Control method of omni-directional mobile molten metal automatic dumping robot

Abstract

The invention relates to a control method of an omni-directional mobile molten metal automatic dumping robot, the robot comprises a vehicle body, a portal assembly, a lifting frame, a translation plate and a fork arm carrier, and the control method comprises the following specific steps: when goods are taken, the vehicle body is firstly subjected to safety inspection, and then travels to a corresponding position to be prepared for positioning; goods taking operation is carried out after pose recognition and automatic adjustment; in the unloading process, the truck body advances to a ready unloading point, the fork arm carrier is controlled to stretch forwards and descend to the height capable of entering a cargo area, and the truck body is ready to be placed; continuously controlling the vehicle body to creep at an extremely low speed, and then descending the fork arm carrier to separate from the goods; during pouring, the fork arm carrier is controlled to be lifted to a preset height, and the fork arm carrier is controlled to execute transverse movement, so that the carried molten metal container is in contact and butt joint with the sprue gate of the heat preservation furnace; and then, the fork arm carrier is controlled to rotate, the container is driven to tilt, and the molten metal is injected into the heat preservation furnace along a preset track. The full-process unmanned, intelligent and high-safety molten metal carrying and dumping operation is achieved.

Description

Technical Field

[0001] This invention relates to the field of casting robot technology, and more specifically to a control method for an omnidirectional mobile automatic molten metal dumping robot. Background Technology

[0002] In high-temperature industrial fields such as metallurgy, casting, and metal composite material preparation, the transfer, pouring, and casting of molten metal (such as molten steel, molten aluminum, and molten copper) is one of the core production processes. This process typically involves transporting containers (such as ladles or crucibles) containing high-temperature molten metal from the smelting station or buffer zone to the holding furnace, mold, or casting machine, and then performing a precise pouring operation. Due to the extremely high temperature, large weight, and high fluidity of molten metal, and the fact that spillage can cause serious safety accidents (such as explosions, fires, equipment damage, and personal injury), there has long been an urgent need for automation and intelligent technologies in its handling and pouring operations.

[0003] Currently, the operating methods in this field can be mainly divided into the following categories:

[0004] Traditional manual and semi-mechanized operations rely on overhead cranes (bridge cranes) to lift large ladles, which are then moved and tilted remotely by operators from the ground or in the control room. This method has significant drawbacks: operators are exposed to high-temperature radiation and potential splashing risks at close range, resulting in high labor intensity and danger; tilting accuracy depends on operator experience, making consistency and reproducibility difficult to guarantee, and easily leading to molten metal splashing or inaccurate pouring volumes; operational efficiency is low, and it is difficult to achieve precise timing coordination with upstream smelting and downstream forming processes.

[0005] Track-mounted or stationary automated equipment: such as tilting carts that travel along fixed tracks or robotic arms fixed to specific workstations. This type of equipment achieves a degree of automation, avoiding direct exposure of personnel to hazardous environments. However, its mobility is severely limited: the track laying or fixed equipment results in a rigid working range, making it difficult to flexibly adapt to changes in workstations or process paths under multi-variety, small-batch production models; it also leads to low utilization of factory space; and equipment failure can easily cause the entire production line to stop.

[0006] Existing AGV / Mobile Robot Applications: In recent years, some companies have attempted to use Automated Guided Vehicles (AGVs) equipped with simple lifting mechanisms to transport empty containers. However, for fully loaded containers carrying molten metal, existing technologies have significant shortcomings:

[0007] Insufficient navigation and positioning accuracy: In complex workshop environments (with high temperature heat radiation, metal vapor, oil stains on the ground and vibration interference), traditional magnetic guidance and QR code navigation methods have poor reliability, while laser navigation is prone to positioning drift if it is not optimized for highly reflective surfaces such as metal containers and furnaces, and cannot meet the millimeter-level docking accuracy required for dumping operations.

[0008] Lack of rigidity and freedom of motion: The lifting mechanism of ordinary AGVs usually only has simple vertical lifting function, and cannot achieve fine adjustment of the container in the horizontal plane (lateral movement) and longitudinal movement (forward extension), and even more so, it lacks the function of accurately tilting the container around the axis. This makes it difficult for the robot to actively compensate for the position and angle deviation between itself and the pouring port of the holding furnace, so as to achieve "alignment" and "docking".

[0009] The lack of a comprehensive safety awareness and control strategy throughout the entire process is a significant issue. Existing solutions often focus on "handling" but lack integrated safety controls for high-risk actions such as "picking up and placing" and "tipping." For example, how can we ensure the safe and collision-free insertion of the forks into the container support holes when picking up and placing containers? How can we guarantee the absolute stability of high-center-of-gravity loads during movement? How can we control the tilting speed and angle during tipping to ensure a smooth injection of molten metal and prevent splashing or spillage? These all require a comprehensive control method that integrates information from multiple sensors and possesses active safety detection and adaptive adjustment capabilities. Summary of the Invention

[0010] To address the aforementioned technical problems, the present invention aims to provide a control method for an automated molten metal dumping robot that combines omnidirectional mobility, high-precision positioning and docking capabilities, multi-degree-of-freedom precision motion execution, and intelligent safety control throughout the entire process. This method is crucial for overcoming current bottlenecks in the automation of high-temperature metal logistics and realizing key processes in "unmanned" workshops. It not only completely liberates operators from dangerous and harsh environments, enhancing the inherent level of production safety, but also improves production quality and efficiency through precise and programmable operations, driving the transformation and upgrading of the high-temperature manufacturing industry towards intelligence and flexibility.

