Material tower monitoring circuit and monitoring method

Abstract

The invention relates to a material tower monitoring circuit and a monitoring method, the material tower monitoring circuit is arranged in a holder in a material tower feed port area and interacts with a background server, and a scanning track is generated to drive a laser ranging module of the holder to obtain volume measurement data in a material tower; the material tower monitoring circuit comprises a data acquisition circuit, a data transmission circuit, a master control cooperation circuit and a power supply management circuit. The data acquisition circuit comprises a power supply anti-interference circuit and a signal anti-interference circuit; the power supply anti-interference circuit is located between the power supply and the laser ranging module and used for processing surge and frequency noise caused by electromagnetic interference in the material tower. The signal anti-interference circuit is located between the power supply and a serial port communication line of the laser ranging module so that signals of the laser ranging module can be stable. According to the material tower monitoring circuit, the defect that stable transmission cannot be achieved under strong electromagnetic environment interference in the prior art is overcome, meanwhile, non-contact measurement of materials in the material tower is achieved, and the measurement accuracy is improved.

Description

Technical Field

[0001] This invention relates to the field of monitoring circuit technology, and in particular to a monitoring circuit and monitoring method for a material tower. Background Technology

[0002] As a core material storage and scheduling hub in industries such as agriculture, chemicals, and feed production, feed towers directly determine the timing of replenishment, storage utilization, and safe operation of equipment based on the 3D state of the materials inside (such as real-time volume, dynamic stacking morphology, and overall material distribution). This is crucial for the accuracy of production scheduling and the reliability of safe operation and maintenance. Furthermore, feed towers are often deployed in remote locations and clusters (e.g., livestock farms require sterile or low-bacterial environments, and entry procedures are complex; farms may have 10+ feed towers scattered across tens of thousands of acres, and chemical plants may have multiple workshops with feed towers distributed across different areas), highlighting the need for subsequent system maintenance and functional iteration. However, existing feed tower data acquisition solutions are limited by the versatility and limitations of their technical design and lack of maintenance capabilities, making it difficult to meet the requirements of precise, highly stable, and low-maintenance-cost monitoring of large-scale feed tower clusters. In other words, in large-scale livestock farming and bulk grain storage, accurately grasping the remaining material volume within feed towers is crucial for supply chain management.

[0003] Existing technology provides a feed tower monitoring solution, such as patent number 202422849188.9, named Feed Tower Multi-Parameter Monitoring System. It uses a weighing sensor installed inside the support column of the feed tower, an angle sensor installed on the outer side of the middle part of the tower body, and a temperature measuring tube vertically installed inside the tower body to realize the daily weight change of feed in the feed tank through three weighing sensors at the lower end of the support column. The monitored data is sent to the background monitoring terminal for storage and easy retrieval later.

[0004] The above-mentioned improvement to the monitoring of the material tower is still in terms of mechanical structure. It depends on the structure of the material tower, and its modification cost is extremely high. Moreover, long-term load-bearing causes zero-point drift of the sensor, which requires regular manual calibration and maintenance.

[0005] With the development of non-contact measurement, how to apply non-contact measurement to the field of material tower monitoring and realize the detection of volume inside the material tower using low-cost single-point laser ranging to transmit to the cloud has become an urgent problem to be solved. Summary of the Invention

[0006] (a) Technical problems to be solved

[0007] In view of the above-mentioned shortcomings and deficiencies of the prior art, the present invention provides a material tower monitoring circuit and monitoring method, which solves the defect of unstable transmission under strong electromagnetic interference in the prior art, and realizes non-contact measurement of materials in the material tower, thereby improving the measurement accuracy.

[0008] (II) Technical Solution

[0009] To achieve the above objectives, the main technical solutions adopted by the present invention include:

[0010] In a first aspect, embodiments of the present invention provide a tower monitoring circuit, wherein the tower monitoring circuit is disposed in a gimbal in the feed inlet area of ​​the tower and interacts with a backend server, for generating a scanning trajectory to drive the laser ranging module of the gimbal to acquire volume measurement data within the tower; the tower monitoring circuit includes:

[0011] Data acquisition circuit, data transmission circuit, main control coordination circuit, power management circuit;

[0012] The main control and coordination circuit includes a microcontroller, which is connected to a power management circuit, a data transmission circuit and a data acquisition circuit, and interacts with the back-end server to realize three-dimensional data acquisition of the material volume in the tower, as well as anomaly handling and stable data transmission.

[0013] The data acquisition circuit includes: a power supply anti-interference circuit and a signal anti-interference circuit for the laser ranging module in the gimbal; the power supply anti-interference circuit is located between the power supply and the laser ranging module to process surges and frequency noise caused by electromagnetic interference in the material tower; the signal anti-interference circuit is located between the power supply and the serial communication line of the laser ranging module to stabilize the signal of the laser ranging module.

[0014] The data transmission circuit includes: an anti-interference circuit corresponding to the external antenna of the material tower, one end of which is connected to the second power supply, and the other end is set on the serial communication line between the 4G communication module and the main control coordination circuit; used to suppress electromagnetic surges in the power supply circuit and reduce interference noise in the data line.

[0015] The power management circuit adopts a dual-mode external power supply, converting external photoelectric power into a first power supply and a second power supply to power the data acquisition circuit, data transmission circuit and main control coordination circuit.

[0016] Optionally, the power supply anti-interference circuit includes: a bidirectional transient voltage suppression TVS diode - D8, a high-frequency filter capacitor - C33, and a low-frequency filter capacitor - C34;

[0017] The TVS diode, high-frequency filter capacitor C33, and low-frequency filter capacitor C34 are all connected in parallel between the first power supply and the laser ranging module. They are used to filter out surges, high-frequency noise, and low-frequency noise generated by electromagnetic interference in the power supply line and output a stable electrical signal to the laser ranging module.

[0018] Optionally, the signal anti-interference circuit includes: a first resistor R33 and a second resistor R34, the first ends of the first resistor and the second resistor are both connected to a first power supply, and the second ends of the first resistor and the second resistor are respectively set on the serial communication line between the laser ranging module and the main control coordination circuit to stabilize the TTL level of the serial communication.

[0019] Optionally, the anti-interference circuit of the data transmission circuit includes:

[0020] TVS diode D2, common mode inductor L4, current limiting resistor and filter capacitor;

[0021] The TVS diode D2 is positioned across the second power supply.

[0022] A common-mode inductor L4 is connected in series in the power supply circuit of the 4G communication module to suppress electromagnetic surges generated by the start-up and shutdown of the tower motor;

[0023] In the data lines of the 4G communication module, a current-limiting resistor is connected in series and a ceramic capacitor is connected in parallel to reduce the bit error rate caused by signal interference.

[0024] Optionally, the microcontroller chip of the main control coordination circuit is equipped with a segmented transmission module, and the microcontroller chip is equipped with a running area, an upgrade area, and a FLASH storage area.

[0025] Optionally, the tower monitoring circuit also includes: a first stepper motor drive circuit and a second stepper motor drive circuit;

[0026] The first stepper motor drive circuit and the second stepper motor drive circuit are connected to the microcontroller through their respective hex inverter circuits. Each hex inverter circuit is used to stabilize the control signal and to buffer and shape the control signal to reduce electromagnetic interference.

[0027] Optionally, the tower monitoring circuit further includes: a first position feedback circuit corresponding to the horizontal axis encoder and a second position feedback circuit corresponding to the pitch axis encoder.

[0028] Both the first and second position feedback circuits are used to feed back the multiphase pulse signals from their respective encoders to the microcontroller.

[0029] Both the first position feedback circuit and the second position feedback circuit are dual voltage comparators, used to identify the edge of the pulse signal and ensure the stable transmission of the pulse valid signal.

[0030] Secondly, embodiments of the present invention also provide a method for monitoring materials inside a material tower, comprising a pan-tilt unit installed within the enclosed space of the material tower, the pan-tilt unit containing the aforementioned material tower monitoring circuit, the material tower monitoring circuit interacting with a backend server, the method comprising:

[0031] After the microcontroller of the tower monitoring circuit is initialized, it outputs a synchronous pulse signal to the data acquisition circuit to realize data acquisition. This enables the dual motion axes in the pan-tilt unit to move and measure distance based on the synchronous pulse signal, and the microcontroller to obtain feedback of encoder position information to obtain the acquisition signal.

