Remote travel automatic positioning and anchoring system and method for a stacker-reclaimer

Abstract

The present application relates to the technical field of stacker reclaimer control, in particular to a stacker reclaimer remote walking automatic positioning and anchoring system and method, comprising a positioning sensing module, a PLC control system, a remote control module, an anchoring execution module and a communication link module, the positioning sensing module comprising an absolute value encoder and a laser ranging sensor; the method realizes automatic operation through system initialization, remote instruction receiving, data acquisition and two-step verification, cooperative positioning solution, anchoring or unanchoring execution and interlocking control; the core is to adopt double-sensor cooperative positioning and Kalman filter data fusion, combined with data synchronization and effectiveness verification, positioning deviation ≤±5mm; through limit switch signal feedback and timing threshold determination, anchoring action interlocking protection is established. The present application solves the problems of low positioning accuracy, poor reliability and complex operation of traditional technology, realizes remote one-key control, and improves operation safety and efficiency.

Description

Technical Field

[0001] This invention relates to the field of stacker-reclaimer control technology, specifically to a remote automatic positioning and anchoring system and method for stacker-reclaimers. Background Technology

[0002] Stacker-reclaimers are core material handling equipment in industrial settings such as bulk cargo terminals, thermal power plants, and steel mills. The precise positioning and reliable anchoring of their trolleys directly affect operational efficiency, equipment safety, and production continuity. In actual operation, stacker-reclaimers need to travel back and forth on long-distance tracks, and after completing their work, they must quickly and accurately stop at the preset anchoring position and complete anchoring.

[0003] Currently, the travel positioning and anchoring methods of stacker-reclaimers mainly suffer from the following technical defects:

[0004] 1. Insufficient positioning accuracy: Traditional positioning methods often rely on a single absolute encoder or laser rangefinder. A single sensor is easily affected by working conditions (such as pulse counting errors caused by wheel slippage in the encoder, and measurement deviations caused by dust obstruction in the laser sensor), which cannot meet the requirements of high-precision anchoring. It is easy for the anchoring plate and the anchoring pit to misalign, resulting in mechanical jamming or anchoring failure.

[0005] 2. Lack of interlocking protection for anchoring action: Most existing anchoring systems are executed in steps of "positioning-anchoring" without a sound signal feedback interlocking mechanism. When the anchoring plate is not fully inserted or detached from the anchoring pit, the limit switch malfunctions, or there is a signal transmission delay, the system cannot identify the abnormality in time and still judges that the anchoring or unanchoring is completed, which poses a safety hazard to the equipment operation.

[0006] 3. Poor data reliability: Traditional systems do not perform synchronous verification and validity screening of sensor-collected data. When sensor signals are interrupted, data transmission is delayed, or there is instantaneous interference, the system is prone to performing positioning and anchoring actions based on invalid data, resulting in inaccurate positioning or anchoring failure. Frequent manual intervention is required to troubleshoot, which seriously affects production efficiency.

[0007] Therefore, developing a remote automatic positioning and anchoring technology for stacker-reclaimers with high-precision collaborative positioning, comprehensive interlocking protection, and high data reliability has become a key requirement for solving the pain points of existing technologies and improving the safety and efficiency of industrial bulk material handling operations. Summary of the Invention

[0008] To address the shortcomings of existing technologies, the purpose of this invention is to provide a remote automatic positioning and anchoring system and method for stacker-reclaimers that features high-precision collaborative positioning, comprehensive interlocking protection, and high data reliability.

[0009] The technical solution adopted by this invention to solve its technical problem is:

[0010] A remote automatic positioning and anchoring system for a stacker-reclaimer includes a positioning sensor module, a PLC control system, a remote control module, an anchoring execution module, and a communication link module.

[0011] The positioning sensing module includes an absolute encoder and a laser rangefinder: the absolute encoder is installed on both sides of the drive wheels of the stacker-reclaimer trolley to collect the number of wheel rotation pulses in real time; the laser rangefinder is fixed to the end of the track to collect the straight-line distance between the stacker-reclaimer trolley and the laser sensor mounting reference point in real time.

[0012] The PLC control system includes PLC substations and a PLC master station. The PLC substations are installed in the electrical control box of the stacker-reclaimer and are connected to the positioning sensor module and the anchoring execution module to perform coordinated positioning by the absolute encoder and the laser rangefinder. The PLC master station is located in the electrical room of the stacker-reclaimer and communicates with the PLC substations via Ethernet.

[0013] The remote control module is the host computer in the production scheduling center control room, and it communicates with the PLC master station.

