Intelligent container transfer platform

Abstract

The invention relates to the technical field of transfer platforms, in particular to an intelligent container transfer platform which comprises a guide vehicle, an automatic docking module, an environment sensing module and a central control system, a bearing table is mounted at the top end of the guide vehicle, a positioning guide assembly is mounted at the top of the guide vehicle, and an anti-displacement limiting mechanism is mounted at the top of the guide vehicle. The automatic docking module comprises two industrial cameras and four first laser displacement sensors, the two industrial cameras are installed at the front end and the rear end of the top of the guide vehicle respectively, and the four first laser displacement sensors are installed at the four corners of the bearing table respectively; the central control system is in communication connection with the automatic butt joint module, the positioning guide assembly, the anti-displacement limiting mechanism and the environment sensing module, and the intelligent container transfer platform aims at solving the problem that in the butt joint stage of an existing intelligent container transfer platform, due to the lack of an effective automatic correction mechanism, a container is often difficult to align to the platform effectively.

Description

Technical Field

[0001] This invention relates to the field of transshipment platform technology, specifically to a smart container transshipment platform. Background Technology

[0002] The intelligent container transfer platform is an automated transfer system built around the entire process of container receiving, storage, loading and unloading. It integrates core technologies such as intelligent scheduling, real-time monitoring, and data analysis. Through a central control system, the platform can automatically identify transfer needs, plan the optimal operation process, track cargo status and equipment operation information in real time, and organize and analyze the data generated during the transfer process to optimize operational strategies, reduce human intervention, and ultimately achieve unmanned, efficient, and safe container transfer. In the actual operation of the platform, automated guided vehicles (AGVs) are the key execution carriers that undertake physical transfer tasks.

[0003] During the docking phase, existing intelligent container transfer platforms often fail to align containers effectively with the platform due to the lack of an effective automatic correction mechanism. This can lead to lateral or longitudinal positional deviations. Once in the transfer phase, these deviations can cause uneven stress on the connecting components between the platform and the container, accelerating equipment wear and even causing structural damage. They can also trigger a shutdown due to deviations exceeding the safety range. Furthermore, each relocation requires manual intervention, increasing labor costs and disrupting normal operations, severely impacting the efficiency and safety of the transfer process. Summary of the Invention

[0004] The purpose of this invention is to provide a smart container transfer platform to solve the problem that existing smart container transfer platforms often fail to align containers effectively with the platform during the docking phase due to the lack of an effective automatic correction mechanism.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] The intelligent container transfer platform includes a guided vehicle, an automatic docking module, an environmental sensing module, and a central control system. A support platform is mounted on the top of the guided vehicle, along with a positioning and guiding component and an anti-displacement limiting mechanism. The automatic docking module includes two industrial cameras and four first laser displacement sensors. The two industrial cameras are respectively mounted at the front and rear ends of the top of the guided vehicle, and the four first laser displacement sensors are respectively mounted at the four corners of the support platform. The central control system is communicatively connected to the automatic docking module, the positioning and guiding component, the anti-displacement limiting mechanism, and the environmental sensing module, and is used to receive data and output control commands.

[0007] Preferably, there are six sets of positioning and guiding components, each corresponding to two sets on each of the two long sides and one set on each of the two short sides of the support platform, and four sets of anti-displacement limiting mechanisms, each corresponding to one of the four corners of the support platform.

[0008] Preferably, the positioning and guiding component includes a guide telescopic member, which is driven by a hydraulic telescopic cylinder installed inside the guide vehicle to achieve up-and-down sliding telescopic movement. The inner surface of the guide telescopic member is provided with a guide slope for guiding.

[0009] Preferably, the positioning and guiding assembly further includes a fixed seat and a supporting swing arm. The fixed seat is fixedly connected to the top of the guide vehicle, and one end of the supporting swing arm is rotatably connected to the fixed seat. The back of the guide telescopic component is provided with an embedding groove for the supporting swing arm to be rotatably embedded.

