Bulk cargo terminal ship unloader intelligent lighting system and control method thereof

Abstract

The present application relates to the technical field of intelligent lighting, and is a bulk cargo terminal ship unloader intelligent lighting system and a control method thereof.The system comprises an edge server, a multi-mode communication unit, a terminal control unit and terminal equipment, wherein the terminal control unit is connected to the edge server and the terminal equipment through the multi-mode communication unit, the multi-mode communication unit takes a switch as a communication hub, and realizes bidirectional data transmission between the terminal control unit and the edge server and the terminal equipment through an optical-electrical transceiver, an optical fiber tail fiber box and a Profinet optical cable and an industrial Ethernet.The present application realizes intelligent management of the whole life cycle of the lighting system through integration of intelligent sensing, adaptive control and multi-level communication technology, and achieves synergistic adaptation of dynamic energy saving and efficient lighting.

Description

Technical Field

[0001] This invention relates to the field of intelligent lighting technology, and in particular to an intelligent lighting system and control method for a bulk cargo terminal unloader. Background Technology

[0002] Lighting systems are fundamental supporting facilities for industrial equipment and environments. Currently, traditional industrial lighting mostly adopts a manual switch control mode and is widely used in industrial settings such as ports and factories.

[0003] Traditional industrial lighting systems rely on manual judgment and switch operation, which has significant drawbacks: on the one hand, lights often remain on 24 hours a day in non-working areas, resulting in serious energy waste; on the other hand, manual operation is slow to respond, and in emergency situations, it is easy to miss turning off or miscontrol. Moreover, the lighting system and the main equipment are in an information silo, unable to match the equipment's operating status with the needs of the working area, which increases energy consumption and reduces the convenience of lighting management, making it difficult to adapt to the intelligent and energy-saving requirements of modern industrial scenarios.

[0004] Therefore, there is a need to provide a control system and method that can intelligently adjust the lighting brightness according to operational requirements. Summary of the Invention

[0005] To address the aforementioned technical problems, this invention provides an intelligent lighting system and control method for bulk cargo terminal unloaders. This invention is applicable to complex industrial scenarios with high dust, strong vibration, and extreme temperature and humidity, such as port machinery, bulk cargo machinery, coke oven machinery, and smart factories. By integrating intelligent sensing, adaptive control, and multi-level communication technologies, it achieves intelligent management of the entire lifecycle of the lighting system, realizing a synergistic adaptation between dynamic energy saving and high-efficiency lighting.

[0006] The technical means employed in this invention are as follows:

[0007] A smart lighting system for a bulk cargo terminal unloader includes: an edge server, a multi-mode communication unit, a terminal control unit, and terminal devices. The terminal control unit connects to both the edge server and the terminal devices via the multi-mode communication unit. The multi-mode communication unit uses a switch as its communication hub and achieves bidirectional data transmission between the terminal control unit and the edge server and terminal devices via photoelectric transceivers, fiber optic pigtail boxes, Profinet optical cables, and industrial Ethernet. The terminal devices include: lamps of various power ratings, a light sensor, a dust sensor, and a human infrared sensor. The terminal control unit can automatically adapt to environmental changes and operational requirements in the industrial scenario by analyzing the current operational nature and environmental conditions, enabling adaptive dimming and multi-mode lighting switching.

[0008] Furthermore, the intelligent lighting system also includes an intelligent distribution box; the internal circuit design of the intelligent distribution box is as follows: all the incoming terminals of the distribution box are integrated with lightning protection devices, and the isolation couplers are adapted to the high lightning strike risk environment of the port to achieve electrical isolation between the power supply and the control signal; the power supply after isolation and coupling is connected to the circuit controller to realize the power distribution of multiple lighting loads and support the regional and scene-based adjustment of intelligent lighting.

[0009] Furthermore, the multi-mode communication unit uses the industrial intelligent gateway as a communication relay in the transmission layer, interconnecting PLC control commands, sensor signals, and lighting circuit execution signals to support remote monitoring and intelligent linkage functions; it is connected to the terminal equipment through a terminal block.

[0010] This invention also provides an intelligent lighting control method for a bulk cargo terminal unloader based on an intelligent lighting system, comprising: calculating an effective illuminance value by dual-verifying the input signal using a cloud platform weather system and raw light sensor data; calculating the average illuminance of the industrial area based on the environmental conditions of the industrial area; calculating the required supplementary illuminance value based on the effective illuminance value and the average illuminance of the industrial area; and correcting the required supplementary illuminance value by considering the influence of temperature, humidity, and dust conditions on the illuminance under the current environment, thereby obtaining an illuminance value that meets the illuminance requirements and realizing intelligent lighting adjustment.