[0014] The anchoring execution module includes electric push rods symmetrically arranged on both sides of the stacker-reclaimer. The output end of the electric push rod is connected to an anchoring plate, which is used to push the anchoring plate into or out of the anchoring pit at the preset anchoring point on the ground outside the track. Each anchoring point is equipped with a limit switch to provide feedback on the anchoring and unanchoring completion signals.

[0015] The communication link module includes an Ethernet communication module and a fiber optic communication link. The PLC substation establishes a connection with the PLC master station through the Ethernet communication module. The PLC master station communicates with the server in the production scheduling center computer room through the fiber optic communication link. The server connects to the host computer through the Ethernet communication module.

[0016] As a preferred embodiment, a further technical solution of the present invention is:

[0017] Preferably, the limit switch includes a lower limit switch and an upper limit switch. The lower limit switch is set in the anchoring pit, and a fixed bracket is provided outside the anchoring pit. The upper limit switch is installed on the fixed bracket. A trigger block is fixed at the tail end of the anchoring plate. The trigger block moves synchronously with the anchoring plate and is triggered by physical collision and squeezing of the lower limit switch and the upper limit switch.

[0018] Preferably, the anchoring execution module further includes local operation components symmetrically arranged on both sides of the stacker-reclaimer. The local operation components include a sealed housing, an anchoring control button, an anchor release control button, and a terminal block. The sealed housing is mounted on a fixed bracket. The anchoring control button and the anchor release control button are respectively connected to the terminal block via wires. The terminal block is connected to the PLC substation via a cable. The electric push rod is connected to the PLC substation via a cable through the terminal block.

[0019] This invention also discloses a remote automatic positioning and anchoring method for a stacker-reclaimer, which is implemented using a remote automatic positioning and anchoring system for the stacker-reclaimer. The specific steps are as follows:

[0020] S1: System initialization, preset the stacker-reclaimer trolley wheel rolling radius R, encoder pulses per revolution P, laser sensor mounting reference point coordinates X0, Kalman filter process noise covariance Q, and observation noise covariance R. k Data synchronization error threshold, deviation threshold between positioning coordinates and preset anchoring position, and low-speed fine-tuning speed parameters of the trolley; a one-dimensional positioning coordinate system is established with the starting end of the trolley's travel track as the coordinate origin (0,0) and the trolley traveling along the track towards the material pile as the positive X-axis. The initial positioning coordinates are set as the measured values ​​of the trolley's standby position.

[0021] S2: Remote command reception. After the stacker-reclaimer completes its operation, the PLC control system receives a one-click anchoring command from the host computer of the production scheduling center.

[0022] S3: Data Acquisition and Verification. The number of wheel rotation pulses N is acquired using an absolute encoder, and the straight-line distance D between the trolley and the laser sensor mounting reference point is acquired using a laser rangefinder. laser N and D laser After time synchronization processing, the data is transmitted to the PLC control system; the PLC control system performs data synchronization validity verification and sensor data validity verification.

[0023] S4: Cooperative positioning calculation. If the data validity verification is successful, the PLC control system processes the collected data through the cooperative positioning algorithm and calculates and outputs the optimal positioning coordinates of the stacker-reclaimer trolley. ;

[0024] S5: Anchored execution, optimal positioning coordinates When the deviation from the preset anchoring position meets the deviation threshold, the PLC control system drives the electric push rod to push the anchoring plate into the anchoring pit until the lower limit switch in the limit switch is triggered. The signal is fed back to the host computer to complete the automatic anchoring. If the deviation threshold is not met, the control system controls the trolley to make low-speed fine-tuning according to the trolley's low-speed fine-tuning speed parameter until the accuracy requirements are met before performing the anchoring action.

[0025] S6: Automatic anchor release. When it is necessary to release the anchor, the PLC control system receives a one-key anchor release command from the host computer, drives the electric push rod to lift the anchor plate and remove it from the anchor pit, until the upper limit switch in the limit switch is triggered, and the signal is fed back to the host computer to complete the anchor release.

[0026] Preferably, in step 1, the noise covariance Q of the Kalman filtering process is 10. -3 Observation noise covariance Rk =5×10 -2 The data synchronization error threshold is ≤1ms, the deviation threshold between the positioning coordinates and the preset anchor position is ≤±5mm, and the low-speed fine-tuning speed parameter of the trolley is 5mm / s.

[0027] Preferably, in step S3, the data synchronization validity verification specifically involves verifying... and If the synchronization error meets the preset data synchronization error threshold, the system will proceed to sensor data validity verification; if the data synchronization error does not meet the threshold, the system will be deemed to have failed to synchronize data. The PLC control system will immediately prohibit the execution of subsequent actions and generate a synchronization fault signal to feed back to the host computer, prompting the operator to check the communication link and data synchronization module.

