A dual-control scrap container spreader and its lifting method

Abstract

This invention discloses a dual-control waste container spreader and its lifting method, relating to the field of waste transfer technology. The method introduces dual control logic: the first layer is a safety interlock logic based on a finite state machine, which actively blocks unloading commands in the lifting lock state by real-time monitoring of weight, angle and encoder data, fundamentally eliminating misoperation; the second layer is a precise unloading logic based on PID algorithm and multi-sensor fusion, which realizes closed-loop control of the opening angle and speed of the container bottom door, supports position closed-loop or speed-trajectory collaborative control mode, and ensures the digitalization and precision of the unloading process.

Description

Technical Field

[0001] This invention relates to the field of waste transfer technology, and more specifically to a dual-control waste container lifting device and its lifting method. Background Technology

[0002] Currently, in waste handling and transfer operations, waste container spreaders are key equipment, and their operation relies on a relatively simple control mode. The common control method is single-loop control, where operators directly control the forward and reverse rotation of the winch via one or a set of buttons, thereby controlling the winding and unwinding of the wire rope to lock and open the container bottom door. This traditional control mode has revealed several technical shortcomings in practical applications.

[0003] First, the safety assurance logic of existing control methods is relatively basic. It relies heavily on the operator's experience and real-time attention, lacking comprehensive perception and intelligent processing capabilities regarding the lifting equipment's operational status. If an operator, due to fatigue, distraction, or misjudgment, incorrectly triggers the unloading command, especially when the waste bin is in a lifting state, the bottom door may accidentally open in mid-air, causing serious safety accidents such as material spillage, equipment damage, and even personal injury. Due to the lack of real-time status monitoring and proactive protection mechanisms, this operational risk always exists and is difficult to effectively avoid.

[0004] Secondly, the precision of unloading operations is difficult to guarantee. Operators can only manually control the release of the wire rope based on experience, making it impossible to precisely control the opening angle of the bottom door. This leads to potentially inaccurate unloading positions and difficulty in effectively adjusting the unloading speed, making it easy for materials to spill and generate dust during unloading, especially for lightweight or powdery waste materials, where dust pollution is particularly prominent, causing environmental pollution and affecting the health of workers. Furthermore, the inability to flexibly adjust the opening degree according to material characteristics and unloading requirements also limits operational efficiency and the level of refined management.

[0005] Furthermore, existing lifting equipment generally lacks effective self-diagnostic capabilities. When abnormal operating conditions occur, such as wire rope slippage or jamming, or mechanical failure of the winch, the system cannot identify and issue warnings in a timely manner. Operators need to rely on observation or hearing to detect the problem, which leads to delayed fault detection. This may not only delay maintenance and reduce operational efficiency, but in some cases, delayed fault response may even exacerbate equipment damage or cause more serious safety issues.

[0006] Therefore, it is necessary to propose a dual-control scrap container lifting device and its lifting method to solve the above problems. Summary of the Invention

[0007] The purpose of this invention is to solve the problems of high safety risks, low unloading accuracy, and lack of fault self-diagnosis capability in the existing waste container spreader control methods.

[0008] To achieve the above objectives, the present invention specifically adopts the following technical solution:

[0009] A lifting method for a dual-control scrap container spreader includes the following steps:

[0010] a. Obtain real-time data from the weight sensor to determine the load status of the waste bin;

[0011] b. Based on the load status and real-time data from the angle sensor, the operating state of the lifting device is shifted between multiple preset finite states, which include at least: standby initial state, lifting lock state, and unloading preparation state.

[0012] c. In the hoisting locked state, the system blocks all unloading execution commands intended to open the bottom door of the container;

[0013] d. In the unloading preparation state, the system unlocks the unloading execution command and receives the target opening parameter or the preset unloading trajectory parameter set by the operator;

[0014] e. Based on the target opening parameter or the unloading trajectory parameter, as well as the real-time feedback data from the angle sensor and encoder, the opening and closing actions of the bottom door of the box are precisely controlled through a closed-loop control algorithm.

[0015] Furthermore, the plurality of preset finite states also include a discharge in progress state and a fault state.

[0016] Furthermore, the transition condition between the standby initial state and the hoisting lock state for the hoisting operation state is: the weight sensor detects that the weight value continuously exceeds the first preset threshold W0, and the angle sensor detects that the bottom door of the box is in a closed state.

