CN116216533A - Unmanned grab ship unloader - Google Patents
Unmanned grab ship unloader Download PDFInfo
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- CN116216533A CN116216533A CN202211716149.0A CN202211716149A CN116216533A CN 116216533 A CN116216533 A CN 116216533A CN 202211716149 A CN202211716149 A CN 202211716149A CN 116216533 A CN116216533 A CN 116216533A
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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
- 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
- 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
- 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
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Ship Loading And Unloading (AREA)
Abstract
The invention provides an unmanned grab ship unloader. The invention comprises a grab ship unloader body, a grab ship unloader accurate positioning system and an unmanned grab ship unloader control system, wherein the grab ship unloader body is used for realizing the conventional ship unloader operation function of the grab ship unloader and comprises a trolley, a cart running device, a main beam arm support mechanism, a grab ship mechanism and a cab; the accurate positioning system of the grab ship unloader comprises a mechanism positioning unit, a grab pose detection unit, a scanning and identifying unit and a data acquisition unit; the unmanned grab ship unloader control system comprises: the system comprises an airborne control unit, a remote control unit, a video monitoring management unit and a decision analysis unit; the invention can realize the accurate positioning detection and identification of all mechanisms, grab buckets, ships, hatches and materials of the grab ship unloader. 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.
Description
Technical Field
The invention relates to the technical field of grab ship unloaders, in particular to an unmanned grab ship unloader.
Background
The grab ship unloader is used as important ship unloading equipment of bulk cargo wharf, and at present, a semi-automatic and manual combined operation mode is still commonly adopted, so that the intelligent degree and the unmanned degree are low. The development of unmanned grab ship unloader has become the development trend of industry under the current global initiative of developing artificial intelligence and intelligent manufacturing. In addition, when a driver manually operates and controls the grab ship unloader to carry out ship unloading operation, 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
According to the technical problem, unmanned grab ship unloader is provided, unmanned ship unloader operation of bulk cargo wharf grab ship unloader is achieved, automatic dynamic tracking planning and intelligent real-time scheduling of operation tasks are achieved on the basis of guaranteeing real-time data processing of automatic operation of the grab ship unloader, and high efficiency and safety of grab ship unloader operation flows such as bucket closing and taking, bucket entering and exiting, grab ship cabin, grab ship aerial swing control and bucket throwing are guaranteed. The unmanned grab ship unloader technology can greatly reduce the number of operators and labor cost. The invention adopts the following technical means:
An unmanned grab ship unloader comprises a grab ship unloader body, a grab ship unloader accurate positioning system and an unmanned grab ship unloader control system,
the grab ship unloader body is used for realizing the conventional ship unloading operation function of the grab ship unloader and comprises a trolley, a cart running device, a main girder arm support mechanism, a grab bucket mechanism and a cab;
the accurate positioning system of the grab ship unloader comprises a mechanism positioning unit, a grab pose detection unit 14, a scanning identification unit and a data acquisition unit, wherein the mechanism positioning unit, the grab pose detection unit and the scanning identification unit are respectively in communication connection with the data acquisition unit; the mechanism positioning unit is used for calibrating a trolley position value, detecting a boom pitching angle, calibrating a large vehicle position value and detecting a cab position value; the grab bucket pose detection unit is used for detecting the grab bucket running space position and the grab bucket pose; the scanning and identifying unit is used for detecting ships, hatches and materials in real time; the data acquisition unit is used for receiving the data acquired by the mechanism positioning unit, the grab bucket pose detection unit and the scanning identification unit;
the unmanned grab ship unloader control system comprises: 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 body 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 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, so that the single-cabin task planning function is realized.
Further, the grab ship unloader body further comprises a portal frame mechanism, a tower frame mechanism, a feeding mechanism and a machine room mechanism, wherein the portal frame mechanism is used as a main supporting structure of the grab ship unloader, the cart running device is arranged at the lower part of the sea-land side portal frame mechanism, and the cart running device is used for the grab ship unloader to move along a wharf track; the main beam arm support mechanism is arranged above the portal frame mechanism and is used for providing a track required by the operation of the grab ship unloader trolley, so that the trolley can move on the main beam arm support mechanism; the arm support part of the main beam arm support mechanism can be lifted in a pitching way; the tower mechanism is positioned above the main beam, and is provided with a steel wire rope pulley for pitching the arm support and a hook device for locking the hook after the arm support is pitching and the arm support is pitching to a high point; the feeding mechanism is arranged at the lower part of the portal mechanism and consists of a hopper and a feeding device, the hopper is used for receiving materials grabbed from the cabin of the ship by the grab mechanism, and then the materials are transmitted to a quay ground belt by the feeding device; the machine room mechanism is arranged at the rear end of the main girder arm support mechanism and is used for driving the grab bucket ship unloader to finish the pitching actions of the trolley, the grab bucket and the arm support, the grab bucket mechanism is hung below the trolley through a steel wire rope, and the steel wire rope is used for dragging to finish the ship unloading process flow of grabbing materials from the cabin to the hopper.
Further, the mechanism positioning unit performs calibration of the position value of the trolley by arranging a laser ranging device on the trolley mechanism, specifically, arranging position calibration modules in the front end area of the arm support, the main trolley area and the rear girder area so as to realize calibration detection of the position value of the main trolley, wherein the position calibration modules comprise sea side laser ranging devices arranged in the front end area of the arm support, reflecting plates arranged on the sea side of the main trolley, land side laser ranging devices arranged in the rear girder area and reflecting plates arranged on the land side of the main trolley, wherein the sea side laser ranging devices and the land side laser ranging devices respectively adopt linear laser ranging devices, and the detection distance of the sea side laser ranging devices and the land side laser ranging devices is not less than 80m;
a position detection module is arranged at a motor of a main trolley of the machine room so as to realize measurement of a position value of the main trolley, and the position detection module comprises an absolute value encoder, wherein the absolute value encoder is used for positioning the operation of the motor of a mechanism of the main trolley in real time;
calculating a real-time calibration detection position value of the main trolley according to the following formula:
L real time ＝(L WS +0.5*L Trolley )/(L WS +L LS )*L Arm support -L LS
Wherein, the central parking space of the main trolley hopper is used as the horizontal position zero position of the main trolley, L WS L is the distance from the sea side of the main trolley to the front end of the arm support, which is detected by a sea side laser range finder LS The distance L from the land side surface of the main trolley to the rear girder detected by the land side laser range finder Trolley Length of main trolley L Arm support The actual distance from the front end of the arm support to the rear girder;
calculating a base position value of the primary trolley according to the following formula:
L foundation ＝a*E Encoding +b
Wherein, the central parking space of the main trolley hopper is used as the horizontal position zero position of the main trolley, E Encoding The measurement data of the absolute value encoder of the main trolley is that a is the conversion data of the absolute value encoder, and b is that the conversion correction value of the absolute value encoder.
