CN116101901A - Unmanned grab ship unloader control system and control method - Google Patents
Unmanned grab ship unloader control system and control method Download PDFInfo
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- CN116101901A CN116101901A CN202211716135.9A CN202211716135A CN116101901A CN 116101901 A CN116101901 A CN 116101901A CN 202211716135 A CN202211716135 A CN 202211716135A CN 116101901 A CN116101901 A CN 116101901A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/16—Applications of indicating, registering, or weighing devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/18—Control systems or devices
- B66C13/22—Control systems or devices for electric drives
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/18—Control systems or devices
- B66C13/40—Applications of devices for transmitting control pulses; Applications of remote control devices
- B66C13/44—Electrical transmitters
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C19/00—Cranes comprising trolleys or crabs running on fixed or movable bridges or gantries
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C2700/00—Cranes
- B66C2700/01—General aspects of mobile cranes, overhead travelling cranes, gantry cranes, loading bridges, cranes for building ships on slipways, cranes for foundries or cranes for public works
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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
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- 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
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention provides a control system and a control method of an unmanned grab ship unloader, wherein the control system comprises the following steps: the machine-mounted control unit is arranged on the grab ship unloader equipment and is used for driving all mechanisms of the grab ship unloader to operate under the control of the remote control unit so as to perform unmanned ship unloading operation; the remote control unit is arranged in the central control room and is used for sending a control instruction to the airborne control unit according to the real-time data acquired by the video monitoring management unit and the decision obtained by the decision analysis unit; the video monitoring management unit is used for realizing omnibearing monitoring on the operation of the grab ship unloader; the decision analysis unit is arranged in an industrial computer in the remote control cabinet of the central control room and is used for carrying out decision analysis on the ship unloading operation of the unmanned grab ship unloader according to the real-time data acquired by the video monitoring management unit. The invention realizes automatic dynamic tracking planning and intelligent real-time scheduling of the operation tasks on the basis of ensuring the real-time performance of the automatic operation data processing of the grab ship unloader.
Description
Technical Field
The invention relates to the technical field of intelligent control, in particular to a control system and a control method of an unmanned grab ship unloader.
Background
The grab ship unloader is used as important ship unloading equipment of bulk cargo wharf, and the operation mode of semi-automatic and manual combination is adopted at present, so that the intelligent and unmanned degree is low. The development of unmanned grab ship unloader control systems has become a development trend under the current age background of advocating the development of artificial intelligence and intelligent manufacturing. In addition, the manual operation of a driver controls the grab ship unloader to carry out ship unloading operation, so that the labor intensity is high and the working environment is poor; the acquisition of the operation task, the cabin moving and the ship unloading operation are completely dependent on manual work, and the operation efficiency, the operation safety and the like cannot be well ensured.
Disclosure of Invention
The invention aims to provide an unmanned grab ship unloader control system and a control method, which realize automatic dynamic tracking planning and intelligent real-time scheduling of an operation task, improve safety and reduce labor cost on the basis of guaranteeing the real-time performance of automatic operation data processing of the grab ship unloader.
For this purpose, the invention provides the following technical scheme:
the invention provides a control system of an unmanned grab ship unloader, which comprises the following components:
the system comprises an airborne control unit, a remote control unit, a video monitoring management unit and a decision analysis unit, wherein the data transmission among the units adopts an Ethernet communication protocol;
the machine-mounted control unit is arranged on grab ship unloader equipment and is used for driving all mechanisms of the grab ship unloader to operate under the control of the remote control unit so as to perform unmanned ship unloading operation;
the remote control unit is arranged in the central control room and is used for sending a control instruction to the airborne control unit according to the real-time data acquired by the video monitoring management unit and the decision obtained by the decision analysis unit so as to realize remote on duty of the working states of the grab ship unloader and the conveying operation line;
the video monitoring management unit comprises a plurality of video monitoring cameras arranged on grab ship unloader equipment and is used for realizing omnibearing monitoring on the operation of the grab ship unloader;
the decision analysis unit is arranged in an industrial computer in the remote control cabinet of the central control room and is used for carrying out decision analysis on ship unloading operation of the unmanned grab ship unloader according to real-time data acquired by the video monitoring management unit, the downward stepping operation is adopted in the grabbing direction, the sea side and the land side are adopted in the trolley direction, the control strategy of preventing the bucket burying is adopted, and the furrow stepping operation is adopted in the trolley direction, so that the single-cabin task planning function is realized.
The invention also provides a control method of the unmanned grab ship unloader, which is applied to the control system of the unmanned grab ship unloader, and comprises the following steps:
the ship approaches the port, the on-board control unit starts to work, and the grab ship unloader is started in unmanned ship unloading operation; simultaneously, the video monitoring management unit starts to work, and the operation of the grab ship unloader is monitored in all directions;
lifting the arm support of the grab ship unloader;
the grab ship unloader runs along the large car track from the bow position to the stern direction to scan the ship;
after the ship is scanned, the grab ship unloader receives a hatch scheduling instruction sent by the remote control unit;
the grab ship unloader is operated to a target operation hatch;
the arm support of the grab ship unloader is put down, and the cab moves to the center position of the hatch;
scanning the hatch and the materials in the cabin;
the grab bucket moves to the position above the hatch, and the grab bucket pose detection function is activated;
the automatic ship unloading operation starts, and the grab ship unloading machine carries out ship unloading operation according to the decision given by the decision analysis unit;
in the operation process, the grab ship unloader receives a remote control instruction of a remote control unit in real time;
when the current hatch works to the cabin needing to be cleared, an operator remotely operates the cabin clearing machine in a central control room to hoist the cabin to the cabin, and automatic cabin clearing work is started;
after the cabin cleaning is completed, unmanned ship unloading operation of the grab ship unloader is completed.
