Energy-saving unloader anti-collision system

Abstract

The utility model discloses an energy -saving type unloading machine anti -collision system for avoiding the collision of first unloading machine and second unloading machine on the same track, including a plurality of position sensors, a plurality of position sensors are installed on first unloading machine and second unloading machine respectively, position sensor is used for real -time monitoring the position of drag chain on first unloading machine and second unloading machine, the anti -collision protection system still includes control system, control system is connected with position sensor through electric signal, control system is used for receiving position sensor information, the anti -collision protection system still includes positioning device, and this patent is in the in -depth study to the walking drag chain of unloading machine, adds anti -collision guarantee encoder + big dipper positioning protection program segment on the basis of reserving original protection function, effectively prevents the collision phenomenon of two unloading machines in the operation process, and cost control adopts the same track technology, reduces the equipment construction cost, and improves the economic benefit while guaranteeing the safety.

Description

Technical Field

[0001] This utility model relates to the field of anti-collision technology for ship unloaders, and in particular to an energy-saving anti-collision system for ship unloaders. Background Technology

[0002] The basic operation process of a ship unloader includes the grab bucket entering the hold to grab materials, closing the grab bucket and lifting it out of the hold, the trolley moving to the top of the hopper to release the materials, and the materials being sent to the overhead belt conveyor via the feeder and material conveying switching device at the bottom of the hopper. The entire machine can travel along the dock surface track and can be anchored after the operation is completed. As a highly efficient special machine for unloading bulk materials, the ship unloader has the ability to grab materials from the hold, lift, transport and unload them to the dock trestle belt. While improving unloading efficiency, it can effectively reduce dust pollution. However, since two ship unloaders share a track during use, there is a risk of collision. Therefore, a reliable anti-collision protection system needs to be designed. Utility Model Content

[0003] This utility model patent aims to address the shortcomings of the prior art by providing an energy-saving anti-collision system for ship unloaders, which solves the technical problem of collision risk when ship unloaders share a track in the prior art.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is: an energy-saving ship unloader anti-collision system, used to avoid collisions between the first ship unloader and the second ship unloader on the same track, including a plurality of position sensors, which are respectively installed on the first ship unloader and the second ship unloader. The position sensors are used to monitor the position of the drag chain on the first ship unloader and the second ship unloader in real time. The anti-collision protection system also includes a control system, which is connected to the position sensors by electrical signals. The control system is used to receive position sensor information. The anti-collision protection system also includes a positioning device.

[0005] Preferably, the position sensor includes a photoelectric sensor and a limit switch.

[0006] Preferably, the control system includes two sets of PLC controllers, which are respectively installed on the first unloader and the second unloader.

[0007] Preferably, the network connection hardware is an Ethernet switch.

[0008] Preferably, the positioning system includes two sets of absolute encoders, which are respectively installed on the traveling wheels of the first and second unloaders.

[0009] Preferably, the positioning system further includes a BeiDou positioning device.

[0010] Preferably, the anti-collision protection system further includes an alarm device, which includes a buzzer and is electrically connected to the PLC controller.

[0011] Preferably, there are three Beidou positioning devices, which are respectively installed on the unloader's hopper platform, the cantilever boom, and the top of the main beam.

[0012] Preferably, the photoelectric sensor and the limit switch are both installed at the front end of the unloader's traveling mechanism.

[0013] The beneficial effects of this utility model are:

[0014] This patent is based on in-depth research on the moving drag chain of the ship unloader. While retaining the original protection functions, it adds an anti-collision protection encoder and a Beidou positioning protection program segment, which effectively prevents collisions between two ship unloaders during operation. Cost control adopts the same track technology, which reduces equipment construction costs and improves economic benefits while ensuring safety. Attached Figure Description

[0015] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0016] Figure 1 This is a schematic diagram of the structure of the ship unloader of this utility model;

[0017] Figure 2 This is a flowchart illustrating the operation of the positioning device in the anti-collision system of this utility model.

