CN116362501A

CN116362501A - Intelligent production management and control system for bulk cargo port

Info

Publication number: CN116362501A
Application number: CN202310321476.4A
Authority: CN
Inventors: 董建伟; 陶冶; 张岩松; 裴永亮; 贾璐; 陈志鹏; 张栋; 李梦尧; 苏青; 杜雨杭; 李世龙; 孟祥峰; 贾然然; 李海滨
Original assignee: Qinhuangdao Yanda Binyuan Technology Development Co ltd
Current assignee: Qinhuangdao Yanda Binyuan Technology Development Co ltd
Priority date: 2023-03-29
Filing date: 2023-03-29
Publication date: 2023-06-30

Abstract

The invention provides a bulk cargo port intelligent production management and control system, which realizes autonomous operation, regulation and control and data receiving and transmitting through an intelligent basic equipment system, and comprises intelligent equipment, terminals and a data acquisition device related to port bulk cargo living management and control; the intelligent production scheduling system decides control instructions of all equipment and terminals in the intelligent basic equipment system based on the production and supply and sales data of the data management system and the ship information data in combination with the set optimization management and control plan; the simulation previewing optimizing system is also utilized to execute comprehensive operation simulation previewing according to the set optimizing management and control plan, and parameters of the management and control optimizing target are optimized according to the previewing operation result; and constructing a three-dimensional simulation platform aiming at material stacking and full-flow equipment to realize three-dimensional display. By adopting the system, the problems of insufficient processing capacity and imperfect scheduling strategy of the existing bulk cargo port are solved, a port whole-flow intelligent scheduling strategy and a production scheme are formed, the production risk is effectively reduced, and the production efficiency is improved.

Description

Intelligent production management and control system for bulk cargo port

Technical Field

The invention relates to the technical field of reliability tests and evaluations, in particular to an intelligent production management and control system for a bulk cargo port, which relates to related technologies such as front-end development, digital twin, big data deduction, system integration and the like, and is mainly constructed for solving the problems of insufficient port information processing capability, lack of scheduling strategies and the like of the existing bulk cargo port.

Background

Along with the development and progress of the times, coastal large-scale ports in China are aware that intelligent ports are new states of transportation of modern ports, and the intelligent ports are based on modern infrastructure, so that the advanced integration of new generation information technologies such as big data, cloud computing, internet of things, digital twin, intelligent control and the like and port transportation business is promoted, and the promotion of port management and control to informatization and intelligent development is supported. The existing bulk cargo port still faces the problems of insufficient port information processing capability, lack of scheduling strategies, lack of a production monitoring system with perfect functions and the like to be solved. How to build a bulk cargo production management and control system to monitor the production plan and the equipment operation state of ports, collect production data at the same time, and provide a scheduling strategy and a production scheme by means of machine learning, deep learning and other methods, so that the reduction of production risk and the improvement of production efficiency become focuses of attention of all bulk cargo ports.

The information disclosed in the background section of the invention is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.

Disclosure of Invention

To solve the above problems, the present invention provides a system for intelligent production control of bulk ports, which in one embodiment comprises: the data management system is connected with the intelligent basic equipment system and the ship information development system and is used for collecting port production flow data, material data, production and marketing data and ship information data in real time, so that data management and data sharing are realized;

the intelligent basic equipment system comprises intelligent equipment, terminals and data acquisition devices related to port bulk cargo living management and control, and can respond to control instructions to realize autonomous operation, regulation and control and data receiving and transmitting;

the intelligent production scheduling system is configured to decide control instructions of all equipment and terminals in the intelligent basic equipment system based on the production, supply and sales data and the ship information data combined with the set optimization management and control plan, and comprises an automatic material piling and taking control subsystem, a production flow management and control subsystem and a ship arrangement intelligent management subsystem;

the simulation previewing optimizing system is configured to execute comprehensive operation simulation previewing according to a set optimization management and control plan based on the data twinning simulating system, and optimize parameters of a management and control optimizing target according to a previewing operation result;

The full-flow dynamic display system is used for constructing a three-dimensional simulation platform for material stacking and full-flow equipment based on a three-dimensional simulation technology, and retrieving data from the data management system for visual and three-dimensional display in response to a user instruction.

In an alternative embodiment, the intelligent production scheduling system adopts a front-end and rear-end separation development mode based on Vue+spring Boot, a Vue driver adopts a library supported by a single file component and a Vue ecosystem to develop a complex single page application, and an expansion development component integration module is arranged based on a Spring Boot framework, so that the system is convenient to fully decouple and expand.

Further, the automatic stacking and taking control subsystem performs stack plane configuration management on a stack yard according to a field/strip/stack management mode, forms a corresponding optimized management and control plan by taking a maximum stock capacity algorithm, a minimum energy consumption algorithm and a minimum time algorithm as targets based on operation task information (including material types, numbers, owners, workload and the like), and formulates three corresponding stacking and taking schemes.

In some embodiments of the present invention, the automatic stacker-reclaimer control subsystem establishes a stacker-reclaimer anti-collision module configured to implement a stacker-reclaimer anti-collision control function according to the following logic:

a triple material pile anti-collision system is adopted between the material piling and taking machine and the material pile, and corresponding multi-stage alarming is set;

The single machine anti-collision adopts a bounding box method to set a large machine anti-collision protection circular area and sets multi-stage alarm;

the stacker-reclaimer walks and prevents bumping with pedestrians, adopt the way that the automatic recognition of the pick-up head combines with millimeter wave radar, and set up the multilevel to report to the police;

the stacker-reclaimer adopts anti-collision sensors arranged on two sides of a cantilever and at the head to prevent collision with surrounding constructions, and is provided with a multi-stage alarm;

setting an area intrusion alarm, setting a stacker-reclaimer operation area, detecting whether mobile working machines, pedestrians and vehicles enter a large machine protection area by adopting a camera graphic acquisition and computer vision algorithm, and alarming in time.

Further, in some embodiments, the production flow management and control subsystem is provided with a belt conveyor flow intelligent control module, which is configured to receive a job plan issued by the intelligent production scheduling system, perform analysis and disassembly, convert the job plan into a task plan, perform flow scheduling according to the plan, comprehensively consider the operation and fault conditions of the existing equipment in the scheduling process, select an optimal path algorithm, implement flow switching according to the job plan by the sequencing flow, and issue instructions to the flow PLC, so as to implement "one-key linkage" full-flow intelligent control.

Optionally, in some embodiments, the intelligent flow control module of the belt conveyor is provided with a flow tracking unit, which is configured to monitor a flow state on the belt conveyor through a flow PLC, so that an operator can know a flow condition on the belt conveyor conveniently, and the flow tracking unit is used as a basis for flow sequential stop control.

Further, the ship arrangement intelligent management subsystem is configured to simulate and calculate ship arrival time through a pre-built ship arrival prediction model based on AIS information acquired in real time or manually input ship type, ship identification code, current position and navigational speed information, and dynamically adjust time weight of a ship mission plan by referring to historical simulation data and actual arrival time.

Preferably, in some embodiments, the ship-handling intelligent management subsystem is further configured to predict and discover comprehensive measurement berth occupancy conflicts, material inventory conflicts, conveyor system conflicts, inventory space conflicts using a comprehensive balance model, and adjust the timing plan based thereon.

Specifically, in an alternative embodiment, the simulation previewing optimization system is configured to: and before operation, according to the latest actual production equipment state acquired from each system of the port service stock yard, taking the latest actual production equipment state as an initial condition, combining the on-site real-time equipment state, simulating and simulating real working conditions to perform virtual production, optimizing a production operation plan according to the completed condition, and simultaneously recommending an optimized operation plan result by the system.

In some embodiments, radar modeling and three-dimensional laser scanning modeling are used as the basis to realize all-dimensional digital storage yard, full-flow material flow tracking and three-dimensional visual display, three-dimensional modeling of a material pile is carried out aiming at different working conditions, all-weather real-time modeling is carried out in the material pile and material taking working process, and latest data is provided for calculation of a material pile working strategy.

