A multi-system coordinated automatic segment transfer method and system

Abstract

The application discloses a kind of multi-system collaborative segment automatic transfer method and system, solve the problem of relatively low segment hoisting efficiency in prior art.The multi-system collaborative segment automatic transfer method of the present application, steps are S1, single segment crane, double segment crane system initialization, enter automatic control mode.S2, through PLC control double segment crane system motion to set initialization position.S3, based on the radar installed on the top of trailer and around, through radar data acquisition module carries out multi-radar point cloud acquisition and data fusion, and the segment on the segment car is identified;Determine whether the current segment transport car exists segment and the number of segments, if there is no segment, then exit automatic mode;If there is segment on the segment transport car, then next step is carried out.The present application establishes central control system, realizes single, double segment crane and segment transport trolley process automatic scheduling and automatic operation, greatly improves construction efficiency, exceeds average efficiency of manual hoisting, reaches industrial level of application.

Description

Technical Field

[0001] This invention relates to the field of tunnel construction technology, and in particular to a segment hoisting system and method. Background Technology

[0002] Tunnel construction involves shield tunneling, segment assembly, segment hoisting, and box culvert assembly. At high speeds, each process must operate efficiently; otherwise, overall construction efficiency will decrease. This is especially true in hazardous geological formations where rapid shield tunneling is crucial, necessitating highly efficient operation of all systems. In the segment transfer process, to improve efficiency, a dual-segment crane is used to transfer two segments from the segment transport vehicle to a segment trolley at a time, then returns to retrieve the next two segments. Alternatively, a single-segment crane picks up the top segment of the two positioned segments, the segment transport trolley moves the lowered segment forward one position, the single-segment crane places the retrieved segment onto the segment transport trolley, and the segment trolley moves it forward another position.

[0003] In recent years, with the rapid development of technology, research related to the automatic hoisting of tunnel segments has gradually emerged. For example, a search reveals an intelligent hoisting method and system for tunnel segments used in tunnel boring machines (TBMs), achieving automatic hoisting of segments. However, the transportation efficiency of a single segment hoist cannot meet the requirements of rapid TBM excavation for subsequent supporting processes. Existing technologies, such as the patent document with authorization announcement number CN111963219B, propose a method and device for transporting segments using single and double segment hoists. However, when using single and double segment hoists in combination, more operators are often required, and the hoisting efficiency is relatively low. Therefore, it is essential to design a multi-system collaborative automatic segment transfer method and system to achieve automatic operation of single and double segment hoists and segment transport vehicles. Summary of the Invention

[0004] To address the shortcomings in the aforementioned background technology, this invention proposes a multi-system collaborative automatic segment transfer method and system, which solves the problem of relatively low segment hoisting efficiency in the prior art.

[0005] The technical solution of the present invention is implemented as follows: a multi-system collaborative automatic transfer method for tunnel segments, comprising the following steps: S1, initialization of single-segment crane and double-segment crane systems, entering automatic control mode.

[0006] S2. The PLC controls the dual-segment crane system to move to the preset initial position.

[0007] S3. Based on the radar installed on the top and around the trailer, the radar data acquisition module performs multi-radar point cloud acquisition and data fusion to identify the segments on the segment transport vehicle; it determines whether there are segments on the current segment transport vehicle and the number of segments. If there are no segments, it exits the automatic mode; if there are segments on the segment transport vehicle, it proceeds to the next step.

[0008] S4. Based on the segment information identified in step S3, calculate the maximum height of each segment, the segment grabbing positioning center, and the height of the segment transport vehicle; and plan the movement path of the segment grabbing hoist according to the left-to-right grabbing principle.

[0009] S5. Based on the movement path of the segment grabber output in step S4, control the dual segment crane to move to the target position of the segment to be grabbed.

[0010] S6. The segment grabbing and precise positioning are performed by using a binocular camera installed under the dual segment crane. The lifting device of the dual segment crane is controlled by PLC to complete the positioning action and then the lifting device is lowered to complete the segment grabbing.

[0011] S7. The lifting device of the dual-segment crane is raised to the set target safe height by controlling the PLC.

[0012] S8. According to the preset segment placement waiting position, the PLC controls the multiple mechanisms of the dual segment crane to work together and move to the segment placement waiting position.

[0013] S9. Determine whether the single segment crane and segment transport trolley are in the initialization position. If the single segment crane and segment transport trolley are in the initialization position, proceed to step 10; otherwise, wait.

[0014] S10. The dual-segment crane identifies and positions the segment placement location. The PLC controls the dual-segment crane to lower the lifting device carrying the segment to the segment transport trolley, thus completing the segment placement.

[0015] S11, the dual-segment crane enters the set initialization position, the PLC sends an automated operation command to the single-segment crane, and the dual-segment crane enters step S3.

[0016] S12. The single-segment crane system uses radar installed on the top and around the trailer to collect and fuse multiple radar point clouds through the radar data acquisition module. It identifies the position of the segments on the segment transport trolley, determines whether there are segments on the current segment transport trolley and the height of the segments. If there are segments, it proceeds to step S13; if there are no segments, the single-segment crane system exits the automatic mode.

