Automatic tool setting system of cold regeneration machine

Abstract

The invention provides an automatic tool setting system of a cold regenerator, and belongs to the technical field of intelligent control of road construction equipment, and the system comprises a multi-source sensing module which is used for obtaining state data of the cold regenerator, including position information of a milling assembly and attitude information of a vehicle body; the fusion control module is in communication connection with the multi-source sensing module and is used for receiving and processing the cold regenerator state data input by the multi-source sensing module, generating a target milling path according to set milling related parameters and adjusting generated deviation; and the auxiliary calibration module is in two-way communication connection with the fusion control module and is used for marking the milling edge in the milling process and correcting the offset generated in the working process of the cold regeneration machine. Through multi-sensor cooperative sensing and intelligent steering control, the tool lap joint deviation is controlled within a small range, the construction quality and efficiency are improved, the operation threshold is lowered, and the method has certain application value in the industry.

Description

TECHNICAL FIELD

[0001] The application relates to an automatic tool alignment system of a cold regenerator, and belongs to the technical field of intelligent control of road construction equipment. BACKGROUND

[0002] When the cold regenerator works, the cold regenerator realizes in-situ regeneration by milling and mixing original pavement materials, and the construction quality is highly dependent on the lap precision of adjacent tool passes. At present, when the cold regenerator is used, the operator adjusts the position by observing the marking line or a reference object with naked eyes, and the transverse deviation is generally high, so that the material thickness in the lap area also deviates, and diseases such as uneven pavement and cracks are prone to occur in the later period. Every time a tool pass is completed, the vehicle needs to be stopped for calibration for several minutes, and the daily effective construction time is reduced to a certain extent, and the influence on long-distance road construction is particularly significant. Under the conditions of strong light (such as noon sunlight), dust (generated by milling operation) or complex terrain (cross slope, pothole), the accuracy of manual judgment is greatly increased. In the existing automatic tool alignment scheme, a single GPS navigation scheme is often used, which cannot identify the micro features of the milling edge, and it is difficult to meet the high-precision lap requirement. SUMMARY

[0003] The purpose of the application is to provide an automatic tool alignment system of a cold regenerator, which controls the tool pass lap deviation within a small range through multi-sensor cooperative sensing and intelligent steering control, improves the construction quality and efficiency, reduces the operation threshold, and has certain application value in the industry.

[0004] To achieve the above purpose, the application adopts the following technical scheme.

[0005] The application provides an automatic tool alignment system of a cold regenerator, comprising:

[0006] A multi-source sensing module is used to acquire cold regenerator state data, including position information of a milling assembly and attitude information of a vehicle body;

[0007] A fusion control module is in communication connection with the multi-source sensing module, used to receive and process the cold regenerator state data input by the multi-source sensing module, generate a target milling path according to the set milling related parameters, and adjust the generated deviation;

[0008] An auxiliary calibration module is in bidirectional communication connection with the fusion control module, used to mark the milling edge in the milling and correct the offset generated in the working process of the cold regenerator.

[0009] Optionally, the multi-source sensing module comprises:

[0010] A positioning unit is used to acquire the absolute position coordinates of the milling assembly and output coordinate data;

[0011] A laser profile sensor is used to identify the relative positions of historically milled edges and output road surface profile point data.

[0012] The vehicle body attitude tilt sensor is used to monitor the attitude of the cold regenerator and output the vehicle body pitch angle data.

[0013] Optionally, the fusion control module includes a main controller, a steering actuator, a steering feedback component, and a human-machine interface terminal;

[0014] The main controller is equipped with a multi-source data fusion algorithm and segmented PID control logic, and is connected to the multi-source sensing module through a communication bus.

[0015] The steering feedback component monitors and outputs the vehicle steering angle to the main controller in real time to adjust the steering angle of the steering actuator.

[0016] The human-machine interface terminal is bidirectionally connected to the main controller and is used for setting milling-related parameters and displaying their status.

[0017] Optionally, the auxiliary calibration module includes a fluorescent knife mark marker and a temperature compensation module;

[0018] The fluorescent tool mark marker is used to spray fluorescent marks along the historical milling edge and is controlled by the digital output port of the main controller.

[0019] The temperature compensation module is used to correct the measured values ​​of the laser profile sensor and is connected to the analog input port of the main controller.

