Full-automatic train loading arm filling system and method

Abstract

The invention discloses a full-automatic train crane pipe filling system and method, and relates to the technical field of crane pipe filling, the full-automatic train crane pipe filling system comprises a canopy, a filling parking identification area is arranged below the canopy; the radar and the monitoring camera are arranged below the canopy in parallel; the crane pipe mechanical arm comprises a fixed supporting column, an inner arm pipe set, an adapter pipe, an outer arm pipe set, a vertical pipe, an inner arm driving mechanism, an outer arm driving mechanism and a vertical pipe driving mechanism. A first network switch, a network hard disk video recorder, an industrial personal computer and a display screen are arranged in the central control room; a second network switch electrically connected with the first network switch, the radar and the monitoring camera and a controller electrically connected with the second network switch are arranged in the control cabinet; and the controller is electrically connected with the inner arm driving mechanism, the outer arm driving mechanism and the vertical pipe driving mechanism. The loading arm is simple in structure and good in stability, automatic positioning, alignment and returning of the loading arm can be achieved through remote operation, potential safety hazards are reduced, and the filling efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of loading arm filling technology, and in particular to a fully automatic train loading arm filling system and method. Background Technology

[0002] In the loading and unloading of liquid hazardous chemicals, the arm alignment methods can be divided into two categories: the traditional manual alignment method and the semi-automatic alignment method.

[0003] Traditional alignment methods rely on operators manually pulling the loading arm to insert it into the tanker truck's opening, posing significant safety hazards and inefficiencies. Operators must stand on top of the tanker truck, increasing their contact with the tanked medium and raising safety risks. Furthermore, the highly repetitive nature of the operation and prolonged work can lead to worker fatigue, increasing the likelihood of errors and potentially causing accidents. With rising labor costs, this traditional model is inefficient and can no longer meet the modern enterprise's demands for safety, automation, and high efficiency, necessitating more advanced alternative technologies.

[0004] To address the shortcomings of traditional methods, the semi-automatic operation mode, by introducing some automated equipment, alleviates safety hazards and worker fatigue to some extent. However, the filling vertical pipe of the loading arm is structurally complex, has a heavy load, and poor structural stability. Furthermore, this mode does not completely solve the problem: operators still need to rely on visual positioning and manual operation, constantly observing the relative position of the loading arm and the tank opening, resulting in complex operation, low efficiency, and low alignment accuracy. In addition, the semi-automatic mode cannot completely eliminate the risk of collision between the loading arm and the tank truck.

[0005] Therefore, how to provide a fully automatic train loading arm filling system and method with simple structure and good stability, which can realize automatic positioning, alignment and return of the loading arm through remote operation, reduce safety hazards, simplify operation process, effectively monitor the entire filling process, and improve filling efficiency is an urgent problem to be solved by those skilled in the art. Summary of the Invention

[0006] In view of this, the present invention proposes a fully automatic train loading arm filling system and method, aiming to solve at least one of the above-mentioned technical problems.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] This invention provides a fully automatic train loading arm filling system, comprising: A canopy is provided, and a designated parking area for filling containers is provided on the road surface below the canopy. A radar and a monitoring camera are installed horizontally side by side below the canopy and above the filling parking sign area; The loading arm includes a fixed support, an inner arm tube assembly, a transfer tube, an outer arm tube assembly, a vertical tube, an inner arm drive mechanism, an outer arm drive mechanism, and a vertical tube drive mechanism. The fixed support is located to the side of the filling stop marking area. One end of the inner arm tube assembly is rotatably connected to and communicates with the upper part of the fixed support. The inner arm drive mechanism is driven by the inner arm tube assembly to drive its horizontal swing. One end of the transfer tube is rotatably connected to and communicates with the other end of the inner arm tube assembly, and the other end of the transfer tube is rotatably connected to and communicates with one end of the outer arm tube assembly. The outer arm drive mechanism is driven by the transfer tube to drive its horizontal swing, thereby causing the outer arm tube assembly to swing horizontally. The upper end of the vertical tube is rotatably connected to and communicates with the other end of the outer arm tube assembly, and its lower end hangs freely. The vertical tube drive mechanism is driven by the outer arm tube assembly to drive its pitch swing, thereby causing the vertical tube to rise and fall. The central control room and control cabinet are provided. The central control room is equipped with a first network switch, a network hard disk recorder and an industrial control computer electrically connected to the first network switch, and a display screen electrically connected to the industrial control computer. The control cabinet is equipped with a second network switch electrically connected to the first network switch, the radar and the monitoring camera, and a controller electrically connected to the second network switch. The controller is electrically connected to the inner arm drive mechanism, the outer arm drive mechanism and the vertical pipe drive mechanism.

[0009] This invention provides a canopy for a fully automated train loading arm filling system. The canopy protects the radar and monitoring camera from rain, ensuring operational stability and measurement accuracy. During operation, the tank car is precisely parked in the designated filling parking area, ensuring accurate radar scanning of the tank car opening. The canopy also protects the tank car's top opening from rain and snow. The radar and monitoring camera generate information about the area around the tank car opening and provide on-site video data, which is transmitted to an industrial control computer and a network video recorder via a first and second network switch. The industrial control computer processes point cloud information to generate tank opening coordinates and displays the overall system status on a screen, sending control commands and tank opening coordinates to the controller. The controller responds to these commands, driving the inner arm tube assembly to swing horizontally via the inner arm drive mechanism, the adapter tube and outer arm tube assembly to swing horizontally via the outer arm drive mechanism, and the outer arm tube assembly to swing pitch via the vertical tube drive mechanism. This allows for precise positioning of the vertical tube directly above the tank car opening and control of its raising and lowering to insert its lower end into the tank car opening for filling.

[0010] As a further improvement to the above technical solution, it also includes a local operation box, which is electrically connected to the inner arm drive mechanism, the outer arm drive mechanism and the vertical tube drive mechanism.