[0010] Preferably, the anti-displacement limiting mechanism includes a fixed bracket, a limiting swing rod, a linkage block, and a limiting plate. The fixed bracket is fixedly connected to the top of the guide vehicle. One end of the limiting swing rod is rotatably connected to the fixed bracket, and the other end is rotatably connected to the linkage block. The linkage block and the limiting plate are fixedly connected.

[0011] Preferably, a position detection sensor is installed on the top of the guide vehicle, and when the anti-displacement limiting mechanism is locked, a locking completion signal is sent through the position detection sensor.

[0012] Preferably, the environmental perception module includes a camera, a visibility sensor, and a millimeter-wave radar. The camera is mounted on the surface of the guided vehicle, the visibility sensor is mounted on the top of the guided vehicle, and the millimeter-wave radar is mounted at the front and rear ends of the guided vehicle.

[0013] Preferably, the central control system receives obstacle data from millimeter-wave radar and cameras, and classifies the operational risk into three levels: low risk, medium risk, and high risk based on the obstacle data.

[0014] Preferably, the low risk is no obstacles, corresponding to a controlled guide vehicle speed of 5 km / h; the medium risk is obstacles within 3-5 m, corresponding to a controlled guide vehicle speed of 1 km / h; and the high risk is obstacles within ≤3 m, corresponding to a controlled guide vehicle braking.

[0015] Compared with the prior art, the beneficial effects of the present invention are:

[0016] 1. Through the dual design of automatic guide ramp correction and limit plate triangular locking, the problem of easy displacement when traditional containers are docked with intelligent transfer platforms is effectively solved, significantly improving the accuracy of the docking process. At the same time, it ensures the stability of the container throughout the transfer process, avoiding uneven equipment stress or safety hazards caused by displacement. Moreover, from the fine adjustment of the intelligent transfer platform position and guide correction to the limit locking, precise connection can be completed without manual intervention. This not only reduces labor costs but also avoids the safety risks that may be caused by manual operation. It also ensures that the docking process can proceed stably in all weather conditions, improving the continuity of operations.

[0017] 2. Relying on a multi-sensor fusion perception system and combined with targeted adverse weather adaptation logic, it can more comprehensively address safety risks in different operating environments, reduce the probability of collision accidents, and improve the reliability of equipment operation. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0019] Figure 2 For the present invention Figure 1 Enlarged view of point A in the middle;

[0020] Figure 3 For the present invention Figure 1 Enlarged view of point B in the middle.

[0021] In the diagram: 1. Guide vehicle; 2. Support platform; 3. Fixed seat; 4. Support swing arm; 5. Embedded groove; 6. Guide telescopic component; 7. Guide slope; 8. Fixed bracket; 9. Limiting swing rod; 10. Linkage block; 11. Limiting plate. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] Please see Figures 1 to 3 The present invention provides a technical solution.

[0024] The intelligent container transfer platform includes a guide vehicle 1, whose frame is made of Q690 high-strength low-alloy structural steel. The wheel set is equipped with eight sets of solid rubber wheels, connected to a drive motor via a planetary reducer. The drive motor supports forward and reverse speed regulation. A carrying platform 2 (suitable for 20-foot standard containers) is mounted on the top of the guide vehicle 1. It also includes a power and range unit, using lithium iron phosphate batteries, installed at the center of gravity of the guide vehicle 1, equipped with a battery management system (BMS) to monitor voltage, current, and temperature in real time. Six positioning and guiding components are installed on the top of the guide vehicle 1, two on each of the two long sides and one on each of the two short sides of the carrying platform 2, used for guiding and correcting deviations when containers fall. Four anti-displacement limiting mechanisms are installed on the top of the guide vehicle 1, located at the four corners of the carrying platform 2, limiting the horizontal movement of containers during transfer.

[0025] It also includes an automatic docking module, which is used to achieve precise positioning and rigid connection between the container and the intelligent transfer platform. The automatic docking module includes two industrial cameras and four first laser displacement sensors. The two industrial cameras are respectively installed at the front and rear ends of the top of the guide vehicle 1 to align with the metal reference block set at the bottom of the container. The four first laser displacement sensors are respectively installed at the four corners of the support platform 2 to detect the vertical distance between the bottom of the container and the support platform 2.

