CN102923578A - Automatic control system of efficient handing operation of container crane - Google Patents
Automatic control system of efficient handing operation of container crane Download PDFInfo
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- CN102923578A CN102923578A CN2012104521969A CN201210452196A CN102923578A CN 102923578 A CN102923578 A CN 102923578A CN 2012104521969 A CN2012104521969 A CN 2012104521969A CN 201210452196 A CN201210452196 A CN 201210452196A CN 102923578 A CN102923578 A CN 102923578A
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Abstract
The invention provides an automatic control system of an efficient handing operation of a container crane, and relates to the technical field of operation and production of container cranes. The machine vision and image recognition location technology is used to locate the relative position of a container and a lifting appliance, an image processing result is transmitted to a crane control system, a bar code location system is mounted near a crane cart track and a crane trolley track to accurately locate the position of the lifting appliance of the crane, then a position closed loop feedback control system is formed, and therefore an image recognition location method and an image recognition location device of the container crane are achieved, a lifting appliance movement closed loop control method of the container crane is achieved, and an automatic container grabbing method and an container grabbing device of the lifting appliance of the crane are achieved.
Description
Technical field
The present invention relates to the work production technical field of container handling crane, particularly to the control technology field of crane hanger.
Background technology
Along with the development of global economy, Container Transport increases rapidly in the world, and the conjack tool is being brought into play extremely important effect at modern logistics, national product in each field.In the container handling crane handling process, adjusting suspender is container handling crane chaufeur the most tired the most time-consuming process to correct position in order to can grasp this process of freight container.New chaufeur often will repeatedly be adjusted crane, dolly, just can make suspender catch freight container.Even also needing to adjust several times suspender, skilled driver grasps freight container.In this course, chaufeur is to bow from the hoisting box to look down.It is tired that this is easy to make chaufeur to produce.On the other hand, along with the fast development of Container Transport industry, the amount of container handling operation is also increasing.Especially in some busy places such as Entry Points for Ocean Shipping/Ocean Cargo, require freight container can finish efficiently loading and unloading operation.Adjust the relative position of suspender and freight container according to traditional container handling crane chaufeur, this just is difficult to reach the requirement of efficiently and accurately.Along with the development of Frequency Conversion Drive Technology and Computer Control Technology, a large amount of up-to-date technologys, new product and new process are applied to modern crane, make hoisting crane towards the future development of electromechanical integration, information intelligent, maximization energy-saving, high efficiency.Huge change has occured with respect to conventional hoist and management mode in the management of container handling crane driver behavior, the various data of freight container, and the container handling crane control system has been proposed higher technical requirements.
In order to improve the work efficiency of container handling, some advanced technology constantly are used.Utilize the advanced person's such as finite element hoisting crane Metal Structure Design method rationally to improve Mechanism of crane, realize the lightweight of hoisting crane.Utilize alternating frequency conversion technique, realized the speed continuous control of hoisting crane.Some automatic control theory and technology also are used for hoisting crane.These technology have all obtained good effect.Along with the development of science and technology, some emerging modes also progressively have been applied in the automatic loading and unloading operation of container handling crane.Japan has proposed a kind ofly at suspender ultrasonic detection device to be installed, and is used for surveying the relative position of suspender and freight container.At home, also have colleges and universities to adopt the mode of machine vision to process the orientation problem of dual container, adopt image processing method, the relative deviation of two freight containers in location is controlled the container spreader motion, and this has also obtained good effect.
Theoretical constantly ripe along with machine vision, and relevant supporting hardware device, software industry become increasingly abundant, machine vision technique has obtained utilization in increasing field.Traditional container handling crane chaufeur easily produces fatigue and efficient is not high, adopts the advanced intelligent technology of machine vision, realizes that the automatic loading and unloading of freight container is an advanced subject of Development of Crane.
Summary of the invention
The objective of the invention is to utilize machine vision and image recognition location technology, propose the efficient loading and unloading operation autonomous cruise speed system of a kind of container handling crane, to improve the work efficiency of container crane job.
