Funnel type bulk cargo loading device

Abstract

The utility model discloses a funnel type bulk cargo loading device, which comprises an image acquisition unit, an image processing unit and a control unit, the weighing and metering unit comprises a plurality of groups of weighing sensors arranged at the joint of the funnel and the loading platform in an array manner, and a weight transmitter connected with the weighing sensors; the positioning sensing unit comprises a plurality of groups of infrared correlation sensors which are arranged on two sides of a driving channel respectively; the gate executing mechanism comprises a servo motor and a gate opening encoder which are mechanically connected with the blanking gate; the warning unit comprises an audible and visual alarm; and an embedded controller is arranged in the operation table and is electrically connected with each execution unit. The vehicle type identification function and the weighing function are combined based on the device. Automatic control over the discharging amount of the bulk material loading and unloading hopper can be achieved, the maximum discharging amount is accurately controlled, the overweight or underload risk is avoided, labor input is reduced, and the safety coefficient in the operation process is improved.

Description

Technical Field

[0001] This utility model relates to the technical field of bulk cargo loading devices, and in particular to a funnel-type bulk cargo loading device with automatic loading control. Background Technology

[0002] As a core piece of equipment in the terminal material handling system, the hopper-type bulk cargo loading device injects bulk materials into the hopper through multiple channels such as grab cranes, belt conveyors, or vibrating feeders, and then loads them quantitatively onto transport vehicles. By establishing a buffered material transfer mechanism, this device effectively decouples the loading / unloading operations of the grab crane from the vehicle transport operations, eliminating the time losses caused by the waiting between the grab crane and the vehicle in traditional operations, and significantly improving the overall operational efficiency of the terminal loading / unloading system.

[0003] However, existing technologies suffer from the following key drawbacks: the lack of a precise real-time metering device at the hopper outlet leads to a discrepancy between the actual loading volume and the target load capacity. This metering inaccuracy easily causes overloading or underloading of transport vehicles—overloading may violate road transport regulations, while underloading results in a waste of transport resources. Current solutions primarily rely on manual experience to adjust the discharge gate, which inherently suffers from significant control lag, low metering accuracy, and high labor costs.

[0004] Therefore, there is an urgent need to develop a funnel-type bulk cargo loading device equipped with an automatic flow control system that requires no manual intervention. Utility Model Content

[0005] This utility model aims to provide an automatic loading device for bulk cargo with automatic loading control, and to achieve automatic loading control based on this hardware structure. The technical solution is as follows:

[0006] A funnel-type bulk cargo loading device includes a funnel, a loading platform, a discharge gate, a support frame, and an operating platform. The loading platform is fixed on the support frame, forming a travel channel. The funnel is connected to the center of the loading platform via a flange, and its discharge port is equipped with an electrically operated discharge gate. The device is characterized by further comprising:

[0007] The image acquisition unit includes an industrial camera and an image processor mounted at the bottom of the loading platform;

[0008] The weighing and metering unit includes multiple sets of weighing sensors arranged in an array at the connection between the funnel and the loading platform, as well as a weight transmitter connected to the weighing sensors.

[0009] The positioning sensing unit includes multiple sets of infrared beam sensors located on both sides of the driving lane.

[0010] The gate actuator includes a servo motor and a gate opening encoder that are mechanically connected to the unloading gate.

[0011] Warning unit, including audible and visual alarm;

[0012] The control panel has a built-in embedded controller and is electrically connected to each execution unit; it includes:

[0013] The data receiving module is electrically connected to the image acquisition unit and the positioning sensing unit, and is configured to receive vehicle parameters and real-time location data.

[0014] The flow calculation module is integrated into the logic circuit of the embedded controller and connected to the weighing unit via a data bus. It is configured to calculate the instantaneous flow rate of the material based on the weight change value collected by the weighing unit.

[0015] The target setting module includes a memory unit for storing the vehicle's rated load and a comparison circuit, configured to generate a target flow rate setting value based on the difference between the rated load and the current load.

[0016] The PID control module is physically connected to the flow calculation module and the target setting module, and is configured to output a gate adjustment signal by comparing the instantaneous flow with the target flow set value.

[0017] The gate drive module is electrically connected to the PID control module and the gate actuator, and is configured to dynamically adjust the gate opening.

[0018] The alarm control module is integrated into the trigger circuit of the embedded controller and connected to the warning unit (70) through a signal transmission channel. It is configured to trigger the warning unit to issue a stop command when the load reaches 95% to 100% of the rated load.