[0018] Figure 3 This is the travel permission program segment for the ship unloader of this utility model;

[0019] Figure 4 This utility model's ship unloader travel permission interlock program segment 1;

[0020] Figure 5 This is segment 2 of the interlocking procedure for the unloader's movement in this utility model;

[0021] The markings in the diagram are: 1. Track; 2. First unloader; 3. Second unloader; 4. Control system; 5. Position sensor; 6. Positioning device; 7. Absolute encoder; 8. Beidou positioning device; 9. Buzzer; 41. PLC controller; 51. Photoelectric sensor; 52. Limit switch. Detailed Implementation

[0022] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0023] like Figure 1-5As shown, an energy-saving anti-collision system for unloading ships is used to prevent collisions between the first unloading ship 2 and the second unloading ship 3 on the same track 1. The system is characterized by including several position sensors 5, which are respectively installed on the first unloading ship 2 and the second unloading ship 3. The position sensors 5 are used to monitor the position of the cable chains on the first unloading ship 2 and the second unloading ship 3 in real time. The anti-collision protection system also includes a control system 4, which is electrically connected to the position sensors 5 and receives information from the position sensors 5. The anti-collision protection system also includes a positioning device 6. The position sensors in this application are installed to monitor the position of the cable chains in real time. For example, photoelectric sensors or limit switches are installed at key nodes or collision-prone areas of the cable chains. When the cable chain approaches an area where a collision may occur, the sensor sends a signal to the control system. This project uses two systems—an absolute encoder (rotary type) and Beidou positioning—to position the unloading ships.

[0024] Preferably, the position sensor 5 includes a photoelectric sensor 51 and a limit switch 52. The photoelectric sensor 51 and the limit switch 52 described in this application are conventional positioning devices in the art. The sensor can be installed at the front end of the unloader's traveling mechanism or on the unloader's cable chain system.

[0025] Preferably, the control system 4 includes two sets of PLC controllers 41, which are respectively installed on the first unloader 2 and the second unloader 3. This application may use a Siemens S7-1500 PLC controller. After receiving the sensor signal, the control system 4 can take corresponding measures, such as reducing the operating speed of the unloader to make the movement of the cable chain more stable; or in an emergency, suspending the relevant actions of the unloader to avoid further deterioration of the collision. At the same time, the control system can feed back alarm information to the operator to prompt him to deal with the abnormal situation in time. The control system 4 is set in the unloader transformer cabinet.

[0026] Preferably, network connection hardware is provided between the two sets of PLC controllers 41.

[0027] Preferably, the network connection hardware is an Ethernet switch, which establishes data communication between the two Siemens S7-1500 PLCs, ensuring the connection between the two S7-1500 PLCs and the corresponding network connection hardware.

[0028] Preferably, the positioning system includes two sets of absolute encoders 7, which are respectively installed on the traveling wheels of the first unloader 2 and the second unloader 3. The absolute encoders assign a unique coded value to each rotational or linear movement position of the shaft using a specific encoding method, for real-time monitoring of the position of the unloader's traveling mechanism. In use, the first unloader 2 can be designated as SU1, and the second unloader as SU2. During operation, the traveling positioning data of the SU1 encoder is collected to the SU1 traveling encoder feedback value, and the traveling positioning data of the SU2 encoder is collected to the SU2 traveling encoder feedback value. The difference between the two sets of data is calculated, and the result is compared with an absolute safety value.

[0029] Preferably, the positioning system further includes a BeiDou positioning device 8. BeiDou positioning uses the principle of satellite radio ranging and rendezvous positioning, similar to the GPS positioning system. Specifically, the user terminal receives signals transmitted by multiple BeiDou satellites, measures the distance between the satellites and the user terminal, and then determines the position coordinates of the user terminal in three-dimensional space using the spatial distance rendezvous method based on this distance information.

[0030] Preferably, the anti-collision protection system further includes an alarm device, which includes a buzzer 9 and is electrically connected to the PLC controller 41.