[0032] The microcontroller verifies the acquired signal, outputs the verified signal, and updates the scanning trajectory simultaneously.

[0033] The microcontroller transmits the verified signal to the backend server via a data transmission circuit; and / or,

[0034] The data transmission circuit receives scanning instructions sent by the backend server and generates synchronization pulse signals for real-time data acquisition.

[0035] Optionally, the monitoring method also includes:

[0036] The data transmission circuit receives upgrade instructions and upgrade information sent by the backend server and transmits them to the microcontroller;

[0037] When the microcontroller verifies that the upgrade information is complete, it writes it into the upgrade area. When the program in the upgrade area is written, it restarts to realize the remote upgrade of the microcontroller. After the remote upgrade, when the program is running normally, it sends a normal running response to the backend server through the data transmission circuit.

[0038] If the program runs abnormally after a remote upgrade, the microcontroller continues to run the program in the running area and sends a response indicating upgrade failure to the backend server via the data transmission circuit.

[0039] (III) Beneficial Effects

[0040] The beneficial effects of this invention are: the material tower monitoring circuit of this invention is applied to the pan-tilt unit, which enables the pan-tilt unit to achieve stable power supply and stable signal transmission in the enclosed material tower with strong electromagnetic interference, and is not affected by the electromagnetic interference of the motor starting and stopping in the material tower, thus realizing stable transmission in a strong electromagnetic environment.

[0041] Furthermore, the material tower monitoring circuit also enables remote upgrades and low-cost operation and maintenance after large-scale deployment, meeting the needs of accurate monitoring, stable transmission and efficient operation and maintenance for large-scale material tower groups. Attached Figure Description

[0042] Figure 1 This is a schematic diagram of the structure of a gimbal including a material tower monitoring circuit provided in an embodiment of the present invention;

[0043] Figure 2 This is a schematic diagram of the structure of the gimbal installed at the feed inlet of the material tower according to an embodiment of the present invention;

[0044] Figure 3 This is a schematic diagram of the structure of a material tower monitoring circuit provided in an embodiment of the present invention;

[0045] Figure 4 A partial structural diagram of the data acquisition circuit provided in an embodiment of the present invention;

[0046] Figure 5 A partial structural schematic diagram of the data transmission circuit provided in an embodiment of the present invention;

[0047] Figure 6 A partial structural schematic diagram of the dual motion axis drive circuit provided in an embodiment of the present invention;

[0048] Figure 7 This is a partial structural diagram of the position feedback circuit provided in an embodiment of the present invention.

[0049] [Explanation of Labels in the Attached Image]

[0050] 1: D8: TVS diode one; D2: TVS diode two; D10: TVS diode three;

[0051] 2: C33: High-frequency filter capacitor 1; C34: Low-frequency filter capacitor 1;

[0052] 3: C31: Third capacitor; C32: Fourth capacitor; C39: Fifth capacitor; C40: Sixth capacitor; C41: Seventh capacitor;

[0053] 4: R33: First resistor; R34: Second resistor; R40: Third resistor; R41: Fourth resistor;

[0054] 5: L4: Common mode inductor. Detailed Implementation

[0055] To better explain and facilitate understanding of the present invention, the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0056] Existing 3D data acquisition or transmission methods are mostly conducted in open scenes or large spaces. The material tower in this application is a cylindrical, enclosed spatial structure, and it exhibits strong electromagnetic interference characteristics. For example, in actual tower operation, electromagnetic surges generated by the start-up and shutdown of the material tower's feeding motor and agitator can cause strong interference to the acquisition end (e.g., sensor signals) and transmission end (e.g., data lines) inside the tower. This can lead to frequent abrupt changes in ranging values ​​at the acquisition end (e.g., errors in laser TOF ranging), and the transmission end's lack of targeted anti-interference design results in an extremely high data packet loss rate. Ultimately, this causes the 3D model generated by the backend server to have gaps and material level calculation deviations exceeding 10%, rendering it unreliable for production decisions.

[0057] Furthermore, existing material collection tower systems are mostly designed for "one-time deployment," making remote upgrades impossible and relying entirely on manual on-site maintenance, resulting in high upgrade costs. If material towers are mostly deployed in remote areas (such as farmland or the edge of chemical industrial parks), on-site personnel must bear transportation and labor costs. On-site upgrades for a single tower (such as fixing software vulnerabilities and optimizing scanning algorithms) require 2-3 people per day. If a cluster of more than 10 towers is involved, the total maintenance cost exceeds 10,000 yuan. Moreover, monitoring must be suspended during the upgrade, which may cause missed material anomaly warnings.

[0058] The existing material tower acquisition system is lagging behind in terms of functional iteration. As production needs change (such as adding material density calculation functions or adapting to new cloud management platform protocols) or potential problems are discovered (such as a decrease in 3D acquisition accuracy under specific working conditions), the existing system cannot be updated remotely. It requires waiting for several weeks or even months of on-site maintenance, resulting in the system being in a state of "functional backwardness" or "risk exposure" for a long time, and unable to adapt to dynamically changing production needs.

[0059] In view of this, this application can provide an integrated material tower monitoring circuit with "3D precise acquisition (laser TOF + dual motion axis collaboration) + industrial-grade anti-interference transmission (4G optimization) + remote operation and maintenance upgrade" specifically for material towers. It is not only suitable for the 3D acquisition logic of the cylindrical space of the material tower, but also can achieve stable transmission in a strong electromagnetic environment. At the same time, it enables remote upgrades and low-cost operation and maintenance after large-scale deployment, meeting the needs of precise monitoring, stable transmission and efficient operation and maintenance of large-scale material tower groups.

[0060] In this embodiment of the invention, the structure of the feed tower remains unchanged. The change is achieved by fixing a hardware acquisition terminal (referred to as a gimbal) with a laser ranging module at the feed tower inlet. Figure 2 As shown, the system enables real-time acquisition of the material volume inside the pylon and transmits the acquired 3D data to a remote backend server for monitoring and processing.

[0061] In other words, in this embodiment of the invention, the real-time measurement of the material volume in the material tower is achieved by using a hierarchical hardware acquisition terminal and a back-end server, thus ensuring the accuracy of the supply chain management system.

[0062] In this embodiment, the hardware acquisition end can utilize a low-cost single-point laser sensor in conjunction with a high-precision closed-loop gimbal, which can achieve full-field scanning inside the material tower while ensuring low power consumption and high robustness in volume detection.

[0063] In this embodiment, the gimbal is installed in the feed inlet area of ​​each feed tower. It is small in size, does not occupy feed tower space, and does not affect feed into the feed tower. For example... Figure 1 As shown, the gimbal in this embodiment may include:

[0064] The system includes a laser ranging module, a dual-axis gimbal mechanism, a drive mechanism, a closed-loop feedback structure, a self-cleaning structure, and a tower monitoring circuit (i.e., a control circuit). The laser ranging module, the dual-axis gimbal mechanism, the drive mechanism, the closed-loop feedback structure, and the self-cleaning structure are all electrically connected to the tower monitoring circuit.

[0065] The laser ranging module includes: an industrial-grade laser ranging sensor (corresponding to...) Figure 1 The laser module in the system is responsible for acquiring the radial distance (r) of the target point. It adopts the phase method or pulse method principle, and its effective range covers 0.05 meters to 100 meters, with a ranging accuracy of millimeters.

[0066] The dual-axis gimbal mechanism is used to support and drive the laser ranging module for two-dimensional scanning. This dual-axis gimbal mechanism includes a horizontal yaw axis and a vertical pitch axis, both of which are connected to the laser ranging sensor.

