WO2022127045A1 - 一种散改集自动化装箱装置及系统 - Google Patents

一种散改集自动化装箱装置及系统 Download PDF

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Publication number
WO2022127045A1
WO2022127045A1 PCT/CN2021/097732 CN2021097732W WO2022127045A1 WO 2022127045 A1 WO2022127045 A1 WO 2022127045A1 CN 2021097732 W CN2021097732 W CN 2021097732W WO 2022127045 A1 WO2022127045 A1 WO 2022127045A1
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Prior art keywords
packing
bulk
containers
container
channel
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PCT/CN2021/097732
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English (en)
French (fr)
Inventor
王学锋
晁艺荧
戈佳威
张永亮
方剑波
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上海海事大学
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Priority to GB2309179.6A priority Critical patent/GB2617928B/en
Publication of WO2022127045A1 publication Critical patent/WO2022127045A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G5/00—Storing fluids in natural or artificial cavities or chambers in the earth
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G65/00—Loading or unloading
    • B65G65/005—Control arrangements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G63/00—Transferring or trans-shipping at storage areas, railway yards or harbours or in opening mining cuts; Marshalling yard installations
    • B65G63/002—Transferring or trans-shipping at storage areas, railway yards or harbours or in opening mining cuts; Marshalling yard installations for articles
    • B65G63/004—Transferring or trans-shipping at storage areas, railway yards or harbours or in opening mining cuts; Marshalling yard installations for articles for containers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G65/00—Loading or unloading
    • B65G65/30—Methods or devices for filling or emptying bunkers, hoppers, tanks, or like containers, of interest apart from their use in particular chemical or physical processes or their application in particular machines, e.g. not covered by a single other subclass
    • B65G65/32—Filling devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G67/00—Loading or unloading vehicles
    • B65G67/02—Loading or unloading land vehicles
    • B65G67/04—Loading land vehicles
    • B65G67/08—Loading land vehicles using endless conveyors
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/08—Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
    • G06Q10/087—Inventory or stock management, e.g. order filling, procurement or balancing against orders

Definitions

  • the invention relates to the field of automatic packing, in particular to a bulk-to-collect automatic packing device and system.
  • Bulk cargo refers to granular materials such as coal, iron ore, and grain, and is also the largest cargo category in ports.
  • Traditional bulk terminal operations include two forms of loading and unloading.
  • the materials on the yard are excavated by the bucket wheel reclaimer and then put into the belt conveyor system and transported to the ship loader at the front of the wharf. Fill all cabins.
  • the ship unloader at the front of the wharf takes out the material from the cabin, and the material grabbed by the grab-type ship unloader is put into the hopper and then falls on the belt conveyor, transported to the rear yard of the wharf, and the continuous ship unloader excavates.
  • the collected materials are put into the belt conveyor by the vertical hoist of the ship unloader, and transported to the yard for deployment by the stacker.
  • the degree of automation is low in the packing process of the bulk-to-consolidate containers in the port area, that is, the packing site and the unloading yard of the bulk carrier are not connected as a whole.
  • the position of the belt conveyor is fixed, requiring manual labor.
  • the efficiency of transporting the container to the packing position of the belt conveyor is low; at the same time, the current container is an ordinary container, and its maximum bearing capacity is lower than that of the bulk container, resulting in a large number of containers being damaged and reducing the service life.
  • the purpose of the present invention is to solve the above-mentioned deficiencies of the prior art, to provide a bulk-to-collection automatic packing device and system, to optimize the port packing process, and to improve the degree of connection and operation efficiency of each process.
  • an automatic packing device for bulk-to-collection including:
  • Onshore bulk yard for stacking and storing bulk cargo
  • an induction guide channel one end of which is connected to the overturning warehouse, for transporting containers out of the overturning warehouse
  • Containers are transported from the inversion warehouse to the packing passage through the induction guide passage, so that the door of each container is aligned with the end of the belt conveyor; after the packing is completed, the containers move along the packing passage. are shipped out of the boxing device.