Compared with the closest prior art, the invention has the following beneficial effects:

the intelligent production management and control system for the bulk cargo port provided by the invention realizes autonomous operation, regulation and control and data receiving and transmitting through an intelligent basic equipment system, and comprises intelligent equipment, terminals and data acquisition devices related to management and control of bulk cargo living in the port; the intelligent production scheduling system decides control instructions of all equipment and terminals in the intelligent basic equipment system based on the production and supply and sales data of the data management system and the ship information data combined with the set optimization management and control plan, and the intelligent basic equipment system comprises an automatic material piling and taking control subsystem, a production flow management and control subsystem and a ship arrangement intelligent management subsystem; forming a full-flow intelligent scheduling strategy and a production scheme based on a multi-layer data management platform, and comprehensively realizing intelligent port high-efficiency monitoring;

Executing comprehensive operation simulation previewing according to a set optimization management and control plan by using a simulation previewing optimizing system, and optimizing parameters of a management and control optimizing target according to a previewing operation result; the management and control parameters are optimized through operation previewing result analysis, so that the suitability of the management and control parameters and the operation working conditions can be ensured, and the accuracy and the safety of port production operation are further ensured.

A three-dimensional simulation platform is built aiming at material stacking and full-flow equipment to realize three-dimensional display, so that patrol and management and control personnel can intuitively analyze production data and realize control in a distributed mode.

Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.

Drawings

The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification, illustrate the invention and together with the embodiments of the invention, serve to explain the invention, without limitation to the invention. In the drawings:

FIG. 1 is a schematic diagram of a system for intelligent production control of bulk ports according to an embodiment of the present invention;

FIG. 2 is an example of a business function diagram of an intelligent production scheduling system in an intelligent production control system provided by the invention;

FIG. 3 is a diagram of a network topology of an intelligent production scheduling system in the intelligent production control system provided by the invention;

FIG. 4 is a diagram of a network architecture of an intelligent production scheduling system in an intelligent production control system according to an embodiment of the present invention;

FIG. 5 is a diagram of a service main frame of an intelligent production scheduling system in the intelligent production control system according to the present invention;

FIG. 6 is a block diagram of an example of a B/S framework system architecture for an intelligent production scheduling system in an intelligent production control system according to an embodiment of the present invention;

FIG. 7 is a flow chart of a stacking scheme decision for an automatic stacking and reclaiming control subsystem in an intelligent production control system according to an embodiment of the present invention;

FIG. 8 is a yard management interface diagram of an automatic stacker-reclaim control subsystem in an intelligent production management and control system provided by the present invention;

FIG. 9 is a conveyor control flow diagram of the automatic stacker reclaimer control subsystem in the intelligent production control system of the present invention;

FIG. 10 is a flow chart of the automatic stacker-reclaim control subsystem in the intelligent production control system according to an embodiment of the present invention;

FIG. 11 is a schematic diagram of a process control subsystem in an intelligent production control system according to an embodiment of the present invention;

FIG. 12 is a schematic block diagram of a ship arrival prediction model in an intelligent production control system according to an embodiment of the present invention;

FIG. 13 is an example of a real-time status diagram of a yard material for an intelligent production control system according to one embodiment of the present invention;

FIG. 14 is an example of a terrain module interface diagram for an intelligent production control system provided by an embodiment of the present invention;

FIG. 15 is an illustration of a stack information interface for an intelligent production control system according to an embodiment of the present invention;

FIG. 16 is an example of an interface diagram of device details of an intelligent production control system according to one embodiment of the present invention;

FIG. 17 is an example of a mainframe operational information interface diagram of an intelligent production control system provided by an embodiment of the present invention;

FIG. 18 is a flow chart of a one-touch linkage operation of the intelligent production control system according to the embodiment of the present invention.

Detailed Description

The following will explain the embodiments of the present invention in detail with reference to the drawings and examples, so that the practitioner of the present invention can fully understand how to apply the technical means to solve the technical problems, achieve the implementation process of the technical effects, and implement the present invention according to the implementation process. It should be noted that, as long as no conflict is formed, each embodiment of the present invention and each feature of each embodiment may be combined with each other, and the formed technical solutions are all within the protection scope of the present invention.

Network devices include, but are not limited to, a single network server, a server group of multiple network servers, or a cloud based cloud computing consisting of a large number of computers or network servers. The computer device may operate alone to implement the invention, or may access a network and implement the invention through interoperation with other computer devices in the network. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. When an element is referred to as being "connected" or "coupled" to another element, it can be directly connected or coupled to the other element or intervening elements may be present.

The automatic operation system is a brand new technology in the bulk cargo transportation industry, and realizes the automatic stacking and taking operation of the stacker-reclaimer in the bulk cargo storage yard. The intelligent port is a new state of modern port transportation, and the existing bulk port still faces the problems of insufficient port information processing capability, lack of scheduling strategies, lack of a production monitoring system with perfect functions and the like to be solved. How to build a bulk cargo production management and control system to monitor the production plan and the equipment operation state of ports, collect production data at the same time, and provide a scheduling strategy and a production scheme by means of machine learning, deep learning and other methods, so that the reduction of production risk and the improvement of production efficiency become focuses of attention of all bulk cargo ports.

Currently existing bulk production management systems have basic equipment status monitoring and shipping equipment scheduling functions, but lack deep parsing of production planning and operation data, such as intelligent port-based bulk management integrated systems provided in document CN115115303a, comprising: the system comprises a cloud computing data center, a harbor district scheduling module, a fault diagnosis module, a cloud management and control platform and a bulk cargo transportation management module. The scheme realizes the collection of port data by using the management and control platform and analyzes the running state of equipment; performing advanced diagnosis and analysis on the management and control equipment, performing fault prediction, and scheduling the management and control equipment; the scheme can predict faults based on equipment state data, but cannot realize integrated intelligent production control;

document CN113689037a proposes a bulk cargo port production scheduling optimization method, which aims at minimizing the time for completing the ship operation, reducing the conflict of the ship loading operation flow, making a ship loading operation plan, optimizing the material loading plan by adopting a multi-objective algorithm, and efficiently distributing the resources such as ships, ship loaders, reclaimers, and the like. According to the scheme, an operation plan is formulated through the optimization setting to optimize the operation flow, the operation efficiency is improved based on prevention of flow conflict, but the optimization degree is limited, the dependence on artificial data is high, and guidance cannot be provided for integral intelligent integral improvement of the port.

In order to solve the problems of insufficient port information processing capability and lack of scheduling strategies, the invention provides a bulk cargo port intelligent production management and control system which comprehensively reflects non-working, fault and belt conveying states of logistics equipment, automatically recommends stacking and taking piles, analyzes the storage capability in real time, optimizes the storage yard layout, optimizes the distribution of goods sources, optimizes the scheduling path planning, realizes intelligent production scheduling, realizes intelligent control of the flow of a belt conveyor, and can realize the following intelligent improvement: (1) Before a piling and taking operation task is carried out, recommending a piling and taking scheme according to a simulation result by a system; (2) Simulating a yard layout through a yard plan, and intuitively displaying inventory information in real time; (3) The system is added with a flow conflict optimization module, so that the execution condition of future plans can be predicted, the weight of the influence factors of each plan to be executed is adjusted, the accuracy of the plan is improved, and the probability of flow conflict is reduced; (4) Simulating and calculating the arrival time of the ship through a ship arrival prediction model;

(5) The designed on-site experience value calculation model can be combined with the start-stop time length of the flow operation, comprehensively analyze the planned operation time length and continuously optimize the calculation model along with the accumulation of operation data.

Furthermore, the intelligent port bulk cargo production management and control operation system is based on the platform overall design concept of an intelligent storage yard operation system, combines domestic complex working condition requirements for customized development, is based on radar modeling and three-dimensional laser scanning modeling, and integrates the technologies of radar material pile anti-collision, space positioning anti-collision, accurate batching control, remote centralized monitoring, digital storage yard, material flow tracking, flow intellectualization, intelligent production management and control, three-dimensional visualization and the like. The system can realize all-weather remote full-automatic operation, has higher operation efficiency than manual operation, better batching precision and improved working environment, and builds intelligent ports of first-class facilities, first-class technology, first-class management and first-class service on the premise of economy and safety of the system.

