Stacker-reclaimer multi-process unified control method and system based on dynamic obstacle avoidance rule

Abstract

The invention relates to the technical field of bulk material storage, in particular to a stacker-reclaimer multi-process unified control method and system based on a dynamic obstacle avoidance rule. The method comprises the following steps: receiving configuration information of stockpiling operation, and generating a rule set and a unified parameter set according to the configuration information; the stacker-reclaimer is controlled to execute stacking operation based on the rule set and the unified parameter set; performing decision judgment according to the operation state, the environment state and the rule set, and if a preset triggering condition is met, generating an equipment control instruction; the equipment control instruction is executed, and the stacker-reclaimer is controlled to execute corresponding actions; and the stacker-reclaimer is controlled to repeatedly execute the stacking operation until the stacking operation is completed, and unified control over multiple processes of the stacker-reclaimer is achieved. According to the method, the environment is sensed in real time through the operable space parameters, intelligent decision making is conducted through the path planning engine, the method can dynamically adapt to the actual working condition of the stockyard, the stockpiling process has high fault-tolerant capacity and adaptability, and the reliability and precision of operation and the utilization rate of the stockyard are greatly improved.

Description

Technical Field

[0001] This invention relates to the field of bulk material storage technology, and in particular to a unified control method and system for multiple processes of stacker-reclaimers based on dynamic obstacle avoidance rules. Background Technology

[0002] In the field of bulk material storage, stacker-reclaimers are core equipment used for the storage and retrieval of bulk materials such as coal and ore. To meet the needs of homogenization and classified storage, the industry has developed various stacking processes, such as chevron stacking, cone stacking, and strata stacking. Although these processes differ in form, their automated control can essentially be reduced to two basic modes: continuous stacking and fixed-point stacking.

[0003] Currently, the mainstream technical solution for automating the above-mentioned processes is to design, write, and debug a dedicated control program independently for each specific stacking process, and even for different variations of the same process. For example, herringbone stacking (continuous mode) requires writing a set of logic for real-time reversal, while conical stacking (fixed-point mode) requires developing another set of logic for monitoring height and step size. The control kernels for these two modes are completely different and cannot be reused.

[0004] The traditional paradigm of one process and one procedure has inherent and insurmountable structural flaws: (1) The system is highly redundant and the development and maintenance costs are high: Each new process means that a new program has to be developed from scratch, resulting in the control system being filled with code "chimneys" that have the same functions but are incompatible with each other. This not only makes the software bloated, but also makes the maintenance, upgrading and troubleshooting of the system extremely complicated, requiring technicians to master multiple sets of logic at the same time, which significantly increases the cost of the whole life cycle.

[0005] (2) Insufficient flexibility and scalability: The control logic is hard-coded in the program. When operational requirements change, such as adjusting process parameters, switching modes, or introducing new processes, the underlying program code must be modified or even redeveloped, making it impossible to achieve a quick response through simple configuration. As a result, the system is rigid and cannot adapt to the increasingly frequent process change requirements of modern bulk material handling stations.

[0006] (3) Low level of intelligence and lack of adaptability: The existing solution relies heavily on preset and fixed path programs. The system cannot perceive or understand the dynamic changes in its working environment (such as the precise shape of the existing material pile), and therefore cannot perform real-time and intelligent path planning and decision-making to deal with emergencies. Its fault tolerance, adaptability and reliability are fundamentally constrained.

[0007] Therefore, there is a need to provide a highly universal, intelligent and scalable control architecture that unifies various heterogeneous material stacking processes into a simple perception-decision-action loop through multi-layered technological innovation. Summary of the Invention

[0008] To address the aforementioned technical problems, this invention provides a unified control method and system for stacker-reclaimers across multiple processes based on dynamic obstacle avoidance rules. The method receives configuration information and generates or invokes a rule set accordingly; the control equipment executes stacking operations based on the rule set and a unified parameter set; the operation and environmental status are acquired in real time; and a path planning engine makes decisions based on the status and rule set, generating equipment control commands to adapt to multiple processes through parameter configuration.

[0009] The technical means employed in this invention are as follows: A unified control method for multiple processes of a stacker-reclaimer based on dynamic obstacle avoidance rules includes: receiving configuration information for a stacking operation and generating a rule set and a unified parameter set based on the configuration information; controlling the stacker-reclaimer to execute the stacking operation based on the rule set and the unified parameter set; acquiring the operation status and environmental status of the stacker-reclaimer in real time; making decisions based on the operation status, environmental status, and the rule set, and generating equipment control instructions if predetermined triggering conditions are met; executing the equipment control instructions to control the stacker-reclaimer to perform corresponding actions; and controlling the stacker-reclaimer to repeatedly execute the stacking operation until the stacking operation is completed, thereby achieving unified control of multiple processes of the stacker-reclaimer.

[0010] Furthermore, obtaining the configuration information includes: a selection instruction for a target template from a plurality of predefined process templates, the process template being associated with the rule set; the rule set contains at least one rule for defining the device behavior logic; The rule set is generated by combining selection instructions for multiple atomic rules in the atomic rule library; the atomic rule library contains multiple atomic rules, each atomic rule corresponding to a basic material stacking control logic and control target.

[0011] Furthermore, the unified parameter set includes: basic material stacking parameters for defining the spatial range of the stacking operation; layer sequence target height parameters for defining the stacking height target of each layer; operable space parameters for dynamically characterizing the operable space; path vector parameters for defining the equipment movement path; and other parameters for defining the stacking operation target.

