CN113562478B - Anti-cheating integrated system for quantitatively loading bulk materials - Google Patents
Anti-cheating integrated system for quantitatively loading bulk materials Download PDFInfo
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- CN113562478B CN113562478B CN202110804172.4A CN202110804172A CN113562478B CN 113562478 B CN113562478 B CN 113562478B CN 202110804172 A CN202110804172 A CN 202110804172A CN 113562478 B CN113562478 B CN 113562478B
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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
- B65G67/00—Loading or unloading vehicles
- B65G67/02—Loading or unloading land vehicles
- B65G67/04—Loading land vehicles
- B65G67/06—Feeding articles or materials from bunkers or tunnels
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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
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
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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
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
- B65G43/08—Control devices operated by article or material being fed, conveyed or discharged
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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
- B65G69/00—Auxiliary measures taken, or devices used, in connection with loading or unloading
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/30—Computing systems specially adapted for manufacturing
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Abstract
The invention discloses a bulk material quantitative loading anti-cheating integrated system which comprises a sales system, a sales logistics information management system and a quantitative loading system, wherein the sales system is used for acquiring order information, dispatching vehicles and self-service card issuing of the dispatched vehicles to achieve binding of the vehicles and the order information, and the sales logistics information management system is used for weighing vehicles in a travelling factory once, automatically identifying and verifying the vehicles, determining the preassembly amount of the materials according to the order information after verification and judging whether the material residual quantity of the quantitative loading system meets the preassembly amount of the materials. The invention opens up the upstream and downstream information transmission, and the interactive response of various systems improves the running reliability of the system and ensures the accurate control of the quantitative automatic loading to the loading quantity.
Description
Technical Field
The invention belongs to the technical field of intelligent control of waste heat power generation systems, and particularly relates to a bulk material quantitative loading anti-cheating integrated system.
Background
In a comprehensive view, the existing quantitative loading system or one-card system in the market only realizes basic flow verification, and has certain dead zones in the aspects of system integration, anti-cheating control and unmanned delivery control, and mainly shows the following two points. Firstly, the system has single function, the upstream and the downstream are not communicated, such as a one-card system, a centralized divergence control system and a safety behavior monitoring system which basically run in island; secondly, real-time information of material loading can not be dynamically monitored, and a plurality of problems such as loading overflow and multiple loading exist.
If the loading process is carried out on a longer cargo compartment, the loading amount can be better controlled through multiple times of unloading at different positions, and if the change of the relative unloading positions is realized through the self-running movement of the vehicle, the retention time and the unloading speed at each unloading position need to be considered, the interval of the unloading positions needs to be considered, the fewer unloading times and the fewer vehicle movement times are ensured, the single unloading amount is easy to control, the previously set unloading times and positions can be adaptively adjusted according to the actual unloading conditions, and under the condition of ensuring the loading safety of materials which are not easy to spill, the materials are loaded as much as possible, and the more reliable automatic adding materials are used for correcting errors generated by automatic loading. The above-mentioned effects cannot be achieved simultaneously by the existing automatic loading method, and therefore further improvement is needed
Disclosure of Invention
In order to overcome the defects of the prior art, the invention provides a quantitative loading anti-cheating integrated system for bulk materials, which is used for solving the technical problems that the system in the prior art has single function, the automatic loading process is complex, a driver is required to frequently drive and move, and materials cannot be added through the automatic loading process to correct errors generated in the loading process.
In order to solve the technical problems, the technical scheme adopted by the invention is as follows:
the bulk material quantitative loading anti-cheating integrated system comprises a sales system, a sales logistics information management system and a quantitative loading system, wherein the sales system is used for acquiring order information, dispatching vehicles and self-service card issuing of dispatched vehicles to achieve binding of the vehicles and the order information, the sales logistics information management system is used for weighing vehicles in a travelling factory once, automatically identifying and verifying the vehicles, determining the preassembly amount of the materials according to the order information after verification and judging whether the material surplus of the quantitative loading system meets the preassembly amount of the materials or not, the quantitative loading system is used for positioning the vehicles and prompting the vehicles to move according to loading requirements to achieve automatic loading of the materials, controlling automatic loading to stop after the actual loading amount reaches the preassembly amount, and the sales logistics information management system is also used for calculating the weight increment value of the vehicles after the vehicles are assembled by means of secondary weighing, comparing the increment value with the preassembly amount to obtain the comparison error between the vehicles, judging whether the vehicles are allowed to leave or not according to the comparison error, judging whether the vehicle is complemented or not and whether unloading management personnel are discharged or not to check reasons.
