Control system of bucket-wheel stacker-reclaimer

Abstract

The invention discloses a control system of bucket-wheel stacker-reclaimers, and relates to the technical field of material handling equipment, the control system comprises a central control room, two bucket-wheel stacker-reclaimers, a stacker-reclaimer track and a large material receiving belt conveyor, a central control PLC, a centralized operation station and a first switch are arranged in the central control room, the centralized operation station is connected with the central control PLC and the first switch. The two bucket-wheel stacker-reclaimers are arranged on the stacker-reclaimer track; the large receiving belt conveyor is arranged on the inner side of the stacker-reclaimer rail, and a cantilever of the bucket-wheel stacker-reclaimer is in butt joint with the large receiving belt conveyor; the bucket-wheel stacker-reclaimer comprises a stacker-reclaimer PLC and a second switch which are connected with each other, and the first switch is connected with the second switch; and the centralized operation station sends an operation task to the stacker-reclaimer PLC, wherein the operation task comprises setting a virtual boundary between the two bucket-wheel stacker-reclaimers. The two bucket-wheel stacker-reclaimers are both arranged on the stacker-reclaimer rails, the space utilization rate of a stock yard is optimized, and meanwhile operation efficiency and safety are improved.

Description

Technical Field

[0001] This invention relates to the field of material handling equipment technology, and in particular to a control system for a bucket wheel stacker-reclaimer. Background Technology

[0002] Bucket wheel stacker-reclaimers are common large-scale loading and unloading equipment in bulk material storage yards, widely used in the stacking and reclaiming of materials such as coal and ore. However, traditional bucket wheel stacker-reclaimers mostly adopt a single-machine, single-rail layout, which has the following main problems: 1. It occupies a large area and has a low utilization rate of material yard space.

[0003] 2. Poor multi-machine collaborative operation capability, making it difficult to meet the needs of efficient operation.

[0004] 3. Although existing unmanned systems have achieved intelligent operation of equipment, they lack the design for optimizing the layout of material yards.

[0005] In recent years, with the development of automation and intelligent technologies, several improvement measures have been proposed, such as unmanned operation and intelligent scheduling systems. However, most of these improvements focus on the automated control and intelligent operation of equipment, lacking optimization design for the overall layout of the material yard. For example, while existing unmanned operation technologies have improved the automation level of equipment, they still cannot solve the problems of space waste and poor collaborative operation capabilities caused by single-machine, single-rail layouts. Summary of the Invention

[0006] The purpose of this invention is to provide a control system for a bucket wheel stacker-reclaimer, which sets two bucket wheel stacker-reclaimers on the stacker-reclaimer track to optimize the utilization of material yard space, while improving operating efficiency and safety.

[0007] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: One aspect of this invention provides a control system for a bucket wheel stacker-reclaimer. The control system includes: a central control room, in which a central control PLC, a centralized operation station, and a first switch are installed. The centralized operation station is connected to both the central control PLC and the first switch. The central control PLC is connected to the first switch. Two bucket wheel stacker-reclaimers and a stacker-reclaimer track are provided, with both bucket wheel stacker-reclaimers mounted on the stacker-reclaimer track. A receiving conveyor belt is located inside the stacker-reclaimer track, and the cantilever of each bucket wheel stacker-reclaimer is connected to the receiving conveyor belt. Each bucket wheel stacker-reclaimer includes a stacker-reclaimer PLC for controlling its operation and a second switch connected to the stacker-reclaimer PLC. The first switch and the second switch are connected. The centralized operation station sends work tasks to the stacker-reclaimer PLC through the first switch and the second switch. The work tasks include setting a virtual boundary between the two bucket wheel stacker-reclaimers.

[0008] In some embodiments, the bucket wheel stacker-reclaimer further includes a positioning module, which includes a first lidar connected to the stacker-reclaimer's PLC. The first lidar constructs environmental positioning by emitting laser pulses and measuring the echo time of the laser pulses. The positioning module also includes a GPS module connected to the stacker-reclaimer's PLC, which locates the bucket wheel stacker-reclaimer by measuring its real-time position via satellite. The positioning module also includes an encoding identification sensor connected to the stacker-reclaimer's PLC. Multiple encoding tags with different numbers are set on the stacker-reclaimer's track, and the encoding identification sensor determines the positioning of the bucket wheel stacker-reclaimer by identifying the number corresponding to the encoding tag.