[0031] Preferably, there are three Beidou positioning devices 8, which are respectively installed on the unloader hopper platform, the cantilever boom, and the top of the main beam.

[0032] Preferably, the photoelectric sensor 51 and the limit switch 52 are both installed at the front end of the unloader's traveling mechanism.

[0033] The specific working method of this application is as follows: 1. Rational design of the cable chain system and path planning: During the design phase of the ship unloader, the operating path of the cable chain is carefully planned to minimize interference with the ship unloader structure or other equipment. 2. Length and allowance design: The length of the cable chain is accurately calculated, and an appropriate allowance is reserved. Insufficient allowance may cause the cable chain to be overstretched during operation, resulting in collisions with surrounding objects; while excessive allowance may cause the cable chain to swing or pile up during movement, increasing the risk of collisions. The length of the cable chain is usually determined based on the maximum working stroke and range of motion of the ship unloader, taking into account a certain safety factor. The length and allowance design accurately calculates the length of the cable chain and reserves an appropriate allowance. Taking the actual engineering embodiment of this application as an example, the total travel distance of the wharf trestle is set to 200m. The first unloader is replaced by SU1, with a travel distance of 100m, and the second unloader is replaced by SU2, with a travel distance of 140m. The total length of the traveling mechanism of a single unloader is 25m. The safety distance between the two unloaders is set to 30m. The two unloaders share a track, which poses a risk of collision. Certain preventive measures need to be set to avoid this. The safety distance for anti-collision of the drag chain is set to 5m. The position of SU1 is set to X1, and the position of SU2 is set to X2; the right side position of the drag chain of SU1 is set to Y1, and the left side position of the drag chain of SU2 is set to Y2; the leftmost position of the wharf is defined as 0m, and the rightmost position of the wharf is defined as 200m. The following equation can be obtained:

[0034]

[0035]

[0036]

[0037]

[0038] The set that can be obtained is:

[0039] II. Sensor Monitoring and Control, Position Sensors: Position sensors are installed to monitor the position of the cable chain in real time. For example, photoelectric sensors or limit switches are installed at critical nodes or collision-prone areas of the cable chain. When the cable chain approaches an area where a collision may occur, the sensor sends a signal to the control system. This project uses two systems for positioning the unloader: an absolute encoder (rotary type) and BeiDou positioning. Absolute Encoder: The absolute encoder assigns a unique coded value to each rotational or linear movement position of the shaft through a specific encoding method. BeiDou Positioning: BeiDou positioning uses the principle of satellite radio ranging and rendezvous positioning, similar to the GPS positioning system. Specifically, the user terminal receives signals transmitted by multiple BeiDou satellites, measures the distance between the satellites and the user terminal, and then uses spatial distance rendezvous to determine the user terminal's position coordinates in three-dimensional space based on this distance information.

[0040] III. Data Transmission and Reading Steps Between Siemens S7-1500 PLCs, and Control System Response: After receiving sensor signals, the control system can take corresponding measures. For example, it can reduce the operating speed of the unloader to make the cable chain movement smoother; or in an emergency, it can suspend the unloader's related actions to prevent further collisions. Simultaneously, the control system can feed back alarm information to the operator, prompting them to handle abnormal situations promptly. Hardware and Software Preparation: Establish data communication between the two Siemens S7-1500 PLCs, ensuring both S7-1500 PLCs and the corresponding network connection hardware (e.g., an Ethernet switch). Software-wise, programming and configuration using TIA Portal are required. Network and Communication Configuration: Create a new project in TIA Portal and add the two S7-1500 PLCs to the project. Assign a unique IP address to each PLC and ensure they are on the same network segment or can communicate with each other via network routing.

[0041] 3. Create an S7 connection. In the "Network View," create an S7 connection, select the communication interfaces of the two PLCs, and configure the connection parameters, including the local ID and remote ID. Typically, the local ID is uniquely specified in the local PLC, while the remote ID is configured in the communication partner PLC.

