Intelligent distribution system, method and medium for bulk grain loading

Abstract

The application relates to an intelligent material distribution system, method and medium for bulk grain loading, and relates to the technical field of intelligent grain loading. The intelligent material distribution system for bulk grain loading comprises a main detection mechanism, which is used for monitoring a bulk grain loading process and collecting target loading data; the target loading data comprises a carriage size, a material surface height and a material pile profile; an auxiliary sensing mechanism is used for monitoring the bulk grain loading process and collecting auxiliary loading data; the auxiliary loading data comprises a bulk grain loading amount, a grain storage amount and a material feeding movement amount; an intelligent control mechanism is used for receiving the target loading data and the auxiliary loading data, and generating and distributing mechanism adjustment instructions according to a preset bulk grain control mechanism; a dynamic execution mechanism is used for controlling corresponding execution equipment to distribute material to a target vehicle according to the mechanism adjustment instructions until the weight reaches a standard or the material level reaches a threshold value, and then the material distribution is stopped; through automatic adaptation to full-size carriages and various grain varieties, layered material distribution improves loading uniformity.

Description

Technical Field

[0001] This application relates to the field of intelligent grain loading technology, and in particular to an intelligent material distribution system, method and medium for loading bulk grain onto trucks. Background Technology

[0002] Intelligent material distribution systems for bulk grain loading typically rely on fixed chutes or swing-type material distribution chutes, depending on manual judgment of the car position and manual adjustment of the angle. Some systems introduce belt scales to achieve quantitative loading (such as railway rapid quantitative loading systems), but there is no real-time material distribution trajectory optimization, and uneven loading and overflow are common, with material distribution uniformity relying on experience.

[0003] With the widespread adoption of PLC control, quantitative loading can be achieved by combining weighing sensors with "preset quantity + gate opening and closing"; some ports / grain depots are piloting automatic limit switches for swing chutes, but the three-dimensional shape of the carriage and the dynamic adaptation of the material drop point are weak, and the material distribution is still an open-loop control, without forming a closed loop of "perception-decision-execution".

[0004] LiDAR, ultrasound, and 3D vision are beginning to be used for carriage outline recognition and material level monitoring. Combined with AI algorithms, they have initially achieved material drop point tracking (such as the "dynamic material distribution" function). However, they are mostly used in the ore and coal industries. Due to dust, fragility, and high hygiene requirements, the material drop is slower in the grain industry. The system is still mainly based on "fixed point and quantity" and the uniformity of material distribution depends on mechanical structure rather than intelligent control.

[0005] Existing patents disclose an automated grain loading system and method based on the fusion of visual and laser data. The system includes a material discharge detection unit, a 3D scanning unit, a multimodal data fusion module, and an automatic loading control system. The material discharge detection unit collects video data from the target vehicle and detects the material discharge amount using a visual analysis deep learning model. The 3D scanning unit acquires the cargo box pose information of the truck in real time and quickly calculates the grain volume using point cloud data. The multimodal data fusion module receives data from the material discharge detection unit and the 3D scanning unit, dynamically adjusts the weights using a Kalman filter algorithm, and fuses the data to obtain the optimal volume estimate. This invention can automatically measure the grain volume on grain-loading trucks, achieving precise automated grain loading and improving loading efficiency.

[0006] The existing technical solutions mentioned above have the following drawbacks: 1. Traditional bulk grain truck loading uses a gravity-flow chute on the side wall of the silo for fixed-point unloading, which has problems such as uneven material distribution, uneven loading and overflow, disordered flow control, insufficient loading accuracy, dust overflow, and high grain breakage rate; 2. The loading process relies on manual adjustment of the vehicle and unloading position, and lacks intelligent material level sensing, automatic path planning and real-time closed-loop control capabilities. It cannot adapt to different truck bed sizes and grain varieties, the material level monitoring is lagging, and it is prone to failures such as material collapse, material breakage, and equipment collision, resulting in low operating efficiency and poor safety. Summary of the Invention

[0007] To address the shortcomings of existing technologies, the purpose of this application is to provide an intelligent material distribution system, method, and medium for bulk grain loading. This system automatically adapts to full-size truck beds and various grain varieties, using layered material distribution to improve loading uniformity. Three-stage flow and speed control enables rapid and precise replenishment without manual intervention. Multiple safety interlocks and anomaly handling logic prevent equipment failures, and operational data is automatically archived and traceable. The overall system achieves sealed, precise, and automated bulk grain loading, significantly improving operational efficiency and reducing grain loss and labor costs.