[0017] S13. Based on the segment information identified in step S12, calculate the maximum height of the segment, the segment grabbing positioning center, and plan the movement path of the segment grabbing hoist.

[0018] S14. Based on the movement path of the segment to be grabbed output in step S13, control the single segment crane to move to the target position of the segment to be grabbed.

[0019] S15. The segment is precisely positioned by using a binocular camera installed under the single segment crane. The lifting device of the single segment crane is controlled by PLC to complete the positioning action and then the lifting device is lowered to complete the segment grabbing.

[0020] S16. The single-segment crane is controlled by the PLC to lift to the set target height, and the PLC sends the segment transport trolley movement command.

[0021] S17. The segment transport trolley automatically transports the segment one workstation in the direction of tunneling.

[0022] S18. Using the PLC to control the single-segment crane, place the segment grabbed in step S15 onto the segment transport trolley.

[0023] S19, the PLC sends a movement command to the segment transport trolley, and the single segment crane returns to the set initial position.

[0024] S20, the segment transport trolley automatically transports the segment one workstation in the direction of tunneling.

[0025] This invention installs radar on the top and around the tunnel boring machine trailer in a specific arrangement to acquire real-time information on the working space of the segment crane and the position of the segments stacked on the segment truck. It controls a dual-segment crane to grab two segments at a time and automatically place them into the segment transport trolley's workstation. The crane then automatically sends a lifting command to a single-segment crane. Upon receiving the command, the single-segment crane grabs the segment using a segment positioning system and automatically sends a command to the segment transport trolley. The segment truck, upon receiving the command, automatically moves forward one workstation and sends an automated operation command to the single-segment crane. The single-segment crane, upon receiving the command, automatically places the grabbed segment into the segment transport trolley's placement station and sends another command to the trolley. The segment truck, upon receiving the command, automatically moves the segment forward one workstation. This multi-system collaborative operation efficiently completes the automated transfer of segments.

[0026] Further optimization, in steps S4 and S13, the specific method for calculating the maximum height of each segment, the segment grabbing positioning center, and the height of the segment transport vehicle based on the identified segment information is as follows: A1. Collect segment point cloud data using radar to identify the segment area to be grabbed; A2. Fit the segment point cloud data using a cylinder extraction method to obtain the axial direction vector N0(a,b,c) of the cylinder corresponding to the segment and a point C0(p,w,n) on the axis; A3. Based on the formula for the perpendicular distance from a point to a line, calculate the distance D from any point P(x,y,z) in the point cloud data to the axis of the cylinder, and use the segment inner diameter R given in the engineering briefing as the constraint target, and iteratively optimize... A4: Calculate the geometric mean of the segment point cloud data to obtain the geometric center P of the segment point cloud, and project the geometric center P onto the optimal cylindrical axis, using the X and Y coordinates of the projection intersection as the segment grabbing positioning center; A5: Extract the highest Z value from the segment point cloud data, superimpose the safety margin H, and determine the height of the segment transport vehicle; A6: Based on the grabbing principle from left to right, combined with the segment grabbing positioning center and the height of the segment transport vehicle, plan the movement path of the segment grabbing hoist.

[0027] The cylinder extraction method includes: based on the random sampling consensus algorithm, randomly sampling at least three non-collinear points from the pipe segment point cloud data to determine the initial cylinder parameters, and iteratively optimizing by counting the number of interior points until convergence is obtained to obtain the axis direction vector N0 and the point C0 on the axis.

[0028] Further preferred, the method for obtaining the projection intersection point is as follows: calculate the dot product of vector C0P and the axial direction vector N0 to obtain the projection scalar t=(C0P·N0) / |N0|², then the coordinates of the projection intersection point are C0+t·N0, and the X and Y coordinates of the intersection point are taken as the grasping positioning center.

[0029] Further optimization involves taking the tunneling direction as the positive X direction, the downward movement of the lifting device as the positive Z-axis direction, and the rightward movement perpendicular to the XZ plane as the positive Y direction. The planned movement path of the lifting device for grabbing the segment includes the X-axis movement distance, the Y-axis movement distance, the lifting position of the lifting device, and the rotation angle of the lifting device.

[0030] Further preferred, the determination of the lifting device rotation angle includes: calculating the rotation angle of the lifting device relative to the reference direction based on the projection direction of the axis direction vector N0 on the horizontal plane, so that the clamping direction of the lifting device is perpendicular to or at a preset angle to the cylindrical axis of the segment.

