Loading and unloading process for bulk-to-container manufacturing box

Abstract

The invention discloses a bulk-to-container manufacturing box loading and unloading process, the loading and unloading process comprises a container truck, a box body and working steps, the container truck is used for transporting raw materials among the working steps of the loading and unloading process, the container truck comprises a lifting module, and the lifting module is used for lifting the box body to be in a vertical shape; the working steps are as follows: S1, establishing a working process of the TOS system; s2, dividing the plurality of working nodes into a box lifting / returning operation process, a box checking operation process, a lifting operation process of a hydraulic lifting vehicle, a box manufacturing and discharging operation process, a box door closing operation process and a lowering operation process of the hydraulic lifting vehicle; and S3, combining the instruction terminals with the working ranges of the overlapped areas under the working nodes. According to the invention, the lifting module is designed and is matched with the flow process, so that the original feeding means is further improved, and the effect of increasing the box making working efficiency is achieved in a semi-automatic feeding system under the condition that the original box body is not changed.

Description

Technical Field

[0001] This invention relates to the field of port transportation, and in particular to a bulk-to-container loading and unloading process. Background Technology

[0002] Bulk-to-container conversion is an abbreviation for the conversion of bulk cargo to containerized transport. It is an important transformation of transportation mode in the logistics and transportation field. It refers to the mode of transporting goods that were originally transported in bulk (such as unpackaged direct loading, bulk in trucks / rail cars / ship holds, etc.) in a way that is now transported in standardized containers. Containers have strong sealing properties, which can reduce the damage to goods caused by wind, rain, dust, and collisions during bulk transportation, such as grain getting damp and ore scattering.

[0003] Bulk-to-container conversion is an important technology for green and environmentally friendly coal transportation at ports and a crucial mode of coal transportation by vehicle. During the container loading and unloading process, each container requires manual unloading by the operator once.

[0004] However, repetitive manual feeding operations cannot significantly improve box-making efficiency. Moreover, the frequent operation can easily lead to operator fatigue and errors, posing both safety and environmental risks. At the same time, the increased number of people required for each work node also increases labor costs. Therefore, improving work efficiency and increasing the cost-effectiveness of the production line is the current trend of technological development. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to overcome the defects of the prior art and provide a bulk-to-container loading and unloading process, which mainly solves the technical problems of low efficiency and low safety of the existing bulk-to-container loading and unloading process.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: This invention provides a bulk-to-container loading and unloading process, the specific steps of which are as follows: S1. Establish the workflow of the TOS system, which includes multiple work nodes and production processes. Based on the TOS system, there are multiple command terminals adapted to multiple work nodes. The multiple command terminals are used to receive and return work node information. S2. Divide multiple work nodes into: container lifting / returning operation process, container inspection operation process, hydraulic lifting vehicle lifting operation process, container making and unloading operation process, container closing operation process, and hydraulic lifting vehicle lowering operation process; complete the container making and unloading process of bulk to container conversion according to the above work node sequence. A container truck and a container body are used to transport raw materials between multiple work nodes. The container truck includes a lifting module for lifting the container body vertically. S3. Merge instruction terminals with overlapping work areas under work nodes, and set up automated production lines for processes other than work nodes in the workflow, thereby reducing the number of personnel and improving work efficiency.

[0007] Preferably, the box making and unloading operation process is located in the material preparation workshop, which includes a driveway, a conveyor belt, a material drop port area, a 3D scanner, a lifting operation box and a container truck power line. A material stacking area is also set up around the material preparation workshop. The command terminal includes a first command terminal to a fourth command terminal, wherein the fourth command terminal is located in the material drop port area.

[0008] Preferably, the container pick-up / return operation process includes: S201. According to the workflow of the TOS system, the first instruction terminal is located on the container truck, and the container truck enters the designated location to pick up the container by following the instructions. S202. The second command terminal is located at the rail-mounted gantry crane. The rail-mounted gantry crane lifts the container of the specified container number from the designated position to the container truck and feeds back to the first command terminal. The first command terminal and the second command terminal simultaneously confirm the information with the TOS system. If the container truck already has a container, the rail-mounted gantry crane records the information of the existing container and sends it to the TOS system. After lifting out the existing container, it replaces it with a container of the specified container number. S203. The cargo handling module under the TOS system records the container number information and binds it to the container truck information.

