Intelligent anti-collision device for double-track bucket wheel machine group
The intelligent anti-collision device, which features multi-dimensional positioning monitoring and graded early warning braking, solves the anti-collision problem of dual-track bucket wheel excavator groups, achieving full-area protection without blind spots, graded protection, and efficient collaborative operation, thereby improving equipment safety and operation and maintenance efficiency.
Patent Information
- Application Number
- CN202611133895.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-07-29
- Publication Date
- 2026-11-03
AI Technical Summary
The existing anti-collision protection system for dual-track bucket wheel excavators has problems such as single monitoring dimensions, lack of hierarchical protection logic, and insufficient safety redundancy, which leads to easy collisions, low operating efficiency, and lack of operation and maintenance data support.
The intelligent anti-collision device, which employs multi-dimensional positioning monitoring, graded early warning braking, and dual-machine collaborative avoidance, includes dual-machine multi-dimensional positioning monitoring components, cross-track interference judgment components, graded anti-collision early warning components, braking components, and data storage and traceability components, to achieve all-area protection without blind spots, intelligent collaborative operation, and efficient operation and maintenance.
It achieves comprehensive protection without blind spots, with 100% accuracy in anti-collision recognition, low equipment wear, high operating efficiency, convenient operation and maintenance, strong adaptability, and long-term data storage and fault traceability functions, ensuring safe and efficient operation of the equipment.
Smart Images
Figure CN123029927A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of safety protection technology for bucket wheel stacker-reclaimers, specifically to an intelligent anti-collision device for a dual-track bucket wheel stacker group. It is suitable for collaborative operation scenarios of two bucket wheel stackers arranged in parallel on dual tracks, realizing anti-collision warning and active braking throughout the operation process to ensure the safe operation of the equipment. Background Technology
[0002] The dual-track parallel arrangement mode supports two bucket wheel excavators to carry out stacking and reclaiming operations simultaneously, greatly improving the material turnover and operational efficiency of bulk material yards, and is currently the mainstream operating configuration for large bulk material yards. However, the existing anti-collision protection system for the collaborative operation of dual-track bucket wheel excavators has many technical shortcomings, which seriously restrict the safe and efficient operation of the equipment.
[0003] Traditional protection methods primarily rely on manual observation and early warning. However, due to the complex environment of the storage yard, blind spots in equipment visibility, operator fatigue, and human negligence, collision risks are high, resulting in extremely poor reliability. Some equipment uses a single distance sensor for collision avoidance monitoring, which can only detect distance in a single direction. This is unsuitable for the complex spatial operating conditions of bucket wheel excavators, which involve multiple overlapping movements such as walking, turning, and pitching. The monitoring dimensions are limited, and the coverage is narrow. Furthermore, with a fixed spacing between the two tracks, the operating trajectories of the two bucket wheel excavators are prone to intersecting. Existing protection systems lack the ability to coordinate the spatial positions of both machines, failing to identify potential cross-track interference hazards and frequently resulting in safety accidents such as rear-end collisions on the same side of the track and cantilever interference collisions across the track.
[0004] In addition, existing anti-collision devices lack tiered protection logic, triggering only a single emergency braking action at dangerous distances. Sudden stops can easily cause large-scale material spillage and impact damage to the mechanical structure of equipment, shortening its service life. Furthermore, most devices lack operational data fault traceability capabilities, making it impossible to trace and analyze collision hazards and abnormal braking events, hindering subsequent equipment maintenance optimization and operational process iteration. Overall, existing anti-collision devices suffer from insufficient safety redundancy, poor adaptability, and low protection accuracy, failing to meet the core requirements for routine safe and efficient collaborative operation of dual-rail bucket wheel excavator groups. Summary of the Invention
[0005] One technical problem to be solved This invention aims to solve the problems of collisions easily occurring when two bucket wheel excavators operate in a dual-track configuration, the single dimension of collision prevention monitoring, the lack of graded protection, and insufficient safety redundancy. It provides an intelligent anti-collision device for dual-track bucket wheel excavator groups, which realizes multi-dimensional position monitoring, graded early warning braking, and dual-machine coordinated avoidance, thereby improving the safety and collaborative efficiency of dual-track bucket wheel excavator operation.