[0028] The sensor data validity verification process involves setting the absolute encoder pulse signal update frequency to be ≥100Hz and ensuring the effective range of the laser ranging sensor measurement value matches the physical length of the track. The verification checks whether the encoder pulse signal update frequency is ≥100Hz and whether the laser ranging value is within the effective range. If either condition is not met, or if there is an interruption in the transmission of either type of sensor signal (interruption duration ≥1s), the sensor data is considered abnormal. The PLC control system then prohibits subsequent actions and generates a sensor fault signal to feed back to the host computer, prompting the operator to check the data transmission loop and hardware. If all conditions are met, the data verification is deemed successful.

[0029] Preferably, the specific process of the collaborative localization algorithm processing the collected data in step 4 is as follows:

[0030] S401: Encoder displacement calculate,

[0031] ;

[0032] in, The rolling radius of the vehicle wheel. This represents the number of encoder pulses. This refers to the number of pulses per encoder revolution.

[0033] S402: Laser ranging coordinate transformation, the formula is as follows.

[0034] ;

[0035] in, The coordinates of the trolley after transformation. Install reference point coordinates for the laser sensor. For laser distance measurement;

[0036] S403: Kalman filter data fusion. Through five iterative steps—state prediction, covariance prediction, Kalman gain calculation, state update, and covariance update—the encoder displacement data and laser coordinate data are fused to output the optimal positioning coordinates. .

[0037] Preferably, the specific steps for Kalman filter data fusion are as follows:

[0038] (1) The state prediction formula is: ;

[0039] in, Let k be the predicted positioning coordinates of the stacker-reclaimer trolley at time k. The optimal positioning coordinates of the vehicle obtained at time k-1 are... The cumulative displacement of the vehicle measured by the absolute encoder at time k is... The cumulative displacement of the trolley measured by the absolute encoder at time k-1;

[0040] (2) The covariance prediction formula is: ;

[0041] in, Let be the covariance of the predicted coordinates at time k, representing the uncertainty of the predicted value; Let be the covariance of the optimal coordinates at time k-1; The preset noise covariance of the Kalman filtering process;

[0042] (3) The formula for calculating Kalman gain is: ;

[0043] in, The Kalman gain at time k is used to adjust the weight ratio between the predicted and observed values. The pre-defined Kalman filter observation noise covariance;

[0044] (4) The state update formula is: ;

[0045] in, The optimal positioning coordinates of the vehicle are obtained at time k. The coordinates of the vehicle after conversion by the laser ranging sensor at time k;

[0046] (5) The covariance update formula is: ;

[0047] in, The covariance of the optimal coordinates at time k is used as the input value for predicting the covariance at the next time step.

[0048] After the preset number of iterations is met, .

[0049] Preferably, it also includes interlocking control of the anchoring action, specifically: during the anchoring execution process in step S5 and the automatic unanchoring process in step S6, the preset signal feedback timing threshold is ≤5s;

[0050] When the anchoring action is triggered, the PLC control system starts timing. If the closing signal of the lower limit switch is not received within the timing threshold of ≤5s and the anchoring completion indicator light on the host computer is not lit, it is determined that the anchoring signal feedback is abnormal.

[0051] When the anchor release action is triggered, the PLC control system starts timing. If the upper limit switch closing signal is not received within the timing threshold of ≤5s and the anchor release completion indicator light on the host computer is not lit, it is determined that the anchor release signal feedback is abnormal.

[0052] When the anchoring signal feedback or the unanchoring signal feedback is abnormal, the PLC control system immediately stops operating and generates a limit fault signal to feed back to the host computer, prompting the operator to check the upper and lower limit control circuits and hardware facilities of the on-site traveling anchoring plate.

[0053] The present invention, which adopts the above technical solution, has the following prominent features compared with the prior art:

[0054] 1. High positioning accuracy: Through the collaborative positioning of absolute encoder and laser rangefinder, combined with Kalman filter data fusion algorithm and dual verification of data synchronization and validity, the positioning deviation is controlled within ±5mm, solving the problem of measurement error of single sensor;

[0055] 2. High safety and reliability: The timing interlock protection for anchoring and deanchoring actions has been established, the limit signal feedback threshold has been clearly defined, and a shutdown alarm mechanism has been set up in case of data abnormality to avoid the risk of anchoring failure or misoperation.

[0056] 3. High degree of automation: Supports remote one-click anchoring and unanchoring by the production scheduling center. When the positioning deviation exceeds the standard, it automatically makes low-speed fine adjustments without manual intervention, which is suitable for automated production needs.