The structural components, connection modes and functional principles of the system according to the embodiment of the present invention will be described in detail below based on the drawings. Although the logical order of operations are depicted in the context of describing the principles of operation of the system architecture, in some cases the operations depicted or described may be performed in a different order than is shown or described herein.

Example 1

Fig. 1 is a schematic structural diagram of a system for intelligent production control of bulk ports according to an embodiment of the present invention, and referring to fig. 1, the system includes:

The data management system is connected with the intelligent basic equipment system and the ship information development system and is used for collecting port production flow data, material data, production and marketing data and ship information data in real time, so that data management and data sharing are realized;

the intelligent basic equipment system comprises an automatic material stacking and taking control subsystem, a production flow management and control subsystem and a ship arrangement intelligent management subsystem, wherein each subsystem comprises intelligent equipment and terminals related to port bulk cargo life management and control, and can realize autonomous operation, regulation and control and data receiving and transmitting in response to control instructions;

According to the embodiment of the invention, the production plan of the corresponding task is issued to the intelligent production scheduling system according to the user demand of the production and marketing system, then the operation instruction is issued to the central control flow PLC, the central control flow PLC analyzes the instruction and issues the instruction to each single machine of the basic equipment and the stock ground management system, each single machine starts to walk to the operation position and completes stacking, then material stacking and taking operation is started, after the operation workload is completed, the operation is automatically stopped, the operation is returned to the position appointed by the system, the server side updates the site stock ground model data, and the whole operation flow is completed by one key.

The intelligent production scheduling system adopts a B/S architecture and a Web development mode, has the advantages of easy expansion, high system stability, advanced architecture and the like, is completely compatible with a browser, is convenient to use, and is convenient to increase an access point in a later period without installing a client. The B/S architecture can conveniently realize the access of the server, and the PC terminal equipment can be accessed through a browser.

The invention combines advanced technical ideas and various data of the storage yard, realizes the optimization of the storage yard layout and the resource distribution, and improves the storage capacity of the storage yard. The method is characterized in that links such as ship arrangement, yard live condition, unit production, ship loader, stacker-reclaimer, conveyor belt and the like are continuously monitored and predicted, and an algorithm model suitable for the links is matched with the links, so that intelligent scheduling of stacking, loading and unloading production operation is realized, system instruction communication is realized, accurate batching is realized, turnover rate is improved, no-load rate is reduced, and full-flow automation of all loading, unloading, stacking and unloading production except the ship unloader is realized. The main functions are formulated according to specific actual service requirements, including but not limited to the main function points shown in fig. 2.

The intelligent production scheduling system based on WEB development has the following characteristics: 1) The pure WEB structure integrates information processing and information inquiry, and authorized personnel can process the information at any time and any place through a browser; 2) The production flow starting and ending point and the whole process function control comprise the functions of production planning management, production performance management, inventory management, quality management, equipment operation management and the like; 3) The system has good expandability and maintainability; the system network topology is shown in fig. 3.

The intelligent production scheduling system adopts a front-end and rear-end separation development mode based on Vue+spring Boot. The front end is mainly responsible for page display and interaction logic; the back end is mainly responsible for business and data interfacing, and multiple versions can be customized and developed. The software infrastructure uses Windows as a basic operating system environment, is matched with a Java platform and a SqlServer database, is based on a Spring Boot framework of the current advanced open source, integrates other development components, ensures performance, fully decouples each module, and can be easily expanded in the later period; the basic service layer adopts a micro-service architecture, divides a single application unified in the traditional set into a plurality of basic services, and carries out service management and RPC call through Dubbo; the service interface layer adopts resource architecture design of RESTful style, and an interface model is simplified; the terminal application layer is a browser, as shown in fig. 4.

Preferably, in one embodiment, the present invention employs an enterprise service bus ESB (Enterprise Service Bus), which provides the most basic connection hub in the network, an essential element in constructing an enterprise nervous system.

Specific functions of the service bus ESB include: (1) The ESB is uniformly managed, deployed, configured and monitored as a key path of the service integration platform, and under the support of perfect user roles and authorities, a uniform path is formed from management to development, so that the access, encapsulation and release of the service can be effectively managed at each layer, and the realization of each step is easier; the multi-angle monitoring management also has a very clear statistical analysis on the service running condition, the consumed condition and the like. (2) The service distribution, the service bus ESB should have the service which is distributed into standard after being converted by the built-in protocol after being accessed into the application system by using different protocols, and is registered to the service library for other systems to use. (3) The service integration can be realized by arranging a plurality of services according to a certain rule to form a new service with relatively large granularity. (4) The resource catalog library is indispensable in the whole data service integration platform, all service providers issue services to the resource catalog, all service consumers inquire the existing services from the resource catalog, apply for the services and can use the services after being authorized, and the service consumers only need to acquire related service use from the resource catalog library and do not need to care about the specific positions of the services. The service bus frame pattern is shown in fig. 5.

The B/S framework is realized by adopting the Vue2.0 technology and is a progressive framework for constructing a user interface. The design of the incremental development from bottom to top is adopted by the Vue, and the core library of the Vue only focuses on the view layer, so that the Vue is very easy to integrate with other libraries or existing projects. On the other hand, the Vue is fully capable of driving complex single-page applications developed by adopting single-file components and libraries supported by the Vue ecosystem, and the goal of Vue.js is to realize responsive data binding and combined view components through an API as simple as possible; the B/S framework system architecture is shown in FIG. 6. The system platform is based on configuration and an interface-oriented programming mode, and has high coding flexibility, strong expansibility and low maintenance cost; the method has the advantages that rich application integration interfaces for port industry are provided, the development period of projects is shortened, and the later maintenance difficulty is greatly reduced; a visualization workflow designer and an intelligent workflow engine are provided.

And the intelligent storage yard and the automatic material stacking and taking operation are realized based on the automatic material stacking and taking control subsystem, and the storage yard is subjected to material stack plane configuration management (X/Y axis) according to a management mode of the yard/strip/stack. Before an operation task is carried out, stacking and material taking stacks are automatically recommended, and an optimized stacking and material taking scheme is provided; analyzing the stacking capacity in real time; optimizing the layout of a storage yard; optimizing the distribution of the goods sources.

Further, before the material piling and taking operation task is carried out, corresponding optimized management and control plans are formed by taking a maximum storage capacity algorithm, a minimum energy consumption algorithm and a minimum time algorithm as targets based on operation task information (including material types, numbers, owners, operation amounts and the like) respectively, and three corresponding piling and taking schemes are formulated for users to flexibly select, as shown in fig. 7.

When the intelligent control system is in practical application, operation algorithm setting and storage can be performed in advance according to historical piling records and operation effects, the intelligent control algorithm is used as an intelligent control algorithm for presetting an optimal control plan, when the intelligent control system has operation requirements, the operation parameter calling algorithm is directly introduced, different optimal control plans are further formed, and corresponding piling plans are formulated.

The route unit standard energy consumption information is configured by pre-registering a route of a material transported from a source end to a destination end. And when the related path plan is used, measuring and calculating a plan energy consumption index according to the unit standard energy consumption information.

The automatic material piling and taking control subsystem is further configured to analyze the piling capacities of different material piles in the material yard in real time, wherein the real-time analysis piling capacities are core parts of the intelligent material yard, and in an alternative embodiment, the real-time theoretical storage capacity, occupied space and stackable quantity of each material pile are calculated according to the actual measurement volume of the material pile, and storage data balance is carried out by combining the measured quantity of the piles, so that fine management of the material piles is realized; and recording different stacking intervals and volumes of each stack according to the feedback value of the secondary automatic control subsystem.