  • the induction guide channel includes:
  • a first conveyor belt for carrying and conveying containers
  • warning area located at one end of the induction guide channel close to the packing channel
  • the first weight sensor The first weight sensor.
  • the packing channel includes:
  • each of the assembly areas being provided below the end of the belt conveyor, each of the assembly areas including a second weight sensor.
  • each of the assembly areas further includes a position sensor for monitoring whether the empty container is delivered in place.
  • a plurality of closed passages to be loaded are also included, one end of which is connected to the onshore bulk yard for transporting bulk cargo from the onshore bulk yard, and the other end is connected to the beginning of the belt conveyor.
  • the to-be-installed closed channel comprises:
  • a unit door which is arranged at one end of the closed passage to be loaded and the onshore bulk storage yard;
  • the third weight sensor is the third weight sensor.
  • the closed channel to be installed further includes a controller for controlling the opening and closing of the unit door.
  • the third conveyor belt is reversible.
  • a bulk-to-collection automatic packing system is used for the packing device, and the system comprises:
  • a data acquisition system which collects the weight signal from the first sensor, the second sensor and the third sensor and converts it into an electrical signal; collects the switch signal of the unit door and converts it into an electrical signal;
  • the data processing system receives the electrical signal of the data acquisition system, judges the running state of the packing process according to the electrical signal, and issues instructions;
  • a mechanical control system which receives instructions from the data processing system and controls the operation of the first conveyor belt, the second conveyor belt and the third conveyor belt;
  • the data acquisition system, the data processing system and the mechanical control system are electrically connected.
  • the weight sensor on the packing channel can monitor the weight of the packed goods, and stop loading when the critical weight is reached, which not only ensures economic benefits (maximum loading volume), but also meets the requirements of not exceeding the maximum load-bearing capacity .
  • FIG. 1 is a schematic diagram of the bulk-to-collection automatic packing device of the present invention.
  • FIG. 2 is a schematic diagram of the overturning warehouse, the induction guiding channel and the boxing channel of the bulk-to-collection automatic boxing device of the present invention.
  • FIG. 3 is a schematic diagram of the bulk-to-collection automatic packing system of the present invention.
  • FIG. 4 is a flow chart of the packing process of the bulk-to-collection automatic packing device of the present invention.
  • 1- onshore bulk storage yard 2- closed channel to be loaded, 3- belt conveyor, 4- turnover warehouse, 5- induction guide channel, 51- waiting area, 52- warning area, 6- packing channel, 61-Assembly area, 62-Position sensor, 63-Second weight sensor.
  • the bulk-to-collection automatic packing device disclosed in the present invention includes an onshore bulk storage yard 1 integrated into a whole system, a number of closed channels 2 to be loaded, a number of belt conveyors 3, a turning warehouse 4, an induction Guide channel 5 and packing channel 6.
  • the closed channel 2 to be installed and the belt conveyor 3 are arranged in a one-to-one correspondence.
  • the onshore bulk storage yard 1 is placed on the shore of the bulk carrier, instead of the traditional bulk storage yard, and its scale meets the national construction standards, and it is a cuboid.
  • the height is 4 meters, and the width will be set according to the specific size of the port.
  • Onshore bulk yard 1 is divided into three categories according to the storage weight: 25,000-50,000 tons, 51-150,000 tons, and more than 150,000 tons.
  • the to-be-installed closed channel 2 is a circular pipe with both sides closed, and is of the same material as the container.
  • the specific number of closed passages 2 to be loaded can be determined according to the needs of the port area, and the maximum number that can be set is the total length of the onshore bulk yard 1 / [2.5 (container width) + safety distance].
  • Each closed aisle 2 to be loaded includes a unit door, a third conveyor belt and a third weight sensor.
  • the closed channel 2 to be loaded is parallel to the ground, one end of which is welded with the onshore bulk storage yard 1 , and the other end is connected to the belt conveyor 3 . In this example, the closed channel 2 to be installed and the belt conveyor 3 overlap each other.
  • the unit door is located at the connection between the closed channel 2 to be loaded and the onshore bulk storage yard 1.
  • a push-pull unit door is used to play the bayonet function.
