport ship's cabin hatch collected by the camera in real time and the laser radar The transport ship height data collected by the three optical radars are transmitted to the industrial computer respectively, and the industrial computer preprocesses the transmitted data and extracts the position and size of the transport ship's cabin hatch; the lifting mechanism encoder data, luffing mechanism encoder data, slewing mechanism encoder data, walking mechanism encoder data and grab bucket operation type data of the gantry crane are respectively transmitted to the industrial computer through the PLC controller, and the position of the portal crane grab bucket is calculated by the industrial computer; the industrial computer compares the relative positions of the portal crane grab bucket and the transport ship's cabin hatch, and determines the collision risk between the portal crane grab bucket and the transport ship's cabin hatch.

2. The portal crane grab bucket and cabin hatch anti-collision system according to claim 1, characterized in that: The laser radar 1 and the camera are respectively installed under the operator's cab of the gantry crane, the laser radar 2 is installed under the trunk beam of the gantry crane, the laser radar 3 is installed in the middle of the sea survey beam of the gantry crane, and the PLC controller and the industrial computer are respectively installed in the operator's cab of the gantry crane.

3. The portal crane grab bucket and cabin hatch anti-collision system according to claim 1, characterized in that: The PLC controller is used to control the lifting, luffing, slewing, traveling and grab opening and closing of the portal crane.

4. The portal crane grab bucket and ship cabin hatch anti-collision system according to claim 1, characterized in that: The grab bucket operation type data includes: empty or full load.

5. A method for preventing a portal crane grab bucket from colliding with a ship cabin hatch, using the system for preventing a portal crane grab bucket from colliding with a ship cabin hatch according to claim 1, characterized in that: The specific steps include: Step 1: Start the anti-collision system; Step 2: The industrial computer calculates the center position of the portal crane grab bucket based on the lifting mechanism encoder data, the luffing mechanism encoder data, the slewing mechanism encoder data, and the traveling mechanism encoder data of the portal crane; Step 3: The industrial computer processes the gantry crane grab bucket contour data collected by the laser radar 1, laser radar 2 and camera and combines it with the grab bucket operation type data transmitted by the PLC controller to obtain the grab bucket contour point set P grap ; Step 4: Scan and collect the outline of the hatch of the transport ship in the lower operating area according to the laser radar 1 and laser radar 2 to obtain the 3D point cloud data of the hatch of the transport ship. Then, the industrial computer pre-processes the 3D point cloud data and combines it with the outline data and position data of the hatch of the transport ship collected by the camera to obtain the boundary point set P of the hatch of the transport ship. hatch ; Step 5: The industrial computer uses a deep learning algorithm to segment the boundary points of the portal crane bucket and the boundary points of the transport ship's hold hatch, and calculates the shortest distance D from the boundary point of the portal crane bucket to the boundary point of the transport ship's hold hatch. min ; Step 6. Set the safety distance threshold d safe and collision threshold d collsion , the shortest distance D calculated in step 5 min and the safety distance threshold d safe and collision threshold d collsion Compare the edges and make status judgment and response.

6. The method for preventing collision between a portal crane grab bucket and a ship cabin hatch according to claim 5, characterized in that: In the step 1, after the anti-collision system is started, the system performs a self-check. If the self-check is abnormal, the system issues a fault alarm.

7. The method for preventing collision between a portal crane grab bucket and a ship cabin hatch according to claim 5, characterized in that: In step 5, the shortest distance D from the boundary point of the gantry crane grab bucket to the boundary point of the transport ship's cabin port is calculated. min The steps are as follows: Portal crane grab bucket boundary point p=(x p ,y p ,z p ) and the boundary point of the transport ship's hatch q=(x q ,y q ,z q The Euclidean distance D(q,p) between two nodes is calculated as follows: Among them, LiDAR 1, LiDAR 2 and LiDAR 3 scan the cabin of the transport ship and establish the world coordinate system, x p 、y p and z p are the coordinate values ​​of the boundary point p of the gantry crane grab bucket in the world coordinate system; q 、y q and z q are the coordinate values ​​of the boundary point q of the transport ship's hatch in the world coordinate system; Here, |pq| represents the minimum distance between any boundary point p of the portal crane grab bucket and any boundary point q of the transport ship's hatch.

8. The method for preventing collision between a portal crane grab bucket and a ship cabin hatch according to claim 7, characterized in that: In step six, the shortest distance D calculated in step five is min and the safety distance threshold d safe and collision threshold d collsion The specific status judgment and response are as follows: If D min ≤d collsion , the state judgment is: collision; the response is: system alarm, driver observe carefully; If d collsion <D min ≤d safe ,Status judgment is: warning; Response is: system issues a warning, driver observes; If D min >d safe , the status is judged as: safe; the response is: continue normal operation.

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