Train bulk cargo loading and unloading system and method

Abstract

The invention discloses a train bulk cargo loading and unloading system and method.The train bulk cargo loading and unloading system comprises a carriage recognition unit, a grabbing unit and a PLC, and the carriage recognition unit and the grabbing unit are both coupled with the PLC; the grabbing unit comprises a lifting motor module, a first absolute value encoder, an opening and closing motor module, a second absolute value encoder and a grab bucket module. The input end of the lifting motor module and the input end of the opening and closing motor module are coupled with the PLC. The lifting motor module and the opening and closing motor module are accurately controlled through the PLC, it is ensured that lifting and opening and closing steel wire ropes are stressed at the same time, and the problems of single machine overload and steel wire rope overload are solved; a lifting absolute value encoder and an opening and closing absolute value encoder are adopted, the height and the opening degree of the grab bucket are monitored respectively, real-time communication with the PLC is achieved, it is ensured that the controller can monitor the numerical values of the encoders in real time, and accurate control over the grab bucket is achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of train bulk material handling technology, and more particularly, to a train bulk material handling system and method. BACKGROUND

[0002] In the smelting industry, bulk materials such as ore, coke, etc. are often transported by train. Currently, there are many problems in the process of train bulk material handling. The traditional handling method often relies on manual operation, which not only has low efficiency, but also is prone to handling errors due to human factors, affecting the progress and quality of work. Moreover, the lack of accurate car position and material distribution information makes it difficult for the grab to accurately aim when grabbing the material, resulting in material residue or excessive grabbing, increasing the difficulty and cost of subsequent processing.

[0003] In addition, the traditional grab system has many shortcomings: 1) low automation, requiring a large amount of manual operation, high labor cost, and low handling efficiency; 2) poor positioning accuracy, the grab is prone to deviation during grabbing and unloading, affecting the handling quality; 3) low safety, especially in complex operating environments, the grab is prone to twisting during descent and lifting, leading to safety accidents.

[0004] Chinese patent document (application number: 202311707233.0, application date: 2023.12.13) discloses a material handling system, which includes a material handling module for handling material; a data acquisition module for acquiring real-time state data of the current handling material and the transport vehicle model; an automatic control module electrically connected with the material handling module and the data acquisition module, the automatic control module controls the material handling module according to the real-time state data collected by the data acquisition module; the above-mentioned scheme, although the data acquisition module is set to effectively identify the weight and quantity information of the material and the transport tool in real time, reduces the error of manual counting, weighing and identification, and the automatic control module is set to make the system have high reliability, scalability, safety, etc., but it does not solve the above technical problems.

[0005] Therefore, there is an urgent need for an efficient, accurate and safe train bulk material handling system and method. SUMMARY

[0006] Therefore, the present application provides an efficient, accurate and safe train bulk material handling system and method.

[0007] In a first aspect, the present application provides a train bulk material handling system, comprising: a car recognition unit, a grabbing unit and a PLC controller.

[0008] The carriage recognition unit is coupled with the PLC controller, and the carriage recognition unit comprises a laser radar scanning module, a data processing module and a WMS warehouse management module, wherein,

[0009] The laser radar scanning module is coupled with the data processing module, and the laser radar scanning module is arranged on a travelling crane to acquire three-dimensional point cloud data of a carriage and send the three-dimensional point cloud data to the data processing module.

[0010] The data processing module is coupled with the laser radar scanning module to receive a three-dimensional point cloud data signal output by the laser radar scanning module, process the three-dimensional point cloud data, obtain carriage parameters and send the carriage parameters to the WMS warehouse management module.

[0011] The WMS warehouse management module is coupled with the data processing module to switch to a train unloading mode, input a train parking range, select a material type or a material grabbing and discharging bin of each carriage according to the carriage parameters output by the data processing module, generate a train unloading work order and send the train unloading work order to the travelling crane and the grabbing module to perform grabbing, wherein the carriage parameters comprise a carriage position, a carriage size, a material distribution and a material thickness.

[0012] The grabbing unit is coupled with the PLC controller, and the grabbing unit comprises a hoisting motor module, a first absolute value encoder, an opening and closing motor module, a second absolute value encoder and a grab bucket module, the grab bucket module comprises a hoisting drum and a hoisting steel wire rope wound on the hoisting drum, an opening and closing drum and an opening and closing steel wire rope wound on the opening and closing drum, and a bucket body controlled to ascend and descend and open and close through the hoisting steel wire rope and the opening and closing steel wire rope, wherein,

[0013] An input end of the hoisting motor module is coupled with the PLC controller, and an output end of the hoisting motor module is connected to an input end of the hoisting drum, the hoisting motor module is used to drive the hoisting drum to realize winding and unwinding of the hoisting steel wire rope through rotation of the hoisting drum.

[0014] An output end of the hoisting drum is connected to an input end of the first absolute value encoder, and an output end of the first absolute value encoder is connected to the PLC controller, and the first absolute value encoder is used to monitor a height of the grab bucket module.

[0015] An input end of the opening and closing motor module is coupled with the PLC controller, and an output end of the opening and closing motor module is connected to an input end of the opening and closing drum, the opening and closing motor module is used to drive the opening and closing drum to realize winding and unwinding of the opening and closing steel wire rope through rotation of the opening and closing drum.