[0011] To achieve the objectives of the invention described above, the present invention adopts the following technical solution:

[0012] A control method for an omnidirectional mobile automatic molten metal dumping robot, characterized in that: the robot includes a vehicle body, a gantry assembly, a lifting frame, a translation plate, and a forklift; the vehicle body includes a rigid frame and steering wheel modules, with four steering wheel modules respectively located at the four corners of the rigid frame; a main controller is also installed on the vehicle body; the gantry assembly is slidably mounted on the vehicle body via a slide table, and the slide table is also equipped with a forward motor for driving the slide table forward and backward; the lifting frame is slidably mounted at the front of the gantry assembly, and the gantry assembly is also equipped with a lifting cylinder for driving the lifting frame; the translation plate... The sliding plate is slidably mounted at the front of the lifting frame. The fork carriage is rotatably mounted at the front of the sliding plate via a rotating block. The sliding plate is also equipped with a translation motor for driving the lateral movement of the sliding plate and a drive assembly for driving the rotating block to rotate. One end of the vehicle body is equipped with a navigation lidar and a blind spot lidar, and the two corners of the other end of the vehicle body are equipped with bottom lidars. The mast assembly is equipped with four sets of wire encoders for detecting the lateral movement distance, lifting distance, front-to-back distance, and rotation angle of the fork carriage. The fork carriage is also equipped with a multi-line lidar. The specific steps are as follows:

[0013] During pickup: The main controller on the vehicle receives the task from the scheduling system. Before the vehicle starts, it first performs a safety check to see if the fork carriage is within the safe area in terms of up / down, left / right, forward / backward, and tilt positions. If it is not within the safe area, it is adjusted to the safe area before the vehicle moves forward to the corresponding position. After arriving at the ready pickup point, the multi-line laser radar installed under the fork carriage is used to identify the position of the carrier end face in the corresponding storage location. The position is judged based on the identification results. If it exceeds the safety adjustment threshold, a warning is reported. The system intervenes and sends a task to return to the standby point to the vehicle. The vehicle waits at the standby point to receive the task again. Within the safety adjustment threshold range, the position is adjusted. The fork carriage angle, height, and left / right position are adjusted using a wire encoder to ensure that the fork carriage is within the safe threshold for entering the carrier opening. After picking up the goods, the fork carriage rises to a safe distance. Before the robot accepts the next movement task, the raised fork carriage and load are completely retracted into the vehicle's stable area.

[0014] During unloading: The main controller on the vehicle receives the dispatching command and controls the vehicle to move forward to the ready loading position. Before the vehicle starts, the safety self-check of the fork carriage is also performed. The vehicle moves forward to the ready unloading point, and then controls the vehicle to slowly enter the warehouse area. The fork carriage is controlled to extend forward and descend to the height that can enter the loading area, ready to be placed. The vehicle continues to be controlled to creep at a very low speed. Then the fork carriage descends to detach from the goods, and then the reset action is performed, and the vehicle drives away.

[0015] During tipping: The vehicle's main controller receives the work instructions from the scheduling system, controls the robot to move to the predetermined work position on the side of the target holding furnace, then controls the fork carriage to rise to the preset tipping height, and controls the fork carriage to perform lateral movement, so that the container carrying the molten metal comes into contact with the pouring port of the holding furnace; then, controls the fork carriage to rotate around its axis, drives the container to tip, and allows the molten metal to be injected into the holding furnace along a predetermined trajectory.

[0016] As a preferred solution: During the pickup process, the vehicle is navigated to the pre-pickup point of the target station using a fusion positioning system of navigation lidar and blind spot lidar, and before entering the point, the forks are raised to the recognition height.

[0017] As a preferred solution: During the picking process, after the forklift is raised to the recognition height, the vehicle detection signal is triggered, and the multi-line LiDAR is activated. The multi-line LiDAR scans the front face of the vehicle, and the point cloud is processed by the algorithm to extract the center points of the two support legs. The lateral deviation y and yaw angle deviation θ of the vehicle relative to the vehicle body are calculated. It is determined whether the deviation is within the threshold range. If it exceeds the threshold, it is judged as "abnormal posture", a warning log is reported, the dispatch system intervenes, and an instruction is issued to return the vehicle to the standby point. If it is within the threshold, the automatic adjustment process is initiated.

[0018] As a preferred solution, the automatic pose adjustment and retrieval process is as follows:

[0019] Position adjustment: The main controller calculates the amount of adjustment required based on the identified lateral deviation, and then fine-tunes the position of the vehicle body to align the target fork carriage with the carrier insertion hole;

[0020] Fine-tuning of heading: Controlling the vehicle to make a small-angle spin to correct the heading angle deviation θ.