  • Remote control unit door switch When the unit door is opened, the packing process begins; when the unit door is closed, the packing process ends.
  • the third conveyor belt is a reversible conveyor belt, and after the packing process is completed, the residual bulk cargo in the conveyor belt can be reversely transported to the onshore bulk yard 1 through reverse operation.
  • the third weight sensor can measure the weight of the residual bulk cargo in the closed aisle 2 to be loaded. When the container is full, if the weight measured by the third weight sensor is greater than 0, the third conveyor belt will be transported in reverse until the third weight sensor measures The weight is equal to 0. Since the closed channel 2 to be loaded is a fully closed structure, when bulk cargo such as coal is stored therein, it can prevent the bulk cargo from being blown into the air, causing environmental pollution.
  • the belt conveyor 3 is used to transfer the bulk cargo from the onshore bulk yard 1 into the container.
  • the beginning end of the belt conveyor 3 is connected to the closed channel 2 to be installed, and the end is inclined upward, so that the height of the belt conveyor 3 is higher than the door of the container.
  • the packing device is provided with a reversing warehouse 4 for placing empty containers and turning the container over until the door of the container is upward. After the packing process is over, use the site-specific equipment to restore it to a horizontal state.
  • the induction guide channel 5 includes a first conveyor belt and a first weight sensor.
  • the first conveyor belt is used for carrying and conveying the containers to be loaded.
  • One end of the induction guide channel 5 close to the packing channel 6 is provided with a warning area 52 , and the rest area is a waiting area 51 .
  • the first weight sensor senses that the first container to be loaded passes through the warning area 52, the closed aisle 2 to be loaded and the belt conveyor 3 start to start.
  • the containers to be loaded of the latter batch wait in sequence in the waiting area 51 at the induction guide channel 5 .
  • a second conveyor belt is provided on the packing channel 6 for carrying and transporting the containers.
  • the packing channel 6 includes several assembly areas 61 , each assembly area 61 is arranged below the end of the belt conveyor 3 , and each assembly area 61 includes a second weight sensor 63 .
  • the second conveyor belt transports the batch of containers; at the same time, transports the next batch of containers to be loaded to the assembly area 61 .
  • each assembly area 61 also includes a position sensor 62 to monitor whether empty containers are delivered in place.
  • the position sensor 62 may be a photosensitive sensor, an infrared sensor, or the like.
  • the second weight sensor 63 can function to monitor whether the empty container is delivered in place. When the weight measured by the second weight sensor 63 is 0, the container to be loaded is not delivered in place, and when the weight measured by the second weight sensor 63 is the weight of the empty container, the container to be loaded is delivered in place.
  • the following method can be used.
  • the instantaneous speed V is collected, and the distance in a small period of time can be obtained by calculation. Therefore, the time is processed as follows: with 100ms as the basic unit, the instantaneous speed V i is collected at the beginning of each 100ms, And calculate the separation distance S i for each area:
  • the present invention also provides a kind of automatic packing system for bulk-to-collection, including:
  • a data acquisition system which collects the weight signal from the first sensor, the second sensor and the third sensor and converts it into an electrical signal; collects the switch signal of the unit door and converts it into an electrical signal;
  • the data processing system receives the electrical signal of the data acquisition system, judges the running state of the packing process according to the electrical signal, and issues instructions;
  • a mechanical control system which receives instructions from the data processing system and controls the operation of the first conveyor belt, the second conveyor belt and the third conveyor belt;
  • the data acquisition system, the data processing system and the mechanical control system are electrically connected.
  • the three subsystems all send out control commands through wireless transmission, and are connected in series working mode to form a fully automatic digital information system. .
  • a packing process of the present invention includes the following steps:
  • the container to be loaded is turned from the side of the box door to the door upward in the turnover warehouse 4, and is transported by the carrier vehicle from the turnover warehouse 4 to the induction guide channel 5.
  • the speed of the first conveyor belt of the induction guide channel 5 is v 1 ;
  • the belt conveyor 3 transports the bulk cargo into the containers.