[0016] The output end of the opening and closing reel is connected to the input end of the second absolute value encoder, and the output end of the second absolute value encoder is connected to the PLC controller, and the second absolute value encoder is used to monitor the opening degree of the grab bucket module.

[0017] The PLC controller is coupled with the laser radar scanning module to control the laser radar scanning module to automatically complete the scanning work of the carriage; the PLC controller is coupled with the data processing module to control the data processing module to complete the processing of the three-dimensional point cloud data and obtain the carriage parameters; the PLC controller is coupled with the WMS warehouse management module to control the WMS warehouse management module to automatically generate the unloading car operation order and issue the grabbing instruction; the PLC controller is coupled with the lifting motor module and the opening and closing motor module respectively to control the lifting steel wire rope and the opening and closing steel wire rope to be stressed simultaneously; the PLC controller is connected with the first absolute value encoder and the second absolute value encoder respectively to receive the height of the grab bucket module output by the first absolute value encoder and the opening degree of the grab bucket module output by the second absolute value encoder, and control the action of the grab bucket module.

[0018] The laser radar scanning module in the carriage recognition unit can obtain three-dimensional point cloud data of the carriage, and then the data processing module processes to obtain accurate carriage parameters. This enables the system to accurately identify the position, size and other information of the carriage, providing accurate basis for subsequent grabbing operation, and improving the accuracy and efficiency of loading and unloading; the WMS warehouse management module realizes intelligent planning and scheduling of the operation process, without frequent manual intervention, further improving the loading and unloading efficiency.

[0019] Through the PLC controller, the lifting motor module and the opening and closing motor module are accurately controlled to ensure that the lifting steel wire rope and the opening and closing steel wire rope are stressed simultaneously, avoiding single machine overload and steel wire rope overload problems; two sets of absolute value encoders are used for lifting and opening and closing to monitor the height and opening degree of the grab bucket respectively, and real-time communication is realized with the PLC controller to ensure that the controller can monitor the values of the encoders in real time, and accurate control of the grab bucket is realized. This accurate control can ensure accurate grabbing and unloading of the grab bucket, reduce material spillage and waste, and improve operation stability.

[0020] The laser radar scanning module, the data processing module, the WMS warehouse management module, the lifting motor module and the opening and closing motor module are all connected with the PLC controller to realize integrated control of the whole system. Through the collaborative work between the modules, the system can automatically complete a series of operations such as carriage recognition, operation order generation, grabbing and unloading of the grab bucket, greatly reducing the labor intensity and improving the automation level and safety of the operation.

[0021] Optionally, a first frequency converter is arranged between the PLC controller and the lifting motor module, an input end of the first frequency converter is coupled with the PLC controller, and an output end of the first frequency converter is connected with an input end of the lifting motor module.

[0022] A second frequency converter is arranged between the PLC controller and the opening and closing motor module, an input end of the second frequency converter is connected with the PLC controller, and an output end of the second frequency converter is connected with an input end of the opening and closing motor module.

[0023] The frequency converters are connected with the PLC controller, and the rotation speed of the motor is controlled, so that the precise control of the grab bucket is realized.

[0024] Optionally, a rotating shaft of the first absolute value encoder is connected with a main shaft of the lifting drum.

[0025] A rotating shaft of the second absolute value encoder is connected with a main shaft of the opening and closing drum.

[0026] In the present application, the rotating shaft of the absolute value encoder is connected with the main shaft of the drum, so that the synchronous rotation of the absolute value encoder and the drum is ensured.

[0027] Optionally, the data processing module is used for converting three-dimensional point cloud data into image data, identifying the position, vehicle type and size of the carriage through image processing, obtaining accurate parameters of the carriage, and transmitting the accurate parameters of the carriage to the WMS warehouse management module, wherein the accurate parameters of the carriage include the position, size, material distribution and material thickness of the carriage.

[0028] Optionally, the laser radar scanning module adopts a 3D laser radar, which has the characteristics of high resolution and long distance detection capability.

[0029] Optionally, the model of the PLC controller is SIMATIC S7-1200, which has the advantages of high integration, high reliability and flexible programming.

[0030] Optionally, the grab bucket module includes one lifting drum and one opening and closing drum.

[0031] The grab bucket module further includes four lifting steel wires, two of which are wound on the lifting drum, and the other two are connected with the trolley device of the crane through a pulley block.

[0032] The grab bucket module further includes four opening and closing steel wires, two of which are wound on the opening and closing drum, and the other two are connected with the trolley device of the crane through a pulley block.

[0033] The grab module also includes an upper support beam, and the lifting drum and the opening and closing drum are fixed on the upper support beam;

[0034] The bucket body is fixed on the upper support beam and connected to the crane trolley device through the lifting wire rope and the opening and closing wire rope.

[0035] In this application, an eight-rope design is adopted, which has a multi-point anti-sway function, effectively preventing the grab bucket from twisting during descent and lifting, and eliminating the occurrence of train bucket entanglement caused by grab bucket twisting.