[0008] This was achieved using the following technical solutions: In a first aspect, this application provides an intelligent fabric placement system for loading bulk grain onto trucks, comprising: The main detection mechanism is used to monitor the loading process of bulk grain onto trucks and collect target loading data, including truck dimensions, material level height, and material pile outline. The auxiliary sensing mechanism is used to monitor the bulk grain loading process and collect auxiliary loading data, including bulk grain loading volume, grain bin storage volume, and feeder movement volume. The intelligent control mechanism is used to receive target loading data and auxiliary loading data, and generate and distribute mechanism adjustment commands according to the preset bulk grain control mechanism. A dynamic actuator, used to control the corresponding actuator to deliver material to the target vehicle according to mechanism adjustment commands, until the weight reaches the target or the material level reaches the threshold, and then stops delivering material. This includes: The lifting tower, equipped with the main detection mechanism and auxiliary sensing mechanism, is used to transport bulk grain to the target loading layer; A bulk grain scale is installed on the lifting tower and located below the bulk grain inlet to weigh the falling bulk grain. The buffer bin, installed on the lifting tower and located below the bulk grain scale, is used to buffer the fluctuations caused by the falling of bulk grain, forming a uniform and continuous flow of bulk grain. The rail conveyor, installed on the lifting tower and located below the buffer bin, is used to transport the bulk cargo machine back and forth along the parallel rails of the car body; A bulk loader is a moving chute installed on the rail conveyor. It is used to control the even distribution of bulk grain along the entire length of the carriage according to the moving and lifting strokes until the material level reaches the threshold. Weighbridges are used to weigh the amount of bulk grain loaded in a truck bed in real time until the weight meets the standard.

[0009] By adopting the above technical solution, data on the size of the truck bed, the outline of the material pile, and the loading amount are collected by the fusion of main and auxiliary multi-sensor systems. The movement and lifting stroke of the bulk loader are dynamically adjusted by the closed-loop feedback control algorithm. Combined with the dual threshold judgment of the weighbridge weight and the material level, the automation, precise distribution, and dual anti-overflow control of bulk grain loading are realized, which significantly improves loading efficiency and safety.

[0010] Secondly, this application also provides an intelligent method for loading bulk grain onto trucks, which adopts the following technical solution; An intelligent method for loading bulk grain onto trucks includes: Locate the vehicle to be loaded, and in conjunction with the preset target loading area, detect and scan the vehicle to be loaded to determine the vehicle type; Based on the vehicle type, the corresponding bulk grain distribution path is matched and planned, a distribution timetable is generated, and the weight of grain in the car is monitored. The bulk grain distribution process is monitored according to the distribution time schedule to obtain the height of the material surface in the truck bed, and the bulk grain flow rate is controlled in conjunction with the loading level stage threshold. Based on the preset target loading volume and target material level, verify the grain weight and material level in the car body to determine that the vehicle loading is complete. Based on the width of the carriage and its rectangular outline, monitor the height of the material surface at a single point and calculate the position difference of the material surface at a single point. If the difference in material level at a single point is greater than the preset tolerance threshold, the bulk grain distribution path will be corrected according to the path type to obtain the optimal distribution path. Based on the type of grain, the loading level threshold, the bulk grain loading speed range, and the single-point dwell time are adjusted and modified to complete the bulk grain loading and distribution.

[0011] By adopting the above technical solution, the material distribution path and timing are matched based on vehicle type. The bulk grain flow rate is controlled by linkage between material surface height and stage threshold. Combined with the single-point material surface difference tolerance correction path and the adaptive adjustment parameters of grain type, the automated uniform material distribution and weight-material level dual closed-loop precise control of bulk grain loading are realized, which significantly improves loading efficiency, flatness and adaptability.

[0012] Furthermore, the vehicle to be loaded is located, and in conjunction with the preset target loading area, the vehicle is detected and scanned to determine its type, including: The vehicle to be loaded is moved and its center coordinates are obtained. The preset target loading area is analyzed to obtain the center coordinates of the loading area; If the vehicle's center coordinates coincide with the loading area's center coordinates, it is determined that the vehicle to be loaded is located in the target loading area, and a vehicle scanning signal is generated. The vehicle to be loaded is scanned based on the vehicle scanning signal to obtain the dimensions of the cargo box, generate the rectangular outline of the cargo box, and obtain the initial height of the material surface; Based on the safe material level threshold k and the dimensions of the car body, calculate the effective volume V of the car body: V = L × W × (Hk); L is the length of the car body, W is the width of the car body, and H is the height of the car body; Based on the grain bulk density coefficient γ and the effective volume of the car body, the target loading capacity Q is matched: Q = γ × V; Based on the vehicle compartment size data and vehicle type threshold range, the vehicle type is determined, including: If the vehicle body size data is within the first type threshold range, then the current vehicle type is determined to be a small car; If the vehicle body size data is within the second type threshold range, then the current vehicle type is determined to be a medium-sized vehicle; If the vehicle body size data is within the third type threshold range, then the current vehicle type is determined to be a large vehicle.

[0013] By adopting the above technical solution, the scanning is triggered by the coincidence detection between the vehicle positioning and the center coordinates of the loading area. The effective volume and target loading amount are calculated based on the size of the cargo box. Combined with the size threshold, the small, medium or large vehicle type is automatically determined. This achieves precise alignment, adaptive quantitative matching and vehicle type classification of the loading vehicle, which significantly improves the automation level and operation efficiency of the bulk grain loading system.