[0026] The positioning and guiding assembly includes a fixed base 3, a supporting swing arm 4, and a guide telescopic component 6. The guide telescopic component 6 is driven by a hydraulic telescopic cylinder installed inside the guide vehicle 1 to achieve up-and-down sliding telescopic movement. The inner surface of the guide telescopic component 6 is provided with a guide slope 7 for guidance. When the intelligent transfer platform arrives at the loading and unloading point below the crane, it sends a mechanical trigger signal to the crane. After receiving the mechanical trigger signal, the crane lowers the container. The bottom of the container is aligned with the top of the bearing platform 2. During the lowering process, the guide slope 7 on the surface of the guide telescopic component 6 provides guidance. If there is a horizontal deviation in the container, the bottom of the container slides along the slope of the guide slope 7, and the deviation is automatically corrected under the guidance, so that the container is aligned with the body of the guide telescopic component 6.

[0027] The fixed base 3 is fixedly connected to the top of the guide vehicle 1. One end of the support swing arm 4 is rotatably connected to the fixed base 3. The support swing arm 4 is rotated by the first angular displacement swing cylinder (swing angle 90°) installed on the top of the guide vehicle 1. Specifically, the output end of the angular displacement swing cylinder moves through the surface of the fixed base 3 and is fixedly connected to the support swing arm 4. The back of the guide telescopic component 6 is provided with an embedding groove 5 for the support swing arm 4 to rotate and embed. When the guide telescopic component 6 extends to guide the container to fall, the support swing arm 4 is rotated so that one end of the support swing arm 4 is embedded in the embedding groove 5. The support logic is that after the support swing arm 4 is embedded in the embedding groove 5, it forms a triangular support structure with the guide telescopic component 6, which resists lateral pressure ≥50kN, and avoids the guide telescopic component 6 from deforming due to the container pressing down.

[0028] The anti-displacement limiting mechanism includes a fixed bracket 8, a limiting swing rod 9, a linkage block 10, and a limiting plate 11. The fixed bracket 8 is fixedly connected to the top of the guide vehicle 1. One end of the limiting swing rod 9 is rotatably connected to the fixed bracket 8, and the other end is rotatably connected to the linkage block 10. The linkage block 10 and the limiting plate 11 are fixedly connected. The limiting plate 11 is L-shaped, with a 5mm thick rubber pad pasted on the inner side to prevent scratches. The limiting swing rod 9 is rotated by the second angular displacement swing cylinder (swing angle 120°) installed on the top of the guide vehicle 1. When the container is aligned with the guide telescopic component 6 and placed on the support platform 2, the second angular displacement swing cylinder is activated, which drives the limiting swing rod 9 to rotate. The limiting swing rod 9 drives the limiting plate 11 to move towards the container in a rotating manner. When the limiting plate 11 is close to the container, the linkage block 10 and the limiting swing rod 9 will rotate until the limiting plate 11 is in a vertical state and in contact with the surface of the container, forming a triangular support, which limits the container from the four corners.

[0029] The docking process is as follows: the intelligent transfer platform arrives at the target area 1m away, the drive motor decelerates to 0.5km / h, two industrial cameras and the first laser displacement sensor start synchronously. The industrial cameras identify the metal reference block at the bottom of the container and output the horizontal deviation value (X / Y axis), while the first laser displacement sensor outputs the vertical distance value (Z axis) and transmits it to the central control system. The central control system calculates the adjustment amount and controls the drive motor to fine-tune the position of the intelligent transfer platform (X / Y axis deviation ≤ 5mm). After completion, the central control system sends a positioning completion signal to the intelligent transfer platform; the telescopic cylinder drives the guide telescopic component 6 to extend, and the first angular displacement swing cylinder drives the support swing arm 4 to embed into the embedding groove 5. The intelligent transfer platform sends a docking permission signal to the crane; the crane lowers the container, the bottom of the container slides along the guide ramp 7 to correct the deviation, and it falls smoothly onto the bearing platform 2. The first laser displacement sensor detects... Once the load is in place, the second angular displacement swing cylinder drives the limit swing rod 9 to rotate, causing the limit plate 11 to fit against the container and form a limit. A position detection sensor is installed on the top of the guide vehicle 1. The position detection sensor sends a locking completion signal. The position detection sensor can be a second laser displacement sensor. The laser emission direction is perpendicular to the outer surface of the limit plate 11. The working logic is that, based on the preset locking position threshold (e.g., when the limit plate 11 is vertical, the sensor detection distance is 120mm±0.5mm), during the rotation of the limit plate 11, the second laser displacement sensor outputs distance data to the central control system in real time. When the distance is stable within the threshold range and lasts for 50ms, the system determines that the locking is complete and triggers a signal. The weighing sensor at the bottom of the carrying platform 2 detects the load and compares it with the estimated value (deviation ≤5%). After confirming that the load is normal, the intelligent transfer platform sends a transfer start signal.

