Control method for rapid alignment and collision prevention of material yard scraper reclaimer and discharging car

Abstract

The invention relates to a control method for rapid alignment and collision prevention of a scraper reclaimer and a discharging car in a stock yard. The control method comprises the steps that S1, position reference points of the scraper reclaimer and the discharging car are set and automatically aligned, and rail reference points are determined; automatically calibrating the position of the reference point; s2, automatic anti-collision setting of the scraper reclaimer and the unloading vehicle: position signal transmission and integration: acquiring position signals of the scraper reclaimer and the unloading vehicle and a scraper angle value of the scraper reclaimer in real time, outputting the positions of the unloading vehicle and the scraper reclaimer and a scraper angle calculation value through PLCs (Programmable Logic Controller) on respective vehicles, and accessing into a wireless transmission module; the position signal is transmitted to a central control main PLC by using a wireless communication technology; and an anti-collision program is compiled in the central control main PLC system. The method can effectively solve the problem that manual judgment of the relative positions of the stock yard scraper reclaimer and the discharging car is not accurate, so that the two cars collide with each other, automatic linkage of the two cars and rapid alignment of the positions of the cars are achieved, and therefore the authenticity and reliability of position detection are improved.

Description

Technical Field

[0001] This invention relates to the field of industrial automation and intelligent control technology, and in particular to a control method for rapid alignment and collision prevention between a scraper reclaimer and an unloading vehicle in a material yard. Background Technology

[0002] The raw material areas, specifically the ore and coal yards, are typically enclosed C-type yards. Each workshop houses two material storage racks. The coal yard workshop spans approximately 75.5m and is about 580m long. The two material racks are separated by a partition wall. The maximum stack width of a single rack is approximately 29m, and the maximum stack height is approximately 17m. Within each rack, several small grid stacks are arranged at regular intervals to accommodate the storage needs of different coal types. Two stacking conveyor belts and two unloading cars are installed on the platform above the workshop for stacking materials. The conveyor belts are configured with a width of 1400mm, a belt speed of 2m / s, and a capacity of 1200t / h. Two semi-gantry scraper reclaimers (rated reclaiming capacity 700t / h) are installed on the two material racks below. After the reclaimers remove the material, it is output by the conveyor belts. The output conveyor belts are configured with a width of 1200mm, a belt speed of 2m / s, and a capacity of 700t / h. The scraper conveyor and unloading trolley in each material bar are controlled independently. During operation, the scraper often collides with the unloading trolley when the scraper is picking up material, causing production accidents and equipment accidents.

[0003] Problems with the original anti-collision control method: (1) The relative positions of the two vehicles are manually confirmed to determine whether a collision will occur. The material yard is dusty and has low visibility, so visual judgment of the safe distance is prone to errors; the coded position feedback and the actual offset position are prone to deviation, resulting in misjudgment; the operability is low and the labor intensity is high. (2) The encoder needs to be manually adjusted periodically to be aligned, which requires a large amount of manpower and is cumbersome to operate. Summary of the Invention

[0004] To address the aforementioned problems, the present invention aims to provide a control method for rapid alignment and collision prevention between a scraper reclaimer and an unloading trolley in a material yard. This method enables automatic interlocking of the two vehicles and rapid alignment of their positions, improving the accuracy and reliability of position detection. It effectively solves the problem of inaccurate manual judgment of the relative positions of the scraper reclaimer and the unloading trolley in the material yard, which can lead to collisions between the two vehicles.

[0005] The technical solution adopted in this invention is as follows: The present invention proposes a control method for rapid alignment and collision prevention between a scraper reclaimer and an unloading vehicle in a material yard, which specifically includes the following steps: S1. Setting and automatic alignment of reference points for scraper reclaimer and unloading vehicle: S1.1 Determine the orbital reference point; S1.2 Automatic calibration of reference point position; S2. Automatic anti-collision setting between scraper reclaimer and unloading vehicle: S2.1 Position Signal Transmission and Integration: Real-time acquisition of position signals of the scraper reclaimer and unloading vehicle, as well as the scraper angle value of the scraper reclaimer, and output of the calculated position and scraper angle values ​​of the unloading vehicle and scraper reclaimer through the PLC on their respective vehicles to the wireless transmission module; S2.2 Utilize wireless communication technology to transmit position signals to the central control PLC; S2.3. Compile an anti-collision program in the central control main PLC system.

[0006] Furthermore, step S1.1 specifically includes: setting a physical reference point in the middle area of ​​the scraper reclaimer and the unloading vehicle track, and the position of the reference point must meet the following requirement: the scraper of the scraper reclaimer and the unloading vehicle funnel are on the same vertical line.