[0006] Two technical solutions To achieve the above objectives, the technical solution adopted by the present invention is as follows: A smart anti-collision device for a dual-track bucket wheel excavator group includes: The stockyard control system includes a bulk material stockyard, which is equipped with two parallel tracks. The main control system for the bucket wheel excavator includes a main control system for bucket wheel excavator A and a main control system for bucket wheel excavator B, and both the main control systems for bucket wheel excavator A and bucket wheel excavator B are electrically connected to the central control system of the stockpile. The core functional component layer includes a dual-machine multi-dimensional positioning and monitoring component, a cross-track interference judgment component, a graded anti-collision and early warning component, a braking component, a dual-machine cooperative avoidance component, and a data storage and traceability component. All of these components are integrated into the bucket wheel excavator main control system. The field actuator layer includes a travel drive motor, a slewing drive motor, a cantilever pitching mechanism, and an audible and visual alarm.
[0007] Further definition of the above technical solution: The main control system of the bucket wheel excavator includes bucket wheel excavator A and bucket wheel excavator B, which are slidably installed on double parallel tracks, which include parallel tracks A and B.
[0008] Further clarification of the above technical solution: The dual-machine multi-dimensional positioning and monitoring component includes a track positioning encoder, a laser rangefinder, and a GNSS+inertial navigation positioning module. This component forms the basis for collision avoidance. Both bucket wheel excavators A and B are equipped with three monitoring units: first, a track positioning encoder installed on the traveling wheels to accurately collect displacement data and determine the absolute position on the track; second, laser rangefinders symmetrically positioned on both sides of the bucket wheel excavator's gantry to monitor the distance between equipment on the same side of the track in real time; and third, a GNSS+inertial navigation positioning module installed in the driver's cab. The GNSS positioning module determines position, velocity, and time information by receiving satellite signals, but its positioning accuracy decreases or even fails when satellite signals are blocked or interfered with. The inertial navigation system relies on accelerometers and gyroscopes to measure the acceleration and angular velocity of the vehicle, obtaining position, velocity, and attitude information through integration. It does not depend on external signals, but errors accumulate over time. The GNSS + inertial navigation positioning module uses a fusion algorithm to complement GNSS and inertial navigation information. When satellite signals are good, GNSS information is used to calibrate the inertial navigation; when satellite signals are lost, the inertial navigation is relied upon to maintain positioning, thus achieving more stable and accurate positioning. It acquires the three-dimensional spatial coordinates of the bucket wheel excavator, adapts to position compensation under rotation and pitch movements, and enables real-time mutual transmission of positioning data between the two excavators to construct a dynamic position map.
[0009] Further limitations on the above technical solution: Cross-track interference determination component: includes a track spacing reference module and a spatial interference algorithm module, pre-stores the fixed spacing reference value of the two tracks, and combines the spatial coordinates, rotation angle and cantilever length of the two bucket wheel excavators to calculate in real time whether there is a risk of cross-track spatial interference between the cantilever and the gantry, determine the critical interference area, identify cross-track collision hazards in advance, and avoid the blind spot of traditional protection that only monitors the same side track.
[0010] Further limitations on the above technical solution: The graded anti-collision warning and braking component is configured with four levels of protection logic to adapt to different risk levels. Level 1 warning safety distance: distance > 15m, with a light audible and visual warning to alert operators; Level 2 warning alert distance: 8-15m, enhanced audible and visual warning, locking the bucket wheel excavator's speed-up function, maintaining only constant / decelerated speed; Level 3 warning avoidance distance: 3-8m, automatically triggering a deceleration command and simultaneously pushing avoidance suggestions; Level 4 emergency braking distance: < 3m, forcibly cutting off the travel and slewing drive power, activating the parking brake, and providing graded protection to avoid damage to the equipment from sudden stops.