The invention has the advantages and positive effects that: according to the unmanned grab ship unloader control system and the unmanned grab ship unloader control method, on the basis of guaranteeing the real-time performance of automatic operation data processing of the grab ship unloader, automatic dynamic tracking planning and intelligent real-time scheduling of an operation task are achieved, so that the grab bucket of the ship unloader is high in efficiency and safety in ship unloading operation flows of closing and taking materials in a ship cabin, controlling the grab bucket to enter and exit the ship cabin, controlling the grab bucket to swing in the air, throwing the grab bucket and the like, and the safety is high and high in efficiency and reliability. The unmanned grab ship unloader control system technology is applied, the number of operators can be reduced to a great extent, the intelligent degree is high, and the labor cost is saved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings may be obtained according to the drawings without inventive effort to a person skilled in the art.
FIG. 1 is a schematic diagram of a control system of an unmanned grab ship unloader in an embodiment of the invention;
FIG. 2 is a schematic diagram of an on-board control unit according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a remote control unit according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of a video monitoring management unit according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of a remote operation and maintenance unit according to an embodiment of the present invention;
FIG. 6 is a flow chart of the automatic ship unloading operation control of the unmanned grab ship unloader in the embodiment of the invention.
Detailed Description
In order that those skilled in the art will better understand the present invention, a technical solution in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in which it is apparent that the described embodiments are only some embodiments of the present invention, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the present invention without making any inventive effort, shall fall within the scope of the present invention.
It should be noted that the terms "first," "second," and the like in the description and the claims of the present invention and the above figures are used for distinguishing between similar objects and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used may be interchanged where appropriate such that the embodiments of the invention described herein may be implemented in sequences other than those illustrated or otherwise described herein. Furthermore, the terms "comprises," "comprising," and "having," and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a list of steps or elements is not necessarily limited to those steps or elements expressly listed but may include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus.
As shown in fig. 1, the control system of the unmanned grab ship unloader in the embodiment of the invention mainly comprises: the system comprises an airborne control unit U1, a remote control unit U2, a video monitoring management unit U3, a remote operation and maintenance unit U4 and a decision analysis unit U5, wherein the data transmission among the units adopts an Ethernet communication protocol. Wherein:
and the machine-mounted control unit U1 is arranged on the grab ship unloader equipment and is used for driving each mechanism of the grab ship unloader to operate and carrying out ship unloading operation. As shown in fig. 2, includes: PLC processor, actuating mechanism, encoder and limit switch. The PLC processor is used for receiving the signals of the encoder and the limit switch and controlling the driving mechanism to finish the ship unloading action; the driving mechanism is used for receiving the instruction of the PLC processor and completing the corresponding ship unloading action; the encoder is used for measuring and calculating the running position of each driving mechanism; the limit switch is used for detecting the running state of each running mechanism.
The remote control unit U2, as shown in fig. 3, includes: the system can provide a safe interlocking control function for the grab ship unloader and the material conveying operation line, and a safe and reasonable material flow conveying start and stop control flow is formed. The central server is used for receiving the operation instruction of the wharf production scheduling system and the operation data of the airborne control unit and sending a ship unloading operation instruction to the airborne control unit; the remote operation platform is used for manual operation, manual intervention is performed when the unmanned grab ship unloader control system fails, the remote operation is used for removing the failure, and in addition, the remote operation platform can display video pictures acquired by the video monitoring management unit on a display of the remote operation platform in real time.
The video monitoring management unit U3 includes: the system comprises a video acquisition unit, a control unit and a monitoring display unit. The video acquisition unit consists of video monitoring cameras arranged at key positions on the grab ship unloader, and is used for acquiring video information of the whole grab ship unloader, and the specific camera arrangement is shown in fig. 4 and table 1. The control unit is arranged on the grab ship unloader motor, and comprises an optical fiber switch, a hard disk video recorder, a streaming media server and an Ethernet switch, and is used for receiving, transmitting, backing up and storing transmission data of the video acquisition unit, and simultaneously realizing the functions of automatic switching, automatic focusing, automatic following and the like of video monitoring pictures according to the actual operation working condition of the grab ship unloader. The monitoring display unit is divided into two parts, one part is an onboard monitoring display device arranged in a cab of the grab ship unloader, and the monitoring display device comprises a liquid crystal display and an onboard operation keyboard and is used for monitoring video images of operators during local operation of the grab ship unloader; the other part is a remote monitoring display device arranged at a remote operation station of the wharf central control room, and the remote monitoring display device comprises a liquid crystal display and a remote operation keyboard and is used for monitoring video images of operators when the grab ship unloader performs unmanned remote operation. That is, the video data collected by the video monitoring management unit U3 can be displayed on a display in the cab of the grab ship unloader and on a remote operation table in the central control room in the remote control unit U2, respectively. The video data between the video acquisition unit and the control unit is transmitted by an on-board optical fiber through an Ethernet protocol; the communication between the on-board monitoring display device of the cab and the control unit in the monitoring display unit is transmitted by an on-board optical fiber through an Ethernet protocol, and the communication between the remote monitoring display device of the remote operation station of the central control room of the wharf and the control unit is transmitted by an on-board optical fiber, a reel optical fiber and a wharf fixedly laid optical fiber through an Ethernet protocol.
