Intelligent roadway stacking device for wharf

Abstract

The invention provides an intelligent roadway stacking device for a wharf, and relates to the technical field of wharf roadway stacking appliances, the device is composed of a hardware structure and a software system cooperatively, the hardware structure comprises a portal frame, a sliding rail, a mounting seat, a moving frame, a stacking frame, a lifting mechanism, a moving mechanism, a detection mechanism and a plurality of sensors and driving parts, an execution carrier is provided for physical carrying of goods, and three-dimensional space movement of the stacking frame, goods conveying and state detection can be achieved; and the software system covers a hardware interface, a sensing data processing module, a control decision module and an execution driving module, and completes data acquisition, filtering calibration, intelligent decision and instruction execution. Through cooperation of software and hardware, automation of wharf stacking operation is achieved, manual intervention is not needed, operation efficiency is greatly improved, high throughput is adapted, potential safety hazards are monitored and eliminated in real time, accurate positioning is achieved, goods are stably transported, the problems that a traditional device depends on manpower, potential hazards are large, positioning precision is insufficient, and goods are prone to being damaged are effectively solved, and efficient and safe operation of a wharf is assisted.

Description

Technical Field

[0001] This invention relates to the field of dockway stacking equipment technology, and in particular to an intelligent dockway stacking device. Background Technology

[0002] In port terminal operations, cargo stacking and transshipment are core links in ensuring smooth logistics. With the development of international trade and the continuous increase in terminal cargo throughput, traditional stacking equipment has gradually revealed the following key problems: 1. Cargo loading and unloading rely on manual assistance or semi-automated equipment. The conveyor belt angle is fixed and cannot be flexibly adjusted according to the loading and unloading position. The transfer process takes a long time and is difficult to adapt to high throughput requirements. 2. There is no real-time monitoring mechanism for cargo weight and placement status. Overloading can easily lead to equipment failure, and cargo misplacement can easily cause stack collapse, posing a safety hazard. 3. The lack of precise horizontal and vertical positioning mechanisms prevents the stacking racks from quickly aligning with the target shelf level, increasing operational errors and time costs; 4. Without an effective fixing structure during transportation, goods are prone to shaking and falling, leading to damage to goods or interruption of operations.

[0003] To address the aforementioned issues, existing technologies have not yet proposed a comprehensive solution that balances automation, intelligence, safety, and accuracy. Therefore, there is an urgent need for an intelligent roadway stacking device for docks to fill this technological gap. Summary of the Invention

[0004] This invention aims to solve the problems of low efficiency, lack of intelligent detection, insufficient positioning accuracy, and inadequate cargo securing in existing dock stacking devices, and provides an intelligent aisle stacking device for docks to achieve efficient, safe, and precise cargo stacking operations.

[0005] To solve the above-mentioned technical problems, the present invention provides an intelligent aisle stacking device for docks, comprising a software system and a hardware structure; the software system is communicatively connected to the hardware equipment of the stacking device, the hardware equipment including a gantry frame, slide rails, mounting bases, moving frames, stacking frames, lifting mechanisms, moving mechanisms, detection mechanisms, and multiple sensors and driving components, the moving mechanism including a conveyor belt, and the software system including: The hardware interface module is used to establish communication connections with various components in the hardware device, supporting analog-to-digital signal conversion and multi-communication protocol adaptation; the various components in the hardware device include position sensors, pressure sensors, linear motors, first motors, second motors, electric actuators, and cylinders; The perception data processing module receives stacking position information collected by various sensors. The stacking position information includes horizontal position and lifting height data of the stacking rack collected by the position sensor and weight data of the goods collected by the pressure sensor. After filtering, calibration and fusion processing of the stacking position information, the module outputs equipment position information and goods status information including whether the weight exceeds the standard and whether the placement is stable. The control decision module has built-in operation process logic and control algorithm. Based on the equipment location information, cargo status information and the preset operation parameters of the storage module, it generates drive control instructions. The operation process logic includes cargo transportation, lifting and positioning, cargo fixing and unloading control logic. The execution driver module converts control commands into execution signals and sends them to each driver component through the hardware interface module to control coordinated actions. The safety monitoring module monitors the equipment position offset, cargo weight, and drive component operating load in real time. When parameters exceed preset safety thresholds, it sends an abnormal signal to trigger an emergency shutdown or adjustment.