[0021] Height Confirmation: Confirm the fork carriage height is within the range where it can be safely inserted into the carrier hole using a cable encoder;

[0022] Lateral shift pickup: The main controller controls the target fork carriage to shift laterally based on the identified required lateral shift distance, and uses the impact plate on the fork carriage as an auxiliary judgment to determine that the pickup has been completed;

[0023] Lifting and Resetting: After successful pickup, the fork carriage is raised to a safe height, then the vehicle body is reversed to a safe position, the fork carriage is returned to the predetermined position, and the vehicle leaves the warehouse.

[0024] As a preferred solution: During the tilting step, the main controller controls the fork carriage to rotate around the axis, driving the container to tilt for the first time, injecting some molten metal into the furnace, and then maintaining the tilt angle for several seconds. After the first tilt is completed, the fork carriage is raised and then slightly adjusted laterally to the next target position. The fork carriage is then controlled to perform a second rotation to completely empty the remaining molten metal in the container, and the position is maintained for several seconds again to ensure no residue remains.

[0025] As a preferred embodiment: the slide is provided with rollers on both sides, the middle of the vehicle body is provided with a recess to accommodate the slide, the two sides of the recess are provided with guide rails A, the rollers are set in the guide rails A, the lower part of the guide rails A is also provided with a rack A, the slide is also provided with a rotating shaft, and the two ends of the rotating shaft are respectively fixed with gears A that mesh with the rack A. The forward motor drives the rotating shaft to rotate, and the slide moves through the cooperation of the gears A and the rack A.

[0026] As a preferred embodiment: the gantry assembly is provided with a guide rail B, and the lifting frame is provided with guide wheels on both sides. The guide wheels are disposed in the guide rail B. The gantry assembly is also provided with a lifting cylinder. The piston rod of the lifting cylinder is fixed with a support wheel. The support wheel is provided with a chain. The two ends of the chain are fixed to the gantry assembly and the lifting frame respectively. The length of the chain on both sides of the support wheel is changed by the movement of the lifting cylinder, thereby causing the lifting frame to be raised or lowered.

[0027] As a preferred embodiment: a rack B is also fixed on the lifting frame, a translation motor is fixed on the translation plate, and a gear is fixed on the output shaft of the translation motor. Through the meshing of the gear and the rack B, the translation plate moves laterally on the lifting frame.

[0028] As a preferred embodiment: the upper and lower ends of the lifting frame are respectively provided with guide rails C, the upper and lower ends of the translation plate are respectively fixed with L-shaped connecting plates, the connecting plates are provided with translation wheels, and the translation wheels are arranged in the guide rails C.

[0029] As a preferred embodiment: the fork carriage is fixed to the rotating block, the rotating block is provided with a worm gear, and the drive assembly is a motor and a worm connected to the output shaft of the motor. The worm gear and worm cooperate to drive the rotating block to rotate.

[0030] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0031] This invention designs a basic structure for a robot and an automated control method for the entire process of "picking up, unloading, and dumping", realizing unmanned, intelligent, and highly safe operation of molten metal handling and dumping.

[0032] This invention, through a four-steering wheel module, endows the robot with the ability to move in any direction and rotate in place within confined spaces, solving the fundamental problems of poor flexibility and fixed working range of traditional track-based equipment, and realizing a flexible production layout. Furthermore, through the coordination of the gantry, lifting frame, translation plate, and rotating forklift, this invention achieves precise adjustment of the load in four dimensions: forward / backward, lifting, lateral, and rotation. This enables the robot to actively compensate for positional deviations and accurately complete container insertion, docking, and tipping actions, which is the key mechanical foundation for achieving automated tipping.

[0033] This invention integrates navigation lidar, blind spot radar, bottom radar, cable encoder, and fork multi-line lidar to construct a comprehensive perception system encompassing global navigation, local obstacle avoidance, and precise end-effector identification and posture feedback. This solves the problem of insufficient reliability of single sensors in high-temperature industrial environments, providing data assurance for end-to-end safety control. Furthermore, each operational stage (pre-start, picking, unloading, and tipping) incorporates built-in safety detection (such as safety zone self-checks and threshold judgments) and standardized action sequences, embedding safety logic into the control core to effectively prevent major accidents such as collisions, tipping, or molten metal spills caused by misoperation or improper posture. Attached Figure Description

[0034] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments of this application and their descriptions are used to explain this application and do not constitute a limitation thereof.

[0035] Figure 1 and Figure 2 These are schematic diagrams of the robot of the present invention from two different angles;

[0036] Figure 3 This is a structural schematic diagram of the vehicle body and slide of the present invention;

[0037] Figure 4 This is a structural schematic diagram of the gantry assembly, lifting frame, and forklift of the present invention;

[0038] Figure 5 This is a structural schematic diagram of the lifting frame, the translation plate, and the forklift of the present invention;

[0039] Figure 6 This is a schematic diagram of the robot's pickup task process according to the present invention;

[0040] Figure 7 This is a schematic diagram of the unloading task process of the robot of the present invention;

[0041] Figure 8 This is a schematic diagram of the tilting task process of the robot of the present invention.