[0009] Preferably, the box inspection procedure includes: S211. When the container truck enters the inspection point area, the holder of the first command terminal leaves the container truck and walks around to check the integrity of the container, while recording the information and feeding it back to the TOS system. S212. The third command terminal is located in the container inspection area. The holder of the third command terminal checks the overall quality of the container and the cleanliness of the inside of the container. When the verification is correct, the holder of the third command terminal opens the container door and fixes it to the locked area in the open position. At the same time, the lead seal information is scanned to the TOS system, and the TOS system binds the lead seal, truck and container number information of the container a second time. If the verification is incorrect, the third command terminal will send feedback to the TOS system, and the TOS system will reassign the container to the first command terminal. At this time, the truck will return to step S201.

[0010] Preferably, the lifting operation procedure of the hydraulic lift vehicle includes: S221. The container truck enters the lane of the container manufacturing workshop and connects the lifting module of the container truck to the lifting operation box and power line. The lifting module forms the container body at a vertical angle with the open container door facing upwards, and the container door is directly facing the material drop area. S222. During the lifting module's workflow, the holder of the first command terminal confirms whether the lifting process interferes with the upper equipment in the material preparation workshop. If no interference occurs, feedback is sent to the fourth command terminal after the lifting module stops. If interference occurs, the emergency stop button located in the lifting operation box is pressed, and feedback is sent to the TOS system, which then provides a corresponding solution to the holder of the first command terminal.

[0011] Preferably, the box-making and material-discharging operation process includes: S231. The material drop section of the lane includes the material drop point and the walking area. The holder of the fourth command terminal is located in the walking area to observe the lifting status of the box. The S232.TOS system's production management system is based on automated CTOS. It selects the box-making mode corresponding to the box for operation. Before the material unloading process, the 3D scanner detects the lifting of the box in the lane in real time. After the 3D scanner confirms that the box has been lifted into place, it transmits information to the bulk-to-container control cabinet inside the box-making workshop. The bulk-to-container control cabinet simultaneously links the flip-up plate and dust baffle at the conveyor belt to switch. Then, the unloading point continuously unloads material from the opened box door. S233. After the material feeding process is completed, the conveyor belt flap switches to the other side, and the TOS system outputs a reminder to the fourth instruction terminal.

[0012] Preferably, the closing door operation procedure includes: S241. The fourth instruction terminal holder confirms the completion of the container manufacturing report to the TOS system, lowers the folding ladder to the container closing platform in the walking area, then removes the lead seal from the container door, locks it, and closes the container door. Finally, the holder returns to the walking area and puts away the folding ladder.

[0013] Preferably, the lifting module includes: The power source includes a hydraulic mechanism and an electric motor for driving the hydraulic mechanism; The sockets are located on both sides of the container truck and are used to connect the lifting control box and the container truck's power cord. The lifting control box contains a PLC controller. The control system includes distributed slave stations, actuators, and feedback mechanisms located on the truck, and is communicatively connected to the lifting control box.

[0014] Preferably, there are at least four lanes in step S221, and the fourth instruction terminals of every two lanes are combined into one; the TOS system is mounted in the system host, and the system host further includes: a data storage module, a timing unit and a processing scheme unit.

[0015] Preferably, the working steps further include: S4. Container unloading and loading process. The transportation routes include: ship, rail crane, container truck, forklift and stacking area. The workflow is formulated based on the actual transportation route and the transportation plan stored in the data storage module of the TOS system.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This invention, by incorporating a lifting module and working in conjunction with the process of this invention, further improves the original feeding method, thereby increasing the efficiency of box making in a semi-automatic feeding system without altering the original box body.

