Anti-hoisting method for automatic rail-mounted gantry crane integrated system

Abstract

The invention relates to the technical field of automatic rail-mounted gantry crane integrated systems, in particular to an automatic rail-mounted gantry crane integrated system anti-hoisting method which comprises the steps that a laser radar continuously scans three-dimensional point cloud data of a container truck, and a controller judges whether the container truck reaches a first preset position or not; whether the positions of the lifting appliance and the container reach a second preset position or not is judged through the three-dimensional point cloud data, if the positions reach the second preset position, a scanning line of the laser radar is aligned with a gap between a flat car of the container truck and the bottom face of the container, scanning distance measurement is conducted, and if the gap between the flat car and the bottom face of the container is smaller than a first preset threshold value, the lifting appliance is started; or the included angle between the plane where the flat car is located and the ground is larger than a second preset threshold value, it is judged that the lock at the bottom of the container is not separated from the flat car, a signal is sent to the controller, and the controller controls the lifting appliance to stop lifting. The problems that an existing automatic rail-mounted gantry crane integrated system is prone to misjudgment in the container hoisting process, and the operation efficiency is affected are solved.

Description

Technical Field

[0001] This invention relates to the field of automated rail-mounted gantry crane integrated systems, and more specifically to a method for preventing the automated rail-mounted gantry crane integrated system from being lifted. Background Technology

[0002] Existing automated rail-mounted gantry crane systems use laser detection to prevent container trucks from being lifted. Specifically, a 2D lidar sensor is installed approximately 1.7 meters above the ground on the side of the lane, at the center line of the crane. It scans the connection point between the container truck and the vehicle to determine if there are any obstacles. If a connection is detected, lifting is stopped, the container truck and container are separated, and then the lifting operation continues. Therefore, this method is susceptible to errors if even a small amount of foreign object is present at the connection point, affecting operational efficiency. Summary of the Invention

[0003] This invention provides a method for preventing lifting in an automated rail-mounted gantry crane integrated system, in order to solve the problem that existing automated rail-mounted gantry crane integrated systems are prone to misjudgment during the lifting of containers, which affects the efficiency of operation.

[0004] This invention provides a method for preventing lifting in an automated rail-mounted gantry crane integrated system, comprising the following steps:

[0005] The lidar on the container rail crane continuously scans the three-dimensional point cloud data of the container truck and sends it to the controller, which then determines whether the container truck has reached the first predetermined position. The system uses 3D point cloud data to determine whether the spreader and container have reached the second predetermined position. If they have, the LiDAR scan line is aligned with the gap between the flatbed of the container truck and the bottom of the container to perform scanning and distance measurement. If the gap between the flatbed and the bottom of the container is less than the first preset threshold, or the angle between the plane where the flatbed is located and the ground is greater than the second preset threshold, it is determined that the lock on the bottom of the container has not disengaged from the flatbed. A signal is sent to the controller, which controls the spreader to stop lifting until the lock on the bottom of the container disengages from the flatbed, and then lifting begins.

[0006] Beneficial effects: This invention uses lidar to continuously scan the three-dimensional point cloud data of container trucks, achieving accurate determination of the first predetermined position of the container trucks. This lays the foundation for subsequent lifting operations and avoids misalignment of the spreader caused by positioning deviations of the container trucks, reducing the causes of misjudgment from the initial stage of the operation. Moreover, after the spreader and container reach the second predetermined position, the lidar does not need to switch equipment or interrupt scanning. It can accurately measure the distance between the flatbed truck and the bottom surface of the container by simply adjusting the scanning line angle. This achieves seamless connection between alignment detection and lock disengagement detection, avoiding misjudgment caused by multiple equipment switching, data transmission delays, or perception blind spots in existing solutions. This invention simultaneously determines the gap between the flatbed truck and the bottom of the container and the size of a first preset threshold, as well as the angle between the plane where the flatbed truck is located and the ground and the size of a second preset threshold. This avoids misjudgments caused by a gap between the flatbed truck and the bottom of the container when at least one lock is not disengaged from the flatbed truck. It avoids the limitations of existing solutions with a single judgment standard and significantly reduces the probability of misjudgment. Moreover, the entire judgment process is uniformly received and analyzed by the controller from the point cloud data of the lidar, without the need for manual intervention. When the controller detects that the lock is not disengaged, it immediately controls the spreader to stop lifting until the lock is completely disengaged before restarting lifting. This avoids equipment damage and cargo loss caused by accidental lifting, as well as the decrease in work efficiency caused by shutdowns and repeated adjustments due to misjudgments.