[0020] Optionally, the main controller is configured as follows:

[0021] Baseline information is acquired by recording the baseline path and initial contour through a multi-source sensing module, and controlling the fluorescent marker to spray marking lines.

[0022] Generate a target path. Calculate the target path based on the set milling width and overlap amount. The parallel distance between the target path and the reference path is the difference between the milling width and the overlap amount.

[0023] Multi-source bias fusion, fusing the total bias of the multi-source sensing modules. The main controller is also equipped with a filtering algorithm to remove the total deviation. Vibration noise in;

[0024] Dynamic steering adjustment adjusts the total deviation by controlling the steering angle of the steering mechanism. This results in a total deviation Less than the set value.

[0025] Optionally, the total deviation The following conditions must be met:

[0026] when If the angle is less than or equal to the first threshold, maintain the current steering angle.

[0027] When the first threshold < When the value is less than or equal to the second threshold, the steering angle is related to... They are in a direct proportional relationship;

[0028] when When the second threshold is reached, the main controller triggers an audible and visual alarm and generates a control command to reduce the speed of the cold regenerator.

[0029] Optionally, the total deviation is expressed as:

[0030] ;

[0031] in, This represents the absolute deviation of the positioning unit. The relative deviation of the laser profile sensor. This is the attitude compensation amount from the vehicle body tilt angle sensor; , , They are respectively , , The weighting coefficients.

[0032] Optionally, the main controller monitors the status of the sensors in the multi-source sensing module in real time and adjusts the weighting coefficients of the multi-source data fusion algorithm according to the sensor status.

[0033] When the positioning variance of the positioning unit is greater than its set value, the value is reduced. Increase ;

[0034] When the edge recognition success rate of the laser contour sensor is less than its set value, increase the... , reduce ;

[0035] When the attitude angle drift rate of the vehicle body tilt sensor exceeds its set value, reduce the... Increase .

[0036] Optionally, the steering actuator includes an electro-hydraulic proportional valve and a steering cylinder;

[0037] The electro-hydraulic proportional valve receives commands from the PWM output port of the main controller to drive the steering cylinder, thereby achieving steering adjustment at a set angle.

[0038] Optionally, the human-machine interaction terminal also supports multi-language switching and displays real-time deviation curves, sensor status indicators, and fault codes;

[0039] The fault codes include sensor communication interruption and deviation exceeding the threshold.

[0040] Compared with the prior art, the beneficial effects achieved by the present invention are as follows:

[0041] 1. Significantly improved accuracy: The multi-source perception fusion and steering closed-loop control adopted in this invention keep the overlap deviation of the cutter within a very small range, which greatly reduces the deviation compared with manual operation, thus improving the smoothness and compaction qualification rate of the recycled road surface.

[0042] 2. The elimination of manual parking calibration saves operating time, resulting in an increase in the average daily construction mileage and improved equipment utilization in practical applications.

[0043] 3. The use of fluorescent markers ensures that the laser recognition rate remains at a high level in various environments, while the introduction of multi-source fusion algorithms greatly improves the reliability of construction.

[0044] 4. During the operation of the cold recycling machine, operators no longer need to rely on experience to make judgments, which reduces labor costs and management difficulty.

[0045] 5. The steering priority control strategy has a shorter deviation correction time, making it particularly suitable for continuous construction on long straight sections. Attached Figure Description

[0046] Figure 1 This is a schematic diagram of the architecture of the automatic tool setting system for a cold regeneration machine provided in an embodiment of the present invention;

[0047] Figure 2 This is a schematic diagram of the main controller control flow provided in an embodiment of the present invention. Detailed Implementation

[0048] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the embodiments of the present invention and the specific features in the embodiments are detailed descriptions of the technical solution of the present invention, rather than limitations thereof. In the absence of conflict, the embodiments of the present invention and the technical features in the embodiments can be combined with each other.

[0049] It should be noted that the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A alone, A and B simultaneously, or B alone. Additionally, the character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0050] Example 1

[0051] This embodiment describes an automatic tool setting system for a cold recycling machine, such as... Figure 1As shown, it includes three main modules: a multi-source sensing module, a fusion control module, and an auxiliary calibration module.

[0052] The multi-source sensing module is used to acquire the position information of the milling components and the attitude information of the vehicle body, and specifically includes the following parts:

[0053] Unit: In this embodiment, the Huace T300 high-precision positioning module is used. This module has high horizontal positioning accuracy. Update frequency 10Hz, output via CAN interface Formatted coordinate data.