[0036] Secondly, this application provides a method for loading and unloading bulk materials on a train, employing the aforementioned train bulk material loading and unloading system, comprising the following steps:

[0037] The WMS warehouse management module's interface is switched to the unloading mode, the train stopping range is entered, and the lidar scanning module is driven to scan the train carriages to obtain three-dimensional point cloud data. The data processing module converts the three-dimensional point cloud data into a binary image, performs dilation, erosion, and connected component processing in sequence, calculates the position, type, and size of each carriage, obtains the carriage parameters, and transmits them to the WMS warehouse management module.

[0038] In the WMS warehouse management interface of the WMS warehouse management module, select the material type of each car or the material grabbing and unloading bin, and the WMS warehouse management module will automatically generate an unloading operation order and send it to the crane to perform grabbing.

[0039] During the grasping process, the WMS library management module calculates and obtains the grasping point position based on the scanning results of the lidar scanning module;

[0040] When the PLC controller executes the grabbing action, it moves the trolley to the designated grabbing point. After the bucket descends to the safe height of the train car, it decelerates and descends. Once the bucket reaches the material surface and the data processing unit of the train bulk material loading and unloading system confirms the technical details through torque verification and weight information transmission, it begins grabbing the material. After grabbing the material, the grab bucket is slowly raised to the safe height of the train car, and then quickly raised. During the descent and lifting process, the torque changes of the opening and closing wire rope and the hoisting wire rope are monitored in real time. A network distribution of the entire torque is established, and a fuzzy control strategy is adopted to avoid wire rope entanglement and channel malfunction.

[0041] Compared with the prior art, the train bulk material loading and unloading system and method provided by the present invention achieves at least the following beneficial effects:

[0042] Firstly, the laser radar scanning module in the vehicle compartment recognition unit can obtain three-dimensional point cloud data of the vehicle compartment, and accurate vehicle compartment parameters are obtained through the data processing module. This enables the system to accurately identify the position, size and other information of the vehicle compartment, providing accurate basis for subsequent grabbing operation, and improving the accuracy and efficiency of loading and unloading; the WMS warehouse management module realizes intelligent planning and scheduling of the operation process, without frequent manual intervention, further improving the loading and unloading efficiency.

[0043] Secondly, through the PLC controller, the lifting motor module and the opening and closing motor module are precisely controlled to ensure that the lifting and opening and closing steel wire ropes are simultaneously stressed, avoiding single machine overload and steel wire rope overload problems; two sets of absolute value encoders are used for lifting and opening and closing, respectively monitoring the height and opening degree of the grab bucket, and communicating with the PLC controller in real time, so that the controller can monitor the values of the encoders in real time, and realize accurate control of the grab bucket. This precise control can ensure accurate grabbing and unloading of the grab bucket, reduce material spillage and waste, and improve operation stability.

[0044] Thirdly, the laser radar scanning module, the data processing module, the WMS warehouse management module, the lifting motor module and the opening and closing motor module are connected with the PLC controller, realizing integrated control of the whole system. Through the cooperative work between the modules, the system can automatically complete a series of operations such as vehicle compartment recognition, operation work order generation, grabbing and unloading of the grab bucket, greatly reducing the labor intensity and improving the automation level and safety of the operation.

[0045] Of course, any product implementing the present application does not necessarily need to achieve all the technical effects described above at the same time.

[0046] Other features of the present application and its advantages will become apparent from the following detailed description of exemplary embodiments thereof, taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0047] The accompanying drawings incorporated in and forming a part of the specification, illustrate embodiments of the present application and, together with the description, serve to explain the principles of the application.

[0048] Figure 1 is a schematic diagram of a train bulk material loading and unloading system in an embodiment of the present application;

[0049] Figure 2 is a schematic diagram of another train bulk material loading and unloading system in an embodiment of the present application;

[0050] Figure 3 is a schematic diagram of a grab bucket module in a train bulk material loading and unloading system in an embodiment of the present application;

[0051] Figure 4 is a flowchart of a train bulk material loading and unloading method in an embodiment of the present application.

[0052] wherein,

[0053] In the figure, 101, data processing module; 102, WMS warehouse management module; 103, laser radar scanning module; 200, PLC controller; 301, lifting motor module; 302, opening and closing motor module; 303, lifting drum; 304, opening and closing drum; 305, first absolute value encoder; 306, second absolute value encoder; 307, first frequency converter; 308, second frequency converter; 1-bucket body; 2-lifting steel wire rope; 3-opening and closing steel wire rope; 4-transmission shaft; 5-gear coupling; 6-trolley rail. DETAILED DESCRIPTION

[0054] Various exemplary embodiments of the present application will now be described in detail with reference to the accompanying drawings. It should be noted that the relative arrangement of the components and steps set forth in the examples, as well as the numerical expressions and values, are not limitations on the scope of the present application unless otherwise specifically stated.

[0055] The following description of at least one exemplary embodiment is merely exemplary in nature and is in no way intended to limit the scope of the application its application or uses.

[0056] Techniques, methods, and devices known to those of ordinary skill in the relevant art can not be discussed in detail herein. However, where appropriate, such techniques, methods, and devices can be viewed as part of the specification.

[0057] In all of the examples shown and discussed herein, any specific values should be interpreted as merely exemplary and not as a limitation. Thus, other examples of the exemplary embodiments can have different values.