[0019] Furthermore, the operating console peripherals include:

[0020] Emergency stop button, red mushroom-shaped;

[0021] Touchscreen with IP65 protection rating;

[0022] The wireless communication module supports 4G / Bluetooth dual-mode transmission.

[0023] Furthermore, the funnel is pyramidal in shape, with a rectangular outlet. The pyramidal shape facilitates docking with the vehicle body, enabling rapid loading.

[0024] Furthermore, the optical axis of the industrial camera forms a 30°-45° depression angle with the center line of the vehicle channel.

[0025] Furthermore, the image acquisition unit also includes a stabilizing gimbal, which is bolted to the bottom surface of the loading platform. The gimbal includes a three-axis gyroscope, a micro stepper motor, and a laser marker, which projects a positioning baseline in the vehicle's path. The laser marker improves vehicle positioning accuracy.

[0026] Furthermore, the bottom of the support frame is provided with four traction wheel sets, along with pads and counterweights. The traction wheel sets include:

[0027] Two steering wheel sets are arranged on the river side of the support frame, with a wheel diameter of Φ560mm;

[0028] Two directional wheel sets are arranged on the land side of the support frame, with a wheel diameter of Φ560mm;

[0029] All tires are made of solid polyurethane material and have V-shaped anti-skid patterns on the tread.

[0030] The four support legs of the support frame are raised by pads and fixed by counterweights, thereby lifting the traction wheel assembly off the ground.

[0031] This structure achieves a balance between rapid equipment relocation and operational stability.

[0032] Furthermore, the mounting structure of the weighing sensor includes:

[0033] Prestressed adjusting bolts penetrate the flange of the loading platform;

[0034] Waterproof junction box with integrated temperature compensation circuit.

[0035] Stress-adjusting bolts solve the sensor drift problem under moving conditions, and temperature compensation circuits solve the sensor temperature drift problem under operating conditions, ensuring accurate weighing data.

[0036] Furthermore, the infrared beam sensor array includes:

[0037] Height-adjustable column, with a lifting range of 800-1200mm;

[0038] Three sets of infrared emitters, with a vertical spacing of 300mm;

[0039] Three sets of receivers are arranged on the opposite side to form a three-dimensional detection light curtain.

[0040] The adjustable infrared light curtain adapts to different vehicle models, ensuring the vehicle's positioning accuracy in the driving lane.

[0041] Furthermore, the servo motor is a worm gear reducer motor with a reduction ratio of 30:1;

[0042] The scale accuracy of the gate opening encoder is 1°;

[0043] The gate opening and closing mechanism also includes a manual emergency crank, located at the motor output shaft end.

[0044] Furthermore, the audible and visual alarm integrates:

[0045] Dual-color LED warning light, diameter Φ150mm;

[0046] Waterproof horn speaker, output frequency 2kHz-4kHz;

[0047] Magnetic mounting base with an adsorption force of ≥200N.

[0048] Compared with the prior art, the significant feature of this utility model is that, based on the combination of vehicle type recognition function and weighing function of this device, the automatic control of the material discharge amount of the bulk material loading and unloading hopper can be realized, the maximum discharge amount can be accurately controlled, the risk of overloading or underloading can be avoided, the manual input can be reduced, and the safety factor during operation can be improved. Attached Figure Description

[0049] Figure 1 This is a front view of the funnel-type bulk cargo loading device of this utility model;

[0050] Figure 2 This is a side view of the funnel-type bulk cargo loading device of this utility model;

[0051] Figure 3 This is a system block diagram of the funnel-type bulk cargo loading device of this utility model. Detailed Implementation

[0052] To further illustrate the various embodiments, the present invention provides accompanying drawings. These drawings are part of the disclosure of the present invention and are mainly used to illustrate the embodiments, and can be used in conjunction with the relevant descriptions in the specification to explain the operating principles of the embodiments. With reference to these drawings, those skilled in the art should be able to understand other possible implementations and the advantages of the present invention. Components in the drawings are not drawn to scale, and similar component symbols are generally used to represent similar components.

[0053] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments.

[0054] Example 1:

[0055] like Figure 1 , Figure 2 and Figure 3 As shown, the funnel-type bulk cargo loading device of this embodiment consists of mechanical structural components and a control system. The mechanical structural components include a funnel 1, a loading platform 2, a discharge gate 3, a support frame 4, an operating platform 5, a ladder 6, and pads 12, etc. The support frame 4 fixes the loading platform 2 and forms a travel channel.