[0011] Further limitations on the above technical solution: Dual-machine cooperative avoidance component: The core is a priority determination module and an avoidance path planning module. The preset operation priority can be manually switched. When a level 3 avoidance warning is triggered, the low-priority bucket wheel machine automatically performs the avoidance action. In the same-side track scenario, it moves to the safe area. In the cross-track interference scenario, it retracts the cantilever or adjusts the rotation angle. The high-priority bucket wheel machine maintains operation. After the avoidance is completed, it automatically resumes the operation state without manual intervention.
[0012] Further limitations on the above technical solution: Data storage and traceability component: Real-time recording of dual-machine positioning data, early warning braking trigger time, and avoidance action information, with a storage period of no less than 90 days, supporting traceability analysis of abnormal collision events, providing data support for operation and maintenance optimization, and reserving interfaces to connect to the yard central control system to achieve remote monitoring.
[0013] Further limitations on the above technical solution: the laser rangefinder sensor is equipped with a dustproof and waterproof protective shell to adapt to outdoor operation conditions; the cooperative avoidance component can be adapted to temporary maintenance scenarios, when the bucket wheel excavator sends a locking signal for maintenance, another device automatically avoids the maintenance area.
[0014] Three beneficial effects Compared with the prior art, the present invention provides an intelligent anti-collision device for dual-track bucket wheel excavator groups, which has the following beneficial effects: 1. Comprehensive protection with no blind spots and high accuracy. This invention uses multi-dimensional positioning monitoring combined with spatial interference algorithms to simultaneously cover the risk of rear-end collisions on the same side of the track and the risk of spatial interference across tracks, completely eliminating the monitoring blind spots of traditional protection. The collision identification accuracy can reach 100%, fully adapting to the complex operating conditions of bucket wheel excavators with multiple superimposed actions, and greatly improving the safety of equipment operation.
[0015] 2. Tiered protection mechanism, low equipment wear. Through a four-level tiered early warning and braking logic, corresponding protective actions are matched according to the risk level, abandoning the traditional single emergency braking mode. This effectively avoids problems such as mechanical impact on equipment and material spillage caused by sudden stops, reducing the probability of equipment failure and maintenance costs, and extending the service life of equipment.
[0016] 3. Intelligent collaborative operation with high work efficiency. Equipped with dual-machine priority determination and automatic path planning and avoidance functions, it can achieve rapid response and avoidance within 2 seconds in high-risk working conditions. Low-priority equipment automatically avoids obstacles while high-priority equipment continues to operate without manual coordination and intervention. While ensuring safety, it maximizes the maintenance of work continuity and improves the efficiency of dual-machine collaborative operation.
[0017] 4. Convenient operation and maintenance, and strong adaptability. It has long-term data storage and fault tracing functions, which can quickly locate the cause of abnormal events and provide data support for equipment operation and maintenance and process optimization; the sensor adopts a dustproof and waterproof structure design, which is suitable for harsh outdoor operating environments, and can also be adapted to the transformation and upgrading of different models of dual-rail bucket wheel excavators, making it highly versatile and practical. Attached Figure Description
[0018] Figure 1 This is a system block diagram of the present invention; Figure 2 This is a schematic diagram of the internal structure of the bulk material stockpile in the present invention (side section). Figure 3 This is a cross-sectional internal structure diagram of the bulk material storage yard of the present invention; Figure 4 This is a front view of the bulk material storage yard according to the present invention.
[0019] Among them, 1. Bulk material storage yard; 2. Bucket wheel excavator A; 3. Bucket wheel excavator B; 4. Track positioning encoder; 5. Laser rangefinder sensor; 6. GNSS + inertial navigation positioning module; 7. Graded early warning braking module; 8. Track A; 9. Track B. Detailed Implementation
[0020] The following is in conjunction with the appendix Figure 1-4 The present invention will be described in further detail below.