The device comprises a cab, a mechanism positioning unit, a cab positioning module, a PLC control unit and a PLC control unit, wherein the cab is provided with a cab main beam, a gray bus code scale is additionally arranged in the cab to detect the cab position value, specifically, the cab positioning module is used for acquiring the position value data of the cab, and comprises a code scale arranged below the main beam of the arm support and a U-shaped code reader arranged at the top of the cab, wherein the code scale is arranged in a U-shaped groove of the U-shaped code reader, two sides of the U-shaped code reader are respectively provided with an infrared signal transmitting end and an infrared signal receiving end, the U-shaped code reader moves along the code scale along with the cab in the running process of the cab, and the positioning code of the code scale at the current position is read in the process and is transmitted to the PLC control unit for conversion through an Ethernet protocol to obtain the corresponding cab position value;
The cab driving unit drives the operation cab according to the position value data of the cab, which is obtained by the cab positioning module, and comprises a frequency converter arranged in an electric control cabinet of the cab and a driving motor arranged at the top of the cab, wherein the input end of the frequency converter is connected with the output end of a wire inlet contactor, and the input end of the wire inlet contactor is connected with the output end of a wire inlet breaker; one output end of the frequency converter is connected with the brake resistor, the other output end of the frequency converter is connected with the input end of the motor starter, and the output end of the motor starter is connected with the driving motor at the top of the cab;
cab position values are calculated according to the following formula:
P cab ＝0.8*E Encoding +K Correction
Wherein P is Cab Indicating cab position value, E Encoding Representing the positioning code, K, read by the U-shaped code reader Correction Indicating the converted correction value.
Further, the grab bucket pose detection unit detects grab bucket running space position and grab bucket pose by arranging a laser scanning device and a visual recognition device on a cab platform, and comprises:
acquiring first grab bucket pose data acquired by a three-dimensional laser scanning device, wherein the three-dimensional laser scanning device is arranged on a cab platform;
Acquiring second grab bucket pose data acquired by a visual recognition device, wherein the visual recognition device is arranged on a cab platform;
the first grab bucket pose data is used as a reference, and the second grab bucket pose data is used for calibrating the first grab bucket pose data, so that final grab bucket pose data is generated;
calculating calibrated grapple spatial position data according to the following formula:
P fixing device ＝P Inspection and detection +K 1 *(P School and school -P Inspection and detection )
Wherein P is Fixing device For calibrated grab bucket spatial position data, P Inspection and detection Grab bucket space position data, P, acquired for three-dimensional laser scanning device School and school Grab bucket space position data, K, acquired for visual recognition device 1 Correcting coefficients for spatial positions;
calculating calibrated grapple dumping angle data according to the following formula:
ω tilting and fixing ＝ω Tilting inspection +K 2 *(ω Tilting correction -ω Tilting inspection )
Wherein omega Tilting and fixing Omega as calibrated grapple dumping angle data Tilting inspection Grab bucket dumping angle data omega acquired by three-dimensional laser scanning device Tilting correction Grab bucket dumping angle data K acquired by the visual recognition device 2 The inclination angle correction coefficient is used;
calculating corrected rotation angle data of the grab bucket according to the following formula:
ω return to fix ＝ω Rechecking +K 3 *(ω Correction method -ω Rechecking )
Wherein omega Return to fix To calibrate corrected grab bucket rotation angle data omega Rechecking For grab bucket rotation angle data omega acquired by a three-dimensional laser scanning device in a detection unit Correction method Grab bucket rotation angle data K acquired by the visual recognition device 3 The rotation angle correction coefficient.
Further, the scanning recognition unit carries out real-time detection of boats and ships, hatch, material through setting up laser scanning device at cab platform and girder hank point location, includes:
carrying out ship scanning through a ship laser scanning device, wherein the ship scanning device is arranged at a girder twisting point;
the hatch and the material laser scanning device are arranged on a cab platform and are provided with a tripod head, and the hatch and the material can be rapidly scanned through rotation of the tripod head;
further comprises: performing ship inclination prevention early warning according to a ship scanning result, specifically comprising:
and carrying out ship transverse inclination early warning judgment according to the following formula:
when omega Transverse inclination ＝arctan(|(H Sea water -H Land and land )/(L Sea water -L Land and land )|)>ω Transverse inclination allowing When the ship is determined to be excessively inclined transversely, wherein omega Transverse inclination Is transverse to the shipInclination angle value H Sea water Is the sea side edge height of the ship, H Land and land Is the land side edge height of the ship, L Sea water Is the horizontal position of the sea side edge of the ship, L Land and land Omega is the horizontal position of the land side edge of the ship Transverse inclination allowing The maximum allowable value of the transverse inclination angle of the ship;
and carrying out ship longitudinal inclination early warning judgment according to the following formula:
when omega Pitching of ＝arctan(|(H Ship bow -H Stern of ship )/(P Ship bow -P Stern of ship )|)>ω Trim allowance When the ship is determined to have excessive longitudinal inclination, wherein omega Pitching of Is the longitudinal inclination angle value of the ship, H Ship bow Is the height of the bow of the ship, H Stern of ship Is the height of the ship stern, P Ship bow Omega is the horizontal position of the ship bow Trim allowance Is the maximum allowable value of the longitudinal inclination angle of the ship, P Stern of ship The horizontal position of the stern of the ship;
the scanning recognition unit carries out real-time detection of boats and ships, hatch, material through setting up laser scanning device at cab platform and girder hank point location, still includes: carrying out hatch anti-collision early warning according to a hatch scanning result, and specifically comprising the following steps:
the sea-land side collision safety distance is calculated according to the following formula: s is S Sea and land ＝a*L Grab bucket +b, where S Sea and land Is the sea-land side anti-collision safety distance, a is the sea-land side anti-collision safety coefficient, L Grab bucket The length value is the length value when the grab bucket is opened, and b is an anti-collision safety correction value;
the left and right side crash-proof safety distances are calculated according to the following formula: s is S (left and right) ＝A*W Grab bucket +b, where S (left and right) Is the left-right side anti-collision safety distance, A is the left-right side anti-collision safety coefficient, W Grab bucket The grab bucket width value;
will be away from the sea-land side edge S of the hatch Sea and land The area within the range is divided into a sea-land side anti-collision early warning area, and the left side edge S and the right side edge S of the hatch are separated (left and right) The area in the range is divided into a left side anti-collision early warning area and a right side anti-collision early warning area, and in the ship unloading operation, the grab bucket enters the sea-land side anti-collision early warning area or the left side anti-collision early warning area and the right side anti-collision early warning area, namelyAnd sending out an anti-collision warning of the hatch.
Further, the on-board control unit includes: 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;
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.
Further, the remote control unit includes: 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 console is used for manual operation, manual intervention is performed when the unmanned grab ship unloader control system fails, and remote operation is used for removing faults;
the unmanned grab ship unloader control system further comprises: 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.
Further, the unmanned grab ship unloader performs unmanned control based on the following method:
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.
Further, the method further comprises the following steps: 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;
the remote debugging and remote operation and maintenance work of the grab ship unloader are completed;
further comprises: 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;
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;
The grab ship unloader carries out ship unloading operation according to the decision given by the decision analysis unit, and comprises the following steps:
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; the grab bucket is controlled to move to corresponding operation units in other column operation combinations in the group of the column operation combination where the operation unit is located in a stepping mode along the running direction of the cart by a second control strategy, the first control strategy control and the second control strategy control are repeated until all operation units in all column operation combinations in the group finish unloading, then the grab bucket is controlled to move to operation units in all column operation combinations in the other group in a stepping mode along the running direction of the cart, and the first control strategy control and the second control strategy control are repeated until all operation units in an operation area finish unloading, so that ship unloading operation is finished;
Further comprises: 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.
