CN203229326U - Intelligent container gantry crane loading and unloading control system - Google Patents

Abstract

The utility model discloses an intelligent container gantry crane loading and unloading control system based on a laser scanning positioning technology. The container gantry crane intelligent loading and unloading control system mainly comprises the components including a hanger path control module, a laser scanning sensor, a video monitoring camera, a touch control display screen and the like, and can be used for performing positioning identification and path optimization on a yard contour and a hanger (or a hung container) according to scheduling instructions of a wharf management operating system, distance measuring information of a trolley-mounted laser scanning sensor and intelligent algorithms of scanning positioning identification and path optimization control, so that the hanger (or the hung container) is loaded and unloaded in position along an optimized path. The container gantry crane intelligent loading and unloading control system can significantly improve the operation efficiency, reduce the running energy consumption, reduce container collision accidents and lighten the labor intensity, and then further expands the scheduling function of the wharf management operating system, so that the intelligent container gantry crane loading and unloading control system can be widely used for various tire type or rail type gantry cranes of container yards.

Description

Container gantry crane intelligence loading and unloading control system

Technical field

The utility model relates to a kind of automatic loading and unloading control setup for the container depot gauntry crane, especially loads and unloads control system based on the container gantry crane intelligence of laser-scan location technology.

Background technology

Continuous development along with world economy, trade presents the situation that year after year increases progressively for many years always both at home and abroad, the significant advantage that maritime industry is big because of its freight volume, cost is low, the dock container loading and unloading capacity is also unprecedented soaring, cargo loading and transporting and operating speed almost completely depend on carrying and the collecting and distributing speed of freight container, and container handling efficient has become the cycle of advancing to clear out a harbour that restricts, raising port logistics level of service, reduced the significant problem of related industry chain cost.Many defectives such as the container handling of transfer crane (abbreviation gauntry crane) still relies on driver's manual control to finish at present, and the ubiquity handling efficiency is low, operation energy consumption is high, labour intensity is big, potential safety hazard is many.In stockyard turnover case process, the driver is high by case position and the heap of range estimation perception gauntry crane below, the goal box position that provides according to job instruction is handled cart, dolly and suspender and is finished loading and unloading, at last by estimating to check and confirm the performance of job instruction again.For avoiding the case accident of bumping of the improper initiation of manual operation, the gauntry crane operating instruction requires suspender to walk doorframe path (rather than shortest path), thereby has seriously restricted operating efficiency, significantly increased operation energy consumption.For improving the handling efficiency of freight container, just require gauntry crane operation accelerating, driver's control action to accelerate, because the influence of factors such as muscle power, mood and environment, misoperation can take place in driver unavoidably, causes gauntry crane and hits the case accident, causes unnecessary economic loss.

Implementation energetically along with national energy-saving and emission-reduction policy, harbour operation operating system (being called for short TOPS) presses for integrated suspender path optimization control function, in the hope of the unmanned intelligence loading and unloading of round Realization container depot, for port logistics enterprise ensures safety, cost efficiency.According to statistics, at present in the gauntry crane automatic assembling and disassembling system ubiquity identification location of grinding and many deficiencies such as path optimization's algorithm is impracticable, operation time long, disturbed influence is big, accuracy of positioning is poor, level of intelligence is low.

The utility model content

Technical problem to be solved in the utility model is: for overcoming in that to grind the ubiquitous identification of gauntry crane automatic assembling and disassembling system location and path optimization's algorithm impracticable, operation time is long, accuracy of positioning is poor, level of intelligence is low, reliability is difficult to many deficiencies such as assurance, the utility model provides a kind of container gantry crane intelligence loading and unloading control system based on the laser-scan location technology, can run the dispatch command of operating system and the ranging information that dolly carries the laser-scan sensor according to harbour, according to intelligent algorithms such as the identification of scanning location and path optimization's controls, stockyard profile and suspender (or being hung freight container) are positioned identification and path optimization, suspender (or being hung freight container) is put in place along optimizing the path loading and unloading.