Preferably, when the quantitative loading system is used for automatic loading, firstly, the loading opening is controlled to sequentially load materials for a plurality of times from front to back relative to the longitudinal direction of the cargo compartment, when one loading is completed, the distance of the forward movement of the vehicle by a driver is equal to the distance between adjacent loading positions, the top of a material pile formed by single loading is not higher than the safety loading height, namely the maximum height of the material pile which cannot be scattered outwards completely when the vehicle moves, the loading is stopped immediately when the actual loading amount reaches the pre-loading amount in the loading process, otherwise, the loading speed is controlled by a 3D model formed by modeling, and the loading speed is gradually reduced after the distance from the top of the material pile to the safety loading height reaches a certain threshold value until the material pile height reaches the safety loading height.
Preferably, the distance between the blanking positions is set according to the ratio of the size of the cargo box to the safe blanking height, the height of the center of the valley area between the tops of the adjacent material piles after the actual blanking is calculated in real time according to the 3D model in the blanking process, if the height is too low, the distance between the adjacent blanking positions after the actual blanking is reduced, and if the height is too low, the distance between the adjacent blanking positions after the actual blanking is increased.
Preferably, the loading method of the quantitative loading system further comprises a filling loading process, and the filling loading process is used for performing feeding operation, and specifically comprises the following steps: the material is filled in the cargo box and a plurality of material piles are formed, the vehicle moves forwards and backwards slowly, the top height of the material pile generated by filling the material is not higher than the maximum material discharging height, the system calculates the corresponding material discharging speed according to the actual shape and the height of each part of the material top in the cargo box on the 3D model, and the filling height difference between the maximum material discharging height and the actual height before filling the top at each position is in direct proportion to the material discharging speed at the position.
Preferably, after the material discharging process below the safe discharging height is completed when the quantitative loading system automatically loads for the first time, the condition that the actual loading quantity is not enough to be preassembled is met, at this time, the discharging opening is positioned at the discharging position at the rearmost part of the vehicle, the vehicle slowly backs up backwards, and the loading method of the quantitative loading system adopts the filling loading process to load.
Preferably, the quantitative loading system further comprises a laser radar arranged near the feed opening, cameras arranged on the front side and the rear side of the bin and capable of acquiring images of the top of the cargo box, and a ranging sensor arranged on a fixed structure on the outer side of the feed opening and used for ranging towards the right lower side, wherein the ranging sensor adopts an ultrasonic ranging sensor; the laser radar is used for acquiring radar point cloud data, the system carries out 3D modeling on the basis of the radar point cloud data through an automatic loading intelligent detection algorithm which is trained independently, the camera acquires images of the top of the cargo box to identify the relative height of the top of the material pile relative to the cargo box, and the ranging sensor is arranged on a fixed structure of the blanking opening and is used for measuring the absolute height of the material below the blanking opening; the relative height acquired and identified by the camera is used for correcting local data of a material pile model in 3D modeling, and the absolute height measured by the ranging sensor is used as a height reference of the same position of the 3D modeling to adjust the data of the whole model.
Preferably, the quantitative loading system comprises a stock bin, a flashboard arranged at an opening at the bottom of the stock bin, a loading belt scale arranged below the flashboard, a loading machine arranged below a discharge end of the loading belt scale and a loading wagon balance arranged on the ground below the loading machine; the loading machine is provided with a lifting discharger serving as a discharging opening, the length of the loading wagon balance is not smaller than the sum of the total length of the vehicle and the total length of a cargo compartment of the vehicle, and the vehicle is positioned on the loading wagon balance in the automatic loading process.
Preferably, the quantitative loading system comprises a stock bin fixedly arranged, a switch pneumatic valve arranged at the bottom opening of the stock bin, a bulk weighing scale communicated with the switch pneumatic valve and a loading machine positioned below a discharge hole of the bulk weighing scale; the loading machine is provided with a lifting discharger serving as a discharging opening, and the bulk weighing scale is a solid flowmeter or a rotor scale.
The invention has the advantages that: the system and the method have the advantages that the information transmission between the upstream and the downstream is completed, meanwhile, the system comprises a marketing system, a marketing logistics information management system, a quantitative loading system and a centralized control room, multiple systems respond interactively, the running reliability of the system is improved, the accurate control of quantitative automatic loading on the loading quantity is ensured, and the problems that the loading quantity rechecking order requirement is difficult to control, such as overdriving quantity overdriving, following loading delivery and the like of a driver are avoided.
The scheme uses the 3D modeling of the 32-line laser radar to scan the vehicle condition and the material level height in real time, and has higher accuracy and precision; an AI artificial intelligence algorithm is adopted, the manual operation is learned autonomously, and the automatic loading is controlled intelligently; and the information acquisition capacity of the automatic loading is improved by comprehensively detecting through a plurality of sensors and correcting the 3D modeling result through other sensor signals, and the real-time adjustment of the blanking position interval according to the real-time 3D modeling is realized through the novel automatic loading method, so that the dynamic monitoring and the dynamic control of the automatic loading are realized. The scheme also utilizes the filling loading process to realize a small amount of loading requirements under the error condition or the condition that the loading is close to the safety limit, and ensures that the actual loading quantity accords with the preassembly quantity provided by the order information.