[0067] Drive mechanism: A horizontal axis motor drive for driving the horizontal yaw axis (i.e., yaw axis or yaw rotor) to achieve 0°-360° rotation, and a pitch axis motor drive for driving the vertical pitch axis (i.e., pitch axis or pitch rotor) to achieve 0°-240° adjustment. This drive mechanism includes: a horizontal axis stepper motor corresponding to the horizontal yaw axis, and a pitch axis stepper motor corresponding to the vertical pitch axis. The two stepper motors are coupled to their respective rotors. The minimum step angle of each stepper motor is adjustable, enabling effective control of scan density during data acquisition.

[0068] Closed-loop feedback structure: used for real-time monitoring and feedback of the precise angular position of the rotating shaft, reducing the accuracy requirements of motion control. This closed-loop feedback structure includes: a horizontal axis encoder and a pitch axis encoder, such as... Figure 1 As shown. For example, high-resolution absolute encoders can be installed at the ends of the yaw axis and pitch axis shafts, respectively. In this embodiment, the yaw axis encoder is installed on the output shaft of the yaw axis stepper motor, and the pitch axis encoder is installed on the output shaft of the pitch axis stepper motor, respectively, for real-time feedback of angle values ​​θ (yaw angle) and φ (pitch angle).

[0069] Self-cleaning structure: installed at the end of the lens's range of motion in the laser ranging module (e.g., ... Figure 1 The brush shown is driven by a stepper motor, which moves the lens of the laser sensor back and forth relative to the brush. The silo monitoring circuit can automatically start the cleaning mode according to the preset cleaning cycle or the dust sensor signal to remove dust from the lens surface and ensure the accuracy of distance measurement.

[0070] In this embodiment, the tower monitoring circuit receives instructions from the backend server or preset task instructions locally. It can generate a scanning trajectory corresponding to the laser ranging module, and then send pulse signals to the drive mechanism corresponding to the stepper motor of the gimbal. The stepper motor controls the laser ranging module to rotate and measure distance according to the pulse signals. At this time, the microcontroller acquires the angle data of the two encoders in real time, and forms three-dimensional data (θ, φ, L) with the angle data (θ, φ) of the encoders and the distance information L measured by the laser module, and sends it to the backend server.

[0071] like Figure 3 As shown, the material tower monitoring circuit may include: a data acquisition circuit, a data transmission circuit with an integrated 4G communication chip / communication module, a power management circuit, and a main control and coordination circuit with an integrated MCU (i.e., microcontroller).

[0072] The data acquisition circuit in this embodiment may have signal anti-interference and power supply anti-interference circuits, which can process the surge and frequency noise caused by electromagnetic interference in the tower, so that the laser ranging module can work stably.

[0073] The 4G communication chip in the data transmission circuit supports the 4G-LTE wireless communication protocol and uses the lightweight MQTT (Message Queuing Telemetry Transport) protocol for bidirectional communication with the backend server, ensuring stable, low-bandwidth data transmission even in agricultural environments with weak signal coverage. This embodiment uses a 4G communication chip as an example; in practice, chips with other communication protocols can also be integrated to achieve fast and efficient data communication.

[0074] Power management circuit: integrates MPPT solar charging controller and high-capacity lithium battery pack (mode 1), while retaining DC 12 / 24V wired power supply interface (mode 2) to adapt to outdoor environments without mains power.

[0075] The MCU (microcontroller) is responsible for motion control calculation and data encapsulation.

[0076] In this embodiment, the backend server is responsible for receiving point cloud data transmitted from the PTZ and executing core algorithms, including point cloud coordinate transformation, noise filtering, surface reconstruction, and volume calculation, ultimately generating a visualized 3D model (such as a 3D model of a stockpile) and an inventory report.

[0077] The gimbal in this embodiment enables low-cost, high-precision non-contact measurement within a 100-meter range inside the material tower, while also eliminating measurement blind spots caused by dust and irregular material surfaces.

[0078] To better illustrate the tower monitoring circuit in this embodiment, the following will be combined with... Figures 3 to 7 Please provide a detailed explanation.

[0079] like Figure 3 As shown, the material tower monitoring circuit includes: a data acquisition circuit, a data transmission circuit, a main control coordination circuit, and a power management circuit. These circuits work together to achieve a closed loop of "acquisition-synchronization-storage-transmission". Specifically, the laser TOF ranging module works in conjunction with dual motion axes to perform collaborative scanning, acquiring 3D point cloud data of the material surface inside the material tower (i.e., pitch axis angle, horizontal rotation axis angle, and distance between the laser and the material surface).

[0080] In this embodiment, the laser ranging module uses an industrial-grade laser TOF sensor with a ranging range within 60m and an accuracy of ±2mm. The laser module in the laser ranging module communicates with the microcontroller of the main control circuit via serial communication (TXD corresponds to RXD0, and RXD corresponds to TXD0), see [link to documentation]. Figure 4 As shown.

[0081] The data acquisition circuit includes: a power supply anti-interference circuit for processing surges and frequency noise caused by electromagnetic interference in the tower; and a signal anti-interference circuit for the laser ranging module in the pan-tilt unit. The signal anti-interference circuit is used to ensure the stable operation of the laser ranging module.

[0082] like Figure 4 As shown, the power supply anti-interference circuit includes: a bidirectional transient voltage suppression TVS diode - D8, a high-frequency filter capacitor - C33, and a low-frequency filter capacitor - C34; the signal anti-interference circuit includes: a first resistor R33 and a second resistor R34.

[0083] The TVS diode, high-frequency filter capacitor C33, and low-frequency filter capacitor C34 are all connected in parallel to the first power supply to filter out surges, high-frequency noise, and low-frequency noise generated by electromagnetic interference in the power supply line, so that the laser ranging module can effectively avoid measurement errors.

[0084] In this embodiment, the bidirectional TVS, also known as bidirectional diode one, is used for overvoltage protection. When a voltage spike occurs in the power supply line (such as a surge caused by electromagnetic interference), the TVS will quickly break down and conduct, clamping the voltage to a safe range of about 3.3V (the first power supply voltage) to prevent excessive voltage from damaging the power supply circuit of the laser ranging module.

[0085] The high-frequency filter capacitor C33 can be a 100nF ceramic capacitor: responsible for high-frequency filtering, with fast response speed to high-frequency signals and low capacitive reactance, can bypass high-frequency power supply noise (such as high-frequency ripple generated by electromagnetic interference) in the power supply line to ground, reducing the impact of high-frequency interference on the working stability of the laser ranging module.

[0086] The low-frequency filter capacitor C34 can be a 10uF capacitor, such as an electrolytic capacitor, responsible for low-frequency filtering. It has a small capacitive reactance to low-frequency signals and can filter out low-frequency voltage ripple in the power supply line (such as low-frequency fluctuations generated by power conversion), further stabilizing the 3.3V power supply voltage and ensuring a stable power supply for the laser ranging module.

[0087] Figure 4 The first resistor R33 and the second resistor R34 are connected in parallel between the laser ranging module and the first power supply. That is, the first ends of the first resistor and the second resistor are both connected to the first power supply, and the second ends of the first resistor and the second resistor are respectively set on the serial communication line between the laser ranging module and the main control coordination circuit to stabilize the TTL level of the serial communication.

[0088] In this embodiment, the resistance values ​​of both the first resistor R33 and the second resistor R34 are 1 kΩ, which can stabilize the electrical signal of serial communication and solve the problem of signal instability caused by other methods in the surrounding environment of the material tower. In other embodiments, the resistance values ​​of both the first resistor R33 and the second resistor R34 are 4.7 kΩ.

[0089] Specifically, the first and second resistors prevent the pins of the laser ranging module (i.e., the RXD receive pin and the TXD transmit pin) from floating and stabilize the idle level. The UART serial port's idle state is high by default. If the above pins are not pulled, they are in a "floating" state (i.e., the level is unstable), which is easily triggered to a low level by electromagnetic interference (such as the electromagnetic surge of the material tower motor), resulting in communication errors. The pull-up resistors (i.e., the first and second resistors) can stabilize the pins at a high level and ensure the accuracy of the signal in the idle state.