[0007] In one optional implementation, the second preset threshold is 6°-10°.

[0008] The above-mentioned angle range is within the transition range of equipment operation. If the angle is too small, it will easily lead to response lag and insufficient adjustment. If the angle is too large, it will easily cause excessive action or structural impact. 6°-10° can balance response sensitivity and operation stability.

[0009] In one alternative implementation, the lidar is installed on an anchor post below the crossbeam of the container rail crane. The horizontal projection of the lidar is parallel to the center line of the lane and the horizontal distance between it and the edge of the lane is 0.8m-1.0m.

[0010] The positioning of the lidar ensures the overall stability of the system and reduces vibration, effectively guaranteeing the accuracy and lifespan of the radar detection. The detection field covers key areas of the lane without obstruction, enabling stable identification of lane boundaries, container truck positions, and driving deviations. The distance setting balances detection range with safe clearance, preventing scratches and collisions with container trucks. At the same time, the installation location facilitates wiring, maintenance, and calibration, simplifying the structural layout and improving the safety and positioning reliability of the rail-mounted gantry crane operation.

[0011] In one alternative implementation, the lidar is positioned horizontally at a height of 1.6m-2.0m above the ground.

[0012] The installation height of the lidar can avoid common interference such as ground debris, container truck tires, and personnel movement, ensuring a clear and stable detection field of view. It can also effectively cover the outline of container trucks, lanes, and operating areas to meet the needs of positioning and collision avoidance detection. At the same time, it avoids the detection blind spots caused by excessively high installation and the problem of being vulnerable to collision damage if installed too low, thus balancing detection effectiveness, equipment safety, and operational reliability.

[0013] In one alternative implementation, the lidar is positioned horizontally 1.8m above the ground.

[0014] The lidar is installed 40cm-60cm above the flatbed platform to facilitate scanning the outline of the container.

[0015] In one optional implementation, when the container truck arrives at the first predetermined position, the lidar scans the set position information on the flatbed truck, and compares the center point of the container position on the flatbed truck with the center point of the spreader stored in the system according to the set position information, and calculates the front-to-back deviation, left-to-right deviation and deflection angle of the flatbed truck relative to the spreader when it is located on the center line of the current lane; the controller controls the movement of the trolley and the tilting of the spreader according to the above calculation results, so that the position and angle of the spreader are synchronized with the container, and at the same time adjusts the position of the container truck until the deviation value meets the standard.

[0016] By using LiDAR for real-time scanning and positioning, and precise comparison between the center point of the container and the center point of the spreader, the system directly obtains the front-to-back deviation, left-to-right deviation, and deflection angle. The positioning is intuitive, accurate, and responsive. The controller provides real-time closed-loop control of the trolley's movement and the spreader's tilt, while simultaneously adjusting the position of the container truck. This achieves full-dimensional dynamic matching of the spreader and container's position and posture, effectively shortening the alignment adjustment time, improving operational efficiency, reducing manual intervention and repeated alignment, lowering the risk of collisions, and enhancing the accuracy and safety of automated rail-mounted gantry crane operations. It is adaptable to the alignment needs of container trucks in various scenarios, demonstrating strong reliability and adaptability.