The reserves, occupied space, expandable space and the like of each material are analyzed and summarized in real time, and an alarm is given when the reserves, occupied space, expandable space and the like of each material are lower than a set minimum inventory limit value; calculating the position and the volume of each empty field material pile, and the types and the corresponding weights of storable materials; the quantity of each material which can be put in a warehouse in the material yard is summarized in real time; predicting the warehouse-in capacity in a future period according to the current operation task, and sending out an alarm in advance for processing when the warehouse-in capacity is predicted to be smaller than the ball-out plan; wherein, the ball discharge refers to the formation of pellets after processing the raw materials, and the raw materials are used for processing.

The automatic stacking and taking control subsystem also sets a public area and a fixed area to dynamically configure stacking position information in a field/strip/stack plane management mode, can flexibly manage fixed stacking positions and variable stacking positions, and optimizes the layout of a storage yard.

Further, in one embodiment, the goods condition is analyzed according to the production and supply and sales data and the goods stacking and taking requirements in a set period, the storage positions of the storage sites are distributed according to a set goods condition storage position matching algorithm, further, a distribution rule is specifically set to form a rule configuration table which is related to the distribution rule, and in practical application, the system can automatically recommend the stack positions according to the rule configuration table. And comparing the corresponding volume of the ball number with the continuously stackable volume, and judging that the distance between the material pile and the adjacent material pile meets the set safe distance condition after the material pile is piled along, so that the adoption of the pile along is possible. The stock yard deposit allocation rules shown in the following table may be employed:

When the new material pile is required, the automatic material pile taking control subsystem selects material pile empty positions according to the following rules: according to the volume corresponding to the number of the balls, preferentially selecting a vacancy with smaller space; if only consecutive empty sites are available, the new stockpile location should be located to the left of the consecutive empty sites.

Preferably, the automatic operation instruction of the stacker-reclaimer can be obtained through internally establishing a material pile PLC data model converted by a three-dimensional model.

In order to realize safe operation of the stacker-reclaimer and prevent collision accidents between adjacent stackers, between the stacker-reclaimer and a stacker, between a stacker-reclaimer track and the periphery, and the like, as a further improvement of the invention, in one embodiment, an automatic stacker-reclaimer control subsystem establishes a safe and reliable stacker-reclaimer anti-collision system, a multi-stage alarm system is arranged, and an anti-collision control function of the stacker-reclaimer is realized, and the method comprises the following steps:

1) A triple material pile anti-collision system is adopted between the material piling and taking machine and the material pile, and a multi-stage alarm is arranged.

2) The single machine anti-collision adopts a bounding box method to set a large machine anti-collision protection circular area, and multi-stage alarm is set.

3) The stacker-reclaimer walks and prevents bumping with the pedestrian, adopts the mode that camera automatic identification and millimeter wave radar combined together to set up multistage warning.

4) The stacker-reclaimer adopts anti-collision sensors arranged on two sides of a cantilever and on the head to prevent collision with surrounding structures, and is provided with a multi-stage alarm.

5) Increasing area intrusion alarm, setting a stacker-reclaimer operation area, adopting a camera graph acquisition and computer vision algorithm to detect whether mobile working machines, pedestrians, vehicles and the like enter a large machine protection area or not, and alarming in time.

The automatic material piling and taking control subsystem is also provided with a stock yard inventory real-time management module, which comprises an inventory management unit, a real-time inventory management unit, a volume model calculation unit and a volume calculation unit. Optionally, in one embodiment, the inventory checking management unit is configured to respond to a checking instruction sent by the subsystem according to a checking plan, and the checking instruction drives the scanner device to scan the corresponding stock areas, and performs the inventory checking operation on all the stock areas or the designated material strips to form an inventory checking report. In practical application, the inventory checking management function is displayed by performing laser imaging and volume calculation by an image server, calculating the residual weight of the current stock pile through a stock checking model, and storing the calculated residual weight into a database, wherein the data are uniformly managed in a full-flow dynamic display system.

The real-time inventory management unit scans the volume change of the material stacks along with each operation, combines the delivery metering data, performs aging inventory management on each material stack, performs variable tracking on the occupied area of the material stacks and the occupied area of the stock areas along with a time axis and performs deduction on the occupied area of the stock areas, and provides data support for optimal inventory and timely approach. Aging inventory management generally does not occupy working time disc libraries alone, communicates with a full-flow dynamic display system, and provides data support. Based on the information, the information of the stock area, the position information of the stacker-reclaimer and the like can be displayed by the comprehensive state monitoring interface, and the information comprises stock data of each stock bar of the stock area, the working state of the stacker-reclaimer and the like.

Specifically, the calculation data of the belt conveyor scale is monitored in real time, communication is established between the belt conveyor scale and the on-site belt conveyor scale, the weight of the current stockpile is calculated according to the on-site belt conveyor scale, the in-out site weight of raw materials is calculated in real time and updated in real time, and the weight is stored in a database. And providing calculation data of the volume model in real time, specifically establishing communication with an intelligent operation center of the stacker-reclaimer, and carrying out laser scanning of a material pile and collecting three-dimensional data while the stacker-reclaimer works. After one operation is completed, transmitting the real-time scanning result to the background through the network to perform volume calculation by the image server, calculating the residual weight of the current stockpile through the inventory making model, and storing the residual weight into a database.

Further, the volume model calculation module determines the stock volume as follows: and (3) carrying out three-dimensional modeling through the point cloud data fed back by the laser scanner, and adopting a data imaging technology to fit the surface shape of the material pile by the material piling and taking machine to obtain the material storage volume of the whole material yard.

Specifically, the volumetric calculation by volumetric calculation of the reconstructed stockpile (three-dimensional model), comprising: (1) Dividing the material pile into triangles with the side length of 10cm to 20cm on the horizontal plane, and respectively calculating to take the small triangle as an upper plane; the bottom of the material pile is the volume of the pentahedron of the lower surface and is accumulated. (2) In the vertical direction, the material pile is divided into several layers according to actual requirements, such as density, and the volumes of the layers are respectively calculated.

In practical application, the automatic stacking and taking control subsystem realizes the management of stacking authority through signing in and signing out the stacking file, and realizes the automatic function of the stacker-reclaimer through rational planning. The yard management interface is shown in fig. 8.

The stack file includes stack "key" data such as stack field number, seed, coordinates xtinium, ymin, ymax, etc.

During actual management, whether the conflict with the track configuration occurs can be verified according to the field number, which comprises the following principles: the boundary cannot invade a certain distance by taking the Y-axis coordinate of the track as a reference; and cannot exceed a certain distance with reference to the X-axis coordinates of the track. I.e. the stockpile must be defined in an area that is accessible for the equipment to move on the yard track. The yard management human-machine interface HMI is in communication connection with the PLC, so that the stack information checking-in and checking-out function is realized, and the stack file checking-in is applicable to any equipment with checked-out stack files.

The production flow control subsystem further comprises a flow conflict optimization module. The production flow control subsystem is also provided with an intelligent control module for the flow of the belt conveyor, adopts a control mode of a free flow, decides the flow rule of the belt conveyor by a mode of dynamically generating the flow at the starting point and the end point, and performs flow control, namely, the available flows between a certain starting point and the end point are automatically combined according to the upstream-downstream relation of the equipment.

The scheme can be flexibly adapted to different flow operation scenes and is suitable for future capacity expansion or reconstruction. And (3) managing a flow group, compiling a full-period (24 hours) belt conveyor flow plan operation menu, dynamically managing the operation condition of each flow, automatically converting into an aging menu according to a time sequence, and realizing all-weather one-key production. The conveyor control flow is shown in fig. 9.

Through setting up flow PLC and managing the material flow state detection data on the belt conveyor, can make things convenient for operating personnel to know the material flow condition on the belt conveyor, regard as the basis of flow sequential stop control simultaneously. The flow process data can be further provided to provide auxiliary basis for flow management, and the flow tracking flow is shown in fig. 10.

Considering that the starting power consumption of the belt conveyor is much higher than the power consumption of the stable operation, in a preferred embodiment, the production flow management and control subsystem selects the material conveyor and the belt running on two sides of the corresponding material yard according to the material type, and the selection of the belt conveyor and the material conveyor is realized by taking the energy consumption as the optimal target according to the following rules:

And acquiring the working states of each belt conveyor and each material conveyor, if the belt conveyors and the material conveyors are running, selecting the material conveyor and the belt closest to the wharf, and after the operation of the material conveyors and the belt is finished, omitting a starting procedure and directly piling.