[0011] Furthermore, the calculation of the effective illuminance value specifically includes: Substituting the raw light sensor data and cloud platform weather system data into the moving weighted average formula, the raw illuminance sequence collected by the sensor is then calculated. x t 3, x t 2, x t 1, x t} Calculate the smoothed effective illuminance value:

[0012] in, , , , These are the weighting coefficients. , The original illuminance at the current moment. This is the value from the previous collection. This is the value from the second previous data collection. This is the value from the third previous data collection.

[0013] Furthermore, the average illuminance of the industrial area is expressed as:

[0014] in, This represents the target average illuminance in the work area; This represents the luminous flux of a single lamp. Indicates the number of lights in the area; Indicates the light utilization coefficient in industrial settings; This indicates the maintenance factor that takes into account the light decay caused by dust accumulation on the luminaires; A This indicates the area of ​​the illuminated region.

[0015] Furthermore, the required supplemental illuminance values... Represented as:

[0016] in, η This is the effective utilization coefficient of natural light.

[0017] Furthermore, the illuminance value that meets the illuminance requirement is expressed as: The calculation formula is:

[0018] Where, Δ T Indicates the temperature decay coefficient; Δ H Indicates the humidity attenuation coefficient; Δ D This represents the dust attenuation coefficient.

[0019] Compared with the prior art, the present invention has the following advantages: The intelligent lighting system and control method for bulk cargo terminal ship unloaders provided by this invention can simultaneously adapt to the needs of multiple scenarios such as complex weather, dynamic operations and personnel inspections, and take into account lighting accuracy, operational stability and energy saving. It not only fills the gap in the field of adaptive intelligent lighting control for ship unloaders, but also provides core technical support for realizing on-demand lighting, safe and efficient, green and energy-saving intelligent operation of bulk cargo terminal ship unloaders.

[0020] This invention utilizes technologies such as human body recognition, intelligent dimming, and edge computing to enable on-demand lighting and supports one-click switching between various scene modes, including standby, operation, maintenance, and nighttime inspection, thereby improving operational safety and efficiency.

[0021] This invention significantly reduces electricity costs by combining dynamic dimming and on-demand lighting strategies (such as automatic shutdown in non-work areas) with energy consumption monitoring.

[0022] The system of this invention supports two-way communication between the cloud platform and the on-site intelligent power distribution box, and realizes refined control of the lighting system through the cloud. It can ensure that the lighting quality is accurately matched to the operation requirements of the ship unloader, and minimize lighting energy consumption, thus achieving the dual goals of high efficiency, energy saving and operational safety. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a flowchart illustrating the intelligent lighting system for the bulk cargo terminal unloader in this invention.

[0025] Figure 2 This is a schematic diagram of the intelligent power distribution box configured on the bulk material grab unloader in an embodiment of the present invention.

[0026] In the diagram: 1. Intelligent power distribution box; 2. Fiber optic pigtail box; 3. Optical transceiver; 4. Switch; 5. Edge server; 6. Ship unloader control system; 7. Terminal control panel. Detailed Implementation

[0027] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0028] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0030] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0031] like Figure 1 As shown, this invention provides an intelligent lighting system for a bulk cargo terminal unloader, comprising: an edge server, a multi-mode communication unit, a terminal control unit, and terminal equipment. The terminal control unit connects to both the edge server and the terminal equipment via the multi-mode communication unit. The multi-mode communication unit uses a switch as its communication hub and achieves bidirectional data transmission between the terminal control unit and the edge server and terminal equipment via photoelectric transceivers, fiber optic pigtail boxes, Profinet optical cables, and industrial Ethernet, including lighting status feedback and control command issuance. The terminal equipment includes: lamps of various power ratings, a light sensor, a dust sensor, and a human infrared sensor. The terminal control unit can automatically adapt to environmental changes and operational requirements in the industrial scenario by analyzing the current operational nature and environmental conditions, achieving environmental adaptive dimming and multi-mode lighting switching functions.

[0032] In a specific implementation, as a preferred embodiment of the present invention, the intelligent lighting system further includes an intelligent power distribution box; The intelligent distribution box's internal circuit design integrates surge protectors at all incoming lines, and uses isolation couplers to adapt to the high lightning strike risk environment of ports, achieving electrical isolation between power supply and control signals. This ensures the purity of PLC control signals, preventing power supply interference with control commands, and also prevents control circuit faults from affecting the power supply circuit, thus improving the system's anti-interference capability. The isolated and coupled power supply is then routed to the circuit controller to distribute power to multiple lighting loads, supporting zoned and scene-specific adjustments for intelligent lighting.