TABLE 1
The remote operation and maintenance unit U4, as shown in fig. 5, includes: the monitoring picture 001, the operation desk 002, the industrial personal computer 003, the dispatching instruction sending device 004 and the on-site information acquisition device 005 are arranged in the grab ship unloader, and are used for realizing the work of remote debugging, remote operation and maintenance and the like of the grab ship unloader equipment. The monitoring picture, the operation desk, the industrial personal computer and the scheduling instruction sending device are all positioned in a remote debugging scheduling center and are respectively used for realizing the functions of on-site picture monitoring, remote operation, scheduling instruction data processing, scheduling instruction sending and the like; the on-site information acquisition device is positioned on the grab ship unloader and is used for acquiring on-site video and audio data of actual operation of the grab ship unloader.
The decision analysis unit U5 is arranged in an industrial computer in a remote control cabinet of the central control room and is used for decision analysis of ship unloading operation of the unmanned grab ship unloader, downward stepping operation is adopted in the grabbing direction, sea side and land side stepping operation are adopted in the trolley direction, control strategies of preventing bucket burying are adopted in the trolley direction, furrow stepping operation is adopted in the trolley direction, and a single cabin task planning function is achieved.
In a specific implementation, the on-board control unit U1 and the decision analysis unit U5 perform the unmanned grab ship unloader ship unloading operation in the following manner, and specifically comprises the following steps:
s101, in order to facilitate the control of grabbing materials by the grab ship unloader, dividing an operation area of an area in a cabin of the grab ship unloader into a plurality of operation units:
the operation unit is divided into n column operation combinations along the running direction of the cart, and each column operation combination is divided into m operation units along the running direction of the cart.
Further, in order to facilitate the planning of the ship unloading operation flow, the method further comprises the step of dividing the area in the grab ship unloading machine cabin into a left side anti-collision early warning area, a right side anti-collision early warning area, a sea side anti-collision early warning area, a land side anti-collision early warning area and a central operation area; left side anticollision early warning district: a region within a left-right range from the left hatch S along the traveling direction of the cart; the right side anticollision early warning area: a region within a left-right range from the right hatch S along the traveling direction of the cart; sea side anticollision early warning area: along the running direction of the trolley, the distance from the sea-side hatch S to the sea-land area except the left side and the right side anti-collision early warning areas; land side anti-collision early warning area: along the running direction of the trolley, the distance from the sea-side hatch S to the sea-land area except the left side and the right side anti-collision early warning areas; wherein S sea land is a sea land side anti-collision safety distance, and S is a left and right side anti-collision safety distance; central work area: and removing cabin areas except the left side anti-collision early warning area, the right side anti-collision early warning area, the sea side anti-collision early warning area and the land side anti-collision early warning area.
Further, in order to avoid collision risk of the grab bucket at the hatch of the grab bucket ship unloader, materials in the left side anti-collision early warning area, the right side anti-collision early warning area, the sea side anti-collision early warning area and the land side anti-collision early warning area in the cabin are not directly grabbed in the ship unloading operation process of the grab bucket ship unloader, so that the materials piled in the central operation area are required to be subjected to ship unloading operation flow planning; specifically, the central operation area is divided into a plurality of operation units: dividing n longitudinal operation combinations with the width of L according to the number n of the operation points of the cart along the running direction of the cart, wherein L is the length of the grab bucket; dividing each column operation combination into m operation units with length W along the running direction of the trolley; there are a total of m x n units of work in the central work area.
In this embodiment, the central working area has 7 cart working points in the cart running direction, and 7 column working combinations are corresponding, and 5 working units are divided in each column combination along the cart running direction, so that the central working area has 35 working units in total.
S102, before ship unloading operation starts, monitoring material accumulation conditions of all operation units in an operation area in real time through a grab ship unloader, and selecting an initial operation unit; starting from the initial operation unit, completing the ship unloading operation of the materials piled in the central operation area according to the steps S103 to S105;
the method comprises the steps of scanning and identifying the height of material accumulation in each operation unit through a grab ship unloader, calculating the average height of material accumulation in all operation units in each column of column operation combination, selecting the column operation combination with the highest average height of material accumulation as an initial operation combination, and selecting the operation unit with the highest material accumulation height as the initial operation unit in the operation units in the initial operation combination, wherein the selected initial operation unit is beneficial to material filling when the grab grabs materials, has more grabbing quantity, and can avoid risks such as bucket burying and grab dumping.
S103, a first control strategy (grabbing direction control strategy): step-down operation, which gives consideration to preventing the bucket burying;
the operation flow sequentially comprises the steps of closed bucket material taking, air flight, hopper material discharging and control return.