[0017] Furthermore, the transition condition between the lifting device operation state and the lifting lock state and the unloading preparation state is: the weight sensor detects that the weight value continuously drops below the first preset threshold W0.

[0018] Furthermore, the closed-loop control algorithm in step e adopts the PID (proportional-integral-derivative) algorithm. Based on the error between the target opening parameter or the unloading trajectory parameter and the real-time feedback of the angle sensor, the control quantity is calculated and output to drive the winch motor to operate until the error meets the preset accuracy requirements.

[0019] Furthermore, the closed-loop control algorithm also incorporates feedforward control to improve the system response speed.

[0020] Furthermore, it also includes a fault self-diagnosis step: in the hoisting lock state or the unloading state, the theoretical displacement of the winch motor detected by the encoder is compared with the actual displacement corresponding to the actual angle change of the bottom door detected by the angle sensor. If the deviation between the two exceeds a preset threshold, it is determined that the wire rope is slipping or jamming abnormally, and a stop command and alarm information are issued.

[0021] Furthermore, the method also includes a load fluctuation suppression step: during the unloading process, when the weight sensor detects a sudden change in load, the controller dynamically adjusts the parameters of the closed-loop control algorithm to suppress the shaking of the bottom door of the container.

[0022] Furthermore, the method also includes a self-learning function: the system records data such as weight changes, angle trajectories, and time consumption of historical unloading operations, establishes a material unloading characteristic model through machine learning algorithms, and optimizes unloading parameters in subsequent operations based on the model.

[0023] A dual-control scrap container spreader, comprising:

[0024] The controller is used to execute the lifting method of the dual-control scrap container spreader described above;

[0025] A weight sensor is used to monitor the load of the waste bin in real time and transmit the data to the controller;

[0026] An angle sensor is used to monitor the opening angle of the bottom door of the box in real time and transmit the data to the controller;

[0027] An encoder is used to monitor the rotational stroke of the winch in real time and transmit the data to the controller;

[0028] The human-machine interface is used to receive operator instructions and display equipment status;

[0029] A winch is used to receive instructions from the controller and drive the wire rope to control the opening and closing of the bottom door of the box.

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

[0031] 1. This invention can sense the operating status of the lifting device in real time. Under any unsafe working conditions, the system can actively block all potentially dangerous unloading operation commands, thus achieving "anti-accidental touch and anti-misjudgment" at the software level. It fundamentally eliminates safety accidents caused by operator misoperation or misjudgment, and is more intelligent and reliable than simply relying on mechanical structures for passive protection, significantly improving operational safety.

[0032] 2. This invention achieves precise control of the opening angle and speed of the bottom door by introducing a PID closed-loop control algorithm and a unloading mode that supports trajectory planning. It can adjust the opening degree, speed, and opening trajectory of the bottom door with digital precision according to different material characteristics and unloading requirements. This effectively solves the problems of inaccurate unloading, material scattering, and severe dust generation associated with traditional methods, greatly improving the level of refined management and environmental performance of unloading operations.

[0033] 3. This invention, through deep fusion analysis of multi-sensor data, can diagnose potential equipment faults online in real time, such as wire rope slippage or jamming. Once an anomaly is detected, the system can promptly issue an alarm and take protective shutdown measures to prevent the fault from escalating. Attached Figure Description

[0034] Figure 1 This is a front view schematic diagram of the structure of the present invention.

[0035] Reference numerals: 1. Weight sensor; 2. Angle sensor; 3. Winch. Detailed Implementation

[0036] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0037] Please see Figure 1 A dual-control scrap container spreader and its lifting method are disclosed, aiming to improve the safety, accuracy, and intelligence of scrap container spreader operations. The spreader is a large steel frame structure used to connect and lift scrap containers. The scrap containers have openable hatches at the bottom, which are controlled by a winch 3 on the spreader via wire ropes.

[0038] 1. Composition and setup of the lifting gear hardware system

[0039] The dual-control waste container spreader of the present invention mainly includes the following key components in its hardware system, and is configured as follows:

[0040] Controller: A high-performance programmable logic controller (PLC) or an industrial-grade embedded computer serves as the core control unit. This controller is installed inside the main structure of the lifting device in a specially designed enclosed electrical control cabinet. The cabinet is fixed to the side or top of the main frame beam of the lifting device; its location was chosen to ensure dustproof, waterproof, corrosion-resistant, and vibration isolation, while also ensuring appropriate wiring distances to sensors and actuators to minimize signal transmission loss and interference. The controller is responsible for receiving all sensor data, executing intelligent control algorithms, generating control commands, and communicating with the human-machine interface.