[0090] The serial port pin output capability of existing laser ranging modules is usually weak, especially for long-distance transmission (such as when the distance between the laser ranging module and the microcontroller is slightly large). The first and second resistors can help improve the signal drive strength, reduce signal attenuation, and allow the signal, i.e. the ranging data, to be transmitted to the other end device more reliably.

[0091] To enhance anti-interference capabilities, the material tower environment contains interference sources such as motors and solenoid valves. Pins that are not pulled up are easily "pulled off" by external interference signals. The first and second resistors, which act as pull-up resistors, can reduce the high impedance sensitivity of the pins and reduce the impact of electromagnetic interference on communication signals. In other words, they can reduce the interference of communication signals between the laser ranging module and the microcontroller and avoid errors in the acquired laser data.

[0092] like Figure 5As shown, the data transmission circuit includes: an anti-interference circuit corresponding to the external antenna of the material tower (i.e., the external suction cup antenna of the material tower). One end of the anti-interference circuit is connected to the second power supply, and the other end is respectively set on the serial communication line of the 4G communication module and the main control coordination circuit; it is used to suppress electromagnetic surges in the power supply circuit and reduce interference noise of the serial communication data line.

[0093] The anti-interference circuit corresponding to the external antenna of the material tower includes:

[0094] TVS diode D2, common mode inductor L4, current limiting resistors (such as the third resistor R40 and the fourth resistor R41) and filter capacitors (such as the third capacitor C31 and the fourth capacitor C32 with a value of 100nF).

[0095] The TVS diodes D2 are connected in parallel across the two ends of the second power supply and are located in the circuit between the common-mode inductor L4 and the second power supply.

[0096] In this embodiment, a common-mode inductor (L4) and a TVS diode D2 are provided in the power supply circuit of the 4G communication module to suppress electromagnetic surges generated by the start and stop of the tower motor;

[0097] In the data lines of the 4G communication module, a current-limiting resistor (such as the third resistor R40 and the fourth resistor R41) is connected in series and a ceramic capacitor (such as the third capacitor C31 and the fourth capacitor C32) is connected in parallel to reduce the bit error rate caused by signal interference. In this embodiment, the third circuit R40 and the third capacitor C31 are used as one group, and the fourth resistor R41 and the fourth capacitor C32 are used as another group to process signal interference.

[0098] The 4G communication module supports LTE Cat-1 network and uses a 5V power supply. The 4G communication module's antenna interface (ANT) is connected to an external high-gain suction cup antenna (compatible with the metal casing of the material tower for signal shielding).

[0099] In this embodiment, a common-mode inductor L4 is connected in series in the power supply circuit of the 4G communication module to suppress electromagnetic surges generated by the start and stop of the tower motor; a current-limiting resistor is connected in series and a 100nF ceramic capacitor is connected in parallel in the data line to reduce the bit error rate caused by signal interference.

[0100] The function of the common mode inductor L4 is to suppress electromagnetic surges in the power supply circuit (generated by the start and stop of the tower motor). When it is close to the 4G communication module, it can directly block the surge from being conducted into the module, thus avoiding power supply interference that could cause the 4G communication module to crash or malfunction.

[0101] Current-limiting resistors are used to limit signal current, which not only protects the serial port interface of the 4G communication module, but also weakens the energy of interference signals, reducing their impact in the early stages of interference signals entering the line.

[0102] A 100nF ceramic capacitor is used to filter out high-frequency interference noise in the data line. When placed close to the receiving end, it can directly stabilize the level of the receiving pin and avoid serial port errors caused by interference.

[0103] Figure 3 The main control and coordination circuit includes a microcontroller, which is connected to a power management circuit, a data transmission circuit and a data acquisition circuit, and interacts with the back-end server to realize three-dimensional data acquisition of the material volume in the tower, as well as anomaly handling and stable data transmission.

[0104] The microcontroller uses an industrial-grade chip (such as STM32F103), with a main frequency of 72MHz, and supports high-speed DMA and multiple serial port communication; the specific functions implemented are as follows:

[0105] Data reception: Receives ranging data from the laser ranging module via serial port, receives position data from the dual motion axis encoder, and buffers synchronization data;

[0106] Anomaly Handling: When invalid data from the laser ranging module is detected (such as ranging exceeding the range), a secondary scan of the dual motion axes is triggered to ensure the integrity of the point cloud.

[0107] Transmission linkage: When not in scanning mode, receive instructions from the backend server (such as heartbeat, run, rescan, running status, etc.) and provide timely feedback;

[0108] Once the scan is complete, the microcontroller uploads the data via a data transmission circuit. The backend server retrieves the data, analyzes it, and either issues a command to perform a follow-up scan or confirms that the data is complete.

[0109] Data storage: Once the data is fully acquired, it is organized and stored in a FLASH / independent data storage area, ensuring data integrity even in the event of power failure, and facilitating access by the backend server later. In other embodiments, the microcontroller may also store the data in an independent data storage area.

[0110] Dust Cleaning: Microcontroller Data Acquisition Process: After the microcontroller sends a command via serial port, it records the time difference until data is acquired. If the time difference exceeds a certain threshold, dust cleaning is initiated. The dust cleaning process involves the motor rotating to a specific position, causing the structural brushes to repeatedly brush the laser lens, removing dust.

[0111] Interference suppression: Voltage filtering is used between each VCC and GND in the microcontroller. In this embodiment, an interference suppression circuit is set between the microcontroller and the first power supply, which consists of diode D10, fifth capacitor C39, sixth capacitor C40, and seventh capacitor C41 to ensure the stability of the microcontroller's power supply. In this embodiment, the fifth capacitor C39, sixth capacitor C40, and seventh capacitor C41 are all 100nF.

[0112] The power management circuit adopts a dual-mode external power supply, converting external photoelectric power into a first power supply (3.3V) and a second power supply (5V) to power the data acquisition circuit, data transmission circuit and main control coordination circuit.

[0113] In this embodiment, the external 24VDC is converted to 5V by the switching power supply module to power the 4G communication module, encoder, and stepper motor driver; the 5V is then converted to 3.3V by the linear voltage regulator chip to power the laser ranging module and microcontroller chip.

[0114] The tower monitoring circuit also includes: the first stepper motor drive circuit and the second stepper motor drive circuit corresponding to the dual motion axes in the gimbal;

[0115] like Figure 6 As shown, the first stepper motor drive circuit and the second stepper motor drive circuit are connected to the microcontroller through their respective hex inverter circuits. Each hex inverter circuit is used to stabilize the control signal and buffer and shape the control signal to reduce electromagnetic interference.

[0116] In this embodiment, the hex inverter circuit is connected to the GPIO pins of the microcontroller to enable the laser to rotate vertically and horizontally. The main function of the hex inverter circuit revolves around the adaptation and stable transmission of motor drive control signals. Specifically, in the context of the project (enclosed material tower, dual-axis motion drive), the function is as follows:

[0117] Enhanced signal driving capability: The output drive current of the GPIO pins of microcontrollers is usually weak (e.g., the output current of the GPIO of a microcontroller is about 20mA), while the stepper motor drive circuit has certain requirements for the driving capability of the input signal in industrial environments (where there is a lot of electromagnetic interference in the material tower); the hex inverter circuit can provide stronger output driving capability, ensure that the control signal is stably transmitted to the motor drive circuit, and avoid drive abnormalities caused by signal attenuation.

[0118] The material tower environment contains interference sources such as motor start-stop and solenoid valves. The control signal output by the microcontroller is easily affected by noise, resulting in blurred edges. The six inverter circuit of the stepper motor drive circuit can buffer and shape the signal, making the high and low level edges of the output signal clearer, reducing the impact of electromagnetic interference on motor drive control, and improving the position accuracy and stability of dual motion axis scanning.

[0119] like Figure 7 As shown, the tower monitoring circuit also includes: a first position feedback circuit corresponding to the horizontal axis encoder and a second position feedback circuit corresponding to the pitch axis encoder. Both the first and second position feedback circuits are used to feed back the multiphase pulse signals of their respective encoders to the microcontroller.