[0058] It should be noted that like reference numerals and letters refer to like items in the following drawings, and thus, once an item is defined in one drawing, it need not be discussed further in subsequent drawings.

[0059] Example 1

[0060] Referring to Figure 1 , Figure 3 as shown, Figure 1 is a schematic diagram of a train bulk material handling system in an embodiment of the present application; Figure 3 is a schematic diagram of a grab module in a train bulk material handling system in an embodiment of the present application. The embodiment provides a train bulk material handling system, which includes a car identification unit, a grabbing unit, and a PLC controller 200;

[0061] The carriage recognition unit is coupled with the PLC controller 200, and the carriage recognition unit comprises a laser radar scanning module 103, a data processing module 101 and a WMS warehouse management module 102; the laser radar scanning module 103 is coupled with the data processing module 101, and the laser radar scanning module 103 is arranged on the travelling crane and is used for acquiring three-dimensional point cloud data of the carriage and sending the three-dimensional point cloud data to the data processing module 101;

[0062] The data processing module 101 is coupled with the laser radar scanning module 103 and is used for receiving a three-dimensional point cloud data signal output by the laser radar scanning module 103, processing the three-dimensional point cloud data, obtaining accurate parameters of the carriage and sending the accurate parameters to the WMS warehouse management module 102;

[0063] The WMS warehouse management module 102 is coupled with the data processing module 101 and is used for switching to a train unloading mode, inputting a train parking range, selecting a material type or a material grabbing and discharging bin of each carriage according to the carriage parameters output by the data processing module 101, generating a train unloading work order and sending the train unloading work order to the travelling crane and the grabbing module to execute grabbing, wherein the carriage parameters comprise a carriage position, a carriage size, a material distribution and a material thickness;

[0064] The grabbing unit is coupled with the PLC controller 200, and the grabbing unit comprises a hoisting motor module 301, a first absolute value encoder 305, an opening and closing motor module 302, a second absolute value encoder 306 and a grabbing bucket module, the grabbing bucket module comprises a hoisting drum 303 and a hoisting steel wire rope 2 wound on the hoisting drum, an opening and closing drum 304 and an opening and closing steel wire rope 3 wound on the opening and closing drum, and a bucket body 1 controlled to ascend and descend and open and close through the hoisting steel wire rope 2 and the opening and closing steel wire rope 3,

[0065] The input end of the hoisting motor module 301 is coupled with the PLC controller 200, the output end of the hoisting motor module 301 is connected with the input end of the hoisting drum 303, and the hoisting motor module 301 is used for driving the hoisting drum 303 to realize winding and unwinding of the hoisting steel wire rope 2 through rotation of the hoisting drum 303;

[0066] The output end of the hoisting drum 303 is connected with the input end of the first absolute value encoder 305, and the output end of the first absolute value encoder 305 is connected with the PLC controller 200, and the first absolute value encoder 305 is used for monitoring the height of the grabbing bucket module;

[0067] The input end of the opening and closing motor module 302 is coupled with the PLC controller 200, the output end of the opening and closing motor module 302 is connected with the input end of the opening and closing drum 304, and the opening and closing motor module 302 is used for driving the opening and closing drum 304 to realize winding and unwinding of the opening and closing steel wire rope 3 through rotation of the opening and closing drum 304;

[0068] The output end of the opening and closing reel 304 is connected to the input end of the second absolute value encoder 306, and the output end of the second absolute value encoder 306 is connected to the PLC controller 200; the second absolute value encoder 306 is used to monitor the opening degree of the grab bucket module;

[0069] The WMS warehouse management module 102, the laser radar scanning module 103, the data processing module 101, the lifting motor module 301 and the opening and closing motor module 302 are all connected with the PLC controller 200, wherein,

[0070] The PLC controller 200 is coupled with the laser radar scanning module 103, and is used to control the laser radar scanning module 103 to automatically complete the scanning work on the car body; the PLC controller 200 is coupled with the data processing module 101, and is used to control the data processing module 101 to complete the processing of the three-dimensional point cloud data and obtain the car body parameters; the PLC controller 200 is coupled with the WMS warehouse management module 102, and is used to control the WMS warehouse management module 102 to automatically generate a car unloading operation work order and issue a grabbing instruction; the PLC controller 200 is coupled with the lifting motor module 301 and the opening and closing motor module 302 respectively, and is used to control the lifting steel wire rope 2 and the opening and closing steel wire rope 3 to be stressed at the same time; the PLC controller 200 is connected with the first absolute value encoder 305 and the second absolute value encoder 306 respectively, and is used to receive the height of the grab bucket module output by the first absolute value encoder 305 and the opening degree of the grab bucket module output by the second absolute value encoder 306, and control the action of the grab bucket module.

[0071] Specifically, as shown in Figure 1 、 Figure 3 , the embodiment provides a train bulk cargo loading and unloading system, which comprises a car body identification unit, a grabbing unit and a PLC controller 200; the car body identification unit and the grabbing unit are coupled with the PLC controller 200, and the PLC controller 200 controls the car body identification unit and the grabbing unit to operate.