[0012] Furthermore, the target height parameter of the layer sequence is an ordered array, and the stacking mode is uniformly controlled by the positive and negative attributes of the array element values ​​in the ordered array; when the array element value is positive, the fixed-point stacking mode is enabled to reach the target height defined by the array element value and trigger stepping; when the array element value is negative, the continuous stacking mode is enabled, and the forward obstruction perceived in real time is used as the condition for triggering turning.

[0013] Furthermore, the operable space parameter is a dynamically updated graph data structure used to characterize the reachability of equipment vertices at each height level within the stacking area; the maintenance of the operable space parameter specifically includes: recording the positions of equipment vertices that have completed stacking; periodically reconstructing the closed boundary of the occupied space based on the fixed position of the equipment; updating the availability status identifier of all equipment vertices according to the closed boundary, and marking vertices located within the closed boundary as unavailable.

[0014] Furthermore, the decision-making process specifically includes: receiving the strategy intent output by the rule set; and, based on the strategy intent and the environmental state, calculating the equipment control command for controlling the stacker-reclaimer's actions through collision detection and decision logic.

[0015] Furthermore, the equipment control commands include the target position of the equipment movement, the movement speed, the rotation angle, and the pitch angle.

[0016] This invention also provides a unified control system for a stacker-reclaimer with multiple processes based on dynamic obstacle avoidance rules, specifically including: a rule base, a decision module, and a control module, wherein: the rule base is used to store a unified parameter set and a rule set; the decision module is used to make decisions and judgments during the stacking operation based on the real-time acquired operation status, environmental status, and the rule set loaded from the rule base, and to generate equipment control instructions when trigger conditions are met; the control module is used to execute the equipment control instructions to control the stacker-reclaimer to perform corresponding actions.

[0017] Compared with the prior art, the present invention has the following advantages: This invention creates a three-tiered architecture consisting of a parameterized process target layer, a perception and execution layer, and a decision-making and planning layer. It replaces multiple independent control programs with a unified core control logic (perception-decision-action loop). In particular, by creatively differentiating and unifying the two basic control modes—continuous and fixed-point—through the positive and negative values ​​of the hierarchical target height parameter, it fundamentally eliminates system redundancy and achieves a high degree of reuse of hardware resources and software architecture.

[0018] This invention eliminates the reliance on pre-defined process procedures. Users can define or create new material stacking processes by configuring parameters and combining atomic rules. Adding a new process or modifying process parameters only requires configuring and expanding the rule base, without modifying the core control code, greatly reducing the development, debugging, and maintenance costs and technical difficulties in the later stages.

[0019] This invention's system senses the environment in real time through operable spatial parameters and makes intelligent decisions through a path planning engine. It can dynamically adapt to the actual working conditions of the material yard (such as the shape of the existing stockpile and boundary constraints) rather than rigidly executing a preset path. This gives the stockpiling process a high degree of fault tolerance and adaptability, significantly improving the reliability, accuracy, and utilization rate of the material yard.

[0020] The method of this invention completely liberates operators from complex manual mode switching, process debugging, and height judgment. By simply selecting the process and starting or combining rules and starting, fully automatic or even intelligent stacking operations can be completed. This is an important milestone in the control of stacker-reclaimers, moving from program automation to intelligent decision-making. Attached Figure Description

[0021] 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 some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a framework diagram of the unified control method for multiple processes of a stacker-reclaimer based on dynamic obstacle avoidance rules in this invention.

[0023] Figure 2 This is a flowchart of the multi-process unified control method for stacker-reclaimers based on dynamic obstacle avoidance rules in this invention.

[0024] Figure 3 This is a schematic diagram illustrating the collaborative relationship of the core parameters in this invention.

[0025] Figure 4 This is a schematic diagram illustrating the dynamic evolution of the operable space parameters in this invention.

[0026] Figure 5 This is a schematic diagram illustrating the evolution of path vector sequence parameters in this invention.

[0027] Figure 6 This is a flowchart of the internal decision-making logic of the path planning engine in this invention.

[0028] Figure 7 This is a schematic diagram of rule combination and template application in the atomic rule base of this invention. Detailed Implementation

[0029] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0030] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] 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 scope of exemplary embodiments according to the invention. 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.

[0032] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0033] like Figure 1As shown, the present invention provides a unified control method for multiple processes of a stacker-reclaimer based on dynamic obstacle avoidance rules, including: receiving configuration information of stacking operations, and generating a rule set and a unified parameter set according to the configuration information; in a preferred embodiment of the present invention, the acquisition of configuration information includes: a selection instruction for a target template from a plurality of predefined process templates, wherein the process template is associated with the rule set; the rule set contains at least one rule for defining the behavior logic of the equipment.

[0034] The rule set is generated by combining selection instructions from multiple atomic rules in the atomic rule library; the atomic rule library contains multiple atomic rules, each atomic rule corresponding to a basic material stacking control logic and control target.

[0035] This invention abandons the traditional process-procedure model, deconstructing the process into atomized rules (such as rule-based fixed-point material stacking, rule-based vertical priority, and rule-based height-based material replenishment). The system can construct any new process or replenishment strategy by freely combining these atomic rules, achieving unlimited flexibility and scalability.

