CN111056326B - Operation control system and method for stacker-reclaimer - Google Patents
Operation control system and method for stacker-reclaimer Download PDFInfo
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- CN111056326B CN111056326B CN201811207258.3A CN201811207258A CN111056326B CN 111056326 B CN111056326 B CN 111056326B CN 201811207258 A CN201811207258 A CN 201811207258A CN 111056326 B CN111056326 B CN 111056326B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G65/00—Loading or unloading
- B65G65/005—Control arrangements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G65/00—Loading or unloading
- B65G65/02—Loading or unloading machines comprising essentially a conveyor for moving the loads associated with a device for picking-up the loads
- B65G65/04—Loading or unloading machines comprising essentially a conveyor for moving the loads associated with a device for picking-up the loads with pick-up shovels
Abstract
The invention provides a stacker-reclaimer operation control system and a method, belonging to the field of port equipment. This stacker-reclaimer operation control system includes: the system comprises an upper signal interaction device, a lower signal interaction device and a monitoring platform, wherein the upper signal interaction device and the lower signal interaction device are arranged in a cargo yard; the upper signal interaction device and the lower signal interaction device are communicated by adopting a wireless frequency modulation signal; and the upper signal interaction device is communicated with the monitoring platform by adopting a WIFI wireless network. The system and the method of the invention realize the wireless communication between the upper signal interaction device and the lower signal interaction device, can eliminate the interference of low-frequency signals on signal transmission, effectively avoid the problems of short service life and low efficiency of wired connection, realize the automatic operation of material stacking and taking, greatly reduce the production cost and improve the production efficiency.
Description
Technical Field
The invention belongs to the field of port equipment, and particularly relates to a control system and method for operation of a stacker-reclaimer.
Background
Stacker-reclaimers are large pieces of equipment that are often used in bulk storage yards. The stacker-reclaimer comprises an arm support, the arm support can move, a rail is arranged on the arm support, a conveying belt and a bucket wheel capable of moving on the rail are arranged on the rail, and the stacker-reclaimer can be used for stacking and reclaiming goods in a goods yard where the stacker-reclaimer is located. When the materials outside the cargo yard need to be stacked in the cargo yard, the materials outside the cargo yard are sequentially conveyed to the position near the bucket wheel through the movement of the conveying belt, the bucket wheel rotates to scoop the materials on the conveying belt, and the materials fall from the bucket wheel and fall into the designated position in the cargo yard when the scooped materials rotate to the other side along with the bucket wheel; when the materials in the goods yard need to be taken out of the goods yard, the bucket wheel shovels the materials from the goods stack in the goods yard, and when the shoveled materials rotate to the other side along with the bucket wheel, the materials fall down from the bucket wheel and fall onto the conveying belt, and the conveying belt moves to convey the materials out of the goods yard.
The operation states of the stacker-reclaimer comprise forward, backward, left shift, right shift, pitching, reclaiming (forward transmission of a bucket wheel) and stacking (reverse rotation of the bucket wheel). When the material stacking and taking operation is carried out, an operator in a control room arranged on the arm support is required to operate an operation disc, the control room PLC is used for sending out instructions of all operation postures, the upper data interaction device is used for collecting all the instructions sent out by the control room PLC and sending all the instructions to the lower data interaction device positioned below the arm support, and the lower data interaction device is used for controlling the execution PLC to drive a corresponding motor to carry out the operation according to the received instructions so as to complete the operation postures of forward movement, backward movement, left shift, right shift, pitching, material taking (forward rotation of a bucket wheel) and material stacking (reverse rotation of the bucket wheel).
In traditional stacker-reclaimer, control room PLC passes through the signal BUS line and is connected with the mutual device of upper portion signal, and the execution PLC passes through the signal BUS line and is connected with the mutual device of lower part signal, and the mutual device of upper portion signal carries out wired connection through scalable winding displacement with the mutual device of lower part signal, because the mutual device setting of upper portion signal is on the cantilever crane, moves along with the cantilever crane, and the mutual device of lower part data is fixed, at the operation in-process, scalable winding displacement needs the operation of stretching out and drawing back for a long time.
The traditional stacker-reclaimer operation has the following disadvantages:
1. because the operator in the control room can not observe the panoramic view of all goods in the storage yard, at least one person is required to be equipped in the storage yard to observe the conditions of the storage yard during the whole operation period, the stacking type of the goods stack is given by the person in the storage yard at any time, the stacking type comprises the stack length, the stack width, the stack height, the stack type and the whole position, the condition is informed to the operator in the control room in real time, and the operator finishes the material stacking and taking operation according to the command of the person in the storage yard; in the whole operation process, operators in a control room need to be configured with personnel in a goods yard for a long time to report the situation of the goods pile at any time, and because the size of the goods pile is large, a plurality of personnel may need to be configured at different positions in the goods yard, so the labor cost is greatly increased; moreover, the judgment of personnel in the freight yard on the condition of the freight pile is not always accurate, and the personnel may need to communicate with an operator in a control room for many times to adjust the posture of the stacker-reclaimer, so that the production efficiency and the accuracy are greatly reduced;
2. the upper data interaction device and the lower data interaction device are connected by adopting a telescopic flat cable, the flat cable is exposed in an outdoor environment for a long time, and due to the telescopic operation in a long time, the flat cable is easy to age and deform, and needs to be replaced in time when the production requirement cannot be met, so that the production efficiency is reduced, and the production cost is increased.