When arctan (H) Height difference /L Center distance )>ω Stacking angle When the bucket burying risk exists, the bucket burying risk does not exist; wherein H is Height difference For the height difference of the material accumulation of the current operation unit and the peripheral operation units, L Center distance For the horizontal center distance omega between the current operation unit and the peripheral operation units Stacking angle The natural stacking angle of the materials in the current operation unit is set; the bucket burying risk means that when the current operation unit point positions continue to operate, materials at the peripheral operation unit point positions naturally slide down to bury the grab buckets at the current operation unit point positions, and in order to avoid the bucket burying risk, the operation method provided by the invention timely adjusts the direction of the trolley in a stepping manner according to the grab bucket burying risk judging principle. In the embodiment of the invention, the material accumulation condition of each operation unit in the operation area is monitored in real time by adopting a laser scanning identification technology, wherein the material accumulation condition comprises the height of material accumulation and the natural accumulation angle of the material.
After the grab bucket is controlled to reach the operation unit, one operation flow is completed, and then whether the bucket burying risk exists or not is judged according to the material accumulation conditions of the current operation unit and the peripheral operation units: if no bucket burying risk exists, controlling the grab bucket to step downwards in the current operation unit and judging the operation flow of the next cycle and the bucket burying risk until the current operation unit finishes unloading, and entering step S104; if there is a risk of burying the grab bucket, the grab bucket is stopped stepping downwards at the point of the current operation unit, and the step S104 is entered.
S104, a second control strategy (trolley direction control strategy): the sea side and the land side respectively perform stepping operation, and prevent the bucket burying;
controlling the grab bucket to move to the next operation unit step by step along the column operation combination where the current operation unit is located, and repeating the step S103 in the next operation unit; if the grab bucket reaches the sea side edge, stepping to the land side to move to the next operation unit; when all the operation units in the column operation combination where the current operation unit is located have completed the above operation, the process proceeds to step S105.
S105, a third control strategy (cart direction control strategy): furrow type stepping operation;
all column operation combinations are numbered according to the sequence, and then divided into two subgroups according to the parity of the numbers; and (3) controlling the grab bucket to move from one operation unit of the final operation of the step S104 to the corresponding operation unit in other column operation combinations in the group to which the column operation combination of the operation unit belongs in a stepping manner along the operation direction of the cart, repeating the step S103 and the step S104 until all operation units in all column operation combinations in the group are unloaded, then controlling the grab bucket to move from the operation unit of each column operation combination in the other group in the stepping manner along the operation direction of the cart, and repeating the step S103 and the step S104 until all operation units in the operation area are unloaded, thereby indicating that the ship unloading operation is completed.
The cart direction control strategy provided by the invention adopts a stepping mode by combining operation at intervals of one column, and aims to enable materials in a central operation area to form furrow type accumulation, so that a better material filling rate can be obtained in the process of grabbing a grab bucket by closing the grab bucket.
In specific implementation, the remote control unit U2 realizes remote duty on the working states of the grab ship unloader and the material conveying line by carrying out cooperative control on the airborne control unit U1 and the material conveying line control unit. Wherein, defeated material line control unit sets up in the defeated material line of pier, accomplishes the operation that the material was transported by the pier to rear stock ground through pier belt, transfer station, transportation belt. The material conveying line control unit specifically comprises: wharf belt driving mechanism and detection element thereof, transfer station material handling mechanism and detection element thereof, and transfer belt driving mechanism and detection element thereof. The dock belt driving mechanism and the detection element thereof are used for conveying materials from a discharging point of a dock ship unloader to a transfer station and detecting the conveying state of the materials; the material handling mechanism of the transfer station and the detection element thereof are used for transferring materials from a wharf belt to a transfer belt and detecting the material transfer state; the transfer belt driving mechanism and the detection element thereof are used for conveying materials from a feeding point of a transfer station to a rear material field and detecting the material conveying state of the materials.
The control flow of the stream delivery start is as follows:
s201, a remote control unit U2 receives a material flow conveying starting instruction;
s202, starting a material yard device and a transfer belt;
s203, after the dock belt conveyor transfer belt at the transfer station is confirmed to be correctly docked, the dock belt is started;
s204, after the fact that the ship unloader feeding system is correctly docked with the wharf belt is confirmed, starting the ship unloader feeding system;
wherein the confirming comprises determining whether the feeding path of the feeding system of the ship unloader (such as feeding through the dock belt) in the feeding command sent by the central control system is consistent with the feeding path displayed by the current state of the feeding system of the ship unloader (such as current docking with the dock belt).
S205, completing the material flow conveying start, and formally operating the ship unloading and material conveying operation line.
The control flow of the stream delivery stop is as follows:
s301, a remote control unit U2 receives a material flow conveying stopping instruction;
s302, stopping feeding to a wharf belt by a ship unloader feeding system;
s303, stopping the operation of the wharf belt;
s304, stopping running of material yard equipment of the transfer belt conveyor;
s305, stopping conveying the material flow, and stopping the operation of the ship unloading and conveying line.
In specific implementation, the control unit in the video monitoring management unit U3 can realize the functions of automatic switching, automatic focusing, automatic following and the like of the video monitoring picture according to the actual operation working condition of the grab ship unloader.