[0036] The stacker-reclaimer is controlled to perform stacking operations based on a rule set and a unified parameter set. In a preferred embodiment of the present invention, the unified parameter set includes: basic material stacking parameters for defining the spatial range of the stacking operation; layer sequence target height parameters for defining the stacking height target of each layer; operable space parameters for dynamically characterizing the operable space; path vector parameters for defining the equipment movement path; and other parameters for defining the stacking operation target.

[0037] In a preferred embodiment of this invention, the stacking target height parameter is an ordered array. The stacking mode is uniformly controlled by the positive or negative attribute of the array element values. When the array element value is positive, a fixed-point stacking mode is activated to reach the target height defined by the array element value, triggering stepping. When the array element value is negative, a continuous stacking mode is activated, using real-time detected obstacles ahead as the condition for triggering turning. Through different array assignment strategies, the stacking target height parameter can flexibly adapt to the stacking height requirements of various processes such as conical, herringbone, and layered stacking.

[0038] In a preferred embodiment of this invention, the operable space parameters are dynamically updated graph data structures used to characterize the reachability of equipment vertices at each height level within the stacking area. Maintaining the operable space parameters specifically includes: recording the positions of equipment vertices that have completed stacking; periodically reconstructing the closed boundaries of occupied spaces based on the fixed positions of the equipment; and updating the availability status identifiers of all equipment vertices according to the closed boundaries, marking vertices within the closed boundaries as unavailable. By constructing a basic boundary for material stacking, a closed polygon defined by the coordinates of ground vertices is used to uniquely and forcibly limit the physical scope of the stacking operation in space, ensuring that all operations do not exceed the predetermined area.

[0039] In implementation, the operable space parameters for each height level include the following data structure: vertex_set: Used to store and manage the positions and states of all planned and executed stacking operations of the equipment vertices. Each vertex contains its horizontal coordinates (X,Y) and a boolean status flag is_occupied (True indicates that the stacking of the point has been completed, False indicates that the stacking of the point is planned but has not yet been executed).

[0040] convex hull: A computational geometry tool consisting of a sequence of coordinate points, dynamically generated from the set of already stacked points in vertex_set where is_occupied=True. This convex hull defines the maximum convex boundary formed by the currently stacked area, and its interior space represents the theoretically largest potential area for further stacking operations.

[0041] By leveraging the combined effects of parameters, clear operational objectives and boundaries were defined for the system across both spatial and vertical dimensions, fundamentally resolving the "why rotate" question and ensuring the controllability and purposefulness of the entire process. The parameter collaboration and decision-making process is as follows: The path planning engine first uses convex_hull for coarse-grained spatial feasibility screening: it quickly determines whether candidate points are located inside the convex hull using computational geometry algorithms (such as ray casting), and only points that pass the screening are considered potential targets.

[0042] The engine then queries the vertex_set to perform fine-grained state availability checks: excluding points from potential targets whose state is already is_occupied=True (occupied).

[0043] Through the aforementioned two-level screening mechanism, the system can efficiently select a significantly reduced set of spatially feasible candidate points from numerous candidates. This mechanism ensures that all subsequent decisions are made only within the currently operable spatial range. Subsequently, the path planning engine integrates other process rules (such as longitudinal priority and efficiency optimization) to ultimately calculate a unique equipment movement command from this candidate set. The convex hull is dynamically updated based on the already stockpiled area, ensuring the real-time nature and accuracy of the spatial information used by all decision-making levels. The existence of this model solves the core problem of "where is the obstruction," providing unprecedented and precise environmental perception capabilities for intelligent decision-making.

[0044] The system acquires the real-time operating status and environmental status of the stacker-reclaimer; makes decisions based on the operating status, environmental status, and rule set; and generates equipment control commands if predetermined triggering conditions are met. In a preferred embodiment of the invention, the decision-making process specifically includes: receiving the strategy intent output by the rule set; and calculating the equipment control commands for controlling the actions of the stacker-reclaimer based on the strategy intent and environmental status through collision detection and decision logic.

[0045] In a specific implementation, as a preferred embodiment of the present invention, the equipment control commands include the target position of the equipment movement, the movement speed, the rotation angle, and the pitch angle.

[0046] Execute equipment control commands to control the stacker-reclaimer to perform corresponding actions; control the stacker-reclaimer to repeatedly perform stacking operations until the stacking operation is completed, thereby achieving unified control of multiple processes of the stacker-reclaimer.

[0047] The path planning engine is the system's brain, receiving strategic intents from atomic rules (such as requesting a step or prioritizing vertical movement) and querying the environmental status provided by operable space parameters in real time. Through built-in decision logic (such as priority judgment, collision detection, and alternative solution generation), it transforms abstract intents into specific, unambiguous device action commands (such as moving +2.5 meters vertically). The collaborative work between the rule set and the path planning engine perfectly solves the "how to turn" problem, achieving intelligent and automated decision-making.

[0048] This invention also provides a unified control system for a stacker-reclaimer with multiple processes based on dynamic obstacle avoidance rules, specifically including: a rule base, a decision module, and a control module, wherein: the rule base is used to store a unified parameter set and a rule set; the decision module is used to make decisions and judgments during the stacking operation based on the real-time acquired operation status, environmental status, and the rule set loaded from the rule base, and to generate equipment control instructions when trigger conditions are met; the control module is used to execute the equipment control instructions to control the stacker-reclaimer to perform corresponding actions.

