Intelligent train car unloading control system

Abstract

The utility model relates to an intelligent train carriage unloading control system, including external detection sensor, still include main control unit, a plurality of 3D laser scanners, a plurality of image recognition camera, a plurality of data acquisition module, data processing server and video data server, a plurality of external detection sensor's output electric connection data acquisition module, and data acquisition module electric connection data processing server, 3D laser scanner's output connects data processing server, and a plurality of image recognition camera are arranged on unloading machine, car cleaner and belt feeder respectively, and image recognition camera's output connects video data server, and video data server's output connects data processing server, data processing server and main control unit communication connection, and main control unit is connected with unloading machine controller, car cleaner controller and belt feeder controller communication respectively. The utility model provides the hardware basis for unloading machine, car cleaner and belt feeder automatic collaborative work.

Description

Technical Field

[0001] This utility model relates to the field of bulk material conveying technology, specifically to an intelligent train carriage unloading control system. Background Technology

[0002] Currently, many ports and terminals both domestically and internationally use open-top train carriages to transport coal, iron ore, and other commodities. However, due to space constraints at port terminals, the loading and unloading of these open-top train carriages is mostly done manually using loading and unloading equipment. The operating range of this equipment and the movement of its various mechanisms are all manually controlled by the driver. Bulk materials are first unloaded from the train carriages onto the ground, then loaded onto trucks using bulldozers, loaders, and other machinery, and finally transported to designated locations by truck. This traditional unloading method results in dusty unloading areas at port terminals, harsh working conditions, high labor intensity for workers, and a lack of effective safety interlocking between different pieces of equipment.

[0003] To address this, unloading machines, washing machines, and belt conveyors are combined to form an assembly line operation. Workers operate the unloading machine to feed materials from the truck bed onto the belt conveyor for transport. The washing machine then removes any residue from the truck bed, which is also transported onto the belt conveyor. While this improves efficiency, the coordination between the equipment in the entire unloading process is poor, and operational efficiency and safety depend entirely on the driver's skill and cooperation.

[0004] Therefore, in order to solve the above problems, there is an urgent need for a train car unloading control system to realize the automated production line operation of unloading machine, washing machine and belt conveyor. Summary of the Invention

[0005] This invention addresses the problem of low automation and inability to achieve collaborative operation in existing train car unloading devices by proposing an intelligent train car unloading control system. The system includes a data processing server that comprehensively processes data from multiple data acquisition modules. A main controller simultaneously controls the unloading machine, cleaning machine, and conveyor belt. Image detection features are established using an image recognition camera, and material detection features are established using a 3D laser scanner. This provides the hardware foundation for the automatic collaborative operation of the unloading machine, cleaning machine, and conveyor belt.

[0006] To achieve the above objectives, this utility model proposes an intelligent train car unloading control system, including multiple unloading machines, multiple cleaning machines, and multiple belt conveyors. Each unloading machine is equipped with an unloading machine controller, each cleaning machine is equipped with a cleaning machine controller, and each belt conveyor is equipped with a belt conveyor controller. External detection sensors are installed on the unloading machines, cleaning machines, and belt conveyors. The system also includes a main controller, multiple 3D laser scanners, multiple image recognition cameras, multiple data acquisition modules, a data processing server, and a video data server.

[0007] The output terminals of the multiple external detection sensors are electrically connected to a data acquisition module, and the data acquisition module is electrically connected to a data processing server;

[0008] Multiple 3D laser scanners are respectively installed below the unloading machine and the cleaning machine. The output end of the 3D laser scanner is connected to the data processing server. Multiple image recognition cameras are respectively installed on the unloading machine, the cleaning machine and the belt conveyor. The output end of the image recognition camera is connected to the video data server. The output end of the video data server is connected to the data processing server.

[0009] The data processing server is connected to the main controller, which in turn is connected to the unloading machine controller, the cleaning machine controller, and the belt conveyor controller.

[0010] Furthermore, the external detection sensors installed on the unloading machine include an unloading machine body positioning sensor, an unloading machine scraper stroke sensor, an unloading machine scraper lifting sensor, and an unloading machine chain tension detection sensor;

[0011] The external detection sensors installed on the cleaning machine include the cleaning machine body positioning sensor, the cleaning machine sweeper stroke sensor, the cleaning machine sweeper lifting sensor, and the cleaning machine sweeper chain tension detection sensor;

[0012] The external detection sensors installed on the belt conveyor include a belt misalignment switch, a pull rope switch, an anti-tear switch, a speed detection sensor, and a material flow detection sensor;

[0013] The data acquisition module includes a distributed remote I / O system, the output of an external detection sensor is connected to the input of the distributed remote I / O system, and the output of the distributed remote I / O system is connected to a data processing server.