Disclosure of Invention
The invention aims to solve the problems in the prior art and provides a stacker-reclaimer operation control system and method, which adopt high-frequency signals to realize data interaction between an upper signal interaction device and a lower signal interaction device and adopt a historical instruction set to realize automatic operation of the stacker-reclaimer, thereby reducing the production cost and improving the production efficiency.
The invention is realized by the following technical scheme:
a stacker-reclaimer operation control system, comprising: the system comprises an upper signal interaction device, a lower signal interaction device and a monitoring platform, wherein the upper signal interaction device and the lower signal interaction device are arranged in a cargo yard;
the upper signal interaction device and the lower signal interaction device are communicated by adopting a wireless frequency modulation signal;
and the upper signal interaction device is communicated with the monitoring platform by adopting a WIFI wireless network.
The upper signal interaction device includes:
PLC serial data acquisition module: the device is used for acquiring a digital signal sent by the control room PLC, wherein the digital signal is an action instruction; the action command is determined by the PLC in the control room according to the action of an operator in the control room, and the action of the operator comprises the following steps: advancing, retreating, left, right, bending, pitching, taking and stacking;
an upper frequency modulation module: during manual operation, the PLC serial data acquisition module is used for modulating the frequency of the digital signal acquired by the PLC serial data acquisition module into a high-frequency analog signal and sending the high-frequency analog signal to the upper transmitting module; during automatic operation, the system is used for sequentially modulating the frequency of a historical instruction set sent by the monitoring platform into high-frequency analog signals and sending the high-frequency analog signals to the upper transmitting module;
an upper transmitting module: the device is used for sending the high-frequency analog signal sent by the upper frequency modulation module to the lower signal interaction device;
an upper receiving module: the upper part de-frequency module is used for receiving the high-frequency analog signal sent by the lower part signal interaction device and sending the received high-frequency analog signal to the lower part;
an upper frequency-demodulating module: the upper part receiving module is used for receiving a high-frequency analog signal sent by the upper part receiving module and sending the high-frequency analog signal to a human-computer interface;
WIFI wireless data send receiving module: the system is used for communicating with a monitoring platform and comprises the steps of sending an action instruction acquired by a PLC serial data acquisition module to the monitoring platform, sending information input by a human-computer interface to the monitoring platform and receiving a message without matching information or a matched historical instruction set from the monitoring platform;
a human-computer interface: the WIFI wireless data transmitting and receiving module is used for inputting information by an operator and transmitting the information to the WIFI wireless data transmitting and receiving module; displaying the digital signal sent by the upper part frequency-decoding module; if the information without the matching information is received, the information without the matching information is displayed, if the matched historical instruction set is received, an operator is prompted to select automatic operation or manual operation through a human-computer interface, if the operator selects the automatic operation, the WIFI wireless data transmitting and receiving module is informed to transmit the matched historical instruction set to the upper frequency modulation module, and if the operator selects the manual operation, the PLC serial data acquisition module is informed to start to acquire the action instruction transmitted by the PLC in the control room.
The information input by the operator on the human-machine interface comprises: the method comprises the steps of (1) stacking information, operation type information, personnel information and operation start and stop information;
the stack information includes: stack length, stack width, stack height, stack type, goods;
the job type information includes: stacking and taking materials;
the personnel information includes: the shift and the job number;
the operation start-stop information comprises: the operation starts and the operation ends.
The lower signal interaction device includes:
a lower receiving module: the upper part signal interaction device is used for receiving a high-frequency analog signal sent by an upper part transmitting module in the upper part signal interaction device and sending the high-frequency analog signal to a lower part frequency-demodulating module;
a lower part frequency-demodulating module: the device is used for demodulating the high-frequency analog signal sent by the lower receiving module into a digital signal and sending the digital signal to the execution PLC;
a lower frequency modulation module: the frequency modulation module is used for modulating the digital signal sent by the execution PLC into a high-frequency analog signal and sending the high-frequency analog signal to the lower transmitting module;
a lower part transmitting module: and the upper receiving module is used for sending the high-frequency analog signal sent by the lower frequency modulation module to the upper signal interaction device.