[0049] Example This embodiment uses the common conical multi-row stacking process in a bulk material yard as an example to demonstrate the specific application of this control system. The goal of this process is to stack multiple rows of conical stockpiles along the width-length direction within a designated rectangular stockyard area, requiring the stockpiles to be neatly arranged, uniform in height, and not exceeding predetermined boundaries.

[0050] The overall structure of the stacker-reclaimer multi-process unified control system based on this embodiment is as follows: Figure 1 As shown, its core includes a rule base, a decision module (containing a path planning engine), and a control module, forming a complete "perception-decision-action" closed loop.

[0051] 1. System initialization and parameter configuration The operator accesses the "Process Configuration" page through the HMI (Human Machine Interface), clicks the "Create Process" button, and the system then provides a rule selection interface and parameter configuration panel.

[0052] (1) Rule selection and combination: The operator selects the following atomic rules sequentially from the system's atomic rule library to combine and define the behavioral logic of the new process: Fixed-point material stacking: Specifies the use of fixed-point material stacking mode.

[0053] Rule-based initial cone stacking: Defines the initial stage of material stacking. The equipment cantilever starts working from a preset low height point and gradually increases the height of the cantilever during the stacking process according to the formation of the material pile until the target height of the layer is reached.

[0054] Longitudinal priority rule: Specifies that stockpiling and moving should be prioritized along the length of the stockyard.

[0055] Multiple vertical arrangement rules: Specifies that multiple columns of materials need to be stacked.

[0056] Regular column distribution: Specifies that multiple columns of material piles are evenly distributed along the width of the material yard.

[0057] Extended replenishment rule: Specifies that a strategy of extending the length of the material pile should be adopted in subsequent replenishment operations.

[0058] After making the selection, the operator clicks the "Generate Process" button.

[0059] (2) Process simulation and verification: After receiving the instruction, the path planning engine calls the default parameters according to the combination logic of the above rules, and calculates and dynamically displays the three-dimensional forming process of the example material pile generated according to these rules in real time in the simulation interface. The example material pile is evenly distributed in multiple columns and can be extended at the end.

[0060] The operator reviews the simulation results and confirms that the process meets the expected "conical multi-row stacking" technology. They then click the "Output Process" button to confirm.

[0061] (3) Process storage and naming: The system saves the rule combination to the rule base and automatically names it as stacking process n (n is the serial number). The operator can add an intuitive custom name (such as "Standard Conical Multi-column - Extendable") and process description (such as "Used for stacking evenly distributed conical columns in a rectangular area, supporting subsequent lengthening and replenishment") to the process, thereby completing the creation of the new process.

[0062] (4) Parameter set loading: When the operator selects to run this new process on the main interface, the system loads the corresponding rule set from the rule base and loads or generates the following unified parameter set: It should be noted that the unified parameter set is not static. The system's built-in parameter management module monitors the currently active rule set and its parameter sequence in real time.

[0063] Dynamic loading: When rules are added to or removed from the rule set, the system will automatically load or unload the specific parameters that the rule depends on and add or remove them from the management scope of the unified parameter set.

[0064] Conflict detection and user confirmation: During the stacking operation, if a parameter modification request (whether from automatic system adjustment or manual input) has a potential conflict with the current operation status (such as attempting to set a new starting point in an already stacked area), the system will not execute it immediately. Instead, it will pause the current operation, trigger the conflict diagnosis program, and pop up a confirmation dialog box through the HMI interface to inform the operator of the conflict content and the consequences of the modification, and request the final instruction.

[0065] This dynamic parameter management mechanism ensures that the system, while possessing high flexibility, will never execute dangerous or contradictory operations, thereby guaranteeing the safety and reliability of the operation.

[0066] Operator input parameters: These must be entered based on the specific on-site conditions of this operation. For example: foundation_boundary (material stacking foundation boundary): [10,300,10,400,60,400,60,300].

[0067] This parameter requires the operator to input the actual geodetic coordinates of the material yard area for this operation. This coordinate sequence defines a rectangular material yard area that is 50 meters long and 100 meters wide. Except for special rules (such as rules for lengthening material replenishment or rules for widening material replenishment), all material stacking operations are restricted to this area.

[0068] lift_step: 1.0.

[0069] This parameter defines the fixed height increment of the stack arm each time it is raised when the "Initial Cone Stacking" rule is executed.

[0070] min_boom_distance (minimum cantilever drop): 2.0.

[0071] This parameter defines the minimum vertical distance that must be maintained between the discharge head and the top of the stockpile, used to control dust.

[0072] first_stack_point: (38, 378) tuple type. This parameter defines the initial horizontal geodetic coordinates at which the first cone-shaped stack begins to be stacked in the "regular start cone stacking" process.

[0073] The process of determining this parameter reflects the system's intelligence and interactivity. After loading the rule set, the parameter management module automatically checks the completeness of its parameters. When it detects that the rule's starting cone stack is activated but the `first_stack_point` parameter has not yet been assigned a value, the system automatically executes the following steps: Calculation and Highlighting Recommendation: Based on the foundation_boundary and the current device location, the system calculates an optimized default first stockpile point using a built-in algorithm and highlights it in the top view of the stockyard in the HMI interface.

[0074] User confirmation and fine-tuning: The system then pops up the first stockpile point selection interface, where the operator can intuitively drag or click the highlighted markers to move them to the desired starting position. This process eliminates the need for manual coordinate input, greatly simplifying the operation.