[0057] 4. Excellent fault tolerance: It is equipped with sensor data retry verification and accurate fault indication functions, which can quickly locate problems in communication links, data transmission or limit circuits, reduce manual troubleshooting costs and ensure production continuity. Attached Figure Description

[0058] Figure 1 This is a flowchart of the automatic positioning and anchoring system in an embodiment of the present invention;

[0059] Figure 2 This is a data transmission structure diagram in an embodiment of the present invention. Detailed Implementation

[0060] The present invention will be further illustrated below with reference to specific embodiments. The purpose of this illustration is solely to provide a better understanding of the invention. Therefore, the examples given do not limit the scope of protection of the present invention.

[0061] The daily operating environment of the stockpile is characterized by high dust concentration, frequent strong winds (with instantaneous maximum wind speeds reaching 25 m / s), and large diurnal temperature variations (-10℃ to 40℃), which places stringent requirements on the positioning accuracy, anchoring reliability, and weather resistance of the stacker-reclaimer. Traditional stacker-reclaimers use a single encoder for positioning and manual on-site anchoring, resulting in a positioning deviation of ±50 mm. Anchoring operations require two operators per unit, taking approximately 15 minutes, and pose safety hazards for personnel operating in windy conditions.

[0062] Therefore, this embodiment provides a remote automatic positioning and anchoring system for a stacker-reclaimer, including a positioning sensing module, a PLC control system, a remote control module, an anchoring execution module, and a communication link module. The positioning sensing module includes an absolute encoder and a laser rangefinder: the absolute encoder is installed on both sides of the drive wheels of the stacker-reclaimer trolley to collect the number of wheel rotation pulses in real time; the laser rangefinder is fixed to the end of the track to collect the straight-line distance between the stacker-reclaimer trolley and the laser sensor mounting reference point in real time; the PLC control system includes PLC substations and a PLC master station. The PLC substation is installed in the electrical control box of the stacker-reclaimer and communicates with the positioning sensor module and the anchoring execution module to perform coordinated positioning by the absolute encoder and laser rangefinder. The PLC master station is located in the electrical room of the stacker-reclaimer and communicates with the PLC substation via Ethernet. The remote control module is the host computer in the production scheduling center control room and communicates with the PLC master station. The anchoring execution module includes electric push rods symmetrically arranged on both sides of the stacker-reclaimer. The output end of the electric push rod is connected to an anchoring plate, which is used to push the anchoring plate into or out of the anchoring pit at the preset anchoring point on the ground outside the track. For example, a large bulk cargo terminal yard is equipped with 3 DQ1500 / 1500.30 stacker-reclaimers with a total operating track length of 1200m. There are 12 anchoring pits evenly distributed along the track (spaced 100m apart), and the anchoring pit size is 300mm×300mm×500mm (length×width×depth). Each anchoring point is equipped with a limit switch to provide feedback signals indicating that anchoring and unanchoring are complete. The communication link module includes an Ethernet communication module and a fiber optic communication link. The PLC substation establishes a connection with the PLC master station through the Ethernet communication module. The PLC master station communicates with the production scheduling center server through the fiber optic communication link. The server connects to the host computer through the Ethernet communication module.

[0063] The absolute encoder is a Pepperl+Fuchs PVM58N-011AGR0BN-1213 model from Germany, installed on both sides of the drive wheel axle of the stacker-reclaimer trolley. It is rigidly connected to the axle via a flexible coupling to ensure synchronization between wheel rotation and encoder pulse acquisition. The acquisition frequency is set to 200Hz, higher than the preset minimum update frequency of 100Hz, improving data reliability. The laser rangefinder is a SICKDME5000-112 model from Germany, with a measurement range of 0.5m to 500m, a measurement accuracy of ±1mm, and a resolution of 0.1mm. It is fixed to a concrete bracket at the end of the track (near the starting end of the stockpile), installed 1.5m above the track surface, with the laser emission direction parallel to the track centerline. The PLC substation is a Siemens S7-1511C model, equipped with an Ethernet communication module CP1543-1 and an integrated analog input module SM1231, installed inside the stacker-reclaimer trolley's electrical control box. The PLC master station uses a Siemens S7-1516F PLC with safety control functions. It is located in the stacker-reclaimer electrical room and communicates with the PLC substations via industrial Ethernet (Profinet protocol) with a communication rate of 100Mbps and a data transmission delay of ≤50ms.

