Buffer system for spreader of a reach stacker, reach stacker and working method

Abstract

The present application belongs to the field of measurement technology, and particularly relates to a distance measuring method, especially relates to a spreader buffer system for a stacker crane, a stacker crane and a working method, wherein the spreader buffer system for the stacker crane determines the ultrasonic sensor module to be used through a control module, groups distance data obtained by the ultrasonic sensor module, and uses smaller distance data obtained by two ultrasonic sensor modules in the same group as the distance between the spreader mechanism and the container, and controls the spreader mechanism to slow down when the distance is less than a preset distance; and the control module is configured to determine the data change amount of the two ultrasonic sensor modules in the same group in real time, and then determine whether the ultrasonic sensor modules need to be regrouped, thereby realizing accurate distance detection of the ultrasonic sensor module and ensuring accurate control of the spreader mechanism.

Description

Technical Field

[0001] This invention belongs to the field of measurement technology, specifically relating to distance measurement, and more particularly to a forklift lifting buffer system, a forklift, and its working method. Background Technology

[0002] In the specific scenario of side inspection of truck-mounted containers in port yards, the laser sensor's laser will produce an uncertain return angle when it hits the corrugated steel plate structure of the container side panel, causing the laser detection to fail. When using ultrasonic sensors, there are several possible scenarios when the ultrasonic sensor hits a corrugated steel plate structure. The first distance is obtained when the shot hits the "peak" of the corrugated steel plate structure; When the shot hits the "valley" of the corrugated steel plate structure, a second distance is obtained; The signal is lost when the bullet hits the "sloping" surface of the corrugated steel plate structure. Existing technologies, through simple filtering and dual-sensor redundancy, can only partially mitigate fluctuations and cannot fundamentally eliminate signal loss caused by inclined plane reflections or distinguish between actual distance changes and corrugated peak-valley fluctuations. Consequently, the detected distance may be a change in the actual distance or a fluctuation in the corrugated steel plate structure, making it impossible to obtain accurate distance data. Therefore, it is necessary to design a forklift buffer system, a forklift, and a working method.

[0003] It should be noted that the information disclosed in this background section is only for understanding the background technology of this application concept, and therefore, the above description is not considered to constitute prior art information. Summary of the Invention

[0004] This disclosure provides at least one embodiment of a forklift lifting buffer system, a forklift, and a working method thereof.

[0005] In a first aspect, embodiments of this disclosure provide a forklift spreader buffer system, comprising: A control module, a lifting mechanism electrically connected to the control module, and several ultrasonic sensor modules; The ultrasonic sensor modules are arranged side by side on the stacker. When the stacker is facing the container, at least two ultrasonic sensor modules are aligned with different peaks of the corrugated steel plate structure of the container side wall, at least two ultrasonic sensor modules are aligned with different troughs of the corrugated steel plate structure of the container side wall, and a redundant ultrasonic sensor module is aligned with different troughs or peaks of the corrugated steel plate structure of the container side wall. Furthermore, two adjacent ultrasonic sensor modules are aligned with the peaks and troughs of the same band of the corrugated steel plate structure of the container side wall, respectively. The control module is configured to determine which ultrasonic sensor modules to use, group the distance data acquired by the selected ultrasonic sensor modules, and use the smaller distance data acquired by two ultrasonic sensor modules in the same group as the distance between the spreader mechanism and the container. When the distance is less than a preset distance, the spreader mechanism is controlled to perform buffer deceleration; and The control module is configured to determine the data change of two ultrasonic sensor modules in the same group in real time, and then determine whether the ultrasonic sensor modules need to be regrouped.

[0006] In one alternative implementation, the ultrasonic sensor module both emits and receives the echoes of ultrasonic waves.