  • the speed of the first conveyor belt of the induction guide channel 5 is v 2 , and v 2 is close to 0;
  • the third conveyor belt of the closed channel 2 to be loaded works at a low speed, and the belt conveyor 3 stops working.
  • the second conveyor belt of the channel 6 transports the full container out of the packing channel 6, and then the container is transported away by the carrier vehicle; after that, the speed of the second conveyor belt of the induction guide channel 5 becomes v 1 , and the container to be loaded is transported.
  • the belt conveyor 3 transports the bulk cargo into the container;
  • the waiting time refers to the time from when the container to be loaded is transported to the assembly area 61 to when the container to be loaded is full.
  • the actual waiting time is lower than the set waiting time, it means that the turning process in the turning warehouse 4 is delayed.
  • the third conveyor belt of the closed channel 2 to be loaded works at a low speed, and the belt conveyor 3 stops working and waits for the turning warehouse 4 Continue to complete the unpacking;
  • weight measured by the third weight sensor on the closed aisle 2 to be loaded is greater than 0, it means that there is residual bulk cargo in the closed aisle 2 to be loaded, and the third conveyor belt of the closed aisle 2 to be loaded runs in the reverse direction to return the residual bulk cargo to the land go to bulk yard 1;
  • weight measured by the third weight sensor on the closed aisle 2 to be loaded is equal to 0, it means that the bulk cargo in the closed aisle 2 to be loaded has been transported, and the unit door of the closed aisle 2 to be loaded is closed, and the packing process ends.
  • the present invention can improve the efficiency of the automatic packing process.
  • W is the total weight of the bulk cargo to be unloaded on the bulk carrier
  • w represents the weight of a single container
  • T cs represents the bulk cargo from the bulk carrier to the In the storage area
  • T S means that the current container is loaded until the next continuous empty.
  • the arrival time of the container is also the one-time working time of the automatic bayonet.
  • T S1 means the traditional container changing time
  • T S2 means the container changing time of the automatic packing strip
  • T 0 means the one-time loading time of the goods
  • L means the current time The actual distance between the geometric center of the loaded container and the geometric center of the next consecutive empty container projected on the packing strip, that is, the distance that the packing strip works once.
  • the total time of the traditional bulk cargo packing operation can be calculated as: And the total time of the designed automatic packing operation: in Therefore, compared with the traditional packing operation, the efficiency of the automatic packing process is as follows: Simultaneously the above formula 1234 can be obtained Among them, the traditional box changing time T S1 , the cargo packing time T 0 , the total time T cs for the bulk cargo to leave the belt conveyor 3 , and the total weight W of the bulk cargo to be unloaded are the quantities actually measured after completing one packing task , the distance L between containers, the maximum loading weight w of a single container, the average running speed of the packing strip are known quantities.
  • a bulk carrier carrying 5,000 tons of coal is transported in a 20-inch container with a maximum deadweight of 20 tons.
  • the time for the container point is about 5 minutes, and the time for packing is about 20 minutes.
  • the interval between the containers to be loaded before optimization is about 3 minutes.
  • the average running speed of the packing strip is 0.4m/s, and the improved efficiency after optimization is at least 9.54%. (That is, if one packing task takes 24 hours, at least 2.39 hours can be saved by adopting the automatic packing process).