The monitoring platform comprises:
WIFI wireless module: the device is used for receiving information on a human-computer interface sent by a WIFI wireless data sending and receiving module in the upper signal interaction device and action instructions collected by a PLC serial data collection module; sending a historical instruction set matched with information on a human-computer interface or a message without matched information to a WIFI wireless data sending and receiving module in an upper signal interaction device;
stacker-reclaimer database: generating historical operation information according to the information on the human-computer interface received by the WIFI wireless module and the action instruction acquired by the PLC serial data acquisition module and storing the historical operation information;
a matching module: whether historical operation information matched with the received information on the human-computer interface exists in the stacking and taking database or not is judged according to the information on the human-computer interface received by the WIFI wireless module, if yes, the matched historical operation information is called from the stacking and taking database, a historical instruction set in the historical operation information is sent to the WIFI wireless module, and if not, a message without the matched information is sent to the WIFI wireless module.
The history job information includes:
the method comprises the steps that an operation number, goods stack information, operation type information, personnel information, operation start and stop information and a historical instruction set of one-time operation are collected;
the historical instruction set comprises all action instructions collected by the upper signal interaction device in the process of one-time operation;
each operation has a unique operation number, namely one operation number corresponds to one historical instruction set;
the action instruction comprises a string of binary digits which are sequentially a start bit, an address code, an action number, a timestamp TIME, a check bit CRC and a stop bit;
the start bits of all action instructions are 00010000;
the address code is an IP address of the control room PLC;
the action number comprises 8 bits, and the first bit to the eighth bit respectively represent forward, backward, left, right, pitch, take and stack;
the timestamp TIME is used for recording the TIME of the action instruction;
the check bit CRC is used for checking the action instruction;
the termination bits of all the action instructions are 00110000;
the high-frequency analog signal is represented by a signal larger than 900HZ, namely 0 in the action command is represented by a signal larger than 900Hz, and 1 in the action command is represented by a signal larger than the signal representing 0 by at least 300 Hz.
The operation control method of the stacker-reclaimer realized by the operation control system of the stacker-reclaimer comprises the following steps:
step 6, the monitoring platform sends a historical instruction set in historical operation information matched with the goods stack to be operated to the upper signal interaction device, an operator is prompted to select automatic operation or manual operation on a human-computer interface, if the operator selects the automatic operation, the upper signal interaction device sends the historical instruction set to the lower signal interaction device in sequence according to time sequence, the lower signal interaction device starts automatic stacking and material taking operation according to the historical instruction set until the operation is finished, then the operation is switched to step 7, and if the operator selects the manual operation, the operation is returned to step 3;
and 7, ending.
The operation of judging whether historical operation information matched with the goods stack to be operated exists by the monitoring platform in the step 2 comprises the following steps:
(21) judging whether historical operation information which is the same as the goods type and the operation type of the goods stack to be operated can be searched from a stacker-reclaimer database, if so, sequentially storing all the historical operation information which is the same as the goods type and the operation type of the goods stack to be operated into a first search queue, then turning to the step (22), and if not, turning to the step (25);
(22) judging whether historical job information which is the same as the stack type of the to-be-operated stack can be searched from the first search queue, if so, sequentially storing the historical job information which is the same as the stack type of the to-be-operated stack in the first search queue into the second search queue, then turning to the step (23), if not, judging whether historical job information of which the stack type is rectangular can be searched from the first search queue, if so, sequentially storing the historical job information of which the stack type is rectangular in the first search queue into the second search queue, then turning to the step (23), and if not, turning to the step (25);
(23) judging whether historical operation information of the stack length, the stack width and the stack height which are all less than or equal to the stack length, the stack width and the stack height of the to-be-operated stack can be searched from the second search queue, if so, sequentially storing the historical operation information of the stack length, the stack width and the stack height which are all less than or equal to the stack length, the stack width and the stack height of the to-be-operated stack into a third search queue, and then turning to the step (24); if not, the step (25) is carried out;
(24) judging that historical operation information matched with the goods stack to be operated exists, and then turning to the step (26);
(25) judging that no historical operation information matched with the goods stack to be operated exists, and then turning to the step (26);
(26) and then, the process is ended.
Said step (24) further comprises:
judging whether the quantity of the historical operation information in the third search queue is equal to 1, if so, the historical operation information is the historical operation information matched with the goods stack to be operated, if not, the historical operation information with the smallest difference with the goods stack to be operated is found, and the historical operation information is used as the historical operation information matched with the goods stack to be operated;
the operation of finding the historical operation information with the smallest difference with the goods stack to be operated comprises the following steps:
firstly, calculating the difference value Q between each piece of historical work information in the third search queue and the to-be-worked stack by the following formula:
Q＝(Ln-Lh)+(Wn-Wh)+(Hn-Hh)
wherein the content of the first and second substances,
ln represents the stack length of the to-be-operated stack, Lh represents the stack length of the historical operation information, Wn represents the stack width of the to-be-operated stack, Wh represents the stack width of the historical operation information, Hn represents the stack height of the to-be-operated stack, and Hh represents the stack height of the historical operation information;
then, arranging all Q values in a descending order; and if the minimum Q is N, the corresponding N pieces of historical operation information are all the historical operation information with the minimum difference with the goods stack to be operated.
The operation of prompting the operator to select automatic operation or manual operation in the human-computer interface in the step 6 further comprises:
and if N historical instruction sets matched with the goods stack to be operated exist, prompting an operator to select one historical instruction set for automatic operation.