[0064] Specifically, the limit switches include a lower limit switch and an upper limit switch. The lower limit switch is installed inside the anchoring pit, and a fixed bracket is provided outside the anchoring pit. The upper limit switch is installed on the fixed bracket. A trigger block is fixed to the tail end of the anchoring plate. The trigger block moves synchronously with the anchoring plate, and the lower and upper limit switches are triggered by physical collision and pressure. Specifically, both the lower and upper limit switches can be Schneider Electric XCK-M121 mechanical limit switches with an IP67 protection rating. The lower limit switch is fixed to the center of the bottom of the anchoring pit, 50mm from the bottom. The upper limit switch is installed on the top of the fixed bracket outside the anchoring pit, aligned with the extreme position on the anchoring plate. The collision pressure between the trigger block and the limit switch is set to 5~8N to avoid damage from overpressure. The anchoring plate is made of Q355B steel plate, and the trigger block is made of 45# steel with surface hardening treatment to improve wear resistance.

[0065] Furthermore, in this embodiment, the anchoring execution module also includes local operation components symmetrically arranged on both sides of the stacker-reclaimer. The local operation components include a sealed housing, an anchoring control button, a de-anchoring control button, and a terminal block. The sealed housing is mounted on a fixed bracket. The anchoring control button and the de-anchoring control button are respectively connected to the terminal block via wires. The terminal block is connected to the PLC substation via a cable. The electric push rod is connected to the PLC substation via a cable through the terminal block.

[0066] like Figure 1 , Figure 2Accordingly, this embodiment discloses a remote automatic positioning and anchoring method for a stacker-reclaimer, which is implemented using a remote automatic positioning and anchoring system for the stacker-reclaimer. The specific steps are as follows:

[0067] S1: System initialization, preset the stacker-reclaimer trolley wheel rolling radius R, encoder pulses per revolution P, laser sensor mounting reference point coordinates X0, Kalman filter process noise covariance Q, and observation noise covariance R. k The following parameters are set: data synchronization error threshold, deviation threshold between positioning coordinates and preset anchor position, and low-speed fine-tuning speed parameters of the trolley. A one-dimensional positioning coordinate system is established with the starting end of the trolley's traveling track as the coordinate origin (0,0) and the trolley traveling along the track towards the material pile as the positive X-axis. The initial positioning coordinates are set as the measured values ​​of the trolley's standby position.

[0068] Wherein, the noise covariance of the Kalman filter process is Q=10. -3 Observation noise covariance R k =5×10 -2 The data synchronization error threshold is ≤1ms, the deviation threshold between the positioning coordinates and the preset anchor position is ≤±5mm, and the low-speed fine-tuning speed parameter of the trolley is 5mm / s.

[0069] S2: Remote command reception. After the stacker-reclaimer completes the bulk coal transfer operation, the operator clicks the "one-click anchoring" button on the host computer in the production scheduling center. The command is transmitted to the PLC master station via the fiber optic communication link with a transmission delay of 0.3ms. The PLC control system successfully receives the command and sends a "command received successfully" signal back to the host computer.

[0070] S3: Data Acquisition and Verification. The number of wheel rotation pulses N is acquired using an absolute encoder, and the straight-line distance D between the trolley and the laser sensor mounting reference point is acquired using a laser rangefinder. laser N and D laser After time synchronization processing, the data is transmitted to the PLC control system; the PLC control system performs data synchronization validity verification and sensor data validity verification.

[0071] Specifically, the data synchronization validity verification involves verifying... and The system checks whether the synchronization error meets the preset data synchronization error threshold. If it does, the system proceeds to sensor data validity verification. If it does not meet the threshold, the system is deemed to have failed in data synchronization. The PLC control system immediately prohibits subsequent actions and generates a synchronization fault signal to the host computer, prompting the operator to check the communication link and data synchronization module. Specifically, the sensor data validity verification requires that the preset absolute encoder pulse signal update frequency be ≥100Hz and that the effective range of the laser ranging sensor measurement value match the physical length of the track. The system checks whether the encoder pulse signal update frequency is ≥100Hz and whether the laser ranging value is within the effective range. If either condition is not met, or if there is an interruption in the transmission of either type of sensor signal (interruption duration ≥1s), the sensor data is deemed abnormal. The PLC control system prohibits subsequent actions and generates a sensor fault signal to the host computer, prompting the operator to check the data transmission loop and hardware facilities. If all conditions are met, the data verification is deemed successful.

[0072] S4: Cooperative positioning calculation. If the data validity verification is successful, the PLC control system processes the collected data through the cooperative positioning algorithm and calculates and outputs the optimal positioning coordinates of the stacker-reclaimer trolley. .

[0073] The specific process by which the cooperative localization algorithm processes the collected data is as follows:

[0074] S401: Encoder displacement calculate,

[0075] ;

[0076] in, The rolling radius of the vehicle wheel. This represents the number of encoder pulses. This represents the number of pulses per encoder revolution.

[0077] S402: Laser ranging coordinate transformation, the formula is as follows.