[0054] Laser profile sensor: Keyence selected The two-dimensional laser scanner has a scanning width of 2m, a resolution of 0.5mm, and a sampling frequency set at 500Hz. It outputs road surface contour point cloud data through an Ethernet interface.

[0055] Vehicle attitude tilt sensor: adopts Dual-axis tilt sensor, measurement range: Precision The update frequency is 100Hz, and the vehicle pitch angle is output through the CAN interface.

[0056] The fusion control module, communicatively connected to the multi-source sensing module, receives and processes data input from the multi-source sensing module, generates a target milling path based on set milling-related parameters, and adjusts any resulting deviations. Specifically, this includes:

[0057] Main controller: Uses the original EPEC 5050 controller from the cold regenerator main unit, supporting 16 channels of 16-bit analog input, 16 channels of digital input, and 8 channels of PWM output, with a calculation cycle of [missing information]. It is equipped with a multi-source data fusion algorithm and segmented PID control logic, and is connected to the multi-source sensing module through a communication bus.

[0058] Steering actuator: includes an electro-hydraulic proportional valve and a double-acting steering cylinder. The proportional valve receives a PWM signal from the controller to control the extension and retraction of the cylinder, thereby achieving... Steering angle adjustment.

[0059] Steering feedback component: Employs a displacement sensor built into the steering cylinder, which outputs... Analog signal corresponding Steering angle, accuracy The steering angle is fed back to the EPEC 5050 controller in real time.

[0060] Human-Machine Interface Terminal: Reuses the host's 7-inch TFT touchscreen, communicates with the controller via the CANopen protocol, displays real-time deviation, sensor status (normal / abnormal), and control curves, and supports overlap (…). In addition to parameter settings, the human-machine interface terminal also supports multi-language switching and displays real-time deviation curves, sensor status indicators, and fault codes; among which, fault codes include sensor communication interruption, deviation exceeding threshold, etc.

[0061] The auxiliary calibration module, which communicates bidirectionally with the fusion control module, is used to mark milling edges during milling and correct offsets generated during the operation of the cold regenerator. Specifically, it includes:

[0062] Fluorescent knife mark marker: Composed of a miniature diaphragm pump, a fluorescent agent storage tank, and a fan-shaped nozzle, it is installed at the right and left outlets of the milling chamber and sprays... A biodegradable fluorescent agent with a wavelength that is visible at a distance ≥5m and a visibility time ≥8 hours under ultraviolet light excitation.

[0063] Temperature compensation module: Employs DS18B20 digital temperature sensor (measuring range) precision It is mounted on the housing of the laser profile sensor and communicates with the controller via a single bus to correct temperature drift (compensation factor of 0.02% per °C).

[0064] We are now offering a cold recycling machine with the following parameters: milling width 2300mm, average working speed 6m / min, and original controller EPEC 5050.

[0065] The device was modified to install a mounting point 0.5m directly above the milling rotor. The antenna is connected to the controller's expansion interface via an RS232 cable.

[0066] A laser profile sensor is installed by drilling a hole in the right side wall of the milling chamber, with the downward angle adjusted to 30°, and connected to the controller via an Ethernet switch.

[0067] A vehicle attitude tilt sensor is installed at the end of the steering shaft, and the signal cable is connected to the analog input channel of the controller.

[0068] The fusion algorithm and control logic were developed in the EPEC 5050 programming software (CODESYS V3.5), and the firmware was generated and updated to the controller via USB.

[0069] Construction conditions: A secondary highway cement-stabilized base course recycling project, with an air temperature of 25℃, humidity of 60%, and a road surface cross slope of 1.5°.

[0070] During construction, the main controller EPEC 5050 performs important operations, such as... Figure 2As shown, it includes the following steps:

[0071] Step S1, Baseline Information Acquisition:

[0072] During the first cut, the operator manually controls the equipment to move along the designed route. The EPEC 5050 controller records the RTK-GPS coordinates (X1(t), Y1(t)) every 0.5 seconds to generate the baseline path. (Storage capacity ≥ 10,000 points, meeting the construction requirements of 1km); The laser contour sensor synchronously collects the initial road surface contour as a reference benchmark; The controller triggers the fluorescent marker through the digital output port (24V) to spray continuous marking lines L along the milled edge.