[0014] Furthermore, based on the vehicle type, the corresponding bulk grain distribution path is matched and planned, a distribution timing table is generated, and the weight of the grain in the wagon is monitored, including: If the vehicle type is a small car, then match the N-point equally divided template, and divide the car body equally according to the width of the car body, and calculate the corresponding path node coordinates and cloth movement sequence; If the vehicle type is a medium-sized vehicle, then match the S-shaped reciprocating template and serpentine along the length of the carriage to cover the width of the carriage, and calculate the corresponding path node coordinates and cloth movement sequence; If the vehicle type is a large vehicle, then match the layered template with a back shape, and lay the fabric layered from the edge of the carriage inwards, calculating the corresponding path node coordinates and fabric movement order; The initial cloth path is generated based on the path node coordinates and cloth movement order, combined with the dwell time at a single point. The initial laying path is verified. If the path has no collisions, covers the entire carriage, and has no blind spots at the edges and corners, then the initial laying path is determined to be a bulk grain laying path. The timing of the bulk grain distribution path is decomposed to generate a distribution timing table and the weight of the grain in the wagon is obtained.

[0015] By adopting the above technical solution, the cloth path nodes are generated based on the vehicle model adaptive matching N-point equal division, S-shaped reciprocating or back-shaped layered template. Collision verification and full coverage determination ensure no blind spots, and the data is converted into a time series table to dynamically monitor the weight of the car body, which significantly improves the path adaptability, coverage uniformity and operation efficiency of bulk grain cloth.

[0016] Furthermore, based on the grain distribution timeline, the grain distribution process is monitored to obtain the material level in the truck bed. Combined with the loading level stage thresholds, the grain flow rate is controlled in a coordinated manner, including: According to the material placement path type and the material placement sequence table, the bulk grain placement process is monitored, and the height of the material surface at a single point is detected. If the height of a single material level is within the first material level threshold range, the current car is determined to be empty, and the single-point loading rate is calculated. If the single-point loading rate is within the initial loading threshold range, then the bulk grain loading speed is determined to be within the first speed range; If the single-point loading rate is within the mid-term loading threshold range, then the bulk grain loading speed is determined to be within the second speed range; If the single-point loading rate is within the final loading threshold range, then the bulk grain loading speed is determined to be within the third speed range. If the height of a single material level is within the second material level threshold range, the current carriage is determined to be in a half-fill state, and the bulk grain flow rate is kept constant according to the second speed range. If the height of a single material level is within the third material level threshold range, the current car is determined to be full, and the bulk grain flow rate is kept constant according to the third speed range until the upper limit of the current material level threshold range is reached, at which point the material distribution stops. If the absolute distance change value of the height of a single point material surface for x consecutive periods is greater than the warning threshold, then the single point overflow or single point collapse is determined according to the sign of the absolute distance change value, and an alarm notification is generated. If the height of all individual material surfaces meets the standard, then the height of the material surface in the car body is calculated comprehensively.

[0017] By adopting the above technical solution, based on the material level stage threshold and loading rate zoning algorithm, the bulk grain loading speed (first to third speed range) is dynamically adjusted. Through continuous periodic mutation detection, overflow or collapse is prevented, and segmented precise flow control and abnormal early warning of the bulk grain distribution process are realized, which significantly improves the uniformity and safety of loading.

[0018] Furthermore, based on the preset target loading volume and target material level, the weight of the grain in the wagon and the material level in the wagon are verified to determine that the vehicle loading is complete, including: If the weight of the grain in the car is greater than or equal to the preset target total load, or if the height of the material in the car is greater than or equal to the preset target height, then the current vehicle is considered to have completed loading.

[0019] By adopting the above technical solution, based on the dual threshold logic OR algorithm, loading is determined to be complete when either the weight of the car body or the height of the material surface reaches the preset target, effectively preventing overload and overflow, and improving the robustness and safety of loading control.

[0020] Thirdly, this application also provides a storage medium storing at least one instruction, at least one program, code set, or instruction set, wherein the at least one instruction, at least one program, code set, or instruction set is loaded and executed by a processor to implement the intelligent material placement method for bulk grain loading as described above.

[0021] In summary, the beneficial technical effects of this application are as follows: By fusion of main and auxiliary multi-sensor data to collect data on truck dimensions, material pile outline and loading volume, and using closed-loop feedback control algorithm to dynamically adjust the movement and lifting stroke of the bulk loader, combined with dual threshold judgment of weighbridge weight and material level, the automation, precise distribution and dual anti-overflow control of bulk grain loading are realized, which significantly improves loading efficiency and safety. Based on vehicle model adaptive matching, N-point equal division, S-shaped reciprocating or back-shaped layered templates are used to generate cloth path nodes. Collision verification and full coverage determination ensure no blind spots, and the data is converted into a time series table to dynamically monitor the weight of the car body, thereby improving the path adaptability, coverage uniformity and operation efficiency of bulk grain cloth. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the intelligent fabric placement system for bulk grain loading in this application; Figure 2 This is a schematic diagram of the dynamic actuator in this application; Figure 3 This is a flowchart illustrating the intelligent material placement method for loading bulk grain in this application. Detailed Implementation

[0023] The present application will be further described in detail below with reference to the accompanying drawings.