[0009] In some embodiments, the stacker-reclaimer PLC obtains the current position of the bucket wheel stacker-reclaimer through the positioning module, and sends the current position of the bucket wheel stacker-reclaimer to the centralized operation station through the second switch and the first switch; the centralized operation station receives the work task, plans the work area and work path according to the work task and the current position of the bucket wheel stacker-reclaimer, and sends the work task, work area and work path to the central control PLC; the central control PLC sends the work task, work area and work path to the stacker-reclaimer PLC through the first switch and the second switch, and the stacker-reclaimer PLC controls the bucket wheel stacker-reclaimer to work according to the work task, work area and work path.

[0010] In some embodiments, the bucket wheel stacker-reclaimer further includes an obstacle detection module, which includes an ultrasonic sensor and a second lidar connected to the stacker-reclaimer's PLC.

[0011] In some embodiments, the central control room further includes a display module, a video server, and a third switch; the bucket wheel stacker-reclaimer further includes a fourth switch and a high-definition camera; the display module is connected to the third switch through the video server; the high-definition camera is connected to the fourth switch; and the third switch is connected to the fourth switch. The centralized operation station includes a manual operation module and an integrated video operation station; the manual operation module is connected to the central control PLC; and the first switch is connected to both the integrated video operation station and the third switch.

[0012] In some embodiments, the bucket wheel stacker-reclaimer further includes a stack shape processing computer and a laser scanner. The stack shape processing computer is connected to the second switch and the laser scanner, respectively. The laser scanner is used to scan the surface of the material pile to generate three-dimensional data of the stack shape. The control system further includes a mapping drone. The mapping drone is wirelessly connected to the first switch. The mapping drone scans the material yard to generate a three-dimensional map of the material yard.

[0013] In some embodiments, the bucket wheel stacker-reclaimer further includes a progress detection module, which includes a material flow sensor and a bucket wheel rotation speed sensor connected to the stacker-reclaimer's PLC. The centralized operation station adjusts the bucket wheel rotation speed of the bucket wheel stacker-reclaimer based on the flow data from the material flow sensor.

[0014] In some embodiments, a dynamic load sensor is installed on the stacker-reclaimer track. The dynamic load sensor is connected to the central control PLC. The central control PLC sends the load data of the load sensor to the centralized operation station. The centralized operation station adjusts the stacking and reclaiming speed of the bucket wheel stacker-reclaimer according to the load data of the dynamic load sensor.

[0015] In some embodiments, the central control room further includes an engineering station and a data server connected to the first switch. The data server is used to receive and store various algorithm programs entered by the engineering station. The various algorithm programs include a genetic algorithm. The centralized operation station uses the genetic algorithm to intelligently allocate the work tasks of the bucket wheel stacker-reclaimer. When the engineering station enters the genetic algorithm, it trains the genetic algorithm. The training method includes: obtaining historical work data of the bucket wheel stacker-reclaimer through the data server; training the genetic algorithm using the historical work data to obtain a genetic algorithm model; simulating different work scenarios of the bucket wheel stacker-reclaimer to optimize the genetic algorithm model; and storing the optimized genetic algorithm model in the data server.

[0016] In some embodiments, the multiple algorithm programs further include an adaptive control algorithm, wherein the centralized operation station acquires real-time operation data and equipment status information of the bucket wheel stacker-reclaimer in real time, and adjusts the operation data of the bucket wheel stacker-reclaimer through the adaptive control algorithm.

[0017] According to an embodiment of the present invention, a control system for a bucket wheel stacker-reclaimer has at least the following beneficial effects: by setting both bucket wheel stacker-reclaimers on the stacker-reclaimer track, the two bucket wheel stacker-reclaimers can share the same track, significantly reducing the track footprint and optimizing the space layout of the material yard.

[0018] The system uses high-definition cameras, material flow sensors, and bucket wheel rotation speed sensors to monitor the operating status and track usage of each bucket wheel stacker-reclaimer in real time. Multiple algorithms are used to optimize multi-machine collaborative operation, automatically allocate tasks and generate work plans, avoid track resource conflicts, and improve operating efficiency.

[0019] The equipment is located by first using a lidar and GPS module, and then further corrected by combining the coded identification sensor and the coded tags on the stacker-reclaimer track to achieve accurate positioning of the equipment and ensure stable operation of the equipment on the common track.

[0020] By installing dynamic load sensors on the stacker-reclaimer track, the load on the track can be monitored in real time, ensuring the safety of equipment operation and reducing maintenance costs.

[0021] By combining the ultrasonic sensor and the second lidar of the obstacle detection module with video surveillance and data analysis, a more reliable operating environment is provided for the system, enabling timely detection and handling of potential safety hazards.