[0011] The beneficial effects of the above technical solution are: operators can directly control the movement of the loading arm through the local control box, such as the horizontal swing of the inner arm assembly, the transfer pipe and the outer arm assembly, the pitch swing of the outer arm assembly, and the movement and lifting of the vertical pipe, thereby completing the current tank truck filling operation.

[0012] As a further improvement to the above technical solution, the inner arm tube assembly includes a fixed feed tube, a rotating bracket, and an inner arm tube; the inner arm drive mechanism includes an inner arm servo driver and an inner arm servo motor; the fixed feed tube is fixed to the upper part of the fixed support column, and its upper end is the feed port; the inner arm tube is horizontally arranged, and one end of its tube is rotatably connected to and communicates with the lower end of the fixed feed tube; the lower end of the rotating bracket is rotatably connected to the fixed support column, and the upper end of the rotating bracket is fixedly connected to both ends of the inner arm tube along its length for support; the inner arm servo driver is located in the control cabinet and is electrically connected to the controller and the inner arm servo motor; the fixed end of the inner arm servo motor is fixed to the fixed feed tube, and its rotation drive end is driven to one end of the inner arm tube to drive it to swing horizontally.

[0013] The beneficial effects of the above technical solution are: the rotating bracket can rotate to support the inner arm tube and swing synchronously with the inner arm tube, thus improving stability. The fixed feed pipe inlet is used to connect to the external medium conveying pipeline, thereby introducing the conveying medium into the inner arm tube. The controller precisely controls the rotation angle of the inner arm servo motor's rotation drive end through the inner arm servo driver, thereby achieving precise control of the horizontal swing angle of the inner arm tube.

[0014] As a further improvement to the above technical solution, the outer arm drive mechanism includes an outer arm servo driver and an outer arm servo motor; the outer arm servo driver is located in the control cabinet and is electrically connected to the controller and the outer arm servo motor; the fixed end of the outer arm servo motor is fixed to the other end of the inner arm tube and its rotation drive end is connected to one end of the adapter tube to drive its horizontal swing, thereby driving the outer arm tube assembly to swing horizontally.

[0015] The beneficial effects of the above technical solution are: the controller can precisely control the rotation angle of the outer arm servo motor rotation drive end through the outer arm servo driver, thereby precisely controlling the horizontal synchronous swing angle of the adapter pipe and the outer arm pipe assembly.

[0016] As a further improvement to the above technical solution, the outer arm tube assembly includes an outer arm tube and a spring cylinder balancing mechanism; the vertical tube drive mechanism includes a vertical tube servo driver and a vertical tube servo motor; one end of the outer arm tube is rotatably connected to and communicates with the other end of the adapter tube; the upper end of the vertical tube is rotatably connected to and communicates with the other end of the outer arm tube; one end of the spring cylinder balancing mechanism is hinged to the other end of the adapter tube, and the other end is hinged to the middle of the outer arm tube; the vertical tube servo driver is located in the control cabinet and is electrically connected to the controller and the vertical tube servo motor; the fixed end of the vertical tube servo motor is fixed to the other end of the adapter tube, and its rotation drive end is connected to one end of the outer arm tube, thereby driving the outer arm tube to pitch and swing.

[0017] The beneficial effects of the above technical solution are as follows: the horizontal swing angle of the outer boom tube is precisely controlled by the outer boom servo driver; the controller precisely controls the rotation angle of the rotary drive end of the vertical tube servo motor through the vertical tube servo driver, thereby enabling precise pitch swing angle of the outer boom tube and thus achieving precise control of vertical tube lifting and lowering. The spring cylinder balancing mechanism plays a role in balancing and stabilizing the outer boom tube, further ensuring the stability of the vertical tube servo motor's control over vertical tube lifting and lowering.

[0018] Another aspect of the present invention provides a fully automatic method for filling train loading arms, which, using the aforementioned fully automatic train loading arm filling system, includes the following steps: S1: After confirming that the tanker truck is parked in the filling parking area through the monitoring camera, the operator opens the tanker truck opening and starts the filling system; S2: Scan the top of the tanker truck with radar to generate point cloud information, and transmit the point cloud information to the industrial control computer through the first network switch and the second network switch; S3: The industrial control computer processes the point cloud information, identifies and locates the tank truck opening, generates the three-dimensional spatial coordinates of the tank opening center, and transmits the three-dimensional spatial coordinate information to the controller through the first network switch and the second network switch. S4: The controller calculates the swing angle of the inner arm tube group, the transfer tube and the outer arm tube group based on the three-dimensional spatial coordinate information, and transmits the swing angle information to the corresponding inner arm drive mechanism, outer arm drive mechanism and vertical tube drive mechanism through the second network switch. S5: The inner arm drive mechanism, outer arm drive mechanism and vertical pipe drive mechanism drive the inner arm pipe assembly, transfer pipe and outer arm pipe assembly to move according to the allocated swing angle information, thereby inserting the vertical pipe into the tank truck mouth for filling. S6 After filling is completed, the inner arm drive mechanism, outer arm drive mechanism and vertical tube drive mechanism drive the inner arm tube assembly, transfer tube and outer arm tube assembly to reverse the movement, so that the vertical tube automatically returns to the initial position.

[0019] As a further improvement to the above technical solution, in step S1, the filling parking marking area is a parking area marked by ground markings. The ground markings include any one of color coating, reflective strips, and laser projection lines, which are used to guide the tank truck to park accurately in the predetermined position. The monitoring camera collects images of the ground markings and the outline of the tank truck, and the industrial control computer detects the relative position of the ground markings and the outline of the tank truck through image processing algorithms to confirm whether the tank truck is completely located within the filling area.

[0020] As a further improvement to the above technical solution, in step S3, the steps for the industrial control computer to process the point cloud information include: S31: Preprocess the point cloud data within the ROI region, including denoising and enhancement, and convert the 3D point cloud data into a grayscale image; S32: Use a detection algorithm to identify the rim area of ​​a tank in a grayscale image; S33: Extract the point cloud data of the corresponding tank opening area; S34: Filter and register the point cloud data; S35: Fit the tank opening plane and boundary based on point cloud data, and calculate the three-dimensional spatial coordinates of the tank opening center.