[0030] It also includes an environmental perception module, which includes cameras, one on each side of the guided vehicle 1, with a recognition distance of 5-30m; a visibility sensor, installed on the top of the guided vehicle 1, with a sampling period of 1s; and millimeter-wave radar, installed at the front and rear ends of the guided vehicle 1 to detect obstacles on the road ahead. In the safety protection logic, obstacle avoidance protection is implemented when the millimeter-wave radar detects an obstacle within 5m, the software system immediately sends a deceleration command to reduce the speed to 1km / h; when the obstacle enters the 3m range, an emergency braking command is sent, the brakes are activated, and an audible and visual alarm is triggered; after the obstacle is removed, a reset command is sent manually through the central control system, and the intelligent transfer platform releases the brakes and resumes driving. In case of severe weather, when the visibility sensor detects visibility <50m, the system automatically switches to rain and fog mode: the millimeter-wave radar detection frequency is increased from 10Hz to 20Hz, the driving speed is reduced to 3km / h, and the safe distance is extended to 10m.

[0031] The central control system includes an industrial-grade PLC controller. It communicates with the automatic docking module, positioning and guiding components, anti-displacement and limiting mechanism, and environmental sensing module to receive data and output control commands. The central control system receives obstacle data from millimeter-wave radar and cameras in real time, dynamically adjusting the path with a path update cycle of 1 second. Based on obstacle data, the operational risk is categorized into three levels: low risk (no obstacles), medium risk (obstacles within 3-5m), and high risk (obstacles within ≤3m). Correspondingly, the central control system outputs signals to the motor controller of the guided vehicle 1 via Ethernet to control the drive motor to maintain a speed of 5 km / h. For medium risk, the drive motor is decelerated to 1 km / h. For high risk, the central control system triggers the braking of the guided vehicle 1 (e.g., electromagnetic brake) and cuts off the drive motor power, then issues an alarm. The distance ranges of 3-5m and ≤3m are determined based on inertial braking experiments with the guided vehicle 1 carrying a 20-ton load and a road surface friction coefficient of 0.6.

[0032] The communication protocol is as follows: internal communication between the units of the guide vehicle 1 (drive motor, sensor, cylinder) is via the Profinetv2.4 protocol; external communication between the intelligent transfer platform and the central control system and the crane is via Ethernet (TCP / IP protocol); and communication between the intelligent transfer platform and the weighing sensor and the battery management system is via the Modbus-RTUv1.0 protocol.

[0033] The connection logic of each module is as follows: After the crane completes the unloading of the container, it sends a task ready signal to the central control system; upon receiving the signal, the central control system matches an idle intelligent transfer platform and issues a transfer task to it via Ethernet; after receiving the task, the software system of the intelligent transfer platform arrives at the loading and unloading point, and the industrial camera and laser displacement sensor simultaneously collect data; after the positioning correction algorithm processes the collected data, the drive motor fine-tunes the position of the intelligent transfer platform; after the fine-tuning is completed, the guide telescopic component 6 extends, and the support swing arm 4 completes the support action; the intelligent transfer platform then sends a docking permission signal to the crane; after receiving the signal, the crane lowers the container; after the container is in place, the anti-displacement limit mechanism completes the locking action; after the weighing sensor detects the load and confirms that it is normal, the intelligent transfer platform sends a transfer start signal; during the transfer process, the environmental perception module collects surrounding environmental data in real time; the safety decision algorithm performs risk assessment on the collected data and outputs corresponding control commands to the drive motor and alarm unit according to the assessment results.