[0031] Further optimization involves using a binocular camera for precise positioning of the tunnel segment during acquisition. Specifically, this involves: acquiring images of the tunnel segment using the binocular camera; identifying and extracting the image coordinates of at least two positioning pin holes on the segment, denoted as PM1(u1,v1) and PM2(u2,v2), respectively; based on the calibration parameters of the binocular camera and the current pose of the lifting device, projecting the three-dimensional coordinates of the corresponding two positioning pins on the lifting device onto the image plane to obtain the image coordinates of the positioning pins, denoted as XM1(m1,n1) and XM2(m2,n2), respectively; and calculating the control deviation of the lifting device positioning pins relative to the tunnel segment positioning pin holes based on the image coordinates PM1 and PM2 of the tunnel segment positioning pin holes and the image coordinates XM1 and XM2 of the positioning pins on the lifting device.

[0032] The control deviation includes translational deviation and / or rotational deviation; the translational deviation is determined based on the offset between the average value of the positioning pin hole image coordinates PM1, PM2 and the average value of the positioning pin image coordinates XM1, XM2; the rotational deviation is determined based on the angle between the positioning pin hole connecting vector PM1PM2 and the positioning pin connecting vector XM1XM2.

[0033] Based on the control deviation, a motion control command for the lifting device is generated, driving the lifting device to adjust its position in the horizontal and / or rotational directions, so that the positioning pin is aligned with the positioning pin hole, thereby achieving precise positioning and gripping.

[0034] A multi-system collaborative automatic segment transfer system employs the aforementioned multi-system collaborative automatic segment transfer method. Specifically, it includes: a point cloud acquisition module, which uses multiple lidar sensors installed on and around the trailer to collect real-time point cloud information of the segment crane's working space and the segment to be picked up, transmitting the point cloud information to a segment identification module and a crane motion planning module; the segment identification module and the crane motion planning module, based on the collected point cloud information of the single and double segment crane's working space and the segment transport vehicle, output the target position and highest position of the segment on the segment truck and segment transport trolley, and plan the motion path of each crane. The system comprises a segment crane motion control module, which controls the forward and backward movement, left and right translation, lifting gear rotation, and lifting actions of single and double segment cranes, based on the crane movement path planned by the segment identification module and the crane motion planning module. This module can perform these actions individually or simultaneously. A vision recognition module uses multiple binocular cameras to identify the distance between the positioning hole of the segment to be grabbed and the positioning pin of the lifting gear, the target placement position of the segment, and whether a segment exists in the placement area. A multi-system collaborative control module automatically plans the motion state of each system based on the operating status of the single and double segment cranes and the segment transport trolley. The multi-system collaborative automatic segment transport method and system established according to this invention can efficiently transport segments, improve tunnel construction efficiency, and ensure construction safety.

[0035] The beneficial effects of this invention are as follows: This invention proposes a multi-system collaborative automatic transfer method and system for tunnel segments. By establishing a central control system, it realizes automatic scheduling and automated operation of single and double tunnel segment cranes and tunnel segment transport trolleys, which greatly improves construction efficiency, exceeds the average efficiency of manual hoisting, and reaches the level of industrial application.

[0036] This invention achieves fully automated closed-loop control of the entire process of tunnel segment identification, grasping, transportation, and placement. Through unified PLC scheduling of dual-segment and single-segment cranes, combined with a layered perception architecture of radar coarse positioning and binocular vision fine positioning, the system can operate stably in harsh environments such as low light and high dust levels in tunnels. It can complete continuous segment transportation operations without manual intervention, significantly reducing labor intensity, eliminating safety hazards associated with manual operations, and significantly improving the automation level and operational safety of tunnel construction.

[0037] This invention employs a collaborative relay operation mode combining dual-segment cranes and single-segment cranes to construct a highly efficient segment logistics production line. The dual-segment cranes can simultaneously grab two segments and transfer them to a transport trolley, while the single-segment crane takes over to complete subsequent precise placement and segmented transportation. The two devices achieve seamless connection through PLC command interlocking and status handshakes. This mode significantly increases the segment processing capacity per cycle. Simultaneously, through an initialization position reset mechanism and multi-mechanism collaborative motion planning, it eliminates the positional deviations accumulated over long-term operation, ensuring consistent positioning accuracy and efficiency across multiple cycles. This effectively shortens auxiliary operation time in tunnel excavation and accelerates the overall construction progress. Attached Figure Description

[0038] To more clearly illustrate the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0039] Figure 1 This is a control flow diagram of the present invention;

[0040] Figure 2 This is a schematic diagram of the working state of the present invention. Detailed Implementation

[0041] 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. 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.

[0042] Example 1, as Figure 1 As shown, a multi-system collaborative automatic segment transfer method is described, with the tunneling direction as the positive X direction, the downward movement of the lifting device as the positive Z-axis, and the rightward movement perpendicular to the XZ plane as the positive Y direction. The specific steps are as follows: S1, the single segment crane and double segment crane systems are initialized and enter the automatic control mode; the automation mode replaces manual operation, establishing the automated operation tone from the system startup stage, reducing manual intervention links, reducing the probability of human error, and laying the foundation for subsequent unmanned operation of the entire process.