[0041] Weight sensor 1: This configuration includes multiple load cells, for example, four or more, arranged symmetrically. These sensors are mounted on the connection mechanism between the spreader and the scrap container. Specifically, they are integrated into the four corner connections of the spreader's top lifting lugs for hooking the scrap container, or mounted on the tension bars at the connection points between the spreader's main load-bearing beam and the scrap container's anchor points. As the scrap container is lifted, its total weight is transferred through these connection points. Weight sensor 1 can measure the load on the scrap container accurately and in real time, converting the analog signal into a digital signal and transmitting it to the controller.

[0042] Angle Sensor 2: A high-precision absolute or incremental rotary encoder is selected as the angle sensor 2. This sensor is directly mounted on the main hinge or shaft of the bottom hatch of the waste container. The sensor body is fixed to the container structure, and its rotation axis is aligned with and mechanically connected to the rotation axis of the hatch. When the bottom hatch opens or closes, the rotating component inside the sensor rotates accordingly, outputting the precise opening angle of the hatch in real time, with 0° as the fully closed state and 90° as the fully open state, and transmitting the data to the controller.

[0043] Encoder: A high-resolution incremental or absolute rotary encoder is selected. This encoder is mounted on the output shaft of the hoist 3 motor or directly on the rotating shaft of the hoist 3 drum. By monitoring the number of rotations and direction of the hoist 3 motor or drum, the encoder can accurately calculate the theoretical winding and unwinding length and speed of the wire rope, transmitting this data as feedback signals to the controller.

[0044] Human-Machine Interface (HMI): Industrial-grade touchscreens or wireless remote controls can be used.

[0045] If it is a touchscreen, it is installed in front of the control console inside the crane operator's cab, or at the ground control station.

[0046] If a wireless remote control is used, it should be handheld for easy operation by the operator on-site. The human-machine interface displays the current working status of the spreader in real time, such as the weight of the scrap bin, the opening degree of the bottom door, the current operating mode, and fault alarms. It also receives operator input, such as mode selection, target opening degree setting, start / stop control, and fault reset.

[0047] Winch 3: Composed of a motor, reducer, drum, and brake. Winch 3 is mounted centrally above the main frame structure of the spreader. Its wire rope is guided by a pulley system and ultimately connects to the bottom hatch of the scrap container. The controller sends control signals, such as PWM (Pulse Width Modulation) signals, to the motor of Winch 3 to control the motor's speed and direction, precisely controlling the winding and unwinding of the wire rope, thereby opening and closing the bottom hatch of the container.

[0048] 2. Specific implementation process of hoisting method

[0049] The specific implementation process of the dual-control waste container hoisting method proposed in this invention is as follows:

[0050] 2.1 Step 1: System Initialization and Self-Test

[0051] 1. When the spreader system is powered on for the first time or at the start of each work cycle, the controller will automatically start and execute internal program initialization.

[0052] 2. The controller then begins reading the initial data from all connected sensors. First, it performs zero-point calibration on weight sensor 1, i.e., calibrates it to zero under no-load conditions. It then verifies whether angle sensor 2 indicates 0° when the bottom door is closed. If there is a deviation, it performs software compensation and checks the encoder initialization status.

[0053] 3. Perform a self-test on the communication links between the controller and each sensor, actuator, and human-machine interface to confirm that the data transmission links are unobstructed, without interruption or error.

[0054] 4. If, during the self-test, any sensor fails to provide valid data or the data exceeds the preset safety range—for example, if the reading of weight sensor 1 is abnormally high under no-load conditions, or if the communication link fails—the controller will immediately determine that the system is in an abnormal state and enter a fault state (S4). At this time, the system will stop all further actions and display detailed fault information through the human-machine interface, such as "weight sensor 1 fault" or "communication abnormality," and issue an audible and visual alarm, awaiting operator troubleshooting and handling.

[0055] 5. If all self-tests pass, the controller determines that the system is in normal working condition, and the lifting device enters the initial standby state (S0). In this state, the waste bin is unloaded, the bottom door is closed, and the system is ready to receive work instructions.