[0021] As a further improvement to the above technical solution, the fully automatic train loading arm filling system also includes a manual and automatic switching system; if an abnormality occurs before the automatic filling system is turned on or during operation, the operator can switch the control to manual mode through the manual and automatic switching system and control the movement of the loading arm robotic arm through the local operation box.

[0022] As a further improvement to the above technical solution, the fully automatic train loading arm filling system also includes a human-machine interface, which is connected to the controller to display the tank opening positioning results, the movement status of the loading arm, and the filling progress, and supports operators to manually adjust parameters or intervene in the filling process.

[0023] As can be seen from the above technical solution, compared with the prior art, the present invention discloses a fully automatic train loading arm filling system and method, which has the following advantages and beneficial effects.

[0024] 1. This invention can achieve precise positioning of the can opening, improve filling efficiency, reduce the safety risks of manual operation, and control the operation through a remote upper interface, effectively reducing the labor intensity of operators and avoiding the problem of relying on a large number of people for monitoring.

[0025] 2. The loading arm of the present invention has a simple structure, light end mass, small load, and good structural stability. By setting a transition pipe between the inner and outer arm tubes, the horizontal and pitch swing functions of the outer arm tube are realized. The vertical tube can hang down naturally to maintain a vertical state. The pitch swing of the outer arm tube controls the lifting and lowering of the vertical tube, making the control more flexible. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0027] Figure 1 A schematic diagram of the overall structure of a fully automatic train loading arm filling system according to the present invention.

[0028] Figure 2 A schematic diagram of the robotic arm structure of a fully automatic train loading arm filling system according to the present invention.

[0029] In the diagram: 1. Canopy; 11. Filling and parking area sign; 2. Radar; 3. Surveillance camera; 4. Loading arm; 41. Fixed support; 42. Inner arm tube assembly; 421. Fixed feed tube; 422. Rotating support; 423. Inner arm tube; 43. Transfer tube; 44. Outer arm tube assembly; 441. Outer arm tube; 442. Spring cylinder balancing mechanism; 45. Vertical tube; 46. Inner arm drive mechanism; 461. Inner arm servo driver; 462. Inner arm servo motor; 47. Outer arm... 471. Arm drive mechanism; 472. Arm servo driver; 48. Arm servo motor; 49. Pipe drive mechanism; 40. Pipe servo driver; 41. Pipe servo motor; 42. Pipe servo motor; 5. Central control room; 51. First network switch; 52. Network hard disk recorder; 53. Industrial computer; 54. Display screen; 55. Control console; 6. Control cabinet; 61. Second network switch; 62. Controller; 7. Local operation box; 8. Supplementary lighting; 9. Tank truck; 91. Tank opening. Detailed Implementation

[0030] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0031] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0032] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0033] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0034] According to embodiments of the present invention, such as Figure 1 and Figure 2 As shown, a fully automated train loading arm filling system includes: a canopy 1, a radar 2, a monitoring camera 3, a loading arm robotic arm 4, a central control room 5, and a control cabinet 6.

[0035] A designated parking area for filling containers is provided on the road surface below the canopy 1; radar 2 and monitoring camera 3 are horizontally and fixedly installed at the lower end of the canopy 1 and above the designated parking area for filling containers.

[0036] The loading arm 4 includes a fixed support 41, an inner arm tube assembly 42, a transfer tube 43, an outer arm tube assembly 44, a vertical tube 45, an inner arm drive mechanism 46, an outer arm drive mechanism 47, and a vertical tube drive mechanism 48. The fixed support 41 is located to the side of the filling and parking area. One end of the inner arm tube assembly 42 is rotatably connected to and communicates with the upper part of the fixed support 41. The inner arm drive mechanism 46 is driven by the inner arm tube assembly 42 to drive its horizontal swing. One end of the transfer tube 43 is rotatably connected to and communicates with the other end of the inner arm tube assembly 42, and the other end of the transfer tube 43 is rotatably connected to and communicates with one end of the outer arm tube assembly 44. The outer arm drive mechanism 47 is driven by the transfer tube 43 to drive its horizontal swing, thereby causing the outer arm tube assembly 44 to swing horizontally. The upper end of the vertical tube 45 is rotatably connected to and communicates with the other end of the outer arm tube assembly 44, and its lower end hangs freely. The vertical tube drive mechanism 48 is driven by the outer arm tube assembly 44 to drive its pitch swing, thereby causing the vertical tube 45 to rise and fall.

[0037] The central control room 5 is equipped with a first network switch 51, a network hard disk recorder 52 and an industrial control computer 53 electrically connected to the first network switch 51, and a display screen 54 electrically connected to the industrial control computer 53; the control cabinet 6 is equipped with a second network switch 61 electrically connected to the first network switch 51, radar 2 and monitoring camera 3, and a controller 62 electrically connected to the second network switch 61; the controller 62 is electrically connected to the inner arm drive mechanism 46, the outer arm drive mechanism 47 and the vertical pipe drive mechanism 48.

[0038] In this embodiment, the canopy 1 of the fully automated train loading arm filling system protects the radar 2 and monitoring camera 3 from rainwater intrusion, thereby ensuring operational stability and measurement accuracy. During operation, the tank car is precisely parked in the filling parking area, ensuring that the radar 2 can accurately scan the tank opening 91 of the tank car 9. The canopy 1 also protects the tank opening on the top of the tank car to withstand rain and snow. Among them, radar 2 and monitoring camera 3 are used to generate information around the tank truck opening and on-site video information, and transmit them to industrial control computer 53 and network hard disk recorder 52 through first network switch 51 and second network switch 61. In addition to processing point cloud information to generate tank opening coordinate information, industrial control computer 53 also displays the status information of the entire system through display screen 54, and sends control commands and tank opening coordinate information to controller 62. Controller 62 is used to respond to control commands, and can drive inner arm tube group 42 to swing horizontally through inner arm drive mechanism 46, drive transfer tube 43 and outer arm tube group 44 to swing horizontally through outer arm drive mechanism 47, and drive outer arm tube group 44 to swing pitch through vertical tube drive mechanism 48, so as to accurately move and position vertical tube 45 directly above the tank truck opening, and control vertical tube 45 to lift and lower so that its lower end is inserted into the tank truck opening for filling.