[0017] 2. This invention also optimizes the box-making process, forming multiple process node schemes for the work steps, and determines the required staff according to the necessary nodes. By combining the efficiency of container trucks, it realizes the allocation of staff and the merging of positions, enabling fewer staff to complete the merging of positions with overlapping coverage within the same scope. Furthermore, it can expand the number of positions when necessary, preventing the waste of manpower. Attached Figure Description

[0018] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the system modules in an embodiment; Figure 2 This is a flowchart of the working steps of the embodiment; Figure 3 This is a schematic diagram of the hourly work efficiency within a week in an embodiment; Figure 4 This is a schematic diagram of the lifting module system in an embodiment; Figure 5 This is a schematic diagram of the lifting module circuit connection in an embodiment. Detailed Implementation

[0019] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0020] In the first embodiment, as Figure 1-2 As shown, the present invention provides a bulk-to-container loading and unloading process. The loading and unloading process includes specific working steps, and the working steps also include working nodes. The container trucks in the working steps are used to transport raw materials between multiple working nodes. The container trucks include lifting modules, and the lifting modules are used to lift the container body vertically. The lifting module uses the truck's own frame, which is used to support the box, and the hydraulic support structure to form a fulcrum by descending vertically at the rear. At the same time, the frame is rotated 90 degrees around the top of the fulcrum, and the box is rotated as well until the box is in a vertical state. Before the box is rotated, it is fixed to the frame by locks. There is no door at the rear of the box. After the box is rotated, the rear of the box falls directly to the ground. The circuit connection diagram of its lifting module is as follows: Figure 4 As shown, the detailed operation process is as follows: 1. Park the container truck with the container door open in the driveway of the material preparation workshop (the position must be correct). 2. The truck driver gets out of the truck and connects the main power and control power plugs of the lifting module to the socket (the indicator light will light up when the plugs are in place). 3. Start the oil pump motor remotely or manually (or start automatically after a 10-second delay). 4. Automatic locking of the lock (when the buckle lock of the frame is in the unlocked state, the locking command is triggered to fix the box to the frame, and the box will be flipped after the frame is flipped). 5. The outrigger lifting mechanism extends automatically (the action stops when it reaches the limit). 6. Hydraulic cylinder lifting action (the action stops when the cylinder reaches the limit); 7. The housing is raised to the correct position (the oil pump automatically stops to prevent malfunction). 8. Workers close the box door and apply lead seals, then close the box door securely; 9. Loading and unloading workers can remotely or manually operate the main hydraulic cylinder to lower (the action stops when it reaches the limit, or it enters the automatic lowering program after 10 seconds of descent). 10. Automatic lock unlocking (the lock on the cabinet is in the locked state, and the unlocking command is triggered at this time); 11. The outrigger lifting mechanism retracts (the retraction stops when it reaches the limit). 12. Place the box in place (the oil pump will automatically stop running); 13. The truck driver unplugs the main power and control power plugs; 14. The truck driver gets on the truck, starts the engine, and drives away.

[0021] Furthermore, the specific working steps are as follows: S1. Establish the workflow of the TOS system, which includes multiple work nodes and production processes. Based on the TOS system, there are multiple command terminals adapted to multiple work nodes. The multiple command terminals are used to receive and return work node information. The TOS system is operated by the central control operator, who adjusts the production process or issues commands to multiple work nodes according to the actual situation. S2. Divide multiple work nodes into: container lifting / returning operation process, container inspection operation process, hydraulic lifting vehicle lifting operation process, container making and unloading operation process, container closing operation process, and hydraulic lifting vehicle lowering operation process. Complete the container making and unloading process of bulk to container conversion according to the above work node sequence. A container truck and a container body are used to transport raw materials between multiple work nodes. The container truck includes a lifting module for lifting the container body vertically. S3. Merge instruction terminals with overlapping work areas under work nodes, and set up automated production lines for processes other than work nodes in the workflow to reduce the number of personnel and improve work efficiency. Since the loading and unloading process is set up in a unified manner, the target locations of the work need to be divided when the workflow is formulated. According to the steps of S1, the work nodes are divided in the TOS system according to the actual work sequence, and corresponding command terminals are assigned to the work nodes. In S2, the work nodes are further refined. The workflows here are all necessary sequential workflows for the centralized modification. Other work nodes can be added as needed, such as sampling processes or on-site testing. Finally, in S3, the overall workflow is further optimized, allowing the same command terminals within the work scope to be merged to reduce the number of personnel. When working in conjunction with the aforementioned lifting module, it also aligns with the purpose of setting up automated production lines for processes other than work nodes in this step. This allows conventional packing processes, such as using telescopic belts and telescopic chutes, as well as loaders and hoppers, to automatically drive the transformation of the box's own shape, thereby reducing repetitive work that requires manual operation and creating an automated workflow that increases work efficiency.