[0043] S2. The PLC controls the dual-segment crane system to move to the preset initial position. Standardizing the initial position improves operational consistency. The crane is pre-positioned to the set reference position, eliminating positional deviations left over from the previous operation. This provides a unified spatial reference for subsequent segment identification and path planning, improving repeatability accuracy.

[0044] S3. Based on the radars installed on and around the trailer, the system uses a radar data acquisition module to collect and fuse multi-radar point clouds to identify the segments on the segment transport vehicle. It determines whether segments exist on the current segment transport vehicle and the number of segments. If no segments are found, the system exits automatic mode; otherwise, it proceeds to the next step. The multi-radar layout achieves comprehensive coverage. Multiple radars are deployed on and around the trailer, forming a three-dimensional cross-scanning network, effectively eliminating blind spots of a single radar. This is particularly effective in handling complex scenarios such as segment stacking and obstruction, and vehicle structure occlusion, ensuring the integrity of the point cloud data. Through a multi-radar point cloud data fusion algorithm, point cloud data from different perspectives and with different precision are registered, denoised, and completed, suppressing single-radar measurement errors and random noise, significantly improving the accuracy and reliability of segment identification.

[0045] S4. Based on the segment information identified in step S3, calculate the maximum height of each segment, the segment grabbing and positioning center, and the height of the segment transport vehicle. Following the left-to-right grabbing principle, plan the movement path of the segment grabbing hoist. Utilizing the geometric characteristic of the segment's upper surface being a cylindrical arc surface, fit the axial direction vector and a point on the axis using a cylinder extraction method. Combined with the inner diameter specified in the engineering handover, iterative optimization is performed to ensure that the calculated segment geometric parameters closely match the actual physical dimensions, resulting in high positioning accuracy.

[0046] Specifically, the method for calculating the maximum height of each segment, the segment grabbing positioning center, and the height of the segment transport vehicle based on the identified segment information is as follows: A1. Collect segment point cloud data through radar to identify the segment area to be grabbed; the radar is a three-dimensional lidar or millimeter-wave radar.

[0047] A2: The cylinder extraction method is used to fit the point cloud data of the pipe segment to obtain the axial direction vector N0(a,b,c) of the cylinder corresponding to the pipe segment and a point C0(p,w,n) on the axis; wherein, the cylinder extraction method includes: based on the random sampling consensus algorithm, randomly sampling at least three non-collinear points from the point cloud data of the pipe segment to determine the initial cylinder parameters, and iteratively optimizing by counting the number of interior points until convergence to obtain the axial direction vector N0 and the point C0 on the axis.

[0048] A3: Based on the formula for the perpendicular distance from a point to a line, calculate the distance D from any point P(x,y,z) in the point cloud data to the cylindrical axis. Using the inner diameter R of the pipe segment given in the engineering briefing as the constraint target, iteratively optimize the axis direction vector N0 and the position of point C0 on the axis to minimize the deviation between the distance D obtained from all point cloud data and the inner diameter R, thereby determining the optimal cylindrical axis parameters. The iterative optimization involves establishing a system based on Σ(D... i -R)² is the optimization model that minimizes the objective function, where D i Let N0 be the perpendicular distance from the i-th point to the cylinder axis. The least squares method or the Levenberg-Marquardt algorithm is used to jointly optimize the axis direction vector N0 and the point C0 on the axis.

[0049] A4: Calculate the geometric mean of the segment point cloud data to obtain the geometric center P of the segment point cloud; the geometric center P is obtained by calculating the arithmetic mean of the X, Y, and Z coordinates of all points in the segment point cloud data to obtain P; then project the geometric center P onto the optimal cylindrical axis, and use the X and Y coordinates of the projection intersection as the segment grabbing and positioning center; the projection intersection is obtained by calculating the dot product of the vector C0P and the axis direction vector N0 to obtain the projection scalar t=(C0P·N0) / |N0|², then the coordinates of the projection intersection are C0+t·N0, and the X and Y coordinates of this intersection are taken as the grabbing and positioning center.

[0050] A5: Extract the highest Z value from the segment point cloud data, superimpose the safety margin H, and determine the height of the segment transport vehicle; the safety margin H ranges from 50mm to 200mm, and the specific value is determined based on the surface flatness of the segment and the structural dimensions of the lifting device.

[0051] A6: Based on the left-to-right grasping principle, and considering the segment grasping positioning center and the height of the segment transport vehicle, the movement path of the segment grasping lifting device is planned. The planned movement path includes the X-axis movement distance, Y-axis movement distance, lifting position, and rotation angle. Determining the rotation angle involves calculating the rotation angle of the lifting device relative to the reference direction based on the projection direction of the axis direction vector N0 on the horizontal plane, ensuring that the clamping direction of the lifting device remains perpendicular to or at a preset angle to the cylindrical axis of the segment. Before planning the movement path, multiple segments are prioritized from left to right, and the grasping positioning center and transport vehicle height of each segment are calculated sequentially based on the prioritization results to generate a continuous lifting device movement trajectory.