If the two belts of the target strip field are occupied, the waiting time of the belt close to the production line is long, and the waiting time of the belt on the other side is short, and the selection of the belt is determined after specific power consumption is required;

the production flow management and control subsystem synchronously realizes the selection of the belt conveyor and the material conveyor by taking space optimization and energy consumption optimization as targets according to the following rules: and selecting a material machine and a belt close to a production line or a wharf to stack. If the nearest feeder and belt are occupied, the other side feeder and belt of the same production line are selected. If both sides are occupied, the plan enters a wait state.

The space optimization is the same as the time optimization flow rule, and the time optimization flow refers to the space optimization flow rule.

Further, the production flow management and control subsystem is configured to implement spatially optimized ball-out stacker operations according to the following flow:

1. obtaining a ball-out plan message (variety, quantity and time) from a production and marketing system interface; 2. analyzing the plan message;

3. sequencing all the ball discharging plans by taking the ball discharging time as a reference; 4. judging the stacking position and mode according to the material types;

5. Selecting a material pile: firstly selecting a material pile of the same kind, secondly selecting a material pile with the smallest stacking volume in the material piles of the same kind, and if the material piles of the same kind cannot meet the requirements, stacking by adopting a vacancy, and performing the step 7;

6. judging the ball quantity and the continuously stackable volume of the material pile selected in the step 5, wherein the ball quantity is smaller than the continuously stackable volume, adopting a cover stack, and judging whether the ball quantity is completely stackable in a stacking mode or not if the ball quantity is larger than the continuously stackable volume; step 7, otherwise, returning to step 5 to reselect the material pile;

7. selecting a material machine and a belt stacker which are close to a production line; 8. judging the starting time; 9. estimating the completion time; 10. and (3) finishing.

When the production flow management and control subsystem realizes the ball discharging and stacking operation with optimal time, the stacking position is judged according to the material types; 5. selecting a closest stockpile or empty site: firstly, selecting a material pile of the same kind, and selecting a material pile closest to a factory from the material piles of the same kind; and comparing the distance between the material pile and the leftmost vacancy and the distance between the material pile and the factory, selecting the material pile for the step 6 if the material pile distance is the smallest, otherwise selecting the new vacancy stacking for the step 7.

6. Judging the corresponding volume of the ball number and the continuously stackable volume of the material pile selected in the step 5: the ball outlet quantity is smaller than the continuously stackable volume, and a cover stack is adopted; and (3) judging whether the ball is piled up in a pile-up mode or not if the ball output number is larger than the continuously piled up volume, and if so, carrying out the step 7, otherwise, returning to the step 5. 7. And selecting a material machine and a belt close to the production line for stacking.

When the production flow management and control subsystem realizes the ball discharging and stacking operation with optimal energy consumption, 5, selecting a running material machine and a belt after judging the stacking position according to the material types;

6. selecting a material pile: according to the selected belt and the material machine, determining a material yard close to a production line, selecting material piles of the same kind in the material yard, and selecting a material pile with the smallest continuously stacking volume in the material piles of the same kind; if the material piles of the same type cannot meet the requirements, returning to the step 5, and reselecting the material machine and the belt; otherwise, adopting the empty space to stack, and carrying out the step 8.

7. Judging the corresponding volume of the ball number and the continuously stackable volume of the material pile selected in the step 6; the volume of the number of balls is smaller than the volume which can be continuously piled, and a cover stack is adopted; and (3) judging whether the ball is piled up in a pile-up mode or not if the ball output number volume is larger than the continuously piled up volume, and if so, carrying out the step 8, otherwise, returning to the step 6.

The production flow management and control subsystem is configured to realize space-optimal ship unloading and stacking operation according to the following flow:

1. obtaining a ship unloading plan message from a production and marketing system interface; 2. analyzing the plan message; 3. sequencing all ship unloading plans by taking time as a reference; 4. selecting a vacancy: the ship unloading and stacking mode is ship-by-ship stacking, so that empty positions are directly selected for stacking; selecting a space that can hold all of the material of the vessel and is closest to the quay; 5. selecting a material machine and a belt close to a wharf for stacking; 6. judging the starting time; 7. estimating the completion time; 8. and (3) finishing.

When the production flow management and control subsystem realizes the ship unloading and stacking operation with optimal time, after the stacking position is judged according to the material types, the closest vacancy is selected, and the ship unloading and stacking mode is that one ship is stacked, so that the vacancy is directly selected for stacking, and all the materials of the ship can be stacked and the closest vacancy is selected. Selecting a material machine and a belt stacker which are close to the wharf.

When the production flow management and control subsystem realizes the ship unloading and stacking operation with optimal energy consumption, all feeding plans are ordered by taking time as a reference, and then a running feeder and a belt are selected; and then selecting a material pile: according to the selected belt and machine, a yard near the dock is determined, and a void is selected in the yard.

The production flow management and control subsystem is configured to realize space-optimal feeding operation according to the following flow:

1. obtaining a feeding plan message from a production and marketing system; 2. analyzing the plan message; 3. sequencing all feeding plans according to a time reference; 4. judging the stacking position according to the material types;

5. selecting a material pile: selecting the material piles of the same kind, and selecting the material pile with the smallest residual volume from the material piles of the same kind

6. Judging the sizes of the selected material pile and the feeding volume; the volume of the selected material pile is larger than the feeding volume, and the step 7 is carried out; otherwise, the material pile is reselected in the step 5; ( If all the material piles of the same type can not meet the feeding requirement independently, selecting a plurality of material piles to feed together, wherein the selection principle is as follows: and sequentially feeding materials by a material pile with the smallest volume until the feeding is completed. )

When the production flow management and control subsystem realizes the feeding operation with optimal time, after judging the stacking position according to the material types,

5. selecting a material pile: the material piles of the same kind are selected firstly, and then the material pile closest to the factory is selected from the material piles of the same kind.

6. Judging the corresponding volume of the feeding quantity and the volume of the material pile selected in the step 5; step 7, if the feeding quantity volume is smaller than the stockpile volume, returning to step 5 if the feeding quantity volume is larger than the stockpile volume; (if all the material piles of the same type cannot meet the feeding requirement independently, selecting a plurality of material piles for feeding together, wherein the selection principle is that the material piles with the smallest volume are sequentially fed until the feeding is completed.) 7, selecting a material machine and a belt close to a production line for feeding;

when the production flow management and control subsystem realizes the material taking and feeding operation with optimal time, after sequencing all feeding plans according to a time reference, selecting a running material machine and a belt;

5. selecting a material pile: determining a stock yard close to a production line according to the selected belt and the selected material machine, selecting the same kind of stock piles in the stock yard, and selecting the stock pile with the smallest volume in the same kind of stock piles; if the material piles of the same type cannot meet the requirements, returning to the step 5, and reselecting the material machine and the belt;

6. Judging the feeding quantity and the volume of the material pile selected in the step 5; the step 7 is carried out when the feeding quantity is smaller than the volume of the material pile; the feeding quantity is larger than the volume of the material pile, and the step 5 is carried out; (if all the material piles of the same type cannot meet the feeding requirement independently, a plurality of material piles are selected for feeding together, and the selection principle is that the material piles with the smallest volume are sequentially fed until the feeding is completed.) optionally, in one embodiment, the process of taking materials and feeding a ship is similar to the process of feeding operation with the optimal space, and the difference is that a material machine and a belt close to a ship position are selected for material piling.

