Detection system for working process of car dumper

Abstract

The utility model provides a system for detecting the working process of a car dumper, which is characterized in that a PLC (Programmable Logic Controller) is connected with a car pressing beam position sensor to obtain the position information of a car pressing beam pressed on a carriage; the PLC is connected with the car leaning plate position sensor to obtain position information of the car leaning plate abutting against the carriage; the PLC obtains the turnover angle position information of the car dumper, and obtains the turnover limit and return position information through the turnover over-travel switch and the return over-travel switch; the PLC is connected with the incremental encoder to obtain speed information for controlling the operation of the turnover motor based on the frequency converter; the PLC obtains video information of the vehicle pressing beam and the vehicle leaning plate based on the vehicle pressing beam detection camera shooting assembly, the PLC obtains video information of the compartment overturning process based on the overturning detection camera shooting assembly, and the video information is displayed through the display screen. The system can detect the working process of the car dumper through a sensor and a video, and stable operation of the car dumper is guaranteed.

Description

Technical Field

[0001] The utility model belongs to the technical field of train derailment prevention, and in particular relates to a working process detection system for a car tipper. Background Art

[0002] A car tipper is a highly efficient, large-scale, professional equipment for unloading open railway cars loaded with bulk materials. Compared with other open railway car unloading machines, car tippers have the characteristics of clean unloading, large unloading capacity, high unloading efficiency, and high degree of automation. The current car tippers can improve unloading efficiency, reduce labor intensity, and realize automated operations. At the same time, they can greatly improve the working conditions of workers and significantly reduce the operating costs of enterprises. Based on the above advantages, car tippers are currently widely used by large enterprises such as ports, coal, coking, power plants, metallurgy, etc. that need to handle a large amount of bulk materials.

[0003] In order to ensure the stable operation of the tipping machine, corresponding detection devices will be configured when the tipping machine is running, such as position sensors, limiters, etc. For position sensors and limiters, they can get the signal, and then effectively control it through PLC technology.

[0004] However, currently, the monitoring of the tipping machine is still achieved by using sensors and limiters. There is a lack of on-site video monitoring, and it is impossible to analyze the on-site video of the tipping machine, which affects the stable operation of the tipping machine. Utility Model Content

[0005] The utility model provides a working process detection system for a car tipping machine. The system can detect the working process of the car tipping machine through two methods, namely, sensors and videos, to ensure stable operation of the car tipping machine.

[0006] The working process detection system of the tipping machine includes: PLC controller, car pressing beam position sensor, car support plate position sensor, car pressing beam detection camera assembly, overturning overtravel switch, return overtravel switch, absolute encoder, incremental encoder, overturning detection camera assembly and display screen;

[0007] The PLC controller is connected to the car pressing beam position sensor to obtain the position information of the car pressing beam pressed on the car body;

[0008] The PLC controller is connected to the position sensor of the car support plate to obtain the position information of the car support plate abutting against the car body;

[0009] The PLC controller is respectively connected to the overturning overtravel switch and the return overtravel switch by absolute encoder communication to obtain the overturning angle position information of the tipping machine, and obtains the overturning limit and return position information through the overturning overtravel switch and the return overtravel switch;

[0010] The PLC controller obtains the speed information of the flip motor based on the inverter control by connecting with the incremental encoder;

[0011] The PLC controller obtains video information of the car pressing beam and the car support plate based on the car pressing beam detection camera component, and obtains video information of the car flipping process based on the flipping detection camera component and displays it on the display screen.

[0012] It should be further explained that it also includes: a memory; the memory stores the YOLO-V2 algorithm and the K-means clustering algorithm;

[0013] The PLC controller detects the position information of the hold-down beam and the support plate in the video information of the hold-down beam and the support plate based on the YOLO-V2 algorithm and the K-means clustering algorithm, and displays it on the display screen.

[0014] It should be further explained that the memory also stores a heatmap key point detection algorithm;

[0015] The PLC controller detects the position information of the car after it is flipped back to its original position in the video information of the car flipping process based on the heatmap key point detection algorithm.

[0016] It should be further explained that it also includes: a pusher detection camera assembly for capturing video information of the pusher arm operation area;

[0017] The PLC controller obtains the video information of the operation process of the pusher arm based on the pusher detection camera component and displays it on the display screen.