[0014] Comprehensive and targeted external detection sensors were installed to address the different operating characteristics and key components of unloading machines, cleaning machines, and belt conveyors. The distributed remote I / O system boasts excellent compatibility and scalability, accommodating the connection of various types and numbers of external detection sensors. With system upgrades and expansions, new detection sensors can be easily added without large-scale modifications to the system architecture, enhancing system flexibility and scalability.

[0015] Furthermore, the data processing server includes an industrial PC, a data acquisition card, a network card, and a 3D scanning interface module. The industrial PC is connected to the data acquisition module via the data acquisition card, and the output of the industrial PC is connected to the main controller and the video data server via the network card.

[0016] The industrial PC communicates with the 3D laser scanner via a 3D scanning interface module.

[0017] The data processing server possesses powerful computing and data processing capabilities, enabling rapid processing and analysis of the large amounts of sensor data transmitted by the data acquisition module, point cloud data from the 3D laser scanner, and image information processed by the video data server. This ensures that the system can make timely and accurate decisions.

[0018] The image recognition camera is installed above the side of the unloading machine and the cleaning machine's traveling platform, above the drive motor of the belt conveyor, and above the system belt of the belt conveyor.

[0019] The image recognition camera is connected to a data switch, which is communicatively connected to a video data server. The video data server includes a processor, a storage system, and a network interface. The processor communicates with the data switch through the network interface, and is connected to a network card through the network interface. The processor communicates with the main controller through the network card.

[0020] Image recognition cameras are used to capture key information such as serial numbers and model specifications on the outer walls of train carriages. These cameras are installed above the belt conveyor drive motor and the system belt to identify whether the belt conveyor drive motor is operating normally (e.g., motor speed, presence of abnormal vibration or temperature rise) and whether the belt is running normally (e.g., whether the belt is misaligned, slipping, or tearing, the accumulation of material on the belt, and whether the material flow is uniform). A video data server acquires the image information and transmits the data to a data processing server.

[0021] Furthermore, the main controller includes a host computer, which is equipped with a wireless communication module. The host computer communicates with the unloading machine controller, the cleaning machine controller, and the belt conveyor controller through the wireless communication module. The unloading machine controller, the cleaning machine controller, and the belt conveyor controller include PLC controllers.

[0022] The beneficial effects of this utility model through the above technical solution are as follows:

[0023] (1) This utility model deploys external detection sensors, 3D laser scanners and image recognition cameras on the unloading machine, cleaning machine and belt conveyor to collect equipment status, car body model and material data in real time. After being processed by the data acquisition module, data processing server and video data server, the main controller communicates with the unloading machine controller, cleaning machine controller and belt conveyor controller, which provides the hardware foundation for the fully automatic operation and collaborative operation of each device in the entire unloading process. It realizes the automation of the unloading process, the safety interlocking of equipment and collaborative operation, improves efficiency, reduces labor intensity and reduces reliance on manual labor. Attached Figure Description

[0024] Figure 1 This is one of the system schematic diagrams of an intelligent train carriage unloading control system according to this utility model;

[0025] Figure 2 This is a schematic diagram of the data processing server of an intelligent train carriage unloading control system according to this utility model;

[0026] Figure 3 This is a schematic diagram of the video data server of an intelligent train carriage unloading control system according to this utility model;

[0027] Figure 4 This is the second system schematic diagram of an intelligent train carriage unloading control system according to this utility model;

[0028] Figure 5 This is a schematic diagram showing the positions of the unloading machine, cleaning machine, and carriage in an intelligent train carriage unloading control system according to this utility model.

[0029] The reference numerals are as follows: 1 is the unloading machine controller, 2 is the cleaning machine controller, 3 is the belt conveyor controller, 4 is the external detection sensor, 5 is the main controller, 6 is the 3D laser scanner, 7 is the image recognition camera, 8 is the data acquisition module, 9 is the data processing server, 10 is the video data server, 11 is the data switch, and 12 is the wireless communication module. Detailed Implementation

[0030] Example 1

[0031] like Figures 1-5 As shown, an intelligent train car unloading control system includes multiple unloading machines, multiple cleaning machines, and multiple belt conveyors. Each unloading machine is equipped with an unloading machine controller 1, each cleaning machine is equipped with a cleaning machine controller 2, and each belt conveyor is equipped with a belt conveyor controller 3. External detection sensors 4 are installed on each unloading machine, cleaning machine, and belt conveyor. The system is characterized by further including a main controller 5, multiple 3D laser scanners 6, multiple image recognition cameras 7, multiple data acquisition modules 8, a data processing server 9, and a video data server 10.