[0007] Furthermore, step S1.2 specifically includes: setting an automatic alignment proximity switch at the reference point; and writing a control program: that is, when the scraper reclaimer or unloading vehicle moves to the reference point position, the proximity switch sends a trigger signal, and the program automatically outputs the calculated value of the changed position as the reference point position.

[0008] Furthermore, step S2.3 specifically includes: writing a logic judgment program in the host computer of the central control main PLC: a. judging whether the relative position of the two vehicles is less than the safe distance; b. judging whether the scraper angle of the scraper reclaimer is within the collision range; c. judging whether the two vehicles will collide based on the relative position of the two vehicles and the scraper angle of the scraper reclaimer, and outputting a comprehensive logic control command. If a collision is expected, a stop command is output, which is then output by the central control main PLC to the PLCs of the unloading vehicle and the scraper reclaimer for control.

[0009] Compared with the prior art, the present invention has the following advantages: (1) Quick alignment of two vehicles: Add a proximity switch to increase the reference point for the vehicle's running position. When the vehicle runs to the reference point, it will automatically align itself, replacing the manual zeroing of the encoder. (2) Automatic collision avoidance between two vehicles: The position signals of the two vehicles are transmitted to the central control PLC through wireless transmission, and a logic control program is written. The two vehicles are interlocked for collision avoidance control through logic judgment, which replaces the manual confirmation of safe position and manual control operation. Attached Figure Description

[0010] Figure 1 A schematic diagram showing the track reference points for the unloading car and the scraper reclaimer; Figure 2 A schematic diagram of the control program for automatic calibration of the track reference point positions of the unloading car and the scraper reclaimer; Figure 3 This is a schematic diagram of the logic judgment principle of the central control main PLC; Figure 4 This is a schematic diagram illustrating the principle of collision prevention. Detailed Implementation

[0011] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0012] See appendix Figure 1-4 The specific implementation process of the control method for rapid alignment and collision prevention between the scraper reclaimer and the unloading vehicle in the material yard proposed in this invention is as follows: S1. Setting and automatic alignment of reference points for scraper reclaimer and unloading vehicle: S1.1 Determine the orbital reference point: such as Figure 1 As shown, a physical reference point is set at a position 300 meters from the scraper reclaimer and the unloading vehicle track (track range: 0-580m from west to east). The position of this reference point must meet the following requirement: the scraper of the scraper reclaimer and the unloading vehicle funnel are on the same vertical line.

[0013] S1.2 Automatic Calibration of Reference Point Position: An automatic alignment proximity switch is set at the reference point position; a control program is written: when the scraper reclaimer or unloading vehicle travels 300m to the reference point position, the proximity switch sends a trigger signal, and the program automatically outputs the calculated position value of that point as 300m. Figure 2 As shown, this avoids the need for manual adjustment of the encoder to set the position output to 300m.

[0014] The purpose of setting position reference points and automatic alignment is to enable automatic vehicle alignment, ensure the reliability of position detection, and ensure the accuracy of collision avoidance program interval calculation.

[0015] S2. Automatic anti-collision setting between scraper reclaimer and unloading vehicle: S2.1 Position Signal Transmission and Integration: Real-time acquisition of position signals of the scraper reclaimer and unloading vehicle, as well as the scraper angle value of the scraper reclaimer, and output of the calculated position and scraper angle values ​​of the unloading vehicle and scraper reclaimer through the PLC on their respective vehicles to the wireless transmission module; The application of wireless transmission technology is the key to realizing the interconnection between the two vehicles, that is, to enable data communication between the independent scraper reclaimer and the unloading vehicle; S2.2 Utilize wireless communication technology to transmit position signals to the central control PLC; S2.3 Write an anti-collision program in the central control main PLC system: Write a logic judgment program in the central control main PLC host computer: a. Determine if the relative position of the two vehicles is less than the safe distance, such as 30 meters; b. Determine if the scraper angle of the scraper reclaimer is within the collision range, such as 32° < actual angle < 41°; c. Based on the relative position of the two vehicles and the scraper angle of the scraper reclaimer, comprehensively determine whether a collision will occur, and output a comprehensive logic control instruction. If a collision is expected, output a stop instruction, and output it through the central control main PLC to the respective PLCs of the unloading vehicle and the scraper reclaimer for control. Figure 3 As shown.

[0016] Collision avoidance principle: (1) Condition a: Distance judgment, the relative distance between the two vehicles is less than 30 meters, which is the collision zone (whether the scraper reclaimer and the unloading vehicle are in the collision zone): (2) Condition b: Scraper angle judgment, judge whether the scraper angle is within the angle range that will cause a collision, such as the scraper angle of the scraper reclaimer: 33.4 < actual angle < 38.9, then a collision will occur. (3) Comprehensive judgment: When condition a and condition b are both met, it is determined that there is a risk of collision, and a stop command is generated.