When the grab ship unloader runs in main actions, the grab ship unloader can be automatically switched to the cameras corresponding to the combination in the display picture of the monitoring display unit, and the automatic switching control flow of the monitoring picture comprises the following steps:
s401, activating a monitoring picture automatic switching function;
s402, the arm support ascends and descends in a pitching mode, and monitoring pictures are automatically switched to cameras # 9, #10, #17, #22 and # 26;
s403, lifting, opening and closing, running the trolley, and automatically switching the monitoring picture to cameras # 1, #4, #17, #22 and # 26;
s404, the cart runs left, and the monitoring picture is automatically switched to cameras # 6, #11, #14 and # 16;
s405, the cart runs in the right direction, and the monitoring picture is automatically switched to cameras # 6, #12, #13 and # 15;
s406, completing the ship unloading operation, and closing the automatic switching function of the monitoring picture.
In the operation process of the ship unloader, the moving track of the grab bucket can be monitored in real time by the #4 camera, but in the operation process of the grab bucket, as the distance between the grab bucket and the camera is continuously changed, the camera also needs to be continuously focused, and a better monitoring picture can be obtained. Therefore, the system is provided with an automatic focusing function, and the image display of the optimal shooting size of the target object can be obtained in real time. The automatic focusing control flow of the monitoring picture comprises the following steps:
s501, activating an automatic focusing function of a monitoring picture;
s502, the grab bucket operates, and the camera automatically focuses;
s503, completing the ship unloading operation, and closing the automatic focusing function of the monitoring picture.
The autofocus scheme is as follows:
w focusing= (S target/S screen-50%) (W far focus-W near focus);
wherein, W focusing is a focal length adjusting value, S target is the size of a target object in a picture, S screen is the whole size of a screen in the picture, W far focus is the maximum focal length of far focus, and W near focus is the minimum focal length of near focus.
In the ship unloader operation process, can track the control in real time by #4 camera to grab bucket movement track, consequently the system need control # 4 camera angle to track the movement track of grab bucket in real time, the control flow is followed to the control flow automatically to the control picture includes:
s601, activating a monitoring picture automatic following function;
s602, the grab bucket runs, and the camera automatically follows;
s603, completing ship unloading operation, and closing the automatic following function of the monitoring picture.
The automatic following scheme is as follows:
omega shot = arctan ((L grab-L shot)/(H shoot-H grab));
wherein omega is the real-time angle adjustment of camera, L grab bucket is grab bucket horizontal distance, L is the camera horizontal distance, H is the camera height, H grab bucket is grab bucket height.
In specific implementation, the remote operation and maintenance unit U4 realizes the works of remote debugging, remote operation and maintenance and the like of the grab ship unloader equipment in the following manner, and specifically comprises the following steps:
s701, a communication connection is established between the remote operation and maintenance unit U4 and the airborne control unit U1 as well as the video monitoring management unit U3;
s702, the remote operation and maintenance unit U4 completes signal testing by sending a scheduling instruction; debugging personnel monitor the field device safety element signals in real time in a remote debugging and dispatching center through a video monitoring management unit U3;
after the communication connection is established, the signal test of the safety element is started, the remote operation and maintenance unit U4 sends a scheduling instruction, and the signal test of the safety element such as a close stop button, a limit switch and the like is completed. And the debugging personnel monitor the safety element signal of the field device in real time at a remote debugging and dispatching center.
S703, a remote operation and maintenance unit U4 sends a scheduling instruction to sequentially complete testing actions; the debugging personnel monitors the single-mechanism running state of the field device and the actual audio-video environment of the field device in real time in a remote debugging and dispatching center;
after the safety element signal test is completed, the action test of the grab ship unloader single mechanism is started, the remote operation and maintenance unit U4 sends a scheduling instruction, and the action test of the lifting, opening and closing, trolley, pitching and other mechanisms is completed sequentially. And the debugging personnel monitors the single-mechanism running state of the field device and the actual audio-video environment of the field device in real time in the remote debugging and dispatching center.
S704, a remote operation and maintenance unit U4 sends a scheduling instruction, and an on-site operator performs no-load test on the grab ship unloader; the debugging personnel monitor the no-load running state of the field device and the actual audio-visual environment of the field device in real time in a remote debugging and dispatching center;
after the single-mechanism action test is completed, the grab ship unloader idle load test is started, the remote operation and maintenance unit U4 sends a scheduling instruction, and on-site operators perform the grab ship unloader idle load test. And the debugging personnel monitor the no-load running state of the field device and the actual audio-visual environment of the field device in real time in a remote debugging and dispatching center.
And S705, completing remote debugging and remote operation and maintenance work of the grab ship unloader.
After the no-load test of the grab ship unloader is finished, the remote debugging and remote operation and maintenance work is finished, and the equipment can be put into normal use.
In the process of remote debugging and remote operation and maintenance of the grab ship unloader, the remote operation and maintenance unit U4 sequentially sends data delay detection signals to the airborne control unit U1 and the video monitoring management unit U3 at regular time, after the airborne control unit U1 and the video monitoring management unit U3 receive the data delay detection signals, the remote operation and maintenance unit U4 immediately sends data delay detection feedback signals to the remote operation and maintenance unit U4, after the remote operation and maintenance unit U4 receives the data delay detection feedback signals returned by the two units, data delay time operation is carried out on the time sent by the data delay detection signals and the time received by the data delay detection feedback signals, and meanwhile the data delay time is compared with a threshold value to judge the real-time performance of data communication of a remote engineer station.