[0018] It should be further explained that the PLC controller extracts features of the boom end, coupler, and carriage position based on the YOLO-V2 algorithm and K-means clustering algorithm, obtains the position information of the boom end, coupler, and carriage through feature point position extraction, and displays it on the display screen.

[0019] It should be further explained that it also includes: a track detection camera assembly for capturing image information of the dumper track and the ground track;

[0020] The PLC controller is connected to the track detection camera assembly to obtain the alignment status of the tipping machine track and the ground track captured by the track detection camera assembly, and displays it on the display screen.

[0021] It should be further explained that it also includes: a reducer temperature sensor and a hydraulic station liquid level sensor;

[0022] The PLC controller obtains the reducer temperature information by connecting with the reducer temperature sensor and displays it on the display screen;

[0023] The PLC controller obtains the hydraulic station liquid level information by connecting to the hydraulic station liquid level sensor and displays it on the display screen.

[0024] It should be further explained that the PLC controller is connected to the industrial computer through the Ethernet module.

[0025] It should be further explained that the PLC controller is connected to an emergency stop button.

[0026] It should be further explained that the PLC controller adopts S7-400-PLC controller, or adopts FX3G-PLC controller, or adopts C200HX-PLC controller.

[0027] It can be seen from the above technical solutions that the utility model has the following advantages:

[0028] The utility model provides a car tipping machine working process detection system equipped with a car pressing beam position sensor, a car support plate position sensor, a car pressing beam detection camera assembly, a flip overtravel switch, a return overtravel switch, an absolute encoder, an incremental encoder, a flip detection camera assembly and a display screen, so as to realize the synchronous monitoring of the operating status of the car tipping machine by the sensor and the camera assembly.

[0029] The utility model adopts visual technology to effectively collect and monitor multiple working positions of the tipping machine, realizes multi-angle monitoring and separate analysis and judgment of each area, and improves the pertinence of monitoring. Once a fault or abnormality occurs, it can be discovered in time, and the fault can be visualized immediately to ensure the stable operation of the tipping machine. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In order to more clearly illustrate the technical solution of the utility model, the drawings required for use in the description will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the utility model. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0031] Figure 1 This is a schematic diagram of the tipping machine working process detection system. DETAILED DESCRIPTION

[0032] In order to make the purpose, features and advantages of the utility model more obvious and easy to understand, the technical scheme of the utility model will be clearly and completely described below in combination with the drawings in the specific embodiment. Obviously, the embodiments described below are only part of the embodiments of the utility model, not all of them. Based on the embodiments in this patent, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this patent.

[0033] like Figure 1 As shown, the working process detection system of the car tipping machine provided by the utility model includes: PLC controller, car pressing beam position sensor, car support plate position sensor, car pressing beam detection camera assembly, overturning overtravel switch, return overtravel switch, absolute encoder, incremental encoder, overturning detection camera assembly and display screen. According to actual needs, the car tipping machine can also involve car shifting machine, car pushing machine, car pulling platform, belt conveyor, bucket wheel machine, etc.

[0034] The working process of the car tipper of this embodiment may include the following process: the locomotive pushes the entire train of heavy cars to the preset position of the car tipper. The arm of the car pusher falls down and is in place, just hooked with the train hook, and then the hook is removed. After the hook is removed, the car pusher moves forward and pushes the car into the tipping position of the car tipper, and the induction proximity switch senses the arrival signal. The arm automatically unhooks, lifts up, and the upper limit is in place.

[0035] During the working process of the car tipper, the clamping mechanism composed of the car pressing beam and the car support plate presses the carriage. Due to its own weight, the side of the carriage is pressed to ensure the stability of the train. The entire car tipping process is completed by the main command controller. After flipping in place, it returns to the original path and returns to its place. The car pusher pulls the next car to the car tipper. The empty car that has completed coal unloading in the car tipper is pushed out of the car tipper to the car transfer platform by the incoming car. When the empty car arrives at the car transfer platform and is in place, the wheel clamp clamps the wheels of the car and fixes it on the car transfer platform. Then the car transfer platform is translated to the position of the empty car pusher, the wheel clamp is released, and the empty car pusher pushes the empty car to the empty car track.

[0036] Based on the above process, the PLC controller obtains the position information of the press beam pressed on the car body by connecting with the car hold beam position sensor; the PLC controller obtains the position information of the car hold plate abutting against the car body by connecting with the car rest plate position sensor; the PLC controller communicates with the flip overtravel switch and the return overtravel switch with absolute encoders respectively to obtain the flip angle position information of the tipping machine, and obtains the flip limit and return position information through the flip overtravel switch and the return overtravel switch.