Compared with the prior art, the invention has the beneficial effects that: the system and the method of the invention realize the wireless communication between the upper signal interaction device and the lower signal interaction device, can eliminate the interference of low-frequency signals on signal transmission, effectively avoid the problems of short service life and low efficiency of wired connection, realize the automatic operation of material stacking and taking, greatly reduce the production cost and improve the production efficiency.
Drawings
FIG. 1 is a schematic diagram of the system of the present invention;
FIG. 2 is a diagram showing a structure of an operation command issued by a control room PLC;
FIG. 3 is a block diagram of the steps of the method of the present invention.
Detailed Description
The invention is described in further detail below with reference to the accompanying drawings:
as shown in fig. 1, the system of the present invention comprises: the system comprises an upper signal interaction device 1, a lower signal interaction device 2 and a monitoring platform 3, wherein the upper signal interaction device and the lower signal interaction device are arranged in a cargo yard; the upper signal interaction device 1 and the lower signal interaction device 2 are communicated by adopting a wireless frequency modulation signal, and the upper signal interaction device 1 and the monitoring platform 3 are communicated by a WIFI wireless network;
the upper signal interaction device 1 is positioned in a control room on the arm support and is used for receiving various instructions sent by an operator in the control room; the lower signal interaction device 2 is positioned below the arm support and is used for directly controlling various actions of the stacker-reclaimer.
Wherein the upper signal interaction device 1 comprises:
the PLC serial data acquisition module 11: the device is used for acquiring a digital signal sent by a control room PLC (shown as a number 4 in figure 1), and the digital signal is an action instruction; the action command is determined by the PLC in the control room according to the action of an operator in the control room, and the action of the operator comprises the following steps: advancing, retreating, left, right, bending, pitching, taking and stacking;
upper frequency modulation module 12: during manual operation, the PLC serial data acquisition module is used for modulating the frequency of the digital signal acquired by the PLC serial data acquisition module 11 into a high-frequency analog signal and sending the high-frequency analog signal to the upper transmitting module 13; during automatic operation, the system is used for sequentially modulating the frequency of the historical instruction set sent by the monitoring platform 3 into high-frequency analog signals and sending the high-frequency analog signals to the upper transmitting module;
upper transmitting module 13: the device is used for sending the high-frequency analog signal sent by the upper frequency modulation module 12 to the lower signal interaction device;
the upper receiving module 14: for receiving the high frequency analog signal sent by the lower signal interaction device and sending the received high frequency analog signal to the upper frequency-demodulating module 15. The high-frequency analog signal sent by the lower signal interaction device is a state signal for executing the PLC, and is used for ensuring normal communication, namely the upper signal interaction device sends an instruction to be the lower signal interaction device, the lower signal interaction device sends feedback information according to the execution condition, for example, after the upper signal interaction device sends a sent action instruction, the lower signal interaction device returns a state signal indicating whether the action instruction is normally executed to the upper signal interaction device;
the upper frequency-demodulating module 15: for demodulating the high-frequency analog signal sent from the upper receiving module 14 into a digital signal, and sending the digital signal to the human-machine interface 17;
the WIFI wireless data sending and receiving module 16: the system is used for communicating with the monitoring platform 3, and comprises the steps of sending the action instruction collected by the PLC serial data collection module 11 to the monitoring platform 3, sending the information input by the human-computer interface 17 to the monitoring platform 3, and receiving the information without matching information or a matched historical instruction set from the monitoring platform 3;
the human-machine interface 17: the WIFI wireless data transmitting and receiving module 16 is used for inputting information by an operator and transmitting the information to the WIFI wireless data transmitting and receiving module; displaying the digital signals sent by the upper part frequency-decoding module 15, namely displaying the execution condition of each action instruction; if the information without matching information is received, the information without matching is displayed, if the matched historical instruction set is received, an operator is prompted to select automatic operation or manual operation through the human-computer interface 17, if the operator selects the automatic operation, the WIFI wireless data transmitting and receiving module 16 is informed to transmit the matched historical instruction set to the upper frequency modulation module 12, and if the operator selects the manual operation, the PLC serial data acquisition module 11 is informed to start acquiring the action instruction received by the PLC in the control room.
As shown in Table 1, the information input by the stacker-reclaimer operator on the human-computer interface comprises stack information, operation type information, personnel information and operation start-stop information, wherein the stack information comprises: stack length (stack length), stack width (stack width), stack height (stack height), stack type (circular or rectangular), cargo (coal or charcoal, also more detailed as coal foam, blue coal or coke, etc.); the job types include: stacking and taking materials; the personnel information includes: the shift and the job number; the operation start-stop information includes: the operation starts and the operation ends.
TABLE 1
For a round stack, the stack length, stack width and stack height are recorded in the operation information, and when judging whether automatic operation is available or not, if the stack types are different, the rectangular stack in the historical operation information can be suitable for the round stack to be operated, but the round stack in the historical operation information is not suitable for the rectangular stack to be operated.