[0022] It should be understood that the above general description and the following detailed description are merely exemplary and do not limit this disclosure. Attached Figure Description

[0023] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a block diagram illustrating the control system principle of the bucket wheel stacker-reclaimer according to an embodiment. Figure 2 This is a schematic diagram of the structure of two bucket wheel stacker-reclaimers distributed on the stacker-reclaimer track according to an embodiment.

[0025] The following are the annotations in the attached diagram: 1. Stacker-reclaimer track; 2. Bucket wheel stacker-reclaimer; 3. Receiving conveyor belt. Detailed Implementation

[0026] 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.

[0027] In the description of this invention, it should be understood that the terms "middle", "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0028] The terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first," "second," or "third" may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0029] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "docking," "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0030] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many forms and should not be construed as limited to the examples set forth herein; rather, they are provided so that the description of this disclosure will be more complete and fully convey the concept of the exemplary embodiments to those skilled in the art. The drawings are merely illustrative of this disclosure and are not necessarily drawn to scale. The same reference numerals in the drawings denote the same or similar parts, and therefore repeated descriptions of them will be omitted.

[0031] The technical solutions of the embodiments of this application are briefly described below: According to some embodiments, such as Figures 1 to 2 As shown, this application provides a control system for a bucket wheel stacker-reclaimer 2, the control system comprising: Central control room, such as Figure 2 As shown, the central control room is equipped with a central control PLC, a centralized operation station and a first switch. The centralized operation station is connected to the central control PLC and the first switch respectively, and the central control PLC is connected to the first switch. Two bucket wheel stacker-reclaimers 2 and stacker-reclaimer track 1, such as Figure 1 As shown, both bucket wheel stacker-reclaimers 2 are mounted on stacker-reclaimer tracks 1; Large conveyor belt 3, such as Figure 1 As shown, the receiving conveyor belt 3 is located inside the stacker-reclaimer track 1, and the cantilever of the bucket wheel stacker-reclaimer 2 is connected to the receiving conveyor belt 3. The two bucket wheel stacker-reclaimers 2 have identical circuit and mechanical structures, such as Figure 2 As shown, one of the bucket wheel stacker-reclaimers 2 includes a stacker-reclaimer PLC that controls the operation of the bucket wheel stacker-reclaimer 2 and a second switch connected to the stacker-reclaimer PLC. The first switch and the second switch are connected. The centralized operation station sends work tasks to the stacker-reclaimer PLC through the first switch and the second switch. The work tasks include setting a virtual boundary between the two bucket wheel stacker-reclaimers 2.

[0032] Specifically, one end of the cantilever of the bucket wheel stacker-reclaimer 2 is seamlessly connected to the receiving conveyor belt 3, and the other end of the cantilever of the bucket wheel stacker-reclaimer 2 is connected to the bucket wheel. The bucket wheel stacker-reclaimer 2 also includes circuit control modules such as a movement control module and a stacking-reclaiming steering control module, but these are all commonly used existing technologies, so they will not be described in detail in this application.

[0033] The workflow is as follows: In the stacking operation, the material is conveyed via the receiving conveyor belt 3 to the conveyor belt on the cantilever, and then conveyed via the cantilever to the bucket wheel. Finally, the bucket wheel evenly stacks the material on the stockpile. In the reclaiming operation, the bucket wheel removes the material from the stockpile and then conveys it via the conveyor belt on the cantilever to the receiving conveyor belt 3, which then conveys it to the next process.

[0034] In practice, the operator inputs task information into the centralized control station, which intelligently allocates two tasks suitable for the two bucket wheel stacker-reclaimers 2. These two tasks are then sent to the stacker-reclaimer PLCs of the two bucket wheel stacker-reclaimers 2 via a first and a second switch. Both tasks include a virtual boundary set between the two bucket wheel stacker-reclaimers 2, and the location of this virtual boundary is recorded. The stacker-reclaimer PLC controls the corresponding bucket wheel stacker-reclaimer 2 to operate based on the received tasks. Alternatively, the operator can directly control the two bucket wheel stacker-reclaimers 2 through the centralized control station.

[0035] This application sets both bucket wheel stacker-reclaimers 2 on the stacker-reclaimer track 1, which improves the space utilization of the material yard. At the same time, the operation tasks include a virtual boundary set between the two bucket wheel stacker-reclaimers 2, which can prevent the two bucket wheel stacker-reclaimers 2 from entering each other's operation area. The centralized operation station intelligently allocates two tasks suitable for the two bucket wheel stacker-reclaimers 2, ensuring that the two devices can work together to cover the stacking and reclaiming needs of the entire material yard, while avoiding collisions and operation conflicts between the two bucket wheel stacker-reclaimers 2.

[0036] The following is in conjunction with the appendix to this instruction manual. Figures 1 to 2 The preferred embodiments of this disclosure will be further described in detail below.