[0017] In one optional implementation, the system calculates the offset of the center point of the flatbed truck and the center point of the spreader on the horizontal plane, as well as the deflection angle of the flatbed truck and the spreader, in three-dimensional space using the set position information on the flatbed truck. Then, it calculates the front-to-back deviation, left-to-right deviation, and deflection angle of the flatbed truck relative to the spreader when it is located on the center line of the current lane.

[0018] By setting position information, the horizontal offset and deflection angle between the center point of the container and the center point of the spreader are calculated in three-dimensional space. These are then converted into front-to-back, left-to-right, and deflection deviations under the lane centerline reference. The positioning reference is unified and the calculation logic is rigorous, which can eliminate positioning errors caused by lane deviation and vehicle posture, improve alignment accuracy, realize full-dimensional posture recognition and deviation correction, provide stable and reliable input data for automated control, adapt to complex working conditions, and effectively improve the alignment efficiency and safety of spreaders and containers.

[0019] In one alternative implementation, the designated position information on the flatbed is the raised three-dimensional feature of the lock head on the flatbed.

[0020] Using the raised three-dimensional features of the lock on the flatbed truck as the set position information, the feature has a fixed geometry, high recognition, and is not easily worn or deformed. The lidar can identify it stably and accurately, and it is not affected by light, paint or environmental interference. It has strong detection stability and reliability, and can provide a stable and reliable benchmark for calculating the center point of the container, effectively improving the positioning accuracy and the system's anti-interference ability, and is suitable for the complex operating environment of the port.

[0021] In one alternative implementation, the position is considered satisfactory when the deviation is less than 5 cm.

[0022] This deviation value ensures the reliability of the detection.

[0023] In one alternative implementation, when a container truck is loading a container, a lidar scans the outline of the container on the flatbed truck to obtain the container's position and deflection angle.

[0024] It directly scans the container outline to obtain position and deflection angle, making the detection object intuitive and clear. No additional positioning marks are required, eliminating calibration and maintenance steps. It has strong real-time performance and rapid response, and can directly reflect the actual posture of the container, providing a true and reliable positional basis for spreader alignment. It is compatible with various container types, simplifies the system structure, and improves the adaptability and stability of automated operations. Attached Figure Description

[0025] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0026] Figure 1 This is a flowchart illustrating the anti-lifting method of the automated rail-mounted gantry integrated system according to an embodiment of the present invention. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] The following is combined with Figure 1 Embodiments of the present invention are described.

[0029] According to an embodiment of the present invention, a method for preventing lifting of an automated rail-mounted gantry crane integrated system is provided, comprising the following steps: The lidar on the container rail crane continuously scans the three-dimensional point cloud data of the container truck and sends it to the controller, which then determines whether the container truck has reached the first predetermined position. The system uses 3D point cloud data to determine whether the spreader and container have reached the second predetermined position. If they have, the LiDAR scan line is aligned with the gap between the flatbed of the container truck and the bottom of the container to perform scanning and distance measurement. If the gap between the flatbed and the bottom of the container is less than the first preset threshold, or the angle between the plane where the flatbed is located and the ground is greater than the second preset threshold, it is determined that the lock on the bottom of the container has not disengaged from the flatbed. A signal is sent to the controller, which controls the spreader to stop lifting until the lock on the bottom of the container disengages from the flatbed, and then lifting begins.

