Intelligent weighing system for battery swapping hooklift trucks

Abstract

This invention provides an intelligent weighing system for a battery-swapping hooklift truck, belonging to the field of intelligent weighing technology. The system includes: an image recognition module, electrically connected to a weighing controller, for collecting identification information on the garbage bins and transmitting it to the weighing controller for bin identification; a weighing sensing module, also electrically connected to the weighing controller, including multiple force sensors arranged at different loading positions on the hooklift truck, for collecting force signals and transmitting them to the weighing controller during garbage bin loading and unloading; a display module, electrically connected to the weighing controller, for displaying weighing data, identification information, and alarm information; an alarm module, also electrically connected to the weighing controller, for issuing an alarm when the weighing controller detects overload or abnormality; and a data recording module, also electrically connected to the weighing controller, for storing identification information and weighing data for each operation. This method achieves accurate weighing, intelligent identification, and automatic early warning, solving problems such as difficulty in controlling overload, mixed use of garbage bins, and data loss.

Description

Technical Field

[0001] This invention relates to the field of intelligent weighing technology, and in particular to an intelligent weighing system for a battery swapping hooklift truck. Background Technology

[0002] Battery-swapping hooklift trucks are widely used in the collection and transfer of urban and rural domestic waste, requiring frequent loading of garbage containers of different sizes during operation. Currently, the state has strict regulations on overloading and exceeding weight limits for special vehicles, but the current weighing methods have significant shortcomings: firstly, the cumulative weighing through the container lifting mechanism results in large errors and requires manual intervention; secondly, the weighing system installed on only one side of the front wheel of the garbage container cannot adapt to different container sizes; and thirdly, the displacement sensor installed on the main beam has low measurement accuracy and is easily damaged. Therefore, there is an urgent need for a weighing system that can accurately weigh, intelligently identify different container sizes, and automatically record data to achieve efficient and compliant transportation. Summary of the Invention

[0003] In view of this, the purpose of this invention is to provide an intelligent weighing system for battery swapping hooklift trucks, which can achieve accurate weighing, intelligent identification and automatic early warning, and solve the problems of difficult overload control, mixed use of boxes and missing data.

[0004] In a first aspect, embodiments of the present invention provide an intelligent weighing system for a battery-swapping hooklift truck. The system includes: a weighing controller, an image recognition module, a weighing sensor module, a display module, an alarm module, and a data recording module. The image recognition module, electrically connected to the weighing controller, is used to collect identification information on the garbage bin and transmit it to the weighing controller for bin identification. The weighing sensor module, electrically connected to the weighing controller, includes multiple force sensors arranged at different loading positions on the hooklift truck, used to collect force signals and transmit them to the weighing controller during the garbage bin loading and unloading states. The display module, electrically connected to the weighing controller, is used to display weighing data. The system includes: identification information and alarm information; an alarm module, electrically connected to the weighing controller, used to issue an alarm prompt when the weighing controller determines overload or abnormality; and a data recording module, also electrically connected to the weighing controller, used to store identification information and weighing data for each operation. The weighing controller is configured to: calculate the full-load weight and vehicle mass based on the first force signal collected during hook loading; calculate the empty weight and net weight of waste based on the second force signal collected during unloading; generate an operation record containing multi-stage weighing results based on the identification information, full-load weight, vehicle mass, empty weight, and net weight of waste; and trigger the alarm module when alarm conditions are met.

[0005] In a preferred embodiment of the present invention, the image recognition module includes: a weighing recognition camera and an image recognition unit; the weighing recognition camera is installed on the front end of the hook arm and is used to collect the nameplate image of the unique identification nameplate on the garbage bin; the image recognition unit is integrated into the weighing controller and is used to perform image preprocessing, feature extraction and matching recognition with the pre-stored nameplate database on the nameplate image, and output the garbage bin code and preset parameters.

[0006] In a preferred embodiment of the present invention, the weighing sensing module includes: at least two weighing plane sensors, installed on the garbage bin bearing surface of the hook arm, for collecting the vertical pressure between the bin and the contact surface of the hook arm; at least six weighing axle sensors, respectively installed in the front and rear axle areas of the vehicle, for collecting axle load distribution signals; at least two weighing system half-axle sensors, installed at the half-axle positions of the vehicle, for assisting in collecting load transmission signals; the weighing plane sensors, weighing axle sensors, and weighing system half-axle sensors are electrically connected to the weighing controller, forming a sensing network covering multiple force points throughout the vehicle.

[0007] In a preferred embodiment of the present invention, the image recognition unit includes: an image preprocessing subunit, a feature extraction subunit, and a matching recognition subunit; the image preprocessing subunit is used to perform grayscale conversion, binarization, and contour extraction preprocessing on the nameplate image; the feature extraction subunit is used to extract the graphic features or coded features of the nameplate from the preprocessed image; the matching recognition subunit is used to compare the extracted features with a pre-stored nameplate database and output the garbage bin code and the corresponding empty weight and bin size parameters; the matching recognition subunit is also used to perform secondary recognition before unloading the garbage bin to confirm the identity of the operating bin and trigger the operation record closed loop.