[0056] The control system consists of an embedded controller 20, an image acquisition unit 30, a positioning sensor unit 40, a weighing and metering unit 50, a gate actuator 60, and an alarm unit 70.

[0057] like Figure 1 and Figure 2 As shown, in this embodiment, traction wheel sets are installed at the four bottom corners of the support frame 4. The support frame 4 is located on both sides of the driving channel, referred to as the river side (referring to the shore side closer to the bulk carrier during operation) and the land side. The river side is equipped with two Φ560mm steering wheels 9, which are mechanically connected to the traction rod 11 and steer and move under the action of the traction rod 11. The land side is equipped with two Φ560mm directional wheels 10 (driven wheels). The tires of both the steering wheels 9 and the directional wheels 10 are made of polyurethane solid tires, and the tread has V-shaped anti-skid patterns to meet the requirements of heavy load, anti-skid, and rapid transfer.

[0058] A loading platform 2 is welded to the top of the support frame 4. A funnel 1 is connected to the center of the platform via a flange. A worm gear driven discharge gate 3 is installed at the discharge port of the funnel cone. A ladder 6 leading to the loading platform 2 is provided on the land side of the support frame 4.

[0059] In this embodiment, the funnel 1 is pyramidal in shape and the discharge port is rectangular, which can be adapted to the vehicle body, simplifying the material discharge control and enabling rapid material discharge.

[0060] In this embodiment, after the equipment is moved to the working position, the support frame 4 is raised by the pad block 12 and then fixed by the counterweight block.

[0061] The image acquisition unit 30 includes an industrial camera and an image processor mounted on the bottom of the loading platform 2; it is used to acquire images of vehicles entering the driving lane. Preferably, the image acquisition unit 30 also includes a gimbal stabilization unit. The gimbal stabilization unit is fixed to the bottom surface of the loading platform 2 by bolts and consists of a three-axis gyroscope, a micro stepper motor, and a laser marker. The camera's optical axis forms a 30°-45° tilt angle with the center line of the driving lane. This specific installation angle ensures complete capture of the vehicle's outline, providing a hardware basis for subsequent manual or automatic system identification of vehicle parameters. The three-axis gyroscope detects platform vibration in real time. When the amplitude is >0.5°, the micro stepper motor drives the camera to perform reverse compensation. The laser marker emits a crosshair reference line with a wavelength of 650nm, forming a 1.5m × 2m positioning area on the floor of the lane.

[0062] The weighing unit 50 includes multiple sets of weighing sensors arranged in an array at the connection between the hopper 1 and the loading platform 2, as well as a weight transmitter connected to the weighing sensors.

[0063] In this embodiment, the funnel 1 is pyramidal in shape. The funnel 1 is connected to the loading platform 2 through four flanges distributed in a square or rectangular pattern. Four weighing sensors 501 are distributed in a square or rectangular pattern at the connection of the funnel flanges.

[0064] Depending on the type of bulk material, hopper 1 can also be conical. The hopper is connected to the loading platform via eight flanges, and eight weighing sensors are evenly distributed at 45° intervals at the flange connections of the hopper.

[0065] The mounting structure of the weighing sensor includes: a prestressed adjusting bolt that runs through the flange of the loading platform 2; and a waterproof junction box with integrated temperature compensation circuitry.

[0066] The prestressing adjustment bolts are made of grade 12.9 high-strength bolts, and are tightened after applying a preload of 10% of the sensor's range. The waterproof junction box has a built-in PT100 temperature sensor, which automatically activates a compensation algorithm when the ambient temperature changes by more than 5°C to ensure accurate weighing data.

[0067] The positioning sensing unit 40 includes infrared beam sensors installed on both sides of the vehicle passage for vehicle positioning. An alarm is triggered when the vehicle reaches the designated loading position. Specifically, it may include: a height-adjustable column with a lifting range of 800-1200mm; three sets of infrared transmitters with a vertical spacing of 300mm; and three sets of receivers arranged on opposite sides, forming a three-dimensional detection light curtain.