[0033] In a specific implementation, as a preferred embodiment of the present invention, the multi-mode communication unit uses the industrial intelligent gateway as a communication relay in the transmission layer, interconnects PLC control commands, sensor signals and lighting circuit execution signals, and supports remote monitoring and intelligent linkage functions; it is connected to the terminal equipment through a terminal block.

[0034] This invention also provides an intelligent lighting control method for a bulk cargo terminal unloader based on an intelligent lighting system, comprising: using a cloud platform weather system and raw light sensor data to double-verify input signals; executing a moving weighted average algorithm to process scenes such as gradual changes in natural daylight to avoid frequent dimming; combining dust concentration and shadow conditions in the work area; adjusting brightness through data analysis and processing; and calculating the effective illuminance value. In a preferred embodiment of this invention, the calculation of the effective illuminance value specifically includes: substituting the raw light sensor data and cloud platform weather system data into the moving weighted average formula to calculate the effective illuminance value from the raw illuminance sequence collected by the sensor. x t 3, x t 2, x t 1, x t} Calculate the smoothed effective illuminance value:

[0035] in, , , , These are the weighting coefficients. , The original illuminance at the current moment. This is the value from the previous collection. This is the value from the second previous data collection. This is the value from the third previous data collection.

[0036] Based on the environmental conditions of the industrial area, the average illuminance of the industrial area is calculated; in a preferred embodiment of the present invention, the average illuminance of the industrial area is expressed as:

[0037] in, This represents the target average illuminance in the work area; This represents the luminous flux of a single lamp, measured in lm. Indicates the number of lights in the area; This represents the light utilization coefficient in industrial settings, which is typically taken as 0.3 to 0.7 due to dust obstruction. This represents the maintenance factor that takes into account the light decay caused by dust accumulation on the lamps; for industrial environments, it is taken as 0.7~0.8. A This indicates the area of ​​the illuminated region.

[0038] The required supplementary illuminance value is calculated based on the effective illuminance value and the average illuminance of the industrial area; in a preferred embodiment of the present invention, the required supplementary illuminance value is... Represented as:

[0039] in, η The effective utilization coefficient of natural light is 0.8-0.9 for sunny days and 0.5-0.7 for high dust levels.

[0040] Taking into account the influence of temperature, humidity, and dust conditions on illuminance in the current environment, the required supplemental illuminance value is corrected to obtain an illuminance value that meets the illuminance requirements, thus achieving intelligent lighting adjustment. In a preferred embodiment of this invention, the illuminance value that meets the illuminance requirements is represented as... The calculation formula is:

[0041] Where, Δ T Δ represents the temperature decay coefficient, ranging from 0.01 to 0.05; H Δ represents the humidity attenuation coefficient, ranging from 0.005 to 0.02; D This indicates that the dust attenuation coefficient is between 0.02 and 0.1.

[0042] Example This embodiment targets a bulk material grab unloader, configuring one intelligent power distribution box. Multiple intelligent power distribution boxes can be configured later depending on the product scale and complexity. The intelligent power distribution box can adopt a network-based control method, connecting the lighting equipment to a local area network platform for intelligent self-control. Multiple lighting controllers and lamps are connected to form a network through networking technology, enabling remote monitoring and control via a cloud platform. Users can remotely control and view the lamps through a mobile platform, achieving centralized management of intelligent lighting. The system uses switch 4 as the communication hub, connecting to optoelectronic transceiver 3 and fiber optic pigtail box 2 via Profinet optical cable to establish a data transmission link. This enables bidirectional data transmission between the intelligent power distribution box 1 and the edge server 5, the unloader control system 6, and the terminal control screen 7, achieving centralized data transmission, reception, and forwarding, and ensuring information exchange between modules.

[0043] In this lighting control system, information about each intelligent distribution box and its subordinate lighting fixtures, sensing sensors, and other equipment (including the number of devices, communication addresses, model parameters, etc.) is uniformly stored in the local storage module of the corresponding intelligent distribution box. Each smart distribution box is equipped with a unique UID code as its identification. The linkage and docking process between the cloud platform and the smart distribution box is as follows: The operator enters the UID code of the target smart distribution box into the cloud platform, and the cloud platform immediately sends an identification matching instruction containing that code to the system; after receiving the instruction, the smart distribution box with the corresponding UID code immediately sends a response signal back to the cloud platform and simultaneously uploads the device information stored locally, completing the precise binding between the cloud platform and the smart distribution box; after successful binding, the cloud platform will access local weather system data in real time (such as sunny and rainy conditions, light intensity forecast, atmospheric visibility, etc.) to form a "dual input" verification mechanism with the local light sensor data collected by the smart distribution box; only when the two types of data are verified and synchronized, the cloud platform will send lighting control instructions to the smart distribution box in combination with the unloader's operating conditions, automatically matching the brightness parameters of the lamps, which avoids adjustment deviations caused by a single data source and ensures the stability and accuracy of the smart lighting system operation.