[0022] Preferably, the box making and unloading operation process is located in the material making workshop, which includes a driveway, a conveyor belt, a material unloading area, a 3D scanner, a lifting operation box and a container truck power line. A material stacking area is also provided around the material making workshop. The command terminal includes a first command terminal to a fourth command terminal, wherein the fourth command terminal is located in the material unloading area. To facilitate the operation of the lifting module, a driveway is installed inside the material preparation workshop, and a material stacking area is set up near the workshop. The materials concentrated in the stacking area are continuously transported to the unloading area via conveyor belts. The lifting operation box and the truck power cable mainly function on the sockets on both sides of the truck. That is, the truck is powered by the truck power cable, which enables the lifting module to lift the container to the unloading area. The container is vertical and carries the goods transported by the conveyor belt. During the container's operation, the 3D scanner continuously monitors whether the container interferes with the internal structure of the material preparation workshop.

[0023] In a further embodiment, the container pick-up / return operation process includes: S201. According to the workflow of the TOS system, the first instruction terminal is located on the container truck, and the container truck enters the designated location to pick up the container by following the instructions. S202. The second command terminal is located at the rail-mounted gantry crane. The rail-mounted gantry crane lifts the container of the specified container number from the designated position to the container truck and feeds back to the first command terminal. The first command terminal and the second command terminal simultaneously confirm the information with the TOS system. If the container truck already has a container, the rail-mounted gantry crane records the information of the existing container and sends it to the TOS system. After lifting out the existing container, it replaces it with a container of the specified container number. S203. The cargo handling module under the TOS system records the container number information and binds it to the truck information; Specifically, in step S201, the TOS system first sends a message to the first instruction terminal according to the workflow arrangement, and the container trucks advance to the parking area according to the entry order and guidance to prepare to pick up the containers; In step S202, the rail-mounted gantry crane, according to the message issued by the second command terminal, will extract the specified container number from the designated location on site and move it to the truck of the first command terminal, and will send feedback from the second command terminal to the first command terminal and the TOS system respectively. In step S203, the TOS system will bind the container number information to the truck based on the cargo handling module. At this time, the rail gantry crane continues to work, raising the spreader to a safe height. Then the truck belonging to the first command terminal can leave the site. The binding function formed by the cargo handling module allows subsequent scanning and detection of license plate information to deduce the corresponding container number information, thereby binding the lead seal number at the subsequent container inspection point with the container number, as well as binding the container manufacturing and unloading tonnage with the container number. This links the tonnage information stored in the container, the container number, and the truck's license plate information under the cargo handling module, and the information from the cargo handling module can be saved to the data storage module.

[0024] In a further embodiment, the box inspection process includes: S211. When the container truck enters the inspection point area, the holder of the first command terminal leaves the container truck and walks around to check the integrity of the container, while recording the information and feeding it back to the TOS system. S212. The third command terminal is located in the container inspection area. The holder of the third command terminal checks the overall quality of the container and the cleanliness of the inside of the container. When the verification is correct, the holder of the third command terminal opens the container door and fixes it to the locked area in the open position. At the same time, the lead seal information is scanned to the TOS system, and the TOS system binds the lead seal, truck and container number information of the container a second time. If the verification is incorrect, the third command terminal will send feedback to the TOS system, and the TOS system will reassign the container to the first command terminal. At this time, the truck will return to step S201. Specifically, in step S211, the container truck continues to move to the inspection point area. After the holder of the first command terminal leaves the vehicle, he / she checks the vehicle information during the truck's movement, and checks the position of the container on the truck and the overall integrity of the container. In the next step, S212, the third-command terminal holder will display the vehicle inspection license plate and check the quality of the cargo box, especially the structure and function of the twist lock system, including the lock seat, lock head, bracket, rivets, lock nose, handle, etc. Then, open the cargo box, raise the safety buckle, check whether the inside of the cargo box is clean and free of debris and accumulated materials, and finally check the condition of the cargo box for any damage, focusing on the top, side panels, bottom panel, and joints. After the inspection is completed, the container driver leaves the truck and places the scanned and bound lead seal into the lead bottle on the truck. At this time, the container door is open, and the lead seal will be used the next time the door is closed. After uploading the lead seal information to the TOS system via the third-command terminal, the third-command terminal holder will leave the truck, and the truck will also leave the inspection point area. Multiple stops in the inspection point area can be handled by a single third-command terminal holder or multiple staff members holding one third-command terminal, so as to form staff merging or staff expansion. This allows for immediate reinforcement when the truck traffic is relatively tight, and allows a single third-command terminal holder to inspect multiple different inspection point areas when traffic is relatively sparse.