[0008] In a preferred embodiment of the present invention, the weighing controller includes: a signal acquisition unit, a load calculation unit, an axle load distribution calculation unit, and a comparison and judgment unit; The signal acquisition unit receives analog force signals collected by each sensor in the weighing sensor module and converts them into digital signals. The load calculation unit calculates the full load weight, empty load weight, net weight of garbage, and total vehicle mass of the garbage bin based on the installation position of each sensor and the preset distance from each sensor to the center of the rear axle of the vehicle, combined with the empty axle load parameters of the vehicle chassis and hook arm. The axle load distribution calculation unit calculates the axle load distribution ratio of the current load on the front and rear axles according to the force distribution of each sensor. The comparison and judgment unit compares the total vehicle mass with a preset total mass threshold, the axle load distribution ratio with a preset axle load threshold, and the empty load weight with a pre-stored empty load weight, and outputs the comparison results.

[0009] In a preferred embodiment of the present invention, the alarm module includes: a weighing alarm horn and a screen display alarm unit; the weighing alarm horn is installed in the cab or on the side of the hook arm; the screen display alarm unit is integrated into the display module; the alarm module is configured to: when the comparison and judgment unit outputs that the total vehicle mass or axle load distribution exceeds the limit, simultaneously trigger the weighing alarm horn to emit a voice alarm and the display module to display text alarm information; when the deviation between the output no-load weight and the pre-stored no-load weight exceeds a preset threshold, trigger the weighing alarm horn to emit a target prompt tone and display an abnormal prompt on the display module.

[0010] In a preferred embodiment of the present invention, the data recording module includes: a local storage unit, a remote communication unit, and a report generation unit; the local storage unit, integrated within the weighing controller, is used to store the garbage bin code, start and end time of the operation, full load weight, empty load weight, net weight of garbage, total vehicle mass, front and rear axle load distribution, and alarm status for each operation; the remote communication unit is used to upload the operation records in the local storage unit to a remote server or management platform; the report generation unit is used to automatically generate statistical reports daily or periodically based on the records stored locally or remotely, and the statistical reports include the usage frequency of each garbage bin, the total net weight of transported garbage, and the number of overload events.

[0011] In a preferred embodiment of the present invention, the upper surface of the weighing plane sensor is provided with a wear-resistant contact layer to resist sliding friction during the loading and unloading of the garbage bin; the weighing shaft sensor and the half-shaft sensor of the weighing system are respectively integrated with maintenance-free bearings to reduce frictional losses between the sensor and the rotating parts.

[0012] In a preferred embodiment of the present invention, the display module is a weighing system screen installed in the driver's cab. The weighing system screen includes: a container information display area for displaying the currently identified garbage container code and preset parameters; a weight data display area for displaying the real-time full load weight, empty load weight, garbage net weight, and total vehicle mass; an axle load status display area for displaying the front and rear axle load distribution values ​​and percentages; and an alarm status bar for displaying overload alarms, axle load over-limit alarms, or incomplete dumping alarm information in a highlighted or flashing manner.

[0013] In a preferred embodiment of the present invention, the exclusive identification nameplate is a graphic nameplate with a unique code; the weighing controller is also configured to automatically update the last usage time and cumulative transport weight of the trash can in the data recording module after the image recognition unit successfully identifies the exclusive identification nameplate.

[0014] The embodiments of the present invention bring the following beneficial effects: This invention provides an intelligent weighing system for a battery swapping hooklift truck. The system includes: a weighing controller, an image recognition module, a weighing sensor module, a display module, an alarm module, and a data recording module. The system includes an image recognition module, electrically connected to the weighing controller, for collecting identification information on the garbage bins and transmitting it to the weighing controller for bin identification; a weighing sensing module, also electrically connected to the weighing controller, comprising multiple force sensors arranged at different loading positions on the hooklift truck, for collecting force signals and transmitting them to the weighing controller during the loading and unloading states of the garbage bins; a display module, electrically connected to the weighing controller, for displaying weighing data, identification information, and alarm information; an alarm module, also electrically connected to the weighing controller, for issuing an alarm prompt when the weighing controller detects overload or abnormality; and a data recording module, also electrically connected to the weighing controller, for storing identification information and weighing data for each operation. The weighing controller is configured to: calculate the full-load weight and vehicle mass based on the first force signal collected during the loading state; calculate the empty weight and net garbage weight based on the second force signal collected during the unloading state; generate an operation record containing multi-stage weighing results based on the identification information, full-load weight, vehicle mass, empty weight, and net garbage weight; and trigger the alarm module when alarm conditions are met. This method enables accurate weighing, intelligent identification, and automatic early warning, solving problems such as difficulty in controlling overload, mixed use of containers, and missing data.

[0015] Other features and advantages of this disclosure will be set forth in the following description, or some features and advantages may be inferred from the description or determined without doubt, or may be learned by practicing the techniques described above.

[0016] To make the above-mentioned objects, features and advantages of this disclosure more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0017] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0018] Figure 1 This is a structural diagram of an intelligent weighing system for a battery swapping hooklift truck provided in an embodiment of the present invention; Figure 2 This is a structural diagram of another intelligent weighing system for a battery swapping hooklift truck provided in an embodiment of the present invention. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] Battery-swapping hooklift trucks are widely used in the collection and transfer of urban and rural domestic waste, requiring frequent loading of garbage containers of different sizes during operation. Currently, the state has strict regulations on overloading and exceeding weight limits for special vehicles, but the current weighing methods have significant shortcomings: firstly, the cumulative weighing through the container lifting mechanism results in large errors and requires manual intervention; secondly, the weighing system installed on only one side of the front wheel of the garbage container cannot adapt to different container sizes; and thirdly, the displacement sensor installed on the main beam has low measurement accuracy and is easily damaged. Therefore, there is an urgent need for a weighing system that can accurately weigh, intelligently identify different container sizes, and automatically record data to achieve efficient and compliant transportation.