[0024] Firstly, referring to Figure 1 The present application discloses an intelligent material distribution system for loading bulk grain, comprising: The main detection mechanism is used to monitor the loading process of bulk grain onto trucks and collect target loading data, including truck dimensions, material level height, and material pile outline. In this embodiment, the ultrasonic radar detection unit is installed above the loading chute / telescopic arm with 3 to 5 channels, covering the entire length and both sides of the truck bed from above; the frequency is 40kHz to 80kHz, the ranging range is 0.2 to 15m, and the accuracy is ±1 to 2cm. It is used to detect the truck bed size, material level height, and real-time material pile outline.

[0025] Auxiliary sensing mechanisms are used to monitor the bulk grain loading process and collect auxiliary loading data. The auxiliary loading data includes the bulk grain loading amount, grain storage amount, and feeding movement amount, including weighbridge (accuracy 0.3%), silo radar, and limit / anti-collision devices. The intelligent control mechanism is used to receive target loading data and auxiliary loading data, and generate and distribute mechanism adjustment commands according to the preset bulk grain control mechanism. Dynamic actuator (refer to) Figure 2 This is used to control the corresponding actuator to deliver material to the target vehicle according to the mechanism adjustment command, until the weight reaches the standard or the material level reaches the threshold, and then stop delivering material, including: The lifting tower, equipped with the main detection mechanism and auxiliary sensing mechanism, is used to transport bulk grain to the target loading layer; A bulk grain scale is installed on the lifting tower and located below the bulk grain inlet to weigh the falling bulk grain. The buffer bin, installed on the lifting tower and located below the bulk grain scale, is used to buffer the fluctuations caused by the falling of bulk grain, forming a uniform and continuous flow of bulk grain. The rail conveyor, installed on the lifting tower and located below the buffer bin, is used to transport the bulk cargo machine back and forth along the parallel rails of the car body; A bulk loader is a moving chute installed on the rail conveyor. It is used to control the even distribution of bulk grain along the entire length of the carriage according to the moving and lifting strokes until the material level reaches the threshold. Weighbridges are used to weigh the amount of bulk grain loaded in a truck bed in real time until the weight meets the standard.

[0026] In this embodiment, the dynamic actuator may include a moving chute / telescopic arm (stroke 0-6m, speed 0.1-1.0m / s), a rotating mechanism (0-180°, rotation speed 1-5° / s), and a variable frequency feeder / belt scale (flow rate adjustable from 20 to 100t / h).

[0027] In this embodiment, the process involves: bulk grain buffering and stabilizing flow → precise alignment and sealing → feeding and movement → precise material distribution via the bulk loader's lifting and lowering mechanism. Within this system, the bulk loader is no longer a stationary unloading point, but rather a "mobile precision material distributor" moving along a track. The buffer silo stabilizes the incoming grain, ensuring a continuous and uniform flow to the track conveyor. The track conveyor, responsible for feeding, sealing, dust removal, and movement, is the core unit of the process. The bulk loader raises and lowers the material distributor according to the loading progress, suppressing dust. This architecture fundamentally avoids the problems of uncontrollable material accumulation height, uneven stress on the truck bed, and repeated forward and backward movement for loading caused by fixed-point loading.

[0028] To ensure a continuous and stable supply of ≥500t / h of material during the movement, it relies on two interconnected process units: The buffer silo located below the weighing scale inside the lifting tower must have a capacity and structure that can effectively eliminate fluctuations in upstream material supply. The design of the buffer silo typically combines a reasonable hopper capacity with a cone hopper angle to ensure that bulk grain can enter the rail conveyor stably.

[0029] To meet the demand for high-volume mobile dispensing, a rail conveyor is required for the feeding mechanism. For highly mobile grains such as soybeans, an electrically controlled gate is used to control the material flow, and this flow is intelligently matched with the moving speed of the rail conveyor and the remaining loading space in the carriage. This achieves a "fast charging at the front and precise replenishment at the back" material distribution strategy, which is crucial for improving dispensing output and loading flatness.

[0030] Track-mounted conveyors need to move smoothly and without vibration, with accurate positioning, along long tracks. Using servo motors or variable frequency motors driven by precision gears and racks or heavy-duty rollers is fundamental to achieving this. The moving speed must be coordinated with the feed flow rate in real time to ensure neither overloading nor underloading.

[0031] Based on the dimensional information obtained from the car body recognition system, the process control system automatically plans the starting point, segment length, and movement rhythm of the material placement. The process path is as follows: starting from the front of the car body, the first segment of loading begins with the bulk loader's telescopic chute loading material from the bottom of the car body. As the material pile increases in height, the bulk loader also gradually rises. Once the preset material pile volume or weight is reached, the track conveyor moves backward a certain distance to begin loading the next segment, iterating in this way until the rear of the car body. Inter-segment movements are connected with a small flow rate to achieve excellent loading flatness.

[0032] By combining higher-precision 3D scanning with real-time weight feedback, the process system can more accurately perceive the three-dimensional morphology of the material surface inside the truck bed, achieving true "surface-following" adaptive material placement, further improving loading quality and space utilization. Through self-learning optimization of process parameters, the system can accumulate successful loading data for different vehicle models and materials, and automatically optimize the optimal number of material placement segments, moving speed, and feeding curve for that vehicle model / material using algorithms, enabling adaptive adjustment of process parameters.