[0075] Automatic precise assignment: After operator confirmation, the system will automatically capture the precise coordinates of the marker and calculate the optimized coordinates. The user can select one set of values ​​and assign it to the first_stack_point parameter.

[0076] This process ensures the accuracy of key parameters while giving operators ample flexibility, achieving a perfect combination of intelligent recommendation and human decision-making. target_height_array (stratified target height sequence): [16.0,16.0,16.0,16.0,16.0].

[0077] This parameter is an ordered array. When all its elements are positive, it indicates that the fixed-point stacking mode is enabled, and the target stacking height for each layer is 16.0 meters. The system will monitor the material height in real time and trigger a stepping action when this target is reached.

[0078] pathing_vector_sequence (path vector sequence): [2,2,5).

[0079] The path vector sequence is an ordered array whose data structure and semantics are uniquely determined by the currently active combination of rules.

[0080] Under the rule combinations applied in this embodiment (rule-based fixed-point stacking, rule-based multi-vertical arrangement, rule-based uniform vertical distribution), the meaning of this array element is as follows: The first element value of 2 indicates that the single step distance of the equipment in the length direction of the material yard is 2 meters.

[0081] The second element value 2 indicates that the single step distance of the equipment in the width direction of the material yard is 2 meters.

[0082] The third element value of 5 indicates that the material yard is divided into 5 equal columns along its width.

[0083] The parsing logic of the sequence depends on the inherent relationships between the parameters and the input order. The system automatically calculates and confirms the constraints between each parameter based on preset rule priorities. If the number of columns is set first (such as the third parameter), the system will automatically calculate and generate the step value in the width direction to achieve even division, corresponding to the even division process.

[0084] If the step value is set first (such as the second parameter), the system will automatically calculate the number of columns that can be arranged based on the total width, corresponding to the non-uniform division process.

[0085] The `pathing_vector_sequence` parameter describes the basic concept of a device path through a vector sequence, such as... Figure 5 As shown, it can define a variety of path shapes, from simple grids to complex arcs.

[0086] The system automatically generates parameters: These parameters are automatically calculated by the system based on the selected rule set and the parameters entered by the operator, using a built-in algorithm.

[0087] The operational space parameter, operational_space_graph, is a hierarchical, dynamically updated graph data structure whose core purpose is to establish a digital, queryable spatial state mapping for each height level.

[0088] Overall structure and core idea: This parameter is a hierarchical, dynamically updated data structure whose core purpose is to provide a dynamic, maximum operable convex hull boundary for each height layer. This convex hull serves as the primary geospatial basis for the path planning engine to make real-time "stacking" judgments.

[0089] This parameter is an ordered dictionary or array of objects, whose elements correspond strictly one-to-one with the stacking layers defined in target_height_array.

[0090] Key / Index: Each layer is indexed using the height value in target_height_array (e.g., 16.0) as a unique identifier.

[0091] Value: Each height value corresponds to a layer data object, which fully describes the spatial state of that height layer.

[0092] Layered data object structure: For each height layer Li, its data structure contains the following fields: layer_height: Float. The target height value corresponding to this layer.

[0093] vertex_set: Dictionary. Its core function is recording. It records the state of all planned and executed stack points (device vertices).

[0094] Data structure for each vertex: vertex_id: String or Int: A unique identifier for a vertex.

[0095] coordinates:(X,Y): The horizontal geodetic coordinates of this vertex.

[0096] is_occupied: Boolean: Status flag, True means that the material stacking at this point has been completed, False means that the material stacking at this point is planned but has not yet been executed.

[0097] convex_hull: List[(X,Y)]: Its core function is computation. It is a sequence of coordinate points, which, when connected sequentially, form a convex hull. This convex hull is the largest convex boundary formed by the currently stacked point set. Its internal space represents the theoretically largest potential region where stacking operations can still be performed.

[0098] is_layer_completed: Boolean: Flag. This flag is set to True when all planned vertices in the vertex_set are is_occupied=True.

[0099] Dynamic update mechanism: During the stockpiling operation, the system uses this data structure to make decisions in the following steps: initialization: The system generates an initial vertex set (all points is_occupied=False) based on the foundation_boundary and device parameters.

[0100] Calculate the initial convex_hull (at this point, the convex hull is the boundary of the entire material yard) based on all points of the initial vertex_set.

[0101] Decision loop (the workflow of the path planning engine): a. Generate candidate points: Generate candidate target points from the current device position in at least eight directions (such as N, NE, E, SE...) based on the step distance.

[0102] b. Convex Hull Inclusion Judgment (Primary Screening): Using algorithms such as ray casting, quickly determine which candidate points are located inside the current convex_hull. Only points located inside the convex hull proceed to the next round of screening; points outside the convex hull are directly eliminated.

[0103] c. Occupancy Status Check (Secondary Filtering): Query the vertex_set and check the is_occupied status of the candidate points that passed step b. Eliminate those points that have been marked as True (occupied).

[0104] d. Decision-making: Scenario A: After step c, candidate points are still available. The path planning engine then combines other rules (such as vertical priority) to select the optimal point and generate a movement instruction.

[0105] Scenario B: After step c, no candidate points are available. This means that all adjacent points within the convex hull region of the current point have been stacked. At this point, the path planning engine initiates jump logic (e.g., guiding the device to the starting point of the next column, or raising the cantilever to the next layer), and resets or updates the current layer's convex_hull to match the new work area.