[0021] Example: This example discloses an intelligent anti-collision device for a dual-track bucket wheel excavator group. The specific structure and assembly relationship are as follows: The entire system consists of four parts: a stockpile central control system, a bucket wheel excavator main control system, a core functional component layer, and a field actuator layer. The stockpile central control system includes a bulk material stockpile 1, within which parallel tracks A8 and B9 are laid, forming a double-parallel operating track. Bucket wheel excavators A2 and B3 are slidably installed on tracks A8 and B9, respectively. The main control systems of bucket wheel excavators A2 and B3 operate independently but are both electrically connected to the stockpile central control system, enabling bidirectional data interaction and remote control.
[0022] All functional modules in the core functional component layer are integrated within the main control system of the bucket wheel excavator, providing core algorithms and data support for intelligent anti-collision protection of the equipment. The dual-machine multi-dimensional positioning monitoring component serves as the basic monitoring unit, with track positioning encoders 4, laser rangefinders 5, and GNSS+inertial navigation positioning modules 6 symmetrically deployed on bucket wheel excavators A2 and B3. Track positioning encoders 4 collect the equipment's displacement and lock the absolute position of the track; laser rangefinders 5 monitor the distance between equipment on the same side in real time, and their external dustproof and waterproof protective shells are suitable for complex outdoor working conditions; GNSS+inertial navigation positioning modules 6 calculate the equipment's three-dimensional spatial coordinates in real time, compensating for positional deviations caused by rotation and pitch movements, and the two machines transmit data in real time to construct a dynamic spatial position map.
[0023] The cross-track interference judgment component pre-stores the reference parameters of the distance between the two tracks. Combined with the real-time spatial coordinates of the two machines, the cantilever rotation angle, and the extension length, it uses a spatial interference algorithm to analyze the interference risk of the cross-track cantilever and gantry in real time, and lock the dangerous area in advance, thus making up for the technical deficiency of traditional protection that only monitors the distance on the same side.
[0024] The graded anti-collision warning component, in conjunction with the braking component, implements a four-level protection strategy, precisely matching the protective action according to the relative distance between the two machines: Level 1 mild warning when the distance is >15m, reminding the operator to pay attention to the working condition; Level 2 warning in the 8-15m range, locking the equipment's speed-up function; Level 3 avoidance warning in the 3-8m range, the equipment automatically decelerates and initiates cooperative avoidance logic; Level 4 emergency braking when the distance is <3m, forcibly cutting off the drive power and initiating the parking brake to prevent collision accidents.
[0025] The dual-machine collaborative obstacle avoidance component achieves intelligent obstacle avoidance by relying on a priority determination module and a path planning module, and the operation priority can be manually switched. When a level 3 warning is triggered, the system automatically determines the equipment priority. Low-priority equipment performs corresponding avoidance actions according to the risk scenario, such as lateral track translation to avoid danger or cross-track interference with boom retraction and angle adjustment to avoid danger. High-priority equipment continues to operate, and the equipment automatically resets and resumes operation after the avoidance is completed. At the same time, this component is adapted to maintenance scenarios. After the maintenance equipment is locked, the operating equipment automatically avoids the maintenance area to ensure maintenance safety.
[0026] The data storage and traceability component records core data such as dual-machine positioning data, early warning braking information, avoidance actions, and operating parameters throughout the entire process, with a storage period of no less than 90 days. It can realize full traceability of abnormal events and also reserves an interface for docking with the central control system to support remote data supervision and operation and maintenance analysis.
[0027] The field actuator layer, as the terminal execution unit, receives instructions from the main control system and completes the equipment's walking, rotating, pitching, and obstacle avoidance actions through the walking drive motor, slewing drive motor, and cantilever pitching mechanism. Different levels of risk warning prompts are achieved through audible and visual alarms.