[0033] The bulk loader has vertical lifting capabilities to ensure a close contact with the material pile in the truck bed. The docking process is smooth, avoiding collisions with the truck bed. The bulk loader employs a "pre-contact flexible enclosure" design, with durable rubber or canvas barriers surrounding the outside of the loader's telescopic chute mechanism. During the initial descent, these barriers make preliminary contact with the truck bed floor, forming a tight and uniform contact surface, physically isolating any channels for dust spillage. As the bulk grain is dispensed, the telescopic chute gradually rises with the pile, maintaining close contact with the pile during this process to prevent dust spillage.

[0034] All equipment used in this process system is sealed. Simultaneously, as the bulk loading machine begins to contact the bottom of the truck bed and form a sealed cavity, the dust collector fan immediately starts, creating a slightly negative pressure environment within the sealed enclosure. This negative pressure rapidly draws any small amount of dust that may escape from the sealed gaps, as well as dust carried by the air induced by the falling material, into the dust collector filter cartridge, achieving near-zero emissions in the process.

[0035] Secondly, referring to Figure 3This application discloses an intelligent method for loading bulk grain onto trucks, comprising: S1: Locate the vehicle to be loaded, and in conjunction with the preset target loading area, detect and scan the vehicle to be loaded to determine the vehicle type; S2: Match and plan the corresponding bulk grain distribution path according to the vehicle type, generate the distribution timing table, and monitor the weight of grain in the car compartment; S3: Monitor the bulk grain distribution process according to the distribution timetable, obtain the material level height in the truck bed, and control the bulk grain flow rate in conjunction with the loading level stage threshold. S4: Based on the preset target loading total and target material level, verify the grain weight and material level in the car body, and determine that the vehicle loading is complete; S5: Based on the width of the carriage and the rectangular outline of the carriage, monitor the height of the material surface at a single point and calculate the position difference of the material surface at a single point; If the difference in material level at a single point is greater than the preset tolerance threshold, the bulk grain distribution path will be corrected according to the path type to obtain the optimal distribution path. S6: Based on the type of grain, modify and adjust the threshold of the loading level stage, the bulk grain loading speed range, and the single-point dwell time to complete the bulk grain loading and distribution.

[0036] In this embodiment: In the automated bulk grain loading system of a port grain transshipment warehouse, when the bulk grain transport vehicle to be loaded enters the identification area, the vehicle is located in real time and its outline is scanned by a three-dimensional lidar. It is identified as a 13-meter standard semi-trailer model, and then matched with the preset "Z-shaped reciprocating" bulk grain distribution path and generated a distribution sequence table including the chute moving speed and start and stop time.

[0037] During loading, the weighbridge continuously monitors the weight of the grain in the truck bed, while the millimeter-wave radar at the end of the chute acquires the height of the material surface in the truck bed in real time. When the material surface height reaches 80% of the height of the side panels of the truck bed, the belt conveyor speed is reduced in conjunction with the loading level stage threshold to control the flow of bulk grain and prevent overflow. When the real-time weight, the preset target loading total and the material surface height all reach the threshold, the loading is considered complete. Subsequently, multiple laser rangefinders are used to monitor the material surface height at a single point along the width of the truck bed and calculate the maximum height difference. If this value exceeds the 5cm tolerance threshold, the currently executed "Z-shaped" path is automatically corrected to a "spiral progressive" path, and the dwell time at each point is increased from 2 seconds to 3 seconds. At the same time, the loading level stage threshold (the full load threshold is reduced from 90% to 85%) and the bulk grain loading speed range (adjusted from 800-1000t / h to 600-800t / h) are dynamically adjusted according to the type of corn being loaded, ultimately completing a level, anti-eccentric loading operation of bulk grain.

[0038] Preferably, step S1 includes: The vehicle to be loaded is moved and its center coordinates are obtained. The preset target loading area is analyzed to obtain the center coordinates of the loading area; If the vehicle's center coordinates coincide with the loading area's center coordinates, it is determined that the vehicle to be loaded is located in the target loading area, and a vehicle scanning signal is generated. The vehicle to be loaded is scanned based on the vehicle scanning signal to obtain the dimensions of the cargo box, generate the rectangular outline of the cargo box, and obtain the initial height of the material surface; Based on the safe material level threshold k and the dimensions of the car body, calculate the effective volume V of the car body: V = L × W × (Hk); L is the length of the car body, W is the width of the car body, and H is the height of the car body; Based on the grain bulk density coefficient γ and the effective volume of the car body, the target loading capacity Q is matched: Q = γ × V; Based on the vehicle compartment size data and vehicle type threshold range, the vehicle type is determined, including: If the vehicle body size data is within the first type threshold range, then the current vehicle type is determined to be a small car; If the vehicle body size data is within the second type threshold range, then the current vehicle type is determined to be a medium-sized vehicle; If the vehicle body size data is within the third type threshold range, then the current vehicle type is determined to be a large vehicle.

[0039] In this embodiment, the parameters of the carriage and materials are as follows: carriage length 4-12m, width 2.2-3.0m, sideboard height 0.8-2.0m; target loading capacity 20-100t; grain bulk density 0.75-0.85t / m³, angle of repose 25°-35°; safety margin material surface distance from the top of the sideboard ≥15-20cm, and off-center loading error ≤±3%.