[0034] The specific steps of this plan are as follows: After the crane completes the initial unloading of the container, it sends a task ready signal to the central control system, indicating that the transfer docking can proceed; after receiving the signal, the central control system matches an idle intelligent transfer platform and sends a specific transfer task (including loading and unloading points and target point locations) to it via Ethernet; after receiving the task, the intelligent transfer platform begins to travel to the loading and unloading point.

[0035] The drive motor of the guided vehicle 1 starts, driving eight sets of solid rubber wheels through a planetary reducer. It travels towards the loading and unloading point according to the path planned by the central control system. The default driving speed is 5 km / h (low risk mode). During the journey, the environmental perception module works in real time. The millimeter-wave radar detects obstacles within 5m of the forward path. If there is an obstacle, the speed is reduced to 1 km / h (medium risk). If the obstacle enters the 3m range (high risk), the emergency brake (electromagnetic brake) is immediately triggered, cutting off the power to the drive motor and triggering an audible and visual alarm. The vehicle can only continue to travel after manual reset. The visibility sensor samples once per second. If the detected visibility is <50m, the vehicle automatically switches to rain and fog mode: the millimeter-wave radar detection frequency is increased to 20Hz, the driving speed is reduced to 3 km / h, and the safe distance is extended to 10m.

[0036] When the intelligent transfer platform arrives at the loading / unloading point at a distance of 1m, the drive motor automatically decelerates to 0.5km / h and simultaneously activates the automatic docking module: two industrial cameras align with the metal reference block at the bottom of the container and output horizontal deviation values ​​(X / Y axis); four first laser displacement sensors detect the vertical distance (Z axis) between the bottom of the container and the support platform 2. After receiving the above data, the central control system calculates the position adjustment amount and controls the drive motor to fine-tune the platform position to ensure that the X / Y axis deviation is ≤5mm. After completion, it sends a positioning completion signal to the platform. After receiving the signal, the platform activates the positioning guide assembly: the hydraulic telescopic cylinder drives the guide telescopic component 6 to extend, preparing to guide the container to fall; the first angular displacement swing cylinder drives the support swing arm 4 to rotate, so that one end of it is embedded in the embedding groove 5 of the guide telescopic component 6, forming a triangular support structure.

[0037] After the positioning and guiding components are ready, the intelligent transfer platform sends a docking permission signal to the crane via Ethernet. Upon receiving the docking permission signal, the crane slowly lowers the container, aligning the bottom of the container with the top of the loading platform 2. During the container's descent, if there is a horizontal deviation, its bottom will slide along the guide ramp 7 inside the guide telescopic component 6 to automatically correct the deviation, ultimately aligning with the guide telescopic component 6 and landing smoothly on the loading platform 2. After the first laser displacement sensor detects that the container is fully positioned, it sends a loading positioning signal to the central control system, triggering the anti-displacement limit mechanism to operate: the second angular displacement swing cylinder drives the limit swing rod 9 to rotate. The limiting lever 9 drives the limiting plate 11 to rotate towards the container via the linkage block 10; the limiting plate 11 gradually approaches the container until it is vertical and in contact with the container surface, forming a triangular support limit; the position detection sensor (second laser displacement sensor) detects the distance to the outside of the limiting plate 11 in real time. When the distance is stable at 120mm±0.5mm for 50ms, the system determines that the locking is complete and sends a locking signal; the weighing sensor at the bottom of the bearing platform 2 detects the container load and compares the detected value with the estimated value. If the deviation is ≤5%, the load is confirmed to be normal, and the intelligent transfer platform sends a transfer start signal to the central control system.

[0038] After receiving the transfer start signal, the central control system allows the platform to travel to the target point and the drive motor resumes operation (default 5km / h). During the transfer, the environmental perception module continuously collects surrounding data and transmits it to the central control system. The central control system performs risk assessment on the data and outputs control commands according to low, medium and high risk levels.