[0025] In a further embodiment, the lifting operation procedure of the hydraulic lift vehicle includes: S221. The container truck enters the lane of the container manufacturing workshop and connects the lifting module of the container truck to the lifting operation box and power line. The lifting module forms the container body at a vertical angle with the open container door facing upwards, and the container door is directly facing the material drop area. S222. During the lifting module's workflow, the holder of the first command terminal confirms whether the lifting process interferes with the upper equipment in the material preparation workshop. If no interference occurs, feedback is sent to the fourth command terminal after the lifting module stops. If interference occurs, the emergency stop button located in the lifting operation box is pressed, and feedback is sent to the TOS system, which then provides a corresponding solution to the holder of the first command terminal. Specifically, in step S221, the container truck arriving at the container manufacturing workshop will park in the corresponding lane, stop in place according to the parking indicator light, brake, turn off the engine, get off the truck, connect the lifting control box and the trailer power cable, check and confirm that there is no fault alarm in the lifting control box, operate the one-button lifting button to lift and rotate the empty container 90 degrees, with the opening of the container facing upwards, directly facing the material drop section of the conveyor belt (such as C12 belt); In step S222, during the trailer lifting process, the holder of the first command terminal constantly confirms whether the support legs are in place and whether the lifting process interferes with the equipment and facilities above; once the container is lifted into place and no abnormalities are found, the personnel evacuate to the duty room to wait for loading.

[0026] In a further embodiment, the box-making and material feeding operation process includes: S231. The material drop section of the lane includes the material drop point and the walking area. The holder of the fourth command terminal is located in the walking area to observe the lifting status of the box. The S232.TOS system's production management system is based on automated CTOS. It selects the box-making mode corresponding to the box for operation. Before the material unloading process, the 3D scanner detects the lifting of the box in the lane in real time. After the 3D scanner confirms that the box has been lifted into place, it transmits information to the bulk-to-container control cabinet inside the box-making workshop. The bulk-to-container control cabinet simultaneously links the flip-up plate and dust baffle at the conveyor belt to switch. Then, the unloading point continuously unloads material from the opened box door. S233. After the material feeding process is completed, the conveyor belt flap switches to the other side, and at the same time the TOS system outputs a reminder to the fourth instruction terminal; Specifically, in step S231, the fourth command terminal observes the lifting status of the box in the walking area. If any abnormality is detected, it reports the information to the first command terminal. In step S232, the automated CTOS is selected. In the industrial control system's buffer chamber interface, the metering chamber corresponding to the box making is selected as the box-making mode. Clicking "Start Operation" initiates the automated material feeding process. During this process, the 3D scanner in the workshop monitors the lifting status of the boxes in each lane in real time. After the 3D scanner confirms that the box has been lifted into position, it outputs information to the ground control box via remote control signal. Figure 5 As shown, the ground control box then transmits the information to the bulk-to-container control cabinet, which in turn issues a material release signal, causing the conveyor belt flapper and dust baffle to switch. After the process is checked and confirmed to be normal, automatic material feeding and release begin. In step S233, after the material release is completed, the system automatically switches the conveyor belt flapper to the other side so that the holder of the fourth instruction terminal can go down to the container door platform to perform the closing, locking, and sealing procedures.