[0042] 4. Programming Communication Instructions: In the main programs (OB1) of both PLCs, use appropriate communication instructions to send and receive data. For bilateral communication, the BSEND and BRCV instructions can be used. These instructions allow data exchange between the two PLCs.

[0043] 5. Configure data blocks: Create corresponding data blocks (DB blocks) in both PLCs to store the data to be sent and received. Ensure that the size and structure of the data blocks match between the communicating parties.

[0044] 6. Program the communication logic: Write the logic in the main program, using communication instructions and data blocks to control the sending and receiving of data.

[0045] 7. Test communication: Compile and download the program to both PLCs, then perform a communication test. Check whether data can be correctly transmitted between the two PLCs. The ship unloader uses two systems for positioning: Beidou and encoder. The program also compares and transmits both sets of data to ensure that if one system fails, the other system can still function independently as a protection mechanism.

[0046] Data parameter comparison: The SU1 encoder's walking positioning data is collected from the feedback value of the SU1 walking encoder, and the SU2 encoder's walking positioning data is collected from the feedback value of the SU2 walking encoder. The difference between the two sets of data is calculated, and the result is compared with 50. When ≥50, M707.6 (encoder walking is allowed to be triggered) is achieved.

[0047] The SU1 BeiDou positioning data was collected to the SU1 BeiDou positioning feedback value, and the SU2 BeiDou positioning data was collected to the SU2 BeiDou positioning feedback value. The difference between the two sets of data was calculated, and the result was compared with 50. When it was ≥50, M707.7 (BeiDou positioning allowed to be triggered).

[0048] The above embodiments are merely preferred technical solutions of this utility model and should not be considered as limitations on this utility model. The protection scope of this utility model should be the technical solution described in the claims, including equivalent substitutions of the technical features described in the claims. That is, equivalent substitutions and improvements within this scope are also within the protection scope of this utility model.

Claims

1. An energy-saving anti-collision system for unloading ships, used to prevent a first unloading ship (2) and a second unloading ship (3) on the same track (1), characterized in that, The system includes several position sensors (5), which are respectively installed on the first unloader (2) and the second unloader (3). The position sensors (5) are used to monitor the position of the drag chain on the first unloader (2) and the second unloader (3) in real time. The position sensors (5) send the position of the first unloader (2) and the second unloader (3) to the control system (4) through electrical signals. The control system (4) is used to receive the information from the position sensors (5). The anti-collision system also includes a positioning device (6).

2. The energy-saving anti-collision system for a ship unloader according to claim 1, characterized in that: The position sensor (5) includes a photoelectric sensor (51) and a limit switch (52).

3. The energy-saving anti-collision system for a ship unloader according to claim 1, characterized in that: The control system (4) includes two sets of PLC controllers (41), which are respectively installed on the first unloader (2) and the second unloader (3).

4. The energy-saving anti-collision system for a ship unloader according to claim 3, characterized in that: Network connection hardware is provided between the two sets of PLC controllers (41).

5. The energy-saving anti-collision system for a ship unloader according to claim 4, characterized in that: The network connection hardware is an Ethernet switch.

6. The energy-saving anti-collision system for a ship unloader according to claim 1, characterized in that: The positioning device (6) includes two sets of absolute encoders (7), which are respectively installed on the wheels of the first unloader (2) and the second unloader (3).

7. The energy-saving anti-collision system for a ship unloader according to claim 6, characterized in that: The positioning device (6) also includes a Beidou positioning device (8).

8. The energy-saving anti-collision system for a ship unloader according to claim 1, characterized in that: The anti-collision system also includes an alarm device, which includes a buzzer (9) and is electrically connected to the PLC controller (41).

9. The energy-saving anti-collision system for a ship unloader according to claim 7, characterized in that: The Beidou positioning device (8) consists of three units, which are respectively installed on the unloader hopper platform, the cantilever boom, and the top of the main beam.

10. The energy-saving anti-collision system for a ship unloader according to claim 7, characterized in that: The photoelectric sensor (51) and the limit switch (52) are both installed at the front end of the unloader's traveling mechanism.

Images