[0006] Preferably, the workflow of the sensing data processing module includes: The hardware interface module receives the original values ​​of the horizontal position and lifting height of the stacking rack from the position sensor, as well as the pressure value and temperature compensation coefficient from the pressure sensor, at a preset frequency. The location data is processed using an extended Kalman filter, and the pressure data is processed using a moving average filter of multiple sample values. Next, position calibration is performed, including position calibration and pressure calibration. Position calibration uses a set scaling factor and offset to calibrate the filtered position data, while pressure calibration uses a temperature compensation factor and gravity parameters to calibrate the filtered pressure data. The weights of the two calibrated plates are then added together to obtain the total weight. If the weight exceeds the preset upper limit, the weight is output as excessive. The stability coefficient is calculated based on the weight distribution of the two plates, and the placement status (stable, slightly offset, or severely offset) is output according to the relationship between the stability coefficient and the threshold. Finally, the calibrated equipment position information and cargo status information are output.

[0007] Preferably, the process by which the control decision module generates driver control commands includes: The sensor data processing module obtains the calibrated horizontal position of the stacking rack, lifting height, total weight of the goods, and stability coefficient. Retrieve preset parameters from the preset storage module, including target position, upper limit of horizontal and vertical speed, reference speed of conveyor belt, weight threshold, delay time, stability threshold and positioning tolerance; Positioning control is achieved by using a PID closed-loop control algorithm, which adjusts the control quantity of the drive component by preset proportional, integral, and derivative coefficients to eliminate position deviation. Process execution: Cargo conveying: When the weight of the cargo reaches the preset minimum detection weight, the second motor is started to drive the conveyor belt. The conveyor belt speed is adaptively adjusted according to the weight of the cargo. When the cargo reaches above the first support plate, the conveyor belt is stopped. Lifting and positioning: The PID algorithm controls the linear motor to adjust the horizontal position of the stacking rack and controls the first motor to adjust the lifting height of the stacking rack until the position deviation does not exceed the positioning tolerance; Cargo fixing: When the stability coefficient reaches the preset stability threshold, the electric push rod is extended and retracted, and the cargo is fixed on both sides by adjusting the tilt angle of the conveyor belt. Unloading: After the stacker reaches the target position, the electric push rod is reset to open the conveyor belt, the cylinder is pushed to form an inclined surface so that the goods slide onto the conveyor belt, and then the second motor is started to transport the goods.

[0008] Preferably, the process by which the execution driving module controls the driving component includes: It communicates with the control decision module via industrial bus and receives control command frames containing drive component identifiers, target parameters, and action timing. For motor-type drive components, including linear motors, first motors, and second motors, the target speed command is converted into a PWM signal with the corresponding duty cycle. For push rod / cylinder type drive components, including electric push rods and cylinders, the target displacement command is converted into a current signal of corresponding magnitude; Signal transmission and feedback: The execution signal is transmitted through the isolation amplifier circuit of the hardware interface module, while the position, current and temperature feedback signals of the driving device are collected at the same time; Cooperative control: The start time of each driving component's action is planned according to the timing parameters in the control command. When the deviation between the actual action of the driving component and the target action does not exceed the preset cooperative accuracy, the next driving component action is triggered.

[0009] Preferably, the software system further includes: The human-machine interaction module communicates with the control decision module and the display module respectively, supports the input of operation parameters and the selection of automatic / manual control modes, receives equipment operating status information and displays it visually through the display module; The storage module stores operation parameters, equipment operation logs, historical sensor data, and preset safety thresholds. Operation parameters include target stacking position, maximum cargo weight, and equipment moving speed.

[0010] Preferably, the lifting mechanism includes a mounting plate fixed to the middle of the movable frame, two first pulleys rotatably mounted in the first mounting groove, and a first motor mounted on the mounting plate. A take-up roller is connected to the output shaft of the first motor, and a steel wire rope is wound on the take-up roller. The other end of the steel wire rope passes over the upper end of the first pulley and is equipped with a reinforcing joint. The two reinforcing joints are respectively fixed to the two sliding frames.