[0040] When a vehicle enters the system, the weighbridge / infrared beam wake-up system is triggered. The radar scans the dimensions of the cargo box and the initial material surface for 1-2 seconds, generates a profile, calculates the effective volume, automatically matches the target loading capacity, and classifies the vehicle as a small / medium / large vehicle. Voice and large screen guide the vehicle to a stop.

[0041] Preferably, step S2 includes: If the vehicle type is a small car, then match the N-point equally divided template, and divide the car body equally according to the width of the car body, and calculate the corresponding path node coordinates and cloth movement sequence; If the vehicle type is a medium-sized vehicle, then match the S-shaped reciprocating template and serpentine along the length of the carriage to cover the width of the carriage, and calculate the corresponding path node coordinates and cloth movement sequence; If the vehicle type is a large vehicle, then match the layered template with a back shape, and lay the fabric layered from the edge of the carriage inwards, calculating the corresponding path node coordinates and fabric movement order; The initial cloth path is generated based on the path node coordinates and cloth movement order, combined with the dwell time at a single point. The initial laying path is verified. If the path has no collisions, covers the entire carriage, and has no blind spots at the edges and corners, then the initial laying path is determined to be a bulk grain laying path. The timing of the bulk grain distribution path is decomposed to generate a distribution timing table and the weight of the grain in the wagon is obtained.

[0042] In this embodiment: the path is matched according to the vehicle type (small car is divided into 3 equal points, medium car is S-shaped back and forth, large car is layered in a U-shape), the path coordinates, movement sequence, speed and dwell time are calculated, the time sequence table is generated and the collision-free and blind-spot-free conditions are verified.

[0043] The path includes S-shaped, zigzag, and equally divided points; the moving speed is divided into three stages (initial 0.6-1.0m / s, middle stage 0.3-0.6m / s, and final stage 0.1-0.3m / s); the material drop height is 0.5-1.5m, the single-point dwell time is 2-10s, and the number of material layers is 3-5.

[0044] Preferably, step S3 includes: According to the material placement path type and the material placement sequence table, the bulk grain placement process is monitored, and the height of the material surface at a single point is detected. If the height of a single material level is within the first material level threshold range, the current car is determined to be empty, and the single-point loading rate is calculated. If the single-point loading rate is within the initial loading threshold range, then the bulk grain loading speed is determined to be within the first speed range; If the single-point loading rate is within the mid-term loading threshold range, then the bulk grain loading speed is determined to be within the second speed range; If the single-point loading rate is within the final loading threshold range, then the bulk grain loading speed is determined to be within the third speed range. If the height of a single material level is within the second material level threshold range, the current carriage is determined to be in a half-fill state, and the bulk grain flow rate is kept constant according to the second speed range. If the height of a single material level is within the third material level threshold range, the current car is determined to be full, and the bulk grain flow rate is kept constant according to the third speed range until the upper limit of the current material level threshold range is reached, at which point the material distribution stops. If the absolute distance change value of the height of a single point material surface for x consecutive periods is greater than the warning threshold, then the single point overflow or single point collapse is determined according to the sign of the absolute distance change value, and an alarm notification is generated. If the height of all individual material surfaces meets the standard, then the height of the material surface in the car body is calculated comprehensively.

[0045] In this embodiment, the scanning cycle is 100-200ms, and sampling is performed at 3 points along the length of the carriage (0.5m) and the width (left / middle / right). Empty material h≤5cm, half material h=H / 2±10cm, full material h≥H−20cm; a sudden change in distance >30cm for 3 consecutive cycles is judged as abnormal.

[0046] At an intelligent bulk grain transfer center, when a four-axle dump truck enters the automated loading station, the system uses lidar to determine the vehicle model, matches a "serpentine + progressive" composite material placement path, and generates a material placement sequence table. During loading, eight millimeter-wave radars at the end of the chute scan the material level at three points (left / center / right) along the length of the truck bed every 0.5m at 150ms intervals. When the height of all measuring points is ≤5cm, it is determined to be an empty state. The single-point loading rate is calculated (e.g., initial loading rate <20%), and the system adjusts the frequency converter of the belt conveyor to 45Hz, corresponding to the first speed range (1200t / h), for rapid bottom placement. As the grain accumulates, the measuring point height enters H / 2±10cm (half-load state), and the loading rate is in the 20%-80% range. The system automatically switches to the second speed range (35Hz). The system maintains a stable material flow (800t / h). When the maximum measuring point height is ≥H-20cm (cargo sideboard height 1.5m, i.e. ≥1.3m), it is determined to be a full-load state with a loading rate >80%. The speed is reduced to the third speed range (20Hz, 400t / h), and the chute is stopped point by point until the height of each point reaches the sideboard height (1.5m), at which point the material is stopped. During this period, if the absolute value of the absolute distance change of a certain point height exceeds 30cm within 3 consecutive scanning cycles (450ms), and the sign is positive, a "single-point overflow" alarm is triggered; if the sign is negative, a "collapse" alarm is triggered. The system immediately stops the material distribution and notifies the on-site personnel for handling. After all single points meet the standard, the height of the cargo box material surface is calculated by weighted average, and the total weight (target 35 tons) and the flatness of the material surface are verified to complete the intelligent and anti-eccentric loading operation of bulk grain.