The data delay time judging formula is as follows:
if T Feedback 1 -T Transmission 1 ＞T Threshold 1 The communication between the remote operation and maintenance unit U4 and the airborne control unit U1 meets the remote debugging requirement;
if T Feedback 2 -T Send 2 ＞T Threshold 2 The communication between the remote operation and maintenance unit U4 and the video monitoring and management unit U3 satisfies the remote requirementDebugging requirements;
if T Feedback 1 -T Transmission 1 ＜T Threshold 1 The communication between the remote operation and maintenance unit U4 and the airborne control unit U1 does not meet the remote debugging requirement;
if T Feedback 2 -T Send 2 ＜T Threshold 2 The communication between the remote operation and maintenance unit U4 and the video monitoring and management unit U3 does not meet the remote debugging requirement;
wherein T is Feedback 1 Indicating the time when the remote operation and maintenance unit U4 receives the data delay detection feedback signal returned by the airborne control unit U1, T Transmission 1 The time of the remote operation and maintenance unit U4 sending the data delay detection signal to the airborne control unit U1 is represented by T Threshold 1 Representing a data delay time permission threshold value between the remote operation and maintenance unit U4 and the onboard control unit U1; t (T) Feedback 2 The time T for the remote operation and maintenance unit U4 to receive the data delay detection feedback signal returned by the video monitoring and management unit U3 is represented Send 2 The time T for the remote operation and maintenance unit U4 to send the data delay detection signal to the video monitoring management unit U3 is represented Threshold 2 Representing a data delay time allowable threshold between the remote operation and maintenance unit U4 and the video monitoring management unit U3.
Taking an unmanned grab ship unloader product as an example, a control method of the unmanned grab ship unloader corresponding to the control system of the unmanned grab ship unloader is described below, and as shown in fig. 6, the control method comprises the following steps:
s801, starting the ship port approaching operation, wherein an airborne control unit U1 starts to work, and the grab ship unloader is started in unmanned ship unloading operation; meanwhile, the video monitoring management unit U3 also starts to work, and the operation of the grab ship unloader is monitored in all directions;
s802, lifting the arm support of the grab ship unloader;
s803, the grab ship unloader runs along the cart track from the bow position to the stern direction, and scans the ship;
s804, after the ship is scanned, the grab ship unloader receives a hatch scheduling instruction sent by the remote control unit U2;
s805, the grab ship unloader is operated to a target operation hatch;
s806, the arm support of the grab ship unloader is put down, and the cab moves to the center position of the hatch;
s807, scanning the hatch and the materials in the cabin;
s808, moving the grab bucket to the position above the hatch, and activating the grab bucket pose detection function;
s809, starting automatic ship unloading operation, and carrying out ship unloading operation by the grab ship unloader according to the decision given by the decision analysis unit U5;
s810, in the operation process, the grab ship unloader receives a remote control instruction of a remote control unit U2 in real time;
the remote control command may be a cabin moving command, a current hatch operation termination, a movement to a new target hatch, etc., and after receiving the remote control command, the process jumps to S807 to restart the operation. If the cabin moving instruction is not received, continuing to operate at the current hatch;
s811, when the current hatch works to the cabin needing to be cleared, an operator lifts the cabin clearing machine into the cabin by remote operation of a central control room, and automatic cabin clearing work is started;
and S812, after the cabin cleaning is completed, the unmanned ship unloading operation of the grab ship unloader is completed.
According to the embodiment, on the basis of ensuring the real-time performance of the automatic operation data processing of the grab ship unloader, the automatic dynamic tracking planning and intelligent real-time scheduling of the operation tasks are realized, so that the grab bucket of the ship unloader is enabled to be high in efficiency and safety in ship unloading operation flows such as closed bucket material taking, grab bucket in-out of the ship cabin, grab bucket aerial swing control, bucket throwing and the like, and the safety is high. The unmanned grab ship unloader control system technology is applied, the number of operators can be reduced to a great extent, the intelligent degree is high, and the labor cost is saved.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and not for limiting the same; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the invention.
Claims (10)
1. An unmanned grab ship unloader control system, the system comprising:
the system comprises an airborne control unit, a remote control unit, a video monitoring management unit and a decision analysis unit, wherein the data transmission among the units adopts an Ethernet communication protocol;
the machine-mounted control unit is arranged on grab ship unloader equipment and is used for driving all mechanisms of the grab ship unloader to operate under the control of the remote control unit so as to perform unmanned ship unloading operation;
the remote control unit is arranged in the central control room and is used for sending a control instruction to the airborne control unit according to the real-time data acquired by the video monitoring management unit and the decision obtained by the decision analysis unit so as to realize remote on duty of the working states of the grab ship unloader and the conveying operation line;
the video monitoring management unit comprises a plurality of video monitoring cameras arranged on grab ship unloader equipment and is used for realizing omnibearing monitoring on the operation of the grab ship unloader;
the decision analysis unit is arranged in an industrial computer in the remote control cabinet of the central control room and is used for carrying out decision analysis on ship unloading operation of the unmanned grab ship unloader according to real-time data acquired by the video monitoring management unit, the downward stepping operation is adopted in the grabbing direction, the sea side and the land side are adopted in the trolley direction, the control strategy of preventing the bucket burying is adopted, and the furrow stepping operation is adopted in the trolley direction, so that the single-cabin task planning function is realized.