[0068] The gate actuator 60 includes a servo motor, a gate opening encoder, and a manual emergency crank, all mechanically connected to the unloading gate 3. Specifically, the servo motor can be a worm gear reducer with a reduction ratio of 30:1; the gate opening encoder can have a scale accuracy of 0.1° and is mounted on the motor output shaft; and the manual emergency crank is located at the end of the motor output shaft. The worm gear reducer motor of the unloading gate is connected to an embedded controller via a CAN bus, and the high-precision gate opening encoder provides a hardware feedback channel for flow regulation.

[0069] A bulkhead vibrator 7 is also installed on one side of the funnel 1 to prevent material discharge jamming caused by problems such as material caking.

[0070] This device uses an embedded controller, which is installed in the control panel 5 (the control panel 5 can be a control room, control box or other structures depending on its size).

[0071] like Figure 3 As shown, the control panel 5 has a built-in embedded controller and is electrically connected to each execution unit; including:

[0072] The data receiving module 21 is electrically connected to the image acquisition unit 30 and the positioning sensing unit 40, and is configured to receive vehicle parameters and real-time location data.

[0073] The flow calculation module 22 is integrated into the logic circuit of the embedded controller and is connected to the weighing unit 50 via a data bus. It is configured to calculate the instantaneous flow rate of the material based on the weight change value collected by the weighing unit 50.

[0074] The target setting module 23 includes a memory unit for storing the vehicle's rated load and a comparison circuit, configured to generate a target flow rate setting value based on the difference between the rated load and the current load.

[0075] PID control module 24 is physically connected to the flow calculation module 22 and the target setting module 23, and is configured to output a gate adjustment signal by comparing the instantaneous flow rate with the target flow rate set value;

[0076] The gate drive module 25 is electrically connected to the PID control module 24 and the gate actuator 60, and is configured to dynamically adjust the gate opening.

[0077] The alarm control module 26 is integrated into the trigger circuit of the embedded controller and is connected to the warning unit 70 through a signal transmission channel. It is configured to trigger the warning unit 70 to issue a stop command when the load reaches 95% to 100% of the rated load.

[0078] The control panel 5 is equipped with an emergency stop button, a touchscreen, and a wireless communication module. The emergency stop button can be a red mushroom-shaped button with an 8mm trigger travel; pressing it directly cuts off the main power supply. The touchscreen displays the loading rate curve in real time, and an alert window pops up when a sudden change in weighing data (>5% of the rated value / second) is detected, or when 95% of the predetermined loading rate is reached. The wireless communication module can use a SIM7600 chip to interact with the terminal dispatch system via the APN private network.

[0079] In this embodiment, the warning unit 70 employs an audible and visual alarm. Specifically, the audible and visual alarm integrates a dual-color LED warning light with a diameter of Φ150mm; a waterproof horn with an output frequency of 2kHz-4kHz; and a magnetic mounting base with an adsorption force ≥200N. This audible and visual alarm can be installed on the support frame via magnetic attraction, bolt fastening, or other methods. The magnetic base ensures reliable operation of the mobile equipment in the complex environment of the dock.

[0080] The operating procedure for this equipment is shown below:

[0081] The operator moves the equipment to the loading area by dragging the tow bar → the support feet are raised and fixed, and the tow wheel is suspended in the air → the vehicle type is selected via the touch screen or the vehicle type is automatically identified by the camera → the system automatically adjusts the height of the infrared light curtain to the position of the truck bed side panel → the truck enters the laser marking area → the weighing unit begins to accumulate the weight of the material → when 95% of the set value is reached, the audible and visual alarm is activated and the yellow light flashes slowly → when loading is completed, the red light flashes quickly and the gate is closed → the data is encrypted and uploaded to the cloud server.

[0082] In summary, based on the device configuration in this embodiment, the following beneficial effects can be achieved:

[0083] 1. By combining vehicle type recognition and weighing, the discharge amount of bulk material loading and unloading hoppers can be automatically controlled, which can accurately control the maximum discharge amount, avoid the risk of overloading or underloading, reduce manual input, and improve the safety factor during operation.

[0084] 2. The mobile support frame allows for relocation and deployment within 30 minutes, improving operational efficiency.

[0085] Although the present invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail may be made to the present invention without departing from the spirit and scope of the present invention as defined in the appended claims, and all such changes shall be within the scope of protection of the present invention.