Drawings
Fig. 1 is a schematic structural diagram of the anti-cheating integrated system for quantitative loading of bulk materials.
Fig. 2 is a system architecture diagram of the bulk material quantitative loading anti-cheating integrated system of the present invention.
FIG. 3 is a schematic view of the construction of a field installation of the quantitative loading system of the present invention.
Fig. 4 is a workflow diagram of the bulk material quantitative loading anti-cheating integrated system of the present invention.
FIG. 5 is a schematic illustration of a single facility of the quantitative loading system in the under-metering control mode of the present invention.
FIG. 6 is a schematic diagram of a single facility of the quantitative loading system in the overhead metering control mode of the present invention.
The marks in the drawings are: 1. the automatic loading device comprises a blanking opening, 2, a laser radar, 3, a cargo compartment, 4, an RFID detection module, 5, an electric bell, 6, a sound column, 7, a voice extension, 8, an LED screen, 9, a stock bin, 10, a flashboard, 11, a liftable discharger, 12, a camera, 13, a loading wagon balance, 14, a PLC (programmable logic controller), 15 and a rotor balance.
Detailed Description
The following detailed description of the embodiments of the invention, given by way of example only, is presented in the accompanying drawings to aid in a more complete, accurate, and thorough understanding of the inventive concepts and aspects of the invention by those skilled in the art.
As shown in fig. 1-6, the mobile phone end in the bulk material quantitative loading anti-cheating integrated system is based on a JAVA platform, and the system adopts an SSM expansion architecture mainly comprising springc 4.0 which is the most advanced under a J2EE architecture. The web page end is B/S architecture design, and is simple and convenient to use, upgrade and expand. The method is compatible with a mainstream relational database platform MySQL/SQL Server/Oracle, and can effectively support enterprise applications of a group company level.
The system deploys a control terminal taking the PLC controller as a core at a key place, so as to realize key data acquisition and logic locking control of equipment; the uploading of the acquired data and the issuing of a system platform control command are realized through OPC service; and the construction of the on-site upper computer control system is realized by applying the configuration software platform. Therefore, the control of the on-site discharging equipment is realized by a mature and stable technology.
Aiming at vehicle loading state analysis, the system models on the basis of radar point cloud data through an autonomous-training automatic loading intelligent detection algorithm, analyzes the position and loading state of a field vehicle in real time, and assists in controlling field equipment to finish the loading process.
The control terminal taking the PLC controller as a core is deployed on site, and original key control equipment on site, such as a power distribution station, related belts and protection, a hydraulic station, a flashboard 10, a belt scale, a solid flowmeter, a bin discharging device and the like, are connected to the PLC controller, so that stable data acquisition and equipment control are realized by using a mature control technology; meanwhile, an OPC server is deployed and used as a middle layer to receive and forward PLC data and write the data into the PLC; and the upper computer control terminal taking the configuration software as a core is deployed on site and used as a site control and display center.
The system not only can realize the centralized control of the loading equipment, but also needs to verify the loading service and the vehicle, and the whole loading process is controlled in an auxiliary manner, so that the whole service is controllable. The system deploys a card swiping terminal and a license plate recognition terminal on site to acquire the service vehicle and service information, and compares the service vehicle and the service information with the original information of a shipping system to avoid misloading or cheating; if the site is in a warehouse and is under a pound, the instrument data can be accessed, so that the loading data is more accurate; and is equipped with information prompting equipment, such as an electric bell 5, a display screen and the like, for prompting the next action of a driver; the service control equipment is connected to the embedded acquisition equipment and uploads and transmits data through hardware service. The identification mode can also adopt a vehicle-mounted RFID technology, and the RFID information of the vehicle is identified through an RFID detection module arranged on a loading site to replace a hairpin, and the RFID information of the vehicle is written in during dispatching.
In order to collect information such as vehicle position, conditions in a hopper and loading state, a laser radar 2 is deployed on site, the information is transmitted to an AI analysis server, an automatic loading intelligent detection algorithm models on the basis of radar point cloud data, key control problems are identified, and a PLC control system is assisted to perform automatic loading control. The bell 5 is used for ringing when loading is finished or abnormal conditions occur, and the short bell and the long bell respectively correspond to the two conditions. The sound column 6 is used for playing sound at the loading site, the voice extension 7 is used for inputting the sound of a driver at the loading site, and the LED screen is used for playing videos, images and characters for prompting the action of the driver.
The data acquisition and uploading are the basis of system realization, and the acquired data are divided into control data related to field loading equipment, control data related to service control equipment, control data related to AI analysis equipment and service data transmitted by an external system. The data is interfaced with the platform application system in a number of ways, such as OPC services, webservices, hardware services, AI algorithms, etc.