The unmanned grab ship unloader provided by the invention realizes automatic dynamic tracking planning and intelligent real-time dispatching of an operation task on the basis of ensuring the real-time performance of automatic operation data processing of the grab ship unloader, so that the grab bucket of the ship unloader is high-efficiency and high-safety in ship unloading operation flows such as bucket closing and taking, bucket in-out and out cabin, grab bucket aerial swing control, bucket throwing and the like, and the safety is higher. 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. On the basis of the conventional positioning scheme that all mechanisms of the grab ship unloader are positioned through the encoder, the positioning accuracy of all mechanisms of the grab ship unloader is enhanced by adding innovative positioning schemes such as a Gray bus, an RFID device and a laser ranging device. Meanwhile, the grab bucket pose detection device is arranged, and the real-time detection function of the grab bucket position and pose is increased through the redundant scanning recognition scheme of laser scanning and visual recognition. In addition, a scanning and identifying device is added, so that real-time detection of ships, hatches and materials is realized. The technology creatively increases the state detection of the grab, the ship, the hatch and the materials on the basis of accurate and reliable positioning of each mechanism of the enhanced grab ship unloader, and creates a bottom hardware foundation for realizing the unmanned grab ship unloader technology.
Drawings
FIG. 1 is a schematic view of an unmanned grab ship unloader of the present invention;
FIG. 2 is a schematic diagram of the body structure of the unmanned grab ship unloader of the present invention;
FIG. 3 is a diagram of the precise positioning system of the grapple ship unloader of the present invention;
FIG. 4 is a schematic diagram of an unmanned grab ship unloader control system of the present invention;
FIG. 5 is a control flow diagram of the unmanned grab ship unloader of the present invention.
In the figure: 1. a gantry mechanism; 2. a tower mechanism; 3. a feeding mechanism; 31. a feeding device; 32. a hopper; 4. a machine room mechanism; 5. a trolley; 6. a cart running mechanism; 7. a main beam arm support mechanism; 8. pulley and hook device; 9. a grab bucket mechanism; 10. a ground belt; 11. a position calibration module; 12. cab positioning device; 13. a scanning and identifying unit; 14. and a grab bucket pose detection unit.
Detailed Description
As shown in fig. 1 to 5, the embodiment of the invention discloses an unmanned grab ship unloader, which comprises: a grab ship unloader body, a grab ship unloader accurate positioning system and an unmanned grab ship unloader control system,
the grab ship unloader body is used for realizing the conventional ship unloader operation function of the grab ship unloader, and comprises: the device comprises a trolley 5, a trolley running device 6, a main girder arm support mechanism 7, a grab bucket mechanism 9 and a cab;
The accurate positioning system of the grab ship unloader aims at strengthening accurate positioning of operation related mechanisms of ship unloading operation and accurate positioning identification of ships and materials for ensuring reliable and stable operation of unmanned ship unloading functions, and specifically comprises the following components: the device comprises a mechanism positioning unit, a grab bucket pose detection unit, a scanning identification unit 13 and a data acquisition unit, wherein the mechanism positioning unit, the grab bucket pose detection unit and the scanning identification unit are respectively in communication connection with the data acquisition unit; the mechanism positioning unit is used for calibrating a trolley position value, detecting a boom pitching angle, calibrating a large vehicle position value and detecting a cab position value; the grab bucket pose detection unit is used for detecting the grab bucket running space position and the grab bucket pose; the scanning and identifying unit is used for detecting ships, hatches and materials in real time; the data acquisition unit is used for receiving the data acquired by the mechanism positioning unit, the grab bucket pose detection unit and the scanning identification unit;
the unmanned grab ship unloader control system comprises: 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 body 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 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, so that the single-cabin task planning function is realized.
Specifically, the grab ship unloader body further comprises a portal frame mechanism 1, a tower frame mechanism 2, a feeding mechanism 3 and a machine room mechanism 4, wherein the portal frame mechanism is used as a main supporting structure of the grab ship unloader, the cart running device is arranged at the lower part of the sea-land side portal frame mechanism and is used for enabling the grab ship unloader to move along a wharf rail; the main beam arm support mechanism is arranged above the portal frame mechanism and is used for providing a track required by the operation of the grab ship unloader trolley, so that the trolley can move on the main beam arm support mechanism; the arm support part of the main beam arm support mechanism can be lifted in a pitching way; the tower mechanism is positioned above the main beam, and is provided with a steel wire rope pulley for pitching the arm support and a hook device 8 for locking the hook after the arm support is pitching and the arm support is pitching to a high point; the feeding mechanism is arranged at the lower part of the portal mechanism and consists of a hopper 32 and a feeding device 31, and is used for receiving materials grabbed from the cabin by the grab bucket mechanism through the hopper and then transmitting the materials to the wharf ground belt 10 through the feeding device; the machine room mechanism is arranged at the rear end of the main girder arm support mechanism and is used for driving the grab bucket ship unloader to finish the pitching actions of the trolley, the grab bucket and the arm support, the grab bucket mechanism is hung below the trolley through a steel wire rope, and the steel wire rope is used for dragging to finish the ship unloading process flow of grabbing materials from the cabin to the hopper.
In the mechanism positioning unit, the trolley mechanism is provided with an incremental encoder on the side of a trolley motor, a laser range finder device is arranged at the front end of an arm support and at the position of a rear girder, meanwhile, a reflecting plate is arranged at the sea side and the land side of a main trolley, front and rear distance measurement values of the trolley are obtained from front and rear directions, the position value detected by the incremental encoder is used as a trolley positioning basic value, and the front and rear distance measurement values of the trolley detected by the laser range finder calibrate the trolley positioning basic value, so that an accurate real-time position value of the trolley is obtained; the pitching mechanism directly detects the pitching angle of the arm support by installing an inclinometer device at the twisting point of the main beam; the method comprises the steps that on the basis of the configuration of an absolute value encoder on a cart trolley, an RFID reading device is arranged on the cart trolley, RFID identification plates are arranged along a dock track at fixed intervals, when the cart mechanism operates, the position value detected by the absolute value encoder is used as a cart positioning basic value, the actual position value corresponding to the position is obtained through the RFID reading device every time the cart passes by one RFID identification plate position along the track, and the cart positioning basic value detected by the absolute value is calibrated, so that accurate positioning of the cart mechanism is realized; the cab mechanism is provided with a Gray bus code ruler along a cab full-travel track, and a U-shaped code reader device is arranged at the top of the cab, and the U-shaped code reader achieves accurate positioning of the cab by acquiring the Gray bus code ruler value corresponding to the current position of the cab.
Specifically, the sea side laser range finder is horizontally arranged on a mounting bracket of a pulley seat positioned at the end part of the arm support, four corners are fixed by bolts, the detection direction is along the arm support to the land side, the detection target is a reflecting plate arranged on the sea side of the main trolley, the center point of the sea side reflecting plate of the main trolley is positioned at the same height as the sea side laser range finder, the size of the sea side reflecting plate of the main trolley is 0.5m from the left edge to the right edge and 1m from the center point; the land side laser range finder is horizontally arranged on a mounting bracket of a sea side platform of a machine room in a rear girder region, four corners are fixed by bolts, the detection direction is along an arm support to the sea side, the detection target is a reflecting plate arranged on the land side of a main trolley, the central point of the main trolley land side reflecting plate and the land side laser range finder are positioned at the same height, the size of the main trolley land side reflecting plate is 0.5m from the left edge and the right edge to the central point, and the distance from the upper edge to the lower edge to the central point is 1m.
In this embodiment, the position calibration module 11 is composed of a sea-side laser range finder installed in the front end region of the arm frame, a reflecting plate installed on the sea side of the main trolley, a land-side laser range finder installed in the rear girder region, and a reflecting plate installed on the land side of the main trolley. The sea side laser range finder and the main trolley sea side reflecting plate form sea side direction position calibration combination, and the land side laser range finder and the main trolley land side reflecting plate form land side direction position calibration combination. The two position calibration combinations realize position calibration detection on the main trolley from front and back directions, and detection data are transmitted to the PLC control unit through an Ethernet protocol.