[0042] The labels in the attached diagram are as follows: 1. Vehicle body; 10. Slide table; 101. Roller; 102. Horizontal wheel; 11. Navigation lidar; 12. Blind spot lidar; 13. Bottom lidar; 14. Column; 15. Forward motor; 151. Rotating shaft; 152. Gear A; 16. Guide rail A; 17. Rack A; 2. Mast assembly; 20. Guide rail B; 21. Lifting cylinder; 22. Support wheel; 23. Chain; 24. Auxiliary wheel; 3. Lifting frame; 31. Guide rail C; 32. Rack B; 4. Translation plate; 40. Connecting plate; 41. Translation wheel; 42. Translation motor; 5. Drive assembly; 6. Rotating block; 7. Fork carriage. Detailed Implementation

[0043] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0044] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0045] Furthermore, in the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "clockwise," and "counterclockwise," 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.

[0046] 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 indicated technical features. 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, unless otherwise stated, "a plurality of" means two or more, unless explicitly defined otherwise.

[0047] 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 connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0048] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0049] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0050] like Figures 1 to 5 As shown, an omnidirectional mobile molten metal automatic dumping robot includes a vehicle body 1, a gantry assembly 2, a lifting frame 3, a translation plate 4, and a fork carriage 7. The vehicle body 1 includes a rigid frame and a steering wheel module integrating drive, steering, braking, and feedback. Four steering wheel modules are respectively set at the four corners of the rigid frame. The vehicle body 1 is also equipped with a main controller for controlling the steering wheel modules. The gantry assembly 2 is slidably mounted on the vehicle body 1 via a slide 10. The slide 10 is also equipped with a forward motor 15 for driving the slide 10 to move back and forth. The lifting frame 3 is slidably mounted at the front of the gantry assembly 2. The gantry assembly 2 is also equipped with a lifting cylinder 21 for driving the lifting frame 3. The translation plate 4 is slidably mounted at the front of the lifting frame 3. The fork carriage 7 is rotatably mounted at the front of the translation plate 4 via a rotating block 6. The translation plate 4 is also equipped with a translation motor 42 for driving the translation plate 4 to move laterally and a drive assembly 5 for driving the rotating block 6 to rotate.

[0051] The gantry assembly 2 is equipped with four sets of wire encoders for detecting the lateral displacement, lifting distance, front-to-back distance, and rotation angle of the fork carriage 7. The fork carriage 7 is also equipped with a multi-line lidar for identifying the carrier's posture and enabling the fork carriage 7 to accurately pick up the carrier. By using the four sets of wire encoders to accurately measure the lateral displacement, lifting, front-to-back distance, and rotation of the fork carriage, a fully closed-loop real-time feedback control of the end effector's spatial posture is achieved. This is the foundation for realizing automated and precise operations (such as automatic hole finding and automatic tilting angle positioning).

[0052] Multi-line LiDAR, mounted on the fork carriage, actively scans the carrier in front, generating high-precision 3D point cloud data. Through algorithms, it identifies the precise position and angle of standard interfaces on the carrier (such as pallet fork holes), guiding the robot to automatically adjust the fork posture. This enables "foolproof" automatic forking, significantly reducing the requirements for on-site environmental setup and initial placement accuracy, and improving the level of automation.

[0053] One end of the vehicle body 1 is also equipped with a column 14, and the top of the column 14 is equipped with a navigation lidar 11 and a blind spot lidar 12. Arranging the main sensors on the column improves the field of view and also avoids interference from high temperature radiation, steam and dust on the ground to a certain extent, thus improving the reliability of the system. The two corners of the other end of the vehicle body 1 are also equipped with bottom lidars 13 for positioning and perception. The navigation lidar (usually installed at the top) provides the main global map building and self-localization information; the blind spot lidar supplements the information of nearby low obstacles; the bottom lidar is installed at the corner of the vehicle body and is specifically used to perceive obstacles, tracks, potholes and for alignment reference when accurately parking. The combination of the three constitutes a multi-layered safety perception system with no blind spots.

[0054] SLAM (Simultaneous Localization and Mapping) technology based on LiDAR enables robots to achieve autonomous path planning, obstacle avoidance, and centimeter-level accuracy positioning in complex and dynamic workshop environments. This is the core guarantee for their safe and reliable omnidirectional movement and automated task execution.

[0055] The specific control steps of the robot of the present invention are as follows:

[0056] During pickup: The main controller on the vehicle receives the task from the scheduling system. Before the vehicle starts, it first performs a safety check to see if the fork carriage is within the safe area in terms of up / down, left / right, forward / backward, and tilt positions. If it is not within the safe area, it is adjusted to the safe area before the vehicle moves forward to the corresponding position. After arriving at the ready pickup point, the multi-line laser radar installed under the fork carriage is used to identify the position of the carrier end face in the corresponding storage location. The position is judged based on the identification results. If it exceeds the safety adjustment threshold, a warning is reported. The system intervenes and sends a task to return to the standby point to the vehicle. The vehicle waits at the standby point to receive the task again. Within the safety adjustment threshold range, the position is adjusted. The fork carriage angle, height, and left / right position are adjusted using a wire encoder to ensure that the fork carriage is within the safe threshold for entering the carrier opening. After picking up the goods, the fork carriage rises to a safe distance. Before the robot accepts the next movement task, the raised fork carriage and load are completely retracted into the vehicle's stable area.