[0011] Preferably, the moving mechanism includes connecting plates hinged to both sides of the stacking frame, a conveyor belt located at one end of the stacking frame, a support frame installed on the outside of the conveyor belt, the rear end of the support frame being hinged to the other end of the connecting plate, and a second motor installed on one side of the support frame.

[0012] Preferably, the detection mechanism includes a first support plate and a second support plate installed on the top surface of the stacking rack. The first support plate and the second support plate are hinged at their proximal ends. The pressure sensor is installed on the bottom surface of the second support plate, and the bottom end of the pressure sensor is installed on the top surface of the stacking rack. A second mounting groove is provided inside the stacking rack, and the cylinder is installed in the second mounting groove. The telescopic end of the cylinder is hinged to the bottom surface of one end of the first support plate.

[0013] Compared with related technologies, the intelligent roadway stacking device for docks provided by this invention has the following beneficial effects: 1. This solution utilizes the synergy of hardware structure and software system. On the hardware side, the second motor drives the conveyor belt for automatic cargo transport, and the electric push rod can flexibly adjust the conveyor belt's tilt angle to adapt to different loading and unloading positions, eliminating the need for manual adjustment. The linear motor and the first motor respectively drive the stacking rack for horizontal movement and vertical lifting, enabling flexible movement of the stacking rack in three-dimensional space. In the software system, the control decision module automatically generates drive control commands based on the equipment position and cargo status information output by the perception data processing module, combined with preset parameters from the storage module. The execution drive module converts these commands into execution signals to drive hardware actions. The entire process requires no manual intervention, effectively reducing manual assistance, shortening cargo transfer time, meeting the high-throughput operation requirements of the terminal, and solving the problems of traditional stacking devices relying on manual labor and being inefficient. This effectively improves the efficiency of terminal stacking operations and achieves a high degree of automation.

[0014] 2. This solution addresses both cargo status monitoring and equipment operation monitoring. On the hardware side, a pressure sensor installed on the bottom of the second support plate collects real-time pressure data related to cargo weight. A position sensor monitors the stacker's position and provides feedback on equipment operation status. The software system's sensing data processing module filters, calibrates, and fuses the pressure data, calculates the total cargo weight and stability coefficient, and determines whether the cargo is overloaded or placed stably. If overloaded or severely offset, it outputs status information promptly. The safety monitoring module monitors parameters such as equipment position offset and drive component load in real time. When parameters exceed preset safety thresholds, it immediately sends an abnormal signal to trigger an emergency shutdown or adjustment, preventing equipment failure due to overload or stack collapse caused by cargo offset. This solves the problems of traditional devices lacking real-time monitoring and posing significant safety hazards.

[0015] 3. This solution utilizes a combination of hardware and software. For positioning, position sensors collect real-time data on the horizontal position and lifting height of the stacking rack. The sensing data processing module employs an extended Kalman filter to process the position data, eliminating noise interference. Position calibration then compensates for deviations, outputting accurate equipment position information. The control decision module uses a PID closed-loop control algorithm. Based on the deviation between the target position and the actual position, it drives the linear motor and the first motor to adjust the stacking rack position, ensuring the position deviation does not exceed the positioning tolerance. This allows the stacking rack to quickly and accurately align with the target shelf level, solving the problem of insufficient positioning accuracy in traditional devices. For cargo transportation, when the cargo stability coefficient meets the standard, the control decision module controls the extension and retraction of the electric push rod. By adjusting the conveyor belt's tilt angle, the cargo is fixed on both sides, preventing it from shaking or falling during transportation. During unloading, the electric push rod resets, and the cylinder pushes the first support plate to form an inclined surface, coordinating with the conveyor belt to transport the cargo, ensuring stable cargo transportation throughout and reducing cargo damage and operational interruptions.