The system function is realized as the core of the platform, the platform management function is used for realizing the basic management of the platform, the service management function is used for realizing the auditing of various service information, various loading control modes and the real-time viewing and the retention of the on-site service video.
The system is connected with the delivery management system through the interface to acquire data, and the sales and marketing information management system can be connected with the inventory management system to acquire information of materials stored in the warehouse and the bin 9, so that the system interacts with other systems to complete intelligent judgment and control of the business; when the system is displayed, the management of the system can be finished through a service platform management interface, the display and control of the field device can be finished through an upper computer control interface, the video system is an independent operation system, and the video system can be displayed on a large screen in a centralized manner to assist management personnel to monitor or remotely load; while the system may extend the mobile end application.
The system also structurally comprises the following devices and corresponding control modules: dust removal integrated bulk machine control: the bulk machine mainly comprises a transmission bracket, a hoisting mechanism, a transmission device, a rope loosening mechanism, a channel steel seat, a material level gauge, a dust collection fan, a blanking pipe, a dust collection pipe and a bulk head. The material flows into the charging bucket by the dead weight through the discharging pipe, and the dust between the discharging pipe and the dust collecting pipe is discharged into a dust collecting bag or a dust warehouse through the dust collecting fan. The discharging pipe and the dust suction pipe are telescopic pipes, and the lifting of the bulk head is realized by a winch transmission system, a safety control device and a rope loosening mechanism by means of descending and ascending of the telescopic pipes.
Middleware program: and the content of the all-purpose card system: the system uploads the vehicle loading information (material variety, vehicle number information, vehicle tare weight, vehicle gross weight and the like), and downloads weighing data, order information, vehicle information and the like.
Video monitoring: and LED display, prompting driver loading information
Intelligent voice prompt: the voice module is added, radar detection and judgment are carried out, a driver is prompted through power amplification, sound column 6 or electric bell 5 sound amplification, the vehicle is moved forwards, stops, moves backwards, moves leftwards and moves rightwards, and intelligent voice prompt is used for controlling loading.
Specifically, the bulk material quantitative loading anti-cheating integrated system comprises a sales system, a sales logistics information management system, a quantitative loading system and a centralized control room, wherein the sales system is used for acquiring and maintaining order information, dispatching vehicles before entering a factory and self-service dispatching vehicles to achieve binding of the vehicles and the order information, the sales logistics information management system is used for weighing the vehicles once in the factory, automatically identifying the vehicles and checking the vehicles with information input by an inserting card, judging whether the material residual quantity of the quantitative loading system meets the pre-loading quantity of the materials according to the order information after the verification, selecting early warning or allowing the quantitative loading system to load according to the judgment result of the verification result and the material residual quantity, the quantitative loading system is used for positioning the vehicles and prompting the vehicles to move according to loading requirements, stopping loading the vehicles after the actual loading quantity of the automatic loading vehicles reaches the pre-loading quantity, the sales logistics information management system is also used for weighing the vehicles twice and checking the information of the vehicles, comparing the calculated weights of the vehicles with the pre-loading quantity with the information of the inserting card, comparing the calculated weights of the vehicles with the calculated weights of the vehicles after the pre-loading quantity reaches the pre-loading quantity, and comparing the calculated weights with the pre-loading quantity with the threshold value when the pre-loading quantity is smaller than the threshold value, and comparing the calculated values with the allowable loading quantity is greater than the threshold value when the threshold value is not smaller than the threshold value, and the practical loading system is calculated, and the loading system is larger than the loading system is calculated, and the loading error is compared with the threshold value when the loading system is smaller than the threshold value is compared with the threshold if the loading system is smaller.
Wherein the pin system operates as follows.
Order information maintenance: and (5) sorting information acquired by an external system or manually input by a person into order information for storage and maintenance.
Front dispatch of vehicle in factory: and selecting a proper vehicle to dispatch according to the requirements of an external system or manual input so as to extract a proper amount of materials for transportation.
Self-help card issuing by driver: and writing relevant order information into a new card to be issued according to the order information in the self-service card issuing system, wherein the order information at least comprises vehicle model requirements, material types and quantity and preassembly quantity information corresponding to the order, and the vehicle binds the order information and the preassembly quantity information.
The sales logistics information management system comprises the following steps when the automatic loading is operated.
Vehicle is weighed once in factory: the vehicle was weighed once on the wagon balance as it entered the factory: the obtained primary weighing result is used as the basis for calculation.
And warehousing the vehicle, and identifying the vehicle number information by RFID or vehicle number identification.
The driver gets off the vehicle to insert the vehicle card, and the supply and sales logistics information management system collects order information and preassembly amount information.
And detecting whether the vehicle number and the material variety information meet the consistency of order information or not, and acquiring whether the residual quantity of materials in the quantitative loading system meets the preassembly quantity requirement or not.