[0030] The lidar mounted on the container rail gantry continuously collects and scans 3D point cloud data of the container truck's operating area, stably transmitting the real-time acquired 3D point cloud information related to the overall position, outline, and attitude of the container truck to the controller. The controller analyzes, processes, and compares the 3D point cloud data to determine whether the container truck has moved and stopped at the first predetermined position, ensuring that the starting position meets the basic conditions for subsequent alignment and lifting operations. After confirming that the container truck has reached the first predetermined position, the controller continues to calculate the relative position and attitude relationship between the spreader and the container in real time based on the 3D point cloud data transmitted by the lidar, determining whether the spreader and container have accurately reached the second predetermined position. When it is determined that they have reached the second predetermined position, the controller adjusts the scanning angle and scanning path of the lidar, ensuring that the lidar's scanning line is precisely aligned with the mating gap area between the upper surface of the container truck flatbed and the bottom surface of the container. It performs directional scanning and distance detection on this gap, simultaneously acquiring the attitude data of the plane where the flatbed is located and calculating its tilt angle with the ground. The controller compares the detected gap value with the system's preset first preset threshold and compares the calculated tilt angle with the system's preset second preset threshold. The system compares the values. If the gap between the flatbed truck and the bottom of the container is less than the first preset threshold, or the angle between the plane of the flatbed truck and the ground is greater than the second preset threshold, the system determines that the lock on the bottom of the container and the lock seat on the flatbed truck are not completely disengaged and are still engaged or stuck. At this time, the controller immediately outputs a control signal to the rail-mounted crane actuator to stop the lifting action and prohibits forced lifting. Only after the lidar continuously detects and determines that the lock on the bottom of the container is completely disengaged from the flatbed truck and that the gap and angle meet the safety conditions set by the system will the controller control the spreader to perform normal lifting action. This effectively avoids damage to the container and flatbed truck and operational safety accidents caused by the lock not being disengaged, and ensures the safety and reliability of the automated lifting operation of the rail-mounted crane.

[0031] The absence of a gap between the flatbed and the bottom of the container indicates that a lock on the side where the lidar is installed has not disengaged. However, the presence of a gap does not mean that all locks have disengaged. If a lock on the other side where the lidar is installed is not disengaged, or if at least one lock on the lidar side is not disengaged, a gap between the container and the flatbed may appear in the point cloud information. Therefore, it is necessary to determine the angle between the plane on which the flatbed is located and the ground from the gap.

[0032] Beneficial effects: This invention uses lidar to continuously scan the three-dimensional point cloud data of container trucks, achieving accurate determination of the first predetermined position of the container trucks. This lays the foundation for subsequent lifting operations and avoids misalignment of the spreader caused by positioning deviations of the container trucks, reducing the causes of misjudgment from the initial stage of the operation. Moreover, after the spreader and container reach the second predetermined position, the lidar does not need to switch equipment or interrupt scanning. It can accurately measure the distance between the flatbed truck and the bottom surface of the container by simply adjusting the scanning line angle. This achieves seamless connection between alignment detection and lock disengagement detection, avoiding misjudgment caused by multiple equipment switching, data transmission delays, or perception blind spots in existing solutions. This invention simultaneously determines the gap between the flatbed truck and the bottom of the container and the size of a first preset threshold, as well as the angle between the plane where the flatbed truck is located and the ground and the size of a second preset threshold. This avoids misjudgments caused by a gap between the flatbed truck and the bottom of the container when at least one lock is not disengaged from the flatbed truck. It avoids the limitations of existing solutions with a single judgment standard and significantly reduces the probability of misjudgment. Moreover, the entire judgment process is uniformly received and analyzed by the controller from the point cloud data of the lidar, without the need for manual intervention. When the controller detects that the lock is not disengaged, it immediately controls the spreader to stop lifting until the lock is completely disengaged before restarting lifting. This avoids equipment damage and cargo loss caused by accidental lifting, as well as the decrease in work efficiency caused by shutdowns and repeated adjustments due to misjudgments.

[0033] In one embodiment, the second preset threshold is 6°-10°.

[0034] The first preset threshold can be 3-5mm, and can be set according to actual needs.

[0035] The above-mentioned angle range is within the transition range of equipment operation. If the angle is too small, it will easily lead to response lag and insufficient adjustment. If the angle is too large, it will easily cause excessive action or structural impact. 6°-10° can balance response sensitivity and operation stability.