[0072] The car body identification unit comprises a laser radar scanning module 103, which is coupled with the PLC controller 200 and is arranged on a trolley, and is used to obtain three-dimensional point cloud data of a car body; a data processing module 101, which is coupled with the PLC controller 200 and is used to process the three-dimensional point cloud data to obtain accurate parameters of the car body; and a WMS warehouse management module 102, which is coupled with the PLC controller 200 and is used to switch to a train car unloading mode, input a train parking range, select a material type or a material grabbing and placing bin of each car body, generate a car unloading operation work order and issue the work order to the trolley for grabbing.

[0073] The laser radar scanning module 103 is also coupled with the data processing module 101, and is used to obtain the three-dimensional point cloud data of the car body and send the data to the data processing module 101;

[0074] The data processing module 101 is coupled to the lidar scanning module 103 and is used to receive the three-dimensional point cloud data signal output by the lidar scanning module 103, process the three-dimensional point cloud data, obtain the carriage parameters, and send them to the WMS warehouse management module 102.

[0075] The WMS warehouse management module 102 is coupled to the data processing module 101. Based on the car body parameters output by the data processing module 101, it selects the material type or material grabbing and unloading bin for each car body, generates an unloading work order, and sends it to the crane and grabbing module to execute the grabbing. The car body parameters include the car body location, car body size, material distribution, and material thickness.

[0076] The overhead crane provides structural support and power. According to the system's instructions, it is responsible for driving the grabbing module to move vertically and horizontally to the grabbing point and complete the grabbing operation. The grabbing module is mounted on the crane's hook or lifting device. Driven by the crane, it completes the grabbing and release of materials through its own opening and closing motion. This application does not specifically limit the structure and type of the overhead crane; it can be selected according to actual needs, as long as it can provide power and support to cooperate with the bulk material handling system of this application and cooperate in completing the movement and grabbing of the grabbing module.

[0077] The gripping unit includes a hoisting motor module 301, a first absolute encoder 305, an opening and closing motor module 302, a second absolute encoder 306, and a grab bucket module. The input terminals of the hoisting motor module 301 and the opening and closing motor module 302 are respectively coupled to the PLC controller 200.

[0078] like Figure 3 As shown, the grab bucket module includes a lifting drum 303 and a lifting wire rope 2 wound on the lifting drum, an opening and closing drum 304 and an opening and closing wire rope 3 wound on the opening and closing drum 304, and a bucket body whose lifting and opening / closing are controlled by the lifting wire rope 2 and the opening and closing wire rope 3.

[0079] The output of the hoisting motor module 301 is connected to the input of the hoisting drum 303, the output of the hoisting drum 303 is connected to the input of the first absolute encoder 305, and the output of the first absolute encoder 305 is connected to the PLC controller 200. The hoisting motor module 301 is used to drive the hoisting drum 303. The rotation of the hoisting drum 303 realizes the winding and unwinding of the hoisting wire rope 2, thereby controlling the lifting and lowering action of the grab bucket.

[0080] The output end of the opening and closing motor module 302 is connected to the input end of the opening and closing drum 304, the output end of the opening and closing drum 304 is connected to the input end of the second absolute value encoder 306, and the output end of the second absolute value encoder 306 is connected to the PLC controller 200; the opening and closing motor module 302 is used for driving the opening and closing drum 304, and the opening and closing of the steel wire rope 3 is realized through the rotation of the opening and closing drum 304, so as to control the opening and closing action of the grab bucket;

[0081] The first absolute value encoder 305 is used for monitoring the height of the grab bucket module;

[0082] The second absolute value encoder 306 is used for monitoring the opening degree of the grab bucket module.

[0083] In the embodiment, it should be noted that the laser radar scanning module 103 in the vehicle compartment recognition unit can obtain three-dimensional point cloud data of the vehicle compartment, and then the accurate vehicle compartment parameters are obtained through the data processing module 101. This enables the system to accurately identify the position, size and other information of the vehicle compartment, providing accurate basis for subsequent grabbing operation, and improving the accuracy and efficiency of loading and unloading; the WMS warehouse management module 102 realizes intelligent planning and scheduling of the operation process, without frequent manual intervention, further improving the loading and unloading efficiency.

[0084] In the embodiment, it should be further noted that through the PLC controller 200, the lifting motor module 301 and the opening and closing motor module 302 are accurately controlled, ensuring that the lifting and opening and closing steel wire ropes are stressed at the same time, avoiding single machine overload and steel wire rope overload problems; two sets of absolute value encoders are used for lifting and opening and closing, respectively monitoring the height and opening degree of the grab bucket, and communicating with the PLC controller 200 in real time, ensuring that the controller can monitor the values of the encoders in real time, and realizing accurate control of the grab bucket. This accurate control can ensure accurate grabbing and unloading of the grab bucket, reduce material spilling and waste, and improve operation stability.

[0085] In the embodiment, the laser radar scanning module 103, the data processing module 101, the WMS warehouse management module 102, the lifting motor module 301 and the opening and closing motor module 302 are all connected with the PLC controller 200, realizing integrated control of the whole system. Through the collaborative work between the modules, the system can automatically complete a series of operations such as vehicle compartment recognition, operation work order generation, and grabbing and unloading of the grab bucket, greatly reducing the labor intensity and improving the automation level and safety of the operation.