The lower signal interaction device 2 includes:
lower receiving module 21: the upper part signal interaction device is used for receiving a high-frequency analog signal sent by the upper part transmitting module 13 in the upper part signal interaction device and sending the high-frequency analog signal to the lower part frequency-demodulating module 22;
lower part de-frequency module 22: for demodulating the high-frequency analog signal transmitted from the lower receiving module 21 into a digital signal and transmitting the digital signal to the execution PLC (denoted by numeral 5 in fig. 1);
lower frequency modulation module 23: the frequency modulation module is used for modulating the digital signal sent by the execution PLC into a high-frequency analog signal and sending the high-frequency analog signal to the lower transmitting module 24;
lower transmitting module 24: and the upper receiving module 14 is used for sending the high-frequency analog signal sent by the lower frequency modulation module 23 to the upper signal interaction device.
The monitoring platform 3 comprises:
the WIFI wireless module 31: the system is used for receiving information on a human-computer interface 17 sent by a WIFI wireless data sending and receiving module 16 in the upper signal interaction device and action instructions collected by a PLC serial data collection module 11; sending a history instruction set matched with the information on the human-computer interface 17 or a message without matched information to a WIFI wireless data sending and receiving module 16 in the upper signal interaction device;
stacker-reclaimer database 32: generating and storing historical operation information according to the information on the human-computer interface 17 received by the WIFI wireless module 31 and the action instruction acquired by the PLC serial data acquisition module 11; when generating the historical job information, packaging all action instructions of a job into a historical instruction set of the job, and endowing the job with a unique job number;
the matching module 33: whether historical operation information matched with the received information on the human-computer interface 17 exists in the stacking and reclaiming database 32 is judged according to the information on the human-computer interface 17 received by the WIFI wireless module 31, if yes, the matched historical operation information is called from the stacking and reclaiming database 32, a historical instruction set in the historical operation information is sent to the WIFI wireless module 31, and if not, a message without the matched information is sent to the WIFI wireless module 31.
The history job information includes:
the method comprises the steps that an operation number, goods stack information, operation type information, personnel information, operation start and stop information and a historical instruction set of one-time operation are collected;
the historical instruction set comprises all action instructions collected by the upper signal interaction device in the process of one-time operation;
each job has a unique job number, i.e. one job number corresponds to one historical instruction set.
Fig. 2 shows an action command sent by the control room PLC, which is also an action command collected by the PLC serial data collection module 11 in the upper signal interaction device, where the action command includes a string of digits, which are, in order, a start bit, an address code, an action number, a timestamp TIME, a check bit CRC, and a stop bit; the start bits of all the action commands are 00010000, the end bits of all the action commands are 00110000, the address code in the information is the address of the control room PLC (because a plurality of stacker-reclaimers are possible in a goods yard, different IP addresses are distributed to the control room PLC of each stacker-reclaimer for distinguishing the stacker-reclaimers), the action number in the action command comprises 8 bits, the first digit to the eighth digit respectively represent forward, backward, left, right, pitch, take and pile, wherein, the advancing and retreating are a first group, the left and right are a second group, the bending and pitching are a third group, the taking and piling are a fourth group, at the same time, at most one number in each group is 1, and when the number is 1, the corresponding action is executed, when the number is 0, it indicates that no corresponding action is performed, for example, action number 10100010 indicates that the bucket wheel is moving forward while moving left, and that it is taking material (i.e., the bucket wheel is rotating forward). In order to ensure the transmission quality, a check bit CRC and a TIME stamp TIME are added in the action command, wherein the TIME stamp TIME is used for recording the TIME of the action command.
As the wharf operation field motor equipment generally adopts 380V and 50Hz industrial power supply and has great interference on low-frequency signals, the invention modulates the action command into high-frequency signals for transmission, namely, the high-frequency signals are adopted to transmit the signals between the upper signal interaction device and the lower signal interaction device, thereby ensuring the transmission quality of the signals. The high frequency signal is preferably a signal greater than 900HZ, for example, 0 in the motion command is transmitted at 900HZ, and 1 is transmitted at 1200HZ, so that the interference of the low frequency signal on the signal transmission can be eliminated. And because the data between the upper signal interaction device and the lower signal interaction device are transmitted by adopting high-frequency wireless information, the problems of short service life and low efficiency of wired connection are avoided, the production efficiency is greatly improved, and the production cost is reduced.