When the information is consistent and the material residual quantity is sufficient, the loading controller is electrified, and pre-loading information and loading permission signals are pushed to the quantitative loading system; otherwise, the system early warning is not electrified.
When the residual quantity of the materials is insufficient, the system supplements the materials to the storage bin 9 through the material supplementing system, and when the supplementing materials are sufficient, the system pushes the preassembly quantity information and allows loading signals. When the vehicle information is inconsistent with the vehicle object bound by the order information, an early warning signal is sent to require transportation personnel to exchange and correct the vehicle, and the work of detecting the vehicle number and the material variety information after the vehicle is put in storage is repeated.
The quantitative loading system comprises the following steps: after receiving a loading signal, the quantitative loading control system firstly verifies whether the vehicle stops at a designated position; otherwise, the automatic loading is not performed, and a driver is not allowed to control devices such as a loading machine through a button, and the loading machine is provided with a liftable discharger 11 as a discharging opening 1.
The vehicle position judging device is divided into an infrared grating and a positioning radar: the positioning radar is arranged beside the loader and applied to two modes of a weighing scale and a wagon balance, and the infrared grating is arranged at two ends of the wagon balance and only applied to wagon balance mode selection.
The quantitative loading system monitors the position of the vehicle in real time in the whole loading process, and automatically stops loading once the vehicle is not monitored.
After the vehicle position is judged to meet the requirements, the quantitative loading system prompts a vehicle driver through an LED to finish loading preparation work by self.
After loading preparation work is finished, a preparation completion button is pressed, and the quantitative loading system prompts a driver to control loading through an LED, so that the driver starts loading.
The driver presses the loading button to start loading, and the LED display screen displays the bulk loading prompt.
The quantitative loading system monitors the loading quantity in real time and compares the preassembly quantity.
When the actual loading amount is about to reach the preassembling amount, the quantitative loading system gradually reduces the discharging flow through the analog controller, and the valve is automatically closed until the preassembling amount is reached.
After the actual loading amount reaches the preassembled amount and the valve of the storage bin 9 is closed, the quantitative loading system automatically controls the loading machine to lift, the link of self-service control of the loading machine by a driver is omitted, and the pulling rope sensor equipment is required to be added when the loading machine is controlled to lift.
If the mechanism for automatically lifting the loading machine is not arranged or the mechanism cannot work, the quantitative loading system prompts loading completion through the LED display screen, and a driver gets off the vehicle to lift the loading machine head by self;
after the process is finished, the driver starts to drive out of the warehouse, and the quantitative loading system pushes the actual loading amount to the supply and marketing logistics information management system.
In order to collect and accurately identify the powdery material in real time to form a shape in the cargo compartment 3 of the vehicle during automatic loading, whether the vehicle or the discharging opening 1 is required to move is judged so as to realize the change of the discharging position of the discharging opening 1 relative to the cargo compartment 3, so that the material can be uniformly loaded into the cargo compartment 3, the situation that the material is locally stacked in the cargo compartment 3 too high is avoided, and the material is prevented from being scattered outwards to cause material waste and safety risk when the material moves or is vibrated is avoided. In this scheme, the system is including locating near the laser radar 2 of feed opening 1, locates the camera 12 that both sides can gather cargo compartment 3 top image around the feed bin 9 and locate the range finding sensor that carries out range finding towards under on the feed opening 1 outside fixed knot constructs, range finding sensor adopts ultrasonic wave range finding sensor for avoiding the influence of raise dust to light.
Wherein the camera 12 collects images of the top of the cargo box 3 and identifies the relative height of the top of the material pile at all positions relative to the cargo box 3 according to the relative position difference between the top edge line of the side wall of the cargo box 3 and the position of the top of the material; the laser radar 2 is a 32-line laser radar 2 and is used for collecting radar point cloud data, the system carries out 3D modeling based on the radar point cloud data through an autonomous-training automatic loading intelligent detection algorithm to analyze the position and loading state of the on-site vehicle in real time, and the on-site device is controlled in an auxiliary mode to complete the loading process. The distance measuring sensor is arranged on the fixed structure, and the height of the distance measuring sensor is unchanged when the blanking port 1 can lift the lifting discharger 11, and the distance measuring sensor is specially used for measuring the absolute height of the material below the blanking port 1. Because the powdery material is easy to generate dust during blanking, and light is disturbed, a single sensor is often easy to generate larger error during optical detection. The data of the material pile model in the 3D modeling is corrected based on the relative height acquired and identified by the camera 12, and the absolute height of the material below the feed opening 1 measured by the ranging sensor is used as a height reference of the same position of the 3D modeling to adjust the data of the whole model because of higher accuracy. The system adopts the three detection devices to collect, identify and analyze the data of the material pile in a plurality of modes from multiple angles, so that the interference caused by dust emission is reduced.