[0039] After the intelligent transfer platform arrives at the target point, it sends an arrival signal to the central control system and stops the drive motor, triggering the anti-displacement limit mechanism to unlock (the second angular displacement swing cylinder drives the limit plate 11 to reset); after receiving the unloading signal from the central control system, the target point crane lifts the container off the bearing platform 2; after the first laser displacement sensor detects the removal of the container, it sends an unloading completion signal to the platform; after receiving the unloading completion signal, the platform waits for the next task instruction from the central control system.

[0040] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A container intelligent transfer platform, comprising a guide vehicle (1), an automatic docking module, an environmental sensing module, and a central control system, characterized in that: The top of the guide vehicle (1) is equipped with a support platform (2), the top of the guide vehicle (1) is equipped with a positioning and guiding component, the top of the guide vehicle (1) is equipped with an anti-displacement limiting mechanism, the automatic docking module includes two industrial cameras and four first laser displacement sensors. The two industrial cameras are respectively installed at the front and rear ends of the top of the guide vehicle (1), and the four first laser displacement sensors are respectively installed at the four corners of the support platform (2). The central control system is communicatively connected to the automatic docking module, the positioning and guiding component, the anti-displacement limiting mechanism and the environmental perception module, and is used to receive data and output control commands.

2. The intelligent container transfer platform according to claim 1, characterized in that, The positioning and guiding components consist of six groups, each corresponding to two groups on each of the two long sides and one group on each of the two short sides of the support platform (2). The anti-displacement limiting mechanism consists of four groups, each corresponding to the four corners of the support platform (2).

3. The intelligent container transfer platform according to claim 1, characterized in that, The positioning and guiding component includes a guide telescopic component (6), which is driven by a hydraulic telescopic cylinder installed inside the guide vehicle (1) to achieve up-and-down sliding telescopic movement. The inner surface of the guide telescopic component (6) is provided with a guide slope (7) for guiding.

4. The intelligent container transfer platform according to claim 3, characterized in that, The positioning and guiding assembly also includes a fixed seat (3) and a supporting swing arm (4). The fixed seat (3) is fixedly connected to the top of the guide vehicle (1). One end of the supporting swing arm (4) is rotatably connected to the fixed seat (3). The back of the guide telescopic component (6) is provided with an embedding groove (5) for the supporting swing arm (4) to be rotatably embedded.

5. The intelligent container transfer platform according to claim 1, characterized in that, The anti-displacement limiting mechanism includes a fixed bracket (8), a limiting swing rod (9), a linkage block (10), and a limiting plate (11). The fixed bracket (8) is fixedly connected to the top of the guide vehicle (1). One end of the limiting swing rod (9) is rotatably connected to the fixed bracket (8), and the other end is rotatably connected to the linkage block (10). The linkage block (10) and the limiting plate (11) are fixedly connected.

6. The intelligent container transfer platform according to claim 1, characterized in that, A position detection sensor is installed on the top of the guide vehicle (1). When the anti-displacement limiting mechanism is locked, a locking completion signal is sent through the position detection sensor.

7. The intelligent container transfer platform according to claim 1, characterized in that, The environmental perception module includes a camera, a visibility sensor and a millimeter-wave radar. The camera is installed on the surface of the guided vehicle (1), the visibility sensor is installed on the top of the guided vehicle (1), and the millimeter-wave radar is installed at the front and rear ends of the guided vehicle (1).

8. The intelligent container transfer platform according to claim 7, characterized in that, The central control system receives obstacle data from millimeter-wave radar and cameras, and classifies the operational risk into three levels: low risk, medium risk, and high risk based on the obstacle data.

9. The intelligent container transfer platform according to claim 8, characterized in that, The low risk is no obstacle, corresponding to the driving speed of the guide vehicle (1) being 5km / h; the medium risk is an obstacle within 3-5m, corresponding to the driving speed of the guide vehicle (1) being 1km / h; the high risk is an obstacle within ≤3m, corresponding to the braking of the guide vehicle (1).

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