[0016] In summary, this solution, through the synergy of hardware structure and software system, enables terminal stacking operations to be completed without human intervention. This significantly improves operational efficiency to meet high throughput demands, eliminates safety hazards by monitoring cargo status and equipment operation in real time, and accurately positions stacking racks to stably transport cargo. It effectively solves the problems of traditional stacking devices, such as reliance on manual labor, significant safety hazards, insufficient positioning accuracy, and easy damage to cargo. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall three-dimensional structure of the hardware structure proposed in this invention; Figure 2 This is a schematic diagram of the mobile frame structure proposed in this invention; Figure 3 This is a schematic diagram of the lifting mechanism structure proposed in this invention; Figure 4 This is a schematic diagram of the moving mechanism structure proposed in this invention; Figure 5 This is a schematic diagram of the cross-sectional structure of the stacking rack proposed in this invention; Figure 6 The present invention proposes Figure 1 Enlarged schematic diagram of the structure at part A in the middle; Figure 7 The present invention proposes Figure 2 Enlarged schematic diagram of the structure of part B in the middle; Figure 8 This is a schematic diagram of the software system proposed in this invention.

[0018] The following are the labels in the diagram: 1. Gantry frame; 2. Slide rail; 3. Mounting base; 4. Moving frame; 5. Mounting plate; 6. Stacking frame; 7. Position sensor; 8. First motor; 9. First pulley; 10. Wire rope; 11. Reinforcing joint; 12. Take-up roller; 13. Connecting plate; 14. Conveyor belt; 15. Support frame; 16. Second motor; 17. Second pulley; 18. Electric actuator; 19. First support plate; 20. Second support plate; 21. Pressure sensor; 22. Cylinder; 23. Linear motor. Detailed Implementation

[0019] 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.

[0020] The terminology used in this disclosure is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. The singular forms “group,” “class,” and “the” as used in this disclosure and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and includes any or all possible combinations of one or more of the associated listed items.

[0021] It should be understood that although the terms first, second, third, etc., may be used in this disclosure to describe various information, such information should not be limited to these terms. These terms are used only to distinguish information of the same type from one another. For example, without departing from the scope of this disclosure, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the word "if" as used herein may be interpreted as "when," "when," or "in response to determination."

[0022] Please refer to the following: Figures 1-8 A smart roadway stacking device for a dock includes a software system and a hardware structure. The software system is communicatively connected to the hardware of the stacking device. The hardware includes a gantry frame 1 and two slide rails 2 installed on the upper and lower inner sides of the gantry frame 1. Mounting seats 3 are slidably mounted on both slide rails 2. Two movable frames 4 are installed between the two mounting seats 3. A first mounting groove is formed through the upper end of each movable frame 4. A lifting mechanism is installed on each movable frame 4, and sliding frames are slidably mounted on both movable frames 4. Stacking frames 6 are fixedly connected to the inner sides of the two sliding frames. Moving mechanisms are installed at both ends of the stacking frames 6, and detection mechanisms are installed on the stacking frames 6. The moving mechanisms include a conveyor belt 14. The software system includes: The hardware interface module is used to establish communication connections with various components in the hardware device, supports analog and digital signal conversion and multi-communication protocol adaptation, and realizes sensor data acquisition and drive component control command issuance; the various components in the hardware device include position sensor 7, pressure sensor 21, linear motor 23, first motor 8, second motor 16, electric actuator 18 and cylinder 22. Position sensor 7 is installed at both ends of slide rail 2, pressure sensor 21 is installed on the bottom surface of second support plate 20, and linear motor 23 is installed on one side of slide rail 2; The perception data processing module receives stacking position information collected by various sensors. The stacking position information includes horizontal position and lifting height data of stacking rack 6 collected by position sensor 7 and cargo weight data collected by pressure sensor 21. After filtering, calibration and fusion processing of the stacking position information, the module outputs equipment position information and cargo status information including whether the weight exceeds the standard and whether the placement is stable. The control decision module has built-in operation process logic and control algorithm. Based on the equipment location information, cargo status information and the preset operation parameters of the storage module, it generates drive control instructions. The operation process logic includes cargo transportation, lifting and positioning, cargo fixing and unloading control logic. The execution driver module converts control commands into execution signals and sends them to each driver component through the hardware interface module to control coordinated actions. The safety monitoring module monitors the equipment position offset, cargo weight, and drive component operating load in real time. When parameters exceed preset safety thresholds, it sends an abnormal signal to trigger an emergency shutdown or adjustment.