The 3D modeling formed after the adjustment can be used to determine whether to adjust the position of the discharging opening 1 relative to the cargo compartment 3, but in order to ensure that the actual loading amount of the discharging matches the preassembly amount and ensure the safety of the discharging process, the system firstly sets the safe discharging height during the discharging, that is, the maximum height that the material pile will not spill outwards when moving, and because the top of the highest material pile is usually tapered, the safe discharging height is usually slightly higher than the top edge of the side wall of the cargo compartment 3, and meanwhile, the bottom edge of the tapered top of the material pile is lower than the top edge of the side wall of the cargo compartment 3 and is enough to accommodate the falling material when the top falls.
In the automatic loading process, the system firstly controls the discharging opening 1 to sequentially discharge materials for a plurality of times from front to back relative to the longitudinal direction of the cargo box 3 to enable the cargo box 3 to be gradually full of the materials, so that a driver can not move too many times of vehicles while the process is ensured to realize enough actual loading, and the moving distance is not easy to control and too much time is consumed on the moving vehicles. And if the actual loading quantity reaches the preassembly quantity, stopping the unloading immediately, otherwise, controlling the unloading speed through a 3D model formed by modeling, gradually reducing the unloading speed after the distance from the top of the material pile to the safe unloading height reaches a certain threshold value, and stopping the unloading until the material pile height reaches the safe unloading height. The distance that the driver moved the vehicle forward when the unloading of once was accomplished equals the interval of adjacent unloading position, and the interval of each unloading position is set according to the proportion of goods railway carriage or compartment 3 size and safe unloading height in order to guarantee that the low valley bottom height that forms between the adjacent material heap is unlikely to too low and the displacement distance is unlikely to be too little, and the driver is with the distance that the vehicle moved forward when the unloading of once is accomplished equal to the interval of adjacent unloading position, and the feed opening 1 does not unloading in the removal process. And calculating the height of the center of the valley region between the tops of adjacent material piles after actual blanking in real time according to the 3D model in the blanking process, if the height is too low, reducing the distance between the adjacent blanking positions, otherwise, increasing the distance between the adjacent blanking positions.
After the loading process fills the loading box 3 and the material pile heights reach the safe loading height, if the actual loading amount is not enough, the loading process is filled, the loading box 3 is filled with materials and a plurality of material piles are formed, and the loading opening 1 is positioned at the loading position at the rearmost of the vehicle. The system calculates and determines the center of the valley area between the tops of adjacent material piles as a filling and blanking area through a 3D model, and slowly moves to each filling and blanking area from back to front relative to the longitudinal direction of the cargo box 3 to perform filling and blanking, wherein the height of the tops of the material piles generated by filling and blanking is not higher than the maximum blanking height, and the maximum blanking height is the height of the material piles in the cargo box 3 in a normal running process, which is safe and not easy to spill. When filling and discharging are started, a driver starts the vehicle to slowly reverse backwards, the system calculates the corresponding discharging speed according to the actual shape and the height of each part of the top of the material in the cargo box 3 on the 3D model, wherein the top of the material comprises all the valley areas and the top of the material pile formed before, the discharging speed is maximum at the center of the valley areas in the moving process, the position of the top of each material pile is minimum, and the highest value of the top of the material in the discharging process is ensured not to be larger than the maximum discharging height. Therefore, the system sets a maximum reference height, the maximum reference height is lower than the maximum blanking height, the height is determined according to the maximum blanking speed in the filling and loading process, and a material pile higher than the maximum blanking height can not be formed locally at the corresponding maximum blanking speed under the minimum reversing speed of the vehicle. The difference between the maximum reference height and the actual height before filling the top of each position is proportional to the blanking speed of the position.
The control modes of the quantitative loading system are divided into a lower metering control mode and an upper metering control mode according to the difference of the setting structure and the metering mode.
In the underneath metering control mode, the quantitative loading system structurally comprises: the truck loading belt scale comprises a storage bin 9, a flashboard 10, a truck loading belt scale, a truck loading machine and a wagon balance 13, wherein the flashboard 10 is fixedly arranged at an opening at the bottom of the storage bin 9, the truck loading belt scale is arranged below the flashboard 10, the truck loading machine is positioned below a discharge end of the truck loading belt scale, and the wagon balance 13 is positioned on the ground below the truck loading machine. The discharging end of the loading belt scale can be additionally provided with a device for further accurately measuring the discharging amount such as a rotor scale 15, and if the measuring result of the rotor scale 15 is inconsistent with the loading belt scale, the rotor scale 15 is used as the standard. The length of the wagon balance 13 for loading is not smaller than the sum of the total length of the vehicle and the total length of the cargo box 3 of the vehicle, so that the reliability of the wagon balance in the total weight detection of the vehicle in the whole loading process is guaranteed under the two conditions that the forefront end of the cargo box 3 is located below the liftable discharger 11 and the rearmost end of the cargo box 3 is located below the liftable discharger 11.