[0039] Specifically, the first network switch 51, network hard disk recorder 52, industrial control computer 53, and display screen 54 are all installed on the control console 55 in the central control room 5. By setting the radar scanning parameters, a region of interest (ROI) covering the tank truck opening area is defined to improve processing efficiency.

[0040] In some embodiments, the system further includes a local control box 7, which is electrically connected to the inner arm drive mechanism 46, the outer arm drive mechanism 47, and the vertical tube drive mechanism 48.

[0041] Operators can directly control the movements of the loading arm through the local control box 7, such as the horizontal swing of the inner arm assembly 42, the transfer pipe 43 and the outer arm assembly 44, the pitch swing of the outer arm assembly 44, and the movement and lifting of the vertical pipe, thereby completing the current tanker filling operation.

[0042] In some embodiments, a supplementary light 8 is also included, which is fixedly installed at the lower end of the canopy 1 and corresponds to the side of the radar 2 away from the monitoring camera 3.

[0043] In some embodiments, the inner arm tube assembly 42 includes a fixed feed tube 421, a rotating bracket 422, and an inner arm tube 423; the inner arm drive mechanism 46 includes an inner arm servo driver 461 and an inner arm servo motor 462; the fixed feed tube 421 is fixed on the upper part of the fixed support column 41 and its upper end is the feed port; the inner arm tube 423 is horizontally arranged and one end of its tube is rotatably connected to and communicates with the lower end of the fixed feed tube 421; the lower end of the rotating bracket 422 is rotatably connected to the fixed support column 41, and the upper end of the rotating bracket 422 is fixedly connected to both ends of the inner arm tube 423 in the length direction for support; the inner arm servo driver 461 is disposed in the control cabinet 6 and is electrically connected to the controller 62 and the inner arm servo motor 462; the fixed end of the inner arm servo motor 462 is fixed on the fixed feed tube 421 and its rotation drive end is driven to one end of the inner arm tube 423 to drive it to swing horizontally.

[0044] The rotating bracket 422 can rotate to support the inner arm tube 423 and swing synchronously with the inner arm tube 423, improving stability. The feed port of the fixed feed pipe 421 is used to connect to the external medium conveying pipeline, thereby introducing the conveying medium into the inner arm tube 423. The controller 62 precisely controls the rotation angle of the inner arm servo motor 462 through the inner arm servo driver 461, thereby achieving precise control of the horizontal swing angle of the inner arm tube 423.

[0045] In some embodiments, the outer arm drive mechanism 47 includes an outer arm servo driver 471 and an outer arm servo motor 472; the outer arm servo driver 471 is disposed in the control cabinet 6 and electrically connected to the controller 62 and the outer arm servo motor 472; the fixed end of the outer arm servo motor 472 is fixed to the other end of the inner arm tube 423 and its rotation drive end is connected to one end of the adapter tube 43 to drive its horizontal swing and thereby drive the outer arm tube assembly 44 to swing horizontally.

[0046] The controller 62 precisely controls the rotation angle of the rotating drive end of the outer arm servo motor 472 through the outer arm servo driver 471, thereby precisely controlling the horizontal synchronous swing angle of the adapter pipe 43 and the outer arm tube assembly 44.

[0047] In some embodiments, the outer arm tube assembly 44 includes an outer arm tube 441 and a spring cylinder balancing mechanism 442; the vertical tube drive mechanism 48 includes a vertical tube servo driver 481 and a vertical tube servo motor 482; one end of the outer arm tube 441 is rotatably connected to and communicates with the other end of the adapter tube 43; the upper end of the vertical tube 45 is rotatably connected to and communicates with the other end of the outer arm tube 441; one end of the spring cylinder balancing mechanism 442 is hinged to the other end of the adapter tube 43, and the other end is hinged to the middle of the outer arm tube 441; the vertical tube servo driver 481 is disposed in the control cabinet 6 and electrically connected to the controller 62 and the vertical tube servo motor 482; the fixed end of the vertical tube servo motor 482 is fixed to the other end of the adapter tube 43 and its rotation drive end is connected to one end of the outer arm tube 441, thereby driving the outer arm tube 441 to pitch and swing.

[0048] The horizontal swing angle of the outer boom tube 441 is precisely controlled by the outer boom servo driver 471; the controller 62 precisely controls the rotation angle of the drive end of the vertical tube servo motor 482 through the vertical tube servo driver 481, thereby enabling precise pitch swing angle of the outer boom tube 441 and thus achieving precise control of the lifting and lowering of the vertical tube 45. The spring cylinder balancing mechanism 442 plays a role in balancing and stabilizing the outer boom tube 441, further ensuring the stability of the vertical tube servo motor 482's control over the lifting and lowering of the vertical tube 45.

[0049] Specifically, the adapter pipe 43 is a 90-degree curved bend; the inner arm pipe 423 is bent at both ends in opposite directions at a 90-degree angle to form curved elbows; the outer arm pipe 441 is bent at both ends in the same direction at a 90-degree angle to form curved elbows. The upper end of the vertical pipe 45 is bent at a 90-degree angle to form a curved elbow.

[0050] Specifically, radar 2 and monitoring camera 3 are connected to industrial control computer 53 and network hard disk recorder 52 via second network switch 61 and first network switch 51, respectively. Industrial control computer 53 is connected to controller 62 via first network switch 51 and second network switch 61, respectively. Controller 62 is connected to inner arm servo driver 461, outer arm servo driver 471 and vertical tube servo driver 481 via second network switch 61. Inner arm servo driver 461, outer arm servo driver 471 and vertical tube servo driver 481 are respectively connected to inner arm servo motor 462, outer arm servo motor 472 and vertical tube servo motor 482 on the corresponding loading arm.