The technical scheme that its technical matters that solves the utility model adopts is: container gantry crane intelligence loading and unloading control system is mainly by suspender path control module, the laser-scan sensor, the video monitoring pick up camera, assemblies such as touch-sensitive display screen constitute, the ranging information that suspender path control module (SRCM) is carried laser-scan sensor (LMS) according to dispatch command and the dolly of TOPS, according to intelligent algorithms such as predetermined scanning location identification and path optimization's controls, after stockyard profile and suspender (or being hung freight container) positioned identification and path optimization, control command is sent to master/slave station Programmable Logic Controller (PLC); PLC according to operating handle switch, revolve information such as lock open and-shut mode, dolly and spreader position coder etc., after control command compared, judges and confirm, drive trolley travelling motor, suspender lifting motor and revolve the lock switching mechanism by actuator and contactless switch, suspender (or being hung freight container) is put in place along optimizing the path loading and unloading, logout is returned to SRCM and TOPS simultaneously; When receiving the operating handle switch signal, system switches to automatic mode manual mode (be automatic mode until manual switchover) immediately; When runawaying or the system failure occurs, the exportable urgency of trouble diagnosing handler is stopped and alerting signal; Be to improve system safety and property convenient for control, the user also can monitor operation process and adjusts by video monitoring pick up camera (VSC) and touch-sensitive display screen (TS).

The beneficial effects of the utility model are: can be by intelligent algorithms such as the identification of scanning location and path optimization's controls, suspender (or being hung freight container) is put in place along optimizing the path loading and unloading, can significantly improve operating efficiency, reduce operation energy consumption, reduce and hit the case accident and reduce labor intensity, thereby further expanded the scheduling feature of TOPS, can be widely used in all kinds of rubber-tyreds and the orbit type gantry of container depot.

Description of drawings

Below in conjunction with drawings and Examples the utility model is further specified.

Fig. 1 is the intelligent loading and unloading operation signal of container piling site tyre hoister in the utility model.

Fig. 2 is that the structure of tyre crane intelligence loading and unloading control system in the utility model is formed.

Fig. 3 is the user interface of tyre crane intelligence loading and unloading control system in the utility model.

The specific embodiment

Below with reference to accompanying drawing the utility model is further described.

In the embodiment shown in fig. 1, the intelligent loading and unloading operation of container piling site tyre hoister relates generally in the utility model: tyre crane (1), freight container (2), truck (3), dolly (11), suspender (12), crossbeam (13), laser-scan sensor (111), suspender reflecting plate (121), crossbeam reflecting plate assemblies such as (131), wherein: storage yard container vertically is deposited in the tyre crane below according to the order of sequence, the truck passage is positioned at tyre crane below one side, dolly is level run on the track of tyre crane top, suspender links to each other with lifting mechanism on the dolly by hoist cable, crossbeam at the tyre crane shank on the top, the crossbeam reflecting plate is vertically mounted on the crossbeam, suspender reflecting plate level is installed in duel spreader frames top and circular arc reflecting surface towards laser-scan sensor (determining the coordinate position in the reflecting surface center of circle by at least three continuous laser scanning points on the reflecting surface), laser-scan sensor window mouth down is installed on the dolly, the laser-scan face is parallel with the XY coordinate plane, and intersect with crossbeam reflecting plate and suspender reflecting plate, be illustrated as tyre crane cart and come to a complete stop that system carries out motion control to dolly and suspender, dolly among the figure according to laser-scan location recognizer and suspender path optimization control algorithm under the state, suspender and quilt are hung freight container left side on tyre crane and are used respectively deeply with last limit on the right-right-hand limit position, the corresponding expression of shallow dichromatism.