In the overhead metering control mode, the quantitative loading system structurally comprises: the bulk weighing scale comprises a stock bin 9 fixedly arranged, a switch pneumatic valve arranged at the opening of the bottom of the stock bin 9 and a bulk weighing scale communicated with the switch pneumatic valve, wherein the bulk weighing scale is a solid flowmeter or a rotor scale 15. The cargo box 3 of the vehicle is located below the liftable discharger 11 and advances or retreats according to the loading condition, thereby allowing the cargo box 3 to be uniformly filled with material everywhere in front and rear.
For large-capacity vehicles, the wagon balance weighing can avoid accumulated errors caused by long-time weighing of the bulk weighing scale, so that the weighing effect is more accurate; the bulk weighing scale can be used for weighing the current accumulated discharge quantity at any time, is sensitive to the change of the discharge quantity increment caused by the change of the discharge speed, and can calculate the feeding quantity of the cargo box 3 more rapidly to judge whether to move the vehicle to adjust the discharging position of the cargo box 3.
The sales logistics information management system comprises the following steps when the sales logistics information management system operates after automatic loading.
And (5) carrying out secondary weighing through the wagon balance when the vehicle leaves the factory.
Besides normal business judgment, the supply and sales logistics information management system has a weight comparison judgment function, the wagon balance weight obtained by secondary weighing is subtracted from the wagon balance weight obtained by primary weighing to obtain the increased weight of the loaded vehicle, the weight increase value is close to the actual loading amount under normal conditions, few powdery materials possibly fall off from the top of the vehicle during transportation and movement, but the error value is smaller than a certain threshold (the maximum value of errors possibly occurring is counted through multiple experiments and is used as the threshold), and the system configuration compares the error value with the preassembly amount to determine whether the error is within an error control range.
The comparison error is within the error control range (0-2 tons), and the weighing and delivery are normally carried out when the error is small; and if the error is slightly larger, corresponding discharging or feeding work is carried out according to the positive and negative values of the error, generally, the quantitative loading system is returned, corresponding discharging or feeding work is carried out according to the calculated comparison error, and the previous weighing and weight comparison process is repeated when leaving a factory.
The staff in the centralized control room monitors through the quantitative loading system, when the vehicle position judgment occurs and the real-time monitoring of the vehicle position is abnormal, the staff on duty can conduct centralized processing on abnormal conditions, the loading process is remotely controlled when site abnormality cannot be solved, and loading prompts can be provided through voice or LED screens on loading sites, so that a driver can load.
When the error exceeds the control range, the system early warning is performed, and human intervention is needed, so that the error exceeds the normal possible situation, and human intervention is needed to prevent the malicious cheating of the driver.
While the invention has been described above with reference to the accompanying drawings, it will be apparent that the invention is not limited to the above embodiments, but is capable of being modified or applied to other applications without modification, as long as various insubstantial modifications of the inventive concept and technical solutions are adopted, all within the scope of the invention.
Claims (6)
1. Anti-cheating integrated system for quantitatively loading bulk materials, which is characterized in that: the system comprises a sales system, a sales logistics information management system and a quantitative loading system, wherein the sales system is used for acquiring order information, dispatching vehicles and self-service card dispatching of the dispatched vehicles to achieve binding of the vehicles and the order information, the sales logistics information management system is used for weighing the vehicles in a travelling factory once, automatically identifying and checking the vehicles, determining the preassembly amount of the materials according to the order information after checking and judging whether the material residual quantity of the quantitative loading system meets the preassembly amount of the materials, the quantitative loading system is used for positioning the vehicles and prompting the vehicles to move according to loading demands to achieve automatic loading of the materials, controlling the automatic loading to stop after the actual loading amount reaches the preassembly amount, and the sales logistics information management system is also used for weighing the vehicles ready for delivery for a second time to calculate the weight increment value after the loading of the vehicles, comparing the increment weight with the preassembly amount to obtain the comparison error between the weight increment value and the preassembly amount, judging whether the vehicles are allowed to leave, whether the replenishing and discharging operations are carried out according to the comparison error and whether the reason is checked by a discharging manager;
when the quantitative loading system is used for automatic loading, firstly, the longitudinal direction of a loading opening (1) relative to a cargo box (3) is controlled to sequentially load materials for a plurality of times from front to back, when one-time loading is completed, the distance of the forward movement of a vehicle by a driver is equal to the distance between adjacent loading positions, the top of a material pile is formed by single-time loading, namely, the maximum height of the material pile which cannot be scattered outwards completely when the vehicle moves is not higher than the safety unloading height, the loading is stopped immediately when the actual loading amount reaches the preassembly amount in the unloading process, otherwise, the unloading speed is controlled by a 3D model formed by modeling, and the unloading speed is gradually reduced after the distance from the top of the material pile to the safety unloading height reaches a certain threshold value until the material pile height reaches the safety unloading height, and then the unloading is stopped;
the distance between the blanking positions is set according to the size of the cargo box (3) and the proportion of the safe blanking height, the height of the center of the valley area between the tops of the adjacent material piles after the actual blanking is calculated in real time according to the 3D model in the blanking process, if the height is too low, the distance between the adjacent blanking positions after the actual blanking is reduced, and if the height is too low, the distance between the adjacent blanking positions after the actual blanking is increased.
