Funnel intelligent automatic loading system

Abstract

The utility model provides a funnel intelligence automation loading system, including PLC controller and the edge computing box, loading camera, outdoor display screen, loudspeaker, pilot lamp, license plate recognition camera and sensor module that all communication connection thereof. The utility model has the advantages of: single loading efficiency is improved obviously, and the operation time efficiency is shortened by more than 25% than the traditional mode; support 7x24 hours all time period continuous operation, break through manual operation time limit; whole process automation operation can complete loading task without manual intervention; significantly reduce the labor cost, and personnel investment reduces by more than 60% than the traditional mode.

Description

Technical Field

[0001] This utility model belongs to the field of automated loading of port machinery, and in particular relates to an intelligent automated loading system for hoppers. Background Technology

[0002] Automated loading of cargo in ports refers to the unmanned loading operation of goods from the port yard to the transport vehicle through intelligent equipment, the Internet of Things, and artificial intelligence technologies. Traditional hopper loading systems have many drawbacks: 1. High dependence on manual intervention: The position of the vehicle, the height of the material and the flow rate need to be determined manually, which not only leads to high labor intensity, but also low loading efficiency.

[0003] 2. Poor uniformity of loading: The accumulation of materials in the truck bed can easily cause the center of gravity to shift, creating a safety hazard during transportation. Utility Model Content

[0004] In view of this, the present invention aims to propose a funnel-based intelligent automated loading system to solve at least one of the problems existing in the prior art.

[0005] To achieve the above objectives, the technical solution of this utility model is implemented as follows: A hopper-based intelligent automated loading system includes a PLC controller and an edge computing box, a loading camera, an outdoor display screen, a horn, indicator lights, a license plate recognition camera, and a sensor module, all of which are communicatively connected to the PLC controller. The PLC controller and the edge computing box are installed on one side of a port mobile hopper. A horn and an indicator light are also installed below one side of the port mobile hopper. An outdoor display screen and a license plate recognition camera are installed on one side of the double-layer grille at the front of the port mobile hopper, and a loading camera is installed on the other side of the double-layer grille at the front of the port mobile hopper. The sensor module is also installed on the port mobile hopper.

[0006] Furthermore, the sensor module includes a gate displacement sensor, an encoder, a material height detection sensor, and a vehicle position detection sensor. The gate displacement sensor is installed on the gate travel path of the port mobile funnel, the encoder is installed at the chute lifting reel of the port mobile funnel, the material height detection sensor is installed below the second-layer grid of the port mobile funnel, and the vehicle position detection sensor is installed on one side of the outdoor display screen.

[0007] Furthermore, the gate displacement sensor is used to collect gate travel data and transmit the gate travel data to the PLC controller.

[0008] Furthermore, the encoder detects the lifting height of the chute by detecting the number of rotations and angle of the reel.

[0009] Furthermore, the loading camera is used to observe the loading situation inside the vehicle.

[0010] Furthermore, the outdoor display screen is used by the edge computing box to control the outdoor display screen to display the image from the vehicle camera.

[0011] Furthermore, the material height detection sensor is used to detect the material height inside the truck to determine whether it is full.

[0012] Furthermore, the number of material height detection sensors is two.

[0013] Furthermore, the vehicle position detection sensor is used to collect truck position data and transmit the truck position data to the edge computing box.

[0014] Furthermore, the license plate recognition camera is used to collect license plate data and transmit the license plate data to the edge computing box.

[0015] Furthermore, the loudspeaker is used to play a designated voice message to prompt the truck driver whether the vehicle can be moved.

[0016] Furthermore, the indicator lights use different colors to indicate to the truck driver whether the vehicle can be moved.

[0017] Furthermore, it also includes a linear laser line, which is installed above the vehicle position detection sensor.

[0018] Compared with existing technologies, the funnel-based intelligent automated loading system of this utility model has the following advantages: The present invention discloses a funnel-type intelligent automated loading system, which significantly improves the efficiency of single loading and shortens the operation time by more than 25% compared with the traditional mode; it supports continuous operation 24 / 7, breaking through the time limit of manual operation; the entire process is automated and can complete the loading task without human intervention; it significantly reduces labor costs, reducing personnel input by more than 60% compared with the traditional mode. Attached Figure Description

[0019] The accompanying drawings, which form part of this utility model, are used to provide a further understanding of the utility model. The illustrative embodiments of the utility model and their descriptions are used to explain the utility model and do not constitute an undue limitation of the utility model. In the drawings: Figure 1 This is a schematic diagram showing the installation of the port mobile funnel in the overall structure described in this embodiment of the utility model; Figure 2 This is a schematic diagram of the wiring of the port mobile funnel according to an embodiment of the present utility model. Detailed Implementation

[0020] It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments of the present invention can be combined with each other.