1, laser-scan location recognizer

1) the X-axis coordinate of laser-scan sensor optical axis

When [s, θ] satisfies | ε _Br|=| Y _s-Y _r-ssin θ | → min and

The time, [s _Br, θ _Br]=[s, θ], x _s=s _BrCos θ _Br

2) rope point plane mid point waves/X of balance position, Y-axis coordinate under the hoist cable

$x_m=x_s-s_m\·\cos {\mathrm{\θ}}_m$ ， $y_m=Y_s-s_m\·\sin {\mathrm{\θ}}_m$ ；

$x_{m-1}=x_s-s_{m-1}\·\cos {\mathrm{\θ}}_{m-1}$ ， $y_{m-1}=Y_s-s_{m-1}\·\sin {\mathrm{\θ}}_{m-1}$ ；

$x_{m-2}=x_s-s_{m-2}\·\cos {\mathrm{\θ}}_{m-2}$ ， $y_{m-2}=Y_s-s_{m-2}\·\sin {\mathrm{\θ}}_{m-2}$ ；

$x_{\mathrm{cc}}=\frac{(y_m-y_{m-2})({y_{m-1}}^2-{y_{m-2}}^2+{x_{m-1}}^2-{x_{m-2}}^2)+(y_{m-1}-y_{m-2})({y_{m-2}}^2-{y_m}^2+{x_{m-2}}^2-{x_m}^2)}{2(x_{m-1}-x_{m-2})(y_m-y_{m-2})-2(x_m-x_{m-2})(y_{m-1}-y_{m-2})}$ ，

$y_{\mathrm{cc}}=\frac{(x_m-x_{m-2})({x_{m-1}}^2-{x_{m-2}}^2+{y_{m-1}}^2-{y_{m-2}}^2)+(x_{m-1}-x_{m-2})({x_{m-2}}^2-{x_m}^2+{y_{m-2}}^2-{y_m}^2)}{2(y_{m-1}-y_{m-2})(x_m-x_{m-2})-2(y_m-y_{m-2})(x_{m-1}-x_{m-2})}$ ；

$r_{\mathrm{cc}}=\sqrt{{(x_{\mathrm{cc}}-x_m)}^2+{(y_{\mathrm{cc}}-y_m)}^2}$ ；

When satisfying | ε _Hr|=| r _Cc-R _Hr| → min and | e _h|=| x _Cc-x _s+ W _Sh-W _Hr|≤E _HmaxThe time,

$x_{\text{hi}}=x_{\text{cc}}?W_{\text{hr}}$ ， $y_{\text{hi}}=y_{\text{cc}}?H_{\text{hr}}$ ；

$x_{\text{h}}=x_{\text{s}}?W_{\text{sh}}$ ， $y_{\text{h}}=Y_{\text{s}}+H_{\text{sp}}?\sqrt{{(Y_{\text{s}}+H_{\text{sp}}?y_{\text{hi}})}^2+{(x_{\text{s}}?W_{\text{sh}}?x_{\text{hi}})}^2}$ 。

3) X of stockyard and vehicle-mounted container end face mid point, Y-axis coordinate (n=1,2 ..., 7)

Work as when [s, θ] satisfies | ε _n|=| x _s-X _n-scos θ | → min and

The time, [s _Nt, θ _Nt]=[s, θ], y _n=Y _s-s _NtSin θ _Nt

When [s, θ] satisfies Y _s-ssin θ＜y _nAnd

The time, [s _Nt, θ _Nt]=[s, θ],

2, suspender path optimization control algorithm

$s_x=\frac{{{\stackrel{\&CenterDot;}{x}}_{\mathrm{<figure-callout\; id="2"\; label="s"\; filenames="HDA00002828514500011.png,HDA00002828514500031.png"\; state="\{\{state\}\}">s</figure-callout>}}}^2}{2g{f}_x}+E_{h\max }+W_i$ ， $s_y=\frac{{{\stackrel{\&CenterDot;}{y}}_h}^2}{2g{f}_y}+Y_{h\max }-H_h-5H_c$ ；

1) inlet stroke

1. lift stage

$x_h=x_7$ ， $y_h=y_7+H_c+H_h\&RightArrow;y_7+Y_{h\max }-4H_c$ 。

2. go up a slope the stage

When , j=a, a+1 ..., n(n satisfies x _n≤ x _H0-W _c-s _x) time;

x _h=x _H0→ x _j+ W _c+ s _x, y _h=y _H0→ y _j+ Y _Hmax-4H _c, [x _h, y _h] satisfy k _h=min (k _u).