[0120] The position feedback circuit in this embodiment can be a differential receiver (specifically, a dual voltage comparator) used to identify pulse signal edges and ensure stable transmission of valid pulse signals. This dual voltage comparator optimizes the reliability and compatibility of the encoder pulse signal, adapting to the signal transmission requirements of industrial-grade material tower environments.

[0121] Both the X-axis (horizontal axis) and Y-axis (pitch axis) are equipped with encoders. The multi-phase pulse signals output by the encoders are input to the microcontroller via differential receivers, enabling real-time feedback of the motion axis position to the microcontroller. The core of using differential receivers is to automatically and accurately acquire the multi-phase pulse signals from the incremental encoders, achieving real-time feedback of the motion axis position and speed.

[0122] In environments with strong electromagnetic interference (such as surge interference from the start and stop of dual-axis motors) in a material tower, the encoder's output pulse signal is prone to distortion problems such as burrs and blurred edges. By setting a reasonable reference threshold voltage, the differential receiver can shape the irregular encoder signal into a regular rectangular wave, ensuring that the microcontroller can accurately identify the pulse edges and improve the position feedback accuracy of the dual-axis motors.

[0123] The encoder's output level (5V for some industrial encoders) may be incompatible with the microcontroller's 3.3V TTL level; the differential receiver can be configured with a reference voltage to convert the encoder's signal level to a level standard compatible with the microcontroller, thus avoiding signal reading errors caused by level mismatch.

[0124] Dust and electromagnetic noise in the environment of the signal anti-interference filter tower can easily mix into the encoder signal, forming invalid low-amplitude noise; the differential receiver can filter out noise signals below the threshold voltage through the threshold voltage, retaining only the valid encoder pulse signal, reducing the bit error rate of position feedback, and ensuring the accuracy of the dual motion axis scanning trajectory.

[0125] In the transmission path between the signal-driven encoder and the microcontroller, the signal may be attenuated due to distance or interference; the differential receiver, as a high-gain comparator, can enhance the driving capability of the signal and ensure that the pulse signal is stably transmitted to the position acquisition channel of the microcontroller.

[0126] According to another aspect of the present invention, in this embodiment, the microcontroller in the main control coordination circuit is provided with a segmented transmission module, and the microcontroller chip is provided with a running area, an upgrade area, and a FLASH storage area.

[0127] The hardware aspect of this embodiment is as follows: The basic support design for remote upgrades requires adaptation and modification of existing hardware modules of the system (e.g., the 4G communication module needs to support large file segmentation transmission; the microcontroller needs a large FLASH to facilitate the reservation of Bootloader partition and upgrade control pins; the storage module needs to be divided into "running area / upgrade area").

[0128] Remote upgrades in material tower scenarios need to address the issue of "industrial environment reliability" (e.g., how to roll back in case of sudden power failure during upgrade, how to retransmit upgrade packages damaged by electromagnetic interference, and how to ensure uninterrupted data storage of critical monitoring data during upgrades). These upgrade control logics specific to material tower scenarios (e.g., "upgrade status feedback mechanism based on 4G heartbeat packets" and "program rollback design with dual-zone storage") can serve as a "hardware-software co-operation solution." In this embodiment, the microcontroller partitioning scheme is described below:

[0129]

[0130] Signal processing flow:

[0131] The overall signal control and processing flow refers to the closed-loop control logic across the entire chain, from "acquisition triggering → data synchronization → processing and transmission → cloud interaction → operation and maintenance upgrades". Its core is to use a microcontroller to uniformly schedule signals from each module, achieving full controllability throughout the entire process of "signal generation – processing – feedback – iteration". The specific process is as follows:

[0132] Initialization signal configuration: The microcontroller outputs a configuration signal (i.e., after power-on, it outputs the initial configuration signal) to complete the parameter initialization of the laser TOF, dual motion axes, 4G communication module, encoder, and remote upgrade module (including scanning trajectory, communication baud rate, and upgrade partition division).

[0133] Synchronization signal acquisition trigger: The microcontroller outputs a 10Hz synchronization pulse to trigger the synchronous acquisition of the laser TOF ranging signal and the dual motion axis position signal (dual encoder). The signal is transmitted to the microcontroller at high speed via DMA; that is, the microcontroller outputs a synchronization pulse to trigger the dual motion axes and synchronously acquire the position signals of the dual motion axes; when the motion axis is at the required position of the trajectory, the laser TOF ranging is triggered.

[0134] Data processing and signal calibration: The microcontroller verifies the acquired signals (double comparison of position signals and determination of the validity of ranging signals) and outputs matching three-dimensional point data;

[0135] Anti-interference transmission signal: The microcontroller outputs a transmission control signal, which is then transmitted to the backend server via the anti-interference line (common mode inductor + RC filter) of the 4G communication module.

[0136] The 4G communication module also receives scheduling / refresh signals from the backend server, feeds them back to the microcontroller, and outputs control signals to drive the motion axis to perform corresponding actions;

[0137] Data storage signal: The data storage chip stores data separately to prevent data loss during power failure.

[0138] Remote upgrade signal closed loop: The backend server pushes the upgrade package signal, which is transmitted to the microcontroller via the 4G communication module. The microcontroller outputs partitioned storage signals (running area + upgrade area). After the program update is completed, it sends back an upgrade success signal. The signal acquisition is uninterrupted throughout the process.

[0139] In this embodiment, the gimbal can achieve precise, all-around data acquisition without blind spots and can avoid material failures. Compared with traditional solutions, it can capture three-dimensional data inside the material tower through the collaboration of laser ranging module and dual motion axes.

[0140] For example, no dead angle coverage: scanning the material tower structure, collecting dead angles <0.5%, 3D point cloud coverage rate 99.5% (traditional <60%), avoiding local blockages and internal wall voids;

[0141] Industrial-grade precision: Laser ranging ±2mm + dual feedback positioning ±0.05mm, 3D material level deviation <1%, early warning of bridging and segregation 2-3 hours in advance, reducing production failures by 80%+;

[0142] Dust interference resistant: The laser can work stably in environments with dust ≤200mg / m³, solving the problem of failure of traditional sensors.

[0143] based on Figure 3 The data transmission circuit shown provides stable and reliable data signals, effectively supporting the decision-making and processing of the backend server. 4G transmission is optimized for strong electromagnetic interference, resulting in a low packet loss rate. This embodiment employs a combined architecture of common-mode inductor, current-limiting resistor, filter capacitor, and TVS protection to ensure a data packet loss rate of <0.1% (compared to the traditional 5%), ensuring distortion-free 3D models received by the backend server. Furthermore, it eliminates signal blind spots; the high-gain suction cup antenna (≥8dBi) in this embodiment allows for stable transmission even in weak signal areas (remote farmland, park edges).

[0144] It should be noted that the PTZ in this embodiment can achieve autonomous remote upgrades, changing the traditional manual operation and maintenance method, eliminating the need for manual on-site maintenance, and adapting to multi-tower clusters. Specifically, 4G over-the-air upgrades take 5-10 minutes per tower and 1 hour to complete for a 10-tower cluster (compared to 2-3 days per tower in the traditional method), reducing labor costs by 80%. Furthermore, it enables rapid iterative repairs, with backend server commands triggering function updates (such as adding density calculations) and vulnerability patches, reducing the cycle from weeks to hours, and increasing system security by 90%.

[0145] The gimbal in this embodiment can be adapted to multiple scenarios: high industrial value and cross-industry applicability: by adjusting the dual-axis travel, it can adapt to 1-10m diameter towers, covering scenarios such as agriculture, chemical industry, and feed industry; wide temperature stability: the core components support -20℃~85℃, without the need for additional temperature control; multi-tower management: reducing the cost of large-scale management.

[0146] In this embodiment, the application of the gimbal to the material tower can achieve the functions of cost reduction, quality improvement and efficiency enhancement. For example, the annual maintenance cost of a single tower is reduced from 12,000 to 3,600, and 10 towers can save 84,000 per year, with a 60% reduction in flow rate; 3D material level accuracy is ±1%, downstream production error is reduced by 90%, and product qualification rate is increased by 5%-8%; efficiency enhancement: multi-tower management efficiency is increased by 5 times, replenishment response time is reduced from 30 minutes to 5 minutes, and warehouse utilization rate is increased by 15%.