In specific implementation, as a preferred embodiment of the invention, the position measurement module consists of an absolute value encoder, wherein the absolute value encoder is arranged at a main trolley motor inside a grab ship unloader machine room and is used for positioning the operation of the main trolley mechanism motor in real time. The data of the main trolley position measured by the absolute value encoder is transmitted to the PLC module through an Ethernet transmission protocol.
In specific implementation, the PLC module calculates the real-time calibration detection position value of the main trolley according to the following formula:
L real time ＝(L WS +0.5*L Trolley )/(L WS +L LS )*L Arm support -L LS
Wherein, the central parking space of the main trolley hopper is used as the horizontal position zero position of the main trolley, L WS L is the distance from the sea side of the main trolley to the front end of the arm support, which is detected by a sea side laser range finder LS The distance L from the land side surface of the main trolley to the rear girder detected by the land side laser range finder Trolley Length of main trolley L Arm support The actual distance from the front end of the arm support to the rear girder;
calculating a base position value of the primary trolley according to the following formula:
L foundation ＝a*E Encoding +b
Wherein, the central parking space of the main trolley hopper is used as the horizontal position zero position of the main trolley, E Encoding The measurement data of the absolute value encoder of the main trolley is that a is the conversion data of the absolute value encoder, and b is that the conversion correction value of the absolute value encoder.
In addition, the PLC module is used for calibrating the data of the position measurement module according to the data of the position calibration module, and finally obtaining an accurate position value of the main trolley, and in one implementation mode, the basic data can be calibrated in a weighted superposition mode. In this embodiment, the main trolley of the grab ship unloader is pulled by a steel wire rope to move to the sea side or the land side respectively, the motor of the grab ship unloader is located in the machine room, and the absolute value encoder of the main trolley in the position measuring module can judge the position of the main trolley mechanism by detecting the running distance of the motor of the main trolley, but due to factors such as inertia, simple pendulum and the like, a certain detection error occurs in the mode, and the actual position of the main trolley cannot be measured truly and effectively. And the detection of the laser range finder in the position calibration module can compensate the measurement error, and calibrate and correct the position value of the main trolley, so that the accurate position of the main trolley is obtained. Meanwhile, laser ranging measurement is carried out on the main trolley from two directions of the sea side and the land side respectively, detection errors caused by factors such as vibration of the arm support and deflection of the arm support can be eliminated, and the positioning accuracy of the main trolley is further improved. In conclusion, the technical scheme of the invention can realize the function of calibrating the main trolley of the grab ship unloader, and in the running process of the main trolley mechanism of the grab ship unloader, the positioning precision of the main trolley is improved, the positioning safety of the equipment is ensured, and meanwhile, the reliable hardware performance guarantee is provided for the development of the intelligent grab ship unloader technology.
The mechanism positioning unit is used for detecting cab position values by additionally arranging a Gray bus coding ruler on the cab, and specifically comprises the following steps:
A. the method comprises the steps that position value data of a cab are obtained through a cab positioning module, the cab positioning module comprises a coding ruler arranged below a boom main beam and a U-shaped code reader arranged at the top of the cab, the coding ruler is arranged in a U-shaped groove of the U-shaped code reader, two sides of the U-shaped code reader are respectively an infrared signal transmitting end and an infrared signal receiving end, the U-shaped code reader moves along the coding ruler along with the cab in the cab operation process, positioning codes of the coding ruler at the current position are read in the process, and the positioning codes are transmitted to a PLC (programmable logic controller) unit through an Ethernet protocol to be converted, so that corresponding cab position values are obtained.
Specifically, the coding ruler is arranged in a U-shaped groove of the U-shaped code reader, two sides of the U-shaped code reader are respectively an infrared signal transmitting end and an infrared signal receiving end, the U-shaped code reader moves along the coding ruler along with the cab in the operation process of the cab, the positioning codes of the coding ruler at the current position are read in the process, and the positioning codes are transmitted to the PLC module for conversion through an Ethernet protocol, so that the corresponding cab position value is obtained. And the PLC module converts the positioning code to obtain a corresponding cab position value. The cab parking space is used as a cab travel zero point, and a cab position value conversion formula is as follows:
P Cab ＝0.8*E Encoding +K Correction ；
Wherein P is Cab Indicating cab position value, E Encoding Representing the positioning code, K, read by the U-shaped code reader Correction Indicating the converted correction value.
B. The cab driving unit drives the operation cab according to the position value data of the cab, which is obtained by the positioning unit, and comprises a frequency converter arranged in an electric control cabinet of the cab and a driving motor arranged at the top of the cab, wherein the input end of the frequency converter is connected with the output end of a wire inlet contactor, and the input end of the wire inlet contactor is connected with the output end of a wire inlet breaker; one output end of the frequency converter is connected with the brake resistor, the other output end of the frequency converter is connected with the input end of the motor starter, and the output end of the motor starter is connected with the driving motor at the top of the cab.
Accurate location of cab can further be realized based on the cab position that detects, specifically includes:
a. based on a positioning operation control method, the cab of the grab ship unloader is moved to the center position of a ship hatch after leaving parking, and the condition in the cabin is observed manually by a driver or scanned and identified by a scanner and a camera device;
b. based on a positioning operation control method, a cab leaves the center position of a ship hatch and moves to the side edge position of the hatch land side, and the side edge condition of the hatch land side is observed manually by a driver or scanned and identified by a scanner and a camera device;
c. Based on a positioning operation control method, a cab leaves a land side edge position of a hatch and moves to a sea side edge position of the hatch, and a driver manually observes the sea side edge condition of the hatch or scans and identifies the sea side edge condition of the hatch by a scanner and a camera device;
d. based on a positioning operation control method, a cab moves to a center position of a ship hatch from a sea side edge position of the hatch, and a grab ship unloader starts ship unloading operation in a cabin;
e. after the grab ship unloader finishes the ship unloading operation in the cabin, the cab leaves the center of the ship hatch based on the positioning operation control method, and moves back to the cab parking space, so that the ship unloading operation is finished.
The positioning operation control method specifically comprises the following steps:
T＝T adding +T Even distribution +T Reduction of
T Even distribution ＝(S Target object -0.5×V×T Adding -0.5×V×T Reduction of )/V
Wherein T is the operation time of the cab and T Adding For accelerating the operation time of the cab, T Even distribution For the constant-speed operation time of the cab, T Reduction of For the cab to slow down the running time S Target object And V is the maximum operating speed of the cab, wherein the distance from the target operating point to the initial operating point is the distance from the target operating point to the initial operating point.
By installing the laser scanning device and the visual recognition device on the cab platform, the grab bucket pose data acquired by the laser scanning device is taken as the main data, and the grab bucket pose data acquired by the visual recognition device is taken as the correction value, so that the accurate detection of the data such as the space position of the grab bucket, the grab bucket pose and the like is realized.
Specifically, the grab bucket pose detection scheme adopts two different detection technologies of three-dimensional laser scanning and visual recognition, forms a redundant detection scheme and improves the accuracy of system detection. The three-dimensional laser scanning technology has strong environmental adaptability and high detection precision, can meet the complex operation environment of a bulk cargo wharf, has slightly lower detection precision compared with the three-dimensional laser scanning technology, but has quicker data processing response, visual display effect and complementary advantages, and improves the overall reliability of system detection.