[0073] Step S2, Target Path Generation:

[0074] The milling width W is preset to 2.3m via the touchscreen. Based on the milling width W and the overlap D (default 8cm, adjustable range 5cm-10cm), the controller calculates the target path for the second cut using a coordinate rotation and translation algorithm. ,satisfy and The parallel distance is WD (e.g., when W=2.3m and D=8cm, the parallel distance is 2.22m).

[0075] Step S3, Multi-source bias fusion:

[0076] During the second cut, the controller integrates three types of data in real time:

[0077] absolute deviation of positioning unit Current RTK-GPS coordinates (X2(t), Y2(t)) and target path Lateral distance (along the vertical direction of travel);

[0078] Relative deviation of laser profile sensor The laser sensor uses the Canny edge detection algorithm to identify the fluorescent marker line L and the milled step (height difference ≥ 3cm) and calculates the deviation relative to the reference edge.

[0079] Attitude compensation amount of vehicle body tilt angle sensor The pitch angle output by the vehicle attitude tilt sensor Roll angle Through formula (Unit: cm) Compensates for measurement errors caused by the tilt of the machine body;

[0080] Total deviation of multi-source sensing modules ,in, , , They are respectively , , The corresponding weighting coefficients are initially set as follows: =0.6、 =0.3、 =0.1, removed by Kalman filtering Vibration noise in the middle.

[0081] Step S4, Dynamic Steering Adjustment:

[0082] The total deviation is adjusted by controlling the steering angle of the steering mechanism so that the total deviation is less than the set value. The controller adopts a segmented control strategy that prioritizes steering.

[0083] when When the angle is ≤1cm, the output maintains the current steering angle (PWM duty cycle remains unchanged).

[0084] When 1cm < When ≤3cm, the target steering angle Kp is the steering proportional coefficient (Kp=1° / cm when speed ≤2m / min, Kp=0.5° / cm when speed >2m / min). The PWM output is adjusted by the PID algorithm (proportional coefficient 8, integral time 0.5s, derivative time 0.1s) so that the actual steering angle gradually approaches the target value.

[0085] when >3cm: Triggers the main unit's audible and visual alarm (buzzer + flashing red LED), while the cold regenerator reduces its speed to 1m / min, and Kp increases to... Accelerate the correction speed until the deviation is ≤3cm, then restore the normal control parameters.

[0086] Step S5, Fault Tolerance Mechanism:

[0087] If the RTK-GPS positioning variance > 0.01m² (signal loss), then Adjusted to 0.3. Increased to 0.6;

[0088] If the laser sensor's edge recognition success rate is <80% (no marker line detected for 30 consecutive frames), then Adjust to 0.1. Increased to 0.8;

[0089] If the vehicle attitude tilt sensor drift rate is >0.5° / s, then Adjusted to 0.05. Increased to 0.65;

[0090] All sensor malfunctions are displayed via a fault code (e.g., “E01-GPS Unlocked”) on the touchscreen and stored in the controller log (keeping the most recent 100 records).

[0091] The cold regeneration machine equipped with this system has been tested and found to have excellent working performance. The test data is shown in Table 1.

[0092] Table 1 Test Data

[0093]

[0094] In summary, the multi-source sensing fusion and steering closed-loop control employed in this invention minimize the overlap deviation during each cut, significantly reducing deviations compared to manual operation. This results in improved pavement smoothness and compaction pass rates. The elimination of manual parking and calibration saves operating time, increasing daily construction mileage and equipment utilization in practical applications. The use of fluorescent markers maintains a high laser recognition rate across various environments, while the introduction of multi-source fusion algorithms greatly enhances construction reliability. During cold recycling machine operation, operators no longer need to rely on experience, reducing labor costs and management complexity. The steering-priority control strategy results in shorter deviation correction times, making it particularly suitable for continuous construction on long straight sections.

[0095] The embodiments of the present invention have been described above with reference to the accompanying drawings. However, the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the present invention without departing from the spirit and scope of the claims. All of these forms are within the protection scope of the present invention.