[0086] In the embodiment, the rotating shaft of the first absolute value encoder 305 is connected with the main shaft of the lifting drum 303; the rotating shaft of the second absolute value encoder 306 is connected with the main shaft of the opening and closing drum 304. The rotating shaft of the absolute value encoder is connected with the main shaft of the drum, ensuring that the absolute value encoder and the drum realize synchronous rotation.

[0087] In the embodiment, the data processing module 101 is configured to convert the three-dimensional point cloud data into image data, identify the position, model and size of the carriage through image processing, obtain the accurate parameters of the carriage, and transmit the accurate parameters of the carriage to the WMS warehouse management module 102.

[0088] In the embodiment, the laser radar scanning module 103 adopts a 3D laser radar, which has the characteristics of high resolution and long-distance detection capability.

[0089] In the embodiment, the PLC controller 200 is of the SIMATIC S7-1200 type, which has the advantages of high integration, high reliability and flexible programming.

[0090] Specifically, in the embodiment, the grab bucket module includes one lifting drum, one opening and closing drum, four lifting steel wires 2 and four opening and closing steel wires 3. Each lifting drum is wound with two lifting steel wires 2, and each opening and closing drum is wound with two opening and closing steel wires 3. The other two lifting steel wires 2 and the other two opening and closing steel wires 3 are connected to the crane trolley device through a pulley block. The grab bucket module further includes an upper beam, and the lifting drum 303 and the opening and closing drum 304 are fixed on the upper beam. The bucket body 1 is fixed on the upper beam and connected to the crane trolley device through the lifting steel wires 2 and the opening and closing steel wires 3. The crane trolley device includes a transmission shaft 4, and four gear couplings 5 are arranged on the transmission shaft 4. The lifting steel wires 2 and the opening and closing steel wires 3 are connected to the drum group on the crane trolley device through a pulley block. A trolley guardrail 6 is arranged on the crane trolley to prevent high-altitude falling and the like.

[0091] In the embodiment, the lifting steel wires 2 control the lifting and lowering of the bucket body 1, and the opening and closing steel wires 3 control the grabbing and unloading of the bucket body 1. The eight-wire design has a multi-point anti-swing function, which can effectively prevent the twisting of the grab bucket during the lifting and lowering process and eliminate the phenomenon of train skin hanging caused by the twisting of the grab bucket.

[0092] Embodiment 2

[0093] In some optional embodiments, in combination with Figure 2 as shown, Figure 2 is a schematic view of another train bulk material loading and unloading system in the embodiment of the application. A first frequency converter 307 is arranged between the PLC controller 200 and the lifting motor module 301. The input end of the first frequency converter 307 is connected to the PLC controller 200, and the output end of the first frequency converter 307 is connected to the input end of the lifting motor module 301.

[0094] A second frequency converter 308 is arranged between the PLC controller 200 and the opening and closing motor module 302. The input end of the second frequency converter 308 is connected to the PLC controller 200, and the output end of the second frequency converter 308 is connected to the input end of the opening and closing motor module 302.

[0095] In this embodiment, the frequency converter is used to control the grab bucket lifting motor and the grab bucket opening and closing motor respectively, the frequency converter is connected with the PLC controller, and the rotation speed of the motor is controlled, so that the accurate control of the grab bucket is realized.

[0096] Embodiment 3

[0097] Figure 4 The flow chart of the train bulk cargo handling method in the embodiment of the application. In this embodiment, the automatic bulk cargo handling train for smelting is taken as an example, and the handling method flow chart is as shown in Figure 4 The specific process is as follows:

[0098] S100, in the WMS warehouse management interface, switching to the unloading train mode is selected, the train parking range is input, the laser radar is driven to scan the train compartment, after the scanning is completed, the three-dimensional point cloud data is acquired, the data processing module converts the three-dimensional point cloud data into a specific size binary image, and inflation, corrosion and connected domain processing are sequentially performed, so that the positions, types and sizes of the compartments are calculated, the accurate parameters of the compartments are acquired, and the WMS warehouse management module is transmitted;

[0099] S200, in the WMS warehouse management interface, the material type or material grabbing and discharging bin of each compartment is selected respectively, the warehouse management system automatically generates a train unloading work order, and the work order is issued to the crane for execution of grabbing;

[0100] S300, during the grabbing work, first, the WMS warehouse management module calculates the grabbing point position according to the scanning result of the laser radar, the position of the large car is compensated according to the length of the compartment, and the position of the small car is compensated according to the width of the compartment; the specific grabbing point compensation is realized by calculating the distance between the scanning bucket body 1 and the compartment frame;

[0101] S400, when the PLC executes the grabbing, first, the crane is moved to the specified grabbing point, the grab bucket is lowered to the safe height of the compartment and then is lowered at a reduced speed, when the grab bucket reaches the material surface, the torque and weight information are transmitted to the data processing unit in the train bulk cargo handling system obtained in embodiment 1 and embodiment 2, and after the technical confirmation is completed, the grabbing of the material is started. Specifically, the bucket body controls the rising, lowering, opening and closing of the bucket body through the steel wire rope, the other end of the steel wire rope is connected to the two drums of the trolley structure, a weight sensor is installed on the bearing seat of the drum, and the weight of the bucket body is fed back to the central control system through the sensor;