[0037] According to some embodiments, such as Figure 2 As shown, the bucket wheel stacker-reclaimer 2 also includes a positioning module, which includes a first lidar connected to the stacker-reclaimer's PLC. The first lidar constructs environmental positioning by emitting laser pulses and measuring the echo time of the laser pulses. The positioning module also includes a GPS module connected to the stacker-reclaimer PLC. The GPS module uses satellites to measure the real-time position of the bucket wheel stacker-reclaimer 2. The positioning module also includes an encoding recognition sensor connected to the stacker-reclaimer PLC. Multiple encoding tags with different numbers are set on the stacker-reclaimer track 1. The encoding recognition sensor determines the positioning of the bucket wheel stacker-reclaimer 2 by recognizing the number corresponding to the encoding tag.

[0038] Specifically, an angle sensor is also installed on the cantilever of the bucket wheel stacker-reclaimer 2. The cantilever can rotate, tilt upwards, and tilt downwards. When it tilts upwards or downwards, a certain tilt angle will be generated. The angle sensor can monitor the positioning information of the cantilever in real time and accurately.

[0039] Based on the above embodiments, after the first lidar emits a laser pulse, the laser pulse will be reflected when it encounters an object. By obtaining the echo time of the reflected echo and combining it with the speed of light, the distance to the object can be accurately calculated, and then a three-dimensional point cloud model can be constructed to achieve environmental positioning.

[0040] During installation, the optimal installation positions for the first lidar and GPS modules are determined based on the dimensions and operating range of the bucket wheel stacker-reclaimer 2. High-precision mounting brackets are used to secure the first lidar and GPS modules to the bucket wheel stacker-reclaimer 2, ensuring their stability and data accuracy.

[0041] Furthermore, the bucket wheel stacker-reclaimer 2 is also equipped with multiple landmark / beacon sensors. Beacons and landmarks are set up in the material yard at preset intervals (such as every 50 meters) and their positions are accurately marked. The location can be identified by multiple landmark / beacon sensors.

[0042] This application improves the accuracy and reliability of equipment positioning by combining a first lidar, a GPS module, and multiple landmark / beacon sensors, ensuring that the bucket wheel stacker-reclaimer 2 and its cantilever can accurately determine their own position in complex material yard environments.

[0043] The positioning module utilizes specialized data fusion software to preprocess data collected from various sensors, including the first LiDAR, GPS module, beacons, and landmarks (e.g., coordinate transformation, time synchronization). Then, a Kalman filtering algorithm is applied to fuse the data, continuously iterating and optimizing the filtering parameters to improve the accuracy and stability of the positioning data. The fused positioning data is sent in real-time to the stacker-reclaimer PLC, which then transmits it to the central control station. This enhances positioning accuracy and anti-interference capabilities, providing reliable position information for the automatic alignment and path tracking of the bucket wheel stacker-reclaimer 2.

[0044] Furthermore, the stacker-reclaimer track 1 is also equipped with coded labels, which can be QR code labels or magnetic coded labels, arranged at certain intervals (e.g., one label every 10 meters). A unique coding rule is designed to ensure that each label's code is unique and easily identifiable. Using a dedicated label installation tool, the coded labels are securely installed on the stacker-reclaimer track 1.

[0045] A coding identification sensor is installed on the bucket wheel stacker-reclaimer 2. When the equipment runs to the location of the coded label on the stacker-reclaimer track 1, the coding identification sensor automatically scans and reads the label information. After receiving the label information, the stacker-reclaimer PLC compares it with other positioning data to determine the precise position of the bucket wheel stacker-reclaimer 2 on the track. This provides accurate track position information for the bucket wheel stacker-reclaimer 2, assisting it in precise positioning and navigation, providing auxiliary positioning methods during operation, improving the equipment's navigation accuracy, and ensuring that the equipment can operate accurately according to the planned path.

[0046] The bucket wheel stacker-reclaimer 2 is positioned by combining a first lidar, GPS module and multiple landmark / beacon sensors. Then, it is further corrected by combining the coding identification sensor and the coding label on the stacker-reclaimer track 1 to achieve accurate positioning of the bucket wheel stacker-reclaimer 2 and its cantilever, ensuring the stable operation of the bucket wheel stacker-reclaimer 2 and its cantilever.