[0021] Based on this, this invention provides an intelligent weighing system for a battery-swapping hooklift truck. The system includes: a weighing controller, an image recognition module, a weighing sensor module, a display module, an alarm module, and a data recording module. The image recognition module, electrically connected to the weighing controller, is used to collect identification information on the garbage bin and transmit it to the weighing controller for bin identification. The weighing sensor module, also electrically connected to the weighing controller, includes multiple force sensors arranged at different loading positions on the hooklift truck, used to collect force signals and transmit them to the weighing controller during the garbage bin loading and unloading states. The display module, electrically connected to the weighing controller, is used to display weighing data. The system includes identification and alarm information; an alarm module, electrically connected to the weighing controller, issues an alarm when the weighing controller detects overload or abnormality; and a data recording module, also electrically connected to the weighing controller, stores identification information and weighing data for each operation. The weighing controller is configured to: calculate the full-load weight and vehicle mass based on the first force signal collected during hooking; calculate the empty weight and net weight of waste based on the second force signal collected during unloading; generate an operation record containing multi-stage weighing results based on identification information, full-load weight, vehicle mass, empty weight, and net weight of waste; and trigger the alarm module when alarm conditions are met. This method achieves accurate weighing, intelligent identification, and automatic early warning, solving problems such as difficulty in controlling overload, mixed use of containers, and data loss.

[0022] To facilitate understanding of this embodiment, a detailed description of the intelligent weighing system for a battery swapping hooklift truck disclosed in this embodiment of the invention will be provided first.

[0023] Example 1 This invention provides an intelligent weighing system for a battery swapping hooklift truck. Figure 1This is a structural diagram of an intelligent weighing system for a battery-swapping hooklift truck provided in an embodiment of the present invention. Figure 1 As shown, the intelligent weighing system for the battery swapping hooklift truck can include the following structure: a weighing controller, an image recognition module, a weighing sensor module, a display module, an alarm module, and a data recording module.

[0024] The image recognition module is electrically connected to the weighing controller and is used to collect the identification information on the garbage bin and transmit it to the weighing controller for bin identification.

[0025] The weighing controller is the central processing unit of the system. It can be an embedded controller with an integrated ARM or RISC architecture, and has built-in analog-to-digital conversion circuits and algorithm processing units. It receives box information from the image recognition module and force signals from the weighing sensor module, performs data fusion calculations, and controls the display, alarm, and recording modules to perform corresponding operations.

[0026] The image recognition module is connected to the weighing controller via a CAN bus or Ethernet and is responsible for collecting visual markings on the trash cans. Its core function is to "identify the trash can's identity," enabling the system to distinguish between trash cans of different sizes and weights.

[0027] The weighing sensor module, which is electrically connected to the weighing controller, includes multiple force sensors arranged at different load positions on the hooklift truck. These sensors are used to collect force signals and transmit them to the weighing controller during the loading and unloading of the garbage bin.

[0028] The weighing sensor module is connected to the weighing controller via analog signal lines or a digital bus. It contains multiple force sensors arranged at different load-bearing positions on the hooklift truck (such as the load-bearing surface, axle, and half-axle). It collects signals at two key time points: first, in the "hook-on state" when the garbage container is just hooked onto the truck, at which time the force signal is collected when it is fully loaded; second, in the "unloading state" when the empty container is placed after the garbage is dumped, at which time the force signal is collected when it is unloaded.

[0029] The "hook-loaded" state refers to the state in which the garbage bin is lifted from the ground by the hook arm and placed completely on the vehicle's load-bearing surface, at which point the garbage bin is fully loaded with garbage.

[0030] The unloading state refers to the state in which the empty garbage bin is placed back on the vehicle's load-bearing surface after the garbage bin has been emptied at the garbage treatment plant.

[0031] The display module is electrically connected to the weighing controller and is used to display weighing data, identification information, and alarm information.

[0032] The display module is connected to the weighing controller via an LVDS or HDMI interface to provide the driver with real-time feedback on the identification results, weight data, and alarm status.

[0033] The alarm module is electrically connected to the weighing controller and is used to issue an alarm when the weighing controller detects an overload or abnormality.

[0034] The alarm module is connected to the weighing controller via an I / O control line, and emits an audible and visual alarm when there is an overload or abnormality.

[0035] The data recording module, electrically connected to the weighing controller, is used to store the identification information and weighing data for each operation.

[0036] The data recording module is connected to the weighing controller via an internal bus or an external communication interface for persistent storage of work data.

[0037] The weighing controller is configured to: calculate the full load weight and vehicle mass based on the first force signal collected in the hook-loading state; calculate the empty load weight and garbage net weight based on the second force signal collected in the unloading state; generate an operation record containing multi-stage weighing results based on the identification information, full load weight, vehicle mass, empty load weight and garbage net weight; and trigger the alarm module when the alarm conditions are met.

[0038] Among them, the first force signal and the second force signal correspond to the force value data sets collected by each sensor in the two states of hooking and unloading, respectively.

[0039] The full load weight is the total weight of the trash can when it is full of trash.

[0040] The total vehicle mass is the weight of the vehicle itself plus the total weight of the fully loaded garbage bins.

[0041] The empty weight is the weight of the empty garbage bin after the garbage has been dumped.