[0052] S5. Based on the motion path of the segment grabber output in step S4, control the dual-segment crane to move to the target position of the segment to be grabbed. The motion path calculated in step S4 is directly used as the control input, realizing a closed loop of the entire link from environmental perception and path decision to motion execution. The data format of each link is unified and the interface is seamlessly connected, reducing intermediate conversion errors and improving the overall response speed and control consistency of the system.

[0053] S6. Precise positioning of the tunnel segments is achieved using a binocular camera installed beneath the dual-segment crane. The crane's lifting device, controlled by a PLC, completes the positioning action and is then lowered to grab the segment. After precise positioning and alignment, the lifting device is directly lowered to complete the grab, eliminating the need for secondary movement or realignment. This reduces time loss and accumulated errors in intermediate steps, improving the continuity and success rate of each grab operation. Precise positioning ensures accurate alignment of the positioning pins and pin holes, avoiding mechanical collisions and damage to the segment surface caused by forced lowering, protecting the integrity of the segment's concrete structure, and extending the service life of the lifting device and the segment.

[0054] S7. The lifting device of the dual-segment crane is controlled by PLC to lift to the set target safety height. After lifting to the preset target safety height, sufficient safety clearance is formed between the bottom of the segment and the transport vehicle and surrounding obstacles to avoid collision accidents caused by vehicle shaking or path deviation during the lifting process, thus ensuring the safety of equipment and personnel.

[0055] S8. According to the preset segment placement waiting position, the PLC controls the multi-mechanism of the dual segment crane to work together and move to the segment placement waiting position; the preset segment placement waiting position serves as an intermediate buffer node, decoupling the transfer operation of the dual segment crane from the receiving operation of the single segment crane. The two processes can run independently and be connected asynchronously, improving the throughput and anti-interference capabilities of the entire segment transfer line.

[0056] S9. Determine whether the single-segment crane and segment transport trolley are in the initialization position. If they are, proceed to step 10; otherwise, wait. By determining whether the single-segment crane and transport trolley are in the initialization position, a safety interlock condition is established between the dual-segment crane and the receiving equipment. Segment placement can only be performed when both are ready, avoiding segment suspension or misplacement accidents caused by the receiving end not being in place.

[0057] S10. The dual-segment crane identifies and positions the segment placement location. The PLC controls the crane to lower the lifting device carrying the segment onto the segment transport trolley, completing the segment placement. Before placement, a second position identification and positioning is performed to compensate for potential position drift and vibration deviations that may occur during the long-distance transport in step S8, ensuring the segment is accurately placed at the designated load-bearing position on the transport trolley. The placement location identification can employ the same or different sensing solutions as the grasping stage (such as binocular vision, radar, or a combination thereof). The optimal identification method can be flexibly selected based on the characteristics of the placement environment, improving the system's adaptability to different construction scenarios.

[0058] S11. The dual-segment crane enters the set initialization position, and the PLC sends an automated operation command to the single-segment crane. The dual-segment crane then proceeds to step S3. After completing the segment placement, the dual-segment crane automatically returns to the initialization position and sends an automated operation command to the single-segment crane via the PLC. This achieves seamless operation between the dual-segment crane and the single-segment crane, constructing a cyclical automated production line of "grab-transfer-handover-re-grab" without the need for manual intervention in scheduling.

[0059] S12. The single-segment crane system, based on radars installed on the top and around the trailer, uses a radar data acquisition module to collect and fuse multi-radar point clouds to identify the position of segments on the segment transport trolley. It determines whether a segment exists on the trolley and its height. If a segment exists, proceed to step S13; otherwise, the single-segment crane system exits automatic mode. A similar multi-radar point cloud acquisition and fusion system is deployed in the segment transport trolley area corresponding to the single-segment crane. This system performs point cloud data registration and completion based on the crane's operating height and viewing angle characteristics, eliminating blind spots caused by trolley structural obstruction and differences in segment placement posture.

[0060] S13. Based on the segment information identified in step S12, calculate the maximum height of the segment, the segment grabbing and positioning center, and plan the movement path of the segment grabbing hoist. This step is the same as step S4. The single-segment hoist directly reuses the cylinder extraction and path planning algorithm in step S4, including cylinder axis fitting, geometric center projection, maximum height calculation, and left-to-right grabbing principle, ensuring complete consistency between the dual-segment hoist and the single-segment hoist in segment positioning logic, and reducing algorithm development and verification costs.

[0061] S14. Based on the motion path of the segment to be grabbed output in step S13, control the single segment crane to move to the target position of the segment to be grabbed. The single segment crane structure is lighter than the double segment crane, and the inertial load of the trolley travel, trolley lateral movement and lifting mechanism is smaller. Based on the same path planning accuracy, the single segment crane can respond to motion commands with higher acceleration and speed, shortening the arrival time from the waiting position to the target position.