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Environmental & Geological Engineering (AREA)
  • General Life Sciences & Earth Sciences (AREA)
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  • Aviation & Aerospace Engineering (AREA)
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Abstract

一种散改集自动化装箱装置及系统，包括：陆上散装堆场（1），用于堆放及存储散货；若干皮带机（3），用于将散货由陆上散装堆场（1）传送至集装箱内，其末端向上倾斜；翻转仓库（4），用于放置空集装箱，并将集装箱翻转至箱门向上；感应引导通道（5），其一端连接翻转仓库（4），用于将集装箱从翻转仓库（4）中运出；及装箱通道（6），与感应引导通道（5）的另一端相连；集装箱由翻转仓库（4）经感应引导通道（5）运至装箱通道（6）上，使每个集装箱的箱门对准皮带机（3）的末端；装箱完成后，集装箱沿装箱通道（6）被运出装箱装置。该散改集自动化装箱装置及系统能够优化港口装箱过程，提高每个过程的衔接程度以及作业效率。

Description

一种散改集自动化装箱装置及系统 技术领域
本发明涉及自动化装箱领域，具体涉及一种散改集自动化装箱装置及系统。
背景技术
散货是指煤炭、铁矿石、粮食等颗粒状物料，也是港口最大宗的货类。传统散货码头作业包括装船和卸船两种形态。装船作业时，堆场上的物料由斗轮取料机挖取后放入皮带机系统，输送到码头前沿的装船机上，通过装船机的移动和输料悬臂的仰俯，将物料装满各个船舱。卸船作业时，码头前沿的卸船机将物料从船舱中取出，抓斗式卸船机抓取的物料放入漏斗后落在皮带机上，输送到码头后方堆场，连续式卸船机挖取的物料经卸船机垂直提升机放入皮带机，输送到堆场通过堆料机进行布放。
散改集，即将散货改为集装箱的方式进行运输，主要应用于包含海、铁的多式联运。散改集是目前我国航运领域一项重要的创新，目的是顺应绿色化的时代要求，加速多式联运的探索，深化运输方面的技术改革，目前，国内大多数海港已经开始在多式联运中落实此项创新。然而，由于目前港口装箱工艺尚未及时改进，仍使用传统作业技术，导致一系列的问题随之产生，并阻碍创新此进程。
一方面，港区码头散改集集装箱的装箱过程中，自动化程度较低，即装箱地点与散货船卸货堆场并未连成一个整体，另一方面，皮带机位置固定，需要人工将集装箱运送至皮带机装箱位置，效率较低；同时，现用集装箱为普通集装箱，其最大承重低于散货集装箱，导致大量集装箱被损坏，减少使用寿命。
目前，国内应对散改集技术的发明较少，而上述背景问题不利于此项创新的可持续发展，亟需一种结合信息化技术、提高效率和经济性的发明应对现有技术困境。
发明内容
本发明的目的是解决上述现有技术的不足，提供一种散改集自动化装箱装置及系统，优化港口装箱过程，提高每个过程的衔接程度以及作业效率。
为了达到上述目的，本发明提供了一种散改集自动化装箱装置，包括：
陆上散装堆场，用于堆放及存储散货；
若干皮带机，用于将散货由所述陆上散装堆场传送至集装箱内，其末端向上倾斜；
翻转仓库，用于放置空集装箱，并将集装箱翻转至箱门向上；
感应引导通道，其一端连接所述翻转仓库，用于将集装箱从所述翻转仓库中运出；及
装箱通道，与所述感应引导通道的另一端相连；
集装箱由所述翻转仓库经所述感应引导通道，运至所述装箱通道上，使每个集装箱的箱门对准所述皮带机的末端；装箱完成后，集装箱沿所述装箱通道被运出所述装箱装置。
优选地，所述感应引导通道包括：
第一传送带，用于承载并传送集装箱；
警示区，位于所述感应引导通道靠近所述装箱通道的一端；
等待区，除所述警示区外的区域均为等待区；及
第一重量传感器。
优选地，所述装箱通道包括：
第二传送带，用于承载并传送集装箱；
若干装配区，每个所述装配区设于所述皮带机末端的下方，每个所述装配区包括第二重量传感器。
优选地，每个所述装配区还包括位置传感器，用于监测空集装箱是否运送到位。