In the invention, the pose of the grab bucket is preferably represented by the space position of the grab bucket, the dumping angle of the grab bucket, the rotation angle of the grab bucket and the like, and specifically:
when the position and the posture of the grab bucket are represented by the grab bucket space position, firstly, the grab bucket space position data collected by the three-dimensional laser scanning device and the grab bucket space position data collected by the visual identification device are judged as follows:
when P School and school -P Inspection and detection >P Allow for And when the detection result deviation of the grab bucket space position value in the two detection modes of three-dimensional laser scanning and visual recognition is too large, the detection system reports a fault, and the ship unloader is stopped to operate. Wherein P is Allow for Calibrating the allowable deviation value, P, for the space position of the grab bucket Inspection and detection Grab bucket space position data, P, acquired for three-dimensional laser scanning device School and school And the grab bucket space position data is acquired for the visual recognition device.
When 0 is<P School and school -P Inspection and detection <＝P Allow for When the method is used, the detection results of the three-dimensional laser scanning and the visual identification are relatively close, but a certain deviation exists, the detection data of the three-dimensional laser scanning is required to be calibrated and corrected by adopting the detection data of the visual identification, and the method is as follows:
P fixing device ＝P Inspection and detection +K 1 *(P School and school -P Inspection and detection )
Wherein P is Fixing device For calibrated grab bucket spatial position data, P Inspection and detection Grab bucket space position data, P, acquired for three-dimensional laser scanning device School and school Grab bucket space position data, K, acquired for visual recognition device 1 For the spatial position correction coefficient, K is preferably set in the present embodiment 1 ＝0.3。
When the pose of the grab bucket is represented by the grab bucket dumping angle, firstly, the grab bucket dumping angle data collected by the three-dimensional laser scanning device and the grab bucket dumping angle data collected by the visual identification device are judged as follows:
when omega Tilting correction -ω Tilting inspection >ω Tilting and allowing And when the three-dimensional laser scanning and visual recognition detection modes are adopted, the deviation of the detection result of the grab bucket dumping angle is too large, and the detection system reports a fault and stops the ship unloader. Wherein omega Let the inclination be Calibration deviation allowance, omega, of grab bucket dumping angle Tilting inspection Grab bucket tilting collected for three-dimensional laser scanning deviceInverted angle data, omega Tilting correction Grab bucket dumping angle data collected for visual recognition device
When 0 is<ω Tilting correction -ω Tilting inspection <＝ω Tilting and allowing When the method is used, the detection results of the three-dimensional laser scanning and the visual identification are relatively close, but a certain deviation exists, the detection data of the three-dimensional laser scanning is required to be calibrated and corrected by adopting the detection data of the visual identification, and the method is as follows:
ω tilting and fixing ＝ω Tilting inspection +K 2 *(ω Tilting correction -ω Tilting inspection )
Wherein omega Tilting and fixing Omega as calibrated grapple dumping angle data Tilting inspection Grab bucket dumping angle data omega acquired by three-dimensional laser scanning device Tilting correction Grab bucket dumping angle data K acquired by the visual recognition device 2 For the correction coefficient of the tilting angle, K is preferably set in the present embodiment 2 ＝0.2。
When the pose of the grab bucket is represented by the rotation angle of the grab bucket, firstly, the rotation angle data of the grab bucket collected by the three-dimensional laser scanning device and the rotation angle data of the grab bucket collected by the visual identification device are judged as follows:
when omega Correction method -ω Rechecking >ω Return to allow And when the detection system is used, the three-dimensional laser scanning and visual recognition are performed, the deviation of the detection result of the rotation angle of the grab bucket is overlarge, and the detection system reports a fault and stops the ship unloader from running.
When 0 is<ω Correction method -ω Rechecking <＝ω Return to allow When the method is used, the detection results of the three-dimensional laser scanning and the visual identification are relatively close, but a certain deviation exists, the detection data of the three-dimensional laser scanning is required to be calibrated and corrected by adopting the detection data of the visual identification, and the method is as follows:
ω return to fix ＝ω Rechecking +K 3 *(ω Correction method -ω Rechecking )
Wherein omega Return to fix To calibrate corrected grab bucket rotation angle data omega Rechecking Grab collected by three-dimensional laser scanning device in detection unitBucket rotation angle data, ω Correction method Grab bucket rotation angle data K acquired by the visual recognition device 3 For the rotation angle correction coefficient, K is preferably set in the present embodiment 3 ＝0.2。
The method further comprises the step of carrying out risk judgment on final grab bucket pose data generated after correction, generating an alarm signal when judging that the grab bucket pose data has operation risk, and sending the alarm signal to a control system of the grab bucket ship unloader, and controlling electrodes of the trolley driving mechanism and the lifting driving mechanism to stop. Preferably, there is:
when P Fixing device -P Terminal (A) <D, judging the position of the grab bucket from the end position P by the system Terminal (A) The distance is too close and smaller than the collision allowable value D, the system sends out grab bucket collision alarm, and the trolley and the lifting mechanism are immediately driven to pull the grab bucket back to the safety area.
When omega Tilting and fixing >ω Tilting and leaning When the system judges that the grab bucket dumping angle value is larger than the allowable dumping angle omega of the grab bucket Tilting and leaning The system sends out the grab bucket to topple over and report to the police, and break dolly and hoisting mechanism operation immediately, until the grab bucket resumes steadily.
When omega Return to fix >ω Returning to When the system judges that the dumping angle value of the grab bucket is larger than the allowable rotation angle omega of the grab bucket Returning to The system sends out the excessive warning of grab bucket rotation, and immediately interrupts the operation of the trolley and the lifting mechanism until the grab bucket is restored to be stable.
Because the environment of the bulk cargo wharf is complex, factors such as dust, salt fog and the like have great influence on the detection accuracy of the detection device, the scanning and identification unit selects the laser scanning device to scan and identify ships, hatches and materials. The laser scanning device has strong anti-interference capability and high accuracy, and is suitable for the complex environment of a bulk cargo wharf. Specifically, the scanning and identifying unit is composed of a laser scanning device arranged near the twisting point of the main beam and a laser scanning device which is arranged at the position of the cab platform and is provided with a cradle head. The device is used for realizing accurate detection and identification of ships, hatches and materials. The laser scanning device for ship scanning is designed and installed at the main beam twisting point, the design form ensures that the ship unloader can scan the ship in the lifting posture of the arm support, the ship adaptability is stronger, and particularly, the collision between the arm support and the ship can be avoided when the large ship is scanned. The laser scanning device for hatch and material scanning identification is designed and installed on the cab platform, and due to the mobility of the cab, the laser scanning device is more flexible in working, and can move the cab to the position corresponding to the center of the ship hatch for ships with different sizes, so that the best hatch and material scanning effect can be obtained. In addition, the laser scanning devices for hatch and material scanning and identifying are arranged on the cab platform, the cradle head is arranged, the hatch and the material can be rapidly scanned through rotation of the cradle head, scanning and identifying time is greatly saved, and the overall operation efficiency of the grab ship unloader is improved.