[0028] Working principle: During the equipment installation and commissioning phase, the assembly and calibration of each monitoring component of the two bucket wheel excavators are completed, realizing the linkage adaptation between the track positioning encoder 4 and the traveling wheel, the precise distance measurement of the laser rangefinder 5, the parameter calibration of the GNSS+inertial navigation positioning module 6, the input of the reference value of the double track spacing of the internal track A8 and track B9 of the bulk material storage yard 1, the preset equipment operation priority and the four-level anti-collision distance threshold of the bucket wheel excavators A2 and B3, and the integration and commissioning of each functional component with the main control system of the bucket wheel excavator are completed.
[0029] During normal operation, the dual-machine multi-dimensional positioning monitoring component relies on the track positioning encoder 4, laser rangefinder 5, and GNSS+inertial navigation positioning module 6 to collect real-time data on the walking position and three-dimensional spatial attitude of bucket wheel excavators A2 and B3. The two machines transmit data to each other in real time and update the dynamic spatial position map. The cross-track interference judgment component simultaneously performs spatial risk calculations and monitors the track spacing on the same side of the two machines on tracks A8 and B9 and the potential cross-track interference.
[0030] When the distance between bucket wheel excavators A2 and B3 on the same side track A8 / B9 decreases to 8-15m, the device triggers a level two warning, relying on the sound and light alarm to enhance the sound and light prompts and lock the equipment's speed-up function; when the distance drops to 3-8m, a level three avoidance warning is triggered, the system automatically determines the equipment priority of bucket wheel excavators A2 and B3, and controls the lower priority bucket wheel excavator to move to the safe area of the track or adjust the cantilever posture to complete the avoidance operation; if a sudden working condition causes the distance to drop to less than 3m, the graded warning braking module 7 immediately triggers a level four emergency braking, cuts off the drive power of the travel drive motor and the slewing drive motor, quickly stops the vehicle to avoid danger, and prevents collision accidents.
[0031] For cross-track operations on tracks A8 and B9, if the system determines that the cantilever or gantry of bucket wheel excavators A2 and B3 poses a risk of cross-track interference, it automatically drives the cantilever pitch mechanism and slewing drive motor of the affected equipment without manual intervention. The cantilever retracts, the slewing angle is adjusted, and after eliminating the spatial interference hazard, normal operation automatically resumes. Throughout the entire operation, data from the track positioning encoder 4, laser rangefinder 5, GNSS+inertial navigation positioning module 6, warning records from the graded warning and braking module 7, equipment avoidance actions, and braking information are all stored in real time. Subsequent data tracing can be used to analyze abnormal events and optimize equipment operation and maintenance, achieving dual protection of equipment safety and efficient operation within the bulk material storage yard 1.
Claims
1. An intelligent anti-collision device for a dual-track bucket wheel excavator group, characterized in that, include: The stockyard control system includes a bulk material stockyard, which is equipped with two parallel tracks. The main control system for the bucket wheel excavator includes a main control system for bucket wheel excavator A and a main control system for bucket wheel excavator B, and both the main control systems for bucket wheel excavator A and bucket wheel excavator B are electrically connected to the central control system of the stockpile. The core functional component layer includes a dual-machine multi-dimensional positioning and monitoring component, a cross-track interference judgment component, a graded anti-collision and early warning component, a braking component, a dual-machine cooperative avoidance component, and a data storage and traceability component. All of these components are integrated into the bucket wheel excavator main control system. The field actuator layer includes a travel drive motor, a slewing drive motor, a cantilever pitching mechanism, and an audible and visual alarm.
2. The intelligent anti-collision device for a dual-track bucket wheel excavator group according to claim 1, characterized in that, The main control system of the bucket wheel excavator includes bucket wheel excavator A and bucket wheel excavator B, which are slidably mounted on two parallel tracks, namely track A and track B, which are set in parallel.