[0036] In one embodiment, the lidar is installed on an anchor post below the crossbeam of the container rail crane. The horizontal projection of the lidar is parallel to the center line of the lane and the horizontal distance between it and the edge of the lane is 0.8m-1.0m.

[0037] The lidar is installed on an anchor post below the lower crossbeam of the container rail-mounted gantry crane. This installation location offers high structural rigidity and minimizes operational vibration, ensuring the lidar maintains a stable posture during gantry crane operation, reducing scanning jitter, improving detection accuracy, and preventing interference with spreaders, containers, or other moving parts, thus not affecting the normal operation of the rail-mounted gantry crane. The horizontal projection direction of the lidar is parallel to the centerline of the lane, ensuring its scanning reference is consistent with the lane reference. This facilitates subsequent calculation and comparison of the position and posture of container trucks under a unified reference, improving the accuracy of positioning and deviation calculations. The lidar maintains a horizontal distance of 0.8m-1.0m from the edge of the lane. This distance ensures that the lidar has a suitable scanning field of view and detection distance for the lane and container trucks, achieving stable and clear scanning of the target area, while preventing the lidar from being too close to the lane and being scratched by container trucks. This balances detection effectiveness and equipment safety, meeting the requirements of automated rail-mounted gantry crane operation for detection stability, reliability, and safety.

[0038] The positioning of the lidar ensures the overall stability of the system and reduces vibration, effectively guaranteeing the accuracy and lifespan of the radar detection. The detection field covers key areas of the lane without obstruction, enabling stable identification of lane boundaries, container truck positions, and driving deviations. The distance setting balances detection range with safe clearance, preventing scratches and collisions with container trucks. At the same time, the installation location facilitates wiring, maintenance, and calibration, simplifying the structural layout and improving the safety and positioning reliability of the rail-mounted gantry crane operation.

[0039] In one embodiment, the horizontal position of the lidar is located 1.6m-2.0m above the ground.

[0040] The standard height of the flatbed platform of a container truck is 1.2m–1.4m. Therefore, the horizontal position of the lidar is set 40cm–60cm above the platform, that is, 1.6m–2.0m above the ground.

[0041] The installation height of the lidar can avoid common interference such as ground debris, container truck tires, and personnel movement, ensuring a clear and stable detection field of view. It can also effectively cover the outline of container trucks, lanes, and operating areas to meet the needs of positioning and collision avoidance detection. At the same time, it avoids the detection blind spots caused by excessively high installation and the problem of being vulnerable to collision damage if installed too low, thus balancing detection effectiveness, equipment safety, and operational reliability.

[0042] In one embodiment, the horizontal position of the lidar is located 1.8m above the ground.

[0043] The horizontal position of the lidar can also be any value between 1.6m and 2.0m above the ground, without any specific restrictions.

[0044] The lidar is installed 40cm-60cm above the flatbed platform to facilitate scanning the outline of the container.

[0045] In one embodiment, when the container truck arrives at the first predetermined position, the lidar scans the set position information on the flatbed truck, and compares the center point of the flatbed truck with the center point of the spreader stored in the system according to the set position information, and calculates the front-to-back deviation, left-to-right deviation and deflection angle of the flatbed truck relative to the spreader when it is located on the center line of the current lane; the controller controls the movement of the trolley and the tilting of the spreader according to the above calculation results, so that the position and angle of the spreader are synchronized with the container, and at the same time adjusts the position of the container truck until the deviation value meets the standard.