In this embodiment, the ship anti-inclination early warning is performed according to the ship scanning result, which specifically includes:
a. and carrying out ship transverse inclination early warning judgment according to the following formula:
when omega Transverse inclination ＝arctan(|(H Sea water -H Land and land )/(L Sea water -L Land and land )|)>ω Transverse inclination allowing When the ship is determined to be excessively inclined transversely, wherein omega Transverse inclination Is the transverse inclination angle value of the ship, H Sea water Is the sea side edge height of the ship, H Land and land Is the land side edge height of the ship, L Sea water Is the horizontal position of the sea side edge of the ship, L Land and land Omega is the horizontal position of the land side edge of the ship Transverse inclination allowing The maximum allowable value of the transverse inclination angle of the ship is obtained.
b. And carrying out ship longitudinal inclination early warning judgment according to the following formula:
when omega Pitching of ＝arctan(|(H Ship bow -H Stern of ship )/(P Ship bow -P Stern of ship )|)>ω Trim allowance When the ship is determined to have excessive longitudinal inclination, wherein omega Pitching of Is the longitudinal inclination angle value of the ship, H Ship bow Is the height of the bow of the ship, H Stern of ship Is the height of the ship stern, P Ship bow Omega is the horizontal position of the ship bow Trim allowance Is the maximum allowable value of the longitudinal inclination angle of the ship, P Stern of ship Is the horizontal position of the stern of the ship.
c. The sea-land side collision safety distance is calculated according to the following formula: s is S Sea and land ＝a*L Grab bucket +b, where S Sea and land Is the sea-land side anti-collision safety distance, a is the sea-land side anti-collision safety coefficient, L Grab bucket And b is an anti-collision safety correction value for the length value of the grab bucket when the grab bucket is opened.
d. The left and right side crash-proof safety distances are calculated according to the following formula: s is S (left and right) ＝A*W Grab bucket +b, where S (left and right) Is the left-right side anti-collision safety distance, A is the left-right side anti-collision safety coefficient, W Grab bucket Is the grab bucket width value.
e. Will be away from the sea-land side edge S of the hatch Sea and land The area within the range is divided into a sea-land side anti-collision early warning area, and the left side edge S and the right side edge S of the hatch are separated (left and right) The area in the range is divided into a left side anti-collision early warning area and a right side anti-collision early warning area, and in the ship unloading operation, the grab bucket enters the sea-land side anti-collision early warning area or the left side anti-collision early warning area and the right side anti-collision early warning area, namely, the hatch anti-collision early warning is sent.
In a further preferred embodiment, the laser scanning device at the cab platform scans the material, and according to the material scanning result, the material anti-burying bucket early warning is realized, and the method specifically comprises the following steps:
calculating the material inclination according to the following formula: omega Inclination angle ＝arctan((H Adjacent to -H Target object )/S Spacing of )；
Wherein omega Inclination angle The material stacking inclination angle around the grabbing point for the current target operation is H Adjacent to The material height of the grabbing point is H for adjacent operation Target object Grasping the material height of the point for the current target operation, S Spacing of And the center distance between the adjacent operation grabbing point and the current target operation grabbing point is set. When omega Inclination angle When the natural stacking angle of the working materials is reached, the system sends out the early warning of preventing the materials from being buried.
The unmanned grab ship unloader starts automatic ship unloading operation, in the ship unloading operation process, the ship inclination prevention early warning function, the hatch collision prevention early warning function and the material burying prevention early warning function are started in real time, and once early warning faults occur, the automatic ship unloading operation is interrupted, and the ship unloading operation is switched to a manual remote mode to perform early warning fault treatment. After the early warning fault treatment is completed, switching back to an automatic ship unloading operation mode, and maintaining the real-time detection of the early warning until the ship unloading operation is completed, and closing the scanning and identifying system to stop running.
The data acquisition unit is arranged in the PLC room and consists of a PLC module and a communication module, and an Ethernet communication protocol is adopted to receive data acquired by the mechanism positioning unit, the grab bucket pose detection unit and the scanning identification unit.
The operation flow of the accurate positioning system provided by the invention mainly comprises the following steps: step one: starting the grab ship unloader, and activating the accurate positioning system of the grab ship unloader; step two: the mechanism positioning unit operates, and the data acquisition unit receives the data detected by the mechanism positioning unit in real time; step three: the grab bucket pose detection unit operates, and the data acquisition unit receives the data detected by the grab bucket pose detection unit in real time; step four: the scanning and identifying unit operates, and the data acquisition unit receives the data detected by the scanning and identifying unit in real time; step five: and stopping the operation of the grab ship unloader, and closing the accurate positioning system of the grab ship unloader.
The unmanned grab ship unloader control system in the embodiment of the invention comprises:
and the machine-mounted control unit is arranged on the grab ship unloader equipment and used for driving each mechanism of the grab ship unloader to operate so as to perform ship unloading operation. Comprising the following steps: 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.
A remote control unit comprising: 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.
A video monitoring management unit comprising: 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 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. The video data collected by the video monitoring management unit can be displayed on a display in a cab of the grab ship unloader and a remote operation table in a central control room in the remote control unit 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
A remote operation and maintenance unit comprising: the monitoring picture, the operation desk, the industrial personal computer, the dispatching instruction sending device and the field information acquisition device are arranged in the remote debugging dispatching center and are used for realizing the remote debugging, remote operation and maintenance and other works of 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 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 for preventing bucket burying and furrow stepping operation is adopted in the trolley direction, and a single-cabin task planning function is achieved.
In specific implementation, the on-board control unit and the decision analysis unit perform 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.
The method is characterized by comprising the steps of providing convenience for planning a ship unloading operation flow, and 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.
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 realizes remote on duty of the working states of the grab ship unloader and the material conveying working line by carrying out cooperative control on the airborne control unit and the material conveying working 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 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 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 the implementation, the control unit in the video monitoring management unit 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 object /S Screen panel -50％)*(W Far focus -W Near-focus )；
Wherein W is Focusing Is a focal length adjusting value S Target object For the size of the object in the picture, S Screen panel To the whole size of the screen in the picture, W Far focus For the maximum focal length of far focus, W Near-focus Is the near focal minimum focal length.
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:
ω shooting and photographing device ＝arctan((L Grab bucket -L Shooting and photographing device )/(H Shooting and photographing device -H Grab bucket ))；
Wherein omega Shooting and photographing device For camera real-time angle adjustment, L Grab bucket For the horizontal distance of the grab bucket L Shooting and photographing device For the horizontal distance of the camera, H Shooting and photographing device For camera height, H Grab bucket Is the grab bucket height.
In specific implementation, the remote operation and maintenance unit 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, establishing communication connection between the remote operation and maintenance unit and the onboard control unit and between the remote operation and maintenance unit and the video monitoring and management unit; s702, 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; after the communication connection is established, the signal test of the safety element is started, the remote operation and maintenance unit 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, the remote operation and maintenance unit sends a scheduling instruction to sequentially complete the test action; 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 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, 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; after the single-mechanism action test is completed, the no-load test of the grab ship unloader is started, the remote operation and maintenance unit sends a scheduling instruction, and the on-site operator performs the no-load test of the grab ship unloader. 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 sequentially sends data delay detection signals to the airborne control unit and the video monitoring management unit at regular time, and after the airborne control unit and the video monitoring management unit receive the data delay detection signals, the remote operation and maintenance unit immediately sends data delay detection feedback signals to the remote operation and maintenance unit, after the remote operation and maintenance unit receives the data delay detection feedback signals returned by the two units, the remote operation and maintenance unit carries 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 meanwhile, the data delay time is compared with a threshold value to judge the real-time 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 and the airborne control unit meets the remote debugging requirement; if T Feedback 2 -T Send 2 ＞T Threshold 2 The communication between the remote operation and maintenance unit and the video monitoring management unit meets the remote debugging requirement; if T Feedback 1 -T Transmission 1 ＜T Threshold 1 Then the remote operation and maintenance unit is controlled on-boardCommunication between units does not meet remote debugging requirements; if T Feedback 2 -T Send 2 ＜T Threshold 2 The communication between the remote operation and maintenance unit and the video monitoring management unit does not meet the remote debugging requirement;
wherein T is Feedback 1 The time T for the remote operation and maintenance unit to receive the data delay detection feedback signal returned by the airborne control unit Transmission 1 The time of the remote operation and maintenance unit sending the data delay detection signal to the airborne control unit is represented by T Threshold 1 Representing a data delay time permission threshold between the remote operation and maintenance unit and the onboard control unit; t (T) Feedback 2 The time T for the remote operation and maintenance unit to receive the data delay detection feedback signal returned by the video monitoring management unit Send 2 The time T for the remote operation and maintenance unit to send the data delay detection signal to the video monitoring management unit is represented Threshold 2 Representing a data latency tolerance threshold between the remote operation and maintenance unit and the video surveillance management unit.