[0078] ;

[0079] in, The coordinates of the trolley after transformation. Install reference point coordinates for the laser sensor. For laser distance measurement.

[0080] S403: Kalman filter data fusion. Through five iterative steps—state prediction, covariance prediction, Kalman gain calculation, state update, and covariance update—the encoder displacement data and laser coordinate data are fused to output the optimal positioning coordinates. .

[0081] Specifically, the specific steps of Kalman filter data fusion in this embodiment are as follows:

[0082] (1) The state prediction formula is: ;

[0083] in, Let k be the predicted positioning coordinates of the stacker-reclaimer trolley at time k. The optimal positioning coordinates of the vehicle obtained at time k-1 are... The cumulative displacement of the vehicle measured by the absolute encoder at time k is... The cumulative displacement of the vehicle measured by the absolute encoder at time k-1.

[0084] (2) The covariance prediction formula is: ;

[0085] in, Let be the covariance of the predicted coordinates at time k, representing the uncertainty of the predicted value; Let be the covariance of the optimal coordinates at time k-1; This is the preset noise covariance of the Kalman filtering process.

[0086] (3) The formula for calculating Kalman gain is: ;

[0087] in, The Kalman gain at time k is used to adjust the weight ratio between the predicted and observed values. This is the preset Kalman filter observation noise covariance.

[0088] (4) The state update formula is: ;

[0089] in, The optimal positioning coordinates of the vehicle are obtained at time k. Let k be the real-time coordinates of the vehicle after conversion by the laser ranging sensor.

[0090] (5) The covariance update formula is: ;

[0091] in, The covariance of the optimal coordinates at time k is used as the input value for predicting the covariance at the next time step.

[0092] After the preset number of iterations is met, .

[0093] S5: Anchored execution, optimal positioning coordinates When the deviation from the preset anchoring position meets the deviation threshold, the PLC control system drives the electric push rod to push the anchoring plate into the anchoring pit until the lower limit switch in the limit switch is triggered, and the signal is fed back to the host computer to complete the automatic anchoring; if the deviation threshold is not met, the control system controls the trolley to fine-tune at low speed according to the trolley's low-speed fine-tuning speed parameter until the accuracy requirements are met before performing the anchoring action.

[0094] During the anchoring process in step S5 and the automatic unanchoring process in step S6, a preset signal feedback timing threshold of ≤5s is set. When the anchoring action is triggered, the PLC control system starts timing. If the lower limit switch closing signal is not received within the timing threshold of ≤5s, and the anchoring completion indicator light on the host computer is not lit, it is determined that the anchoring signal feedback is abnormal. When the unanchoring action is triggered, the PLC control system starts timing. If the upper limit switch closing signal is not received within the timing threshold of ≤5s, and the unanchoring completion indicator light on the host computer is not lit, it is determined that the unanchoring signal feedback is abnormal. When the anchoring signal feedback or the unanchoring signal feedback is abnormal, the PLC control system immediately stops the action and generates a limit fault signal to feed back to the host computer, prompting the operator to check the upper and lower limit control circuits and hardware facilities of the on-site traveling anchoring plate.

[0095] S6: Automatic anchor release. When it is necessary to release the anchor, the PLC control system receives a one-key anchor release command from the host computer, drives the electric push rod to lift the anchor plate and remove it from the anchor pit, until the upper limit switch in the limit switch is triggered, and the signal is fed back to the host computer to complete the anchor release.

[0096] This invention enables remote, unmanned operation, reducing the time required for anchoring and unanchoring a single device, decreasing the number of frontline operators, and avoiding safety hazards associated with personnel working in windy or dusty environments, thus saving labor costs. Through multiple protection mechanisms, including data synchronization verification, sensor validity screening, and time-series threshold interlocking, this invention reduces the equipment failure rate from 12% of traditional technologies to 1.5%, significantly shortening troubleshooting time. By optimizing hardware selection, precisely configuring parameters, and innovating algorithms, this invention addresses the pain points of traditional stacker-reclaimers, such as low positioning accuracy, low automation, and significant safety hazards. It is suitable for complex industrial scenarios such as bulk cargo terminals, thermal power plants, and steel mills, and has significant economic value and promotional significance.

[0097] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of the invention. All equivalent changes made based on the description and drawings of the present invention are included within the scope of the present invention.