[0032] The output terminals of the multiple external detection sensors 4 are electrically connected to the data acquisition module 8, and the data acquisition module 8 is electrically connected to the data processing server 9;

[0033] Multiple 3D laser scanners 6 are respectively installed below the unloading machine and the cleaning machine. The output end of the 3D laser scanner 6 is connected to the data processing server 9. Multiple image recognition cameras 7 are respectively installed on the unloading machine, the cleaning machine and the belt conveyor. The output end of the image recognition camera 7 is connected to the video data server 10. The output end of the video data server 10 is connected to the data processing server 9.

[0034] The data processing server 9 is connected to the main controller 5, which in turn is connected to the unloading machine controller 1, the cleaning machine controller 2, and the belt conveyor controller 3.

[0035] The external detection sensors 4 installed on the unloading machine include an unloading machine body positioning sensor (absolute encoder), an unloading machine scraper stroke sensor (absolute encoder), an unloading machine scraper lifting sensor (capacitive limit switch), and an unloading machine chain tension detection sensor (capacitive limit switch).

[0036] The external detection sensors 4 installed on the cleaning machine include the cleaning machine body positioning sensor (absolute encoder), the cleaning machine sweeper stroke sensor (absolute encoder), the cleaning machine sweeper lifting sensor (capacitive limit switch), and the cleaning machine sweeper chain tension detection sensor (capacitive limit switch).

[0037] The external detection sensors 4 installed on the belt conveyor include a belt misalignment switch, a pull rope switch, an anti-tear switch, a speed detection sensor, and a material flow detection sensor;

[0038] The data acquisition module 8 includes a distributed remote I / O system. The output of the external detection sensor 4 is connected to the input of the distributed remote I / O system, and the output of the distributed remote I / O system is connected to the data processing server 9.

[0039] In this embodiment, the absolute encoder is SICK AFS60A, the capacitive limit switch is FTC131, and the distributed remote I / O system is ADAM-6000 series.

[0040] The data processing server 9 includes an industrial PC, a data acquisition card, a network card, and a 3D scanning interface module. The industrial PC is connected to the data acquisition module 8 via the data acquisition card, and the output of the industrial PC is connected to the main controller 5 and the video data server 10 via the network card.

[0041] The industrial PC communicates with the 3D laser scanner 6 via a 3D scanning interface module.

[0042] In this embodiment, the industrial PC is IPC-610L, the data acquisition card is NIPCI-6251, the network card is Intel I350-T4, and the 3D scanning interface module is Micro-EpsilonscanCONTROL2900-3D.

[0043] The image recognition camera 7 is installed above the side of the unloading machine and the cleaning machine's traveling platform, above the drive motor of the belt conveyor, and above the system belt of the belt conveyor.

[0044] The image recognition camera 7 is connected to a data switch 11, which is communicatively connected to a video data server 10. The video data server 10 includes a processor, a storage system, and a network interface. The processor communicates with the data switch 11 through the network interface, and is connected to a network card through the network interface. The processor communicates with the main controller 5 through the network card.

[0045] In this embodiment, the data switch 11 is an S5720-36C-EI-24S-AC switch, the image recognition camera 7 is a DH-IPC-HFW5443M-I2 camera, and the video data server 10 is an IPC-610L. The 3D laser scanner 6 is a Leica RTC360.

[0046] The main controller 5 includes a host computer, which is equipped with a wireless communication module 12. The host computer communicates with the unloading machine controller 1, the cleaning machine controller 2, and the belt conveyor controller 3 through the wireless communication module 12. The unloading machine controller 1, the cleaning machine controller 2, and the belt conveyor controller 3 include PLC controllers.

[0047] In this embodiment, the host computer is a TPC-1260H, the wireless communication module 12 is a CP1243-1 wireless communication module, and the PLC controller is a Siemens S7-1200.

[0048] Example 2

[0049] Based on Embodiment 1, an intelligent train car unloading control system is described in this embodiment for ease of understanding, focusing on the collaborative control of the unloading machine, the cleaning machine, and the belt conveyor.

[0050] The system uses external detection sensors 4 and image recognition cameras 7 installed on the unloading machine, cleaning machine, and belt conveyor to collect real-time data on the position of each operating mechanism of the unloading machine and cleaning machine, the car body model, and the operating status of the belt conveyor. This data is then transmitted to the data acquisition module 8 and the video data server 10. After processing, the main controller 5 integrates the car body data acquired by the 3D laser scanner 6 to construct a 3D operation model. The operation plan is decomposed into work orders that define the operation range, time, and travel distance. The system automatically generates operation strategies for the unloading machine and cleaning machine, as well as a collaborative strategy for the belt conveyor. The system adjusts the belt speed according to the unloading and material handling flow rate and sends instructions to the unloading machine controller 1, cleaning machine controller 2, and belt conveyor controller 3 to enable the intelligent control modules to work collaboratively. At the same time, the system collects real-time status data of the unloading machine, cleaning machine, and belt conveyor to intelligently adjust the overall process strategy.