[0057] During unloading: The main controller on the vehicle receives the dispatching command and controls the vehicle to move forward to the ready loading position. Before the vehicle starts, the safety self-check of the fork carriage is also performed. The vehicle moves forward to the ready unloading point, and then controls the vehicle to slowly enter the warehouse area. The fork carriage is controlled to extend forward and descend to the height that can enter the loading area, ready to be placed. The vehicle continues to be controlled to creep at a very low speed. Then the fork carriage descends to detach from the goods, and then the reset action is performed, and the vehicle drives away.

[0058] During tipping: The vehicle's main controller receives the work instructions from the scheduling system, controls the robot to move to the predetermined work position on the side of the target holding furnace, then controls the fork carriage to rise to the preset tipping height, and controls the fork carriage to perform lateral movement, so that the container carrying the molten metal comes into contact with the pouring port of the holding furnace; then, controls the fork carriage to rotate around its axis, drives the container to tip, and allows the molten metal to be injected into the holding furnace along a predetermined trajectory.

[0059] As a preferred solution: During the pickup process, the vehicle is navigated to the pre-pickup point of the target station using a fusion positioning system of navigation lidar and blind spot lidar, and before entering the point, the forks are raised to the recognition height.

[0060] As a preferred solution: During the picking process, after the forklift is raised to the recognition height, the vehicle detection signal is triggered, and the multi-line LiDAR is activated. The multi-line LiDAR scans the front face of the vehicle, and the point cloud is processed by the algorithm to extract the center points of the two support legs. The lateral deviation y and yaw angle deviation θ of the vehicle relative to the vehicle body are calculated. It is determined whether the deviation is within the threshold range. If it exceeds the threshold, it is judged as "abnormal posture", a warning log is reported, the dispatch system intervenes, and an instruction is issued to return the vehicle to the standby point. If it is within the threshold, the automatic adjustment process is initiated.

[0061] As a preferred solution, the automatic pose adjustment and retrieval process is as follows:

[0062] Position adjustment: The main controller calculates the amount of adjustment required based on the identified lateral deviation, and then fine-tunes the position of the vehicle body to align the target fork carriage with the carrier insertion hole;

[0063] Fine-tuning of heading: Controlling the vehicle to make a small-angle spin to correct the heading angle deviation θ.

[0064] Height Confirmation: Confirm the fork carriage height is within the range where it can be safely inserted into the carrier hole using a cable encoder;

[0065] Lateral shift pickup: The main controller controls the target fork carriage to shift laterally based on the identified required lateral shift distance, and uses the impact plate on the fork carriage as an auxiliary judgment to determine that the pickup has been completed;

[0066] Lifting and Resetting: After successful pickup, the fork carriage is raised to a safe height, then the vehicle body is reversed to a safe position, the fork carriage is returned to the predetermined position, and the vehicle leaves the warehouse.

[0067] As a preferred solution: During the tilting step, the main controller controls the fork carriage to rotate around the axis, driving the container to tilt for the first time, injecting some molten metal into the furnace, and then maintaining the tilt angle for several seconds. After the first tilt is completed, the fork carriage is raised and then slightly adjusted laterally to the next target position. The fork carriage is then controlled to perform a second rotation to completely empty the remaining molten metal in the container, and the position is maintained for several seconds again to ensure no residue remains.

[0068] The vehicle body also integrates a high-precision IMU for measuring vehicle pitch, roll, and angular velocity. The robot's multi-line lidar moves laterally, vertically, forward / backward, and clockwise / counterclockwise along with the forklift. When the multi-line lidar is operating, its field of view must be sufficient to identify reflective stickers on containers, and the vehicle's attitude should be adjusted based on the identification results. The vehicle's navigation primarily utilizes the multi-line lidar for high-precision navigation, achieving an accuracy of ±2cm.

[0069] The lower part of the vehicle body is also equipped with forward and lateral movement safety mechanisms. The forward movement safety mechanism consists of a safety contact edge, an obstacle avoidance lidar, and a blind spot lidar to ensure the safety of the forklift during automatic forward movement. The lateral movement safety mechanism consists of a safety contact edge and an obstacle avoidance lidar to ensure the safety of the forklift during automatic lateral movement. Mechanical anti-collision strips, an emergency stop switch, and a reset button are arranged around the vehicle body. In case of an obstacle in the blind spot or an emergency, the emergency stop button can be used to cut off the power to the vehicle controller. In case of an accident while pouring hot molten metal, the reset button can be used to rotate the fork carriage to a horizontal plane.

[0070] The slide 10 has rollers 101 on both sides, and the middle of the vehicle body 1 has a recess for accommodating the slide 10. The two sides of the recess have guide rails A16, and the rollers 101 are set in the guide rails A16. The lower part of the guide rails A16 also has a rack A17. The slide 10 also has a rotating shaft 151 running through it. The two ends of the rotating shaft 151 are respectively fixed with gears A152 that mesh with the rack A17. The forward motor 15 drives the rotating shaft 151 to rotate. Through the cooperation of the gears A152 and the rack A17, the slide 10 moves.

[0071] The aforementioned structure employs a gear A and rack A meshing transmission method, which, compared to chain or belt drives, offers advantages such as high transmission rigidity, low backlash, high positioning accuracy, and high load-bearing capacity. This is crucial for moving heavy gantry frames, lifting frames, and loads over long strokes with stable forward and backward movement. Furthermore, a rotating shaft connects the gears on both sides, driven by a forward motor, ensuring absolute synchronicity of movement on both sides of the slide and preventing jamming, wear, or structural deformation caused by asynchrony. Simultaneously, the rollers run within guide rail A, primarily bearing vertical load and providing guidance; while the gear and rack provide the driving force. This design decomposes the force, improving motion smoothness and component lifespan.