Claims

1. A remote-traveling automatic positioning and anchoring system for a stacker-reclaimer, characterized in that: It includes a positioning sensor module, a PLC control system, a remote control module, an anchoring execution module, and a communication link module; The positioning sensing module includes an absolute encoder and a laser rangefinder: the absolute encoder is installed on both sides of the drive wheels of the stacker-reclaimer trolley to collect the number of wheel rotation pulses in real time; the laser rangefinder is fixed to the end of the track to collect the straight-line distance between the stacker-reclaimer trolley and the laser sensor mounting reference point in real time. The PLC control system includes PLC substations and a PLC master station. The PLC substations are installed in the electrical control box of the stacker-reclaimer and are connected to the positioning sensor module and the anchoring execution module to perform coordinated positioning by the absolute encoder and the laser rangefinder. The PLC master station is located in the electrical room of the stacker-reclaimer and communicates with the PLC substations via Ethernet. The remote control module is the host computer in the production scheduling center control room, and it communicates with the PLC master station. The anchoring execution module includes electric push rods symmetrically arranged on both sides of the stacker-reclaimer. The output end of the electric push rod is connected to an anchoring plate, which is used to push the anchoring plate into or out of the anchoring pit at the preset anchoring point on the ground outside the track. Each anchoring point is equipped with a limit switch to provide feedback on the anchoring and unanchoring completion signals. The communication link module includes an Ethernet communication module and a fiber optic communication link. The PLC substation establishes a connection with the PLC master station through the Ethernet communication module. The PLC master station communicates with the server in the production scheduling center computer room through the fiber optic communication link. The server connects to the host computer through the Ethernet communication module.

2. The stacker-reclaimer remote traveling automatic positioning and anchoring system according to claim 1, characterized in that: The limit switch includes a lower limit switch and an upper limit switch. The lower limit switch is set in the anchoring pit, and a fixed bracket is provided outside the anchoring pit. The upper limit switch is installed on the fixed bracket. A trigger block is fixed at the tail end of the anchoring plate. The trigger block moves synchronously with the anchoring plate and is triggered by physical collision and squeezing of the lower limit switch and the upper limit switch.

3. The stacker-reclaimer remote traveling automatic positioning and anchoring system according to claim 2, characterized in that: The anchoring execution module also includes local operation components symmetrically arranged on both sides of the stacker-reclaimer. The local operation components include a sealed housing, anchoring control buttons, de-anchoring control buttons, and terminal blocks. The sealed housing is mounted on a fixed bracket. The anchoring control buttons and de-anchoring control buttons are connected to the terminal blocks via wires. The terminal blocks are connected to the PLC substation via cables. The electric push rod is connected to the PLC substation via cables through the terminal blocks.

4. A method for remote automatic positioning and anchoring of a stacker-reclaimer, characterized in that, The stacker-reclaimer remote traveling automatic positioning and anchoring system according to any one of claims 1 to 3 is used, and the specific steps are as follows: S1: System initialization, preset the stacker-reclaimer trolley wheel rolling radius R, encoder pulses per revolution P, laser sensor mounting reference point coordinates X0, Kalman filter process noise covariance Q, and observation noise covariance R. k Data synchronization error threshold, deviation threshold between positioning coordinates and preset anchoring position, and low-speed fine-tuning speed parameters of the trolley; A one-dimensional positioning coordinate system is established with the starting point of the stacker-reclaimer trolley's travel track as the origin (0,0) and the trolley moving along the track toward the material pile as the positive X-axis. The initial positioning coordinates are set as the measured values ​​of the stacker-reclaimer trolley's standby position. S2: Remote command reception. After the stacker-reclaimer completes its operation, the PLC control system receives a one-click anchoring command from the host computer of the production scheduling center. S3: Data Acquisition and Verification. The number of wheel rotation pulses N is acquired using an absolute encoder, and the straight-line distance D between the trolley and the laser sensor mounting reference point is acquired using a laser rangefinder. laser N and D laser After time synchronization processing, the data is transmitted to the PLC control system; the PLC control system performs data synchronization validity verification and sensor data validity verification. S4: Cooperative positioning calculation. If the data validity verification is successful, the PLC control system processes the collected data through the cooperative positioning algorithm and calculates and outputs the optimal positioning coordinates of the stacker-reclaimer trolley. ; S5: Anchored execution, optimal positioning coordinates When the deviation from the preset anchoring position meets the deviation threshold, the PLC control system drives the electric push rod to push the anchoring plate into the anchoring pit until the lower limit switch in the limit switch is triggered. The signal is fed back to the host computer to complete the automatic anchoring. If the deviation threshold is not met, the control system controls the trolley to make low-speed fine-tuning according to the trolley's low-speed fine-tuning speed parameter until the accuracy requirements are met before performing the anchoring action. S6: Automatic anchor release. When it is necessary to release the anchor, the PLC control system receives a one-key anchor release command from the host computer, drives the electric push rod to lift the anchor plate and remove it from the anchor pit, until the upper limit switch in the limit switch is triggered, and the signal is fed back to the host computer to complete the anchor release.