[0051] Specifically, radar 2, monitoring camera 3, supplementary lighting 8, loading arm 4, control cabinet 6, and local operation box 7 are all located on-site (filling operation area). To achieve long-distance signal exchange between the central control room 5 and the site, a first network switch 51 and a second network switch 61 are installed in the central control room 5 and on-site, respectively. The working principle of this fully automatic train loading arm filling system is as follows: First, after the tank car is parked in the filling parking area (filling area), radar 2 scans and photographs the top of the tank car, generating three-dimensional spatial information and sending it to the industrial control computer 53. Second, the industrial control computer 53 processes the three-dimensional spatial information and the generated grayscale information to generate the tank opening center coordinate information, which is then sent to the controller 62. Finally, the controller 62 sends control commands to each servo driver based on the coordinate information, thereby driving the servo motors to move the loading arm 4, causing the vertical pipe 45 to insert into the tank opening and complete the alignment. The industrial control computer 53 is also used to display and store the operating status information of the entire system and supports remote control of the entire system.

[0052] According to another embodiment of the present invention, a fully automatic train loading arm filling method, using a fully automatic train loading arm filling system, includes the following steps: S1: After confirming that the tanker truck is parked in the filling parking area through monitoring camera 3, the operator opens the tanker truck opening and starts the filling system; S2: Scan the top of the tanker truck with radar 2 to generate grayscale and point cloud information, and transmit the point cloud information to the industrial control computer 53 through the first network switch 51 and the second network switch 61. S3: The industrial control computer 53 processes grayscale and point cloud information, identifies and locates the position of the tank truck opening, generates the three-dimensional spatial coordinates of the tank opening center, and transmits the three-dimensional spatial coordinate information to the controller 62 through the first network switch 51 and the second network switch 61. S4: The controller 62 calculates the swing angles of the inner arm tube group 42, the transfer tube 43 and the outer arm tube group 44 based on the three-dimensional spatial coordinate information, and transmits the swing angle information to the corresponding inner arm drive mechanism 46, outer arm drive mechanism 47 and vertical tube drive mechanism 48 through the second network switch 61. S5: The inner arm drive mechanism 46, the outer arm drive mechanism 47 and the vertical tube drive mechanism 48 drive the inner arm tube assembly 42, the transfer tube 43 and the outer arm tube assembly 44 to move according to the allocated swing angle information, thereby inserting the vertical tube 45 into the tank truck opening for filling. S6. After filling is completed, the inner arm drive mechanism 46, the outer arm drive mechanism 47 and the vertical tube drive mechanism 48 drive the inner arm tube assembly 42, the transfer tube 43 and the outer arm tube assembly 44 to move in the opposite direction, thereby causing the vertical tube 45 to automatically return to the initial position.

[0053] Specifically, in step S4, the controller 62 calculates the horizontal swing angle of the inner arm tube 423, the adapter tube 43, and the outer arm tube 441, as well as the pitch swing angle of the outer arm tube 441, based on the three-dimensional spatial coordinate information. This swing angle information is then transmitted to the corresponding inner arm servo driver 461, outer arm servo driver 471, and vertical tube servo driver 481 via the second network switch 61. In step S5, the inner arm servo driver 461, outer arm servo driver 471, and vertical tube servo driver 481 control the corresponding inner arm servo motor 462, outer arm servo motor 472, and vertical tube servo motor 482 to rotate based on the received swing angle information. This, in turn, drives the corresponding inner arm tube 423, adapter tube 43, outer arm tube 441, and vertical tube 45 to move, causing the lower part of the vertical tube 45 to vertically insert into the center of the can opening for filling.

[0054] Specifically, the inner arm servo motor 462, outer arm servo motor 472, and vertical tube servo motor 482 are all servo motors equipped with absolute encoders. The inner arm servo driver 461, outer arm servo driver 471, and vertical tube servo driver 481 are all connected to the controller 62 via the second network switch 61 for real-time communication. In step S6, after filling is completed, based on the information recorded by the absolute encoders built into the inner arm servo motor 462, outer arm servo motor 472, and vertical tube servo motor 482, the corresponding inner arm servo motor 462, outer arm servo motor 472, and vertical tube servo motor 482 are driven to rotate by the inner arm servo driver 461, outer arm servo driver 471, and vertical tube servo driver 481, thereby driving the corresponding inner arm tube 423, adapter tube 43, outer arm tube 441, and vertical tube 45 to reverse and reset, so that the vertical tube 45 automatically returns to its initial position.

[0055] In some embodiments, in step S1, the filling parking marking area is a parking area marked by ground markings. The ground markings include, but are not limited to, any one of high-contrast (relative to road surface color) color coatings, reflective strips, and laser projection lines, which are used to guide the tanker to park accurately in a predetermined position. The monitoring camera 3 collects images of the ground markings and the outline of the tanker. The industrial control computer 53 detects the relative position of the ground markings and the outline of the tanker through image processing algorithms to confirm whether the tanker is completely within the filling area, so as to ensure that the radar 2 can accurately scan the tanker opening in step S2.

[0056] In some embodiments, step S3, in which the industrial control computer 53 processes the point cloud information, includes: S31: Radar 2 is a millimeter-wave radar or lidar, mounted on a fixed bracket on the top of the trestle. Radar 2 is equipped with a dynamically adjustable ROI function to limit the scanning range, ensuring coverage of the target area on top of the tanker truck within the filling parking area, while eliminating background interference from non-target areas; preprocessing the point cloud data within the ROI area, including denoising and enhancement, and converting the three-dimensional point cloud data into a grayscale image. S32: Use a detection algorithm to identify the rim area of ​​a tank in a grayscale image; S33: Extract the point cloud data of the corresponding tank opening area; S34: Filter and register the point cloud data; S35: Fit the tank opening plane and boundary based on point cloud data, and calculate the three-dimensional spatial coordinates of the tank opening center.