[0147] To better understand the above Figure 1 and Figure 3 The measurement process of the gimbal shown above illustrates, from another perspective, the measurement of the stock information of feed towers in livestock farming using the gimbal.

[0148] Gimbal: Installed on top of the livestock feed tower, it includes a communication device, a laser ranging module, a dual-axis motion mechanism (horizontal axis motor drive mechanism and pitch axis motor drive mechanism), a horizontal angle detection device, a pitch angle detection device, and a microcontroller;

[0149] The dual-axis motion mechanism is used to drive the laser ranging module to perform horizontal rotation and pitch swing; the horizontal angle detection device and the pitch angle detection device are used to directly measure the actual rotation angle of the dual-axis motion mechanism in the horizontal rotation and pitch swing directions, respectively.

[0150] The microcontroller is used to send motion commands to the dual-axis motion mechanism when performing scanning measurement tasks, so that the laser ranging module points to multiple different spatial orientations in sequence; after moving in response to each motion command, it synchronously reads the real-time rotation angle values ​​fed back by the horizontal angle detection device and the pitch angle detection device, and triggers the laser ranging module to acquire the corresponding distance value, thereby generating multiple sets of measurement data, and controlling the communication device to upload multiple sets of measurement data;

[0151] The backend server is used to determine the inventory information of materials in the feed tower of the livestock breeding industry based on the multiple sets of measurement data.

[0152] The microcontroller is also used to perform adaptive scanning control, specifically including: determining the local morphological features of the material surface based on at least some of the acquired measurement data; and adjusting the angular step size of the subsequent scanning motion of the dual-axis motion mechanism based on the determination result.

[0153] The microcontroller is also used to: decrease the horizontal angle step size and / or the pitch angle step size in regions where the topographic change is determined to exceed a first threshold; and increase the horizontal angle step size and / or the pitch angle step size in regions where the topographic change is determined to be below a second threshold.

[0154] The backend server can be used to: convert the multiple sets of measurement data into three-dimensional spatial coordinate points; construct a geometric model representing the material surface based on the three-dimensional spatial coordinate points; and calculate the inventory information based on the geometric model; wherein the inventory information includes at least one of the following: material volume, material surface height distribution, remaining percentage, and estimated weight.

[0155] In this embodiment, the entire gimbal is also equipped with a cleaning device within the range of motion of the dual-axis motion mechanism. At this time, the microcontroller is used to control the dual-axis motion mechanism to drive the laser ranging module to move when the preset conditions are met, so that the detection window of the laser ranging module moves to contact the cleaning device and is wiped.

[0156] The preset conditions include at least one of the following: reaching the scheduled cleaning cycle, receiving a remote cleaning command, or determining that the degree of contamination of the detection window exceeds a threshold based on environmental sensor signals. The detection window specifically refers to the optical path area on the laser ranging module where the emitted laser beam is emitted and the echo signal reflected from the material surface is received. In actual products, it is usually composed of an optical lens, a protective lens, or the surface of a protective cover at the front end of the sensor, or a combination of these components. Because it is directly exposed to the measured environment, it is extremely prone to the adhesion of contaminants such as dust and moisture, leading to laser signal attenuation or distortion, making it a critical part affecting ranging accuracy and stability. Cleaning the detection window mentioned in this application refers to physically wiping the outer surface of this optical interface to ensure the unobstructed and clean optical path.

[0157] For example, the cleaning device (i.e., the self-cleaning structure) specifically refers to a fixedly installed cleaning component, typically a strip-shaped or block-shaped soft brush. This cleaning device can be fixedly positioned in a specific, non-working position within the motion space of the dual-axis motion mechanism; this position can be defined as the cleaning station, for example, the end of a lens's movement. The microcontroller then controls the dual-axis motion mechanism to precisely move the laser ranging module to this cleaning station, ensuring close contact between the surface of the laser ranging module's detection window and the brush of the fixed cleaning device. Upon reaching the contact position, the microcontroller further controls the dual-axis motion mechanism (usually the pitch axis) to perform several small-angle reciprocating swings or unidirectional scraping movements on the laser ranging module, generating relative friction between the detection window and the brush, thereby scraping away dust, moisture, and other contaminants adhering to the window. After the cleaning action is completed, the microcontroller then controls the motion mechanism to move the laser ranging module back to the working area, and can choose to continue or restart the scanning measurement task.

[0158] In addition, for scheduled cleaning cycles, the microcontroller has an internal timer that can automatically trigger the cleaning program according to the user's preset or the cycle issued by the backend server (e.g., every 24 hours, or before each scanning task begins), so as to achieve preventive maintenance.

[0159] For receiving remote cleaning commands, users can send immediate cleaning commands remotely via mobile devices. The backend server receives the command and forwards it to the microcontroller, which then responds and executes the cleaning operation, enabling on-demand management.

[0160] For environmental sensor signal-based judgment, the gimbal can integrate additional environmental sensors (such as dust sensors or circuitry for monitoring laser echo intensity). The microcontroller continuously monitors sensor signals, and automatically triggers a cleaning program when data analysis indicates a decrease in the light transmittance of the detection window or a contamination level exceeding a set threshold (e.g., laser echo signal intensity repeatedly falling below normal levels). This mode enables predictive maintenance based on the actual condition of the equipment. In this embodiment, the automated contact cleaning performed by the dual-axis motion mechanism and the overall high-protection design effectively resist the effects of harsh agricultural environments such as high dust and high humidity, solving the problems of sensor window contamination and long-term reliability, and achieving near-maintenance-free stable operation.

[0161] The backend server, i.e., the cloud, is also used to: generate and distribute scanning configuration parameters to the scanning measurement device based on historical data or user input; wherein, the scanning configuration parameters include at least one of scanning angle range and initial angle step size. For example, the backend server mainly relies on two types of input when generating parameters: one is historical data, such as the total volume obtained from the most recent scan, the lowest material level height, the degree of material surface undulation (i.e., the height difference between the highest and lowest points), and the material surface morphology displayed in the 3D model (e.g., whether it is a significant "funnel shape"); the other is direct user instructions, such as preset modes such as "fast scan" or "fine scan" selected through the operation interface. Based on these inputs, the backend server calculates the suggested parameters for this scan through built-in decision logic. For example, when historical data shows a high material level, the backend server will automatically reduce the scanning range of the pitch angle, so that the scan focuses on the material area at the top of the tower, avoiding invalid measurements of the empty bottom; conversely, if the material level is extremely low, the scanning range may be expanded to ensure that the edge material surface is captured. Meanwhile, the backend server sets an initial angle step size: for scenarios with flat material surfaces or where users require rapid scanning, a larger initial step size (e.g., 5.0°) is issued to improve efficiency; for scenarios with high material levels, complex material surfaces, or high precision requirements, a smaller initial step size (e.g., 1.8°) is issued as the basis for dense scanning. These generated parameters (including at least one of the scanning angle range and initial angle step size) are encapsulated into structured instructions and then sent to the microcontroller of the gimbal via a wireless network. After receiving and parsing these parameters, the microcontroller uses them as the baseline configuration for executing the current scanning measurement task. Thus, the system consisting of the gimbal and the backend server constructs a globally intelligent closed loop, enabling the scanning task to continuously optimize itself based on historical results, significantly improving scanning efficiency and system energy efficiency while ensuring measurement accuracy.

[0162] After the microcontroller drives the gimbal motor to the predetermined position, the two encoders passively and precisely measure the actual angles and report the gimbal's final true spatial attitude angles, without participating in real-time adjustment, correction, or closed-loop control of the motor's movement. After acquiring the actual angle values ​​from these two encoders, the microcontroller binds them to synchronously triggered laser ranging data, forming a set of reliable spatial coordinate measurement data. Through this mechanism of reading the actual angles after movement, the microcontroller switches the spatial positioning benchmark from theoretical command values ​​with inherent errors to the actual physical angles measured by the encoders. This eliminates the influence of uncertainties such as mechanical transmission backlash and motor step error from the data source, providing a unique and reliable angle data foundation for subsequent accurate 3D reconstruction and volume calculation.