[0023] In this application, the workflow of the perception data processing module includes: The hardware interface module receives the initial horizontal position value X of the stacker 6 output by the position sensor 7 at a set sampling frequency. a Original value of lifting height Z a , and the pressure value F1 of the first support plate 19, the pressure value F2 of the second support plate 20, and the temperature compensation coefficient T output by the pressure sensor 21; The position data is processed using an extended Kalman filter, while the pressure data is filtered using a moving average filter of multiple sample values ​​to remove high-frequency vibration interference. The algorithm formula for the extended Kalman filter is as follows: ,in This is the optimal estimate at time k. The predicted value at time k-1. The preset Kalman gain, Here, H represents the measured value, and H is the measurement matrix. The pressure data is processed using a moving average filter, and the formula is as follows: , This is the filtered pressure value. This is the value of the nth sample. Then, position calibration is performed, including position calibration and pressure calibration, where position calibration... , Calibration processing includes position calibration. and pressure calibration ;in , The proportional coefficients for position calibration in the calibration horizontal and vertical directions. This represents the amount of offset in the horizontal and vertical directions of compensation. This represents the preset conversion coefficient between pressure and weight, where g is the acceleration due to gravity, and 0.02 represents the temperature compensation correction coefficient. Fusion processing through Calculate the total weight, with the preset weight limit denoted as... ,when Outputs a status indicating that the weight exceeds the limit; via a preset formula. Calculate the stationarity coefficient S when The output should be placed stably. The output is slightly off. The output is severely offset; the final output is the calibrated position information. And cargo status information including weight status and stability coefficient.

[0024] In this application, the control decision module generates drive control instructions in the following manner: The calibrated horizontal position of the stacker 6 is obtained from the sensing data processing module. Lifting height Total weight of goods and the stability coefficient S; obtain preset parameters from the storage module, including the target position. Horizontal movement speed limit Maximum lifting speed 14 base speed of conveyor belt Weight threshold Delay time Stability threshold and positioning tolerance ; Positioning control is achieved using a PID control algorithm, and the formula is as follows: ; in For the control quantity of the drive component, e(t) = target value - current value. In this control scenario, this deviation is reflected in the positional deviation of the equipment or goods during stacking operations (such as the horizontal position deviation of the stacking rack, the lifting height deviation, etc.). e(t) represents the positional deviation. This is the proportional coefficient, used for rapid response to deviations, proportionally amplifying or reducing the current deviation to output initial control action; This is the integral coefficient, used to accumulate historical deviations, eliminate long-standing steady-state errors, and improve control accuracy. The differential coefficient is used to predict the trend of deviation changes, adjust the control quantity in advance, suppress overshoot, and enhance system stability. Through the synergistic effect of these three factors, the control algorithm achieves precise and stable control of the drive components, ensuring the positioning accuracy and smoothness of stacking operations. Workflow logic: Cargo transport control: Set the weight trigger threshold for starting cargo transport. ,when At that time, the second motor 16 is started, and the speed formula is: Braking occurs when the cargo reaches above the first support plate 19; The value represents the weight reference value, and k represents the weight and speed response coefficient. In actual implementation, it can be calibrated through experiments (such as testing the conveying efficiency and energy consumption under different weight loads to select the optimal k value) to control the sensitivity of the motor speed to changes in the weight of the goods. Lifting and positioning control: The linear motor 23 is controlled by a PID algorithm to adjust the horizontal position. Control the first motor 8 to adjust the lifting height. until ; Cargo fixed control: when At that time, the electric actuator 18 is extended or retracted, and the extension / retraction amount is calculated using the following formula: ;in This indicates the basic extension / retraction amount of the electric actuator 18. The coefficient representing the stability and extension response is used to control the influence of cargo stability deviation on the extension of the electric actuator 18. It can be calibrated experimentally, specifically by testing the fixing effect under different stability and cargo types to select the optimal value. interval; Unloading control: After reaching the target position, the electric actuator 18 is reset, and the cylinder 22 pushes the first support plate 19 to form an tilt angle. The second motor 16 is started to transport the goods.