3. descending stage

When The time;

$x_h=x_{\mathrm{<figure-callout\; id="0"\; label="h"\; filenames="HDA00002828514500011.png"\; state="\{\{state\}\}">h</figure-callout>}0}\&RightArrow;\left\{\begin{array}{c}{x}_{j-1},j\&GreaterEqual;a+1\\ x_j,j=a\end{array}\right.$ , y _h=y _H0→ y _j+ H _h+ H _c+ s _y, [x _h, y _h] full k _h=min (k _d) foot.

4. fall the case stage

Work as x _H0=x _aAnd x _Hi→ x _hWhen (suspender stops to wave); x _h=x _H0=x _a, y _h=y _H0→ y _a+ H _h+ H _c

2) outlet stroke

1. lift stage

x _h=x _a，y _h=y _a+H _c+H _h→y _a+Y _hmax-4H _c。

2. go up a slope the stage

When , j=n, n+1 ..., 7(n satisfies x _n〉=x _H0+ W _c+ s _x) time;

x _h=x _H0→ x _j-W _c-s _x, y _h=y _H0→ y _j+ Y _Hmax-4H _c, [x _h, y _h] satisfy k _h=max (k _u).

3. descending stage

When

The time;

$x_h=x_{\mathrm{<figure-callout\; id="0"\; label="h"\; filenames="HDA00002828514500011.png"\; state="\{\{state\}\}">h</figure-callout>}0}\&RightArrow;\left\{\begin{array}{c}{x}_{j+1},j\&le;6\\ x_j,j=7\end{array}\right.$ , y _h=y _H0→ y _j+ H _h+ H _c+ s _y, [x _h, y _h] satisfy k _h=max (k _d).

4. fall the case stage

Work as x _H0=x ₇And x _Hi→ x _hWhen (suspender stops to wave); x _h=x _H0=x ₇, y _h=y _H0→ y ₇+ H _h+ H _c

In the formula: s, θ-laser ranging value and beam angle (measured data according to the laser-scan sensor obtains);

s _Br, θ _Br-laser-scan sensor is to distance measurement value and the beam angle (measured data according to the laser-scan sensor obtains) of crossbeam baffle reflection face;

s _Hr, θ _Hr-laser-scan sensor is to distance measurement value and the beam angle (measured data according to the laser-scan sensor obtains) of suspender baffle reflection face;

s _Nt, θ _Nt-laser-scan sensor is to the stockyard and the distance measurement value of vehicle-mounted container end face axis and beam angle (measured data according to the laser-scan sensor obtains);

s _Nf, θ _Nf-laser-scan sensor is to the stockyard and the distance measurement value of vehicle-mounted container two side elevations and beam angle (measured data according to the laser-scan sensor obtains);

Y _sThe Y-axis coordinate of-laser-scan sensor optical axis (installation site according to the laser-scan sensor is measured);

Y _rThe Y-axis coordinate of-crossbeam baffle reflection face mid point (installation site according to the crossbeam reflecting plate is measured);

X _Smin, X _SmaxThe minimum of-laser-scan sensor optical axis and maximum X-axis coordinate (end position according to trolley travelling is measured);

Y _Hmin, Y _HmaxThe minimum on rope point plane and maximum Y-axis coordinate under-the hoist cable (end position according to the suspender lifting is measured);

ε _BrThe position deviation of-laser scanning point and crossbeam baffle reflection face mid point;

ε _nThe position deviation of-laser scanning point and stockyard and vehicle-mounted container end face mid point;

s _m, θ _m, s _M-1, θ _M-1, s _M-2, θ _M-2The distance measurement value of-3 continuous laser scanning spots and beam angle (measured data according to the laser-scan sensor obtains);

x _m, y _m, x _M-1, y _M-1, x _M-2, y _M-2The X of-3 continuous laser scanning spots, Y-axis coordinate;

x _Cc, y _Cc, e _hThe X-axis that the X/Y axial coordinate of-3 continuous laser scanning spot circumcenter of a triangles and relative suspender end face mid point wave balance position departs from;

r _Cc, ε _Hr-3 external radius of a circles of continuous laser scanning spot and with the deviation of suspender baffle reflection face arc radius;