[0027] In a further embodiment, the closing door operation process includes: S241. The fourth instruction terminal holder confirms the completion of the container manufacturing report to the TOS system, lowers the folding ladder to the container closing platform in the walking area, then removes the lead seal from the container door, locks it, closes the container door, and finally returns to the walking area and puts away the folding ladder. Specifically, the holder of the fourth command terminal reports information to the TOS system via voice recording while in a visual and verbal state, including: Confirm that the material flow has ended, the dust baffle is closed, and the conveyor belt head tee flap has been switched to the other side; Upon reaching the top or bottom of the stairs, securely connect your safety belt to the fixed safety rope. Lower the folding ladder in the walking area and check again to confirm the lifting status of the container truck and the status of the T-joint flap and dust baffle at the head of the conveyor belt. Using the folding ladder, hold on firmly with both hands and descend one step at a time to the platform for closing the box door; Lower the safety latch on the cabinet door, close the cabinet door, and lock it securely using the twist lock system; Remove the vehicle's lead seal and seal the cargo door. Using the folding ladder, hold on firmly with both hands and take one step at a time to return to the top and bottom of the ladder; Retract the safety ladder and hook it in place. Unfasten the safety belt and connect it to the fixed safety rope. Return the personnel to the walking area.

[0028] In a further embodiment, the lifting module includes: The power source includes a hydraulic mechanism and an electric motor for driving the hydraulic mechanism; The sockets are located on both sides of the container truck and are used to connect the lifting control box and the container truck's power cord. The lifting control box contains a PLC controller. The control system includes distributed slave stations, actuators, and feedback mechanisms located on the truck, and is communicatively connected to the lifting control box.

[0029] Specifically, such as Figure 4 As shown, the hydraulic system of a conventional container truck is retained. The drive end of the oil pump is modified to be driven by a motor, with the coupling as the boundary. After the socket is powered on, the PLC controller between the lifting control box and the control system will form a communication loop, allowing the holder of the first command terminal to operate the lifting status of the box based on the lifting control box. This makes the lifting control box compatible with most container trucks. The distributed slave stations are electrically connected to the aforementioned oil pump motor, actuator, and feedback mechanism, respectively, so that the distributed slave stations can drive the actuator to perform lock opening and closing and outrigger raising and lowering during the lifting process; during the lifting and lowering of the housing, the feedback mechanism can also detect the lifting height and the outrigger height to determine whether it is in position, and when it is in position, the distributed slave stations stop driving.

[0030] In a further embodiment, there are at least four lanes in step S221, and the fourth command terminals of every two lanes are combined into one; the TOS system is mounted in the system host, and the system host further includes: a data storage module, a timing unit, and a processing scheme unit; Specifically, through the coordination of the timing unit and data storage module under the TOS system, corresponding personnel arrangement plans can be given according to the daily transportation frequency. For example, even in a workflow sequence with a relatively dense number of trucks, the fourth instruction terminal for every two lanes can be combined into one, and only one operator is required. In a workflow sequence with a relatively sparse number of trucks, the fourth instruction terminal for every four lanes can be combined into one, and only one operator is required. This is especially true in cases where the transported goods need to be transported slowly by conveyor belt, which increases the loading time and the number of trucks is relatively small. In other words, the TOS system combines the workflow schemes stored in the timing unit and data storage module to instantly change different work procedures without altering the original work nodes.

[0031] In a further embodiment, the working steps further include: S4. Container unloading and loading process, the transportation routes include: ship, rail crane, container truck, stacker and stacking area. The workflow is based on the actual transportation route and the transportation plan stored in the data storage module of the TOS system. Specifically, step S4 is divided into two different schemes: unloading from the hull and loading onto the ship. The unloading process includes the following different procedures: A1. Ship – Rail-mounted crane – Material storage area; A2. Ship—rail-mounted crane—container truck—forklift—stocking area; A3. Ship—Harbor crane—Forklift—Storage area; A4. Ship—Harbor crane—Forklift—Container truck—Rail-mounted gantry crane—Storage area; The loading process includes the following different steps: B1. Stockpile area—rail-mounted crane—ship; B2. Stacking area—forklift—container truck—rail-mounted crane—ship; B3. Stockpile area—forklift—harbor crane—ship; B4. Stockpile area—rail-mounted crane—container truck—forklift—harbor crane—ship; It is evident that cargo information in transport vehicles and storage areas also affects the operational efficiency of equipment such as container trucks and rail-mounted cranes. Therefore, when specifying workflows, it is necessary to collect cargo data including that from transport vehicles and storage areas to achieve overall coordination. For example, storage areas are further divided into bulk cargo storage areas and container storage areas. The storage area mentioned in the above process refers to the container storage area, which is used to coordinate the container manufacturing process. The bulk cargo storage area is used for transporting cargo to ships, such as the B1-B4 process.