Claims

1. An automatic tool setting system for a cold recycling machine, characterized in that, include: The multi-source sensing module is used to acquire cold recycling machine status data, including: the position information of the milling components and the attitude information of the vehicle body; The fusion control module is communicatively connected to the multi-source sensing module. It is used to receive and process the cold regenerator status data input by the multi-source sensing module, generate the target milling path according to the set milling-related parameters, and adjust the generated deviations. The auxiliary calibration module, which communicates bidirectionally with the fusion control module, is used to mark the milling edges during milling and correct the offsets generated during the operation of the cold regenerator.

2. The automatic tool setting system for a cold recycling machine according to claim 1, characterized in that, The multi-source sensing module includes: The positioning unit is used to obtain the absolute position coordinates of the milling component and output the coordinate data. A laser profile sensor is used to identify the relative positions of historically milled edges and output road surface profile point data. The vehicle body attitude tilt sensor is used to monitor the attitude of the cold regenerator and output the vehicle body pitch angle data.

3. The automatic tool setting system for a cold recycling machine according to claim 2, characterized in that, The fusion control module includes a main controller, a steering actuator, a steering feedback component, and a human-machine interface terminal; The main controller is equipped with a multi-source data fusion algorithm and segmented PID control logic, and is connected to the multi-source sensing module through a communication bus. The steering feedback component monitors and outputs the vehicle steering angle to the main controller in real time to adjust the steering angle of the steering actuator. The human-machine interface terminal is bidirectionally connected to the main controller and is used for setting milling-related parameters and displaying their status.

4. The automatic tool setting system for a cold recycling machine according to claim 3, characterized in that, The auxiliary calibration module includes a fluorescent knife mark marker and a temperature compensation module; The fluorescent tool mark marker is used to spray fluorescent marks along the historical milling edge and is controlled by the digital output port of the main controller. The temperature compensation module is used to correct the measured values ​​of the laser profile sensor and is connected to the analog input port of the main controller.

5. The automatic tool setting system for a cold recycling machine according to claim 4, characterized in that, The main controller is configured as follows: Baseline information is acquired by recording the baseline path and initial contour through a multi-source sensing module, and controlling the fluorescent marker to spray marking lines. Generate a target path. Calculate the target path based on the set milling width and overlap amount. The parallel distance between the target path and the reference path is the difference between the milling width and the overlap amount. Multi-source bias fusion, fusing the total bias of the multi-source sensing modules. The main controller is also equipped with a filtering algorithm to remove the total deviation. Vibration noise in; Dynamic steering adjustment adjusts the total deviation by controlling the steering angle of the steering mechanism. This results in a total deviation Less than the set value.

6. The automatic tool setting system for a cold recycling machine according to claim 5, characterized in that, The total deviation The following conditions must be met: when If the angle is less than or equal to the first threshold, maintain the current steering angle. When the first threshold < When the value is less than or equal to the second threshold, the steering angle is related to... They are in a direct proportional relationship; when When the second threshold is reached, the main controller triggers a host audible and visual alarm and generates a control command to reduce the speed of the cold regenerator.

7. The automatic tool setting system for a cold recycling machine according to claim 6, characterized in that, The total deviation is expressed as: ； in, This represents the absolute deviation of the positioning unit. The relative deviation of the laser profile sensor. This is the attitude compensation amount from the vehicle body tilt angle sensor; , , They are respectively , , The weighting coefficients.

8. The automatic tool setting system for a cold recycling machine according to claim 7, characterized in that, The main controller monitors the status of the sensors in the multi-source sensing module in real time and adjusts the weighting coefficients of the multi-source data fusion algorithm according to the sensor status. When the positioning variance of the positioning unit is greater than its set value, the value is reduced. Increase ; When the edge recognition success rate of the laser contour sensor is less than its set value, increase the... , reduce ; When the attitude angle drift rate of the vehicle body tilt sensor exceeds its set value, reduce the... Increase .

9. The automatic tool setting system for a cold recycling machine according to claim 3, characterized in that, The steering actuator includes an electro-hydraulic proportional valve and a steering cylinder; The electro-hydraulic proportional valve receives commands from the PWM output port of the main controller to drive the steering cylinder, thereby achieving steering adjustment at a set angle.

10. The automatic tool setting system for a cold recycling machine according to claim 3, characterized in that, The human-machine interaction terminal also supports multi-language switching and displays real-time deviation curves, sensor status indicators, and fault codes. The fault codes include sensor communication interruption and deviation exceeding the threshold.

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