[0062] S15. Precise positioning of the segment is achieved by using a binocular camera installed under the single segment crane. The lifting device of the single segment crane is controlled by PLC to complete the positioning action and lower the lifting device to complete the segment grabbing. A binocular camera is installed under the single segment crane to acquire high-resolution images of the segment positioning pin holes on the transport trolley at close range. By calculating the deviation between the image coordinates and the projection coordinates of the positioning pins of the lifting device, millimeter-level precise positioning is achieved, compensating for the residual deviation in the coarse positioning stage and ensuring accurate alignment between the single segment lifting device and the segment.

[0063] S16. The PLC controls the single-segment crane to lift to the set target height, and sends the segment transport trolley movement command. While controlling the single-segment crane to lift to the target safe height, the PLC sends the segment transport trolley movement preparation command to achieve the timing overlap of the crane action and the trolley response, eliminate the time loss of serial waiting between the two parties, and improve the efficiency of single cycle operation.

[0064] S17. The segment transport trolley automatically transports the segment one workstation in the direction of tunneling.

[0065] S18. Using the PLC to control the single-segment crane, the segment picked up in step S15 is placed on the segment transport trolley. Utilizing the precise positioning achieved by the single-segment crane through binocular vision in the previous steps, the PLC controls the lifting device to lower smoothly and accurately place the segment in the designated bearing position of the transport trolley. The placement accuracy is high, avoiding uneven loading or tilting of the segment.

[0066] S19, the PLC sends a movement command to the segment transport trolley, and the single segment crane returns to the set initial position; the single segment crane returns to the set initial position, eliminating the position deviation accumulated in this operation and restoring to the standard reference state, providing consistent starting conditions for the next segment grabbing from the transport trolley, and ensuring the repeatability of positioning accuracy in multi-cycle operations.

[0067] S20, the segment transport trolley automatically transports the segment one workstation in the direction of tunneling.

[0068] Example 2, a multi-system collaborative automatic transfer method for pipe segments, is further optimized based on Example 1. In this example, the binocular camera performs precise positioning and grasping of pipe segments as follows: B1. Acquire images of pipe segments using a binocular camera, identify and extract the image coordinates of at least two positioning pin holes on the pipe segment, denoted as PM1(u1,v1) and PM2(u2,v2), respectively; Identifying and extracting the image coordinates of the positioning pin holes on the pipe segment includes: performing edge detection, feature extraction and / or pattern matching on the images acquired by the binocular camera, locating the center position of the positioning pin holes, and outputting the image coordinates PM1(u1,v1) and PM2(u2,v2). B2. Based on the calibration parameters of the binocular camera and the current pose of the lifting device, project the three-dimensional coordinates of at least two corresponding positioning pins on the lifting device onto the image plane to obtain the image coordinates of the positioning pins, denoted as XM1(m1,n1) and XM2(m2,n2), respectively. The projection includes: transforming the known three-dimensional coordinates of the positioning pins in the lifting device coordinate system to the camera coordinate system according to the intrinsic parameter matrix, distortion coefficients, and extrinsic parameter matrix of the binocular camera relative to the world coordinate system or the lifting device coordinate system, and then obtaining the image coordinates XM1(m1,n1) and XM2(m2,n2) through perspective projection transformation. B3. Based on the image coordinates PM1, PM2 of the segment positioning pin holes and the image coordinates XM1, XM2 of the positioning pins on the lifting device, calculate the control deviation of the lifting device positioning pins relative to the segment positioning pin holes. Based on the control deviation, motion control commands are generated for the spreader, driving it to adjust its position in the horizontal and / or rotational directions, aligning the positioning pin with the positioning pin hole to achieve precise positioning and gripping. The current position of the spreader is determined by at least one of the crane's trolley running position, the spreader's lifting height, and the spreader's rotation angle.

[0069] The control deviation includes translational deviation and / or rotational deviation; the translational deviation is determined based on the offset between the average value of the positioning pin hole image coordinates PM1, PM2 and the average value of the positioning pin image coordinates XM1, XM2; the rotational deviation is determined based on the angle between the positioning pin hole connecting vector PM1PM2 and the positioning pin connecting vector XM1XM2.

[0070] Example 3: As Figure 2As shown, a multi-system collaborative automatic segment transfer system employs the multi-system collaborative automatic segment transfer method described in Example 2. Specifically, it includes: a point cloud acquisition module, which uses multiple lidar sensors installed on and around the trailer to collect real-time point cloud information of the segment crane's working space and the segment to be picked up, and transmits the point cloud information to the segment identification module and the crane motion planning module; the segment identification module and the crane motion planning module, based on the collected point cloud information of the single segment crane 1, the dual segment crane 2's working space, and the segment transport vehicle, output the target position and highest position of the segment on the segment vehicle 3 and the segment transport trolley 4, and plan the... The movement paths of each crane; the segment crane motion control module, based on the crane movement paths planned by the segment recognition module and the crane motion planning module, controls the forward and backward movement, left and right translation, lifting and lowering actions of single and double segment cranes, whether executed individually or simultaneously; the vision recognition module, through multiple binocular cameras, identifies the distance between the positioning hole of the segment to be grabbed and the positioning pin of the lifting device, identifies and positions the target segment placement location, and identifies whether a segment exists in the segment placement area; the multi-system collaborative control module, based on the operating status of the single and double segment cranes and the segment transport trolley, automatically plans the movement status of each system.