[0056] 2.2 Step Two: Lifting and Automatic Locking (State S0 → State S1)

[0057] 1. The operator sends a command to the controller to lift the waste container by pressing the "lift" button on the remote control or the corresponding icon on the touch screen through the human-machine interface.

[0058] 2. The controller continuously collects data from weight sensor 1 in real time. As the lifting device begins to lift the waste bin, the load detected by weight sensor 1 gradually increases.

[0059] 3. Conditions for entering the hoisting lock state:

[0060] If the real-time weight value detected by the weight sensor 1 continuously exceeds the preset first safety threshold W0, for example, set to 500 kg, it indicates that the waste bin has been lifted off the ground and is in a suspended state, and the false judgment of empty bin or light load has been ruled out.

[0061] Furthermore, this state exceeding the threshold remained stable for a period of time (e.g., 2 seconds).

[0062] At the same time, the angle sensor 2 detects that the bottom door of the box is in a fully closed state. For example, its angle value is within the allowable error range of 0°±2°. When all the above conditions are met, the controller automatically determines that the waste box is in a safe lifting state and immediately switches the operation state of the lifting device to the lifting lock state (S1).

[0063] 4. In the hoisting lock state (S1), the controller will activate the safety interlock mechanism, actively blocking all unloading execution commands intended to open the bottom door of the bin. Even if the operator accidentally touches the "open door" or "unload" button on the human-machine interface in this state, the controller will refuse to execute the command, and the winch 3 will not move, thus fundamentally avoiding the risk of the waste bin being accidentally opened in mid-air.

[0064] 5. In this state, the controller continuously monitors the encoder data and compares it with the feedback from angle sensor 2. If the encoder data shows that the winch 3 rotates in the opposite direction without receiving a rope retraction command, it indicates that the wire rope may have been accidentally released, or that the theoretical wire rope release length does not match the door angle change detected by angle sensor 2, and this abnormality persists for more than a short time threshold, such as 0.5 seconds, the controller will immediately determine that the wire rope may be slipping or jammed. At this time, the system will immediately trigger an audible and visual alarm and display "Abnormal wire rope release" or "Wire rope slippage" alarms on the human-machine interface, while simultaneously executing an emergency stop, locking all actions to prevent accidents.

[0065] 2.3 Step 3: Positioning and Automatic Unlocking (State S1 → State S2)

[0066] 1. The operator hoists the waste bin to the target unloading location, such as above a truck or a designated unloading pit, and begins the lowering operation so that the bottom of the waste bin contacts the support surface, or so that most of the weight is borne by the support surface.

[0067] 2. The controller continuously monitors the data from weight sensor 1 in real time.

[0068] When the real-time weight value detected by weight sensor 1 continues to fall below the first safety threshold W0, it indicates that the waste bin is no longer suspended in the air and its main weight has been borne by the ground or receiving container.

[0069] Furthermore, if the low load state remains stable for a period of time, such as 1 second, and the above conditions are met, the controller will automatically determine that the waste bin is safely in place, release the safety interlock, and switch the lifting device's operating state to the unloading preparation state (S2).

[0070] 3. After entering the unloading preparation state (S2), the controller will unlock the unloading execution command and light up the "Unloading Allowed" indicator light or display the corresponding text on the human-machine interface to prompt the operator that it is now safe to carry out the unloading operation.

[0071] 2.4 Step Four: Mode Selection and Unloading Execution (State S2 → State S3)

[0072] In the unloading preparation state (S2), the operator selects the appropriate unloading mode and sets the parameters through the human-machine interface. The system then enters the unloading in progress state (S3) and begins to execute the unloading action.

[0073] 2.4.1 Mode A: Position Closed-Loop Control Mode

[0074] 1. Parameter setting: The operator can accurately input the desired target opening angle of the bottom door in digital form via touch screen or remote control, for example, set to 30°, 45° or 60°.

[0075] 2. PID control process:

[0076] The controller continuously collects the actual opening angle of the bottom door of the box from the angle sensor 2 in real time.

[0077] Calculate the current angle error: Error = Target opening angle - Actual opening angle.

[0078] The controller calls the built-in PID algorithm to calculate the control input based on this error. The PID algorithm includes:

[0079] Proportional term (P): Proportional to the current error, providing a fast response.