[0037] The PLC controller obtains the speed information of the flip motor controlled by the frequency converter by connecting to the incremental encoder; the PLC controller obtains the video information of the press beam and the car support plate based on the press beam detection camera component; the PLC controller obtains the video information of the car flipping process based on the flip detection camera component and displays it on the display screen.

[0038] It should be noted that the PLC controller is connected to the industrial computer through the Ethernet module. The display screen can be set up in the monitoring room and connected to the industrial computer for monitoring personnel to view and monitor the operation process of the tipping machine in real time.

[0039] In this embodiment, the system also includes: a memory and a track detection camera component for capturing image information of the dumper track and the ground track; the memory stores a heatmap key point detection algorithm, a YOLO-V2 algorithm and a K-means clustering algorithm.

[0040] The PLC controller detects the position information of the press beam and the support plate in the video information of the press beam and the support plate based on the YOLO-V2 algorithm and the K-means clustering algorithm, and displays it on the display screen.

[0041] This is based on the YOLO-V2 algorithm and K-means clustering algorithm to locate the car pressure beam and the car support plate through template matching or SIFT feature point matching to determine whether they have reached the designated position.

[0042] In this embodiment, the PLC controller performs feature extraction on the position of the boom end, coupler, and carriage based on the YOLO-V2 algorithm and the K-means clustering algorithm, obtains the position information of the boom end, coupler, and carriage through feature point position extraction, and displays it on the display screen.

[0043] Here, the PLC controller extracts features from the end of the boom, the coupler, the carriage, etc., performs feature point detection, obtains position information through the feature points, and determines whether there is a risk of collision.

[0044] The PLC controller detects the position information of the car after it is flipped back to its original position in the video information of the car flipping process based on the heatmap key point detection algorithm.

[0045] In this embodiment, the PLC controller is connected to the track detection camera assembly to obtain the alignment status of the tipping machine track and the ground track captured by the track detection camera assembly, and display it on the display screen. Here, based on the binary classification algorithm of deep learning, the "track alignment" and "track misalignment" images can be classified to further detect the docking status of the tipping machine track and the ground track.

[0046] It can be seen that the YOLO-V2 algorithm and K-means clustering algorithm involved in the utility model can be based on a machine learning method of a multi-layer neural network, and can automatically extract features and rules from a large amount of car tipping machine operation data. The car tipping machine related video information can be stored in a memory, and the video image information under normal conditions can be set as a detection reference state, thereby realizing image recognition and detection of the car tipping machine operation process.

[0047] For example, this embodiment involves the phenomenon of empty car derailment and spring misalignment. The system uses the fault abnormal images of spring morphological characteristics as samples, builds a mathematical model, determines the various parameters in the model, and combines model training to find the most approximate expression of the statistical law of spring morphological abnormality. The system continuously collects on-site video streams, analyzes the characteristics of spring morphological abnormalities in the video data, and identifies and diagnoses whether the empty car is derailed or whether the spring is misaligned through a deep learning network structure.

[0048] In an embodiment of the utility model, the system also includes: a reducer temperature sensor and a hydraulic station liquid level sensor; the PLC controller obtains the reducer temperature information by connecting to the reducer temperature sensor and displays it on the display screen; the PLC controller obtains the hydraulic station liquid level information by connecting to the hydraulic station liquid level sensor and displays it on the display screen.

[0049] The PLC controller is connected with an emergency stop button. The PLC controller adopts S7-400-PLC controller, or FX3G-PLC controller, or C200HX-PLC controller.

[0050] The tipper working process detection system provided by the utility model can be implemented in hardware, software, firmware or any combination thereof. The various features as modules, units or components can be implemented together in an integrated logic device or separately as discrete but interoperable logic devices or other hardware devices. In some cases, various features of the electronic circuit can be implemented as one or more integrated circuit devices, such as integrated circuit chips or chipsets.

[0051] If implemented in hardware, the present invention relates to a device, such as a processor or an integrated circuit device, such as an integrated circuit chip or chipset. Alternatively or additionally, if implemented in software or firmware, the technology may be implemented at least in part by a computer-readable data storage medium, including instructions that, when executed, cause a processor to perform one or more of the above methods. For example, a computer-readable data storage medium may store instructions such as those executed by a processor.