E _HmaxIt waves the maximum amplitude of oscillation (caused by the dolly variable-speed operation, measure according to actual operating data) of balance position to rope point plane mid point relatively under the-hoist cable;

H _Br(laser scanning point should have 1 laser scanning point at least on the crossbeam baffle reflection face during apart from maximum to the height of-crossbeam reflecting plate, namely

, δ is the angle resolution of laser scanning point);

R _Hr(laser scanning point should have 3 continuous laser scanning points at least on the suspender baffle reflection face during apart from maximum to the arc radius of-suspender baffle reflection face, namely

, δ is the angle resolution of laser scanning point);

W _c, H _cThe width of-freight container and height (by the international standard regulation, width is 2.438m, highly is 2.438m, 2.591m or 2.896m);

W _iThe gap of-storage yard container (generally getting 0.4m);

H _hRope point is to the discrepancy in elevation of being hung the freight container end face (construction parameter according to suspender is determined) under-hoist cable;

W _Sh-laser-scan sensor optical axis is to the distance (installation site according to the laser-scan sensor is measured) of suspender vertical center line;

H _SpThe discrepancy in elevation of-laser-scan sensor optical axis rope point to the hoist cable (installation site according to the laser-scan sensor is measured);

W _Hr-suspender baffle reflection face the center of circle is to the distance (installation site according to the suspender reflecting plate is measured) of suspender vertical center line;

H _HrThe discrepancy in elevation of-suspender baffle reflection face center of circle rope point to the hoist cable (installation site according to the suspender reflecting plate is measured);

x _s,

X-axis coordinate and the speed of-laser-scan sensor optical axis;

s _x, s _y-hung freight container non-passing sight distance (dolly and suspender when normal operation, when driver's perception is hung after freight container the place ahead or below may bump, from the beginning emergency braking to stopping the shortest required safety distance that do not bump);

f _x, f _yThe brake force coefficient of-dolly, suspender (comprising friction braking and electromagnetic braking);

(the physics constant is got 9.8m/s to g-acceleration due to gravity ²);

The row of n-stockyard and vehicle-mounted container number (schedule information according to the harbour operation management system obtains);

A-heap is got the container depot row number (schedule information according to the harbour operation management system obtains) of target;

X _nThe standard x axial coordinate of-stockyard and vehicle-mounted container end face mid point (schedule information according to the harbour operation management system obtains);

x _n, y _nThe actual measurement X of-stockyard and vehicle-mounted container end face mid point, Y-axis coordinate;

x _Hi, y _Hi, x _h, y _h,

Rope point plane mid point waves/actual measurement X, Y-axis coordinate and the Y-axis speed of balance position under-the hoist cable;

x _Ho, y _HoRope point plane mid point waves actual measurement X, the Y-axis coordinate of balance position under-each stage start of a run hoist cable;

k _u, k _d, k _hThe slope of-suspender potential route and optimal route in each stage stroke of ascents and descents.

In embodiment illustrated in fig. 2, the structure composition of the intelligent loading and unloading of tyre crane control system mainly comprises in the utility model: suspender path control module (SRCM), harbour are runed operating system (TOPS), laser-scan sensor (LMS), video monitoring pick up camera (VSC), touch-sensitive display screen (TS), master/slave station Programmable Logic Controller (PLC), operating handle switch, revolve lock open and-shut mode, dolly position coder, spreader position coder, actuator and contactless switch, trolley travelling motor, suspender lifting motor, are revolved assemblies such as locking switching mechanism; Its principle of work is: the ranging information that suspender path control module is carried the laser-scan sensor according to dispatch command and the dolly of TOPS, according to intelligent algorithms such as predetermined scanning location identification and path optimization's controls, after stockyard profile and suspender (or being hung freight container) positioned identification and path optimization, control command is sent to master/slave station Programmable Logic Controller; Master/slave station Programmable Logic Controller according to operating handle switch, revolve information such as lock open and-shut mode, dolly and spreader position coder etc., after control command compared, judges and confirm, drive trolley travelling motor, suspender lifting motor and revolve the lock switching mechanism by actuator and contactless switch, suspender (or being hung freight container) is put in place along optimizing the path loading and unloading, logout is returned to suspender path control module and TOPS simultaneously; When receiving the operating handle switch signal, system switches to automatic mode manual mode (be automatic mode until manual switchover) immediately; When runawaying or the system failure occurs, the exportable urgency of trouble diagnosing handler is stopped and alerting signal; Be to improve system safety and property convenient for control, the user also can monitor operation process and adjusts by video monitoring pick up camera and touch-sensitive display screen.