[0080] Integral term (I): Eliminate steady-state error and ensure that the bottom door of the box can eventually stabilize at the target angle.

[0081] Differential term (D): predicts the trend of error change, suppresses overshoot and oscillation, and improves the stability and response speed of the system.

[0082] The controller converts the control quantity output by the PID algorithm into speed or torque commands for the winch 3 motor, driving the winch 3 motor to rotate precisely, so that the wire rope is released at a controlled speed, thereby opening the bottom door of the box slowly and smoothly.

[0083] 3. This control process continues, with the controller constantly adjusting the movement of the winch 3 until the deviation between the actual opening angle fed back by the angle sensor 2 and the target opening angle set by the operator is less than the preset allowable error range, for example, ±0.5°. Once this accuracy is achieved, the winch 3 brakes, and the bottom door remains at the target opening position.

[0084] 4. In this mode, encoder data serves as auxiliary feedback to verify the validity of angle sensor 2. The controller compares the theoretical release length of the wire rope calculated by the encoder with the actual angle change detected by angle sensor 2. If there is a significant discrepancy between the two, for example, the encoder shows that the wire rope has been released but the angle sensor 2 reading remains unchanged, an angle sensor 2 fault alarm is triggered, and the system may switch to a fault state (S4).

[0085] 2.4.2 Mode B: Speed-Trajectory Cooperative Control Mode (Advanced Mode)

[0086] 1. Trajectory Setting: The operator selects a preset unloading trajectory template or customizes a multi-segment opening trajectory through the human-machine interface. This trajectory consists of a series of time points, corresponding target angles, and desired angular velocities. For example, it can be set as: "First stage: Open 10° at an angular velocity of 5° / second, hold for 2 seconds (for breaking arches); Second stage: Continue opening to 50° at an angular velocity of 15° / second, hold for 5 seconds (for unloading most of the material); Third stage: Fully open to 90° at an angular velocity of 20° / second (for emptying the container)."

[0087] 2. Based on the set trajectory parameters, the controller internally generates a smooth target angular velocity curve and a target angle curve that vary with time.

[0088] 3. Feedforward and feedback coordinated control:

[0089] Feedforward control: The controller outputs a preliminary control command directly to the hoist motor 3 according to the predetermined target angular velocity curve to achieve rapid trajectory following.

[0090] Feedback Control: Simultaneously, the controller utilizes the real-time feedback of the actual angular velocity and angle of the bottom door from angle sensor 2 to calculate the deviation from the target value and corrects it using a PID algorithm. That is, Error_Speed ​​= Target angular velocity - Actual angular velocity. The PID algorithm adjusts the feedforward control quantity based on this error to eliminate dynamic deviation.

[0091] 4. During the unloading process (S3), weight sensor 1 continuously monitors the load changes of the material inside the waste bin. If a drastic, unexpected change in load value is detected, such as a large piece of waste suddenly falling, causing a momentary shift in the bin's center of gravity or a huge impact on the door, the controller will respond immediately and dynamically adjust the parameters of the PID control algorithm. For example, by increasing the weight of the derivative term (D term) or introducing additional damping control strategies, the system's stability can be enhanced, quickly suppressing the violent shaking or loss of control trend of the bin bottom door caused by sudden load changes, ensuring the smoothness of the door opening process, and preventing further material spillage or impact damage to the equipment.

[0092] 5. In this mode, the controller deeply integrates data from the precise door opening angle and angular velocity feedback provided by angle sensor 2, the actual displacement and speed of the wire rope winding and unwinding provided by the encoder, and the material load change information provided by weight sensor 1. By integrating this data, the controller can comprehensively perceive and precisely control the movement state of the bottom door, achieving a smoother unloading process that better conforms to the preset trajectory.

[0093] 2.5 Step 5: Automatic Reset and Cycling (State S3 → State S0)

[0094] 1. Door closing command: After the unloading operation is completed, the operator issues a command to close the bottom door of the container through the human-machine interface.

[0095] 2. Door Closing Execution: After receiving the command, the controller drives the winch 3 to tighten the wire rope. During this process, the controller continuously monitors the data from the angle sensor 2 to ensure that the bottom door closes smoothly and avoids impact.