[0051] The main controller 5 also establishes an intelligent operation model based on data, generates task orders according to the optimal path and area division, and decomposes them into operation plans containing information such as equipment working area, car type and storage capacity, planned time and belt conveyor start and stop time and speed. It automatically generates unloading, cleaning and collaborative operation strategies and belt operation strategies, drives the unloading machine controller 1 and cleaning machine controller 2 to control the equipment to operate fully automatically, and the belt conveyor controller 3 determines the optimal start and stop time and running speed and feeds back the status to the main controller 5 in real time. The main controller 5 communicates with each controller through the wireless communication module 12, and the data acquisition module 8 interacts with the data processing server 9 and the video data server 10 through the data exchange 11.

[0052] The embodiments described above are merely preferred embodiments of this utility model and are not intended to limit the scope of implementation of this utility model. Therefore, all equivalent changes or modifications made to the structure, features and principles described in the patent claims of this utility model should be included within the scope of the patent application of this utility model.

Claims

1. An intelligent train car unloading control system, comprising multiple unloading machines, multiple cleaning machines, and multiple belt conveyors, wherein each unloading machine is equipped with an unloading machine controller (1), each cleaning machine is equipped with a cleaning machine controller (2), each belt conveyor is equipped with a belt conveyor controller (3), and each unloading machine, cleaning machine, and belt conveyor is equipped with an external detection sensor (4), characterized in that, It also includes a main controller (5), multiple 3D laser scanners (6), multiple image recognition cameras (7), multiple data acquisition modules (8), a data processing server (9), and a video data server (10). The output terminals of the multiple external detection sensors (4) are electrically connected to the data acquisition module (8), and the data acquisition module (8) is electrically connected to the data processing server (9). Multiple 3D laser scanners (6) are respectively located below the unloading machine and the cleaning machine. The output end of the 3D laser scanner (6) is connected to the data processing server (9). Multiple image recognition cameras (7) are respectively installed on the unloading machine, the cleaning machine and the belt conveyor. The output end of the image recognition camera (7) is connected to the video data server (10). The output end of the video data server (10) is connected to the data processing server (9). The data processing server (9) is connected to the main controller (5) for communication. The main controller (5) is connected to the unloading machine controller (1), the cleaning machine controller (2) and the belt conveyor controller (3) for communication.

2. The intelligent train carriage unloading control system according to claim 1, characterized in that, The external detection sensors (4) installed on the unloading machine include the unloading machine body positioning sensor, the unloading machine scraper stroke sensor, the unloading machine scraper lifting sensor and the unloading machine chain tension detection sensor; The external detection sensors (4) set in the cleaning machine include the cleaning machine body positioning sensor, the cleaning machine sweeper stroke sensor, the cleaning machine sweeper lifting sensor and the cleaning machine sweeper chain tension detection sensor; The external detection sensors (4) installed on the belt conveyor include a belt misalignment switch, a pull rope switch, an anti-tear switch, a speed detection sensor, and a material flow detection sensor; The data acquisition module (8) includes a distributed remote I / O system. The output of the external detection sensor (4) is connected to the input of the distributed remote I / O system, and the output of the distributed remote I / O system is connected to the data processing server (9).

3. The intelligent train carriage unloading control system according to claim 1, characterized in that, The data processing server (9) includes an industrial PC, a data acquisition card, a network card and a 3D scanning interface module. The industrial PC is connected to the data acquisition module (8) through the data acquisition card. The output end of the industrial PC is connected to the main controller (5) and the video data server (10) through the network card. The industrial PC communicates with the 3D laser scanner (6) through the 3D scanning interface module.

4. The intelligent train carriage unloading control system according to claim 1, characterized in that, The image recognition camera (7) is installed above the side of the unloading machine and the cleaning machine, above the drive motor of the belt conveyor, and above the system belt of the belt conveyor. The image recognition camera (7) is connected to a data switch (11), which is connected to a video data server (10). The video data server (10) includes a processor, a storage system and a network interface. The processor communicates with the data switch (11) through the network interface. The processor is connected to a network card through the network interface and communicates with the main controller (5) through the network card.

5. The intelligent train carriage unloading control system according to claim 1, characterized in that, The main controller (5) includes a host computer, which is equipped with a wireless communication module (12). The host computer communicates with the unloading machine controller (1), the cleaning machine controller (2), and the belt conveyor controller (3) through the wireless communication module (12). The unloading machine controller (1), the cleaning machine controller (2), and the belt conveyor controller (3) include PLC controllers.

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