[0072] The slide 10 is also equipped with horizontal wheels 102 on both sides, which abut against the side wall of the guide rail A16. The horizontal wheels press firmly against the side wall of the guide rail A, effectively eliminating lateral clearance between the rollers and the guide rail. This prevents lateral swaying or impact on the slide when the robot moves in all directions or is subjected to lateral forces (such as starting, braking, or turning), ensuring high rigidity and smooth operation of the entire upper structure during forward and backward movement, and providing a foundation for precise positioning.

[0073] The gantry assembly 2 is provided with a guide rail B20, and the lifting frame 3 is provided with guide wheels on both sides. The guide wheels are set in the guide rail B20. The gantry assembly 2 is also provided with a lifting cylinder 21. The piston rod of the lifting cylinder 21 is fixed with a support wheel 22. The support wheel 22 is provided with a chain 23. The two ends of the chain 23 are fixed to the gantry assembly 2 and the lifting frame 3 respectively. The length of the chain 23 on both sides of the support wheel 22 is changed by the movement of the lifting cylinder 21, thereby causing the lifting frame 3 to be raised or lowered.

[0074] The aforementioned structure employs a fixed pulley system consisting of a chain and support wheels. The linear stroke of the lifting cylinder piston rod is converted into a change in the length of the chain on both sides via the support wheels, making the movement stroke of the lifting frame approximately twice that of the cylinder. This allows for a larger lifting height using cylinders with shorter strokes, resulting in a more compact equipment structure. Furthermore, the symmetrical arrangement of the chain converts the thrust of the lifting cylinder into a balanced pulling force on both sides of the lifting frame, preventing uneven loading and ensuring the stability of its vertical movement. In addition, the chain is flexible yet possesses extremely high tensile strength. Even in extreme situations (such as mechanical jamming), the chain provides a certain degree of safety buffer, and its failure mode is typically extension rather than instantaneous breakage, making it safer than purely rigid linkages.

[0075] There are two lifting cylinders 21, one of which has an auxiliary wheel 24 on one side of its support wheel 22. The auxiliary wheel 24 is also equipped with a chain 23 connecting the lifting frame 3 and the gantry assembly 2. The auxiliary wheel and the additional chain increase the lifting points of the lifting frame, further distributing the load and making the lifting process smoother.

[0076] A rack B32 is fixed to the lifting frame 3, and a translation motor 42 is fixed to the translation plate 4. A gear is fixed to the output shaft of the translation motor 42. Through the meshing of the gear and the rack B32, the translation plate 4 moves laterally on the lifting frame 3. Guide rails C31 are respectively provided at the upper and lower ends of the lifting frame 3, and L-shaped connecting plates 40 are respectively fixed at the upper and lower ends of the translation plate 4. Translation wheels 41 are provided on the connecting plates 40 and are disposed in the guide rails C31.

[0077] The aforementioned structure enables precise lateral fine-tuning. Utilizing a gear and rack transmission system (B), it ensures high precision and responsiveness in the lateral movement of the translation plate, crucial for accurate alignment between the forks and the pallet holes. The upper and lower L-shaped connecting plates and the translation wheels clamp the guide rail C, forming a "wrap-around" guide structure. This design effectively resists the enormous overturning moment generated by the forward shift of the fork carriage and load center of gravity, ensuring that the translation plate does not pitch or deflect during lateral movement under load, maintaining extremely high rigidity.

[0078] The fork carriage 7 is fixed to the rotating block 6, which is equipped with a worm gear. The drive assembly consists of a motor and a worm connected to the motor's output shaft. The worm gear and worm wheel work together to drive the rotating block 6 to rotate. A worm gear drive is employed. While worms drive worm wheels easily, reverse transmission (worm wheel driving worm) is very difficult, and the worm gear has a natural self-locking characteristic. This means that once the motor stops driving, the rotation angle of the fork carriage and its load will be firmly locked, preventing accidental rotation due to the load's gravity or inertia. This is crucial for maintaining safe posture during the pouring of molten metal.

[0079] Worm gear mechanisms can achieve a large reduction ratio in a compact space, thus obtaining a large enough driving torque to rotate heavy loads with a small motor output.

[0080] The robot of this invention systematically solves the core problems of poor flexibility, low alignment accuracy, high human risk, and low automation in molten metal handling and dumping operations through an omnidirectional mobile chassis, a four-degree-of-freedom high-rigidity forklift, self-locking and synchronization design of key kinematic pairs, and closed-loop control with multi-level sensor fusion, forming a safe, efficient, and intelligent dedicated automation solution.