[0007] In one optional implementation, the ultrasonic sensor module to be used is, i.e. The control module is configured to control each ultrasonic sensor module to emit ultrasonic waves sequentially. When one ultrasonic sensor module emits an ultrasonic wave, the remaining ultrasonic sensor modules receive the echo. The module determines the number of ultrasonic sensor modules that receive the echo when each ultrasonic sensor module emits an ultrasonic wave. When the number of ultrasonic sensor modules that receive the echo is equal to the set number of ultrasonic sensor modules, the ultrasonic sensor that emitted the ultrasonic wave is selected as the ultrasonic sensor module to be used.

[0008] In one optional implementation, the grouping is based on the distance data acquired by the ultrasonic sensor module used, i.e. The control module is configured to acquire distance data between each ultrasonic sensor module and its corresponding peak or trough. When the absolute value of the difference between two distance data is the difference between the peak and the trough, the ultrasonic sensor modules corresponding to the two distance data are grouped together. If the absolute value of the difference between multiple distance data is the difference between the peak and the trough, adjacent ultrasonic sensor modules are grouped together, and any excess ultrasonic sensor modules are removed after grouping.

[0009] In one optional implementation, the determination of whether the ultrasonic sensor modules need to be regrouped, i.e. The control module is configured to acquire distance data detected by two ultrasonic sensor modules in the same group in real time. When the distance data detected by the two ultrasonic sensor modules in the same group changes, if the amount of change of the two distance data is different, the grouping is judged to be abnormal. At this time, the ultrasonic sensor modules used are re-determined and the grouping is re-grouped. Otherwise, the grouping is judged to be normal, and the smaller distance data acquired by the two ultrasonic sensor modules in the same group is used as the distance between the spreader mechanism and the container.

[0010] In one optional implementation, the control module is configured to acquire distance data detected by two ultrasonic sensor modules in the same group in real time when the grouping is normal, and use the smaller distance data as the distance between the spreader mechanism and the container. When the distance is less than a preset distance, the spreader mechanism is controlled to perform buffer deceleration; otherwise, the buffer deceleration is released.

[0011] Secondly, embodiments of this disclosure also provide a forklift machine, comprising: The aforementioned forklift spreader buffer system is used to control the spreader mechanism.

[0012] Thirdly, this disclosure also provides a method for operating the above-described forklift spreader buffer system, comprising: The control module determines which ultrasonic sensor module to use, and groups the distance data acquired by the selected ultrasonic sensor module. The smaller distance data acquired by two ultrasonic sensor modules in the same group is taken as the distance between the spreader mechanism and the container. When the distance is less than a preset distance, the spreader mechanism is controlled to perform buffer deceleration. The control module measures the data changes of two ultrasonic sensor modules in the same group in real time, and then determines whether the ultrasonic sensor modules need to be regrouped.

[0013] In one optional implementation, the control module controls each ultrasonic sensor module to emit ultrasonic waves sequentially. When one ultrasonic sensor module emits an ultrasonic wave, the remaining ultrasonic sensor modules receive the echo. The number of ultrasonic sensor modules that receive the echo when each ultrasonic sensor module emits an ultrasonic wave is determined. When the number of ultrasonic sensor modules that receive the echo is equal to the set number of ultrasonic sensor modules, the ultrasonic sensor that emitted the ultrasonic wave is selected as the ultrasonic sensor module to be used.

[0014] In one optional implementation, the control module acquires the distance data between each ultrasonic sensor module and the corresponding peak or trough. When the absolute value of the difference between two distance data is the difference between the peak and the trough, the ultrasonic sensor modules corresponding to the two distance data are grouped together. If the absolute value of the difference between multiple distance data is the difference between the peak and the trough, the adjacent ultrasonic sensor modules are grouped together, and the excess ultrasonic sensor modules after grouping are removed.

[0015] The beneficial effects of this invention are that the stacker spreader buffer system determines the ultrasonic sensor module to be used through the control module, groups the distance data obtained by the ultrasonic sensor module, and uses the smaller distance data obtained by two ultrasonic sensor modules in the same group as the distance between the spreader mechanism and the container. When the distance is less than a preset distance, the spreader mechanism is controlled to buffer and decelerate. Furthermore, the control module is configured to judge the data change of two ultrasonic sensor modules in the same group in real time, and then determine whether it is necessary to regroup the ultrasonic sensor modules. This achieves accurate distance detection of the ultrasonic sensor modules and ensures precise control of the spreader mechanism.