[0057] In some embodiments, in step S4, when the controller 62 calculates the horizontal swing angle of the inner arm tube 423, the transfer tube 43 and the outer arm tube 441, and the pitch swing angle of the outer arm tube 441, it uses an inverse kinematics solution algorithm based on the kinematic model of the loading arm; at the same time, it uses a forward kinematics solution algorithm based on the kinematic model of the loading arm to calculate the maximum range of motion of each joint of the loading arm (i.e., the rotational joint at the connection between the inner arm tube 423 and the fixed feed tube 421, the rotational joint at the connection between the inner arm tube 423 and the transfer tube 43, and the rotational joint at the connection between the outer arm tube 441 and the transfer tube 43), sets the maximum range of joint movement angles, and avoids obstacles.

[0058] Specifically, kinematic modeling: The controller establishes a kinematic model of the robotic arm based on its actual dimensions and joint connections. The kinematic model is used to clearly describe the geometric relationships of various components such as the inner arm tube, the adapter tube, and the outer arm tube. It can calculate the spatial position of the end effector (vertical tube) of the robotic arm using a set of joint angles (forward kinematics), and conversely, it can also solve for the required joint angles based on the target end effector position (inverse kinematics).

[0059] The inverse kinematics solution (calculation of target joint angles) process is as follows: After obtaining the three-dimensional coordinates of the target point at the can opening, the controller calls the inverse kinematics solution algorithm; based on the established kinematic model, the inverse kinematics solution algorithm converts the target position into the three core joint angle values ​​required to drive the arm movement through analytical calculation: the horizontal rotation angle of the inner arm tube, the horizontal rotation angle of the adapter arm, and the pitch angle of the outer arm tube.

[0060] Forward kinematics application and safety range setting (for obstacle avoidance). Workspace analysis and joint limits: The controller uses a forward kinematics model to simulate and calculate the entire spatial area (workspace) that the end effector of the loading arm can reach. Combining the known location information of fixed obstacles on site (such as supports, equipment, columns, etc.), the controller reverse-engineers the maximum permissible range of motion (joint soft limits) that each joint angle must adhere to in order to ensure that the end effector of the loading arm always moves within the safety area.

[0061] Real-time collision prevention: During automatic alignment, the controller performs the following steps to ensure safety.

[0062] Pre-check: The target joint angle calculated based on the coordinates of the can opening will be immediately compared with the preset joint soft limit range.

[0063] Decision: If all target angles are within the safe range, a smooth motion command is generated; if any angle exceeds the limit, it is determined to be a potential collision path, the controller will refuse to execute and trigger an alarm, prompting manual intervention or replanning.

[0064] In some embodiments, in steps S5 and S6, a fifth-order polynomial interpolation trajectory planning algorithm is used to set effective values ​​for the position, velocity, and acceleration of the starting and ending points of each path segment of the loading arm, thereby generating a smooth motion trajectory to ensure the continuity and smoothness of the loading arm's movements.

[0065] Specifically, the trajectory planning algorithm using fifth-order polynomial interpolation includes the following steps.

[0066] (1) Trajectory planning requirements and constraints: Taking the movement of a single rotary joint (e.g., the pitch joint of the outer arm tube) of a loading arm from its initial position to its target position as an example, the boundary conditions that the planning needs to meet usually include: position constraints, smoothness constraints and total time constraints.

[0067] Position constraint: Starting point angle End point angle (This value is calculated from the inverse kinematics based on the target position of the can opening).

[0068] Smoothness constraint: To ensure smooth and shock-free motion at the start and end points, it is usually required that the velocity and acceleration at the start and end points are zero, i.e. , .

[0069] Total Time Constraint: Specifies the total time required to complete this segment of motion. .

[0070] (2) Generation of a single-segment quintic polynomial trajectory: For a point-to-point motion that satisfies the above boundary conditions, the trajectory of the joint angles changing with time. This can be described by a fifth-degree polynomial: .

[0071] in, For time, ;coefficient to The equations are obtained by substituting the boundary conditions into the system of equations consisting of the polynomial and its first-order (velocity) and second-order (acceleration) derivatives.

[0072] Depend on It can be solved directly. .

[0073] Residual coefficient use Termination condition Solving the simultaneous equations yields the result. Using this method, the controller can generate the joint from... arrive The uniquely determined smooth angle instruction sequence Its corresponding speed and acceleration The curve is also continuous and smooth.

[0074] (3) Splicing and continuous transition of multiple trajectories: For complex motion paths, the total trajectory is divided into multiple segments for planning.

[0075] Intermediate point setting: Specify the start and end positions, velocities, and acceleration values ​​for each segment. The velocity at the intermediate point does not have to be zero, but the state between segments must be continuous, that is: the end position of the previous segment is equal to the start position of the next segment, the end velocity of the previous segment is equal to the start velocity of the next segment, and the end acceleration of the previous segment is equal to the start acceleration of the next segment.

[0076] Segmented solution: For each segment, using its initial and final state values ​​as new boundary conditions, the trajectory coefficients of that segment are calculated by applying the single-segment fifth-degree polynomial solution method described above. Because state continuity is guaranteed, the entire trajectory formed by piecing together the segments is continuous in position, velocity, and acceleration.

[0077] The implementation process is as follows: Based on the can opening positioning result, the controller calculates the final target angle of each joint of the robotic arm through inverse kinematics. According to the total motion time, segmentation strategy, and state constraints of each intermediate point (which can be based on experience or obstacle avoidance algorithms), a multi-segment quintic polynomial trajectory as described above is planned for each joint. During the movement, the controller adjusts the frequency according to the current time. Combined with the trajectory polynomials of each segment, the desired angle of each joint is calculated in real time. and expected speed .

[0078] These expected values ​​are sent as instructions to the servo drives of each joint. The drives use built-in position and speed loop closed-loop control to drive the servo motors to precisely track the trajectory of these instructions.