[0025] In this application, the process of executing the drive module to control the drive device includes: It communicates with the control decision module via industrial bus and receives control command frames containing drive component identifier, target parameters, and action timing; the target parameters include position, speed, and force value, and the command frame format is: [drive component ID, target value, timestamp, checksum]; Signal conversion of control commands: For linear motor 23, first motor 8, and second motor 16, the target speed command is converted into a PWM signal using the following formula: Where D is the PWM duty cycle, For speed coefficient, For the target speed, Basic duty cycle; For the electric actuator 18 and the cylinder 22, the target displacement command is converted into a current signal, and the conversion formula is as follows: Where I is the output current, For displacement coefficient, For the target displacement, This is the starting current; The converted execution signal is sent through the isolation amplifier circuit of the hardware interface module, while the feedback signals (position / current / temperature) of the driving device are collected at the same time. Achieving coordinated control of multiple actuators: Based on the timing parameters in the control commands, through formulas... Plan the start time of each driving component's action, among which As the base time, This is the timing offset; Set the collaborative accuracy to When the feedback signal satisfies: When this happens, the next driver action is triggered.

[0026] In this application, the software system also includes: The human-machine interaction module communicates with the control decision module and the display module respectively, supports the input of operation parameters and the selection of automatic / manual control modes, receives equipment operating status information and displays it visually through the display module; The storage module stores operation parameters, equipment operation logs, historical sensor data, and preset safety thresholds. Operation parameters include target stacking position, maximum cargo weight, and equipment moving speed.

[0027] In this application, the lifting mechanism includes a mounting plate 5 fixedly connected to the middle of the movable frame 4, two first pulleys 9 rotatably installed in the first mounting groove, and a first motor 8 mounted on the mounting plate 5. A take-up roller 12 is connected to the output shaft of the first motor 8, and a steel wire rope 10 is wound on the take-up roller 12. The other end of the steel wire rope 10 passes over the upper end of the first pulley 9 and is equipped with a reinforcing joint 11. The two reinforcing joints 11 are fixedly connected to the two sliding frames respectively.

[0028] It should be further explained that multiple second pulleys 17 are rotatably installed on the inner side of the slide frame, and the movable frame 4 is provided with a sliding groove that moves in conjunction with the second pulleys 17. An electric push rod 18 is hinged to one end of the slide frame, and the telescopic end of the electric push rod 18 is hinged to the top of the support frame 15.

[0029] In this application, the moving mechanism includes connecting plates 13 hinged to both sides of the stacking frame 6, a conveyor belt 14 located at one end of the stacking frame 6, a support frame 15 installed on the outside of the conveyor belt 14, the rear end of the support frame 15 being hinged to the other end of the connecting plate 13, and a second motor 16 installed on one side of the support frame 15.

[0030] It should be further explained that multiple drive rollers and support rollers are installed inside the conveyor belt 14, and belts are sleeved between the shafts of the multiple drive rollers. The surface of the conveyor belt 14 is provided with anti-slip texture, and the output shaft of the second motor 16 is connected to one of the shafts of the drive rollers.

[0031] In this application, the testing mechanism includes a first support plate 19 and a second support plate 20 installed on the top surface of the stacking rack 6. The first support plate 19 and the second support plate 20 are hinged at their proximal ends. A pressure sensor 21 is installed on the bottom surface of the second support plate 20, and the bottom end of the pressure sensor 21 is installed on the top surface of the stacking rack 6. A second mounting groove is provided inside the stacking rack 6. A cylinder 22 is installed in the second mounting groove, and the telescopic end of the cylinder 22 is hinged to the bottom surface of one end of the first support plate 19.

[0032] The working principle of the hardware structure of the intelligent aisle stacking device for docks provided by this invention is as follows: Spatial movement: Gantry 1 provides support, the moving frame 4 is driven by linear motor 23 to move horizontally along the slide rail 2 of gantry 1, and the stacking frame 6 is lifted vertically by the lifting mechanism driven by the first motor 8. The two work together to construct a three-dimensional working space, covering the entire layer of the dock rack.

