CN108178069A - Container handling operation intelligent early-warning system - Google Patents

Abstract

The invention discloses an intelligent early warning system for container loading and unloading operations, which includes a data acquisition module installed on a hanger and a data processing module installed in the driver's cab; wherein, the data acquisition module is provided with a weighing sensor and an inclination sensor; the control And the data integration unit transmits the sensor data to the data processing module through the wireless communication transmission unit; the data processing module is equipped with an industrial control all-in-one machine and an electrical joint control unit connected to the industrial control all-in-one machine, and the electrical joint control unit outputs multiple switches through relays Quantity signal; the industrial control all-in-one machine is also connected to a high-decibel sound and light alarm unit and a power management unit. The present invention can eliminate unbalanced and heavy containers from the source, ensure the safety of railway transportation, realize the automation and intelligence of container loading and unloading, and improve the efficiency of container loading and unloading, which is of great significance.

Description

Intelligent early warning system for container loading and unloading operations

technical field

The invention relates to the field of loading and unloading equipment, in particular to an intelligent early warning system for container loading and unloading operations.

Background technique

Loading and unloading is an integral element and an important link of modern logistics, and it is also an important part of railway freight. Container transportation is the development direction of modern logistics industry. In recent years, the proportion of container transportation in my country's railway freight has been increasing year by year, and many loading and unloading machinery and attachments and rigging suitable for containerization have also been developed and deployed. However, the overturning phenomenon in the process of container loading and unloading has a great impact on safe transportation.

Therefore, a set of gantry crane container eccentric load, eccentric monitoring and FTR lock operation intelligent early warning system is studied. On the basis of network control and three-dimensional display, through automatic control equipment, container loading and unloading can be realized in the gantry crane driver's cab. Intelligent control is of great significance to eliminate unbalanced and heavy containers from the source, ensure the safety of railway transportation, realize the automation and intelligence of container loading and unloading, and improve the efficiency of container loading and unloading.

Contents of the invention

In order to solve the above problems, the present invention provides an intelligent early warning system for container loading and unloading, which realizes the automation and intelligence of container loading and unloading, improves the efficiency of container loading and unloading, and ensures the safety of railway transportation. It is an intelligent early warning system suitable for detecting whether the container is unbalanced or heavy, and whether the FTR lock is uncoupled during the container hoisting operation. It mainly collects and analyzes the status data of the container being hoisted in real time, and transmits the data to the host computer through wireless. , intelligently analyze and identify the causes of container tilting, judge the container's overload and unbalanced load status and whether the FTR lock has been uncoupled, and make corresponding early warning and linkage processing.

The present invention is implemented according to the following technical solutions.

An intelligent early warning system for container loading and unloading operations, the early warning system includes a data acquisition module installed on the hanger and a data processing module installed in the driver's cab; The load cell used to collect the real-time weight of the container, the inclination sensor installed in the collection equipment box to collect the real-time inclination of the container, and the control and data integration unit connected to the inclination sensor and the load cell through the data bus; the control and The data integration unit transmits data to the data processing module through the wireless communication transmission unit; the data acquisition module is also equipped with an intelligent low-power power management unit; the data processing module includes an industrial control integrated machine, and the industrial control integrated machine receives data from The data information of the data acquisition module displays the processed data information on the software interface in the form of three-dimensional animation through the display device; the data processing module is also provided with an electrical joint control unit connected to the industrial control integrated machine, and the electrical joint control The unit outputs multiple switching signals through the relay; the industrial control integrated machine is also connected to the high-decibel sound and light alarm unit and the power management unit.

Further, the wireless communication transmission unit is a Wi-Fi wireless communication module.

Further, the low power consumption power supply module outputs 12V DC power, and the input power comes from the hanger's own power supply or external solar panels and battery components to realize self-power supply.

Further, the inclination sensor communicates with the data acquisition module through the serial port, and the acquisition frequency is set to 50/100Hz. After filtering, the data is uploaded to the host computer 10 times per second; The inclination state of the container is converted into the container deflection angle.

The present invention obtains the following beneficial effects.

On the basis of network control and three-dimensional display, the present invention can realize the intelligent control of container loading and unloading in the door crane driver's cab through the automatic control equipment, and prevent unbalanced and heavy containers from being loaded on the vehicle from the source, and ensure the safety of railways. It is of great significance to ensure the safety of transportation, realize the automation and intelligence of container loading and unloading, and improve the efficiency of container loading and unloading.

(1) Through the application of high-speed wireless network, advanced and controllable sensors and integrated integration methods, it is possible to monitor whether the container is unbalanced and heavy and whether the FTR lock is uncoupled on the display device without on-site inspection, so as to solve the problem of container hoisting. And various safety problems that arise during the lifting and unloading process.

(2) It can greatly improve the quality of hoisting and unloading operations, simplify the daily management process, reduce the pressure of on-site staff, and ensure the safety of container hoisting and unloading operations.