[0081] This invention, by setting up a central controller, allows the robot to be operated manually or switched to fully automatic operation via a host computer scheduling system, significantly improving operational flexibility and system applicability. Simultaneously, the modified vehicle body meets the stringent requirements for strength and stability under high-temperature and heavy-load conditions, ensuring inherent safety during operation. The innovative use of an omnidirectional mobile chassis enables the robot to move straight, laterally, and turn with zero radius within the confined space of a factory floor. It can accurately reach the predetermined workstation beside the holding furnace without repeatedly entering and exiting passageways to adjust its posture, greatly improving mobility and operational efficiency in densely packed equipment environments. By arranging multiple sets of LiDARs with different functions on the vehicle body and mast, the system not only achieves high-precision (navigation accuracy up to ±2cm) autonomous navigation and dynamic obstacle avoidance, but also utilizes multi-line LiDAR for vehicle posture recognition, combined with closed-loop feedback control of the fork posture using a wire encoder, achieving millimeter-level automatic and precise docking and forking, laying the foundation for subsequent stable tipping. This specialized forklift mechanism integrates forward / backward movement, side movement, lifting, and tilting functions, enabling automated operation of the entire process from container pickup, transfer, and tilting. Specifically designed for the high-risk tilting stage, the system incorporates an active safety system including safety detection, threshold judgment, and emergency reset functions. When out-of-range positioning or unexpected deviation is detected, a manual emergency stop reset can be triggered, quickly restoring the forks to a safe zero position, effectively preventing molten metal splashing or spillage and ensuring equipment and personnel safety. From the start of the task, the system rigorously executes a closed-loop control process encompassing safety self-checks, position recognition, adaptive adjustment, stable load recovery, precise movement, controlled tilting, and anomaly handling. This method is logically rigorous, employing multiple safety checks and fault-tolerant mechanisms to ensure high reliability, high repeatability, and process consistency in high-temperature molten metal transfer and tilting operations in an unmanned environment.

[0082] In the description of this specification, 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.

[0083] 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 without departing from the principles and spirit of the present invention. Any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A control method for an omnidirectional mobile molten metal automatic dumping robot, characterized in that: The robot includes a vehicle body (1), a gantry assembly (2), a lifting frame (3), a translation plate (4), and a forklift (7). The vehicle body (1) includes a rigid frame and steering wheel modules. Four steering wheel modules are respectively located at the four corners of the rigid frame. A main controller is also provided on the vehicle body (1). The gantry assembly (2) is slidably mounted on the vehicle body (1) via a slide (10). The slide (10) is also provided with a forward motor (15) that drives the slide (10) to move back and forth. The lifting frame (3) is slidably mounted at the front of the gantry assembly (2). The gantry assembly (2) is also provided with a lifting cylinder (21) for driving the lifting frame (3). The translation plate (4) is slidably mounted on the lifting frame (3). The fork carriage (7) is rotatably mounted on the front of the translation plate (4) via a rotating block (6). The translation plate (4) is also equipped with a translation motor (42) for driving the translation plate (4) to move laterally and a drive assembly (5) for driving the rotating block (6) to rotate. One end of the vehicle body (1) is also equipped with a navigation laser radar (11) and a blind spot laser radar (12). The two corners of the other end of the vehicle body (1) are also equipped with bottom laser radars (13). The mast assembly (2) is equipped with four sets of wire encoders for detecting the lateral displacement distance, lifting distance, front-rear distance and rotation angle of the fork carriage (7). The fork carriage (7) is also equipped with a multi-line laser radar. The specific steps are as follows: When picking up goods: The main controller on the vehicle body receives the task issued by the scheduling system. Before the vehicle body (1) starts, it first performs a safety check to see if the fork carriage (1) is in the safe area in terms of up and down, left and right, front and back, and tilt. If it is not in the safe area, it is first adjusted to the safe area, and then the vehicle body (1) is controlled to move forward to the corresponding position. After arriving at the ready picking point, the multi-line laser radar installed under the fork carriage (7) is used to identify the position of the carrier end face in the corresponding warehouse. The position is judged according to the identification result. If it exceeds the safety adjustment threshold, a warning is reported. The system intervenes and sends a task to the vehicle body (1) to return to the standby point. The vehicle waits at the standby point to receive the task again. The position is adjusted within the safety adjustment threshold range. The fork carriage (7) is adjusted in angle, height, left and right position using a pull-wire encoder so that the fork carriage (7) is within the safety threshold that can enter the carrier hole. After picking up the goods, it rises to the safe distance. Before the robot accepts the next moving task, the raised fork carriage (7) and the load are completely recovered to the vehicle body's stable area. During unloading: The main controller on the vehicle body (1) receives the dispatching instruction and controls the vehicle body (1) to move forward to the ready loading position. Before the vehicle body (1) starts, the safety self-check of the fork carriage (7) is also performed. The vehicle body (1) moves forward to the ready unloading point, and then controls the vehicle body (1) to slowly enter the warehouse area. The fork carriage (7) is controlled to extend forward and descend to the height that can enter the cargo area, ready to be placed. The vehicle body (1) continues to be controlled to creep at a very low speed. Then the fork carriage (7) descends to detach from the cargo, and then the reset action is performed. The vehicle drives away. During tipping: The main controller of the vehicle body (1) receives the operation instructions issued by the scheduling system, controls the robot to move to the predetermined work position on the side of the target heat preservation furnace, then controls the fork carriage (7) to be raised to the preset tipping height, and controls the fork carriage (7) to perform lateral movement so that the metal liquid container is in contact with the pouring port of the heat preservation furnace; then, controls the fork carriage (7) to rotate around its axis, drives the container to tilt, and injects the molten metal into the heat preservation furnace along the predetermined trajectory.