[0042] The net weight of the garbage is the weight of the fully loaded garbage minus the weight of the empty garbage, which is the actual weight of the garbage transported in this shipment.

[0043] Among them, multi-stage weighing results refer to complete operation records that include data from both the "loading stage weighing" and "unloading stage weighing" stages.

[0044] Furthermore, the weighing controller can integrate a multi-channel high-precision ADC (analog-to-digital converter) with a sampling rate of no less than 100Hz to capture dynamic load changes during vehicle operation. The controller also has built-in non-volatile memory (such as EEPROM or Flash) to store preset parameters for each garbage bin (standard empty weight, bin dimensions, maximum allowable load) and the vehicle's own axle load limits.

[0045] The intelligent weighing system for battery swapping hooklift trucks provided in this embodiment of the invention includes: a weighing controller, an image recognition module, a weighing sensor module, a display module, an alarm module, and a data recording module; The system includes an image recognition module, electrically connected to the weighing controller, for collecting identification information on the garbage bins and transmitting it to the weighing controller for bin identification; a weighing sensing module, also electrically connected to the weighing controller, comprising multiple force sensors arranged at different loading positions on the hooklift truck, for collecting force signals and transmitting them to the weighing controller during the loading and unloading states of the garbage bins; a display module, electrically connected to the weighing controller, for displaying weighing data, identification information, and alarm information; an alarm module, also electrically connected to the weighing controller, for issuing an alarm prompt when the weighing controller detects overload or abnormality; and a data recording module, also electrically connected to the weighing controller, for storing identification information and weighing data for each operation. The weighing controller is configured to: calculate the full-load weight and vehicle mass based on the first force signal collected during the loading state; calculate the empty weight and net garbage weight based on the second force signal collected during the unloading state; generate an operation record containing multi-stage weighing results based on the identification information, full-load weight, vehicle mass, empty weight, and net garbage weight; and trigger the alarm module when alarm conditions are met. This method enables accurate weighing, intelligent identification, and automatic early warning, solving problems such as difficulty in controlling overload, mixed use of containers, and missing data.

[0046] Example 2 This invention also provides another intelligent weighing system for battery swapping hooklift trucks; this method is implemented based on the method in the above embodiments.

[0047] Figure 2 A structural diagram of another intelligent weighing system for a battery-swapping hooklift truck provided in an embodiment of the present invention is shown below. Figure 2 As shown, the intelligent weighing system for the battery swapping hooklift truck is described in detail, with each module having a specific structure: The image recognition module includes a weighing recognition camera and an image recognition unit.

[0048] The weighing and identification camera is installed on the front end of the hook arm and is used to capture images of the unique identification plate on the garbage bin.

[0049] The weighing and identification camera is installed on the front crossbeam or side bracket of the hook arm, with the lens facing diagonally downwards to ensure that the camera can clearly capture the nameplate installed on the front of the garbage bin when the vehicle is aligned with it. The camera uses an industrial-grade wide dynamic range image sensor, which is adaptable to complex lighting conditions such as strong outdoor light, backlight, and nighttime.

[0050] Each trash can is equipped with a unique identification plaque, which can be a QR code, a DataMatrix code, or a custom graphic code. The plaque contains information such as the trash can's unique ID, standard empty weight, and dimensions. Made of weather-resistant materials (such as etched stainless steel or highly weather-resistant PVC), the plaque is waterproof, dustproof, and anti-aging, ensuring long-term identifiability for outdoor use.

[0051] The image recognition unit, integrated into the weighing controller, is used to preprocess the nameplate image, extract features, and match and recognize it with the pre-stored nameplate database, outputting the garbage bin code and preset parameters.

[0052] The image recognition unit is not a standalone hardware component, but rather an algorithm software module embedded within the weighing controller. It receives image data from the camera, extracts feature information from the nameplate using image processing algorithms, and compares it with a pre-stored nameplate database within the controller.

[0053] The trash can code is a unique identifier assigned to each trash can by the system, such as "BX-001" or "BX-002", which facilitates backend management and data statistics.

[0054] Among them, the preset parameters and the pre-stored data associated with the garbage bin code include standard empty weight, bin volume, maximum allowable loading capacity, etc.

[0055] For example, when the hooklift truck is aligned with the garbage bin, the camera automatically triggers a capture (which can be triggered via a distance sensor or a manual button) to obtain an image of the nameplate. The image recognition unit first corrects the distortion of the image, then extracts the coded area, decodes it to obtain the garbage bin ID "BX-027", and retrieves the standard empty weight of the bin from the database as "1250kg" and the bin dimensions as "3.2m×1.8m×1.5m", which are then displayed on the screen.

[0056] Furthermore, the image recognition unit can employ a lightweight convolutional neural network model to achieve millisecond-level recognition on an embedded platform. For scenarios where recognition fails (such as damaged nameplates or insufficient lighting), the system can automatically trigger a supplementary light and continuously acquire multiple frames of images for fusion recognition, thereby improving robustness.

[0057] The weighing sensor module includes: At least two weighing plane sensors are installed on the load-bearing surface of the garbage bin mounted on the hook arm to collect the vertical pressure between the bin and the contact surface of the hook arm.

[0058] The weighing plane sensor is installed on the load-bearing surface of the garbage bin mounted on the hook arm. It is usually a thin resistance strain gauge sensor with its upper surface in direct contact with the bottom of the garbage bin. Two sensors are respectively arranged at the front and rear of the load-bearing surface to sense the vertical pressure applied by the bin and to detect whether the bin is placed flat.