[0047] According to some embodiments, when assigning job tasks: The stacker-reclaimer PLC obtains the current position of the bucket wheel stacker-reclaimer 2 through the positioning module, and sends the current position of the bucket wheel stacker-reclaimer 2 to the centralized operation station through the second switch and the first switch; The centralized operation station receives the work task, plans the work area and work path according to the work task and the current position of the bucket wheel stacker-reclaimer 2, and sends the work task, work area and work path to the central control PLC; The central control PLC sends the work task, work area and work path to the stacker reclaimer PLC through the first and second switches. The stacker reclaimer PLC controls the bucket wheel stacker reclaimer 2 to work according to the work task, work area and work path.

[0048] This application can automatically allocate tasks and generate work plans based on real-time positioning, avoiding track resource conflicts and improving work efficiency.

[0049] According to some embodiments, such as Figure 2 As shown, the bucket wheel stacker-reclaimer 2 also includes an obstacle detection module, which includes an ultrasonic sensor connected to the stacker-reclaimer PLC and a second lidar.

[0050] This application enables automatic obstacle avoidance of the bucket wheel stacker-reclaimer 2 by setting up an obstacle detection module. The combination of an ultrasonic sensor and a second lidar improves anti-interference capabilities. When encountering a transparent obstacle, the ultrasonic sensor detects it; when encountering external noise interference, the second lidar detects the obstacle.

[0051] According to some embodiments, such as Figure 2 As shown, the central control room also includes a display module, a video server and a third switch, and the bucket wheel stacker-reclaimer 2 also includes a fourth switch and a high-definition camera. The display module is connected to the third switch through the video server, the high-definition camera is connected to the fourth switch, and the third switch is connected to the fourth switch. The centralized operation station includes a manual operation module and an integrated video operation station. The manual operation module is connected to the central control PLC, and the first switch is connected to the integrated video operation station and the third switch.

[0052] The display module uses a large screen that can be viewed by multiple people at the same time, while the integrated video operation station uses a small screen that can be operated by a single person. The integrated video operation station can both operate and view.

[0053] Specifically, such as Figure 2 As shown, the first and second switches are connected via both wireless and fiber optic connections; the first and third switches are connected via wireless connections; and the third and fourth switches are connected via both wireless and fiber optic connections. These wireless and fiber optic connections complement each other; wired fiber optic transmission is used when the signal is weak, and wireless transmission is used when the fiber optic cable fails.

[0054] According to some embodiments, such as Figure 2 As shown, the bucket wheel stacker-reclaimer 2 also includes a stack shape processing computer and a laser scanner. The stack shape processing computer is connected to the second switch and the laser scanner respectively. The laser scanner is used to scan the surface of the material pile and generate three-dimensional data of the stack shape. The control system also includes a surveying drone, which is wirelessly connected to the first switch. The surveying drone scans the material yard and generates a three-dimensional map of the material yard.

[0055] According to some embodiments, such as Figure 2 As shown, the bucket wheel stacker-reclaimer 2 also includes a progress detection module. The progress detection module includes a material flow sensor and a bucket wheel rotation speed sensor connected to the stacker-reclaimer PLC. The centralized operation station adjusts the bucket wheel rotation speed of the bucket wheel stacker-reclaimer 2 according to the flow data of the material flow sensor.

[0056] According to some embodiments, such as Figure 2 As shown, a dynamic load sensor is installed on the stacker-reclaimer track 1. The dynamic load sensor is connected to the central control PLC. The central control PLC sends the load data of the load sensor to the centralized operation station. The centralized operation station adjusts the stacking and reclaiming speed of the bucket wheel stacker-reclaimer 2 according to the load data of the dynamic load sensor.

[0057] Dynamic load sensors are installed at key locations on the stacker-reclaimer track 1 to monitor the track's load status in real time. These sensors accurately measure the pressure on the track and transmit the data to the central control PLC. The PLC then sends the load data to the centralized control station. The centralized control station analyzes the received load data in real time and immediately triggers an early warning mechanism upon detecting any anomalies. This notifies operators to inspect and address the issues, ensuring the track's safe load-bearing capacity during equipment operation, preventing track deformation or damage due to overload, and ensuring safe equipment operation.

[0058] According to some embodiments, such as Figure 2 As shown, the central control room also includes an engineering station and a data server connected to the first switch. The data server is used to receive and store various algorithm programs entered by the engineering station. The various algorithm programs include a genetic algorithm. The centralized operation station uses the genetic algorithm to intelligently allocate the operation tasks of the bucket wheel stacker-reclaimer 2. When inputting genetic algorithms into the engineer's workstation, the genetic algorithms are trained. Training methods include: Obtain historical operation data of bucket wheel stacker-reclaimer 2 through the data server; The genetic algorithm is trained using historical job data to obtain a genetic algorithm model; The genetic algorithm model was optimized and trained by simulating different operating scenarios of the bucket wheel stacker-reclaimer 2. The optimized genetic algorithm model is stored on a data server.