(3) It ensures the safety of container transportation, saves container hoisting and unloading operation time and a lot of manpower and material resources, can bring greater direct economic benefits to railway production, and has broad application prospects.

Description of drawings

Fig. 1 is a system structure block diagram of the present invention;

Fig. 2 is a flow chart of the system work of the present invention.

Detailed ways

The present invention will be described in detail below with reference to the accompanying drawings and embodiments.

As shown in Figures 1 and 2, an intelligent early warning system for container loading and unloading operations, the early warning system includes a data acquisition module installed on the hanger and a data processing module installed in the driver's cab; wherein, the data acquisition module includes, installed The load cell used to collect the real-time weight of the container on the force lock pins at the four corners of the hanger is installed in the collection device box to collect the real-time inclination of the container. Control and data integration unit; the control and data integration unit transmits data to the data processing module through the wireless communication transmission unit; the data acquisition module is also equipped with an intelligent low-power power management unit; the data processing module includes an industrial control integrated machine, an industrial control integrated The machine receives the data information from the data acquisition module through the wireless communication transmission unit, and displays the processed data information on the software interface in the form of three-dimensional animation through the display device; A control unit, the electrical joint control unit outputs a plurality of switching signals through a relay; the industrial control integrated machine is also connected to a high-decibel sound and light alarm unit and a power management unit.

The wireless communication transmission unit is a Wi-Fi wireless communication module.

The low-power power supply module outputs 12V DC power, and the input power comes from the hanger's own power supply or external solar panels and battery components to achieve self-power supply.

The inclination sensor communicates with the data acquisition module through the serial port, and the acquisition frequency is set to 50/100Hz. After filtering, the data is uploaded to the host computer 10 times per second; the inclination sensor adopts dual-axis measurement, which measures the inclination state of the container in the two directions of length and width. And converted into container deflection angle.

The using method of the present invention is:

The container eccentric load, eccentric weight monitoring and FTR lock operation intelligent early warning system is divided into two parts: the data acquisition module installed on the hanger and the data display module installed in the driver's cab. Among them, the data acquisition module includes the load cell installed on the force lock pins at the four corners of the hanger to collect the real-time weight of the container, the inclination sensor installed in the collection equipment box to collect the real-time inclination of the container, and then the collected data is preliminarily sorted and filtered The data display module transmitted to the driver's cab. The data display module combines the weight data and inclination data, and through data dynamic processing related algorithms, calculates the decoupling of the FTR lock and the total weight, partial weight, and eccentric data of the container, and displays it on the software interface in the form of 3D animation, and gives the most Easy operation buttons. Finally, the system provides a set of relay outputs, which is convenient for users to realize their control functions. The interface of the intelligent early warning system for container eccentric load, eccentric weight monitoring and FTR lock operation is intuitive, easy to operate, and convenient for drivers to learn and use. The composition of the system is shown in Figure 1.

The data acquisition module includes a low-power power supply module, a load cell power supply and data acquisition module, an inclination sensor power supply and data acquisition module, and a Wi-Fi wireless communication module. The main body of the data acquisition module is a circuit board with MCU, which is responsible for data acquisition, data processing and data upload of the sensor. The entire data acquisition module adopts an industrial integration design, which meets the IP65 waterproof and dustproof standard, and can be installed at an appropriate location according to the on-site hanger situation.

Low power consumption power module, using 12VDC power supply, there are 2 power supply methods: most of the four pulley hangers have power supply, and the system configures the adapter according to the specific power supply provided by the hanger; a few hangers have no power supply, and the system is additionally equipped with solar panels+ The storage battery realizes self-power supply. When the circuit board is powered by batteries, the system will work at full capacity after the vibration is sensed. When there is no vibration, the system will sleep with low power consumption to save power. Before sleep, turn off the power supply of all the above-mentioned peripherals. During the test, the host computer can cancel and enter the dormancy mechanism by sending commands.

The load cell power supply and data acquisition module is equipped with special load cells for container twist locks at the four corners of the spreader, and is equipped with an independent high-speed four-way data transmission system, which can measure the weight of the four corners in real time and quickly. Each weight value is uploaded to the all-in-one machine in the driver's cab through wireless Wi-Fi, and converted into the total weight, partial load, and partial weight of the container to determine whether the FTR lock has been decoupled. The angle image is accurately displayed on the display screen of the all-in-one machine.

The power supply and data acquisition module of the inclination sensor communicates with the MCU through the serial port, and the acquisition frequency is set to 50/100Hz, and uploaded to the host computer 10 times per second after filtering. The inclination sensor adopts biaxial measurement, which measures the inclination state of the container in the two directions of length and width respectively and converts it into the container deflection angle. The inclination sensor is a standard inclination sensor manufactured with international advanced high-performance sensitive technology. The sensor monitoring accuracy is higher than 1 degree under any circumstances, and higher than 0.1 degree under static conditions.