2. The control method for an omnidirectional mobile molten metal automatic dumping robot according to claim 1, characterized in that: During the pickup process, the vehicle body (1) navigates to the pre-pickup point of the target station through the fusion positioning system of navigation lidar (11) and blind spot lidar (12), and before entering the point, controls the fork carriage (7) to be raised to the recognition height.

3. The control method for an omnidirectional mobile molten metal automatic dumping robot according to claim 2, characterized in that: In the picking process, after the fork carriage (7) is raised to the identification height, the vehicle detection signal is triggered and the multi-line laser radar is started. The multi-line laser radar scans the front face of the vehicle, and the point cloud is processed by the algorithm to extract the center points of the two support legs. The lateral deviation y and yaw angle deviation θ of the vehicle relative to the vehicle body (1) are calculated. It is determined whether the deviation is within the threshold range. If it exceeds the threshold, it is determined to be "abnormal posture", and a warning log is reported. The dispatch system intervenes and issues an instruction to make the vehicle return to the standby point. If it is within the threshold, the automatic adjustment process will begin.

4. The control method for an omnidirectional mobile molten metal automatic dumping robot according to claim 3, characterized in that: The automatic position adjustment and retrieval process is as follows: Position adjustment: The main controller calculates the amount of adjustment required based on the identified lateral deviation, and adjusts the position of the vehicle body to align the target fork carriage (7) with the carrier insertion hole; Fine-tuning of heading: Controlling the vehicle to make a small-angle spin to correct the heading angle deviation θ. Height Confirmation: Confirm the height of the fork carriage (7) is within the range where it can be safely inserted into the carrier hole using a pull-wire encoder; Lateral shift pickup: The main controller controls the target fork carriage (7) to shift laterally according to the identified required lateral shift distance, and uses the collision plate on the fork carriage (7) as an auxiliary judgment for pickup to be in place; Lifting and Resetting: After the goods are successfully picked up, the fork carriage (7) is raised to a safe height, and then the vehicle body (1) is moved back to a safe position. The fork carriage (7) will be returned to the predetermined position and the vehicle will leave the warehouse.

5. The control method for an omnidirectional mobile molten metal automatic dumping robot according to claim 1, characterized in that: During the tilting process, the main controller controls the fork carriage (7) to rotate around the axis, driving the container to tilt for the first time, injecting some molten metal into the furnace, and then maintaining the tilt angle for several seconds. After the first tilt is completed, the fork carriage (7) is raised and then slightly adjusted laterally to the next target position. The controller controls the fork carriage (7) to perform a second rotation, completely emptying the remaining molten metal in the container, and then maintaining the posture for several seconds to ensure no residue remains.

6. The control method for an omnidirectional mobile molten metal automatic dumping robot according to claim 1, characterized in that: The slide (10) is provided with rollers (101) on both sides. The middle part of the vehicle body (1) is provided with a recess to accommodate the slide (10). The two sides of the recess are provided with guide rails A (16). The rollers (101) are set in the guide rails A (16). The lower part of the guide rails A (16) is also provided with racks A (17). The slide (10) is also provided with a rotating shaft (151). The two ends of the rotating shaft (151) are respectively fixed with gears A (152) that mesh with racks A (17). The forward motor (15) drives the rotating shaft (151) to rotate. Through the cooperation of gears A (152) and racks A (17), the slide (10) moves.

7. The control method for an omnidirectional mobile molten metal automatic dumping robot according to claim 1, characterized in that: The gantry assembly (2) is provided with a guide rail B (20), and the lifting frame (3) is provided with guide wheels on both sides. The guide wheels are set in the guide rail B (20). The gantry assembly (2) is also provided with a lifting cylinder (21) standing upright. The piston rod of the lifting cylinder (21) is fixed with a support wheel (22). The support wheel (22) is provided with a chain (23). The two ends of the chain (23) are fixed to the gantry assembly (2) and the lifting frame (3) respectively. The length of the chain (23) on both sides of the support wheel (22) is changed by the movement of the lifting cylinder (21), thereby causing the lifting frame (3) to be raised or lowered.

8. The control method for an omnidirectional mobile molten metal automatic dumping robot according to claim 1, characterized in that: The lifting frame (3) is also fixed with a rack B (32), and the translation plate (4) is fixed with a translation motor (42). The output shaft of the translation motor (42) is fixed with a gear. Through the meshing of the gear and the rack B (32), the translation plate (4) moves laterally on the lifting frame (3).

9. The control method for an omnidirectional mobile molten metal automatic dumping robot according to claim 1, characterized in that: The upper and lower ends of the lifting frame (3) are respectively provided with guide rails C (31), and the upper and lower ends of the translation plate (4) are respectively fixed with L-shaped connecting plates (40). The connecting plate (40) is provided with translation wheels (41), and the translation wheels (41) are set in the guide rails C (31).

10. The control method for an omnidirectional mobile molten metal automatic dumping robot according to claim 1, characterized in that: The fork carriage (7) is fixed to the rotating block (6). The rotating block (6) is provided with a worm gear. The driving component is a motor and a worm connected to the output shaft of the motor. The worm gear and worm cooperate to drive the rotating block (6) to rotate.

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