[0046] Once the container truck has traveled and accurately reached the first predetermined position within the work area, the lidar installed on the rail-mounted gantry crane performs real-time, continuous 3D scanning and acquisition of the preset position information on the container truck flatbed. This acquires the spatial coordinates and attitude data of that preset position. Using this position information as a reference, the system determines the actual spatial position of the flatbed truck's container center point. The system then compares this actual center point with the theoretical center point of the spreader, which is pre-stored and calibrated within the system. Through spatial geometric calculations, the coordinates are uniformly converted to a coordinate system based on the current lane centerline. This accurately calculates the forward and backward, left and right deviations of the flatbed truck relative to the spreader under the lane centerline reference, as well as the overall deviation. Upon receiving the aforementioned front-to-back deviation, left-to-right deviation, and deflection angle data, the controller outputs control commands in real time according to a preset control algorithm. This drives the rail-mounted trolley to move forward, backward, left, and right, while simultaneously controlling the spreader to tilt to correct the angle deviation. This ensures that the spreader's real-time position, deflection angle, and the actual position and attitude of the container are dynamically synchronized. While adjusting the spreader's attitude, control signals are simultaneously output to fine-tune the parking position of the container truck. This process of detection, calculation, and adjustment is continuously repeated until all calculated deviation values ​​are reduced to within the system's preset allowable range, meeting the operational requirements for precise alignment between the spreader and the container. This lays the foundation for subsequent safe and reliable lifting operations.

[0047] By using LiDAR for real-time scanning and positioning, and precise comparison between the center point of the container and the center point of the spreader, the system directly obtains the front-to-back deviation, left-to-right deviation, and deflection angle. The positioning is intuitive, accurate, and responsive. The controller provides real-time closed-loop control of the trolley's movement and the spreader's tilt, while simultaneously adjusting the position of the container truck. This achieves full-dimensional dynamic matching of the spreader and container's position and posture, effectively shortening the alignment adjustment time, improving operational efficiency, reducing manual intervention and repeated alignment, lowering the risk of collisions, and enhancing the accuracy and safety of automated rail-mounted gantry crane operations. It is adaptable to the alignment needs of container trucks in various scenarios, demonstrating strong reliability and adaptability.

[0048] In one embodiment, the system calculates the offset of the center point of the flatbed truck and the center point of the spreader on the horizontal plane, as well as the deflection angle of the flatbed truck and the spreader, in three-dimensional space using the set position information on the flatbed truck. Then, it calculates the front-to-back deviation, left-to-right deviation, and deflection angle of the flatbed truck relative to the spreader when it is located on the center line of the current lane.

[0049] The system first acquires the preset position information on the flatbed truck. Using this preset position information as the core positioning reference, it performs precise positioning and data analysis on the preset position in a three-dimensional coordinate system. Through spatial geometric calculations, it accurately calculates the actual three-dimensional coordinates of the center point of the flatbed truck's box. Simultaneously, it retrieves the theoretical three-dimensional coordinates of the spreader's center point, which are pre-calibrated and stored within the system. Projecting both three-dimensional coordinates onto the same horizontal plane, it calculates the actual offset between the center point of the flatbed truck's box and the center point of the spreader on the horizontal plane. This offset directly reflects the relative positional difference between the two in the horizontal direction. Furthermore, based on the attitude data from the preset position information, the system calculates the actual deflection angle of the flatbed truck relative to the horizontal plane and the deflection angle of the spreader relative to the preset reference. The system determines the deviation in posture between the two components by turning the corner. Based on this, the system uses the current lane centerline as a unified reference and performs coordinate conversion and deviation integration on the horizontal offset, the deflection angle of the flatbed truck and the spreader obtained above. This further accurately calculates the front-to-back deviation, left-to-right deviation, and overall deflection angle of the flatbed truck relative to the spreader under the lane centerline reference. The entire calculation process is logically rigorous and uses a unified reference, which can effectively eliminate calculation errors caused by inconsistent positioning references. This ensures the accuracy and reliability of various deviation data and provides accurate and effective data support for the subsequent controller to drive the trolley movement, spreader tilting, and container truck position adjustment. It ensures the accuracy of the spreader and container alignment and meets the actual needs of automated operation of rail-mounted gantry cranes.