2. The bulk material quantitative loading anti-cheating integrated system as claimed in claim 1, wherein: the loading method of the quantitative loading system further comprises a filling loading process, and the loading method is used for carrying out material supplementing operation and specifically comprises the following steps: the material is filled in the cargo box (3) and a plurality of material piles are formed, the vehicle moves forwards and backwards slowly, the top height of the material piles generated by filling the material is not higher than the maximum material discharging height, the system calculates the corresponding material discharging speed according to the actual shape and the height of each part of the material top in the cargo box (3) on the 3D model, and the filling height difference between the maximum material discharging height and the actual height before filling the top of each position is in direct proportion to the material discharging speed of the position.
3. The bulk material quantitative loading anti-cheating integrated system as claimed in claim 2, wherein: after the material discharging process below the safe discharging height is completed when the quantitative loading system automatically loads for the first time, the condition that the actual loading quantity is insufficient and the preassembly quantity is met, the discharging opening (1) is positioned at the discharging position at the rearmost part of the vehicle, the vehicle slowly backs up backwards, and the loading method of the quantitative loading system adopts the filling loading process to load.
4. A bulk material quantitative loading anti-cheating integrated system according to any one of claims 1-3, characterized in that: the quantitative loading system also comprises a laser radar (2) arranged near the feed opening (1), cameras (12) arranged on the front side and the rear side of the storage bin (9) and capable of acquiring images of the top of the cargo box (3), and a ranging sensor arranged on a fixed structure on the outer side of the feed opening (1) and used for ranging towards the right lower side, wherein the ranging sensor adopts an ultrasonic ranging sensor; the laser radar (2) is used for acquiring radar point cloud data, the system carries out 3D modeling on the basis of the radar point cloud data through an automatic loading intelligent detection algorithm which is trained independently, the camera (12) acquires images of the top of the cargo box (3) to identify the relative height of the top of the material pile at all positions relative to the cargo box (3), and the ranging sensor is arranged on a fixed structure of the blanking opening (1) and is used for measuring the absolute height of the material below the blanking opening (1); the relative height acquired and identified by the camera (12) is used for correcting local data of a material pile model in 3D modeling, and the absolute height measured by the ranging sensor is used as a height reference of the same position of the 3D modeling to adjust the data of the whole model.
5. The bulk material quantitative loading anti-cheating integrated system as claimed in claim 4, wherein: the quantitative loading system comprises a bin (9) which is fixedly arranged, a flashboard (10) which is arranged at the opening of the bottom of the bin (9), a loading belt scale which is arranged below the flashboard (10), a loading machine which is arranged below the discharge end of the loading belt scale, and a loading wagon balance (13) which is arranged on the ground below the loading machine; the loading machine is provided with a lifting discharger (11) serving as a discharging opening (1), the length of the loading wagon balance (13) is not smaller than the sum of the total length of the vehicle and the total length of a cargo compartment (3) of the vehicle, and the vehicle is located on the loading wagon balance (13) in the automatic loading process.
6. The bulk material quantitative loading anti-cheating integrated system as claimed in claim 4, wherein: the quantitative loading system comprises a stock bin (9) which is fixedly arranged, a switch pneumatic valve which is arranged at the opening of the bottom of the stock bin (9), a bulk weighing scale which is communicated with the switch pneumatic valve, and a loading machine which is positioned below a discharge hole of the bulk weighing scale; the loading machine is provided with a lifting discharger (11) as a discharging opening (1), and the bulk weighing scale is a solid flowmeter or a rotor scale (15).
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| CN114394445A (en) * | 2022-01-13 | 2022-04-26 | 青岛杰瑞工控技术有限公司 | Port granary intelligent loading and unloading system based on industrial internet |
| CN115092713A (en) * | 2022-04-07 | 2022-09-23 | 青岛澳科仪器有限责任公司 | Material quantitative loading system and automatic loading method thereof |
| CN114751215A (en) * | 2022-05-10 | 2022-07-15 | 谭秀芬 | Unmanned quick accurate loading system |
| CN115092705A (en) * | 2022-07-04 | 2022-09-23 | 中国电建集团西北勘测设计研究院有限公司 | Bulk material loading method and system |
| CN115724221A (en) * | 2022-11-15 | 2023-03-03 | 大连科润重工起重机有限公司 | Intelligent bulk material feeding system |
| CN117657832B (en) * | 2024-01-31 | 2024-05-07 | 四川吉埃智能科技有限公司 | Quantitative unmanned loading system and control method |
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