[0059] Vertical pressure is the pressure exerted by the garbage bin on the bearing surface, perpendicular to the contact surface and downwards, and is proportional to the weight of the garbage bin.

[0060] At least six weighing axle sensors are installed in the front and rear axle areas of the vehicle to collect axle load distribution signals.

[0061] The weighing axle sensors are installed between the suspension system and the frame of the front and rear axles of the vehicle. They are usually pin-type or plate-type force sensors used to measure axle load. The six sensors are specifically distributed as follows: one on each side of the front axle, two on each side of the rear axle (for dual rear axle models), or three evenly distributed to achieve accurate measurement of axle load distribution.

[0062] Among them, the axle load distribution signal is the vertical load value of each bearing, reflecting the distribution of the vehicle load between the front and rear axles.

[0063] At least two half-shaft sensors of the weighing system are installed at the half-shaft position of the vehicle to assist in the acquisition of load transmission signals.

[0064] The half-shaft sensor of the weighing system is installed at the connection between the half-shaft and the hub or at the half-shaft bearing seat. It is used to assist in collecting dynamic signals during the load transmission process, and is especially suitable for compensating for transient load changes when the vehicle is turning, accelerating or decelerating.

[0065] Among them, the load transmission signal is a composite signal of torsion and pressure collected by the half-shaft sensor, which is used to correct the weighing error caused by uneven road surface or changes in vehicle posture.

[0066] Among them, the weighing plane sensor, the weighing shaft sensor, and the half-shaft sensor of the weighing system are electrically connected to the weighing controller, forming a sensor network covering multiple force points throughout the vehicle.

[0067] For example, when the garbage bin is loaded, the two planar sensors measure a total pressure of 6500 kg, the six axle sensors measure a front axle load of 2200 kg and a rear axle load of 5800 kg, and the two half-axle sensors measure that the difference in load between the left and right half-axles is within the allowable range. The system integrates these data to calculate the total mass of the vehicle and the axle load distribution.

[0068] Furthermore, all sensors are designed with temperature compensation and have built-in temperature sensors. The weighing controller automatically corrects the sensor output according to the ambient temperature to ensure a weighing accuracy of ±1% over a wide temperature range of -20℃ to 60℃.

[0069] The image recognition unit includes: an image preprocessing subunit, a feature extraction subunit, and a matching and recognition subunit.

[0070] The image preprocessing subunit is used to perform grayscale conversion, binarization, and contour extraction preprocessing on the nameplate image.

[0071] The image preprocessing subunit performs operations such as noise reduction, enhancement, grayscale conversion, binarization, and contour extraction on the original image to remove background interference and highlight the nameplate area.

[0072] Grayscale conversion involves converting a color image into a grayscale image, thus reducing computational load.

[0073] Binarization converts a grayscale image into a black and white image, separating the nameplate area from the background.

[0074] Contour extraction is used to identify the outer boundary of the nameplate, which facilitates positioning and correction.

[0075] The feature extraction subunit is used to extract the graphic or coded features of the nameplate from the preprocessed image.

[0076] Among them, the feature extraction subunit extracts the geometric features (such as corners, edges, and pattern distribution) or coded features (such as the module arrangement of the QR code) of the nameplate from the preprocessed image.

[0077] Among them, graphic features / coded features: graphic features refer to the visual features of the non-coded parts of the nameplate (such as logo, border style); coded features refer to the information contained in the coded area.

[0078] The matching and identification subunit is used to compare the extracted features with the pre-stored nameplate database and output the garbage bin code and the corresponding empty weight and bin size parameters.

[0079] The matching and identification subunit compares the extracted features with a pre-stored database to determine similarity, and outputs the container information with the highest matching degree. Simultaneously, this subunit performs identification again before unloading to ensure that the container identity in the work record is consistent with that at the time of loading, preventing container mixing or recording errors.

[0080] The matching and identification subunit is also used to perform secondary identification before unloading the garbage bin, in order to confirm the identity of the operating bin and trigger the operation record closed loop.

[0081] For example, during loading, the camera captures an image of the nameplate. The preprocessing subunit converts the image to grayscale, binarizes it, and extracts the nameplate outline. The feature extraction subunit identifies the QR code area and decodes it to obtain "BX-027". Before unloading, the system photographs the same nameplate again to confirm that the container ID is still "BX-027". If the recognition results are inconsistent (e.g., another container is mistakenly photographed), the system will issue a prompt and require manual confirmation.

[0082] Furthermore, the matching and identification subunit has a built-in database management function, supporting the addition, deletion, and modification of trash can nameplate information. When an unregistered nameplate is detected, the system automatically prompts "unfamiliar bin" and allows the operator to manually enter the bin parameters to supplement the database.

[0083] The weighing controller includes: a signal acquisition unit, a load calculation unit, an axle load distribution calculation unit, and a comparison and judgment unit.

[0084] The signal acquisition unit is used to receive the analog force signals collected by each sensor in the weighing sensor module and convert them into digital signals.

[0085] The signal acquisition unit receives the analog voltage / current signals output by each sensor, converts them into digital signals via an ADC, and performs digital filtering (such as Kalman filtering) to remove noise.

[0086] The load calculation unit is used to calculate the full load weight, empty load weight, net weight of garbage and total mass of the vehicle based on the installation position of each sensor and the preset distance from each sensor to the center of the rear axle of the vehicle, combined with the empty axle load parameters of the vehicle chassis and hook arm.