[0016] Other features and advantages of the invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention are realized and obtained through the structures particularly pointed out in the description and the drawings.

[0017] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described in detail below with reference to the accompanying drawings. Attached Figure Description

[0018] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0019] Figure 1 A schematic block diagram of a forklift spreader buffer system provided in this embodiment of the present disclosure; Figure 2 A flowchart illustrating the operation of a forklift spreader buffer system provided in this disclosure embodiment; Figure 3 This is a schematic diagram showing the location of an ultrasonic sensor module according to an embodiment of this disclosure. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] As used herein, the phrases “in one embodiment,” “according to one embodiment,” “in some embodiments,” etc., generally refer to the fact that a particular feature, structure, or characteristic following the phrase can be included in at least one embodiment of this disclosure. Therefore, a particular feature, structure, or characteristic can be included in more than one embodiment of this disclosure, such that these phrases do not necessarily refer to the same embodiment. As used herein, the terms “example,” “exemplary,” etc., are used to “serve as an example, instance, or illustration.” Any implementation, aspect, or design described herein as “example” or “exemplary” is not necessarily to be construed as preferred or superior to other implementations, aspects, or designs. Rather, the use of the terms “example,” “exemplary,” etc., is intended to present concepts in a specific manner.

[0022] Existing technologies, through simple filtering and dual-sensor redundancy, can only partially mitigate fluctuations and cannot fundamentally eliminate signal loss caused by inclined plane reflections or distinguish between actual distance changes and corrugated peak-valley fluctuations. Consequently, the detected distance may be a change in the actual distance or a fluctuation in the corrugated steel plate structure, making it impossible to obtain accurate distance data.

[0023] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0024] The following detailed description of some embodiments of the present invention is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0025] like Figure 1 and Figure 2As shown, at least one disclosed embodiment provides a spreader buffer system for a forklift, including: a control module, a spreader mechanism electrically connected to the control module, and a plurality of ultrasonic sensor modules; the ultrasonic sensor modules are arranged side by side on the forklift, and when the forklift is facing a container, at least two ultrasonic sensor modules are aligned with different peaks of the corrugated steel plate structure of the container sidewall, at least two ultrasonic sensor modules are aligned with different troughs of the corrugated steel plate structure of the container sidewall, and a redundant ultrasonic sensor module is aligned with different troughs or peaks of the corrugated steel plate structure of the container sidewall, and adjacent ultrasonic sensor modules are respectively aligned with the container sidewall. The corrugated steel plate structure contains peaks and troughs in the same waveband; the control module is configured to determine the ultrasonic sensor module to be used, group the distance data obtained by the ultrasonic sensor module, and take the smaller distance data obtained by two ultrasonic sensor modules in the same group as the distance between the spreader mechanism and the container. When the distance is less than a preset distance, the spreader mechanism is controlled to perform buffer deceleration; the control module is also configured to judge the data change of two ultrasonic sensor modules in the same group in real time, and then determine whether it is necessary to regroup the ultrasonic sensor modules, thereby realizing accurate distance detection of the ultrasonic sensor modules and ensuring accurate control of the spreader mechanism.

[0026] In this embodiment, the preset distance can be 1.5m.

[0027] In this embodiment, the ultrasonic sensor module can be installed on the support of the spreader mechanism or on the support of the stacker, so as to accurately detect the distance between the spreader mechanism and the container.

[0028] In one alternative implementation, the ultrasonic sensor module both emits and receives ultrasonic echoes, such as the NU40C16TR-1 transceiver.

[0029] In this embodiment, the difference between the crests and adjacent troughs of the corrugated steel plate structure on the side wall of the container is T, and the specific value can be 60mm, etc.