[0059] According to some embodiments, the various algorithm programs also include an adaptive control algorithm, in which the central operation station acquires real-time operation data and equipment status information of the bucket wheel stacker-reclaimer 2, and adjusts the operation data of the bucket wheel stacker-reclaimer 2 through the adaptive control algorithm.

[0060] Based on the above embodiments, this application automatically plans the optimal task allocation scheme through multiple algorithms to ensure that each bucket wheel stacker-reclaimer 2 can efficiently complete the assigned tasks, avoid the bucket wheel stacker-reclaimer 2 being idle or overloaded, and improve the overall operating efficiency.

[0061] The centralized control station collects real-time operational data (such as location, speed, load, etc.) and track usage from various sensors and GPS modules. Based on preset rules and algorithms, it analyzes the collected data in real time and dynamically adjusts task allocation strategies. If necessary, it replans the equipment's operating path or adjusts the operating sequence. This allows for real-time monitoring of the operating status and track usage of the two bucket wheel stacker-reclaimers 2, dynamically adjusting task allocation to ensure smooth workflow and avoid equipment conflicts and resource waste. It ensures real-time optimization of the workflow, timely response to emergencies or equipment failures in the material yard, and guarantees continuous and efficient operations.

[0062] The system uses laser scanners and mapping drones to perform a comprehensive scan of the material yard, generating a high-precision 3D map. This high-precision map includes information such as the location of material piles, track layout, and equipment locations. The map data is imported into a data server for easy access by the central control station, and periodic scanning tasks are set to ensure real-time updates and accurate reflection of the material yard's real-time conditions. This provides accurate material yard environmental information for the path planning algorithm, ensuring that equipment can operate based on the latest material yard conditions.

[0063] After receiving the task, the centralized control station invokes various algorithms from the data server to calculate the optimal operation path based on the material yard map, the current location of the equipment, and the target location of the task. The planned path is then sent to the stacker-reclaimer PLC to guide the operation of the bucket wheel stacker-reclaimer 2.

[0064] Based on task requirements and real-time map data, the centralized operation station uses algorithms to plan the optimal operating path for each piece of equipment, reducing the idle distance and operating time of the equipment, improving overall operating efficiency, and extending the service life of the equipment.

[0065] Work progress sensors (such as material flow sensors and bucket wheel rotation speed sensors) are installed on key components of the bucket wheel stacker-reclaimer 2, and the work site is monitored in real time via a high-definition camera. The material flow sensors, bucket wheel rotation speed sensors, and high-definition cameras transmit the collected data to a centralized control station. This allows for real-time monitoring of the work progress via the material flow sensors, bucket wheel rotation speed sensors, and high-definition cameras installed on the equipment, and the feedback of data to the centralized control station. This enables operators to monitor the work progress in real time, promptly identify and resolve problems that arise during the operation, and ensure that the work task is completed as planned.

[0066] The centralized control station automatically adjusts the equipment's operating parameters using adaptive control algorithms based on real-time feedback of operational data and equipment status information. For example, it adjusts the bucket wheel's rotation speed based on flow data from the material flow sensor, or adjusts the stacking and reclaiming speed based on the load data of the bucket wheel stacker-reclaimer 2. It can automatically adjust operating parameters, such as stacking and reclaiming speed and equipment direction, according to the work progress and equipment status to cope with changes in the material yard environment. This ensures that the equipment maintains efficient and stable operation under different material yard environments and operating conditions, improving the system's robustness and adaptability.

[0067] High-definition cameras are installed at key locations on the bucket wheel stacker-reclaimer 2 (such as the front end of the cantilever and both sides of the bucket wheel). A centralized control station processes the images using image recognition algorithms. Feature points or alignment markers are set on the material pile. The images captured by the cameras are analyzed in real time using image recognition algorithms to calculate the deviation between the bucket wheel stacker-reclaimer 2 and the target position. Based on the deviation information, the centralized control station adjusts the running direction and position of the bucket wheel stacker-reclaimer 2. This improves the alignment accuracy and efficiency of the bucket wheel stacker-reclaimer 2, reduces manual intervention, ensures the equipment can quickly and accurately align to the target position, and improves operational efficiency.

[0068] A laser scanner is installed on the bucket wheel stacker-reclaimer 2. When the stacker-reclaimer 2 approaches the target material pile, the laser scanner is activated to perform a 360-degree scan of the pile surface, generating three-dimensional point cloud data of the pile. The central operation station compares the scanned data with a preset pile model, calculates the optimal alignment point, and automatically adjusts the position and orientation of the equipment. This method uses laser scanning technology to obtain precise shape and position information of the pile, providing a more accurate reference for equipment alignment. The combination of these two alignment methods further improves alignment accuracy, ensuring the accuracy and quality of the stacker-reclaimer operation.