As shown in fig. 3, the stacker-reclaimer operation control method implemented by the stacker-reclaimer operation control system includes:
step 6, the monitoring platform sends a historical instruction set in historical operation information matched with the goods stack to be operated to the upper signal interaction device, an operator is prompted to select automatic operation or manual operation on a human-computer interface, if the operator selects the automatic operation, the upper signal interaction device sends the historical instruction set to the lower signal interaction device in sequence according to time sequence, the lower signal interaction device starts automatic stacking and material taking operation according to the historical instruction set until the operation is finished, then the operation is switched to step 7, and if the operator selects the manual operation, the operation is returned to step 3;
and step 7, the step is ended,
the operation of judging whether historical operation information matched with the goods stack to be operated exists by the monitoring platform in the step 2 comprises the following steps:
(21) judging whether historical operation information which is the same as the goods type and the operation type of the goods stack to be operated can be searched from a stacker-reclaimer database, if so, sequentially storing all the historical operation information which is the same as the goods type and the operation type of the goods stack to be operated into a first search queue, then turning to the step (22), and if not, turning to the step (25);
(22) judging whether historical job information which is the same as the stack type of the to-be-operated stack can be searched from the first search queue, if so, sequentially storing the historical job information which is the same as the stack type of the to-be-operated stack in the first search queue into the second search queue, then turning to the step (23), if not, judging whether historical job information of which the stack type is rectangular can be searched from the first search queue, if so, sequentially storing the historical job information of which the stack type is rectangular in the first search queue into the second search queue, then turning to the step (23), and if not, turning to the step (25);
(23) judging whether historical operation information of the stack length, the stack width and the stack height which are all less than or equal to the stack length, the stack width and the stack height of the to-be-operated stack can be searched from the second search queue, if so, sequentially storing the historical operation information of the stack length, the stack width and the stack height which are all less than or equal to the stack length, the stack width and the stack height of the to-be-operated stack into a third search queue, and then turning to the step (24); if not, the step (25) is carried out;
(24) judging that historical operation information matched with the goods stack to be operated exists, and then turning to the step (26);
(25) judging that no historical operation information matched with the goods stack to be operated exists, and then turning to the step (26);
(26) and (6) ending.
Said step (24) further comprises:
judging whether the quantity of the historical operation information in the third search queue is equal to 1, if so, the historical operation information is the historical operation information matched with the goods stack to be operated, if not, the historical operation information with the smallest difference with the goods stack to be operated is found, and the historical operation information is used as the historical operation information matched with the goods stack to be operated;
the operation of finding the historical operation information with the smallest difference with the goods stack to be operated comprises the following steps:
firstly, calculating the difference value Q between each piece of historical work information in the third search queue and the to-be-worked stack by the following formula:
Q＝(Ln-Lh)+(Wn-Wh)+(Hn-Hh)
wherein the content of the first and second substances,
ln represents the stack length of the to-be-operated stack, Lh represents the stack length of the historical operation information, Wn represents the stack width of the to-be-operated stack, Wh represents the stack width of the historical operation information, Hn represents the stack height of the to-be-operated stack, and Hh represents the stack height of the historical operation information;
then, arranging all Q values in a descending order; and if the minimum Q is N, the corresponding N pieces of historical operation information are all the historical operation information with the minimum difference with the goods stack to be operated.
The operation of prompting the operator to select automatic operation or manual operation in the human-computer interface in the step 6 further comprises:
and if N historical instruction sets matched with the goods stack to be operated exist, prompting an operator to select one historical instruction set for automatic operation.
In the process of automatic operation, an operator does not control the operating lever any more, the operating lever does not act any more, correspondingly, the PLC in the control room does not generate an action instruction, the PLC serial data acquisition module does not acquire any action instruction, at the moment, a historical instruction set sequentially passes through the upper frequency modulation module and the upper transmitting module according to the time sequence and is sent to the lower signal interaction device, and the lower signal interaction device controls the execution PLC to perform corresponding action according to the received action instruction. In the automatic operation process, personnel do not need to be equipped in a goods yard, and an operator does not need to control the stacker-reclaimer, so that the manpower and the financial resources are greatly saved. In the automatic operation process, an operator can also terminate the automatic operation at any time and change the automatic operation into manual operation, so that the flexibility is increased.
The above-described embodiment is only one embodiment of the present invention, and it will be apparent to those skilled in the art that various modifications and variations can be easily made based on the application and principle of the present invention disclosed in the present application, and the present invention is not limited to the method described in the above-described embodiment of the present invention, so that the above-described embodiment is only preferred, and not restrictive.