[0021] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0022] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0023] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0024] like Figure 1 As shown, an intelligent automated loading system for a hopper includes a PLC controller, an edge computing box, a loading camera, an outdoor display screen, a horn, indicator lights, a license plate recognition camera, and a sensor module. The PLC controller and the edge computing box are both installed on one side of the port mobile hopper, and the edge computing box is communicatively connected to the PLC controller. A horn and an indicator light are also installed on the lower side of one side of the port mobile hopper. An outdoor display screen and a license plate recognition camera are installed on one side of the two-layer grille at the front of the port mobile hopper, and a loading camera is installed on the other side of the two-layer grille at the front of the port mobile hopper. The sensor module is also installed on the port mobile hopper.

[0025] The sensor module includes a gate displacement sensor, an encoder, a material height sensor, and a vehicle position sensor. The gate displacement sensor is installed on the gate travel path of the port mobile funnel. The encoder is installed at the chute lifting reel of the port mobile funnel. The material height sensor is installed below the second-layer grid of the port mobile funnel. The vehicle position sensor is installed on one side of the outdoor display screen.

[0026] Advantages of this funnel-type intelligent automated loading system: The efficiency of loading a single vehicle is significantly improved, and the operation time is shortened by more than 25% compared with the traditional mode; it supports continuous operation 24 / 7, breaking through the time limit of manual operation; the entire process is automated and loading tasks can be completed without human intervention; it significantly reduces labor costs, and personnel input is reduced by more than 60% compared with the traditional mode.

[0027] This loading system mainly relies on PLC, edge computing box and sensors to control the funnel and direct the truck to load the truck.

[0028] PLC: Controls gates, chutes, laser lights, horns, and indicator lights; detects gate size, chute height, and material height inside the vehicle; communicates with the edge computing box.

[0029] Edge computing box: performs vehicle location detection, license plate recognition, controls the outdoor display screen to show the on-board camera footage; communicates with PLC.

[0030] Gate detection: The gate detection displacement sensor is installed on the gate travel path. The PLC reads the displacement sensor data and detects the gate opening and closing size.

[0031] Sluice gate detection: The encoder is installed at the sluice gate lifting reel. The lifting height of the sluice gate is detected by detecting the number of rotations and the angle of the reel.

[0032] Loading camera: Installed below the second-layer grille, it allows observation of the loading process inside the vehicle.

[0033] Outdoor display screen: The edge computing box controls the screen to display the camera feed on the truck, providing it to the truck driver for viewing.

[0034] Material height detection: The material height detection sensor is installed below the second-layer grille to directly detect the material height inside the truck and determine whether it is full. In this embodiment, there are two material height detection sensors.

[0035] Vehicle position detection: The vehicle position detection sensor is installed in the middle of the lower part of the funnel. The edge computing box detects the sensor data in real time and can determine the real-time position of the truck.

[0036] License plate recognition camera: The license plate recognition camera is installed below the funnel on the side of the vehicle's front entrance direction. The edge computing box controls the camera to perform license plate recognition.

[0037] Speaker: Plays a designated voice message to prompt the truck driver whether the vehicle can be moved.

[0038] Indicator lights: Different colors indicate to the truck driver whether the vehicle can be moved.

[0039] This loading system also includes a linear laser line, which is installed above the vehicle position detection sensor. When the equipment is activated, two laser lines will appear on the ground on either side of the truck, assisting the truck in maintaining a centered position.

[0040] Working principle of the hopper intelligent automated loading system: After the intelligent automated loading system in the funnel is started, and the staff completes the inspection and the system is ready, the system enters the truck waiting state. When the truck drives under the funnel, the license plate recognition is activated. After successful recognition, the vehicle position detection begins to monitor the truck's position in real time. The horn plays the "Move Forward" voice message, and the indicator light turns green. This continues until the truck drives to the designated area, at which point the horn plays the "Stop" voice message, and the indicator light turns red.

[0041] The PLC controller then activates, controlling the chute to descend to the preset height and simultaneously opening the unloading gate to begin loading material onto the truck. During loading, the PLC monitors the material height data in real time and automatically adjusts the chute's lifting height according to preset parameters to ensure even loading. When the system detects that the material has reached full load, it automatically closes the unloading gate, completing the loading operation at the current position.

[0042] Subsequently, the edge computing box sends a signal to prompt the truck to move forward. The truck driver then moves the truck to the second loading position according to the instructions and repeats the loading process until all materials are loaded.

[0043] Once the truck is fully loaded, the horn will play a "departure" message, and the indicator light will turn yellow, signifying that the loading is complete. The truck will then enter the waiting state again, ready to load the next truck. No human intervention is required throughout the entire process.