[0106] Update mechanism: a. Record: When the stacker completes stacking at a certain vertex, the system sets the is_occupied attribute of that vertex to True.

[0107] b. Convex Hull Reconstruction: The system takes all points in vertex_set where is_occupied==True as input and recalculates convex_hull in real time or periodically. This new convex hull will be smaller than the previous one, allowing for dynamic shrinkage of the operable space.

[0108] The operational space graph is the dynamic evolution of the entire stacking process, including changes in vertex states and convex hull boundaries, such as... Figure 4 The schematic diagrams for series a, 4b, and 4c are shown below.

[0109] 2. Material stacking operation control process The overall execution flow of the method described in this invention is as follows: Figure 2 As shown. The system control module determines the rule to be executed first, "Initial Cone Stack," based on rule priority. Its control flow is as follows: (1) Alignment of stockpiled materials The system controls the stacker-reclaimer to move to the initial coordinates (X, Y) defined by the `first_stack_point` parameter, and adjusts the cantilever rotation and pitch angles to precisely position the unloading head above the predetermined starting point, completing the pre-positioning stacking setup. After alignment, the system enters a waiting state until it receives the "start stacking" command from the central control system. This separates the "alignment" and "stacking" actions, effectively adapting to the uncertain command issuance time in on-site operations.

[0110] (2) Operation at the first stockpile point (initial cone stacking) Upon receiving the stacking instruction, the system control module invokes the processing logic for the rule-based initial cone stacking.

[0111] A. Process Reconfiguration and Parameter Derivation: This rule first reconfigures the operation of the "first stockpile point" and defines it as an independent "single stockpile operation process." The system then automatically derives and configures a dedicated set of parameters based on the objectives of this sub-process. Sub-process boundary: Based on the set target material height (16.0 meters) and the material angle of repose, the system automatically calculates a theoretically square stacking area. The bottom edge of this area is aligned with or parallel to the foundation boundary of the material yard, and its size is uniquely determined by the stacking height and the angle of repose.

[0112] The positioning logic of the first_stack_point is as follows: According to rules, the system pre-places this point on a diagonal line of this theoretical square area. This geometric relationship ensures that when the stacker starts stacking from this point, its diagonal advance path naturally adapts to the square boundary, ultimately forming a standard trapezoidal stack with its bottom aligned with the yard boundary and its upper part a cone, thus maximizing the utilization of the yard space.

[0113] Sub-process layering: Based on the lift_step (lifting step distance, such as 1.0 meters) parameter, the system automatically decomposes the total height (16.0 meters) into multiple sub-layers and generates the corresponding target_height_array (such as [1.0, 2.0, ...,16.0]).

[0114] Sub-process path and space graph: Based on the temporary boundary and layering information derived above, the system automatically calculates the pathing_vector_sequence and initializes the operational_space_graph for this single-stack operation.

[0115] Beneficial effects: This mechanism of dynamically derived parameters greatly simplifies the basic programming. Developers do not need to write dedicated code for every possible starting cone shape; the system can automatically generate all the necessary control parameters based on general rules.

[0116] B. Execution and Space Maximization: The system controls the unloading head to descend to a preset low height point, begins material stacking, and executes the "Initial Cone Stacking" lifting process as described in Section 2.4.

[0117] Core advantage: The most prominent advantage of this process is that it can naturally build a standard stockpile that is approximately a combination of trapezoidal and conical shapes without the need for any special algorithms or mechanisms, thereby maximizing the utilization of stockpile space.

[0118] Core Technology: Its core mechanism lies in the collaboration between the pathing_vector_sequence and the operational_space_graph in a single-heap operation. The cantilever begins piling material at its lowest point, and triggers a stepping motion once the target height of the sub-layer is reached.

[0119] The stepping motion consists of a combination of arm raising and advance. The path planning engine is constrained by a dynamically updated operational space graph when calculating the next action.

[0120] Since forward and backward movements are blocked by the existing material (as shown in the operational_space_graph), the engine automatically selects an oblique direction (such as a 45° angle) as the only feasible advance direction based on the decision logic.

[0121] This process repeats itself, eventually naturally forming a frustum of apyramid material pile with a square base and a cone top. This shape greatly reduces the useless gaps between the conical material piles, thereby maximizing the utilization of the stockpile space.

[0122] Termination judgment and exit mechanism: During the execution of this sub-process, the system continuously monitors two key states: "material pile height" and "material boundary".

[0123] Height and boundary both achieved (standard case): When the system detects that the material height has reached the set target (16.0 meters) and the material pile boundary has expanded to the allowable range of the sub-process boundary, it determines that the initial cone stacking is complete and immediately issues "height achieved" and "boundary achieved" signals. Based on this, the control module controls the system to exit the "first material pile operation" sub-process normally and prepares to execute subsequent rules.

[0124] Reaching the boundary first, but not reaching the height (special case): If the material pile boundary reaches the allowable range of the sub-process boundary first, but the height has not yet reached 16.0 meters, the system issues a "boundary obstruction" signal. The control module will combine the current material height information to recalculate the cantilever height and drop point (e.g., appropriately raising the unloading head position), and continue piling material until the target height is finally reached. After completion, a completion signal is issued and the sub-process is exited.