[0047] Preferably, step S4 includes: If the weight of the grain in the car is greater than or equal to the preset target total load, or if the height of the material in the car is greater than or equal to the preset target height, then the current vehicle is considered to have completed loading.

[0048] In this embodiment, after feeding is started, the chute moves along the path, and the radar monitors the material surface in real time. If the material level rises quickly, the dwell time is shortened. If the height difference exceeds 10cm, the low zone is replenished first. The flow rate is linked in three segments (80-100t / h for <30% loading rate, 40-60t / h for 30%-80% loading rate, and 20-30t / h for >80% loading rate). When the closed-loop deviation of the weighbridge is >±2%, the flow rate / path is finely adjusted.

[0049] Material feeding stops when the weight meets the target or the material level reaches the threshold. Radar scans the entire truck compartment to verify uniformity. Voice and large screen prompts indicate when to release the vehicle. Vehicle, weight, route, and abnormal data are automatically archived.

[0050] Off-center loading suppression: If the difference in material level between the left and right sides is greater than 10cm, reduce the flow rate on the higher side and prioritize feeding the lower side; Overflow protection: If any material level is ≥H−15cm, immediately stop material flow and alarm. Material collapse handling: If the material surface suddenly drops by more than 20cm, pause the material placement alarm and restart it after manual confirmation; Material shortage / empty bin: When the bin level radar is less than 40%, a deceleration alarm will be triggered, and automatic reloading will resume after recovery; Equipment linkage: The chute and feeder are interlocked; the gate will not open if the material is not in position, and the entire equipment will be stopped in case of an emergency.

[0051] The radar is installed at a height of 2.5 to 3.5 meters above the top of the vehicle, with no obstruction when viewed from above; the algorithm adopts a layered S-shaped structure + material level closed loop + flow segmentation, which can be implemented by PLC; the material level threshold, moving speed and dwell time are finely adjusted according to wheat / corn / soybean.

[0052] This application discloses a storage medium storing at least one instruction, at least one program, code set, or instruction set. The at least one instruction, at least one program, code set, or instruction set is loaded and executed by a processor to implement the intelligent grain loading method described above.

[0053] The embodiments described in this specific implementation are preferred embodiments of this application and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. An intelligent fabric placement system for bulk grain loading, characterized in that, include: The main detection mechanism is used to monitor the loading process of bulk grain onto trucks and collect target loading data; the target loading data includes the dimensions of the truck bed, the height of the material surface, and the outline of the material pile. An auxiliary sensing mechanism is used to monitor the bulk grain loading process and collect auxiliary loading data; the auxiliary loading data includes the bulk grain loading amount, the grain storage amount, and the feeding movement amount. The intelligent control mechanism is used to receive target loading data and auxiliary loading data, and generate and distribute mechanism adjustment commands according to the preset bulk grain control mechanism. The dynamic actuator is used to control the corresponding actuator to deliver material to the target vehicle according to the mechanism adjustment command, until the weight reaches the standard or the material level reaches the threshold and then the delivery stops.

2. The intelligent fabric placement system for bulk grain loading according to claim 1, characterized in that, The dynamic actuator includes: The lifting tower, equipped with the main detection mechanism and auxiliary sensing mechanism, is used to transport bulk grain to the target loading layer; A bulk grain scale is installed on the lifting tower and located below the bulk grain inlet to weigh the falling bulk grain. The buffer bin, installed on the lifting tower and located below the bulk grain scale, is used to buffer the fluctuations caused by the falling of bulk grain, forming a uniform and continuous flow of bulk grain. The rail conveyor, installed on the lifting tower and located below the buffer bin, is used to transport the bulk cargo machine back and forth along the parallel rails of the car body; A bulk loader is a moving chute installed on the rail conveyor. It is used to control the even distribution of bulk grain along the entire length of the carriage according to the moving and lifting strokes until the material level reaches the threshold. Weighbridges are used to weigh the amount of bulk grain loaded in a truck bed in real time until the weight meets the standard.

3. An intelligent method for loading bulk grain onto trucks, applied to the system described in any one of claims 1-2, characterized in that, include: Locate the vehicle to be loaded, and in conjunction with the preset target loading area, detect and scan the vehicle to be loaded to determine the vehicle type; Based on the vehicle type, the corresponding bulk grain distribution path is matched and planned, a distribution timetable is generated, and the weight of grain in the car is monitored. The bulk grain distribution process is monitored according to the distribution time schedule to obtain the height of the material surface in the truck bed, and the bulk grain flow rate is controlled in conjunction with the loading level stage threshold. Based on the preset target loading volume and target material level, the weight of the grain in the wagon and the material level in the wagon are checked to determine that the vehicle loading is complete.