2. The unmanned grab ship unloader control system of claim 1, further comprising: the remote operation and maintenance unit is arranged in the remote debugging and dispatching center and is used for realizing remote debugging and remote operation and maintenance of grab ship unloader equipment by combining the field data acquired by the video monitoring and management unit.
3. The unmanned grab ship unloader control system of claim 1, wherein the on-board control unit comprises: the PLC processor, the driving mechanism, the encoder and the limit switch; the PLC processor is used for receiving the signals of the encoder and the limit switch and controlling the driving mechanism to finish the ship unloading action; the driving mechanism is used for receiving the instruction of the PLC processor and completing the corresponding ship unloading action; the encoder is used for measuring and calculating the running position of each driving mechanism; the limit switch is used for detecting the running state of each running mechanism.
4. The unmanned grab ship unloader control system of claim 1, wherein the video monitoring management unit comprises: the system comprises a video acquisition unit, a control unit and a monitoring display unit;
the video acquisition unit consists of video monitoring cameras arranged at key positions on the grab ship unloader and is used for acquiring video information of the whole grab ship unloader;
the control unit is arranged on the grab ship unloader motor, comprises an optical fiber switch, a hard disk video recorder, a streaming media server and an Ethernet switch, and is used for receiving, transmitting, backing up and storing transmission data of the video acquisition unit, and simultaneously realizing automatic switching, automatic focusing and automatic following of video monitoring pictures according to the actual operation working condition of the grab ship unloader;
the monitoring display unit is divided into two parts, wherein one part is an onboard monitoring display device arranged in a cab of the grab ship unloader, and the monitoring display device comprises a liquid crystal display and an onboard operating keyboard and is used for monitoring video images by operators during local operation of the grab ship unloader; the other part is a remote monitoring display device arranged at a remote operation station of the wharf central control room, and the remote monitoring display device comprises a liquid crystal display and a remote operation keyboard and is used for monitoring video images of operators when the grab ship unloader performs unmanned remote operation.
The video data between the video acquisition unit and the control unit is transmitted by an on-board optical fiber through an Ethernet protocol; the communication between the on-board monitoring display device of the cab and the control unit in the monitoring display unit is transmitted by an on-board optical fiber through an Ethernet protocol, and the communication between the remote monitoring display device of the remote operation station of the central control room of the wharf and the control unit is transmitted by an on-board optical fiber, a reel optical fiber and a wharf fixed laying optical fiber through an Ethernet protocol.
5. The unmanned grab ship unloader control system of claim 1, wherein the remote control unit comprises: the central server is used for receiving operation instructions of the wharf production scheduling system and operation data of the airborne control unit and sending ship unloading operation instructions to the airborne control unit; the remote operation platform is used for manual operation, manual intervention is performed when the unmanned grab ship unloader control system fails, and remote operation removes faults.
6. A method of controlling an unmanned grab ship unloader, applied to the unmanned grab ship unloader control system of any one of claims 1 to 5, the method comprising:
the ship approaches the port, the on-board control unit starts to work, and the grab ship unloader is started in unmanned ship unloading operation; simultaneously, the video monitoring management unit starts to work, and the operation of the grab ship unloader is monitored in all directions;
lifting the arm support of the grab ship unloader;
the grab ship unloader runs along the large car track from the bow position to the stern direction to scan the ship;
after the ship is scanned, the grab ship unloader receives a hatch scheduling instruction sent by the remote control unit;
the grab ship unloader is operated to a target operation hatch;
the arm support of the grab ship unloader is put down, and the cab moves to the center position of the hatch;
scanning the hatch and the materials in the cabin;
the grab bucket moves to the position above the hatch, and the grab bucket pose detection function is activated;
the automatic ship unloading operation starts, and the grab ship unloading machine carries out ship unloading operation according to the decision given by the decision analysis unit;
in the operation process, the grab ship unloader receives a remote control instruction of a remote control unit in real time;
when the current hatch works to the cabin needing to be cleared, an operator remotely operates the cabin clearing machine in a central control room to hoist the cabin to the cabin, and automatic cabin clearing work is started;
after the cabin cleaning is completed, unmanned ship unloading operation of the grab ship unloader is completed.
7. The method of controlling an unmanned grab ship unloader according to claim 6, further comprising: remote debugging and remote operation and maintenance of grab ship unloader equipment; comprising the following steps:
the remote operation and maintenance unit is in communication connection with the airborne control unit and the video monitoring management unit;
the remote operation and maintenance unit completes signal testing by sending a scheduling instruction; debugging personnel monitor the field device safety element signals in real time in a remote debugging and dispatching center through a video monitoring management unit;
the remote operation and maintenance unit sends a scheduling instruction to sequentially complete testing actions; the debugging personnel monitors the single-mechanism running state of the field device and the actual audio-video environment of the field device in real time in a remote debugging and dispatching center;
the remote operation and maintenance unit sends a scheduling instruction, and site operators perform no-load test on the grab ship unloader; the debugging personnel monitor the no-load running state of the field device and the actual audio-visual environment of the field device in real time in a remote debugging and dispatching center;
and (5) completing remote debugging and remote operation and maintenance of the grab ship unloader.