The production flow management and control subsystem is configured to realize time-optimal material taking and boarding operations according to the following steps:

1. obtaining a feeding plan message from a production and marketing system; 2. analyzing the plan message; 3. sequencing all feeding plans according to a time reference; 4. judging the stacking position according to the material types; 5. selecting a material pile: firstly, selecting a material pile of the same kind, and then selecting a material pile closest to a wharf from the material piles of the same kind;

6. judging the feeding quantity and the volume of the material pile selected in the step 5, and carrying out the step 7 if the feeding quantity is smaller than the volume of the material pile; the feeding quantity is larger than the volume of the material pile, and the step 5 is returned; ( If all the material piles of the same type can not meet the feeding requirement independently, selecting a plurality of material piles to feed together, wherein the selection principle is as follows: and sequentially feeding materials by a material pile with the smallest volume until the feeding is completed. )

7. Selecting a feeder and a belt close to a wharf for feeding; 8. judging the starting time; 9. estimating the completion time; 10. and (3) finishing.

When the production flow management and control subsystem realizes the material taking and boarding operation with optimal energy consumption, sequencing all feeding plans according to a time reference; selecting a running material machine and a belt;

5. selecting a material pile: determining a stock ground according to the selected belt and the selected feeder, selecting the same type of stock piles in the stock ground, and selecting the stock pile with the smallest volume in the same type of stock piles; if the material piles of the same type cannot meet the requirements, returning to the step 4, and reselecting the material machine and the belt;

6. judging the feeding quantity and the volume of the material pile selected in the step 5; the step 7 is carried out when the feeding quantity is smaller than the volume of the material pile; the feeding quantity is larger than the volume of the material pile, and the step 5 is carried out; (if all the material piles of the same type can not meet the feeding requirement independently, a plurality of material piles are selected for feeding together, and the selection principle is that the material piles with the smallest volume are sequentially fed until the feeding is completed.) the production flow management and control subsystem comprises a belt conveyor flow intelligent control module which is divided into a material flow monitoring unit, a belt conveyor belt speed monitoring unit, a material flow real-time tracking and positioning unit, an intelligent flow control unit, a single belt control unit and the like, and the overall structure is shown in figure 11.

The intelligent decision-making module of the belt conveyor process receives the operation plan issued by the intelligent production scheduling system, analyzes and disassembles the operation plan, converts the operation plan into a task plan, and schedules the process according to the plan; the operation and fault conditions of the existing equipment are fully considered in the scheduling process, an optimal path algorithm is selected, and the material conveying efficiency is improved; the sequencing process realizes the switching of the process according to the operation plan and issues instructions to the process PLC; the flow PLC is used for managing the original system flow substation PLC, realizing the integration of control systems and realizing the control of the whole flow through one-key linkage.

The belt speed monitoring unit of the belt conveyor is provided with a belt speed monitoring switch and a speed measuring sensor on each belt, the pulse number of the speed measuring sensor in each period is continuously obtained through a high-speed counting module, smooth filtering processing is carried out, and then the transmission speed and the walking distance of the belt are obtained according to the radius size of the installed position.

The material flow monitoring unit monitors the position and weight information of the material flow in real time through the instantaneous flow and the accumulated flow of the belt scale.

The material flow tracking unit monitors the real-time position and weight of the whole process of the material on the belt from the inlet to the transfer point to the outlet in real time, and adopts a high-precision material flow tracking method to realize real-time position calculation of the material flow of the belt conveyor and the transfer hopper, ton calculation of any interval of the belt conveyor and the transfer hopper and ton calculation of any few belts in the process.

The single belt control system researches the start and stop functions of the single belt, and the layered sub-modules control, so that the interlocking conditions in the traditional control are optimized, and the start, stop and scram protection of the single belt is realized.

The intelligent flow control module of the belt conveyor realizes intelligent decision by adopting a control mode of a free flow, and performs flow control by adopting a mode of dynamically generating flows at a starting point and a finishing point, namely, the available flows between a certain starting point and a certain finishing point are automatically combined according to the upstream-downstream relation of equipment; providing a material variety and conveying starting and ending point information matching technology, realizing automatic site selection in the process, and avoiding material misplacement conveying; further, the method can provide the whole day sequencing of the processes and the group transmission, overcomes the defect of one-key start of 1 process, and reduces the process start frequency.

The intelligent control module of the belt conveyor flow is provided with a free flow control model construction unit, based on comprehensive process flow demand data and control flow records, carries out learning optimization by combining expert knowledge to construct a free flow control model, carries out flow decision and control functions in an intelligent decision system of the belt conveyor flow according to the process flow of a stock yard and the selection of a starting point and an ending point in practical application, adopts algorithms such as an optimal path and the like, and carries out optimization calculation according to raw material transportation plan information, user operation request information, belt conveyor equipment operation state information, ending point equipment operation state information, equipment fault information, equipment maintenance plan, various monitoring information and the like, automatically searches all available flows between the starting point equipment and the ending point equipment in the system, comprehensively considers the attribute of each flow, and carries out optimization calculation according to the two modes of the path and the energy consumption. Based on the result of the selection, the model controls the flow according to the operation instruction, and comprises control functions of operation reservation, flow selection, flow starting, flow stopping, flow switching (same kind of switching, different kinds of switching, path switching), flow converging and the like.

The flow PLC of the raw material receives a flow instruction and an instruction of which the model parameters are decided by a system through a flow instruction interface, and then corresponds to an operation mode:

the flow instruction is generated by a flow intelligent control module of the belt conveyor, when in practical application, an operator selects or sets main parameters (source points, end points, path marks and the like) related to the flow on a system picture, and then the flow instruction and model parameters are generated by the system and written into a flow intelligent control PLC through OPC to control related intelligent equipment to run autonomously.

Further, the intelligent flow control module of the belt conveyor is further provided with a material flow tracking unit which is configured to monitor the material flow state on the belt conveyor through the flow PLC, so that operators can know the material flow condition on the belt conveyor conveniently, and the material flow tracking unit is used as the basis for flow sequential stop control. Stream process data can be further provided to provide rich information for process management. The method specifically comprises the following steps:

1) Material evacuation time: in order to accurately track the material flow of each device, a material emptying time table is established, and the material emptying time table is used for defining the time for emptying each device and corresponds to the device ID table one by one. On the other hand, the time for conveying the material from the head part of the belt conveyor to the tail part of the belt conveyor is calculated according to the belt length and the rotating speed of the belt conveyor.

2) Stream calculation: to reflect the material flow condition of each device in real time, calculating material flow for each device independently; two data tables of receiving time Tc (stream head) and discharging time Td (stream tail) are respectively set and are in one-to-one correspondence with the equipment ID table.

When the flow is selected, the upstream and downstream relations of the devices in the flow are determined, and the flow calculation is carried out sequentially from the end point to the source point by judging the flow condition of the upstream devices.

3) Optimization of stream tracking: the material flow calculation is to count time in the program by means of the running signal of the equipment, and calculate the head and tail of the material flow; the requirement is independent of the selection of the flow, and even if the equipment is operated manually, the material flow can still be tracked effectively; and the calculation and detection are mutually auxiliary, so that the tracking reliability of the material flow is ensured.

The one-key linkage operation of the intelligent control module of the belt conveyor flow is that after the execution flow is selected by the central control, and relevant stacking and taking parameters are set, all equipment of the selected flow automatically operates according to the sequence by pressing an 'immediate execution' button, wherein the taking equipment (stacker-reclaimer) at a source point automatically moves to a set material pile to automatically take materials, the stacking equipment (stacker-reclaimer, ship loader, top plow discharger and the like) at a destination automatically moves to the set material pile to automatically stack, moves to a set cabin to carry out ship loading operation, or automatically carries out lifting plow at the top of a receiving bin to automatically feed according to the proportioning requirement, thereby realizing the automatic operation of the whole flow.

In the whole running process of the process, the process decision monitoring picture of the belt conveyor can monitor the execution state of the process, the HMI monitoring picture can display various fault alarm information, if serious faults are encountered, the operation is automatically stopped, and after the faults are processed, the process can continue to run normally.

The belt conveyor flow control module tracks the running process of the whole flow, when the conveying amount of the flow reaches the target conveying amount of the current flow, the flow is automatically stopped or switched to other operation flows, the operation is finished, the belt conveyor flow control module records actual result data of the operation, and meanwhile, the actual result data of the operation is sent to the intelligent production scheduling system.