[0071] Based on this system, a sleeper robot is added to automate sleeper removal. The automated operation control of single and double segment cranes and segment transport trolleys can be achieved through manual triggering or a combination of both. The multi-system collaborative automatic segment transfer method and system established according to this invention enables efficient segment lifting operations, improving tunnel construction efficiency and ensuring construction safety. Compared with existing technologies, the multi-system collaborative automatic segment transfer method and system, through the establishment of a central control system, achieves automatic scheduling and automated operation of single and double segment cranes and segment transport trolleys, greatly improving construction efficiency, exceeding the average efficiency of manual lifting, and reaching industrial-grade application levels.

[0072] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A multi-system collaborative automatic segment transfer method, characterized in that: The steps are as follows: S1, Initialize the single-segment crane and double-segment crane systems and enter automatic control mode; S2. Control the dual-segment crane system to move to the preset initial position via PLC; S3. Based on the radar installed on the top and around the trailer, the radar data acquisition module performs multi-radar point cloud acquisition and data fusion to identify the segments on the segment transport vehicle; it determines whether there are segments on the current segment transport vehicle and the number of segments. If there are no segments, it exits the automatic mode; if there are segments on the segment transport vehicle, it proceeds to the next step. S4. Based on the segment information identified in step S3, calculate the maximum height of each segment, the segment grabbing positioning center, and the height of the segment transport vehicle; and plan the movement path of the segment grabbing hoist according to the left-to-right grabbing principle. S5. Based on the movement path of the segment to be grabbed output in step S4, control the dual segment crane to move to the target position of the segment to be grabbed. S6. The segment grabbing and precise positioning are performed by a binocular camera installed under the dual segment crane. The lifting device of the dual segment crane is controlled by PLC to complete the positioning action and the lifting device is lowered to complete the segment grabbing. S7. The lifting device of the double-segment crane is raised to the set target safe height by controlling the PLC. S8. According to the preset segment placement waiting position, the PLC controls the multiple mechanisms of the dual segment crane to work together and move to the segment placement waiting position; S9. Determine whether the single segment crane and segment transport trolley are in the initialization position. If the single segment crane and segment transport trolley are in the initialization position, proceed to step 10; otherwise, wait. S10. The dual-segment crane identifies and positions the segment placement location. The PLC controls the dual-segment crane to lower the lifting device carrying the segment to the segment transport trolley to complete the segment placement. S11. The dual-segment crane enters the set initialization position, the PLC sends an automated operation command to the single-segment crane, and the dual-segment crane enters step S3. S12. The single-segment crane system uses radar installed on the top and around the trailer to collect and fuse multiple radar point clouds through the radar data acquisition module. It identifies the position of the segments on the segment transport trolley, determines whether there are segments on the current segment transport trolley and the height of the segments. If there are segments, it proceeds to step S13; if there are no segments, the single-segment crane system exits the automatic mode. S13. Based on the segment information identified in step S12, calculate the maximum height of the segment, the segment grabbing positioning center, and plan the movement path of the segment grabbing hoist. S14. Based on the movement path of the segment to be grabbed output in step S13, control the single segment crane to move to the target position of the segment to be grabbed. S15. The segment is precisely positioned by a binocular camera installed under the single segment crane. The lifting device of the single segment crane is controlled by PLC to complete the positioning action and the lifting device is lowered to complete the segment grabbing. S16. The single-segment crane is controlled by the PLC to lift to the set target height, and the PLC sends the segment transport trolley movement command. S17. The segment transport trolley automatically transports the segment one workstation in the direction of tunneling. S18. Using PLC to control the single-segment crane, place the segment grabbed in step S15 onto the segment transport trolley. S19, the PLC sends a movement command to the segment transport trolley, and the single segment crane returns to the set initial position; S20, the segment transport trolley automatically transports the segment one workstation in the direction of tunneling.

2. The multi-system collaborative automatic segment transfer method according to claim 1, characterized in that: Based on the identified segment information, the specific method for calculating the maximum height of each segment, the segment grabbing positioning center, and the height of the segment transport vehicle is as follows: A1. Collect segment point cloud data through radar to identify the segment area to be grabbed; A2: The cylinder extraction method is used to fit the point cloud data of the pipe segment to obtain the axial direction vector N0(a,b,c) of the cylinder corresponding to the pipe segment and a point C0(p,w,n) on the axis; A3: Based on the formula for the vertical distance from a point to a line, calculate the distance D from any point P(x,y,z) in the point cloud data to the cylindrical axis. Using the inner diameter R of the pipe segment given in the engineering briefing as the constraint target, iteratively optimize the axis direction vector N0 and the position of point C0 on the axis to minimize the deviation between the distance D obtained from all point cloud data and the inner diameter R, thereby determining the optimal cylindrical axis parameters. A4: Calculate the geometric mean of the segment point cloud data to obtain the geometric center P of the segment point cloud, and project the geometric center P onto the optimal cylindrical axis. Use the X and Y coordinates of the projection intersection as the segment grabbing and positioning center. A5: Extract the highest Z value from the segment point cloud data, add the safety margin H, and determine the height of the segment transport vehicle; A6: Based on the left-to-right grasping principle, and combined with the segment grasping positioning center and the height of the segment transport vehicle, plan the movement path of the segment grasping hoist.