[0102] During the lowering and lifting process, the torque changes of the lifting and opening and closing steel wire ropes are dynamically detected in real time through the gravity sensor on the drum bearing seat, the network distribution of the entire torque is established, the fuzzy control strategy is adopted, and the winding and disorder of the steel wire rope are avoided;

[0103] S500, after the material is grabbed, the grab bucket is lifted to the safety height of the car at low speed, and then is lifted quickly, the torque change of the lifting and opening and closing steel wire ropes is dynamically detected in real time in the process, the segmented speed setting is performed according to the feedback torque of the lifting and opening and closing steel wire ropes, the rotating speed of the motor in the lifting motor module and the opening and closing motor module is controlled through the first frequency converter and the second frequency converter, and accurate control of the grab bucket is realized; specifically, the load weight of the bucket body is set according to the load weight of the bucket body, the load weight of the bucket body is fed back to the central control system through the weight sensor, the running speed of the bucket body is controlled after system operation, real-time synchronization of the opening and closing and lifting steel wire ropes in the lifting process is ensured, winding and disorder of the steel wire ropes are avoided, and the material is discharged; in the lifting process, the torque rising change is dynamically detected to determine whether the hook is hooked to the car body or the car bottom, so that timely parking alarm is realized, and the intrinsic safety of the whole grabbing process is ensured. In the implementation, in order to avoid winding and disorder of the steel wire ropes, the running speed of the steel wire rope is controlled through the rope groove structure of the reel device itself.

[0104] It can be known from the above embodiment that the train bulk cargo loading and unloading system and method provided by the application at least realizes the following beneficial effects:

[0105] 1. The laser radar scanning module in the car body recognition unit can obtain three-dimensional point cloud data of the car body, and accurate car body parameters are obtained through the data processing module. This enables the system to accurately identify the position, size and other information of the car body, providing accurate basis for subsequent grabbing operations, and improving the accuracy and efficiency of loading and unloading; the WMS warehouse management module realizes intelligent planning and scheduling of the operation process, without frequent manual intervention, further improving the loading and unloading efficiency.

[0106] 2. The PLC controller is used to accurately control the lifting motor module and the opening and closing motor module, to ensure that the lifting and opening and closing steel wire ropes are stressed at the same time, to avoid single machine overload and steel wire rope overload problems; two sets of absolute value encoders are used for lifting and opening and closing, to respectively monitor the height and opening degree of the grab bucket, and to communicate with the PLC controller in real time, to ensure that the controller can monitor the values of the encoders in real time, to realize accurate control of the grab bucket. This accurate control can ensure accurate grabbing and unloading of the grab bucket, reduce material spillage and waste, and improve operation stability.

[0107] 3. The laser radar scanning module, the data processing module, the WMS warehouse management module, the lifting motor module and the opening and closing motor module are connected with the PLC controller, to realize integrated control of the whole system. Through the collaborative work between the modules, the system can automatically complete a series of operations such as car body recognition, operation work order generation, grabbing and unloading of the grab bucket, greatly reducing the labor intensity, and improving the automation level and safety of the operation.

[0108] 4. The eight-rope design has multi-point anti-swing function, which can effectively prevent the twisting of the grab bucket during the lowering and lifting process, and eliminate the train skin bucket hanging caused by the twisting of the grab bucket.

[0109] 5. During the lowering and lifting process, the torque change of the lifting and opening and closing steel wire rope is dynamically detected in real time, the network distribution of the entire torque is established, the fuzzy control strategy is adopted, and the running speed of the bucket body is controlled to avoid the winding and disorder of the steel wire rope.

[0110] Although some specific embodiments of the present application have been described in detail by examples, those skilled in the art should understand that the above examples are only for illustration, not for limiting the scope of the present application. Those skilled in the art should understand that the above embodiments can be modified without departing from the scope and spirit of the present application. The scope of the present application is defined by the appended claims.