[0125] First to reach height, but not yet at the boundary (special case): If the material height reaches the target of 16.0 meters first, but the material pile boundary has not yet expanded to the sub-process boundary, the system issues a "height achieved" signal. The control module will recalculate the drop point (e.g., by stepping along the current direction) and continue piling material until the material pile boundary is filled to the allowable range. After completion, a completion signal is issued and the sub-process is exited.

[0126] At this point, the "rule-starting cone stacking" process is complete.

[0127] (3) Lateral interchange stacking Once the "first stockpiling point" operation is completed, the system control module immediately initiates the longitudinal step-by-step stockpiling process based on the principles of "vertical priority" and "vertical arrangement." Its core lies in its forward-looking path planning and dynamic adjustment mechanism. Space pre-occupancy and orientation pre-calculation: Early in the operation at the "first stockpile point," the control system updates a predictive copy of the operational_space_graph based on the anticipated stockpile shape. Based on this copy, the path planning engine pre-calculates feasible advance directions. For example... Figure 5 As shown, the feasible directions are constrained to down, left, and lower left. According to the "rule of longitudinal priority", the engine uniquely selects "down" as the next advance direction from these feasible directions.

[0128] The detailed internal logic flow of the path planning engine in making such decisions is as follows: Figure 6 As shown, it includes receiving policy intent, generating candidate points, collision detection, direction trying, and finally outputting device instructions.

[0129] Dynamic coordinate distribution: When the control module receives the confirmation signal that the "first stack point" operation is completed, it immediately outputs the pre-calculated "downward" advance command to the actuator. The coordinates of the next stack point, which are distributed synchronously, are not fixed values, but are the result of automatic adjustment by the "rule-based starting cone stacking" processing logic based on the actual completion status of the previous stack point (such as the final stack boundary).

[0130] The beneficial effect of this mechanism lies in its ingenious solution to the theoretical calculation error problem caused by the uncertainty of the angle of repose of materials in bulk stockpiling. The system does not require prior knowledge of the precise angle of repose, nor does it require customized programs for each type of material. By dynamically and adaptively adjusting the next stockpiling point based on the actual spatial state after each stockpiling operation, the system can self-correct deviations in the theoretical model, thereby greatly improving the final accuracy of stockpiling operations and its adaptability to different materials, fully demonstrating the intelligence and robustness of the unified control system.

[0131] Subsequently, the system control equipment moves to the dynamically adjusted new coordinate point and calls the "Rule_Starting Cone Stacking" sub-process again. Unlike before, the system sets the stack height parameter to a total height of 16 meters and a stack number of 1, meaning it stacks to the target height in one go and begins building the second stack in this column.

[0132] This process is repeated until the (n-1)th pile in the column is completed.

[0133] For the last (nth) stockpile in this column, the system reuses the exact same layering parameters as the "first stockpile" (i.e., still stacking layers according to lift_step), thus ensuring that both the starting and ending stockpiles of this column are well-structured trapezoidal cubes. This maximizes the utilization of the stockpile space while maintaining the symmetry and aesthetics of the entire column of stockpiles.

[0134] (4) Lateral step stacking Once the last pile of the "vertical step-by-step stacking" process begins operation, the system control module will simultaneously start the pre-calculation process for the next operation point.

[0135] Directional Decision: The path planning engine, based on the rule "Multi-vertical arrangement," attempts to calculate the next stacking point in the vertical direction. After querying the predicted copy of the "operational_space_graph," the engine determines that the path point for continued vertical movement has exceeded the physical boundary defined by "foundation_boundary" or is already occupied, generating a "boundary blocked" signal. According to the established decision logic, the only feasible direction of movement becomes lateral movement "left" (or "right") to switch to the adjacent job column.

[0136] Process strategy decision: Before changing columns, the system determines the position of the new column based on the global operation progress.

[0137] If the new column is located in the middle column of the stacking area, the system will enable the standard fixed-point stacking mode for the new column, that is, call the rule_fixed-point stacking and set the target_height_array parameter to [16.0] (the number of layers is 1), and no more layer stacking will be performed to maximize the efficiency of the operation.

[0138] If the new column is located at the leftmost or outermost column of the stacking area, the system will continue to reuse the complete process logic of "vertical step-by-step stacking", that is, starting from the "first stacking point" of the column (using a layered strategy to stack trapezoidal cubes) to ensure the regularity of the shape of the boundary stack and maximize the utilization of space.

[0139] Coordinate Calculation and Execution: The engine calculates the accurate lateral offset coordinates based on the lateral step value (e.g., ΔW). Once the last stack in the current column is completed, the control module immediately outputs a lateral movement command. The equipment executes the lateral movement, precisely positioning itself to the starting stack point of the new column.

[0140] Process cycle: After the equipment is in place, the system calls the corresponding process logic (efficient standard stacking or layered stacking to ensure shape) based on the decision in step 2 to start a new cycle of operation.

[0141] This process of "horizontal column switching" and "vertical stepping" repeats until all columns of material are stacked, ultimately forming a multi-column material stack array with high internal efficiency and regular boundaries.

[0142] (5) Extended feeding stacking Once the last pile within the planned area is completed, if the system detects that there is still material remaining to be stored, it will automatically activate "rule extension replenishment".