Claims (6)
1. The utility model provides a stacker-reclaimer operation control system which characterized in that: the stacker-reclaimer operation control system includes: the system comprises an upper signal interaction device, a lower signal interaction device and a monitoring platform, wherein the upper signal interaction device and the lower signal interaction device are arranged in a cargo yard;
the upper signal interaction device is positioned in a control room on the arm support and used for receiving various instructions sent by an operator in the control room; the lower signal interaction device is positioned below the arm support and is used for directly controlling various actions of the stacker-reclaimer;
the upper signal interaction device and the lower signal interaction device are communicated by adopting a wireless frequency modulation signal;
the upper signal interaction device is communicated with the monitoring platform through a WIFI wireless network;
the upper signal interaction device includes:
PLC serial data acquisition module: the device is used for acquiring a digital signal sent by the control room PLC, wherein the digital signal is an action instruction;
an upper frequency modulation module: during manual operation, the PLC serial data acquisition module is used for modulating the frequency of the digital signal acquired by the PLC serial data acquisition module into a high-frequency analog signal and sending the high-frequency analog signal to the upper transmitting module; during automatic operation, the system is used for sequentially modulating the frequency of a historical instruction set sent by the monitoring platform into high-frequency analog signals and sending the high-frequency analog signals to the upper transmitting module;
an upper transmitting module: the device is used for sending the high-frequency analog signal sent by the upper frequency modulation module to the lower signal interaction device;
an upper receiving module: the upper part de-frequency module is used for receiving the high-frequency analog signal sent by the lower part signal interaction device and sending the received high-frequency analog signal to the lower part;
an upper frequency-demodulating module: the upper part receiving module is used for receiving a high-frequency analog signal sent by the upper part receiving module and sending the high-frequency analog signal to a human-computer interface;
the upper signal interaction device further comprises:
WIFI wireless data send receiving module: the system is used for communicating with a monitoring platform and comprises the steps of sending an action instruction acquired by a PLC serial data acquisition module to the monitoring platform, sending information input by a human-computer interface to the monitoring platform and receiving a message without matching information or a matched historical instruction set from the monitoring platform;
a human-computer interface: the WIFI wireless data transmitting and receiving module is used for inputting information by an operator and transmitting the information to the WIFI wireless data transmitting and receiving module; displaying the digital signal sent by the upper part frequency-decoding module; if the information without matching information is received, displaying the information without matching, if the matched historical instruction set is received, prompting an operator to select automatic operation or manual operation through a human-computer interface, if the operator selects the automatic operation, informing the WIFI wireless data transmitting and receiving module to transmit the matched historical instruction set to the upper frequency modulation module, and if the operator selects the manual operation, informing the PLC serial data acquisition module to start acquiring the action instruction transmitted by the PLC in the control room;
the information input by the operator on the human-machine interface comprises: the method comprises the steps of (1) stacking information, operation type information, personnel information and operation start and stop information;
the stack information includes: stack length, stack width, stack height, stack type, goods;
the job type information includes: stacking and taking materials;
the personnel information includes: the shift and the job number;
the operation start-stop information comprises: starting and ending the operation;
the lower signal interaction device includes:
a lower receiving module: the upper part signal interaction device is used for receiving a high-frequency analog signal sent by an upper part transmitting module in the upper part signal interaction device and sending the high-frequency analog signal to a lower part frequency-demodulating module;
a lower part frequency-demodulating module: the device is used for demodulating the high-frequency analog signal sent by the lower receiving module into a digital signal and sending the digital signal to the execution PLC;
a lower frequency modulation module: the frequency modulation module is used for modulating the digital signal sent by the execution PLC into a high-frequency analog signal and sending the high-frequency analog signal to the lower transmitting module;
a lower part transmitting module: the upper receiving module is used for sending the high-frequency analog signal sent by the lower frequency modulation module to the upper signal interaction device;
the monitoring platform comprises:
WIFI wireless module: the device is used for receiving information on a human-computer interface sent by a WIFI wireless data sending and receiving module in the upper signal interaction device and action instructions collected by a PLC serial data collection module; sending a historical instruction set matched with information on a human-computer interface or a message without matched information to a WIFI wireless data sending and receiving module in an upper signal interaction device;
stacker-reclaimer database: generating historical operation information according to the information on the human-computer interface received by the WIFI wireless module and the action instruction acquired by the PLC serial data acquisition module and storing the historical operation information;
a matching module: judging whether historical operation information matched with the received information on the human-computer interface exists in a stacker-reclaimer database or not according to the information on the human-computer interface received by the WIFI wireless module, if so, calling the matched historical operation information from the stacker-reclaimer database, sending a historical instruction set in the historical operation information to the WIFI wireless module, and if not, sending a message without the matched information to the WIFI wireless module.
2. The stacker-reclaimer work control system of claim 1, wherein: the history job information includes:
the method comprises the steps that an operation number, goods stack information, operation type information, personnel information, operation start and stop information and a historical instruction set of one-time operation are collected;
the historical instruction set comprises all action instructions collected by the upper signal interaction device in the process of one-time operation;
each operation has a unique operation number;
the action instruction comprises a string of binary digits which are sequentially a start bit, an address code, an action number, a timestamp TIME, a check bit CRC and a stop bit;
the start bits of all action instructions are 00010000;
the address code is an IP address of the control room PLC;
the action number comprises 8 bits, and the first bit to the eighth bit respectively represent forward, backward, left, right, pitch, take and stack;
the timestamp TIME is used for recording the TIME of the action instruction;
the check bit CRC is used for checking the action instruction;
the termination bits of all the action instructions are 00110000;
the high-frequency analog signal is represented by a signal larger than 900HZ, namely 0 in the action command is represented by a signal larger than 900Hz, and 1 in the action command is represented by a signal larger than the signal representing 0 by at least 300 Hz.