8. The unmanned grab ship unloader control method according to claim 7, further comprising: data delay detection, comprising:
in the process of remote debugging and remote operation and maintenance of the grab ship unloader, the remote operation and maintenance unit sequentially sends data delay detection signals to the airborne control unit and the video monitoring management unit at regular time;
when the onboard control unit and the video monitoring management unit receive the data delay detection signals, the data delay detection feedback signals are immediately sent to the remote operation and maintenance unit;
and after the remote operation and maintenance unit receives the data delay detection feedback signals returned by the airborne control unit and the video monitoring management unit, carrying out data delay time operation on the time sent by the data delay detection signals and the time received by the data delay detection feedback signals, and simultaneously comparing the data delay time with a threshold value to judge the real-time performance of the data communication of the remote engineer station.
9. The control method of an unmanned grab ship unloader according to claim 6, wherein the grab ship unloader performs ship unloading according to the decision given by the decision analysis unit, comprising:
dividing an operation area of the cabin interior area of the grab ship unloader into a plurality of operation units;
before the ship unloading operation starts, monitoring the material accumulation condition of each operation unit in an operation area in real time through a grab ship unloader, and selecting an initial operation unit; starting from the initial operation unit, completing the ship unloading operation of the materials piled in the central operation area according to the first control strategy, the second control strategy and the third control strategy;
the first control strategy is a grabbing direction control strategy, and comprises: step-down operation, which gives consideration to preventing the bucket burying; the second control strategy is a trolley direction control strategy, comprising: the sea side and the land side respectively perform stepping operation, and prevent the bucket burying; the third control strategy is a cart directional control strategy, comprising: furrow type stepping operation;
after the grab bucket is controlled to reach the operation unit, the grab bucket is controlled according to a first control strategy to finish one operation flow, and then whether the bucket burying risk exists is judged according to the material accumulation conditions of the current operation unit and the peripheral operation units: if no bucket burying risk exists, controlling according to a first control strategy until the current operation unit finishes unloading, and controlling according to a second control strategy; if the risk of burying the grab bucket exists, stopping downward stepping of the grab bucket at the point position of the current operation unit, and controlling according to a second control strategy;
the grab bucket is controlled to move to the next operation unit in a stepping mode along the column operation combination where the current operation unit is located, and the grab bucket is controlled by the next operation unit according to a first control strategy; if the grab bucket reaches the sea side edge, stepping to the land side to move to the next operation unit; when all the operation units in the column operation combination where the current operation unit is located have completed the operation, controlling according to a third control strategy;
all column operation combinations are numbered according to the sequence, and then divided into two subgroups according to the parity of the numbers; and controlling the grab bucket to move to corresponding operation units in other column operation combinations in the group to which the column operation combination of the operation unit belongs in a stepping manner along the running direction of the cart by controlling one operation unit of the last operation through a second control strategy, repeating the first control strategy control and the second control strategy control until all operation units in all column operation combinations in the group finish unloading, then controlling the grab bucket to move to operation units in all column operation combinations in the other group in a stepping manner along the running direction of the cart, and repeating the first control strategy control and the second control strategy control until all operation units in an operation area finish unloading, so that the ship unloading operation is finished.
10. The method of controlling an unmanned grab ship unloader according to claim 6, further comprising: safety interlock control to grab ship unloader and defeated material line includes: a stream delivery start and a stream delivery stop;
wherein, the control flow of the stream delivery start comprises:
receiving a material flow conveying starting instruction sent by a user;
the stock ground equipment and the transfer belt are started;
after the dock belt conveyor transfer belt at the transfer station is confirmed to be correctly docked, the dock belt is started;
after the correct butt joint of the ship unloader feeding system and the wharf belt is confirmed, the ship unloader feeding system is started;
the material flow conveying and starting are completed, and the ship unloading and conveying operation line runs formally;
the control flow of the stream delivery stop comprises the following steps:
the remote control unit receives a material flow conveying stopping instruction;
the ship unloader feeding system stops feeding to the dock belt;
stopping the wharf belt;
stopping operation of the material yard equipment of the transfer belt conveyor;
and stopping the material flow conveying, and stopping the operation of the ship unloading and conveying line.
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| CN202211716135.9A CN116101901A (en) | 2022-12-29 | 2022-12-29 | Unmanned grab ship unloader control system and control method |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116709034A (en) * | 2023-06-07 | 2023-09-05 | 上海安维尔信息科技股份有限公司 | Ship unloader grab tracking method and system based on video AI |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116709034A (en) * | 2023-06-07 | 2023-09-05 | 上海安维尔信息科技股份有限公司 | Ship unloader grab tracking method and system based on video AI |
| CN116709034B (en) * | 2023-06-07 | 2024-04-16 | 上海安维尔信息科技股份有限公司 | Ship unloader grab tracking method and system based on video AI |
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