[0030] In one optional implementation, the control module is configured to control each ultrasonic sensor module to emit ultrasonic waves sequentially. When one ultrasonic sensor module emits an ultrasonic wave, the remaining ultrasonic sensor modules receive the echo. The number of ultrasonic sensor modules that receive the echo when each ultrasonic sensor module emits an ultrasonic wave is determined. When the number of ultrasonic sensor modules that receive the echo is equal to the set number of ultrasonic sensor modules, the ultrasonic sensor that emitted the ultrasonic wave is selected as the ultrasonic sensor module to be used.

[0031] like Figure 3 As shown, in this embodiment, the number of ultrasonic sensor modules can be 5, which are recorded as ultrasonic sensor modules A1, A2, A3, A4, and A5 respectively. When the forklift is facing the container, A1 can be aligned with a crest of the corrugated steel plate structure on the side wall of the container, A2 can be aligned with a trough, A3 can be aligned with a crest, A4 can be aligned with a trough, and A5 can be aligned with a crest, thus aligning with both crests and troughs.

[0032] In this embodiment, when an ultrasonic sensor module emits an ultrasonic wave, all ultrasonic sensor modules receive the echo, corresponding to the case where the main lobe of the ultrasonic wave hits the flat surface of the container's side. If only some ultrasonic sensor modules receive the echo, it corresponds to the case where the main lobe of the ultrasonic wave hits a non-flat area on the side of the container. When only some ultrasonic sensor modules receive the echo, the ultrasonic sensor module that emitted the ultrasonic wave can be disregarded.

[0033] In this embodiment, if all ultrasonic sensor modules emit ultrasonic waves but none of them receive an echo, then each ultrasonic sensor module is controlled to emit ultrasonic waves again one by one. If, after multiple emission of ultrasonic waves, none of the ultrasonic sensor modules receive an echo, an alarm is triggered, indicating that some of the ultrasonic sensor modules may be malfunctioning.

[0034] In one optional implementation, the grouping is based on the distance data acquired by the ultrasonic sensor modules used. Specifically, the control module is configured to acquire the distance data between each ultrasonic sensor module and its corresponding peak or trough. When the absolute value of the difference between two distance data points is equal to the difference between a peak and a trough, the ultrasonic sensor modules corresponding to the two distance data points are grouped together. If the absolute value of the difference between multiple distance data points is equal to the difference between a peak and a trough, adjacent ultrasonic sensor modules are grouped together, and any excess ultrasonic sensor modules are removed after grouping.

[0035] In this embodiment, if the distance data detected by ultrasonic sensor module A1 and the distance data detected by ultrasonic sensor module A2 have a difference of T, then A1 and A2 can be grouped together, and the distance between the spreader mechanism and the container can be detected by these two ultrasonic sensor modules.

[0036] In this embodiment, if the distance data detected by ultrasonic sensor module A1, ultrasonic sensor module A2, and ultrasonic sensor module A5 are used, and the absolute value of the difference between the distance data of A1 and A2 is T, and the absolute value of the difference between the distance data of A2 and A5 is also T, then because A1 and A2 are adjacent, A1 and A2 can be grouped together, and A5 is excluded.

[0037] In one optional implementation, the determination of whether the ultrasonic sensor modules need to be regrouped involves the control module being configured to acquire distance data detected by two ultrasonic sensor modules in the same group in real time. When the distance data detected by the two ultrasonic sensor modules in the same group changes, if the amount of change in the two distance data is different, the grouping is determined to be abnormal. At this time, the ultrasonic sensor modules to be used are re-determined and the grouping is re-assigned. Otherwise, the grouping is determined to be normal, and the smaller distance data acquired by the two ultrasonic sensor modules in the same group is used as the distance between the spreader mechanism and the container.

[0038] In this embodiment, the distance data changes are detected and acquired by two ultrasonic sensor modules in the same group after the forklift moves.