[0050] By setting position information, the horizontal offset and deflection angle between the center point of the container and the center point of the spreader are calculated in three-dimensional space. These are then converted into front-to-back, left-to-right, and deflection deviations under the lane centerline reference. The positioning reference is unified and the calculation logic is rigorous, which can eliminate positioning errors caused by lane deviation and vehicle posture, improve alignment accuracy, realize full-dimensional posture recognition and deviation correction, provide stable and reliable input data for automated control, adapt to complex working conditions, and effectively improve the alignment efficiency and safety of spreaders and containers.

[0051] In one embodiment, the designated position information on the flatbed truck is the raised three-dimensional feature of the lock head on the flatbed truck.

[0052] Using the raised three-dimensional features of the lock on the flatbed truck as the set position information, the feature has a fixed geometry, high recognition, and is not easily worn or deformed. The lidar can identify it stably and accurately, and it is not affected by light, paint or environmental interference. It has strong detection stability and reliability, and can provide a stable and reliable benchmark for calculating the center point of the container, effectively improving the positioning accuracy and the system's anti-interference ability, and is suitable for the complex operating environment of the port.

[0053] In one alternative implementation, the position is considered satisfactory when the deviation is less than 5 cm.

[0054] The deviation value can be flexibly set according to requirements, and this deviation value ensures the reliability of the detection.

[0055] In one embodiment, when a container truck is loading a container, a lidar scanner scans the outline of the container on the flatbed truck to obtain the container's position and deflection angle.

[0056] When a container truck is loaded with containers and within the operating range of a rail-mounted gantry crane, the lidar installed on the gantry crane activates continuous scanning mode to perform a comprehensive 3D scan of the containers on the flatbed truck. This captures the overall outline features of the containers, including key outline points such as the corners, sides, top, and bottom edges. The acquired 3D point cloud data of the container outline is then processed through filtering, noise reduction, and fitting to eliminate invalid data caused by environmental interference, accurately extracting the actual outline information of the containers. Based on this outline information, spatial coordinates are calculated to determine the actual position coordinates of the containers in 3D space, clarifying the spatial relationship between the containers and the rail-mounted gantry crane spreader and the centerline of the lane. Simultaneously, through... By analyzing the geometric posture of the container outline and combining the coordinate differences of various points on the outline obtained by scanning, the deflection angle of the container relative to the preset benchmark is accurately calculated. This deflection angle can accurately reflect the tilt and deflection state of the container on the flatbed truck. The entire scanning and calculation process does not require additional positioning markers, is simple to operate and has strong real-time performance. It can directly obtain the real position and posture information of the container, providing accurate and reliable data support for subsequent spreader alignment and lifting operations. This ensures that the spreader can achieve precise posture matching with the container, guaranteeing the safety and efficiency of automated lifting operations of the rail-mounted gantry crane. It is adaptable to various working conditions after container loading and effectively avoids operational hazards such as alignment deviations and collisions caused by inaccurate detection of container position and deflection angle.

[0057] It directly scans the container outline to obtain position and deflection angle, making the detection object intuitive and clear. No additional positioning marks are required, eliminating calibration and maintenance steps. It has strong real-time performance and rapid response, and can directly reflect the actual posture of the container, providing a true and reliable positional basis for spreader alignment. It is compatible with various container types, simplifies the system structure, and improves the adaptability and stability of automated operations.

[0058] Specific examples are as follows: For situations where the spreader is 40 feet / double 20 feet / single 20 feet, if the current work task command is not received from the controller and the rail-mounted gantry crane is used for manual operation, the system can comprehensively determine the alignment status of the container truck based on the currently scanned spreader size and the status of the container on the container truck: When the spreader is 40 feet / double 20 feet, if the container on the container truck is 40 feet / double 20 feet, then the midpoint of the container is used for alignment; if the container is a single 20 feet, then the single 20 feet is used for positioning, i.e., if the rail crane operator does not change the size in time. When the spreader is a single 20-foot container, if the container on the container truck is a double 20-foot container, the midpoint of the container closest to the midpoint of the spreader should be used for alignment; if the container on the container truck is a single 20-foot container, it should be positioned as a single 20-foot container; if the container on the container truck is a single 40-foot container, it should be treated as a double 20-foot container, i.e., if the rail crane operator does not change the size in time or the two containers are too close together.