3. A stacker-reclaimer operation control method implemented based on the stacker-reclaimer operation control system of claim 2, characterized in that: the method comprises the following steps:
step 1, an operator firstly operates a stacker-reclaimer to move a bucket wheel to the boundary of a goods stack to be operated, and then inputs goods stack information, operation type information and personnel information of the goods stack to be operated through a human-computer interface;
step 2, sending the stack information, the operation type information and the personnel information of the stack to be operated to a monitoring platform, judging whether historical operation information matched with the stack to be operated exists or not by the monitoring platform, if yes, turning to step 6, if not, displaying no-matching information on a human-computer interface, and then turning to step 3;
step 3, an operator inputs information of starting the operation, and the upper signal interaction device sends the information of starting the operation to the monitoring platform;
step 4, an operator performs stacking and taking operation on the goods stack to be operated by controlling the operating lever, in the operation process, the upper signal interaction device acquires each action instruction of the PLC in the control room in real time, sends each action instruction to the monitoring platform in real time through the WIFI wireless network, and simultaneously converts each action instruction into a high-frequency analog signal to send to the lower signal interaction device; the lower signal interaction device controls the execution PLC to act according to each received action instruction until the operation is finished;
step 5, an operator inputs information of operation termination, the upper signal interaction device sends the information of operation termination to the monitoring platform, the monitoring platform generates historical operation information of the operation, the historical operation information is stored in a stacker-reclaimer database, and then the step 7 is carried out;
step 6, the monitoring platform sends a historical instruction set in historical operation information matched with the goods stack to be operated to the upper signal interaction device, an operator is prompted to select automatic operation or manual operation on a human-computer interface, if the operator selects the automatic operation, the upper signal interaction device sends the historical instruction set to the lower signal interaction device in sequence according to time sequence, the lower signal interaction device starts automatic stacking and material taking operation according to the historical instruction set until the operation is finished, then the operation is switched to step 7, and if the operator selects the manual operation, the operation is returned to step 3;
and 7, ending.
4. The stacker-reclaimer work control method according to claim 3, wherein: the operation of judging whether historical operation information matched with the goods stack to be operated exists by the monitoring platform in the step 2 comprises the following steps:
(21) judging whether historical operation information which is the same as the goods type and the operation type of the goods stack to be operated can be searched from a stacker-reclaimer database, if so, sequentially storing all the historical operation information which is the same as the goods type and the operation type of the goods stack to be operated into a first search queue, then turning to the step (22), and if not, turning to the step (25);
(22) judging whether historical job information which is the same as the stack type of the to-be-operated stack can be searched from the first search queue, if so, sequentially storing the historical job information which is the same as the stack type of the to-be-operated stack in the first search queue into the second search queue, then turning to the step (23), if not, judging whether historical job information of which the stack type is rectangular can be searched from the first search queue, if so, sequentially storing the historical job information of which the stack type is rectangular in the first search queue into the second search queue, then turning to the step (23), and if not, turning to the step (25);
(23) judging whether historical operation information of the stack length, the stack width and the stack height which are all less than or equal to the stack length, the stack width and the stack height of the to-be-operated stack can be searched from the second search queue, if so, sequentially storing the historical operation information of the stack length, the stack width and the stack height which are all less than or equal to the stack length, the stack width and the stack height of the to-be-operated stack into a third search queue, and then turning to the step (24); if not, the step (25) is carried out;
(24) judging that historical operation information matched with the goods stack to be operated exists, and then turning to the step (26);
(25) judging that no historical operation information matched with the goods stack to be operated exists, and then turning to the step (26);
(26) and then, the process is ended.
5. The stacker-reclaimer work control method according to claim 4, wherein: said step (24) further comprises:
judging whether the quantity of the historical operation information in the third search queue is equal to 1, if so, the historical operation information is the historical operation information matched with the goods stack to be operated, if not, the historical operation information with the smallest difference with the goods stack to be operated is found, and the historical operation information is used as the historical operation information matched with the goods stack to be operated;
the operation of finding the historical operation information with the smallest difference with the goods stack to be operated comprises the following steps:
firstly, calculating the difference value Q between each piece of historical work information in the third search queue and the to-be-worked stack by the following formula:
Q=（Ln-Lh）+（Wn-Wh）+（Hn-Hh）
wherein the content of the first and second substances,
ln represents the stack length of the to-be-operated stack, Lh represents the stack length of the historical operation information, Wn represents the stack width of the to-be-operated stack, Wh represents the stack width of the historical operation information, Hn represents the stack height of the to-be-operated stack, and Hh represents the stack height of the historical operation information;
then, arranging all Q values in a descending order; the smallest historical operation information corresponding to Q is the historical operation information with the smallest difference with the goods stack to be operated; and if the minimum Q is N, the corresponding N pieces of historical operation information are the historical operation information with the minimum difference with the goods stack to be operated.
6. The stacker-reclaimer work control method according to claim 5, wherein: the operation of prompting the operator to select automatic operation or manual operation in the human-computer interface in the step 6 further comprises:
and if N historical instruction sets matched with the goods stack to be operated exist, prompting an operator to select one historical instruction set for automatic operation.
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