The present invention includes cart, cart orbit, trolley travelling track, the crane packaged type is engaged on the cart orbit, the trolley travelling track is fixed on the crane top, packaged type cooperates dolly on described trolley travelling track, connects suspender by the anti-steel rope that shakes below dolly; Characterized by further comprising cart running orbit Bar code positioning device, trolley travelling track bar code steady arm and the suspender running orbit Bar code positioning device that hoists, four jiaos at described suspender fixedly mount respectively the CCD camera, described CCD camera has the three-dimensional space position that obtains the suspender place and obtains by the mechanism of the three-dimensional space position image at loading and unloading container place, the CCD camera has the suspender of judgement and by the module of loading and unloading container distance, the CCD camera has suspender and the device that is carried out the wireless signal transmission by the signal of loading and unloading container distance; The wireless signal receiver that cooperates with the device of described wireless signal transmission is connected to the input end of a PLC control center, the hoist output module of operation of output module, the output module of control trolley travelling, the control suspender that described PLC control center has an operation of control cart, the mouth of described PLC control center arrange cart operation control mechanism mouth, trolley travelling operation control mechanism mouth and the suspender operation control mechanism mouth that hoists.
Principle of work of the present invention is: the CCD camera of installing on the suspender, the graphicinformation of Real-time Collection suspender below freight container will be ingested target and convert picture signal to, send special-purpose image processing system to.Use computer image processing technology, according to information such as pixel distribution and brightness, colors, be transformed into digitized signal, to hole, angle and the sideline in Image Segmentation Using, the extraction freight container image, vision system is carried out the feature that various computings come extracting objects to these signals, because the freight container size dimension is known, can realize the coupling of split hair caccuracy, mainly be to obtain data by above-mentioned several steps, utilize the binocular range measurement principle to calculate crane hanger and by the relative position value of loading and unloading container, and the result that will obtain send crane control system to.Simultaneously, set up the container yard information database, record the three-dimensional coordinate position value of each freight container.Write industrial computer control human-computer interaction interface with WINCC.By industrial computer also can the Long-distance Control hoisting crane motion.After crane control system receives control signal, under the position closed loop retroactive effect of Bar code positioning system, accurately move to given position, realize the efficient automatic loading and unloading operation of freight container.
The present invention has increased the industrial computer master mode and has located the automatic loading and unloading master mode based on the freight container of machine vision except traditional joint action table control, remote control control.Native system adopts machine vision, image recognition location technology, calculate crane hanger with by the three-dimensional relative position value of loading and unloading container, the result that PLC control center is calculated sends cart operation control mechanism, trolley travelling operation control mechanism and the suspender operation control mechanism that hoists to, and each control mechanism drives crane operating unit, wheeling mechanism and lifting mechanism motion automatically according to the data message that receives.Hoist running orbit Bar code positioning device Real-time Feedback suspender and by the three-dimensional location coordinates of loading and unloading container of cart running orbit Bar code positioning device of the present invention, trolley travelling track bar code steady arm and suspender, form a closed-loop feedback control system, alleviate the labour intensity of container handling crane chaufeur, thereby realize the purpose of container handling crane automatic loading and unloading high-efficient homework.
Cart operation control mechanism, trolley travelling operation control mechanism and the suspender CCD camera that the operation control mechanism accurately controls on the suspender that hoists is done plane motion, can measure the motion value of CCD camera in the plane by the running orbit Bar code positioning device that hoists by cart running orbit Bar code positioning device, trolley travelling track bar code steady arm and suspender simultaneously, the movable information that recycles known camera is demarcated the CCD camera.
The present invention has added the Bar code positioning system near the large and small Car Track of hoisting crane in traditional hoisting crane goods yard, by the high-speed counter module accurate actual position of positioning crane cart and dolly just.On the one hand, the suspender running orbit Bar code positioning device that hoists can accurately be measured the movement position of suspender, for the Calibration of camera intrinsic parameters of CCD camera provides important guarantee.On the other hand, when the hoisting crane internal processes was automatically controlled suspender and moved by the setup parameter position, the Bar code positioning system had just formed an important position feedback, makes crane hanger can move to accurately the position of appointment.