[0017] The working principle of this invention is as follows: The large detection deviation between the scraper reclaimer and the unloading vehicle is mainly due to the long travel distance, causing cumulative encoder deviation during their movement. Therefore, to reduce this cumulative deviation, this invention eliminates it through automatic positioning, achieving rapid alignment: The reference point position (0-580m from west to east) at 300 meters on both the scraper reclaimer and unloading vehicle tracks is confirmed. At this position, the scraper of the scraper reclaimer and the unloading vehicle's funnel are aligned, and a proximity switch is installed. A control program is written: when the 300m reference point signal is issued, the program automatically sets the encoder output value to 300m. Therefore, as soon as the vehicle passes the 300m position, alignment is achieved, eliminating the deviation, ensuring detection accuracy, and achieving rapid alignment. Figure 1 and Figure 2 As shown.

[0018] Once the two vehicles are quickly aligned, a collision avoidance control program can be designed based on their conditions and the collision scenario. This program transforms the independent control of the two vehicles into interlocked control. The logic control principle is as follows: Figure 3 As shown, the specific implementation steps are as follows: (1) Transmit the position of the scraper reclaimer and the unloading vehicle and the scraper angle of the scraper reclaimer to the central control PLC: Transmit the position information of the two vehicles to the vehicle body PLC respectively, and use wireless communication technology to transmit the position signal to the central control PLC (PLC4 of ER3). (2) Write a logic judgment program in the host computer of the central control PLC: a. Determine whether the relative position of the two vehicles is less than 30m; b. Determine whether the scraper angle of the scraper is within the collision range: 33° < actual angle < 41° (3# scraper); c. Based on the relative position of the two vehicles and the scraper angle of the scraper, determine whether the two vehicles will collide, and output a comprehensive logic control instruction. If a collision will occur, output a stop instruction, and output the control to the unloading vehicle and the scraper take-up machine PLC through the central control PLC.

[0019] By repeatedly testing the collision angle of each scraper reclaimer, the final collision angle range is obtained, which facilitates the setting of program control parameters.

[0020] All matters not covered in this invention are common knowledge.

[0021] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A control method for rapid alignment and collision prevention between a scraper reclaimer and an unloading vehicle in a material yard, characterized in that, The method includes the following steps: S1. Setting and automatic alignment of reference points for scraper reclaimer and unloading vehicle: S1.1 Determine the orbital reference point; S1.2 Automatic calibration of reference point position; S2. Automatic anti-collision setting between scraper reclaimer and unloading vehicle: S2.1 Position Signal Transmission and Integration: Real-time acquisition of position signals of the scraper reclaimer and unloading vehicle, as well as the scraper angle value of the scraper reclaimer, and output of the calculated position and scraper angle values ​​of the unloading vehicle and scraper reclaimer through the PLC on their respective vehicles to the wireless transmission module; S2.2 Utilize wireless communication technology to transmit position signals to the central control PLC; S2.

3. Compile an anti-collision program in the central control main PLC system.

2. The control method for rapid alignment and collision prevention between a scraper reclaimer and an unloading vehicle in a material yard, as described in claim 1, is characterized in that: Step S1.1 specifically includes: setting a physical reference point in the middle area of ​​the scraper reclaimer and the unloading vehicle track, and the position of the reference point must meet the following requirements: the scraper of the scraper reclaimer and the unloading vehicle funnel are on the same vertical line.

3. The control method for rapid alignment and collision prevention between a scraper reclaimer and an unloading vehicle in a material yard, as described in claim 2, is characterized in that: Step S1.2 specifically includes: setting an automatic alignment proximity switch at the reference point; writing a control program: that is, when the scraper reclaimer or unloading vehicle runs to the reference point position, the proximity switch sends a trigger signal, and the program automatically outputs the calculated value of the changed position as the reference point position.

4. The control method for rapid alignment and collision prevention between a scraper reclaimer and an unloading vehicle in a material yard, as described in claim 1, is characterized in that: Step S2.3 specifically includes: writing a logic judgment program in the host computer of the central control main PLC: a. judging whether the relative position of the two vehicles is less than the safe distance; b. judging whether the scraper angle of the scraper reclaimer is within the collision range; c. judging whether the two vehicles will collide based on the relative position of the two vehicles and the scraper angle of the scraper reclaimer, and outputting a comprehensive logic control instruction. If a collision is expected, a stop instruction is output, which is then output by the central control main PLC to the PLCs of the unloading vehicle and the scraper reclaimer for control.

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