[0032] This invention has been implemented in a port to optimize the overall process. Due to the use of semi-automatic improvement, it can further improve the work efficiency of the original conventional container. At the same time, the original container trucks can also operate after the electric conversion, which greatly increases work efficiency while ensuring safety. Before the conversion, the annual expenditure was about 400,000 yuan, and after the conversion, the annual expenditure was about 50,000 yuan, which can save about 350,000 yuan per year. In terms of equipment availability and fault prevention, the monthly failure rate can be reduced by 87%, greatly reducing emergency repair time during operation and eliminating faults such as frequent engine battery power loss at the source. In terms of environmental management, it can reduce carbon emissions by 65 tons per year and eliminate noise pollution from the engine at the source. In terms of manpower arrangement, the lifting operation of the lifting vehicle is assisted by the driver, and the lowering operation of the lifting vehicle is operated by the worker closing the box door, so one ground worker is eliminated. In terms of safety management, the automatic opening and closing of the lock reduces the damage caused by manual opening and closing, and the upper and lower limit of the outriggers ensures the balance of the force points on both sides and avoids cracking of the steel structure caused by abnormal force.

[0033] Regarding specific data such as Figure 3 As shown in the figure, the bar chart data represents the calculated data of the number of containers produced per hour over a week. That is, the number of containers produced per hour in the first week is 13.47, and the number of containers produced per hour in the second week is 12.18, etc. In comparison, the container production efficiency of ports of the same scale without optimization is only 6-8 containers per hour for coal. It can be seen that the improvement of the process of this invention can significantly increase the work efficiency. Even the coal container production capacity of a fully automated system is only 15-20 containers per hour, while the process of this invention can achieve an average of more than 12 containers per hour, which is a significant improvement in efficiency.

[0034] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A bulk-to-container loading and unloading process, characterized in that, The specific working steps of the loading and unloading process are as follows: S1. Establish the workflow of the TOS system, which includes multiple work nodes and production processes. Based on the TOS system, there are multiple command terminals adapted to multiple work nodes. The multiple command terminals are used to receive and return work node information. S2. Divide multiple work nodes into: box lifting / returning operation process, box inspection operation process, hydraulic lifting vehicle lifting operation process, box making and unloading operation process, box closing operation process, and hydraulic lifting vehicle lowering operation process. Complete the containerization and loading / unloading process according to the above work node sequence; A container truck and a container body are used to transport raw materials between multiple work nodes. The container truck includes a lifting module for lifting the container body vertically. S3. Merge instruction terminals with overlapping work areas under work nodes, and set up automated processes for processes other than work nodes in the workflow, thereby reducing the number of personnel and improving work efficiency.

2. The bulk-to-container loading and unloading process according to claim 1, characterized in that, The box-making and unloading operation process is located in the material preparation workshop, which includes a driveway, a conveyor belt, a material drop section, a 3D scanner, a lifting operation box, and a container truck power line. A material stacking area is also set up around the material preparation workshop. The command terminal includes a first command terminal to a fourth command terminal, wherein the fourth command terminal is located in the material drop section.

3. The bulk-to-container loading and unloading process according to claim 1, characterized in that, The procedure for picking up / returning the container includes: S201. According to the workflow of the TOS system, the first instruction terminal is located on the container truck, and the container truck enters the designated location to pick up the container by following the instructions. S202. The second command terminal is located at the rail-mounted gantry crane. The rail-mounted gantry crane lifts the container of the specified container number from the designated position to the container truck and feeds back to the first command terminal. The first command terminal and the second command terminal simultaneously confirm the information with the TOS system. If the container truck already has a container, the rail-mounted gantry crane records the information of the existing container and sends it to the TOS system. After lifting out the existing container, it replaces it with a container of the specified container number. S203. The cargo handling module under the TOS system records the container number information and binds it to the container truck information.