3. The multi-system collaborative automatic segment transfer method according to claim 2, characterized in that: The cylinder extraction method includes: based on the random sampling consensus algorithm, randomly sampling at least three non-collinear points from the point cloud data of the pipe segment to determine the initial cylinder parameters, and iteratively optimizing by counting the number of interior points until convergence is obtained to obtain the axis direction vector N0 and the point C0 on the axis.

4. The multi-system collaborative automatic segment transfer method according to claim 2 or 3, characterized in that: The method for obtaining the projection intersection point is as follows: calculate the dot product of vector C0P and the axial direction vector N0 to obtain the projection scalar t=(C0P·N0) / |N0|², then the coordinates of the projection intersection point are C0+t·N0, and the X and Y coordinates of the intersection point are taken as the grasping positioning center.

5. The multi-system collaborative automatic segment transfer method according to claim 4, characterized in that: With the tunneling direction as the positive X direction, the downward movement of the lifting device as the positive Z-axis, and the rightward movement perpendicular to the XZ plane as the positive Y direction; the planned movement path of the lifting device to be grabbed segment includes the X-axis movement distance, the Y-axis movement distance, the lifting position of the lifting device, and the rotation angle of the lifting device.

6. The multi-system collaborative automatic segment transfer method according to claim 5, characterized in that: The determination of the lifting device rotation angle includes: calculating the rotation angle of the lifting device relative to the reference direction based on the projection direction of the axis direction vector N0 on the horizontal plane, so that the clamping direction of the lifting device is perpendicular to or at a preset angle to the cylindrical axis of the segment.

7. The multi-system collaborative automatic segment transfer method according to claim 1, 2, or 6, characterized in that: The binocular camera-based segment acquisition and precise positioning specifically involves: acquiring segment images using the binocular camera, identifying and extracting the image coordinates of at least two positioning pin holes on the segment, denoted as PM1(u1,v1) and PM2(u2,v2), respectively; based on the calibration parameters of the binocular camera and the current pose of the lifting device, projecting the three-dimensional coordinates of the corresponding at least two positioning pins on the lifting device onto the image plane to obtain the image coordinates of the positioning pins, denoted as XM1(m1,n1) and XM2(m2,n2), respectively; and calculating the control deviation of the lifting device positioning pins relative to the segment positioning pin holes based on the image coordinates PM1 and PM2 of the segment positioning pin holes and the image coordinates XM1 and XM2 of the positioning pins on the lifting device.

8. The multi-system collaborative automatic segment transfer method according to claim 7, characterized in that: The control deviation includes translational deviation and / or rotational deviation; the translational deviation is determined based on the offset between the average value of the positioning pin hole image coordinates PM1, PM2 and the average value of the positioning pin image coordinates XM1, XM2; the rotational deviation is determined based on the angle between the positioning pin hole connecting vector PM1PM2 and the positioning pin connecting vector XM1XM2.

9. The multi-system collaborative automatic segment transfer method according to claim 8, characterized in that: Based on the control deviation, a motion control command for the lifting device is generated, driving the lifting device to adjust its position in the horizontal and / or rotational directions, so that the positioning pin is aligned with the positioning pin hole, thereby achieving precise positioning and gripping.

10. A multi-system collaborative automated segment transfer system, characterized in that: The method for automated transfer of tunnel segments using a multi-system collaborative approach, as described in any one of claims 1 to 9, specifically includes: The point cloud acquisition module uses multiple lidars installed on and around the trailer to collect point cloud information of the working space of the segment crane and the segment to be grabbed in real time, and transmits the point cloud information to the segment recognition module and the crane motion planning module. The segment identification module and the crane motion planning module, based on the point cloud information of the working space of single and double segment cranes and segment transport vehicles, output the target position and the highest position of the segment on the segment vehicle and segment transport trolley, and plan the motion path of each crane; The segment crane motion control module controls the forward and backward movement, left and right translation, lifting and lowering of single and double segment cranes according to the crane motion path planned by the segment identification module and the crane motion planning module. The crane can perform these actions individually or simultaneously. The visual recognition module uses multiple binocular cameras to identify the distance between the positioning hole of the segment to be grasped and the positioning pin of the lifting device, the target placement position of the segment, and whether there is a segment in the segment placement area. The multi-system collaborative control module automatically plans the motion state of each system based on the operating status of the single and double segment cranes and the segment transport trolley.

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