[0079] In some embodiments, a fully automatic train loading arm filling system also includes a manual-automatic switching system; if an abnormality occurs before the automatic filling system is turned on or during operation, the operator can switch the control to manual mode through the manual-automatic switching system and control the movement of the loading arm 4 through the local operation box 7.

[0080] In some embodiments, a fully automatic train loading arm filling system further includes a human-machine interface, which is communicatively connected to the controller to display the tank opening positioning results, the movement status of the loading arm 4, and the filling progress, and supports operators to manually adjust parameters or intervene in the filling process.

[0081] In some embodiments, the specific filling operation steps are as follows: (1) After the operator observes through the monitoring screen that the tanker is parked in the tank filling area, the tank cover is open and there is no one on the top of the tanker, the operator clicks the “Environment Confirmation”, “Automatic Mode” and “Automatic Alignment” buttons in the upper interface in sequence to send control commands to the controller and radar respectively.

[0082] (2) The radar responds to the control command, collects the point cloud data on the top of the tank truck, transmits it to the industrial control computer, receives the data and calculates the spatial coordinates of the tank opening, and then sends the coordinates to the controller. At the same time, the upper interface displays the tank opening plane information and coordinate information.

[0083] (3) After receiving the spatial coordinates of the tank opening, the controller converts the three-dimensional coordinates into the rotation angle of the corresponding servo motor through an algorithm, and sends control commands to the servo driver to control the motor to work, thereby moving the loading arm to insert into the center of the tank opening. The specific working process is as follows: the inner arm servo motor drives the inner arm tube to rotate horizontally, which serves as the basic movement of the entire boom; the outer arm servo motor is installed at the end of the inner arm tube and drives the outer arm tube to perform secondary horizontal extension, together positioning the end of the vertical tube directly above the tank opening; the vertical tube servo motor is installed at the rotational hinge of the outer arm tube to control the overall pitch angle of the outer arm tube, thereby realizing the insertion of the vertical tube into the center of the tank opening.

[0084] (4) After the operator observes through the monitoring screen that the vertical pipe is inserted vertically into the center of the tank opening and the sealing device coaxially sleeved on the vertical pipe has completely sealed the tank opening, the filling is started. During the filling process, the upper interface displays the loading progress and prompts the message "Filling in progress, operation prohibited".

[0085] (5) After filling is completed, the controller controls the loading arm to automatically return to its original position based on the encoder information built into the servo motor, thus completing the filling process. During the entire filling process from the start of positioning to the end of filling, the upper interface displays and records operator information, tank opening coordinates, and servo motor operating status, etc.

[0086] Specifically, the system is equipped with manual and automatic switching functions. Before starting the automatic filling system or if an abnormality is detected during operation, the operator can switch the system control from automatic mode to manual mode using a switch. After switching, the operator can immediately control the movements of the loading arm (such as the movement of the inner and outer arm tubes, and the raising and lowering of the vertical tube) directly through the local control box to complete the filling operation of the current tanker. After the filling operation is completed, the operator needs to click the reset button on the local control box or the remote interface. This operation will execute the system reset procedure, drive the loading arm back to the preset initial position, and clear the current task status, ensuring that the system parameters and environment are restored to a ready state, preparing for the normal start of the next automatic filling process.

[0087] In summary, the fully automated train loading arm system and method proposed in this invention achieves automated loading through a remote operation interface, significantly improving the safety hazards, high labor intensity, and low efficiency of manual loading. The system utilizes radar to precisely locate the tank car opening and automatically adjusts the loading arm position, reducing the risks of direct worker operation, lowering the demand for physical labor, and improving loading speed and operational consistency. Compared to existing loading methods, this system not only enhances safety and efficiency but also provides a new solution for the automation of liquid transportation, possessing high practical value and a wide range of applications.

[0088] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. In addition, those skilled in the art can combine and integrate the different embodiments or examples described in this specification.

[0089] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A fully automated train car swabbing system, comprising: include: A canopy (1) is provided, and a parking area for filling is provided on the road surface below the canopy (1); Radar (2) and monitoring camera (3) are installed horizontally side by side below the canopy (1) and above the filling parking sign area; The loading arm (4) includes a fixed support (41), an inner arm tube assembly (42), a transfer tube (43), an outer arm tube assembly (44), a vertical tube (45), an inner arm drive mechanism (46), an outer arm drive mechanism (47), and a vertical tube drive mechanism (48). The fixed support (41) is located to the side of the filling stop sign area. One end of the inner arm tube assembly (42) is rotatably connected to and communicates with the upper part of the fixed support (41). The inner arm drive mechanism (46) is driven by the inner arm tube assembly (42) to drive it to swing horizontally. The transfer tube (43) is connected to the inner arm tube assembly (42) to drive it to swing horizontally. The other end of the inner arm tube assembly (42) is rotatably connected to and connected to the other end of the outer arm tube assembly (44); the outer arm drive mechanism (47) is driven by the adapter pipe (43) to drive its horizontal swing and thus drive the outer arm tube assembly (44) to swing horizontally; the upper end of the vertical tube (45) is rotatably connected to and connected to the other end of the outer arm tube assembly (44), and its lower end hangs freely; the vertical tube drive mechanism (48) is driven by the outer arm tube assembly (44) to drive its pitch swing and thus drive the vertical tube (45) to rise and fall; The central control room (5) and the control cabinet (6) are provided. The central control room (5) is equipped with a first network switch (51), a network hard disk video recorder (52) electrically connected to the first network switch (51), an industrial control computer (53), and a display screen (54) electrically connected to the industrial control computer (53). The control cabinet (6) is equipped with a second network switch (61) electrically connected to the first network switch (51), the radar (2), and the monitoring camera (3), and a controller (62) electrically connected to the second network switch (61). The controller (62) is electrically connected to the inner arm drive mechanism (46), the outer arm drive mechanism (47), and the vertical pipe drive mechanism (48).

2. The fully automatic train loading system with a loading arm according to claim 1, characterized in that, It also includes a local control box (7), which is electrically connected to the inner arm drive mechanism (46), the outer arm drive mechanism (47) and the vertical tube drive mechanism (48).