[0039] In one optional implementation, the control module is configured to acquire distance data detected by two ultrasonic sensor modules in the same group in real time when the grouping is normal, and use the smaller distance data as the distance between the spreader mechanism and the container. When the distance is less than a preset distance, the spreader mechanism is controlled to perform buffer deceleration; otherwise, the buffer deceleration is released.

[0040] At least one other disclosed embodiment also provides a forklift, including: employing the above-described forklift spreader buffer system to control the spreader mechanism.

[0041] At least one other disclosed embodiment also provides a method for operating the above-described stacker spreader buffer system, comprising: determining the ultrasonic sensor modules to be used through a control module; grouping the ultrasonic sensor modules according to the distance data acquired by the ultrasonic sensor modules; using the smaller distance data acquired by two ultrasonic sensor modules in the same group as the distance between the spreader mechanism and the container; controlling the spreader mechanism to buffer and decelerate when the distance is less than a preset distance; and determining in real time, through the control module, the amount of data change of two ultrasonic sensor modules in the same group, and then determining whether it is necessary to regroup the ultrasonic sensor modules.

[0042] In one optional implementation, the control module controls each ultrasonic sensor module to emit ultrasonic waves sequentially. When one ultrasonic sensor module emits an ultrasonic wave, the remaining ultrasonic sensor modules receive the echo. The number of ultrasonic sensor modules that receive the echo when each ultrasonic sensor module emits an ultrasonic wave is determined. When the number of ultrasonic sensor modules that receive the echo is equal to the set number of ultrasonic sensor modules, the ultrasonic sensor that emitted the ultrasonic wave is selected as the ultrasonic sensor module to be used.

[0043] In one optional implementation, the control module acquires the distance data between each ultrasonic sensor module and the corresponding peak or trough. When the absolute value of the difference between two distance data is the difference between the peak and the trough, the ultrasonic sensor modules corresponding to the two distance data are grouped together. If the absolute value of the difference between multiple distance data is the difference between the peak and the trough, the adjacent ultrasonic sensor modules are grouped together, and the excess ultrasonic sensor modules after grouping are removed.

[0044] In summary, this forklift spreader buffer system uses a control module to determine which ultrasonic sensor modules to use. The system groups the data based on the distance data acquired by these modules, and uses the smaller distance data acquired by two ultrasonic sensor modules in the same group as the distance between the spreader mechanism and the container. When the distance is less than a preset distance, the spreader mechanism is controlled to buffer and decelerate. Furthermore, the control module is configured to continuously monitor the data changes of two ultrasonic sensor modules in the same group, thereby determining whether to regroup the ultrasonic sensor modules. This achieves accurate distance detection of the ultrasonic sensor modules and ensures precise control of the spreader mechanism.

[0045] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A forklift spreader buffer system, characterized in that, include: A control module, a lifting mechanism electrically connected to the control module, and several ultrasonic sensor modules; The ultrasonic sensor modules are arranged side by side on the stacker. When the stacker is facing the container, at least two ultrasonic sensor modules are aligned with different peaks of the corrugated steel plate structure of the container side wall, at least two ultrasonic sensor modules are aligned with different troughs of the corrugated steel plate structure of the container side wall, and a redundant ultrasonic sensor module is aligned with different troughs or peaks of the corrugated steel plate structure of the container side wall. Furthermore, two adjacent ultrasonic sensor modules are aligned with the peaks and troughs of the same band of the corrugated steel plate structure of the container side wall, respectively. The control module is configured to determine which ultrasonic sensor modules to use, group the distance data acquired by the selected ultrasonic sensor modules, and use the smaller distance data acquired by two selected ultrasonic sensor modules in the same group as the distance between the spreader mechanism and the container. When the distance is less than a preset distance, the spreader mechanism is controlled to perform buffer deceleration; and The control module is configured to determine the data change of two ultrasonic sensor modules in the same group in real time, and then determine whether the ultrasonic sensor modules need to be regrouped.

2. The forklift spreader buffer system as described in claim 1, characterized in that: The ultrasonic sensor module both emits ultrasonic waves and receives the echoes of ultrasonic waves.