[0069] Emergency stop buttons are installed in key locations such as the operator's cab, the cantilever, and the traveling mechanism of the bucket wheel stacker-reclaimer 2, ensuring that operators can easily access them from different positions. The emergency stop buttons are connected to the equipment's control system to ensure that pressing the button immediately cuts off the equipment's power supply. This allows operators to quickly stop the equipment in emergencies, preventing accidents and ensuring the safety of personnel and equipment.

[0070] Ultrasonic sensors and a second lidar are installed on the bucket wheel stacker-reclaimer 2 to monitor the distance and relative speed of obstacles around the equipment in real time. A collision warning algorithm is developed to calculate the degree of collision risk based on sensor data. When the risk exceeds a preset threshold, an audible and visual alarm is triggered. This is used to provide early warning of potential collision risks, reminding operators to take timely collision avoidance measures, reducing collision accidents between equipment, and improving operational safety.

[0071] The ultrasonic sensors, second LiDAR, and high-definition camera on the stacker-reclaimer are activated to perform real-time scanning and image acquisition of the operating path. The acquired data is analyzed using an obstacle recognition algorithm to identify the type, size, and location of obstacles. This allows for the timely detection of obstacles in the equipment's operating path, providing a basis for subsequent obstacle avoidance operations and ensuring the safe operation of the equipment.

[0072] After receiving obstacle information, the stacker-reclaimer PLC sends it to the central control station. The central control station immediately activates the path replanning function, calculating a new obstacle avoidance path based on the current position of the equipment and the position of the obstacle using various algorithms. The central control station sends the new path command to the stacker-reclaimer PLC, and the bucket wheel stacker-reclaimer 2 adjusts its running direction and speed according to the command to bypass the obstacle. This dynamic path adjustment ensures that the equipment can automatically avoid obstacles when it encounters them, preventing collisions and ensuring the safety of the equipment and personnel.

[0073] High-definition cameras are installed at key locations in the material yard (such as both ends of the track, the material pile area, and the equipment cross-operation area) as well as on the bucket wheel stacker-reclaimer 2, ensuring that the monitoring range covers the entire material yard. The cameras are connected to the central monitoring system via a network switch to achieve real-time transmission of video signals. Night vision parameters and automatic cruise paths are configured for the cameras to ensure normal operation under different lighting conditions. This provides real-time video monitoring of the material yard and equipment, facilitating remote monitoring of operations by operators and timely detection of abnormal behavior or safety hazards.

[0074] By establishing a safety monitoring data analysis platform that integrates video analytics algorithms and equipment operation data analysis algorithms, the platform processes received video and equipment operation data in real time, identifying abnormal behaviors (such as personnel trespassing into restricted areas or equipment malfunctions) and potential safety hazards (such as excessively high material piles or equipment overloads). When an anomaly is detected, the platform immediately triggers an alarm mechanism, notifying relevant personnel via SMS, audible and visual alarms, etc. This allows for the timely detection and handling of anomalies through real-time analysis of monitoring data, eliminating safety hazards at their inception and ensuring the safety of material yard operations.

[0075] In the description of the above embodiments, specific features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments or examples.

[0076] Although this disclosure has been described with reference to several typical embodiments, it should be understood that the terminology used is descriptive and exemplary, and not restrictive. Because this disclosure can be embodied in many forms without departing from the spirit or substance of this application, it should be understood that the above embodiments are not limited to any of the foregoing details, but should be interpreted broadly within the spirit and scope defined by the appended claims. Therefore, all variations and modifications falling within the scope of the claims or their equivalents should be covered by the appended claims.

Claims

1. A control system for an excavator / reclaimer, characterized in that, The control system comprises: A central control room, wherein a central control PLC, a centralized operation station and a first switch are arranged, the centralized operation station is connected with the central control PLC and the first switch respectively, and the central control PLC is connected with the first switch; Two bucket wheel stacker-reclaimers and a stacker-reclaimer track, wherein the two bucket wheel stacker-reclaimers are arranged on the stacker-reclaimer track; A receiving large belt conveyor, which is arranged on the inner side of the stacker-reclaimer track, and the cantilever of the bucket wheel stacker-reclaimer is connected with the receiving large belt conveyor; The bucket wheel stacker-reclaimer comprises a stacker-reclaimer PLC for controlling the operation of the bucket wheel stacker-reclaimer, and a second switch connected with the stacker-reclaimer PLC, and the first switch and the second switch are connected; The centralized operation station sends a work task to the stacker-reclaimer PLC through the first switch and the second switch, and the work task comprises setting a virtual boundary between the two bucket wheel stacker-reclaimers.