[0087] The load calculation unit converts digital signals into force values ​​based on the calibration coefficients (force-to-voltage conversion coefficients) of each sensor. Then, combining this with the sensor installation position parameters (such as the horizontal distance from each sensor to the rear axle center of the vehicle), it calculates the center of gravity position and total weight of the vehicle body using a torque balance equation. The calculation formula is based on the principle of statics: Total vehicle mass = Vehicle unloaded mass + Sum of forces acting on each sensor.

[0088] The axle load distribution calculation unit is used to calculate the axle load distribution ratio of the current load on the front and rear axles based on the force distribution of each sensor.

[0089] The axle load distribution calculation unit calculates the total load on the front axle and the total load on the rear axle based on the force values ​​of each sensor obtained by the load calculation unit and the axle to which the sensor is located, and calculates the proportion of the front and rear axle loads to the total mass of the vehicle.

[0090] The comparison and judgment unit is used to compare the total vehicle mass with the preset total mass threshold, the axle load distribution ratio with the preset axle load threshold, and the unloaded weight with the pre-stored unloaded weight, and output the comparison results.

[0091] The preset total mass threshold is the maximum total mass allowed by the vehicle announcement, such as 18,000 kg.

[0092] The preset axle load threshold is the maximum allowable load for the front axle and the rear axle, such as 7000 kg for the front axle and 11500 kg for the rear axle.

[0093] For example, the signal acquisition unit collects signals from 10 sensors at a sampling rate of 200Hz. The load calculation unit calculates the total vehicle mass to be 17,500 kg and the full load weight of the garbage to be 9,500 kg. The axle load distribution calculation unit calculates the front axle load to be 6,800 kg and the rear axle load to be 10,700 kg. The comparison and judgment unit finds that the total vehicle mass does not exceed 18,000 kg, but the rear axle load of 10,700 kg exceeds the allowable rear axle load of 10,500 kg, and outputs a "rear axle overload" alarm.

[0094] Furthermore, the load calculation unit incorporates a dynamic weighing algorithm that can distinguish between steady-state weighing when the vehicle is stationary and dynamic weighing when traveling at low speeds (<5km / h). Under dynamic conditions, accuracy is improved through multi-frame data averaging and inertia compensation. When the vehicle is on a slope, the system automatically detects the tilt angle and performs gravity component compensation.

[0095] The pre-stored empty weight is the standard empty weight of the trash can recorded in the nameplate database.

[0096] The comparison and judgment unit compares the calculated value with a preset threshold and outputs a Boolean judgment result.

[0097] The alarm module includes a weighing alarm horn and a screen display alarm unit.

[0098] The weighing alarm horn is installed in the cab or on the side of the hook boom.

[0099] The driver's cab speaker is used to alert the driver, while the side speakers are used to alert external operators. The speakers utilize a digital speech synthesis module to broadcast preset voice messages.

[0100] The alarm unit is displayed on the screen and integrated into the display module.

[0101] The screen display alarm unit is integrated into the display module, and displays alarm information on the screen in the form of highlighting, flashing, red text, etc.

[0102] The alarm module is configured to simultaneously trigger the weighing alarm horn to emit a voice alarm and the display module to display text alarm information when the comparison and judgment unit outputs that the total vehicle mass or axle load distribution exceeds the limit. When the deviation between the output no-load weight of the comparison and judgment unit and the pre-stored no-load weight exceeds a preset threshold, the weighing alarm horn is triggered to emit a target prompt sound, and an abnormal prompt is displayed on the display module.

[0103] Among them, the target prompt tone is a specific prompt tone set for the "not completely dumped" abnormality, such as "beep-beep" double short and double long beeps, which is different from the long beep tone of the overload alarm, making it easier for the driver to identify the abnormality type.

[0104] The preset threshold is the allowable range of no-load weight deviation, which is set at 15% in the handover document. This value can be adjusted in the system settings according to user needs (e.g., 10%-20%).

[0105] For example, when the rear axle exceeds the limit, the horn in the cab will announce "Rear axle overload, please adjust the load," and the alarm status bar on the screen will display "Rear axle overload" in red. When the empty weight is 1450kg and the preset value is 1250kg, the deviation is 16%, which exceeds 15%, the horn will announce "Garbage not completely dumped," and the screen will display "Not completely dumped, please dump again."

[0106] The data recording module includes: a local storage unit, a remote communication unit, and a report generation unit.

[0107] The local storage unit, integrated into the weighing controller, is used to store the garbage bin code, start and end time of the operation, full load weight, empty load weight, net weight of garbage, total vehicle mass, front and rear axle load distribution, and alarm status for each operation.

[0108] The work record is a data set of a single complete operation, including container ID, timestamp, weight at each stage, alarm status, etc.

[0109] The remote communication unit is used to upload job records from the local storage unit to a remote server or management platform.

[0110] The remote communication unit uses a 4G / 5G communication module or a Beidou short message module to upload work records to the cloud management platform in real time, supports breakpoint resume transmission, and ensures automatic retransmission after network recovery.

[0111] The report generation unit is used to automatically generate statistical reports on a daily or periodic basis based on records stored locally or remotely. The statistical reports include the frequency of use of each garbage bin, the total net weight of transported garbage, and the number of overload events.