The computer intelligent mode automatic control has an optimized model, can achieve the optimal decision operation of a control system, and can obtain complete operation records so as to realize the functions of operation actual performance collection, report making, equipment operation rate analysis and the like. Mainly comprises the following functional categories: the operation execution control, the operation reservation control, the operation flow recovery, the flow start control, the flow sequential stop control, the flow uniform stop control, the clearing uniform stop control, the starting point switching control, the end point switching control, the path switching control, the flow converging control, the starting feeding control, the stopping feeding control, the flow resetting control, the slotting control, the starting point automatic slot changing and the end point continuous slot moving.

Further, the ship arrival prediction model construction module is arranged in the ship arrival intelligent management subsystem, based on AIS information obtained in real time or information such as ship type, ship identification code, current position and speed is manually input, the ship arrival prediction model is input to simulate and calculate ship arrival time, historical simulation data and actual arrival time are referred to, time weight of a ship mission plan is dynamically adjusted, the ship arrival prediction model is based on longitude and latitude of a ship, the real-time position of the ship is positioned, and the training data model is embodied by adopting a digital twin technology.

The method comprises three main steps of original data preprocessing, ship typical motion trail acquisition and ship arrival time prediction, wherein the typical motion trail acquisition comprises four sub-steps of ship original trail division and compression, core trail subsection extraction, typical motion trail control point acquisition and typical motion trail control point acquisition result evaluation, and the four sub-steps are key and difficult points for constructing the model, and a model building frame diagram is shown in fig. 12. The original AIS data cannot be directly used, and the original AIS data is preprocessed before a model is built, so that clean available track data are obtained and stored in a database, and the data can be conveniently retrieved and used in the subsequent steps.

Predicting the time of a certain ship from a certain departure port to a destination port, searching historical tracks (including time, position, speed, track direction and the like) from the departure port to the destination port in an AIS database according to the MMSI of the ship, and searching historical track information of the ship which is most similar to the ship according to the information of a ship main scale, load carrying capacity, host power, destination and the like if no historical track information exists in the database; on the basis, in order to improve the operation efficiency, all original navigation tracks of the ship are divided and compressed into a plurality of subsections; then extracting a core track subsection by improving a typical (DBSCAN) algorithm to obtain a core track subsection extraction algorithm; secondly, scanning the core track subsection set to obtain a typical motion track of the ship at the control points, and evaluating the obtained control points to obtain a group of optimal control points to form the typical motion track of the ship; and finally, predicting the arrival time of the ship according to the position and navigational speed information of the subsection of the typical motion trail.

Further, planning is carried out on the tasks in the task planning pool according to the time weight of the ship task plan. According to the service type, the method is divided into a ship unloading preplanning and a ship loading preplanning. Before the ship arrives at the port, the ship arranging plan is not calculated, the execution path and the material pile recommendation are not calculated, after the arrival of the ship is confirmed, the ship arranging plan is adjusted according to the arrival information, and the execution path optimization calculation and the material pile recommendation are started.

After the ship arrives at the port, the arrival information is accessed or the state confirmation is manually carried out in the ship arrangement plan. After the port is confirmed, automatic/manual programming of the ship unloading plan and the ship loading plan is started. The system provides a configuration switch to set an automatic and manual programming mode.

And (5) berthing the ship, and executing unloading and loading tasks. The factors such as time occupation conflict, material stock conflict, conveying system conflict and inventory space conflict need to be comprehensively measured. It is therefore necessary to build an integrated balance model to predict and discover such conflicts and make reasonable adjustments to the timing plan. In practical application, the comprehensive balance model is an algorithm model which is generated by combining with the field actual business requirements, obtaining the time or material space required by each task at present according to the accumulated production experience in an estimated mode, and converting intelligent thinking into a computer language by cooperating with factors such as a time point set, concurrency, processing time, occupied space and the like of each task.

As a further improvement of the present invention, in one embodiment, the present invention provides a simulation previewing optimization system configured to execute comprehensive operation simulation previewing according to a set optimization management and control plan based on a data twin simulation system, and optimize parameters of a management and control optimization target according to a previewing operation result;

In an optional embodiment, when automatic material piling and taking operation is realized, time, workload, material type, material piling information, material conveying equipment state and the like of a future operation plan can be calculated according to operation task information, a maximum storage capacity algorithm, a minimum energy consumption algorithm and a minimum time algorithm are used as targets to respectively call a corresponding intelligent control algorithm to perform simulation operation, and three piling and taking schemes with optimal space, optimal time and optimal energy consumption are respectively searched for recommendation according to a simulation result by adjusting the intelligent control algorithm for selection and execution by an operator; the operator may also adjust the details to form the final stacking scheme.

And then, a three-dimensional simulation platform is built by the full-flow dynamic display system based on a three-dimensional simulation technology for material stacking and full-flow equipment, and data are retrieved from the data management system for visual and three-dimensional display in response to a user instruction.

An aging material dynamic diagram is formulated as a stock yard main interface according to a port stock yard process plan, and the real-time state of the stock yard materials is reflected as shown in figure 13; in the preferred embodiment, the electronic map of the stock yard periodically updates the data of the stock yard, displays the information of each stack in the whole stock yard in an interface in an electronic graphical mode, divides the stock yard into a plurality of areas according to the characteristics of raw materials and the actual working condition of the site, displays the graph according to the specific position and the length of the stock yard, enables a user to intuitively know the real-time information of each stack in the current stock yard, so as to reasonably and normally manage and control the stock yard,

According to port layout and equipment objects, a dynamic operation diagram of a stock yard is formulated as a flow operation main interface, the non-working, fault and material carrying conveying states of logistics equipment are comprehensively reflected, the logistics conveying flow direction and loading and unloading working conditions are demonstrated, and automatic production and control are realized by observing a large screen under normal conditions; meanwhile, the operation table can modify flow data and edit a flow menu according to popup window prompt; data viewing and manipulation functions associated with elements displayed on the interface can be directly used by device clicking and like operations.

The invention is based on radar modeling and three-dimensional laser scanning modeling, realizes omnibearing digital storage yard, full-flow material flow tracking and three-dimensional visual display, comprises a storage yard modeling subsystem, and is configured to adopt a modeling technology combining laser scanning and radar mathematical simulation modeling. And carrying out three-dimensional modeling on the material pile aiming at different working conditions, and carrying out all-weather real-time modeling in the material pile and material taking working process. The material pile modeling mode meets the actual requirement of field operation, and when the next operation is performed, the automatic material pile and material taking control subsystem automatically judges the latest material pile data, and the latest data is preferentially selected to perform calculation of the material pile operation strategy, so that the data is updated in real time.

The terrain module models with actual equal proportions of port yards, wharfs and rear feed areas, and the stacker-reclaimer and belt conveyor models with fine models with animation, with in-plant architecture, out-of-plant logo architecture and shrub construction scenes as shown in fig. 14.

In a stock yard information interface, the shapes of different stock piles of the whole stock yard are displayed, the change condition of a certain stock pile is observed, the stock pile information comprises the number of the stock pile, the center position of the stock pile, the height of the stock pile and the like, and a corresponding gray level diagram is generated by using the height value of the stock pile, so that the shape of the stock pile is displayed. Clicking the name button of the factory area switches different stockpile information interfaces, clicking different stockpiles to display different stockpile information, as shown in fig. 15.

And displaying all the information of the big machines of the stock yard in the equipment information interface, wherein the information comprises stacker and the running states of the stacker and the stacker. Meanwhile, the working state of the belt and the workload of one week of the mainframe are covered, and the corresponding interface for inputting detailed equipment information by clicking the mainframe is clicked. The equipment detailed information interface comprises the working states of the equipment parts, including the working state of a hopper, the pitching angle of the machine, the working time of the machine, the working state of a belt and the like. Sensor information is also included as shown in fig. 16.

And a real-time model visualization module: the real-time model visualization module acquires material pile data through the database and generates a real-time material pile model;

and a real-time operation visualization module: the real-time operation visualization module acquires control data, displays the production operation state of the stacker-reclaimer and the operation state of the yard belt conveyor, positions and emergency alarms of faults of all the stacker-reclaimers, and assists field personnel to better carry out production operation management and control.