2. The control system of claim 1, wherein, The bucket wheel stacker-reclaimer further comprises a positioning module, which comprises a first laser radar connected with the stacker-reclaimer PLC, and the first laser radar constructs an environmental positioning by emitting a laser pulse and measuring the echo time of the laser pulse; The positioning module further comprises a GPS module connected with the stacker-reclaimer PLC, and the GPS module measures the real-time position of the bucket wheel stacker-reclaimer by satellite to position; The positioning module further comprises a code recognition sensor connected with the stacker-reclaimer PLC, and a plurality of code tags with different numbers are arranged on the stacker-reclaimer track, and the code recognition sensor determines the positioning of the bucket wheel stacker-reclaimer by recognizing the number corresponding to the code tag.

3. The control system of claim 2, wherein, The stacker-reclaimer PLC obtains the current position of the bucket wheel stacker-reclaimer through the positioning module, and sends the current position of the bucket wheel stacker-reclaimer to the centralized operation station through the second switch and the first switch; The centralized operation station receives a work task, plans a work area and a work path according to the work task and the current position of the bucket wheel stacker-reclaimer, and sends the work task, the work area and the work path to the central control PLC; The central control PLC sends the work task, the work area and the work path to the stacker-reclaimer PLC through the first switch and the second switch, and the stacker-reclaimer PLC controls the operation of the bucket wheel stacker-reclaimer according to the work task, the work area and the work path.

4. The control system of claim 1, wherein, The bucket wheel stacker-reclaimer further comprises an obstacle detection module, which comprises an ultrasonic sensor and a second laser radar connected with the stacker-reclaimer PLC.

5. The control system of claim 1, wherein, The central control room further comprises a display module, a video server and a third switch, and the bucket wheel stacker-reclaimer further comprises a fourth switch and a high-definition camera, the display module is connected with the third switch through the video server, the high-definition camera is connected with the fourth switch, and the third switch is connected with the fourth switch; The centralized operation station comprises a manual operation module and an integrated video operation station, the manual operation module is connected with the central control PLC, and the first switch is connected with the integrated video operation station and the third switch respectively.

6. The control system of claim 1, wherein, The bucket wheel stacker-reclaimer further comprises a stockpile shape processing computer and a laser scanner, the stockpile shape processing computer is connected with the second switch and the laser scanner respectively, and the laser scanner is used for scanning the surface of a stockpile to generate stockpile shape three-dimensional data. The control system further comprises a surveying and mapping unmanned aerial vehicle, the surveying and mapping unmanned aerial vehicle is wirelessly connected with the first switch, and the surveying and mapping unmanned aerial vehicle scans a stockyard to generate a three-dimensional map of the stockyard.

7. The control system of claim 1, wherein, The bucket wheel stacker-reclaimer further comprises a progress detection module, the progress detection module comprises a material flow sensor and a bucket wheel rotation speed sensor connected with the stacker-reclaimer PLC, and the centralized operation station adjusts the bucket wheel rotation speed of the bucket wheel stacker-reclaimer according to flow data of the material flow sensor.

8. The control system of claim 1, wherein, A dynamic load sensor is installed on the track of the stacker-reclaimer, the dynamic load sensor is connected with the central control PLC, the central control PLC sends load data of the load sensor to the centralized operation station, and the centralized operation station adjusts the stacking and reclaiming speed of the bucket wheel stacker-reclaimer according to the load data of the dynamic load sensor.

9. The control system of claim 1, wherein, The central control room further comprises an engineer station and a data server connected with the first switch, the data server is used for receiving and storing a plurality of algorithm programs input by the engineer station, the plurality of algorithm programs comprise a genetic algorithm, and the centralized operation station intelligently distributes work tasks of the bucket wheel stacker-reclaimer through the genetic algorithm; When the engineer station inputs the genetic algorithm, the genetic algorithm is trained, and the training method comprises: obtaining historical work data of the bucket wheel stacker-reclaimer through the data server; training the genetic algorithm by using the historical work data to obtain a genetic algorithm model; optimizing and training the genetic algorithm model by simulating different work scenarios of the bucket wheel stacker-reclaimer; storing the optimized genetic algorithm model in the data server.

10. The control system of claim 8, wherein, The plurality of algorithm programs further comprise a self-adaptive control algorithm, the centralized operation station obtains real-time work data and equipment state information of the bucket wheel stacker-reclaimer in real time, and adjusts the work data of the bucket wheel stacker-reclaimer through the self-adaptive control algorithm.

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