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, and the control method comprises the following steps:
S801, starting the ship port approaching, wherein an airborne control unit starts to work, and the grab ship unloader is started in unmanned ship unloading operation; meanwhile, the video monitoring management unit 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; 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; s810, in the operation process, the grab ship unloader receives a remote control instruction of a remote control unit 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.
Claims (10)
1. An unmanned grab ship unloader, comprising: a grab ship unloader body, a grab ship unloader accurate positioning system and an unmanned grab ship unloader control system,
the grab ship unloader body is used for realizing the conventional ship unloader operation function of the grab ship unloader, and comprises: the device comprises a trolley, a trolley running device, a main beam arm support mechanism, a grab bucket mechanism and a cab;
the accurate positioning system of the grab ship unloader comprises: the device comprises a mechanism positioning unit, a grab bucket pose detection unit, a scanning identification unit and a data acquisition unit, wherein the mechanism positioning unit, the grab bucket pose detection unit and the scanning identification unit are respectively in communication connection with the data acquisition unit; the mechanism positioning unit is used for calibrating a trolley position value, detecting a boom pitching angle, calibrating a large vehicle position value and detecting a cab position value; the grab bucket pose detection unit is used for detecting the grab bucket running space position and the grab bucket pose; the scanning and identifying unit is used for detecting ships, hatches and materials in real time; the data acquisition unit is used for receiving the data acquired by the mechanism positioning unit, the grab bucket pose detection unit and the scanning identification unit;
the unmanned grab ship unloader control system comprises: 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 body 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 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, so that the single-cabin task planning function is realized.
2. The unmanned grab ship unloader according to claim 1, wherein the grab ship unloader body further comprises a portal mechanism, a tower mechanism, a feeding mechanism and a machine room mechanism, wherein the portal mechanism is used as a main supporting structure of the grab ship unloader, and the cart running device is arranged at the lower part of the sea-land side portal mechanism and is used for the grab ship unloader to move along a wharf rail; the main beam arm support mechanism is arranged above the portal frame mechanism and is used for providing a track required by the operation of the grab ship unloader trolley, so that the trolley can move on the main beam arm support mechanism; the arm support part of the main beam arm support mechanism can be lifted in a pitching way; the tower mechanism is positioned above the main beam, and is provided with a steel wire rope pulley for pitching the arm support and a hook device for locking the hook after the arm support is pitching and the arm support is pitching to a high point; the feeding mechanism is arranged at the lower part of the portal mechanism and consists of a hopper and a feeding device, the hopper is used for receiving materials grabbed from the cabin of the ship by the grab mechanism, and then the materials are transmitted to a quay ground belt by the feeding device; the machine room mechanism is arranged at the rear end of the main girder arm support mechanism and is used for driving the grab bucket ship unloader to finish the pitching actions of the trolley, the grab bucket and the arm support, the grab bucket mechanism is hung below the trolley through a steel wire rope, and the steel wire rope is used for dragging to finish the ship unloading process flow of grabbing materials from the cabin to the hopper.
3. The unmanned grab ship unloader according to claim 1, wherein the mechanism positioning unit performs calibration of the position values of the trolley by arranging laser ranging devices on the trolley mechanism, specifically, arranging position calibration modules on the front end region of the arm frame, the main trolley region and the rear girder region to realize calibration detection of the position values of the main trolley, wherein the position calibration modules comprise a sea side laser ranging device arranged on the front end region of the arm frame, a reflecting plate arranged on the sea side of the main trolley, a land side laser ranging device arranged on the rear girder region, and a reflecting plate arranged on the land side of the main trolley, wherein the sea side laser ranging device and the land side laser ranging device respectively adopt linear laser ranging devices, and the detection distances of the sea side laser ranging device and the land side laser ranging device are not less than 80m;
a position detection module is arranged at a motor of a main trolley of the machine room so as to realize measurement of a position value of the main trolley, and the position detection module comprises an absolute value encoder, wherein the absolute value encoder is used for positioning the operation of the motor of a mechanism of the main trolley in real time;
calculating a real-time calibration detection position value of the main trolley according to the following formula:
L real time ＝(L WS +0.5*L Trolley )/(L WS +L LS )*L Arm support -L LS
Wherein, the central parking space of the main trolley hopper is used as the horizontal position zero position of the main trolley, L WS L is the distance from the sea side of the main trolley to the front end of the arm support, which is detected by a sea side laser range finder LS The distance L from the land side surface of the main trolley to the rear girder detected by the land side laser range finder Trolley Length of main trolley L Arm support The actual distance from the front end of the arm support to the rear girder;
calculating a base position value of the primary trolley according to the following formula:
L foundation ＝a*E Encoding +b
Wherein, the central parking space of the main trolley hopper is used as the horizontal position zero position of the main trolley, E Encoding The measurement data of the absolute value encoder of the main trolley is that a is the conversion data of the absolute value encoder, and b is that the conversion correction value of the absolute value encoder.
4. The unmanned grab ship unloader according to claim 1, wherein the mechanism positioning unit detects the position value of the cab by adding a gray bus code scale to the cab, specifically, the cab positioning module obtains the position value data of the cab, the cab positioning module comprises a code scale arranged below a main beam of the arm support and a U-shaped code reader arranged at the top of the cab, the code scale is arranged in a U-shaped groove of the U-shaped code reader, two sides of the U-shaped code reader are respectively an infrared signal transmitting end and an infrared signal receiving end, the U-shaped code reader moves along the code scale along with the cab in the operation process of the cab, and the positioning code of the code scale at the current position is read in the process and is transmitted to the PLC control unit for conversion through an Ethernet protocol to obtain the corresponding cab position value;
The cab driving unit drives the operation cab according to the position value data of the cab, which is obtained by the cab positioning module, and comprises a frequency converter arranged in an electric control cabinet of the cab and a driving motor arranged at the top of the cab, wherein the input end of the frequency converter is connected with the output end of a wire inlet contactor, and the input end of the wire inlet contactor is connected with the output end of a wire inlet breaker; one output end of the frequency converter is connected with the brake resistor, the other output end of the frequency converter is connected with the input end of the motor starter, and the output end of the motor starter is connected with the driving motor at the top of the cab;
cab position values are calculated according to the following formula:
P cab ＝0.8*E Encoding +K Correction
Wherein P is Cab Indicating cab position value, E Encoding Representing the positioning code, K, read by the U-shaped code reader Correction Indicating the converted correction value.