[0096] 3. Return to initial standby state conditions:

[0097] When angle sensor 2 detects that the bottom door of the box is fully closed, for example, its angle value is within the allowable error range of 0°±1°;

[0098] Furthermore, the weight sensor 1 detects that the load of the waste bin has been restored to the empty bin state, which is lower than the preset second threshold W0_empty. This threshold is slightly higher than the actual weight of the empty bin and is used to determine that the bin has been emptied. When all the above conditions are met, the controller automatically determines that the current operation cycle has been completed, and cancels all operation modes, returning the operation status of the lifting device to the standby initial state (S0), waiting for the next operation command to arrive.

[0099] 3. Implementation of Fault Self-Diagnosis and Adaptive Control

[0100] 3.1 Implementation of Wire Rope Slippage Diagnosis

[0101] 1. The controller continuously collects the number of motor rotation pulses output by the encoder and the opening angle of the bottom door output by the angle sensor 2 in real time.

[0102] 2. Based on the encoder pulse count and the diameter of the winch drum 3, the controller calculates the theoretical winding and unwinding length of the wire rope.

[0103] 3. At the same time, the controller calculates the actual effective displacement of the wire rope corresponding to the actual opening or closing of the bottom door based on the geometry of the bottom door and the reading of the angle sensor 2.

[0104] 4. The controller compares the theoretical extension / retraction length with the actual effective displacement in real time. If the difference between the two continuously exceeds a preset deviation threshold, for example, 5 cm, and this inconsistency lasts for, for example, 1 second, the controller determines that the wire rope has slipped or jammed.

[0105] 5. Fault Response: Once wire rope slippage or jamming is diagnosed, the controller will immediately trigger the following actions:

[0106] Emergency stop: Send an emergency stop command to winch 3, cut off the motor power, and activate the brake.

[0107] Audible and visual alarm: emits an alarm sound and flashes a warning light.

[0108] HMI Display: Displays detailed fault information on the human-machine interface, such as "Wire rope slipping, please check!" or "Winder 3 stuck", and indicates possible causes.

[0109] 3.2 Implementation of Load Fluctuation Suppression

[0110] 1. During the unloading process (S3), the controller continuously monitors the load data fed back by the weight sensor 1 at a high frequency.

[0111] 2. The controller calculates the real-time rate of change of the load data.

[0112] 3. If the rate of change of load is detected to exceed the preset mutation threshold in a short period of time, for example, if the load decreases by more than 100 kg in 0.1 seconds, the controller will determine that a load mutation has occurred, such as a large piece of material suddenly falling.

[0113] 4. In response to sudden load changes, the controller will immediately and dynamically adjust the parameters of the currently running PID control algorithm. Specifically, the weight of the derivative term Kd in the PID algorithm can be increased to enhance the system's responsiveness and damping effect to rapid changes, thereby quickly suppressing the violent shaking of the bottom door caused by sudden load changes. Additionally, the maximum output power or speed limit of the hoist motor 3 can be temporarily adjusted for a smooth transition.

[0114] 3.3 Implementation of self-learning function

[0115] 1. After each complete unloading operation cycle, the system stores the key parameters and process data of this operation in the controller's internal non-volatile memory or an external database. The recorded data includes, but is not limited to:

[0116] The type of material for this operation (if the operator has entered it);

[0117] Initial total weight of the waste bin and weight of the empty bin;

[0118] Weight change curve during unloading;

[0119] The angular trajectory of the bottom door opening and closing (time-angle curve);

[0120] Total time spent on the entire unloading process;

[0121] The PID control parameters (Kp, Ki, Kd) or trajectory control parameters used in this operation.

[0122] 2. The system periodically, or after accumulating sufficient data, utilizes built-in machine learning algorithms such as linear regression analysis, decision tree models, or simple lookup tables and interpolation methods based on historical data to analyze and learn from historical data. For example, the system can establish a correlation model between different material types, such as construction waste, domestic waste, and industrial waste, and their optimal unloading characteristics. The model will attempt to find the optimal door opening speed curve, the optimal target opening degree, or the optimal combination of PID parameters while ensuring unloading efficiency and reducing dust.

[0123] 3. In subsequent unloading operations, when the operator selects a certain material type for unloading, the controller will automatically recommend or load the optimal unloading parameters for that material based on the model established through self-learning. For example, the system can suggest a more suitable door opening trajectory for the material, or automatically adjust the PID parameters to adapt to its unloading characteristics. This allows the system to continuously optimize its control strategy based on actual operational experience, reducing reliance on operator experience and improving operational efficiency and accuracy.