[0163] Optionally, the microcontroller is configured to generate a series of target spatial orientations based on a preset or server-side scanning strategy when performing a scanning measurement task. It then sends pulse commands to the stepper motor drivers of the dual-axis motion mechanism, causing the laser ranging module to sequentially point to these orientations. Furthermore, in response to each motion command and after the mechanism moves, the microcontroller does not record the theoretical command angle, but instead synchronously reads the real-time rotation angle values ​​(i.e., yaw and pitch angles) fed back by the two encoders, and simultaneously triggers the laser ranging module to acquire the distance value at that point, thereby generating a set of measurement data consisting of the yaw angle, pitch angle, and distance value.

[0164] In this embodiment, a high-resolution encoder is introduced to directly feed back the true rotation angle of the dual-axis motion mechanism and synchronously bind it with the laser ranging value, thus constructing a direct measurement closed loop in the hardware. This eliminates the transmission error of the open-loop mechanical system from the data source, making the relative error of volume measurement stably controlled within 1%. This achieves millimeter-level precision reconstruction of irregularly shaped material piles and fundamentally solves the problem of large-scale (10%-20%) estimation deviation caused by the angle of repose and mechanical error in traditional single-point measurement or open-loop scanning.

[0165] In addition, this embodiment also provides a method for measuring the inventory information of feed towers in livestock farming, characterized by comprising:

[0166] The microcontroller sends multiple motion commands to the dual-axis motion mechanism, and after moving in response to each motion command, it synchronously reads the real-time rotation angle values ​​fed back by its horizontal angle detection device (i.e., horizontal axis encoder) and pitch angle detection device (i.e., pitch axis encoder), as well as the distance value measured by its laser ranging module, thereby obtaining multiple sets of measurement data.

[0167] Multiple sets of measurement data are uploaded by controlling the data transmission circuit with a microcontroller.

[0168] The backend server determines the inventory information of materials in the feed tower for livestock farming based on the multiple sets of measurement data.

[0169] Specifically, the backend server first verifies and preprocesses the uploaded raw measurement data, filtering out obviously invalid data points, such as deleting data with distance values ​​exceeding the sensor's range or with excessively weak reflected signal strength. Then, based on these values ​​and the known installation height of the scanning measurement device at the top of the pylon, the backend server uses geometric calculations to locate each measurement point in a unified three-dimensional spatial coordinate system, thereby generating an initial three-dimensional spatial point cloud for subsequent analysis. For example, multiple sets of measurement data are converted into three-dimensional spatial coordinate points; based on these coordinate points, a geometric model representing the material surface is constructed; and based on the geometric model, inventory information is calculated; this inventory information includes at least one of the following: material volume, material surface height distribution, remaining percentage, and estimated weight.

[0170] Due to interference from dust and moisture within the feed tower, the initial point cloud will contain invalid noise points. To address this, the backend server can employ advanced point cloud filtering algorithms for data purification. For example, a statistical outlier removal algorithm can be applied: this algorithm analyzes the distance distribution characteristics of each point and its neighboring points within a certain range, automatically identifying and removing discrete points whose distance distribution significantly deviates from the main point group. This process filters out abnormal data caused by non-material surface reflections (such as airborne dust or occasional flying insects), resulting in a clean, high-quality 3D point cloud that only represents the actual material surface, laying the foundation for accurate modeling.

[0171] Furthermore, to derive the volume of continuous material from discrete point clouds, a continuous surface model capable of mathematical integration must be constructed. The backend server utilizes computational geometry algorithms to perform surface reconstruction. In a preferred embodiment, a constrained Delaunay triangulation algorithm is employed. This algorithm intelligently connects three adjacent points based on the spatial topology of the point cloud, forming numerous non-overlapping triangular patches. These triangular patches ultimately combine to form a continuous and closed triangular mesh surface covering the entire material surface. This mesh model, known as an irregular triangular mesh, can simulate any complex shape of feed accumulation with extremely high fidelity, such as a central cone formed after feeding or a deep funnel formed after discharging, thus mathematically defining the three-dimensional geometric boundary of the material surface.

[0172] Subsequently, based on the aforementioned triangular mesh surface model, the backend server performs spatial volume integration to calculate the net volume of the space occupied by the material. The method involves decomposing the complex volume calculation: for each spatial triangle in the mesh, the volume of the triangular prism enclosed by it and the horizontal reference plane at the bottom of the tower (or a known conical tower bottom model) is calculated. By summing the volumes of all such basic geometries using an efficient algorithm (automatically handling positive and negative signs to accommodate uneven surfaces), the total volume V of the enclosed space is obtained.

[0173] Furthermore, the backend server combines the feed bulk density pre-configured by the user. Through the formula M= The estimated total weight M of the material is calculated using ×V. Simultaneously, the backend server analyzes the 3D point cloud and surface model to extract and generate inventory information, including but not limited to: real-time highest and lowest material levels, material surface contour maps, the percentage of the current volume relative to the full silo volume, and the estimated remaining feeding days based on the consumption rate.

[0174] Finally, the backend server associates and binds all the calculated inventory data with the reconstructed 3D visualization model, and comprehensively displays it on user terminals (such as web browsers or mobile applications) through charts, dashboards, and interactive 3D views. All results are stored in a database, supporting historical trend queries and comparative analysis. Furthermore, the backend server can automatically trigger low inventory warning notifications based on preset inventory thresholds. As an advanced intelligent feature, the backend server also optimizes the global parameters (such as the suggested elevation angle range and baseline scan density) for the next scan task based on the overall results of this scan analysis (such as material level), and sends these suggested parameters to the scanning measurement device.

[0175] The back-end server not only outputs accurate volume and weight data, but also provides multi-dimensional information such as 3D models, feed distribution and trend analysis, which promotes a fundamental transformation of the livestock farming industry from experience-based fuzzy management to digital and intelligent warehousing management based on precise data.

[0176] Furthermore, the microcontroller determines the local morphological features of the material surface based on at least some of the acquired measurement data;

[0177] Based on the judgment result, the microcontroller adjusts the angular step size of the subsequent scanning motion of the dual-axis motion mechanism.

[0178] In this embodiment, the microcontroller decreases the horizontal angle step size and / or the pitch angle step size in regions where the topography change exceeds a first threshold; or increases the horizontal angle step size and / or the pitch angle step size in regions where the topography change is determined to be below a second threshold. For example, the microcontroller is also used to perform adaptive scan control, specifically including: during a single scan, determining the local topography features of the material surface based on at least some of the acquired measurement data; and adjusting the angular step size of the subsequent scan motion of the dual-axis motion mechanism according to the determination result. Specifically, in regions where the topography change exceeds the first threshold, the horizontal angle step size and / or the pitch angle step size are decreased; in regions where the topography change is determined to be below the second threshold, the horizontal angle step size and / or the pitch angle step size are increased.

[0179] For example, the microcontroller selects a series of newly formed spatially adjacent measurement points from the real-time acquired and cached measurement data, forming a local point set to be analyzed. Subsequently, the microcontroller transforms the measurement values ​​(including actual yaw angle, actual pitch angle, and distance) of each point in this set to a unified three-dimensional spatial coordinate system, thereby obtaining the three-dimensional coordinates of each point, where the Z-coordinate represents its altitude value. Next, the microcontroller quantitatively evaluates the undulation and topographic complexity of the material surface in this area by calculating the statistical variance (i.e., altitude variance) of the altitude values ​​of all points within this local point set. Altitude variance is a key mathematical indicator; a larger value indicates more significant altitude differences between points in the area, a more rugged material surface, and a more complex topographic feature; conversely, a smaller variance value indicates a flatter and more uniform material surface. This quantitative evaluation result provides an objective and reliable decision-making basis for the microcontroller to accurately adjust its scanning strategy.