5. The unmanned grab ship unloader according to claim 1, wherein the grab bucket pose detection unit performs grab bucket running space position and grab bucket pose detection by arranging a laser scanning device and a visual recognition device on a cab platform, comprising:
acquiring first grab bucket pose data acquired by a three-dimensional laser scanning device, wherein the three-dimensional laser scanning device is arranged on a cab platform;
Acquiring second grab bucket pose data acquired by a visual recognition device, wherein the visual recognition device is arranged on a cab platform;
the first grab bucket pose data is used as a reference, and the second grab bucket pose data is used for calibrating the first grab bucket pose data, so that final grab bucket pose data is generated;
calculating calibrated grapple spatial position data according to the following formula:
P fixing device ＝P Inspection and detection +K 1 *(P School and school -P Inspection and detection )
Wherein P is Fixing device For calibrated grab bucket spatial position data, P Inspection and detection Grab bucket space position data, P, acquired for three-dimensional laser scanning device School and school Grab bucket space position data, K, acquired for visual recognition device 1 Correcting coefficients for spatial positions;
calculating calibrated grapple dumping angle data according to the following formula:
ω tilting and fixing ＝ω Tilting inspection +K 2 *(ω Tilting correction -ω Tilting inspection )
Wherein omega Tilting and fixing Omega as calibrated grapple dumping angle data Tilting inspection Grab bucket dumping angle data omega acquired by three-dimensional laser scanning device Tilting correction Grab bucket dumping angle data K acquired by the visual recognition device 2 The inclination angle correction coefficient is used;
calculating corrected rotation angle data of the grab bucket according to the following formula:
ω return to fix ＝ω Rechecking +K 3 *(ω Correction method -ω Rechecking )
Wherein omega Return to fix To calibrate corrected grab bucket rotation angle data omega Rechecking For grab bucket rotation angle data omega acquired by a three-dimensional laser scanning device in a detection unit Correction method Grab bucket rotation angle number acquired for visual recognition deviceAccording to K 3 The rotation angle correction coefficient.
6. The unmanned grab ship unloader according to claim 1, wherein the scanning and recognition unit performs real-time detection of ships, hatches, materials by arranging a laser scanning device at the cab platform and the girder winch position, and comprises:
carrying out ship scanning through a ship laser scanning device, wherein the ship scanning device is arranged at a girder twisting point;
the hatch and the material laser scanning device are arranged on a cab platform and are provided with a tripod head, and the hatch and the material can be rapidly scanned through rotation of the tripod head;
further comprises: performing ship inclination prevention early warning according to a ship scanning result, specifically comprising:
and carrying out ship transverse inclination early warning judgment according to the following formula:
when omega Transverse inclination ＝arctan(|(H Sea water -H Land and land )/(L Sea water -L Land and land )|)>ω Transverse inclination allowing When the ship is determined to be excessively inclined transversely, wherein omega Transverse inclination Is the transverse inclination angle value of the ship, H Sea water Is the sea side edge height of the ship, H Land and land Is the land side edge height of the ship, L Sea water Is the horizontal position of the sea side edge of the ship, L Land and land Omega is the horizontal position of the land side edge of the ship Transverse inclination allowing The maximum allowable value of the transverse inclination angle of the ship;
and carrying out ship longitudinal inclination early warning judgment according to the following formula:
when omega Pitching of ＝arctan(|(H Ship bow -H Stern of ship )/(P Ship bow -P Stern of ship )|)>ω Trim allowance When the ship is determined to have excessive longitudinal inclination, wherein omega Pitching of Is the longitudinal inclination angle value of the ship, H Ship bow Is the height of the bow of the ship, H Stern of ship Is the height of the ship stern, P Ship bow Omega is the horizontal position of the ship bow Trim allowance For tilting the vessel longitudinallyMaximum allowable value of inclined angle, P Stern of ship The horizontal position of the stern of the ship;
the scanning recognition unit carries out real-time detection of boats and ships, hatch, material through setting up laser scanning device at cab platform and girder hank point location, still includes: carrying out hatch anti-collision early warning according to a hatch scanning result, and specifically comprising the following steps:
the sea-land side collision safety distance is calculated according to the following formula: s is S Sea and land ＝a*L Grab bucket +b, where S Sea and land Is the sea-land side anti-collision safety distance, a is the sea-land side anti-collision safety coefficient, L Grab bucket The length value is the length value when the grab bucket is opened, and b is an anti-collision safety correction value;
The left and right side crash-proof safety distances are calculated according to the following formula: s is S (left and right) ＝A*W Grab bucket +b, where S (left and right) Is the left-right side anti-collision safety distance, A is the left-right side anti-collision safety coefficient, W Grab bucket The grab bucket width value;
will be away from the sea-land side edge S of the hatch Sea and land The area within the range is divided into a sea-land side anti-collision early warning area, and the left side edge S and the right side edge S of the hatch are separated (left and right) The area in the range is divided into a left side anti-collision early warning area and a right side anti-collision early warning area, and in the ship unloading operation, the grab bucket enters the sea-land side anti-collision early warning area or the left side anti-collision early warning area and the right side anti-collision early warning area, namely, the hatch anti-collision early warning is sent.
7. The unmanned grab ship unloader 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;
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.
8. The unmanned grab ship unloader of claim 7, 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 console is used for manual operation, manual intervention is performed when the unmanned grab ship unloader control system fails, and remote operation is used for removing faults;
the unmanned grab ship unloader control system further comprises: 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.
9. The unmanned grab ship unloader of claim 8, wherein the unmanned grab ship unloader is unmanned controlled based on the following method:
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.
10. The unmanned grab ship unloader of claim 9, 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;
the remote debugging and remote operation and maintenance work of the grab ship unloader are completed;
further comprises: 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;
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;
the grab ship unloader carries out ship unloading operation according to the decision given by the decision analysis unit, and comprises the following steps:
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; the grab bucket is controlled to move to corresponding operation units in other column operation combinations in the group of the column operation combination where the operation unit is located in a stepping mode along the running direction of the cart by a second control strategy, the first control strategy control and the second control strategy control are repeated until all operation units in all column operation combinations in the group finish unloading, then the grab bucket is controlled to move to operation units in all column operation combinations in the other group in a stepping mode along the running direction of the cart, and the first control strategy control and the second control strategy control are repeated until all operation units in an operation area finish unloading, so that ship unloading operation is finished;
Further comprises: 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.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202211716149.0A CN116216533A (en) | 2022-12-29 | 2022-12-29 | Unmanned grab ship unloader |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202211716149.0A CN116216533A (en) | 2022-12-29 | 2022-12-29 | Unmanned grab ship unloader |
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| CN116216533A true CN116216533A (en) | 2023-06-06 |
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| CN202211716149.0A Pending CN116216533A (en) | 2022-12-29 | 2022-12-29 | Unmanned grab ship unloader |
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Cited By (3)
| 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 |
| CN117446538A (en) * | 2023-12-21 | 2024-01-26 | 河南卫华重型机械股份有限公司 | Continuous material taking control method of ship unloader |
| CN117806223A (en) * | 2023-12-28 | 2024-04-02 | 国投中煤同煤京唐港口有限公司 | Automatic ship-loading control system |
-
2022
- 2022-12-29 CN CN202211716149.0A patent/CN116216533A/en active Pending
Cited By (5)
| 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 |
| CN117446538A (en) * | 2023-12-21 | 2024-01-26 | 河南卫华重型机械股份有限公司 | Continuous material taking control method of ship unloader |
| CN117446538B (en) * | 2023-12-21 | 2024-04-05 | 河南卫华重型机械股份有限公司 | Continuous material taking control method of ship unloader |
| CN117806223A (en) * | 2023-12-28 | 2024-04-02 | 国投中煤同煤京唐港口有限公司 | Automatic ship-loading control system |
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