3. A smart anti-collision device for a dual-track bucket wheel excavator group according to claim 1, characterized in that, The dual-machine multi-dimensional positioning and monitoring component includes a track positioning encoder, a laser rangefinder, and a GNSS+inertial navigation positioning module. This component forms the basis for collision avoidance. Both bucket wheel excavators A and B are equipped with three monitoring units: first, a track positioning encoder installed on the traveling wheels to accurately collect travel displacement and determine the absolute position on the track; second, laser rangefinders symmetrically positioned on both sides of the bucket wheel excavator gantry to monitor the distance between equipment ahead and behind on the same side of the track in real time; and third, a GNSS+inertial navigation positioning module installed in the driver's cab of the bucket wheel excavator to acquire the three-dimensional spatial coordinates of bucket wheel excavators A and B, adapting to position compensation during rotation and pitch movements. The two excavators transmit positioning data to each other in real time to construct a dynamic position map.
4. A smart anti-collision device for a dual-track bucket wheel excavator group according to claim 3, characterized in that, GNSS determines position, velocity, and time information by receiving satellite signals. However, positioning accuracy will decrease or even fail when satellite signals are blocked or interfered with. Inertial navigation systems rely on accelerometers and gyroscopes to measure the acceleration and angular velocity of the vehicle and obtain position, velocity, and attitude information through integration. It does not depend on external signals, but errors accumulate over time. The GNSS+INS positioning module uses a fusion algorithm to complement the information from GNSS and INS positioning modules. When satellite signals are good, GNSS information is used to calibrate the INS positioning module. When GNSS satellite signals are lost, the inertial navigation positioning module is used to maintain positioning, thereby achieving more stable and accurate positioning.
5. A smart anti-collision device for a dual-track bucket wheel excavator group according to claim 1, characterized in that, The cross-track interference determination component includes a track spacing benchmark module and a spatial interference algorithm module. It pre-stores the fixed spacing benchmark value of the two tracks, and combines the spatial coordinates, rotation angle and cantilever length of the two bucket wheel excavators. The interference algorithm calculates in real time whether there is a risk of cross-track spatial interference between the cantilever and the gantry, determines the critical interference area, and identifies potential cross-track collision hazards in advance, avoiding the blind spot of traditional monitoring of only the same side track.
6. A smart anti-collision device for a dual-track bucket wheel excavator group according to claim 1, characterized in that, The graded anti-collision warning component and braking component are equipped with four levels of protection logic to adapt to different risk levels. Level 1 warning: distance > 15m, light audible and visual warning to remind the operator to pay attention; Level 2 warning: 8-15m, enhanced audible and visual warning, locks the bucket wheel excavator's speed-up function, and only maintains constant speed / deceleration. Level 3 warning: 3-8m, automatically triggers deceleration command and pushes avoidance suggestions; Level 4 braking: <3m, forcibly cuts off the power to travel and turn, activates the parking brake, and provides tiered protection to avoid damage to the equipment from sudden stops.
7. A smart anti-collision device for a dual-track bucket wheel excavator group according to claim 1, characterized in that, The core of the dual-machine collaborative avoidance component is the priority determination module and the avoidance path planning module. The operation priority is preset. When the level 3 avoidance warning is triggered, the low-priority bucket wheel machine automatically performs the avoidance action. In the same track scenario, it moves to the safe area. In the cross-track interference scenario, it retracts the cantilever or adjusts the rotation angle. The high-priority bucket wheel machine maintains the operation. After the avoidance is completed, it automatically resumes the operation state without manual intervention.
8. A smart anti-collision device for a dual-track bucket wheel excavator group according to claim 1, characterized in that, The data storage and traceability component records dual-machine positioning data, early warning braking trigger time, and avoidance action information in real time, with a storage period of no less than 90 days. It supports traceability analysis of abnormal collision events, providing data support for operation and maintenance optimization. At the same time, it has reserved interfaces to connect to the yard central control system to achieve remote monitoring.
9. A smart anti-collision device for a dual-track bucket wheel excavator group according to claim 3, characterized in that, The laser rangefinder sensor is equipped with a dustproof and waterproof protective shell, making it suitable for outdoor operations. The cooperative avoidance component can be adapted to temporary maintenance scenarios. When the bucket wheel excavator is under maintenance, it sends a locking signal, and another device automatically avoids the maintenance area.