[0044] This intelligent automated loading system uses a combination of PLC, edge computing, and sensors to achieve intelligent loading, and mainly solves the following problems: 1. Achieve precise quantitative loading. Solve the problem of manual overloading and underloading, improve the smoothness of vehicle loading and unloading operations, increase driver satisfaction, and reduce repetitive work.

[0045] 2. Achieve digitalization and visualization of loading operations. Form a closed loop with the production system to realize real-time presentation of vehicle and loading information, data recording and statistics, etc.

[0046] 3. Reduce material spillage during manual loading, improve the environmental protection level of the dock, reduce cleaning time, and improve overall unloading efficiency.

[0047] 4. Achieve remote, unmanned, and minimally staffed operations, as well as one-to-many control, thereby improving the level of intelligence at the port.

[0048] 5. Reduce the number of workers on the dock to lower labor costs and address labor shortages.

[0049] This product is mainly used in automated loading scenarios using mobile hoppers in ports. It utilizes PLCs, edge computing, sensors, etc., to precisely direct truck movement, control the lifting and lowering of the chute, and control the opening and closing of the gate to achieve precise loading, improve loading efficiency, and reduce manpower input.

[0050] like Figure 2 The diagram shows the wiring schematic for a port mobile funnel. The PLC controller and edge computing box are installed within the relay assembly of the port mobile funnel. The outdoor display screen is connected to 220V and connected to the NVR via an HDMI cable. The NVR is connected to the relay assembly via a Cat5e outdoor shielded cable. The relay assembly is connected via data cables to the HJL5 junction boxes for two chute detection encoders, four gate displacement detection sensors, a material height detection sensor, and three indicator lights. The relay assembly is connected via a composite cable to the HJL5 junction box for the vehicle position detection sensor. Finally, the relay assembly is connected via Cat5e outdoor shielded cables to the loading camera and license plate recognition camera.

[0051] It should be noted that this vehicle-mounted system does not involve any improvement to the control program; the control program and electrical components involved are all existing technologies.

[0052] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A funnel-based intelligent automated loading system, characterized in that: The system includes a PLC controller and an edge computing box, a vehicle loading camera, an outdoor display screen, a horn, indicator lights, a license plate recognition camera, and a sensor module, all of which are communicatively connected to the PLC controller and the edge computing box. The PLC controller and the edge computing box are installed on one side of the port mobile funnel. A horn and an indicator light are also installed on the lower side of the port mobile funnel. An outdoor display screen and a license plate recognition camera are installed on one side of the two-layer grille at the front of the port mobile funnel, and a vehicle loading camera is installed on the other side of the two-layer grille at the front of the port mobile funnel. The sensor module is also installed on the port mobile funnel.

2. The hopper-based intelligent automated loading system according to claim 1, characterized in that: The sensor module includes a gate displacement sensor, an encoder, a material height sensor, and a vehicle position sensor. The gate displacement sensor is installed on the gate travel path of the port mobile funnel. The encoder is installed at the chute lifting reel of the port mobile funnel. The material height sensor is installed below the second-layer grid of the port mobile funnel. The vehicle position sensor is installed on one side of the outdoor display screen.

3. The hopper-based intelligent automated loading system according to claim 2, characterized in that: The gate displacement sensor is used to collect gate travel data and transmit the gate travel data to the PLC controller.

4. The hopper-based intelligent automated loading system according to claim 2, characterized in that: The encoder detects the lifting height of the chute by detecting the number of rotations and angle of the reel; the loading camera is used to observe the loading situation inside the vehicle; the outdoor display screen is used by the edge computing box to control the outdoor display screen to display the loading camera image.

5. The hopper-based intelligent automated loading system according to claim 2, characterized in that: The material height detection sensor is used to detect the height of the material inside the truck to determine whether it is full.

6. The hopper-based intelligent automated loading system according to claim 2, characterized in that: The number of material height detection sensors is two.

7. The hopper-based intelligent automated loading system according to claim 2, characterized in that: The vehicle position detection sensor is used to collect truck position data and transmit the truck position data to the edge computing box; the license plate recognition camera is used to collect license plate data and transmit the license plate data to the edge computing box.

8. The hopper-based intelligent automated loading system according to claim 1, characterized in that: The loudspeaker is used to play a designated voice message to prompt the truck driver whether the vehicle can be moved.

9. The hopper-based intelligent automated loading system according to claim 1, characterized in that: The indicator lights use different colors to indicate to the truck driver whether the vehicle can be moved.

10. The hopper-based intelligent automated loading system according to claim 2, characterized in that: It also includes a linear laser line, which is installed above the vehicle position detection sensor.

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