4. The intelligent material placement method for bulk grain loading according to claim 3, characterized in that, The process of locating the vehicle to be loaded, and in conjunction with a preset target loading area, detecting and scanning the vehicle to be loaded to determine the vehicle type includes: The vehicle to be loaded is moved and its center coordinates are obtained. The preset target loading area is analyzed to obtain the center coordinates of the loading area; If the vehicle's center coordinates coincide with the loading area's center coordinates, it is determined that the vehicle to be loaded is located in the target loading area, and a vehicle scanning signal is generated. The vehicle to be loaded is scanned based on the vehicle scanning signal to obtain the dimensions of the cargo box, generate the rectangular outline of the cargo box, and obtain the initial height of the material surface; Based on the safe material level threshold k and the car body size data, the effective volume V of the car body is calculated as follows: V = L × W × (Hk); L is the length of the car body, W is the width of the car body, and H is the height of the car body. Based on the grain bulk density coefficient γ and the effective volume of the car body, the target loading capacity Q is matched: Q = γ × V; The vehicle type is determined by combining the vehicle compartment size data with the vehicle type threshold range.

5. The intelligent fabric placement method for bulk grain loading according to claim 4, characterized in that, The process of determining the vehicle type based on the vehicle compartment size data and a vehicle type threshold range includes: If the vehicle body size data is within the first type threshold range, then the current vehicle type is determined to be a small car; If the vehicle body size data is within the second type threshold range, then the current vehicle type is determined to be a medium-sized vehicle; If the vehicle body size data is within the third type threshold range, then the current vehicle type is determined to be a large vehicle.

6. The intelligent fabric placement method for bulk grain loading according to claim 3, characterized in that, The process of matching and planning corresponding bulk grain distribution paths based on vehicle type, generating a distribution timing table, and monitoring the weight of grain in the wagon compartment includes: If the vehicle type is a small car, then match the N-point equally divided template, and divide the car body equally according to the width of the car body, and calculate the corresponding path node coordinates and cloth movement sequence; If the vehicle type is a medium-sized vehicle, then match the S-shaped reciprocating template and serpentine along the length of the carriage to cover the width of the carriage, and calculate the corresponding path node coordinates and cloth movement sequence; If the vehicle type is a large vehicle, then match the layered template with a back shape, and lay the fabric layered from the edge of the carriage inwards, calculating the corresponding path node coordinates and fabric movement order; The initial cloth path is generated based on the path node coordinates and cloth movement order, combined with the dwell time at a single point. The initial laying path is verified. If the path has no collisions, covers the entire carriage, and has no blind spots at the edges and corners, then the initial laying path is determined to be a bulk grain laying path. The timing of the bulk grain distribution path is decomposed to generate a distribution timing table and the weight of the grain in the wagon is obtained.

7. The intelligent fabric placement method for bulk grain loading according to claim 3, characterized in that, The process of monitoring the bulk grain distribution process according to the distribution timetable, obtaining the material level height in the truck bed, and combining it with the loading level stage threshold to control the bulk grain flow rate includes: According to the material placement path type and the material placement sequence table, the bulk grain placement process is monitored, and the height of the material surface at a single point is detected. If the height of a single material level is within the first material level threshold range, the current car is determined to be empty, and the single-point loading rate is calculated. If the single-point loading rate is within the initial loading threshold range, then the bulk grain loading speed is determined to be within the first speed range; If the single-point loading rate is within the mid-term loading threshold range, then the bulk grain loading speed is determined to be within the second speed range; If the single-point loading rate is within the final loading threshold range, then the bulk grain loading speed is determined to be within the third speed range. If the height of a single material level is within the second material level threshold range, the current carriage is determined to be in a half-fill state, and the bulk grain flow rate is kept constant according to the second speed range; If the height of a single material level is within the third material level threshold range, the current car is determined to be full, and the bulk grain flow rate is kept constant according to the third speed range until the upper limit of the current material level threshold range is reached, at which point the material distribution stops. If the absolute distance change value of the height of a single point material surface for x consecutive periods is greater than the warning threshold, then the single point overflow or single point collapse is determined according to the sign of the absolute distance change value, and an alarm notification is generated. If the height of all individual material surfaces meets the standard, then the height of the material surface in the car body is calculated comprehensively.

8. The intelligent fabric placement method for bulk grain loading according to claim 3, characterized in that, The process of verifying the weight of the grain in the wagon and the height of the material in the wagon based on the preset target loading total and target material level, and determining that the vehicle loading is complete, includes: If the weight of the grain in the car is greater than or equal to the preset target total load, or if the height of the material in the car is greater than or equal to the preset target height, then the current vehicle is considered to have completed loading.

9. The intelligent fabric placement method for bulk grain loading according to claim 3, characterized in that, The intelligent fabric application method further includes: Based on the width of the carriage and its rectangular outline, monitor the height of the material surface at a single point and calculate the position difference of the material surface at a single point. If the difference in material level at a single point is greater than the preset tolerance threshold, the bulk grain distribution path will be corrected according to the path type to obtain the optimal distribution path. Based on the type of grain, the loading level threshold, the bulk grain loading speed range, and the single-point dwell time are adjusted and modified to complete the bulk grain loading and distribution.

10. A storage medium storing at least one instruction, at least one program, a code set, or an instruction set, wherein the at least one instruction, the at least one program, the code set, or the instruction set is loaded and executed by a processor to implement the intelligent grain loading method as described in any one of claims 3-9.

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