In addition, the described judgement suspender of PLC of the present invention control center with comprised the method calibration for cameras that adopts first based on the active vision of CCD camera by the module of loading and unloading container distance after obtain CCD camera inner parameter, then use the image of calibrated CCD collected by camera freight container, the image that collects is carried out pretreatment, based on rgb value, the image segmentation of gray value and line detection method, from the image that gets access to, obtain again the information in container angle hole, then carry out hole, angle coupling, adopt Binocular Vision Principle to calculate the submodule of the relative position value of crane hanger and freight container.
CCD camera on the controlled suspender is done plane motion with suspender, can measure the motion value of CCD camera in the plane by the running orbit Bar code positioning device that hoists by cart running orbit Bar code positioning device, trolley travelling track bar code steady arm and suspender simultaneously, the movable information that recycles known camera is demarcated camera.The method does not need to demarcate thing, utilizes the particularity of this motion can calculate the camera inner parameter.Advantage based on the camera calibration method of active vision is that algorithm is simple, often can obtain linear solution, therefore robustness is higher.
Cart running orbit Bar code positioning device of the present invention comprises the first absolute value bar code and is used for reading the first high speed counting module of the first absolute value bar code, described the first absolute value bar code is fixed on cart orbit one side, and be parallel to the cart orbit, described the first high speed counting module is fixed on the below of cart.
Trolley travelling track bar code steady arm of the present invention comprises second pair of value bar code and is used for reading the second high speed counting module of the second absolute value bar code, described the second absolute value bar code is fixed on trolley travelling track one side, and be parallel to the trolley travelling track, described the second high speed counting module is fixed on the dolly.
Description of drawings
Fig. 1 is the integral structure schematic diagram of apparatus of the present invention.
Fig. 2 is the principle steps figure that machine vision is processed among the present invention.
Fig. 3 is composition frame diagram of the present invention.
Fig. 4 is container spreader control positioning principle figure of the present invention.
The specific embodiment
Below, the specific implementation method of the container handling crane high-efficient homework autonomous cruise speed system that present invention will be described in detail with reference to the accompanying.
As shown in Figure 1, whole formation of the present invention has: crane 13, cart orbit 2, trolley travelling track 1, crane 13 under the control of cart operation control mechanism along large Car Track 2 moving linearlies, trolley travelling track 1 is fixed on crane 13 tops, cooperate dolly 10 at trolley travelling track 1, dolly 10 under the control of trolley travelling operation control mechanism along trolley travelling track 1 moving linearly on the container handling crane girder, by anti-steel rope 8 suspenders 7 that shake, the anti-steel rope 8 that shakes is connected to the hoist mouth of operation control mechanism of suspender below dolly 10.
In a side of cart orbit 2, be fixed with the first absolute value bar code 3 that is parallel to cart orbit 2, the first high speed counting module 4 that is used for reading the first absolute value bar code 3 numerical value is installed below cart.In a side of trolley travelling track 1, be fixed with the second absolute value bar code 12 that is parallel to trolley travelling track 1, at dolly 10 the second high speed counting module 11 that is used for reading the second absolute value bar code 12 numerical value is installed.Suspender 7 can arrive the accuracy of positioning of very high level attitude on large and small Car Track direction.
Four jiaos at suspender 7 fixedly mount respectively a CCD camera 5, four CCD cameras 5 have respectively the real-time three-dimensional locus that obtains suspender 7 places and obtain by the mechanism of the real-time three-dimensional locus image at loading and unloading container 6 places, and have judge suspender with by the module of loading and unloading container distance, the CCD camera also have with suspender with carried out the device that wireless signal sends by the signal of loading and unloading container distance.
Be provided with the wireless signal receiver that cooperates with the device of above-mentioned wireless signal transmission in PLC control center 9, wireless signal receiver is connected to the information that receives the input end of PLC control center 9.