3. The fully automated train hose filling system of claim 2, wherein, The inner arm tube assembly (42) includes a fixed feed tube (421), a rotating bracket (422), and an inner arm tube (423); the inner arm drive mechanism (46) includes an inner arm servo driver (461) and an inner arm servo motor (462); the fixed feed tube (421) is fixed to the upper part of the fixed support column (41), and its upper end is the feed port; the inner arm tube (423) is horizontally arranged, and one end of its tube is rotatably connected to and communicates with the lower end of the fixed feed tube (421); the lower end of the rotating bracket (422) The rotating bracket (422) is rotatably connected to the fixed support column (41), and the upper end of the rotating bracket (422) is fixedly connected to both ends of the inner arm tube (423) in the length direction for support; the inner arm servo driver (461) is set in the control cabinet (6) and electrically connected to the controller (62) and the inner arm servo motor (462); the fixed end of the inner arm servo motor (462) is fixed on the fixed feed tube (421), and its rotation drive end is connected to one end of the inner arm tube (423) to drive it to swing horizontally.

4. The fully automated train hose filling system of claim 3, wherein, The outer arm drive mechanism (47) includes an outer arm servo driver (471) and an outer arm servo motor (472); the outer arm servo driver (471) is located in the control cabinet (6) and is electrically connected to the controller (62) and the outer arm servo motor (472); the fixed end of the outer arm servo motor (472) is fixed to the other end of the inner arm tube (423) and its rotation drive end is connected to one end of the adapter tube (43) to drive it to swing horizontally and thus drive the outer arm tube assembly (44) to swing horizontally.

5. The fully automated train hose filling system of claim 2, wherein, The outer arm tube assembly (44) includes an outer arm tube (441) and a spring cylinder balancing mechanism (442); the vertical tube drive mechanism (48) includes a vertical tube servo driver (481) and a vertical tube servo motor (482); one end of the outer arm tube (441) is rotatably connected to and communicates with the other end of the adapter tube (43); the upper end of the vertical tube (45) is rotatably connected to and communicates with the other end of the outer arm tube (441); one end of the spring cylinder balancing mechanism (442) is hinged to the... The other end of the adapter tube (43) is hinged to the middle of the outer arm tube (441); the vertical tube servo driver (481) is located in the control cabinet (6) and is electrically connected to the controller (62) and the vertical tube servo motor (482); the fixed end of the vertical tube servo motor (482) is fixed to the other end of the adapter tube (43) and its rotation drive end is connected to one end of the outer arm tube (441), thereby driving the outer arm tube (441) to pitch and swing.

6. A fully automated train car swabbing method, characterized by, Using the fully automatic train loading arm filling system according to any one of claims 1-5 includes the following steps: S1: After confirming by monitoring camera (3) that the tank truck is parked in the filling parking area, the operator opens the tank truck opening and starts the filling system; S2: Scan the top of the tanker truck with radar (2) to generate point cloud information, and transmit the point cloud information to the industrial control computer (53) through the first network switch (51) and the second network switch (61). S3: The industrial control computer (53) processes the point cloud information, identifies and locates the tank opening position of the tank truck, generates the three-dimensional spatial coordinates of the tank opening center, and transmits the three-dimensional spatial coordinate information to the controller (62) through the first network switch (51) and the second network switch (61). S4: The controller (62) calculates the swing angles of the inner arm tube group (42), the transfer tube (43) and the outer arm tube group (44) based on the three-dimensional spatial coordinate information, and transmits the swing angle information to the corresponding inner arm drive mechanism (46), outer arm drive mechanism (47) and vertical tube drive mechanism (48) through the second network switch (61). S5: The inner arm drive mechanism (46), the outer arm drive mechanism (47) and the vertical pipe drive mechanism (48) drive the inner arm pipe assembly (42), the transfer pipe (43) and the outer arm pipe assembly (44) to move according to the allocated swing angle information, thereby inserting the vertical pipe (45) into the tank truck opening for filling; S6. After filling is completed, the inner arm drive mechanism (46), the outer arm drive mechanism (47) and the vertical tube drive mechanism (48) drive the inner arm tube assembly (42), the transfer tube (43) and the outer arm tube assembly (44) to reverse their movements, thereby causing the vertical tube (45) to automatically return to its initial position.

7. A fully automated train hose filling method according to claim 6, characterized in that, In step S1, the filling parking marking area is a parking area marked by ground markings. The ground markings include any one of color coating, reflective strips and laser projection lines, which are used to guide the tank truck to park accurately in the predetermined position. The monitoring camera (3) collects images of the ground markings and the outline of the tank truck. The industrial control computer (53) detects the relative position of the ground markings and the outline of the tank truck through image processing algorithms to confirm whether the tank truck is completely located in the filling area.

8. The fully automatic train loading arm filling method according to claim 6, characterized in that, In step S3, the steps by which the industrial control computer (53) processes the point cloud information include: S31: Preprocess the point cloud data within the ROI region, including denoising and enhancement, and convert the 3D point cloud data into a grayscale image; S32: Use a detection algorithm to identify the rim area of ​​a tank in a grayscale image; S33: Extract the point cloud data of the corresponding tank opening area; S34: Filter and register the point cloud data; S35: Fit the tank opening plane and boundary based on point cloud data, and calculate the three-dimensional spatial coordinates of the tank opening center.

9. The fully automatic train loading arm filling method according to claim 6, characterized in that, The fully automatic train loading arm filling system also includes a manual and automatic switching system; if an abnormality occurs before the automatic filling system is turned on or during operation, the operator can switch the control to manual mode through the manual and automatic switching system and control the movement of the loading arm (4) through the local operation box (7).

10. The fully automatic train loading arm filling method according to claim 6, characterized in that, The fully automatic train loading arm filling system also includes a human-machine interface, which is connected to the controller to display the tank opening positioning results, the movement status of the loading arm (4) and the filling progress, and supports operators to manually adjust parameters or intervene in the filling process.

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