3. The forklift spreader buffer system as described in claim 1, characterized in that: The ultrasonic sensor module to be used, namely The control module is configured to control each ultrasonic sensor module to emit ultrasonic waves sequentially. When one ultrasonic sensor module emits an ultrasonic wave, the remaining ultrasonic sensor modules receive the echo. The module determines the number of ultrasonic sensor modules that receive the echo when each ultrasonic sensor module emits an ultrasonic wave. When the number of ultrasonic sensor modules that receive the echo is equal to the set number of ultrasonic sensor modules, the ultrasonic sensor that emitted the ultrasonic wave is selected as the ultrasonic sensor module to be used.

4. The forklift spreader buffer system as described in claim 3, characterized in that: The data is grouped based on the distance data acquired by the ultrasonic sensor module used. The control module is configured to acquire distance data between each ultrasonic sensor module and its corresponding peak or trough. When the absolute value of the difference between two distance data is the difference between the peak and the trough, the ultrasonic sensor modules corresponding to the two distance data are grouped together. If the absolute value of the difference between multiple distance data is the difference between the peak and the trough, adjacent ultrasonic sensor modules are grouped together, and any excess ultrasonic sensor modules are removed after grouping.

5. The forklift spreader buffer system as described in claim 4, characterized in that: The determination of whether the ultrasonic sensor modules need to be regrouped, i.e. The control module is configured to acquire distance data detected by two ultrasonic sensor modules in the same group in real time. When the distance data detected by the two ultrasonic sensor modules in the same group changes, if the amount of change of the two distance data is different, the grouping is judged to be abnormal. At this time, the ultrasonic sensor modules used are re-determined and the grouping is re-grouped. Otherwise, the grouping is judged to be normal, and the smaller distance data acquired by the two ultrasonic sensor modules in the same group is used as the distance between the spreader mechanism and the container.

6. The forklift spreader buffer system as described in claim 5, characterized in that: The control module is configured to acquire distance data detected by two ultrasonic sensor modules in the same group in real time when the grouping is normal, and use the smaller distance data as the distance between the spreader mechanism and the container. When the distance is less than the preset distance, the spreader mechanism is controlled to perform buffer deceleration; otherwise, the buffer deceleration is released.

7. A forklift, characterized in that, include: The forklift spreader buffer system as described in any one of claims 1-6 is used to control the spreader mechanism.

8. A method of operating a forklift lifting device buffer system as described in any one of claims 1-6, characterized in that, include: The control module determines which ultrasonic sensor module to use, and groups the distance data acquired by the selected ultrasonic sensor module. The smaller distance data acquired by two ultrasonic sensor modules in the same group is taken as the distance between the spreader mechanism and the container. When the distance is less than a preset distance, the spreader mechanism is controlled to perform buffer deceleration. The control module measures the data changes of two ultrasonic sensor modules in the same group in real time, and then determines whether the ultrasonic sensor modules need to be regrouped.

9. The working method as described in claim 8, characterized in that: The control module controls each ultrasonic sensor module to emit ultrasonic waves sequentially. When one ultrasonic sensor module emits an ultrasonic wave, the other ultrasonic sensor modules receive the echo. The number of ultrasonic sensor modules that receive the echo when each ultrasonic sensor module emits an ultrasonic wave is determined. When the number of ultrasonic sensor modules that receive the echo is equal to the set number of ultrasonic sensor modules, the ultrasonic sensor that emitted the ultrasonic wave is selected as the ultrasonic sensor module to be used.

10. The working method as described in claim 9, characterized in that: The control module acquires the distance data between each ultrasonic sensor module and its corresponding peak or trough. When the absolute value of the difference between two distance data points is equal to the difference between the peak and the trough, the ultrasonic sensor modules corresponding to the two distance data points are grouped together. If the absolute value of the difference between multiple distance data points is equal to the difference between the peak and the trough, adjacent ultrasonic sensor modules are grouped together, and any excess ultrasonic sensor modules are removed after grouping.

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