PLC control center 9 can be installed on the dolly 10, the hoist output module of operation of output module, the output module of control trolley travelling, the control suspender that PLC control center 9 has a control cart operation, the mouth of PLC control center 9 arrange cart operation control mechanism mouth, trolley travelling operation control mechanism mouth and the suspender operation control mechanism mouth that hoists.
As shown in Figure 2, CCD camera 5 has machine vision module, image segmentation module, characteristic matching module and location Calculation module; Described image segmentation module is provided with rgb value characteristic extracting module, grey value characteristics extraction module and extraction of straight line module; Described image segmentation module is provided with angle hole dimension matching module, sideline location matches module and Container Dimensions matching module; Described location Calculation module is provided with camera parameter demarcating module, logical place judge module and binocular vision locating module.
By four CCD cameras 5 obtain by the photographic intelligence of loading and unloading container 6, the steps such as the demarcation by camera, the pretreatment of image, Target Segmentation, Feature Points Matching, target positioning calculating, calculate suspender 7 with by the relative position of loading and unloading container 6.Then the mode of result of calculation by network communication is sent to PLC control center 9, the automatic loading and unloading container operation is finished in the motions such as control system control crane operating unit, wheeling mechanism, lifting mechanism.
The principle steps that machine vision is processed among the present invention is as shown in Figure 2: this part comprises mainly that characteristics of image is cut apart, Feature Points Matching and location Calculation three parts.Image segmentation is to be partitioned into important unique point from the image that camera gets access to.Because crane hanger is in handling process, be that four of suspender are revolved lock and are inserted in the hole, four angles of freight container, and the hole, angle is in imaging, gray value is very low.Therefore take the container angle hole as principal character.Simultaneously, because freight container is cuboid, more parallel sideline is arranged, so the sideline of freight container also is important feature.In implementation process, taken into full account the color of freight container in the container yard and background color and differed larger actual conditions.Measure by experiment, the freight container image is responsive to red ratio.Analysis image the R value, freight container and background are tentatively separated, obtain image
I 1Then adopt threshold method, from
I 1Extract the lower part of gray value in the image.But the factor meetings such as blocking between the variation of weather and the freight container are adopted the method for multi-threshold so that the gray value in container angle hole changes, and can address this problem.For the low gray-value image that obtains
I 2, then screen according to the shape in container angle hole, kick out of the size that do not meet the hole, angle and the part of shape, finally from image, be partitioned into the container angle hole.Adopt the Hough conversion, from
I 1The sideline of middle extraction freight container is as the auxiliary judgment condition.According to the feature that extracts, carry out Characteristic of Image coupling in two cameras according to angle hole dimension size, the position relationship in freight container sideline, freight container overall dimensions.Native system is the camera calibration that adopts based on the method for active vision.Hoisting crane is accurately controlled on the suspender camera and is done plane motion, simultaneously can be by by near the motion value of Bar code positioning systematic survey camera in the plane the track, and the movable information that recycles known camera is demarcated camera.Positioning crane spreader be to adopt the binocular vision positioning principle by the relative position of loading and unloading container, by the unique point of mating in two cameras, and the result of camera calibration calculates the relative position of container angle hole and suspender.
Fig. 3 is that whole system of the present invention forms frame diagram.Mainly realize by the location of loading and unloading container by the technology that machine vision, image are processed at technological layer, simultaneously, under the closed loop feedback effect of Bar code positioning system, realize the accurate location of crane hanger by hoisting crane " PLC+ frequency converter " control system.At data Layer, by setting up container data storehouse, goods yard, the information such as the three-dimensional coordinate position of storage container and case number (CN).Control system can directly read from data bank by the position of loading and unloading container, controls large and small car operating unit and lifting mechanism and moves to corresponding position, finishes and automatically grabs case work.On the other hand, when certain freight container was placed on certain position in goods yard from suspender, system read the three-dimensional coordinate position of this chest by the Bar code positioning system, and real-time writing data in the data bank.System adopts WINCC to write industrial computer scene interactive interface, and a human, easy to operate interface are provided, and realizes man-machine interaction.Various technology above comprehensive finally form container handling crane high-efficient homework autonomous cruise speed system, and this system is controlled as closed loop feedback by the Bar code positioning system, realize the accurate motion of suspender three-dimensional position.Simultaneously, the method that system adopts machine vision, image to process, the locating container suspender with by the relative position of loading and unloading container, relative position value is passed to crane control system, also can send freight container three-dimensional position value to crane control system by industrial computer, crane control system under the feedback of Bar code positioning system, is finished the automatic loading and unloading of freight container according to the movement position value that receives.