The acceleration sensor data acquisition and wake-up module is responsible for sending acceleration data to the upper computer every 100ms, and the acceleration sensor can be set through the upper computer at the same time. This module still works when the system is in sleep mode, and is responsible for sensing vibration and waking up the MCU.

Wi-Fi wireless communication module, the equipment and the cab communicate through the Wi-Fi wireless communication module, the power supply requirements are controllable, and the power supply is stopped when the power consumption is low. In actual use, a crane (one driver's cab) may be equipped with multiple hangers (multiple acquisition devices), so the acquisition device is the server side, the driver's cab is the client, and the driver's cab is connected to the acquisition device during communication.

The data processing module of the early warning system includes industrial control integrated machine, intelligent early warning software, high-decibel sound and light alarm unit, electrical joint control unit, wireless communication transmission unit and power management unit, which are installed in the driver's cab to facilitate the driver to observe while working The status of the container and FTR lock.

The industrial control all-in-one machine meets industrial standards, has high stability, and has a variety of serial ports, which can adapt to various types of signal input and output.

The intelligent early warning software has the intelligent early warning function of container unbalanced load and heavy load and FTR lock operation. When the FTR lock is not released during unloading and when the container tilt exceeds the preset value during loading, an alarm will be given. The human-machine interface will display the weight values of the four sensors and the inclination angle of the spreader in real time in 3D, and calculate the real-time status of the container. When the measured value When the set critical value is reached, the PLC control system will prohibit the lifting of the container and send out an alarm at the same time. The human-machine interface will automatically sound and light alarm and text warning to remind the driver to pay attention to check whether the goods are loaded incorrectly or the F-TR lock is not released normally. By measuring the weight of the four sensors and the data values of the inclination sensors, a mathematical model is established according to the weight difference and inclination of the sensors to analyze and judge whether the load is eccentric and whether the FTR lock is uncoupled.

The intelligent early warning software can display different sound and light alarms according to the loading status of the container and restrict the lifting and landing of the hook. When the load under the spreader reaches 95% of the maximum load of the crane, the alarm indicator will display, and it can be lifted and lowered; when the load under the spreader reaches the maximum allowable load of the crane, the sound and light will alarm at the same time, and the hook will be controlled to prohibit lifting , can only drop. PLC control technology is used to control the lifting and landing of the hook.

The intelligent early warning software has the function of three-dimensional dynamic display, which displays the status of the container and the position of the center of gravity on the software interface in real time in the form of three-dimensional animation. Relevant data such as weight and partial load, and multi-sided and multi-angle images accurately reflect the status of the container and whether the FTR lock is decoupled. The system can be displayed through the front view, top view, side view, and three views of the container, and the working status of the container can be observed from multiple directions and angles. When unloading, the display of the container is added with the display of the flatbed truck, which is convenient for observing the detached state of the container, and calculates and alarms the status of the container according to the regulations during the unloading process; when loading, it can calculate and alarm the status of the container according to the regulations during the loading process .

Claims (4)

1. An intelligent early warning system for container loading and unloading operations, characterized in that the early warning system includes a data acquisition module installed on the hanger and a data processing module installed in the driver's cab; wherein the data acquisition module includes, installed on the hanger The load cell used to collect the real-time weight of the container on the force lock pins at the four corners of the frame, the inclination sensor installed in the collection equipment box to collect the real-time inclination of the container, and the control and control devices connected to the inclination sensor and the load cell through the data bus Data integration unit; the control and data integration unit transmits data to the data processing module through the wireless communication transmission unit; the data acquisition module is also equipped with an intelligent low-power power management unit; the data processing module includes an industrial control integrated machine, and the industrial control integrated machine passes The wireless communication transmission unit receives the data information from the data acquisition module, and displays the processed data information on the software interface in the form of three-dimensional animation through the display device; the data processing module is also equipped with an electrical joint control unit connected to the industrial control integrated machine , the electrical joint control unit outputs a plurality of switching signals to the outside through the relay; the industrial control integrated machine is also connected to a high-decibel sound and light alarm unit and a power management unit. 2. An intelligent early warning system for container loading and unloading operations according to claim 1, wherein the wireless communication transmission unit is a Wi-Fi wireless communication module. 3. An intelligent warning system for container loading and unloading operations as claimed in claim 1, characterized in that: the low power consumption power supply module outputs 12V DC power supply, and the input power comes from the own power supply of the hanger or an additional solar panel and battery assembly to realize automatic monitoring. powered by. 4. An intelligent early warning system for container loading and unloading operations as claimed in claim 1, characterized in that: the inclination sensor communicates with the data acquisition module through a serial port, the acquisition frequency is set to 50/100Hz, and after filtering, it uploads to the host computer 10 times per second Data; the inclination sensor uses biaxial measurement to measure the inclination state of the container in the two directions of length and width respectively and convert it into the container deflection angle.