4. The bulk-to-container loading and unloading process according to claim 2, characterized in that, The inspection procedure includes: S211. When the container truck enters the inspection point area, the holder of the first command terminal leaves the container truck and walks around to check the integrity of the container, while recording the information and feeding it back to the TOS system. S212. The third command terminal is located in the container inspection area. The holder of the third command terminal checks the overall quality of the container and the cleanliness of the inside of the container. When the verification is correct, the holder of the third command terminal opens the container door and fixes it to the locked area in the open position. At the same time, the lead seal information is scanned to the TOS system, and the TOS system binds the lead seal, truck and container number information of the container a second time. If the verification is incorrect, the third command terminal will send feedback to the TOS system, and the TOS system will reassign the container to the first command terminal. At this time, the truck will return to step S201.

5. The bulk-to-container loading and unloading process according to claim 3, characterized in that, The lifting operation procedure of the hydraulic lifting vehicle includes: S221. The container truck enters the lane of the container manufacturing workshop and connects the lifting module of the container truck to the lifting operation box and power line. The lifting module forms the container body at a vertical angle with the open container door facing upwards, and the container door is directly facing the material drop area. S222. During the lifting module's workflow, the holder of the first command terminal confirms whether the lifting process interferes with the upper equipment in the material preparation workshop. If no interference occurs, feedback is sent to the fourth command terminal after the lifting module stops. If interference occurs, the emergency stop button located in the lifting operation box is pressed, and feedback is sent to the TOS system, which then provides a corresponding solution to the holder of the first command terminal.

6. The bulk-to-container loading and unloading process according to claim 4, characterized in that, The box-making and material feeding operation process includes: S231. The material drop section of the lane includes the material drop point and the walking area. The holder of the fourth command terminal is located in the walking area to observe the lifting status of the box. The S232.TOS system's production management system is based on automated CTOS. It selects the box-making mode corresponding to the box for operation. Before the material unloading process, the 3D scanner detects the lifting of the box in the lane in real time. After the 3D scanner confirms that the box has been lifted into place, it transmits information to the bulk-to-container control cabinet inside the box-making workshop. The bulk-to-container control cabinet simultaneously links the flip-up plate and dust baffle at the conveyor belt to switch. Then, the unloading point continuously unloads material from the opened box door. S233. After the material feeding process is completed, the conveyor belt flap switches to the other side, and the TOS system outputs a reminder to the fourth instruction terminal.

7. The bulk-to-container loading and unloading process according to claim 5, characterized in that, The procedure for closing the cabinet door includes: S241. The fourth instruction terminal holder confirms the completion of the container manufacturing report to the TOS system, lowers the folding ladder to the container closing platform in the walking area, then removes the lead seal from the container door, locks it, and closes the container door. Finally, the holder returns to the walking area and puts away the folding ladder.

8. The bulk-to-container loading and unloading process according to claim 7, characterized in that, The lifting module includes: The power source includes a hydraulic mechanism and an electric motor for driving the hydraulic mechanism; The sockets are located on both sides of the container truck and are used to connect the lifting control box and the container truck's power cord. The lifting control box contains a PLC controller. The control system includes distributed slave stations, actuators, and feedback mechanisms located on the truck, and is communicatively connected to the lifting control box.

9. The bulk-to-container loading and unloading process according to claim 8, characterized in that, In step S221, there are at least four lanes, and the fourth instruction terminal of every two lanes is combined into one; the TOS system is mounted in the system host, and the system host also includes: a data storage module, a timing unit and a processing scheme unit.

10. The bulk-to-container loading and unloading process according to claim 9, characterized in that, The working steps also include: S4. Container unloading and loading process, the transportation routes include: ship, harbor crane, rail crane, container truck, forklift and stacking area. The workflow is formulated based on the actual transportation route and the transportation plan stored in the data storage module of the TOS system.

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