[0033] Drive coordination: The motor drives the moving frame 4 and the stacking frame 6 to move through the transmission mechanism. The second motor 16 drives the conveyor belt 14 to transport goods. The electric push rod 18 adjusts the tilt angle of the conveyor belt 14 and the cylinder 22 pushes the goods to complete the picking, transporting and unloading of goods.

[0034] Sensing and detection: Position sensor 7 collects horizontal / vertical displacement data of stacker 6 in real time, and pressure sensor 21 senses the pressure of the goods. After signal conversion and temperature compensation, the weight and distribution information of the goods are output to provide a basis for control.

[0035] Other embodiments of the invention will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. This application is intended to cover any variations, uses, or adaptations of the invention that follow the general principles of the invention and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of the invention are indicated by the following claims.

[0036] It should be understood that the present invention is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of the invention is limited only by the appended claims.

Claims

1. A smart tunnel stacking device for docks, characterized in that, The system includes a software system and a hardware structure; the software system is communicatively connected to the hardware equipment of the stacking device, the hardware equipment including a gantry (1), a slide rail (2), a mounting base (3), a moving frame (4), a stacking frame (6), a lifting mechanism, a moving mechanism, a detection mechanism, and multiple sensors and driving components, the moving mechanism including a conveyor belt (14), characterized in that the software system includes: The hardware interface module is used to establish communication connections with various components in the hardware device, and supports analog and digital signal conversion and multiple communication protocol adaptation; the various components in the hardware device include a position sensor (7), a pressure sensor (21), a linear motor (23), a first motor (8), a second motor (16), an electric actuator (18), and a cylinder (22). The perception data processing module receives stacking position information collected by each sensor; the stacking position information includes horizontal position and lifting height data of the stacking rack (6) collected by the position sensor (7) and cargo weight data collected by the pressure sensor (21); after filtering, calibration and fusion processing of the stacking position information, the module outputs equipment position information and cargo status information including whether the weight exceeds the standard and whether the placement is stable. The control decision module has built-in operation process logic and control algorithm. Based on the equipment location information, cargo status information and the preset operation parameters of the storage module, it generates drive control instructions. The operation process logic includes cargo transportation, lifting and positioning, cargo fixing and unloading control logic. The execution driver module converts control commands into execution signals and sends them to each driver component through the hardware interface module to control coordinated actions. The safety monitoring module monitors the equipment position offset, cargo weight, and drive component operating load in real time. When parameters exceed preset safety thresholds, it sends an abnormal signal to trigger an emergency shutdown or adjustment.

2. The intelligent roadway stacking device for a dock according to claim 1, characterized in that, The workflow of the sensing data processing module includes: The hardware interface module receives the original values ​​of the horizontal position and lifting height of the stacking rack (6) output by the position sensor (7) and the pressure value and temperature compensation coefficient output by the pressure sensor (21) at a preset frequency. The location data is processed using an extended Kalman filter, and the pressure data is processed using a moving average filter of multiple sample values. Next, position calibration is performed, including position calibration and pressure calibration. Position calibration uses a set scaling factor and offset to calibrate the filtered position data, while pressure calibration uses a temperature compensation factor and gravity parameters to calibrate the filtered pressure data. The weights of the two calibrated plates are then added together to obtain the total weight. If the weight exceeds the preset upper limit, the weight is output as excessive. The stability coefficient is calculated based on the weight distribution of the two plates, and the placement status (stable, slightly offset, or severely offset) is output according to the relationship between the stability coefficient and the threshold. Finally, the calibrated equipment position information and cargo status information are output.