Claims

1. A train bulk material loading and unloading system, characterized in that, include: Carriage identification unit, grasping unit, and PLC controller; The vehicle identification unit is coupled to the PLC controller. The vehicle identification unit includes a lidar scanning module, a data processing module, and a WMS (Warehouse Management System) module. The lidar scanning module is coupled to the data processing module. The lidar scanning module is installed on the vehicle and is used to acquire three-dimensional point cloud data of the carriage and send it to the data processing module. The data processing module is coupled to the lidar scanning module and is used to receive the three-dimensional point cloud data signal output by the lidar scanning module, process the three-dimensional point cloud data to obtain the carriage parameters, and send them to the WMS library management module. The WMS warehouse management module is coupled to the data processing module and is used to switch to the unloading mode, input the train stopping range, select the material type or material grabbing bin for each car according to the car parameters output by the data processing module, generate the unloading operation order, and send it to the train operation and the grabbing module to execute the grabbing. The car parameters include car position, car size, material distribution, and material thickness. The gripping unit is coupled to the PLC controller. The gripping unit includes a lifting motor module, a first absolute encoder, an opening / closing motor module, a second absolute encoder, and a grab bucket module. The grab bucket module includes a lifting drum and a lifting wire rope wound on the lifting drum, an opening / closing drum and an opening / closing wire rope wound on the opening / closing drum, and a bucket body whose lifting and opening / closing are controlled by the lifting wire rope and the opening / closing wire rope. The input terminal of the hoisting motor module is coupled to the PLC controller, and the output terminal of the hoisting motor module is connected to the input terminal of the hoisting drum. The hoisting motor module is used to drive the hoisting drum, and the rotation of the hoisting drum realizes the winding and unwinding of the hoisting wire rope. The output end of the hoisting drum is connected to the input end of the first absolute encoder, and the output end of the first absolute encoder is connected to the PLC controller. The first absolute encoder is used to monitor the height of the grab module. The input terminal of the opening and closing motor module is coupled to the PLC controller, and the output terminal of the opening and closing motor module is connected to the input terminal of the opening and closing drum. The opening and closing motor module is used to drive the opening and closing drum, and the opening and closing wire rope is wound up and unwound through the rotation of the opening and closing drum. The output end of the opening and closing drum is connected to the input end of the second absolute encoder, and the output end of the second absolute encoder is connected to the PLC controller. The second absolute encoder is used to monitor the opening degree of the grab module. The PLC controller is coupled to the lidar scanning module and is used to control the lidar scanning module to automatically complete the scanning of the car body; the PLC controller is coupled to the data processing module and is used to control the data processing module to process the three-dimensional point cloud data and obtain the car body parameters; the PLC controller is coupled to the WMS warehouse management module and is used to control the WMS warehouse management module to automatically generate the unloading work order and issue grabbing instructions; the PLC controller is coupled to the hoisting motor module and the opening and closing motor module respectively and is used to control the hoisting wire rope and the opening and closing wire rope to be under force simultaneously; the PLC controller is connected to the first absolute encoder and the second absolute encoder respectively and is used to receive the height of the grab module output by the first absolute encoder and the opening degree of the grab module output by the second absolute encoder, and control the action of the grab module.

2. The train bulk material loading and unloading system according to claim 1, characterized in that, A first frequency converter is provided between the PLC controller and the hoisting motor module. The input terminal of the first frequency converter is coupled to the PLC controller, and the output terminal of the first frequency converter is connected to the input terminal of the hoisting motor module. A second frequency converter is provided between the PLC controller and the switching motor module. The input terminal of the second frequency converter is connected to the PLC controller, and the output terminal of the second frequency converter is connected to the input terminal of the switching motor module.

3. The train bulk material loading and unloading system according to claim 1, characterized in that, The shaft of the first absolute encoder is connected to the main shaft of the hoisting drum; The shaft of the second absolute encoder is connected to the main shaft of the opening and closing drum.

4. The train bulk material loading and unloading system according to claim 1, characterized in that, The data processing module is used to convert the three-dimensional point cloud data into image data, and to identify the position, model and size of the carriage through image processing, obtain the carriage parameters, and pass the carriage parameters to the WMS library management module.

5. The train bulk material loading and unloading system according to claim 1, characterized in that, The lidar scanning module uses 3D lidar.

6. The train bulk material loading and unloading system according to claim 1, characterized in that, The grab module includes one lifting drum and one opening and closing drum; The grab module also includes four lifting wire ropes, of which two lifting wire ropes are wound around the lifting drum and the other two lifting wire ropes are connected to the crane trolley device through a pulley block. The grab module also includes four opening and closing wire ropes, of which two opening and closing wire ropes are wound on the opening and closing drum, and two lifting wire ropes are connected to the crane trolley device through a pulley block. The grab module also includes an upper support beam, and the lifting drum and the opening and closing drum are fixed on the upper support beam; The bucket body is fixed on the upper support beam and connected to the crane trolley device through the lifting wire rope and the opening and closing wire rope.

7. A method for loading and unloading bulk materials on a train, characterized in that, The train bulk material loading and unloading system according to any one of claims 1-6 includes the following steps: The WMS warehouse management module's interface is switched to the unloading mode, the train stopping range is entered, and the lidar scanning module is driven to scan the train carriages to obtain three-dimensional point cloud data. The data processing module converts the three-dimensional point cloud data into a binary image, performs dilation, erosion, and connected component processing in sequence, calculates the position, type, and size of each carriage, obtains the carriage parameters, and transmits them to the WMS warehouse management module. In the WMS warehouse management interface of the WMS warehouse management module, select the material type of each car or the material grabbing and unloading bin, and the WMS warehouse management module will automatically generate an unloading operation order and send it to the crane to perform grabbing. During the grasping process, the WMS library management module calculates and obtains the grasping point position based on the scanning results of the lidar scanning module; When the PLC controller executes the grabbing action, it moves the trolley to the designated grabbing point. After the bucket descends to the safe height of the train car, it decelerates and descends. Once the bucket reaches the material surface and the torque and weight information are verified by the data processing unit of the train bulk material loading and unloading system, the grabbing of materials begins. After grabbing the materials, the grab bucket is slowly raised to the safe height of the train car, and then quickly raised. During the descent and raising process, the torque changes of the opening and closing wire rope and the hoisting wire rope are dynamically monitored in real time.

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