[0052] The memory of the present invention may include computer storage media, such as random access memory (RAM), read-only memory (ROM), non-volatile random access memory (NVRAM), electrically erasable programmable read-only memory (EEPROM), flash memory, magnetic or optical data storage media, and the like. In some embodiments, a product of manufacture may include one or more computer-readable storage media.

[0053] In some embodiments, the computer-readable storage medium may include a non-volatile medium. The term "non-transitory" storage medium may indicate that the storage medium is not contained in a carrier or propagating signal. In some embodiments, a non-transitory storage medium may store data that may change over time (e.g., in RAM or cache).

[0054] The PLC controller may include one or more processors for execution, such as one or more digital signal processors (DSPs), general-purpose microprocessors, application-specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), or other integrated circuits, or discrete logic circuits. Therefore, the term "processor" as used herein may refer to any of the aforementioned structures or any other structure that is more suitable for implementing the technology described herein. In addition, in some aspects, the functions described in the present disclosure may be provided in software modules and hardware modules.

[0055] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but will conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A working process detection system for a car tipper, characterized in that: include: PLC controller, car pressing beam position sensor, car rest plate position sensor, car pressing beam detection camera assembly, overturning overtravel switch, return overtravel switch, absolute encoder, incremental encoder, overturning detection camera assembly and display screen; The PLC controller is connected to the car pressing beam position sensor to obtain the position information of the car pressing beam pressed on the car body; The PLC controller is connected to the position sensor of the car support plate to obtain the position information of the car support plate abutting against the car body; The PLC controller is respectively connected to the overturning overtravel switch and the return overtravel switch by absolute encoder communication to obtain the overturning angle position information of the tipping machine, and obtains the overturning limit and return position information through the overturning overtravel switch and the return overtravel switch; The PLC controller obtains the speed information of the flip motor based on the inverter control by connecting with the incremental encoder; The PLC controller obtains video information of the car pressing beam and the car support plate based on the car pressing beam detection camera component, and obtains video information of the car flipping process based on the flipping detection camera component and displays it on the display screen.

2. The tipping machine working process detection system according to claim 1 is characterized in that: Also included: a memory; the memory stores a YOLO-V2 algorithm and a K-means clustering algorithm; The PLC controller detects the position information of the hold-down beam and the support plate in the video information of the hold-down beam and the support plate based on the YOLO-V2 algorithm and the K-means clustering algorithm, and displays it on the display screen.

3. The working process detection system of the car tipper according to claim 2 is characterized in that: The memory also stores a heatmap key point detection algorithm; The PLC controller detects the position information of the car after it is flipped back to its original position in the video information of the car flipping process based on the heatmap key point detection algorithm.

4. The working process detection system of the car tipper according to claim 1 or 2, characterized in that: Also includes: A pusher detection camera assembly for capturing video information of the pusher boom operation area; The PLC controller obtains the video information of the operation process of the pusher arm based on the pusher detection camera component and displays it on the display screen.

5. The working process detection system of the car tipper according to claim 4 is characterized in that: The PLC controller extracts features of the boom end, coupler, and carriage position based on the YOLO-V2 algorithm and K-means clustering algorithm. The position information of the boom end, coupler, and carriage is obtained through feature point position extraction and displayed on the display screen.

6. The working process detection system of the car tipper according to claim 1 or 2, characterized in that: Also includes: Track detection camera assembly for capturing image information of the dumper track and the ground track; The PLC controller is connected to the track detection camera assembly to obtain the alignment status of the tipping machine track and the ground track captured by the track detection camera assembly, and displays it on the display screen.

7. The working process detection system of a car tipper according to claim 1 or 2, characterized in that: It also includes: reducer temperature sensor and hydraulic station level sensor; The PLC controller obtains the reducer temperature information by connecting with the reducer temperature sensor and displays it on the display screen; The PLC controller obtains the hydraulic station liquid level information by connecting to the hydraulic station liquid level sensor and displays it on the display screen.

8. The working process detection system of a car tipper according to claim 1 or 2, characterized in that: The PLC controller is connected to the industrial computer through the Ethernet module.

9. The working process detection system of a car tipper according to claim 1 or 2, characterized in that: The PLC controller is connected with an emergency stop button.

10. The working process detection system of a car tipper according to claim 1 or 2, characterized in that: The PLC controller adopts S7-400-PLC controller, or FX3G-PLC controller, or C200HX-PLC controller.

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