5. The remote automatic positioning and anchoring method for a stacker-reclaimer according to claim 4, characterized in that: In step 1, the noise covariance of the Kalman filter process is Q=10. -3 Observation noise covariance R k =5×10 -2 The data synchronization error threshold is ≤1ms, the deviation threshold between the positioning coordinates and the preset anchor position is ≤±5mm, and the low-speed fine-tuning speed parameter of the trolley is 5mm / s.

6. The remote automatic positioning and anchoring method for a stacker-reclaimer according to claim 4, characterized in that: In step S3, the data synchronization validity verification specifically involves verifying... and If the synchronization error meets the preset data synchronization error threshold, the system will proceed to sensor data validity verification; if the data synchronization error does not meet the threshold, the system will be deemed to have failed to synchronize data. The PLC control system will immediately prohibit the execution of subsequent actions and generate a synchronization fault signal to feed back to the host computer, prompting the operator to check the communication link and data synchronization module. The sensor data validity verification is specifically performed as follows: the normal update frequency of the absolute encoder pulse signal is ≥100Hz, and the effective range of the laser ranging sensor measurement value matches the physical length of the track. The verification is performed to check whether the encoder pulse signal update frequency is ≥100Hz and whether the laser ranging value is within the effective range. If either of these conditions is not met, or if there is an interruption in the transmission of the two types of sensor signals, and the interruption duration is ≥1s, it is determined that there is an interruption in the transmission, and the sensor data is determined to be abnormal. The PLC control system prohibits subsequent actions and generates a sensor fault signal to feed back to the host computer, prompting the operator to check the data transmission loop and hardware facilities; if all conditions are met, the data verification is deemed qualified.

7. The remote automatic positioning and anchoring method for a stacker-reclaimer according to claim 4, characterized in that: The specific process of the cooperative localization algorithm processing the collected data in step 4 is as follows: S401: Encoder displacement calculate, ； in, The rolling radius of the vehicle wheel. This represents the number of encoder pulses. This refers to the number of pulses per encoder revolution. S402: Laser ranging coordinate transformation, the formula is as follows. ； in, The coordinates of the trolley after transformation. Install reference point coordinates for the laser sensor. For laser distance measurement; S403: Kalman filter data fusion. Through five iterative steps—state prediction, covariance prediction, Kalman gain calculation, state update, and covariance update—the encoder displacement data and laser coordinate data are fused to output the optimal positioning coordinates. .

8. The stacker-reclaimer remote traveling automatic positioning and anchoring system according to claim 7, characterized in that: The specific steps of Kalman filter data fusion are as follows: (1) The state prediction formula is: ; in, Let k be the predicted positioning coordinates of the stacker-reclaimer trolley at time k. The optimal positioning coordinates of the vehicle are obtained at time k-1. The cumulative displacement of the vehicle measured by the absolute encoder at time k is... The cumulative displacement of the trolley measured by the absolute encoder at time k-1; (2) The covariance prediction formula is: ; in, Let be the covariance of the predicted coordinates at time k, which characterizes the uncertainty of the predicted value; Let be the covariance of the optimal coordinates at time k-1; The preset noise covariance of the Kalman filtering process; (3) The formula for calculating Kalman gain is: ; in, The Kalman gain at time k is used to adjust the weight ratio between the predicted and observed values. The pre-defined Kalman filter observation noise covariance; (4) The state update formula is: ; in, The optimal positioning coordinates of the vehicle are obtained at time k. The coordinates of the vehicle after conversion by the laser ranging sensor at time k; (5) The covariance update formula is: ; in, The covariance of the optimal coordinates at time k is used as the input value for predicting the covariance at the next time step. After the preset number of iterations is met, .

9. The remote automatic positioning and anchoring method for a stacker-reclaimer according to claim 4, characterized in that: It also includes interlocking control of the anchoring action, specifically: during the anchoring execution process in step S5 and the automatic unanchoring process in step S6, the preset signal feedback timing threshold is ≤5s; When the anchoring action is triggered, the PLC control system starts timing. If the closing signal of the lower limit switch is not received within the timing threshold of ≤5s and the anchoring completion indicator light on the host computer is not lit, it is determined that the anchoring signal feedback is abnormal. When the anchor release action is triggered, the PLC control system starts timing. If the upper limit switch closure signal is not received within the timing threshold of ≤5s and the anchor release completion indicator light on the host computer is not lit, it is determined that the anchor release signal feedback is abnormal. When the anchoring signal feedback or the unanchoring signal feedback is abnormal, the PLC control system immediately stops operating and generates a limit fault signal to feed back to the host computer, prompting the operator to check the upper and lower limit control circuits and hardware facilities of the on-site traveling anchor plate.

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