[0112] The statistical report is an analysis report that is summarized periodically, including total transportation volume, container usage frequency, and statistics on overload incidents.

[0113] The report generation unit runs on the weighing controller or cloud server and automatically summarizes data according to the user-selected period (day / week / month) to generate reports in PDF or Excel format.

[0114] The upper surface of the weighing plane sensor is provided with a wear-resistant contact layer to resist sliding friction during the loading and unloading of the garbage bin.

[0115] The wear-resistant contact layer is a layer of high-hardness, low-friction material, such as hardened stainless steel plate, polytetrafluoroethylene (PTFE) coating, or ceramic composite material, applied to the surface where the planar sensor contacts the bottom of the trash can to reduce sliding wear during hooking and unloading.

[0116] Among them, sliding friction is the relative sliding that occurs between the bottom of the garbage bin and the surface of the planar sensor during the hooking and unloading process. Over time, this will wear down the sensor surface and affect the accuracy.

[0117] The weighing shaft sensor and the half-shaft sensor of the weighing system are each integrated with maintenance-free bearings to reduce frictional losses between the sensor and rotating parts.

[0118] Among them, maintenance-free bearings are sealed self-lubricating bearings integrated into the rotating mating parts of the shaft sensor and the half-shaft sensor, such as oil-impregnated powder metallurgy bearings or ceramic rolling bearings, which do not require regular grease filling and reduce maintenance costs.

[0119] The display module is a weighing system screen installed in the cab of the driver's cab. The weighing system screen displays: The bin information display area is used to display the currently identified bin code and preset parameters.

[0120] The bin information display area can be located at the top or left of the screen, displaying the currently identified bin code, bin size, standard empty weight, etc.

[0121] The weight data display area is used to display the real-time full load weight, empty load weight, net weight of garbage, and total vehicle mass.

[0122] The weight data display area can be located in the center of the screen, displaying the real-time full load weight, empty load weight, garbage net weight, and total vehicle mass in large font numbers.

[0123] The axle load status display area is used to display the front and rear axle load distribution values ​​and percentages.

[0124] The axle load status display area can display the ratio of the current value to the limit value of the front and rear axle loads in the form of a progress bar or bar chart, intuitively showing the axle load margin.

[0125] The alarm status bar is used to display overload alarms, axle load over-limit alarms, or incomplete tipping alarms by highlighting or flashing.

[0126] The alarm status bar can be located at the bottom of the screen. It normally displays green "normal" and turns red when an alarm is triggered, displaying the specific alarm content. It supports scrolling to display multiple alarms.

[0127] Among them, the exclusive identification nameplate is a graphic nameplate with a unique code.

[0128] The graphic nameplate uses a QR code or Data Matrix code, which includes the trash can ID and a verification code. The nameplate measures 100mm x 100mm and is installed in a prominent position on the front of the trash can (such as in the center of the front panel). A reflective border can be added around the nameplate for better identification at night.

[0129] The weighing controller is also configured to automatically update the last usage time and cumulative transport weight of the trash can in the data recording module after the image recognition unit successfully recognizes the exclusive identification nameplate.

[0130] The weighing controller automatically updates the "last use time" field of the trash can in the local storage unit after each successful identification of the nameplate and completion of the operation, and adds it to the "cumulative transport weight" field after calculating the net weight of the trash.

[0131] Furthermore, the system can automatically generate container maintenance reminders based on cumulative transport weight and last usage time. For example, when a container's cumulative transport weight exceeds 500 tons or its usage time exceeds 6 months, the system will automatically display a "Container maintenance recommended" prompt upon recognizing the container. In addition, the remote management platform can analyze the turnover efficiency of each container based on usage data and optimize scheduling strategies.

[0132] If the functionality is implemented as a software functional unit and sold or used as an independent product, it can be stored in a processor-executable, non-volatile, computer-readable storage medium. Based on this understanding, the technical solution of this invention, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0133] Finally, it should be noted that the above-described embodiments are merely specific implementations of the present invention, used to illustrate the technical solutions of the present invention, and not to limit it. The scope of protection of the present invention is not limited thereto. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments within the technical scope disclosed in the present invention, or make equivalent substitutions for some of the technical features; and these modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. An intelligent weighing system for a battery-swapping hooklift truck, characterized in that, The system includes: a weighing controller, an image recognition module, a weighing sensor module, a display module, an alarm module, and a data recording module; The image recognition module is electrically connected to the weighing controller and is used to collect the identification information on the garbage bin and transmit it to the weighing controller for bin identification. The weighing sensing module is electrically connected to the weighing controller and includes multiple force sensors arranged at different load positions of the hooklift truck, used to collect force signals and transmit them to the weighing controller in the garbage bin loading and unloading states. The display module is electrically connected to the weighing controller and is used to display weighing data, identification information and alarm information; The alarm module is electrically connected to the weighing controller and is used to issue an alarm prompt when the weighing controller determines that there is an overload or abnormality. The data recording module is electrically connected to the weighing controller and is used to store the identification information and weighing data for each operation. The weighing controller is configured to: calculate the full load weight and vehicle mass based on the first force signal collected in the hooking state; calculate the empty load weight and garbage net weight based on the second force signal collected in the unloading state; generate an operation record containing multi-stage weighing results based on the identification information, the full load weight, the vehicle mass, the empty load weight, and the garbage net weight; and trigger the alarm module when the alarm conditions are met.