Claims

1. A funnel-type bulk cargo loading device, comprising a funnel (1), a loading platform (2), a discharge gate (3), a support frame (4), and an operating platform (5), wherein the loading platform (2) is fixed on the support frame (4) and forms a travel channel; the funnel (1) is connected to the center of the loading platform (2) via a flange, and its discharge port is equipped with an electrically operated discharge gate; characterized in that, Also includes: The image acquisition unit (30) includes an industrial camera and an image processor installed at the bottom of the loading platform (2); The weighing unit (50) includes multiple sets of weighing sensors arranged in an array at the connection between the hopper (1) and the loading platform (2), and a weight transmitter connected to the weighing sensors. The positioning sensing unit (40) includes multiple sets of infrared beam sensors disposed on both sides of the driving lane; The gate actuator (60) includes a servo motor and a gate opening encoder that are mechanically connected to the unloading gate; Warning unit (70), including audible and visual alarm; The control panel (5) has a built-in embedded controller and is electrically connected to each execution unit; including: The data receiving module (21) is electrically connected to the image acquisition unit (30) and the positioning sensing unit (40) and is configured to receive vehicle parameters and real-time location data; The flow calculation module (22) is integrated into the logic circuit of the embedded controller and connected to the weighing unit (50) via a data bus. It is configured to calculate the instantaneous flow rate of the material based on the weight change value collected by the weighing unit (50). The target setting module (23) includes a memory unit for storing the vehicle's rated load and a comparison circuit, configured to generate a target flow rate setting value based on the difference between the rated load and the current load. The PID control module (24) is physically connected to the flow calculation module (22) and the target setting module (23), and is configured to output a gate adjustment signal by comparing the instantaneous flow rate with the target flow rate setting value; The gate drive module (25) is electrically connected to the PID control module (24) and the gate actuator (60) and is configured to dynamically adjust the gate opening. The alarm control module (26) is integrated into the trigger circuit of the embedded controller and connected to the warning unit (70) through a signal transmission channel. It is configured to trigger the warning unit (70) to issue a stop command when the load reaches 95% to 100% of the rated load.

2. The funnel-type bulk cargo loading device according to claim 1, characterized in that, The peripherals of the control panel: Emergency stop button, red mushroom-shaped; Touchscreen with IP65 protection rating; The wireless communication module supports 4G / Bluetooth dual-mode transmission.

3. The funnel-type bulk cargo loading device according to claim 1, characterized in that, The funnel is pyramidal in shape, and the discharge port is rectangular.

4. The funnel-type bulk cargo loading device according to claim 1, characterized in that, The optical axis of the industrial camera is at a 30°-45° downward angle to the center line of the vehicle passage.

5. The apparatus according to claim 1, characterized in that, The image acquisition unit also includes a stabilizing gimbal, which is fixed to the bottom surface of the loading platform by bolts. The stabilizing gimbal includes a three-axis gyroscope, a micro stepper motor, and a laser line marker. The laser line marker projects a positioning baseline in the vehicle passage.

6. The funnel-type bulk cargo loading device according to claim 1, characterized in that, The bottom of the support frame is equipped with four traction wheel sets, along with pads and counterweights. Each traction wheel set includes: Two steering wheel sets are arranged on the side of the support frame (4), with a wheel diameter of Φ560mm; Two directional wheel sets are arranged on the land side of the support frame (4), with a wheel diameter of Φ560mm; All tires are made of solid polyurethane material and have V-shaped anti-skid patterns on the tread. The four support legs of the support frame are raised by pads and fixed by counterweights, thereby lifting the traction wheel assembly off the ground.

7. The funnel-type bulk cargo loading device according to claim 1, characterized in that, The mounting structure of the weighing sensor includes: Prestressed adjusting bolts penetrate the flange of the loading platform (2); Waterproof junction box with integrated temperature compensation circuit.

8. The apparatus according to claim 1, characterized in that, The infrared beam sensor group includes: Height-adjustable column, with a lifting range of 800-1200mm; Three sets of infrared emitters, with a vertical spacing of 300mm; Three sets of receivers are arranged on the opposite side to form a three-dimensional detection light curtain.

9. The funnel-type bulk cargo loading device according to claim 1, characterized in that, The servo motor is a worm gear reducer motor with a reduction ratio of 30:1; The scale accuracy of the gate opening encoder is 1°; The gate opening and closing mechanism also includes a manual emergency crank, located at the motor output shaft end.

10. The funnel-type bulk cargo loading device according to claim 1, characterized in that, The audible and visual alarm integrates: Dual-color LED warning light, diameter Φ150mm; Waterproof horn speaker, output frequency 2kHz-4kHz; Magnetic mounting base with an adsorption force of ≥200N.

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