[0124] Through the detailed embodiments described above, the dual-control waste container spreader and its lifting method proposed in this invention can achieve a high degree of automation, intelligence and safety, effectively solve the pain points in the prior art, and provide an advanced and reliable solution for waste transfer operations.

[0125] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. The scope of patent protection of the present invention shall be determined by the claims. Similarly, any equivalent structural changes made based on the content of the present invention's specification shall also be included within the scope of protection of the present invention.

Claims

1. A lifting method for a dual-control scrap container spreader, characterized in that, Includes the following steps: a. Obtain real-time data from the weight sensor (1) to determine the load status of the waste bin; b. Based on the load state and the real-time data of the angle sensor (2), the working state of the lifting device is transferred between multiple preset finite states, the multiple preset finite states including at least: standby initial state, lifting lock state and unloading preparation state; c. In the hoisting locked state, the system blocks all unloading execution commands intended to open the bottom door of the container; d. In the unloading preparation state, the system unlocks the unloading execution command and receives the target opening parameter or the preset unloading trajectory parameter set by the operator; e. Based on the target opening parameter or the unloading trajectory parameter, as well as the real-time feedback data from the angle sensor (2) and the encoder, the opening and closing actions of the bottom door of the box are precisely controlled by a closed-loop control algorithm.

2. The lifting method of the dual-control scrap container spreader according to claim 1, characterized in that, The multiple preset finite states also include the unloading in progress state and the fault state.

3. The lifting method of the dual-control scrap container spreader according to claim 2, characterized in that, The transition condition between the standby initial state and the hoisting lock state of the lifting device is: the weight sensor (1) detects that the weight value continuously exceeds the first preset threshold W0, and the angle sensor (2) detects that the bottom door of the box is in a closed state.

4. The lifting method of the dual-control scrap container spreader according to claim 2, characterized in that, The transition condition between the lifting device operation state and the lifting lock state and the unloading preparation state is: the weight sensor (1) detects that the weight value continues to drop below the first preset threshold W0.

5. The lifting method of the dual-control scrap container spreader according to claim 1, characterized in that, The closed-loop control algorithm in step e adopts the PID algorithm. Based on the error between the target opening parameter or the unloading trajectory parameter and the real-time feedback of the angle sensor (2), the control quantity is calculated and output to drive the winch (3) motor to operate until the error meets the preset accuracy requirements.

6. The lifting method of the dual-control scrap container spreader according to claim 5, characterized in that, The closed-loop control algorithm also incorporates feedforward control to improve system response speed.

7. The lifting method of the dual-control scrap container spreader according to claim 1, characterized in that, It also includes a fault self-diagnosis step: in the hoisting lock state or the unloading state, compare the theoretical displacement of the winch (3) motor detected by the encoder with the actual displacement corresponding to the actual angle change of the bottom door detected by the angle sensor (2). If the deviation between the two exceeds the preset threshold, it is determined that the wire rope is slipping or jamming abnormally, and a stop command and alarm information are issued.

8. The lifting method of the dual-control scrap container spreader according to claim 1, characterized in that, The method further includes a load fluctuation suppression step: when the weight sensor (1) detects a sudden change in load during the unloading process, the controller dynamically adjusts the parameters of the closed-loop control algorithm to suppress the shaking of the bottom door of the box.

9. The lifting method of the dual-control scrap container spreader according to claim 1, characterized in that, The method also includes a self-learning function: the system records data such as weight changes, angle trajectories and time consumption of historical unloading operations, establishes a material unloading characteristic model through machine learning algorithms, and optimizes unloading parameters in subsequent operations based on the model.

10. A dual-control scrap container spreader, characterized in that, include: A controller for performing the lifting method of the dual-control scrap container spreader according to any one of claims 1 to 9; A weight sensor (1) is used to monitor the load of the waste bin in real time and transmit the data to the controller; An angle sensor (2) is used to monitor the opening angle of the bottom door of the box in real time and transmit the data to the controller; The encoder is used to monitor the rotational stroke of the winch (3) in real time and transmit the data to the controller; The human-machine interface is used to receive operator instructions and display equipment status; The winch (3) is used to receive instructions from the controller and drive the wire rope to control the opening and closing of the bottom door of the box.

Images