[0143] Parameter Adjustment and Logic Reuse: The core operation of this rule is to dynamically expand the length of the original working area, with the expansion increment being a longitudinal advance value (e.g., 2.0 meters). Once the rule monitoring module detects that the `foundation_boundary` parameter has been automatically updated, it immediately notifies the control module. The control module does not need to call any new process rules; instead, it directly re-executes the existing logic for longitudinal step-by-step stacking and transverse reversing stacking based on the new, expanded boundary parameters, calculating a series of new stacking points.

[0144] Execution process: The execution process is as follows: At the end of the completed material pile, the equipment performs a stacking operation along the longitudinal direction in a whole row (i.e., a column of a pile). This column contains multiple stacking points, and its behavior is completely consistent with that of the transverse stacking, which is actually an extension of the longitudinal boundary.

[0145] Core Advantages and Unity: This process creatively demonstrates that lateral reordering and vertical extension are unified in underlying logic. Both can be abstracted as expanding the boundary in one dimension of space and reusing the stacking logic in the other dimension. Based on this unity, the system does not need to develop separate dedicated rules for lateral stacking or extended replenishment. It only needs to adjust the basic parameters through rules to automatically drive the original core logic of vertical stacking to handle the new spatial pattern, greatly reducing code redundancy and demonstrating the powerful scalability of the unified control architecture.

[0146] Cyclic judgment: This extended replenishment process can be repeated until all materials are stockpiled. The system eventually automatically forms a composite stockpile that expands multiple times in the length direction and makes full use of the stockpile space.

[0147] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A unified control method for multiple processes of a stacker-reclaimer based on dynamic obstacle avoidance rules, characterized in that, include: Receive configuration information for stockpiling operations and generate rule sets and unified parameter sets based on the configuration information; The stacker-reclaimer is controlled to perform stacking operations based on the rule set and unified parameter set; Real-time acquisition of the stacker-reclaimer's operating status and environmental conditions; Based on the operation status, environmental status, and rule set, a decision is made and if the predetermined triggering conditions are met, a device control command is generated. Execute the equipment control commands to control the stacker-reclaimer to perform corresponding actions; Control the stacker-reclaimer to repeatedly perform stacking operations until the stacking operation is completed, thereby achieving unified control of multiple processes of the stacker-reclaimer.

2. The multi-process unified control method for stacker-reclaimers based on dynamic obstacle avoidance rules according to claim 1, characterized in that, The acquisition of the configuration information includes: A selection instruction for a target template from a plurality of predefined process templates, the process template being associated with the rule set; the rule set containing at least one rule for defining device behavior logic; The rule set is generated by combining selection instructions for multiple atomic rules in the atomic rule library; the atomic rule library contains multiple atomic rules, each atomic rule corresponding to a basic material stacking control logic and control target.

3. The multi-process unified control method for stacker-reclaimers based on dynamic obstacle avoidance rules according to claim 1, characterized in that, The unified parameter set includes: Basic material stacking parameters used to define the spatial extent of stacking operations; The sequence target height parameter is used to define the stacking height target of each layer; Operable space parameters are used to dynamically characterize the operable space; Path vector parameters used to define the movement path of the device; Other parameters used to define the objectives of the stockpiling operation.

4. The multi-process unified control method for stacker-reclaimers based on dynamic obstacle avoidance rules according to claim 3, characterized in that, The layer sequence target height parameter is an ordered array, and the stacking mode is uniformly controlled by the positive and negative attributes of the array element values ​​in the ordered array. When the array element value is positive, the fixed-point stacking mode is enabled to reach the target height defined by the array element value and trigger stepping. When an array element has a negative value, the continuous stacking mode is enabled, and the turning is triggered by the real-time detected obstruction ahead.

5. The multi-process unified control method for stacker-reclaimers based on dynamic obstacle avoidance rules according to claim 3, characterized in that, The operable space parameters are dynamically updated graph data structures used to characterize the reachability of equipment vertices at each height level within the material stacking area. The maintenance of the operable space parameters specifically includes: Record the position of the top edge of the equipment that has completed material stacking; Based on the fixed location of the device, the closed boundary of the occupied space is periodically reconstructed; Based on the closed boundary, update the availability status flags of all device vertices, and mark vertices located within the closed boundary as unavailable.

6. The multi-process unified control method for stacker-reclaimers based on dynamic obstacle avoidance rules according to claim 1, characterized in that, Making the aforementioned decision-making judgment specifically includes: Receive the policy intent output by the rule set; Based on the stated strategy intent and the stated environmental state, collision detection and decision-making logic is used to calculate equipment control commands for controlling the actions of the stacker-reclaimer.

7. The multi-process unified control method for stacker-reclaimers based on dynamic obstacle avoidance rules according to claim 6, characterized in that, The equipment control commands include the target position of the equipment movement, the movement speed, the rotation angle, and the pitch angle.

8. A unified control system for a stacker-reclaimer based on dynamic obstacle avoidance rules, implemented using the unified control method for multi-process stacker-reclaimers based on dynamic obstacle avoidance rules as described in any one of claims 1-7, characterized in that, Specifically, it includes: The system comprises a rule base, a decision-making module, and a control module, among which: The rule base is used to store a unified set of parameters and a set of rules; The decision module is used to make decisions and judgments based on the real-time acquired operation status, environmental status and rule set loaded from the rule base during the material stacking operation, and to generate equipment control instructions when the triggering conditions are met. The control module is used to execute the equipment control commands to control the stacker-reclaimer to perform corresponding actions.

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