[0044] Based on the actual production operation process of the ship unloader, multiple intelligent lighting modes are provided, including: (1) Work mode When the equipment is not in production, the production lighting is automatically turned off. When the production lighting starts up automatically with the process, the local lighting is at full brightness when the equipment is running, the lighting in the main production areas is maximized, and the lighting in non-production areas is turned off.

[0045] (2) Standby mode Localized lighting is used, illuminating key areas while turning off the rest. Human infrared sensors are installed in personnel passageways or platforms to generate "person presence / departure" signals, which serve as the trigger for starting and stopping the lighting, ensuring adequate illumination in the escalator area and meeting the lighting needs of personnel.

[0046] (3) Inspection mode Nighttime inspections utilize thermal imaging-linked lighting, which works in conjunction with thermal imaging cameras to provide directional illumination and record personnel movement. During nighttime inspections, operators can remotely control all escalator lights from the control room or via a handheld terminal, and simultaneously provide directional enhanced lighting to critical equipment areas to facilitate the detection of equipment malfunctions.

[0047] (4) Maintenance mode When the equipment is being maintained, a lighting strategy can be developed based on the maintenance work. The areas that need maintenance can be selected and the lighting fixtures can be linked and controlled in a coordinated manner. The brightness of the lights in the relevant areas can be precisely adjusted to enhance the local lighting while the brightness of the lights in other areas is reduced or turned off.

[0048] The specific work process during implementation is as follows: On-site maintenance personnel log into the cloud platform and enter the UID code of the 1800t grab unloader power distribution box into the lighting control module. The cloud platform issues an identity matching instruction containing the code. After receiving the instruction, the intelligent power distribution box immediately feeds back a signal and uploads the information stored in the local terminal device, including light sensors, dust sensors, and human infrared sensors. The platform lights and escalator lights are concentrated on the upper and lower platforms of the main beam, while the escalator lights are distributed at each escalator.

[0049] When the ship unloader receives the operation command, the system automatically starts data acquisition: the light sensor provides feedback on real-time illuminance, the dust sensor provides feedback on concentration (meeting the operation standards), and the data is transmitted to the cloud platform via the built-in industrial intelligent gateway in the intelligent power distribution box. Internet-connected weather data: The cloud platform connects to the local meteorological system in real time and displays the current weather as sunny.

[0050] Data verification: The cloud platform compares the two types of data. If the deviation between the local illuminance and the weather system's light intensity is ≤10%, the data is considered synchronized and valid, and control commands can be issued. If the deviation between the two types of data is too large, control commands are issued based on similar weather data from the historical database.

[0051] When the ship unloader starts operation, the ship unloader control system 6 sends operating status signals to the edge server 5 via the switch 4. The edge server 5 combines the dual input data and operating status to calculate the target illuminance and uploads the data to the cloud platform. The edge server 5 sends instructions to the smart gateway via fiber optic cable, and the smart gateway then transmits the instructions to the loop controller, which in turn sends them to the individual lamp controllers to maintain 100% illuminance in the operating area and reduce it to 30% in non-operating areas.

[0052] Boom area (trolley command): Floodlights start at full brightness, auxiliary walkway lights remain at low brightness; Belt conveyor area (material release command): Floodlights start at full brightness, auxiliary walkway lights remain at low brightness; Trolley area (trolley travel command): Move to the left with the trolley, left-side floodlights automatically turn on, lights in the idle area on the right turn off.

[0053] The lighting fixtures execute commands and transmit their operating status back in real time. If the weather turns cloudy, the cloud platform updates the weather data, indicating reduced light intensity. Local sensors synchronously report illuminance deviations of ≤5%, confirming data validity. Edge server 5 automatically calculates supplemental lighting and sends commands to intelligent distribution box 1 to adjust the floodlight illuminance, ensuring the work area maintains adequate illumination. 30 seconds after dimming, the sensors report the actual illuminance, with a deviation from the target of ≤1.3%. The server determines the adjustment is "qualified" and maintains the current parameters.

[0054] If the floodlights in the large vehicle area malfunction, the cloud platform will alarm to indicate that the floodlights under the intelligent power distribution box 1 of the grab unloader are faulty and the lights will go out. On-site operators can switch to manual mode through the terminal control screen or remote control cloud platform and directly issue instructions to the intelligent power distribution box: increase the brightness of nearby floodlights k and the platform lights above to compensate for the illuminance gap of the faulty lights. The cloud platform will record the fault information simultaneously.