In the embodiment shown in fig. 3, the user interface of tyre crane intelligence loading and unloading control system mainly comprises in the utility model: laser scanning image district (1), video monitoring image district (2), dispatch command display space (3), master mode operational zone (4), fault prompting display space (5), control switching manipulation district (6), positions such as (7), logout operational zone, and the user can monitor and operates by touch-sensitive display screen; Laser scanning image district and video monitoring image district are used for showing in real time laser scanning image and the video monitoring image of container piling site tyre hoister loading and unloading operation process respectively, the dispatch command display space is used for showing that the loading and unloading state that TOPS sends (is divided into inlet, outlet and move state such as case), case position, stockyard and quilt are hung information such as case number (CN), it is moving that the master mode operational zone is used for single player, S. A. and automatic isotype, fault points out the display space to be used for information such as tabulation demonstration failure-description and processing prompting, control switching manipulation district is used for operations such as startup and shutdown, and the logout operational zone is used for operations such as checking of loading and unloading operation process operation record and derivation.

Claims (3)

1. a container gantry crane intelligence is loaded and unloaded control system, mainly constituted by suspender path control module, laser-scan sensor, video monitoring pick up camera, touch-sensitive display screen, suspender path control module is according to the dispatch command of harbour operation operating system and the ranging information that dolly carries the laser-scan sensor, according to predetermined scanning location recognizer and path optimization's control algorithm, to stockyard profile, suspender with after being hung freight container and positioning identification and path optimization, control command is sent to master/slave station Programmable Logic Controller; Programmable Logic Controller according to operating handle switch, revolve the lock open and-shut mode, dolly and spreader position encoder information, after control command compared, judges and confirm, drive trolley travelling motor, suspender lifting motor and revolve the lock switching mechanism by actuator and contactless switch, make suspender and quilt be hung freight container and put in place along optimizing the path loading and unloading, simultaneously logout is returned to suspender path control module and harbour operation operating system; When receiving the operating handle switch signal, system switches to manual mode with automatic mode immediately, is automatic mode until manual switchover; When runawaying or the system failure occurs, the exportable urgency of trouble diagnosing handler is stopped and alerting signal; Be to improve system safety and property convenient for control, the user also can monitor operation process and adjusts by video monitoring pick up camera and touch-sensitive display screen.

2. container gantry crane intelligence according to claim 1 is loaded and unloaded control system, the laser reflecting surface of described suspender reflecting plate is arc-shaped structure, be installed in suspender top and reflecting surface towards the laser-scan sensor, determine the coordinate position in the reflecting surface center of circle by at least three continuous laser scanning points on the reflecting surface.

3. container gantry crane intelligence according to claim 1 is loaded and unloaded control system, the user interface of described touch-sensitive display screen mainly comprises the laser scanning image district, the video monitoring image district, the dispatch command display space, the master mode operational zone, fault prompting display space, control switching manipulation district and logout operational zone, laser scanning image district and video monitoring image district are used for showing in real time laser scanning image and the video monitoring image of container piling site tyre hoister loading and unloading operation process respectively, the dispatch command display space is used for showing the loading and unloading state of harbour operation operating system transmission, case position, stockyard and quilt are hung case number (CN) information, it is moving that the master mode operational zone is used for single player, S. A. and automatic mode, fault prompting display space is used for tabulation and shows failure-description and processing prompt message, control switching manipulation district is used for the startup and shutdown operation, and what the logout operational zone was used for loading and unloading operation process operation record checks and derive operation.

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