[0059] If the current task instruction can be received from the controller, i.e., automatic operation of the rail-mounted gantry crane, the system can align the container truck according to the current task. If the task does not match the arriving container truck, for example, the task is for two 20-foot containers, but the container truck only has one 20-foot container, it will report an error to the controller.

[0060] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A method for preventing lifting of an automated rail-mounted gantry (RMG) system integration system, characterized in that, Includes the following steps: The lidar on the container rail gantry continuously scans the three-dimensional point cloud data of the container truck and sends it to the controller, which then determines whether the container truck has reached the first predetermined position. The system uses 3D point cloud data to determine whether the spreader and container have reached the second predetermined position. If they have, the LiDAR scan line is aligned with the gap between the flatbed of the container truck and the bottom of the container to perform scanning and distance measurement. If the gap between the flatbed and the bottom of the container is less than the first preset threshold, or the angle between the plane where the flatbed is located and the ground is greater than the second preset threshold, it is determined that the lock on the bottom of the container has not disengaged from the flatbed. A signal is sent to the controller, which controls the spreader to stop lifting until the lock on the bottom of the container disengages from the flatbed, and then lifting begins.

2. The automated railcar-hoist integrated system anti-lifting method of claim 1, wherein, The second preset threshold is 6°-10°.

3. The automated railcar-hoist integration system anti-lifting method of claim 1, wherein, The lidar is installed on the anchor post below the crossbeam of the container rail crane. The horizontal projection of the lidar is parallel to the center line of the lane and the horizontal distance between it and the edge of the lane is 0.8m-1.0m.

4. The automated railcar-hoist integration system anti-lifting method of claim 3, wherein, The horizontal position of the lidar is located 1.6m-2.0m above the ground.

5. The automated railcar-hoist integration system anti-lifting method of claim 4, wherein, The lidar is positioned horizontally 1.8m above the ground.

6. The automated railcar-hoist integration system anti-lifting method of any one of claims 1 to 5, wherein, Once the container truck reaches the first predetermined position, the lidar scans the set position information on the flatbed truck and compares the center point of the container position on the flatbed truck with the center point of the spreader stored in the system. It calculates the front-to-back deviation, left-to-right deviation, and deflection angle of the flatbed truck relative to the spreader when it is located on the center line of the current lane. The controller controls the movement of the trolley and the tilting of the spreader based on the above calculation results, so that the position and angle of the spreader are synchronized with the container, and at the same time adjusts the position of the container truck until the deviation value meets the standard.

7. The method for preventing lifting of the automated rail-mounted gantry crane integrated system according to claim 6, characterized in that, The system calculates the offset of the center point of the flatbed truck and the center point of the spreader on the horizontal plane, as well as the deflection angle of the flatbed truck and the spreader, in three-dimensional space using the set position information on the flatbed truck. Then, it calculates the front-to-back deviation, left-to-right deviation, and deflection angle of the flatbed truck relative to the spreader when it is located on the center line of the current lane.

8. The method for preventing lifting of the automated rail-mounted gantry crane integrated system according to claim 7, characterized in that, The set position information on the flatbed truck is the raised three-dimensional feature of the lock on the flatbed truck.

9. The automated railcar-hoist integration system anti-lifting method of claim 6, wherein, When the deviation is less than 5cm, the position meets the standard.

10. The automated railcar-hoist integration system anti-lifting method of claim 6, wherein, When a container truck is loading a container, a lidar scanner scans the outline of the container on the flatbed truck to obtain the container's position and deflection angle.

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