[0180] Furthermore, when the analysis results indicate that the current area exhibits drastic changes in material surface morphology and high complexity (e.g., the height variance exceeds a first threshold, the specific value of which can be set according to actual needs), the microcontroller will instruct the dual-axis motion mechanism to reduce the angular step size in the horizontal and pitch directions during subsequent scans. This is equivalent to performing denser measurements in this critical area, deploying more measurement points to ensure accurate capture of details of complex contours such as hopper edges and slopes. Conversely, when the analysis results indicate that the area is relatively flat and has a simple morphology (e.g., the height variance is below a second threshold, the specific value of which can also be set according to actual needs), the microcontroller will instruct the motion mechanism to increase the subsequent angular step size, thereby performing sparse scanning in this area, achieving rapid coverage, and effectively saving scanning time and system power consumption.

[0181] Therefore, the above scheme can significantly improve the overall scanning efficiency and shorten the time of a single operation while ensuring that the measurement accuracy in complex areas is not lost. At the same time, the density distribution of the final generated two-dimensional point cloud data is adaptive to the complexity of the material surface, providing a higher quality data foundation for the subsequent high-fidelity three-dimensional surface reconstruction by the back-end server (i.e., the cloud).

[0182] The microcontroller's locally executed adaptive scanning strategy can dynamically adjust the scanning angle step size based on real-time acquired local point cloud data. It automatically densifies in complex areas of the material surface and automatically thins out in flat areas. While ensuring the accuracy of key feature acquisition, it improves the overall scanning efficiency by 30% to 50%, achieving the best balance between accuracy and work efficiency.

[0183] The above solution enables full-area scanning inside the silo, while ensuring signal stability, power stability, and immunity to electromagnetic interference from the surrounding environment, as well as dust interference inside the silo.

[0184] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0185] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, as well as combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions.

[0186] It should be noted that any reference numerals placed between parentheses in the claims should not be construed as limiting the claims. The word "comprising" does not exclude the presence of components or steps not listed in the claims. The word "a" or "an" preceding a component does not exclude the presence of a plurality of such components. The invention can be implemented by means of hardware comprising several different components and by means of a suitably programmed computer. In claims that enumerate several means, several of these means may be embodied by the same hardware. The use of the terms first, second, third, etc., is merely for convenience of expression and does not indicate any order. These terms can be understood as part of the component names.

[0187] Furthermore, it should be noted that in the description of this specification, the terms "one embodiment," "some embodiments," "embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Furthermore, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0188] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the claims should be interpreted to include both the preferred embodiments and all changes and modifications falling within the scope of the invention.

[0189] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, then this invention should also include these modifications and variations.

Claims

1. A monitoring circuit for a material tower, characterized in that, The tower monitoring circuit is located in the gimbal in the tower inlet area and interacts with the backend server to generate a scanning trajectory to drive the gimbal's laser ranging module to acquire volume measurement data inside the tower. The tower monitoring circuit includes: Data acquisition circuit, data transmission circuit, main control coordination circuit, power management circuit; The main control and coordination circuit includes a microcontroller, which is connected to a power management circuit, a data transmission circuit and a data acquisition circuit, and interacts with the back-end server to realize three-dimensional data acquisition of the material volume in the tower, as well as anomaly handling and stable data transmission. The data acquisition circuit includes: a power supply anti-interference circuit and a signal anti-interference circuit for the laser ranging module in the gimbal; the power supply anti-interference circuit is located between the power supply and the laser ranging module to process surges and frequency noise caused by electromagnetic interference in the material tower; the signal anti-interference circuit is located between the power supply and the serial communication line of the laser ranging module to stabilize the signal of the laser ranging module. The data transmission circuit includes: an anti-interference circuit corresponding to the external antenna of the material tower; one end of the anti-interference circuit is connected to the second power supply, and the other end is set on the serial communication line between the 4G communication module and the main control coordination circuit; it is used to suppress electromagnetic surges in the power supply circuit and reduce interference noise in the data line. The power management circuit adopts a dual-mode external power supply, converting external photoelectric power into a first power supply and a second power supply to power the data acquisition circuit, data transmission circuit and main control coordination circuit.

2. The tower monitoring circuit as described in claim 1, characterized in that: The power supply anti-interference circuit includes: bidirectional transient voltage suppression TVS diode (D8), high-frequency filter capacitor (C33), and low-frequency filter capacitor (C34). The TVS diode, high-frequency filter capacitor (C33), and low-frequency filter capacitor (C34) are all connected in parallel between the first power supply and the laser ranging module. They are used to filter out surges, high-frequency noise, and low-frequency noise generated by electromagnetic interference in the power supply line and output a stable electrical signal to the laser ranging module.

3. The tower monitoring circuit as described in claim 1, characterized in that: The signal anti-interference circuit includes a first resistor (R33) and a second resistor (R34). The first ends of the first resistor and the second resistor are both connected to the first power supply. The second ends of the first resistor and the second resistor are respectively set on the serial communication line between the laser ranging module and the main control coordination circuit to stabilize the TTL level of the serial communication.

4. The tower monitoring circuit as described in claim 1, characterized in that: The anti-interference circuit for the data transmission circuit includes: TVS diode 2 (D2), common mode inductor (L4), current limiting resistor and filter capacitor; The second TVS diode (D2) is positioned across the second power supply. A common-mode inductor (L4) is connected in series in the power supply circuit of the 4G communication module to suppress electromagnetic surges generated by the start-up and shutdown of the tower motor. In the data lines of the 4G communication module, a current-limiting resistor is connected in series and a ceramic capacitor is connected in parallel to reduce the bit error rate caused by signal interference.

5. The tower monitoring circuit as described in claim 1, characterized in that: The microcontroller chip includes a chip transmission module, as well as a running area, an upgrade area, and a FLASH storage area.

6. The tower monitoring circuit as described in claim 1, characterized in that: The tower monitoring circuit also includes: a first stepper motor drive circuit and a second stepper motor drive circuit; The first stepper motor drive circuit and the second stepper motor drive circuit are connected to the microcontroller through their respective hex inverter circuits. Each hex inverter circuit is used to stabilize the control signal and to buffer and shape the control signal to reduce electromagnetic interference.

7. The tower monitoring circuit as described in claim 1, characterized in that: The tower monitoring circuit also includes: a first position feedback circuit corresponding to the horizontal axis encoder and a second position feedback circuit corresponding to the pitch axis encoder; Both the first and second position feedback circuits are used to feed back the multiphase pulse signals from their respective encoders to the microcontroller. Both the first position feedback circuit and the second position feedback circuit are dual voltage comparators, used to identify the edge of the pulse signal and ensure the stable transmission of the pulse valid signal.

8. A method for monitoring materials inside a feed tower, characterized in that, A gimbal is installed within the enclosed space of a material tower, and the gimbal contains a material tower monitoring circuit as described in any one of claims 1 to 7. This material tower monitoring circuit interacts with a backend server. The method includes: After the microcontroller of the tower monitoring circuit is initialized, it outputs a pulse signal to the data acquisition circuit according to the specified scanning trajectory to realize data acquisition. This enables the dual motion axes in the pan-tilt unit to move and measure distance based on the pulse signal, and the microcontroller obtains feedback of encoder position information to obtain the acquisition signal. The microcontroller verifies the acquired signal, outputs the verified signal, and updates the scanning trajectory simultaneously. The microcontroller transmits the verified signal to the backend server via a data transmission circuit; and / or, The data transmission circuit receives scanning instructions sent by the backend server and generates synchronization pulse signals for real-time data acquisition.

9. The method as described in claim 8, characterized in that, Also includes: The data transmission circuit receives upgrade instructions and upgrade information sent by the backend server and transmits them to the microcontroller; When the microcontroller verifies that the upgrade information is complete, it writes it into the upgrade area. When the program in the upgrade area is written, it restarts to realize the remote upgrade of the microcontroller. After the remote upgrade, when the program is running normally, it sends a normal running response to the backend server through the data transmission circuit. If the program runs abnormally after a remote upgrade, the microcontroller continues to run the program in the running area and sends a response indicating upgrade failure to the backend server via the data transmission circuit.

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