3. The intelligent tunnel stacking device for a dock according to claim 2, characterized in that, The process by which the control decision module generates driver control commands includes: The horizontal position, lifting height, total weight of goods and stability coefficient of the calibrated stacker (6) are obtained from the sensing data processing module. Preset parameters are obtained from the preset storage module, including target position, upper limit of horizontal and vertical speed, reference speed of conveyor belt (14), weight threshold, delay time, stability threshold and positioning tolerance; Positioning control is achieved by using a PID closed-loop control algorithm, which adjusts the control quantity of the drive component by preset proportional, integral, and derivative coefficients to eliminate position deviation. Process execution: Cargo conveying: When the weight of the cargo reaches the preset minimum detection weight, the second motor (16) is started to drive the conveyor belt (14), and the speed of the conveyor belt (14) is adaptively adjusted according to the weight of the cargo. When the cargo reaches the top of the first support plate (19), the conveyor belt (14) is stopped. Lifting and positioning: The linear motor (23) is controlled by PID algorithm to adjust the horizontal position of the stacking frame (6), and the first motor (8) is controlled to adjust the lifting height of the stacking frame (6) until the position deviation does not exceed the positioning tolerance; Cargo fixing: When the stability coefficient reaches the preset stability threshold, the electric push rod (18) is extended and retracted, and the cargo is fixed on both sides by adjusting the tilt angle of the conveyor belt (14); Unloading: After the stacker (6) reaches the target position, the control electric push rod (18) is reset to open the conveyor belt (14), the control cylinder (22) is pushed to form an inclined surface so that the goods slide onto the conveyor belt (14), and then the second motor (16) is started to transport the goods.

4. The intelligent tunnel stacking device for a dock according to claim 1, characterized in that, The process by which the execution driver module controls the driver includes: It communicates with the control decision module via industrial bus and receives control command frames containing drive component identifiers, target parameters, and action timing. For motor-type drive components, including linear motor (23), first motor (8), and second motor (16), the target speed command is converted into a PWM signal with the corresponding duty cycle; For push rod / cylinder type drive components, including electric push rod (18) and cylinder (22), the target displacement command is converted into a current signal of corresponding magnitude; Signal transmission and feedback: The execution signal is transmitted through the isolation amplifier circuit of the hardware interface module, while the position, current and temperature feedback signals of the driving device are collected at the same time; Cooperative control: The start time of each driving component's action is planned according to the timing parameters in the control command. When the deviation between the actual action of the driving component and the target action does not exceed the preset cooperative accuracy, the next driving component action is triggered.

5. The intelligent roadway stacking device for a dock according to claim 1, characterized in that, The software system also includes: The human-machine interaction module communicates with the control decision module and the display module respectively, supports the input of operation parameters and the selection of automatic / manual control modes, receives equipment operating status information and displays it visually through the display module; The storage module stores operation parameters, equipment operation logs, historical sensor data, and preset safety thresholds. Operation parameters include target stacking position, maximum cargo weight, and equipment moving speed.

6. The intelligent roadway stacking device for a dock according to claim 1, characterized in that, The lifting mechanism includes a mounting plate (5) fixed to the middle of the movable frame (4), two first pulleys (9) rotatably installed in the first mounting groove, and a first motor (8) mounted on the mounting plate (5). A take-up roller (12) is connected to the output shaft of the first motor (8). A wire rope (10) is wound on the take-up roller (12). The other end of the wire rope (10) passes over the upper end of the first pulley (9) and is equipped with a reinforcing joint (11). The two reinforcing joints (11) are fixed to the two sliding frames respectively.

7. The intelligent roadway stacking device for a dock according to claim 1, characterized in that, The moving mechanism includes connecting plates (13) hinged to both sides of the stacking frame (6), a conveyor belt (14) located at one end of the stacking frame (6), a support frame (15) installed on the outside of the conveyor belt (14), the rear end of the support frame (15) being hinged to the other end of the connecting plate (13), and a second motor (16) installed on one side of the support frame (15).

8. The intelligent roadway stacking device for a dock according to claim 1, characterized in that, The detection mechanism includes a first support plate (19) and a second support plate (20) installed on the top surface of the stacking rack (6). The first support plate (19) and the second support plate (20) are hinged at their near ends. The pressure sensor (21) is installed on the bottom surface of the second support plate (20), and the bottom end of the pressure sensor (21) is installed on the top surface of the stacking rack (6). A second mounting groove is provided inside the stacking rack (6). The cylinder (22) is installed in the second mounting groove. The telescopic end of the cylinder (22) is hinged to the bottom surface of one end of the first support plate (19).

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