Fig. 4 is container spreader control positioning principle figure of the present invention.Crane control system receives movement position information in two ways: 1. industrial computer is by the mode of network communication.2. NI Vision Builder for Automated Inspection sends the relative position value of control system to.This also is two kinds of major control patterns of native system.After crane control system received motor message, the PLC internal processes calculated the movement position value of large and small car operating unit and lifting mechanism automatically, and gave the corresponding speed signal of frequency converter, and each mechanism is moved towards given value.The Bar code positioning system detects the positional value of the large and small mechanism of car of hoisting crane in real time, and with measurement feedback to crane control system.Control system is adjusted the motion of each mechanism according to the error of observed reading and given value, thereby makes each mechanism accurately move to given position.This is the important component part of container handling crane high-efficient homework autonomous cruise speed system.
Claims (4)
1. the efficient loading and unloading operation autonomous cruise speed system of container handling crane, comprise cart, cart orbit, trolley travelling track, the crane packaged type is engaged on the cart orbit, the trolley travelling track is fixed on the crane top, packaged type cooperates dolly on described trolley travelling track, connects suspender by the anti-steel rope that shakes below dolly; Characterized by further comprising cart running orbit Bar code positioning device, trolley travelling track bar code steady arm and the suspender running orbit Bar code positioning device that hoists, four jiaos at described suspender fixedly mount respectively the CCD camera, described CCD camera has the three-dimensional space position that obtains the suspender place and obtains by the mechanism of the three-dimensional space position image at loading and unloading container place, the CCD camera has the suspender of judgement and by the module of loading and unloading container distance, the CCD camera has suspender and the device that is carried out the wireless signal transmission by the signal of loading and unloading container distance; The wireless signal receiver that cooperates with the device of described wireless signal transmission is connected to the input end of a PLC control center, the hoist output module of operation of output module, the output module of control trolley travelling, the control suspender that described PLC control center has an operation of control cart, the mouth of described PLC control center arrange cart operation control mechanism mouth, trolley travelling operation control mechanism mouth and the suspender operation control mechanism mouth that hoists.
2. the efficient loading and unloading operation autonomous cruise speed system of container handling crane according to claim 1, the described judgement suspender that it is characterized in that PLC control center with comprised the method calibration for cameras that adopts first based on the active vision of CCD camera by the module of loading and unloading container distance after obtain CCD camera inner parameter, then use the image of calibrated CCD collected by camera freight container, the image that collects is carried out pretreatment, based on rgb value, the image segmentation of gray value and line detection method, from the image that gets access to, obtain again the information in container angle hole, then carry out hole, angle coupling, adopt Binocular Vision Principle to calculate the submodule of the relative position value of crane hanger and freight container.
3. the efficient loading and unloading operation autonomous cruise speed system of container handling crane according to claim 1 and 2, it is characterized in that described cart running orbit Bar code positioning device comprises the first absolute value bar code and is used for reading the first high speed counting module of the first absolute value bar code, described the first absolute value bar code is fixed on cart orbit one side, and be parallel to the cart orbit, described the first high speed counting module is fixed on the below of cart.
4. the efficient loading and unloading operation autonomous cruise speed system of container handling crane according to claim 1 and 2, it is characterized in that described trolley travelling track bar code steady arm comprises second pair of value bar code and is used for reading the second high speed counting module of the second absolute value bar code, described the second absolute value bar code is fixed on trolley travelling track one side, and be parallel to the trolley travelling track, described the second high speed counting module is fixed on the dolly.
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