2. The intelligent weighing system for battery swapping hooklift trucks according to claim 1, characterized in that, The image recognition module includes: a weighing recognition camera and an image recognition unit; The weighing and identification camera is installed on the front end of the hook arm and is used to capture the image of the unique identification nameplate on the garbage bin. The image recognition unit, integrated within the weighing controller, is used to perform image preprocessing, feature extraction, and matching recognition with a pre-stored nameplate database on the nameplate image, and output the trash can code and preset parameters.

3. The intelligent weighing system for battery swapping hooklift trucks according to claim 1, characterized in that, The weighing sensor module includes: At least two weighing plane sensors are installed on the load-bearing surface of the garbage bin mounted on the hook arm to collect the vertical pressure between the bin and the contact surface of the hook arm. At least six weighing axle sensors are installed in the front and rear axle areas of the vehicle to collect axle load distribution signals; At least two half-shaft sensors of the weighing system are installed at the half-shaft position of the vehicle to assist in the acquisition of load transmission signals; The weighing plane sensor, the weighing shaft sensor, and the weighing system half-shaft sensor are electrically connected to the weighing controller, forming a sensor network covering multiple force points throughout the vehicle.

4. The intelligent weighing system for battery swapping hooklift trucks according to claim 2, characterized in that, The image recognition unit includes: an image preprocessing subunit, a feature extraction subunit, and a matching recognition subunit; The image preprocessing subunit is used to perform grayscale conversion, binarization, and contour extraction preprocessing on the nameplate image; The feature extraction subunit is used to extract the graphic features or coded features of the nameplate from the preprocessed image; The matching and identification subunit is used to compare the extracted features with the pre-stored nameplate database and output the trash can code and the corresponding empty weight and can size parameters. The matching and identification subunit is also used to perform secondary identification before unloading the garbage bin, in order to confirm the identity of the working bin and trigger the closed loop of the operation record.

5. The intelligent weighing system for battery swapping hooklift trucks according to claim 1, characterized in that, The weighing controller includes: a signal acquisition unit, a load calculation unit, an axle load distribution calculation unit, and a comparison and judgment unit; The signal acquisition unit is used to receive the analog force signals collected by each sensor in the weighing sensor module and convert them into digital signals. The load calculation unit is used to calculate the full load weight, empty load, net weight of garbage and total mass of the vehicle based on the installation position of each sensor and the preset distance from each sensor to the center of the rear axle of the vehicle, combined with the empty axle load parameters of the vehicle chassis and hook arm. The axle load distribution calculation unit is used to calculate the axle load distribution ratio of the current load on the front and rear axles based on the force distribution of each sensor. The comparison and judgment unit is used to compare the total mass of the vehicle with a preset total mass threshold, compare the axle load distribution ratio with a preset axle load threshold, compare the unloaded weight with a pre-stored unloaded weight, and output the comparison results.

6. The intelligent weighing system for battery swapping hooklift trucks according to claim 5, characterized in that, The alarm module includes: a weighing alarm horn and a screen display alarm unit; The weighing alarm horn is installed in the cab or on the side of the hook boom. The screen display alarm unit is integrated into the display module; The alarm module is configured to: when the comparison and judgment unit outputs that the total mass of the vehicle or the axle load distribution exceeds the limit, simultaneously trigger the weighing alarm horn to emit a voice alarm and the display module to display text alarm information; When the deviation between the output empty weight and the pre-stored empty weight by the comparison and judgment unit exceeds a preset threshold, the weighing alarm horn is triggered to emit a target prompt sound, and an abnormal prompt is displayed on the display module.

7. The intelligent weighing system for battery swapping hooklift trucks according to claim 1, characterized in that, The data recording module includes: a local storage unit, a remote communication unit, and a report generation unit; The local storage unit is integrated into the weighing controller and is used to store the garbage bin code, start and end time of the operation, full load weight, empty load weight, net weight of garbage, total mass of the vehicle, front and rear axle load distribution and alarm status for each operation. It is a remote communication unit used to upload job records in the local storage unit to a remote server or management platform; The report generation unit is used to automatically generate statistical reports on a daily or periodic basis based on records stored locally or remotely. The statistical reports include the frequency of use of each garbage bin, the total net weight of transported garbage, and the number of overload events.

8. The intelligent weighing system for battery swapping hooklift trucks according to claim 3, characterized in that, The upper surface of the weighing plane sensor is provided with a wear-resistant contact layer to resist sliding friction during the loading and unloading of the garbage bin. The weighing shaft sensor and the half-shaft sensor of the weighing system are each integrated with a maintenance-free bearing to reduce frictional losses between the sensor and the rotating parts.

9. The intelligent weighing system for battery swapping hooklift trucks according to claim 1, characterized in that, The display module is a weighing system screen installed in the driver's cab, and the weighing system screen has: The bin information display area is used to display the currently identified bin code and preset parameters; The weight data display area is used to display the real-time full load weight, empty load weight, net weight of garbage, and total vehicle weight; The axle load status display area is used to display the front and rear axle load distribution values ​​and percentages; The alarm status bar is used to display overload alarms, axle load over-limit alarms, or incomplete tipping alarms by highlighting or flashing.

10. The intelligent weighing system for battery swapping hooklift trucks according to claim 2, characterized in that, The exclusive identification nameplate is a graphic nameplate with a unique code; The weighing controller is also configured to automatically update the last usage time and cumulative transport weight of the trash can in the data recording module after the image recognition unit successfully recognizes the exclusive identification nameplate.

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