In addition, a stand-alone observation mode can be entered by clicking on the main interface factory shed or clicking on a sidebar stand-alone observation button. After entering the stand-alone observation mode, the observation machine is selected by an interface upper side button: the factory area to be observed is clicked first, and then the machine to be observed is selected from the drop-down menu. At this time, the center of the visual angle is the selected machine, the distance between the camera and the machine can be adjusted by using the mouse wheel, and the left mouse button can be dragged to rotate around the machine, so that the machine can be observed in all directions. The right mouse button + right ctrl clicks on the viewing machine, and its running information can be displayed as shown in fig. 17.

Alternatively, the multi-machine viewing interface may be accessed by clicking a multi-machine viewing button of the side function region. Then click the button above to select the observation mode as two-machine or four-machine observation. Clicking the right button selects the machine to be observed, for example, a four-machine observation interface can be adopted, the four-machine observation interface can observe the working states of four machines at a time, and the right button +ctrl of the mouse displays the information of the machine, including the name of the machine, driving information, working time of the machine and the like.

Further, the system includes a job plan management system configured to implement yard job plan management of different jobs according to the following logic: 1) Ship unloading plan: and generating a raw material entry plan according to time sequence by combining the raw material storage site and the occupation condition of a conveying system according to the information such as a purchase plan, a ship model forecast and the like received from an external system. 2) Ball discharge plan: and generating a pellet entry plan according to a pellet factory scheduling schedule and combining the occupation conditions of a pellet storage site and a conveying system. 3) Shipping plans: and generating a transfer cargo or finished product pellet shipment shipping plan according to a sales plan, wharf shipping requirements and ship type information, combining single product storage information and the occupation condition of a conveying system and time sequence. 4) Feeding planning: and according to the production contact list of the pellet system, combining the ore blending structure and the occupation condition of the conveying system, and generating a raw material discharge and loading plan according to a time sequence.

Further, the job plan management system further includes a job plan priority formulation module configured to: and according to the set operation plan priority, an operation plan is compiled. The system provides a priority rule configuration table, and the system performs planning according to the rule configuration table. The priority rules currently provided are referenced below:

The embodiment of the invention can also provide a work plan management system which also comprises a work plan duration estimation module, wherein the work plan duration estimation module is configured to develop a field experience value calculation model according to the estimated demand and the recorded historical data of different work plan durations, comprehensively analyze the planned work duration by combining the start-stop duration of the flow work, and continuously optimize the calculation model along with the accumulation of the work data.

Further, in order to optimize metering management, the metering group calibration management can be realized by integrating the water gauge of the loading and unloading ship, the metering of the belt scale, the metering of the truck scale, the volume scanning of the stacker-reclaimer and the metering of the bin space multi-channel data according to the requirement. The system can select the information such as ship number, material name, arrival time and the like based on the water gauge data to form water gauge data actual results, and can inquire.

Optimal management of belt conveyor scale metering data may be achieved from the following:

acquiring data of each belt conveyor scale in real time through an Ethernet interface, wherein the data comprise accumulation amount, instantaneous flow and belt conveyor speed;

and forming a conveying performance of the belt conveyor according to the operation plan and the on-site operation. If the operation is cross-shift continuous operation, the system automatically cuts off to generate an operation actual score when the shift is cut off;

and automatically sending the generated conveying operation performance to an external system for statistical analysis. The accumulated instantaneous value and the flow instantaneous value can be displayed by a historical trend chart.

The embodiment of the invention is based on an intelligent production scheduling system, a remote automatic control system and a three-dimensional online simulation and prediction optimizing system, corresponding tasks are issued to an intelligent production management and control and production planning system according to user requirements of a production and marketing system, operation instructions are issued to a central control flow PLC, the central control flow PLC analyzes the commands and issues the commands to each intelligent basic single machine and a stock yard management system, each single machine starts to walk to an operation position and completes stacking, then material stacking and taking operation is started, after the operation workload is completed, the system is automatically stopped, the system is returned to a designated position, the server side updates site stock yard model data, the whole operation flow is completed by one key, and a flow chart of one-key linkage operation is shown in figure 18.

In the intelligent production management and control system for the bulk cargo port, each module or unit structure can independently operate or operate in a combined mode according to actual management and control setting requirements and data operation requirements so as to achieve corresponding technical effects.

It is to be understood that the disclosed embodiments are not limited to the specific structures, process steps, or materials disclosed herein, but are intended to extend to equivalents of these features as would be understood by one of ordinary skill in the relevant arts. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting. Reference in the specification to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. Thus, the appearances of the phrase "one embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment.

Although the embodiments of the present invention are described above, the embodiments are only used for facilitating understanding of the present invention, and are not intended to limit the present invention. Any person skilled in the art can make any modification and variation in form and detail without departing from the spirit and scope of the present disclosure, but the scope of the present disclosure is still subject to the scope of the appended claims.

Claims

1. A bulk port intelligent production management and control system, the system comprising:

2. The system of claim 1, wherein the intelligent production scheduling system adopts a front-end and back-end separation development mode based on Vue+spring Boot, a Vue driver adopts a library supported by a single file component and a Vue ecosystem to develop a complex single page application, and an expansion development component integration module is arranged based on a Spring Boot framework, so that decoupling and expansion are facilitated.

3. The system of claim 1, wherein the automatic stacking and reclaiming control subsystem performs stack plane configuration management on a stack yard according to a field/strip/stack management mode, forms a corresponding optimized management and control plan with a maximum storage capacity algorithm, a minimum energy consumption algorithm and a minimum time algorithm as targets based on operation task information, and establishes three corresponding stacking and reclaiming schemes, wherein the operation task information comprises material types, numbers, a cargo owner and operation amounts.

4. The system of claim 1, wherein the automated stacker-reclaimer control subsystem establishes a stacker-reclaimer collision avoidance module configured to implement a stacker-reclaimer collision avoidance control function according to the logic:

5. The system of claim 1, wherein the production process control subsystem is provided with a belt conveyor process intelligent control module configured to receive an operation plan issued by the intelligent production scheduling system, to convert the operation plan into a task plan by analysis and disassembly, to perform process scheduling according to the plan, to comprehensively consider the operation and fault conditions of the existing equipment in the scheduling process, to select an optimal path algorithm, to implement process switching according to the operation plan by the sequencing process, and to issue instructions to the process PLC, to implement "one-key linkage" full-process intelligent control.

6. The system of claim 1, wherein the belt conveyor flow intelligent control module is provided with a flow tracking unit configured to monitor flow conditions on the belt conveyor via the flow PLC, so that an operator can easily understand flow conditions on the belt conveyor and use the flow conditions as a basis for flow on-off control.

7. The system of claim 1, wherein the ship-to-ship intelligent management subsystem is configured to calculate ship arrival time through simulation of a pre-built ship arrival prediction model based on real-time acquired AIS information or manually input ship type, ship identification code, current position, and speed information, and dynamically adjust time weight of a ship mission plan with reference to historical simulation data and actual arrival time.

8. The system of claim 1, wherein the ship-to-ship intelligent management subsystem is further configured to utilize a comprehensive balance model to predict and discover comprehensive measurement berth occupancy conflicts, material inventory conflicts, conveyor system conflicts, inventory space conflicts, and to adjust the timing plan based thereon.

9. The system of claim 1, wherein the simulation preview optimization system is configured to: and before operation, according to the latest actual production equipment state acquired from each system of the port service stock yard, taking the latest actual production equipment state as an initial condition, combining the on-site real-time equipment state, simulating and simulating real working conditions to perform virtual production, optimizing a production operation plan according to the completed condition, and simultaneously recommending an optimized operation plan result by the system.

10. The system of claim 1, wherein the radar modeling and the three-dimensional laser scanning modeling are used as the basis to realize the comprehensive digital storage yard, the full-flow material flow tracking and the three-dimensional visual display, the three-dimensional modeling of the material pile is carried out aiming at different working conditions, the all-weather real-time modeling is carried out in the material pile taking operation process, and the latest data is provided for calculating the material pile operation strategy.