[0055] After the ship unloader completes its operation, the intelligent power distribution box 1 receives a standby mode command: the overall lighting is adjusted to 30% brightness to meet the needs of personnel inspection; after entering standby mode and stopping, the human infrared sensor detects the presence of a human, the edge server 5 receives the sensing signal and executes intelligent lighting, turning off the lighting 10 minutes after receiving a signal that a human has left. The intelligent power distribution box uploads the final operating data, including: specific lighting time, energy saving rate, fault information, data stored on the cloud platform, and reports generated; Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An intelligent lighting system for a bulk cargo terminal unloader, characterized in that, include: Edge server, multi-mode communication unit, terminal control unit and terminal equipment, including: The terminal control unit is connected to the edge server and the terminal device through the multi-mode communication unit. The multi-mode communication unit uses a switch as the communication hub and realizes bidirectional data transmission between the terminal control unit and the edge server and the terminal device through photoelectric transceivers, fiber optic pigtail boxes, Profinet optical cables, and industrial Ethernet. The terminal equipment includes: lamps of various power levels, light sensors, dust sensors, and human infrared sensors; the terminal control unit can automatically adapt to environmental changes and operational needs in industrial scenarios by analyzing the current operation nature and environmental conditions, and realize environmental adaptive dimming and multi-mode lighting switching functions.

2. The intelligent lighting system for bulk cargo terminal unloaders according to claim 1, characterized in that, The intelligent lighting system also includes an intelligent power distribution box; The internal circuit design of the intelligent distribution box is as follows: all distribution box incoming terminals are integrated with lightning protection devices, and are adapted to the high lightning strike risk environment of the port to access isolation couplers to achieve electrical isolation between power supply and control signals; After isolation and coupling, the power supply is connected to the circuit controller to distribute power to multiple lighting loads, supporting the regional and scene-specific adjustment of smart lighting.

3. The intelligent lighting system for bulk cargo terminal unloaders according to claim 1, characterized in that, The multi-mode communication unit uses the industrial smart gateway as a communication relay in the transmission layer, interconnecting PLC control commands, sensor signals, and lighting circuit execution signals to support remote monitoring and intelligent linkage functions; it is connected to the terminal equipment through a terminal block.

4. A method for intelligent lighting control of a bulk cargo terminal unloader based on the intelligent lighting system of the bulk cargo terminal unloader as described in any one of claims 1-3, characterized in that, include: The effective illuminance value is calculated by dual-verifying the input signal with the cloud platform weather system and the raw light sensor data. Calculate the average illuminance of the industrial area based on its environmental conditions. The required additional illuminance value is calculated based on the effective illuminance value and the average illuminance of the industrial area; By taking into account the influence of temperature, humidity, and dust conditions on illuminance in the current environment, the required supplementary illuminance value is corrected to obtain an illuminance value that meets the illuminance requirements, thereby achieving intelligent adjustment of lighting.

5. The intelligent lighting system for bulk cargo terminal unloaders according to claim 4, characterized in that, The calculation of the effective illuminance value specifically includes: Substituting the raw light sensor data and cloud platform weather system data into the moving weighted average formula, the raw illuminance sequence collected by the sensor is then calculated. x t 3, x t 2, x t 1, x t } Calculate the smoothed effective illuminance value: in, , , , These are the weighting coefficients. , The original illuminance at the current moment. This is the value from the previous collection. This is the value from the second previous data collection. This is the value from the third previous data collection.

6. The intelligent lighting system for bulk cargo terminal unloaders according to claim 4, characterized in that, The average illuminance of the industrial area is expressed as: in, This represents the target average illuminance in the work area; This represents the luminous flux of a single lamp. Indicates the number of lights in the area; Indicates the light utilization coefficient in industrial settings; This indicates the maintenance factor that takes into account the light decay caused by dust accumulation on the luminaires; A This indicates the area of ​​the illuminated region.

7. The intelligent lighting system for bulk cargo terminal unloaders according to claim 5 or 6, characterized in that, The required additional illuminance value Represented as: in, η This is the effective utilization coefficient of natural light.

8. The intelligent lighting system for bulk cargo terminal unloaders according to claim 4, characterized in that, The illuminance value that meets the illuminance requirement is expressed as: The calculation formula is: Where, Δ T Indicates the temperature decay coefficient; Δ H Indicates the humidity attenuation coefficient; Δ D This represents the dust attenuation coefficient.

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