优选地，还包括若干待装封闭通道，其一端连接陆上散装堆场，用于将散货从陆上散装堆场中运出，另一端连接所述皮带机的始端。
优选地，所述待装封闭通道包括：
单元门，其设于所述待装封闭通道与陆上散装堆场连接的一端；
第三传送带，用于承载并传送散货；及
第三重量传感器。
优选地，所述待装封闭通道还包括控制器，用于控制单元门的开关。
优选地，所述第三传送带为可逆向转动。
一种散改集自动化装箱系统，用于所述的装箱装置，所述的系统包括：
数据采集系统，采集所述第一传感器、第二传感器和第三传感器将所述的重量信号，并转化为电信号；采集所述单元门的开关信号，并转化为电信号；
数据处理系统，接收数据采集系统的电信号，根据电信号，判断装箱过程的运行状态，下发指令；
机械控制系统，接收数据处理系统的指令，控制第一传送带、第二传送带和第三传送带的运行；
所述数据采集系统、数据处理系统和机械控制系统之间电连接。
本发明的有益效果为：
(1)解决集装箱损坏问题：装箱通道上的重量传感器可以监测装箱货物重量，达到临界重量时，停止装货，既保证经济效益(最大装货量)，又满足不超过最大承重的要求。
(2)解决现有装卸技术衔接不紧密问题：将陆上散装堆场和装箱作业连成一个整体，即包括卸货地、装箱地和集装箱翻转地。卸货至陆上散装堆场，皮带机与陆上散装堆场连接，感应引导通道使集装箱翻转箱门后直接运输至指定位置，无需再人工进行位置对应，形成一体化作业模式，减少损耗时间。
(3)解决换装导致效率较低问题：每次每箱装货完成后，皮带机无需停止作业，通过待装封闭通道暂存待装散货，减少等待所需时间。
附图说明
图1为本发明的散改集自动化装箱装置的示意图。
图2为本发明的散改集自动化装箱装置的翻转仓库、感应引导通道和装箱通道示意图。
图3为本发明的散改集自动化装箱系统示意图。
图4为本发明的散改集自动化装箱装置的装箱过程流程图。
图中，1-陆上散装堆场，2-待装封闭通道，3-皮带机，4-翻转仓库，5-感 应引导通道，51-等待区，52-警示区，6-装箱通道，61-装配区，62-位置传感器，63-第二重量传感器。
具体实施方式
下面将结合附图对本发明的技术方案进行清楚、完整地描述，显然，所描述的实施例是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
如图1所示，本发明公开的散改集自动化装箱装置包括集成为一个整体系统的陆上散装堆场1、若干个待装封闭通道2、若干个皮带机3、翻转仓库4、感应引导通道5和装箱通道6。待装封闭通道2和皮带机3一一对应设置。
散货堆放并存储在陆上散装堆场1中。陆上散装堆场1置于散货船靠泊岸边，代替传统散装堆场，其规模满足国家建设标准，为长方体，在一实施例中，陆上散装堆场1的长为54米，高为4米，宽将根据港口具体规模自行设置。陆上散装堆场1根据存储重量不同分为三类：2.5-5万吨、5.1-15万吨以及15万吨以上。
待装封闭通道2为圆形管道，两侧封闭，与集装箱材质相同。待装封闭通道2的具体数量可根据港区需要自行确定，最多可设置数量为陆上散装堆场1总长度/[2.5(集装箱宽)+安全距离]。每个待装封闭通道2包括单元门、第三传送带和第三重量传感器。待装封闭通道2与地面平行，其一端与陆上散装堆场1焊接，另一端与皮带机3相连。在本例中，待装封闭通道2与皮带机3相互搭接。单元门设于待装封闭通道2与陆上散装堆场1的连接处，本例采用推拉式单元门，发挥卡口功能，即可人工手动开关单元门，也可设置控制器，通过控制器遥控单元门的开关。单元门打开，装箱过程开始；单元门关闭，装箱过程结束。第三传送带为可逆传送带，在装箱过程结束后，能够通过逆向运转，将其内残余的散货反向运输至陆上散装堆场1中。第三重量传感器能够测量待装封闭通道2内残余散货的重量，当集装箱装满后，若第三重量传感器测得的重量大于0，则第三传送带逆向运输，直至第三重量传感器测得的重量等于0。由于待装封闭通道2为全封闭式结构，煤炭等散货存储于其内时，能防止散货不被吹散至空气中，造成环境污染。
皮带机3用于将散货由所述陆上散装堆场1传送至集装箱内。皮带机3的始端连接待装封闭通道2，末端向上倾斜，使皮带机3的高度高于集装箱的箱门处。
正常运输时，集装箱的箱门在侧面，直接打开箱门即可装卸货物。装运散货时，散货是通过皮带机3运送至集装箱内，因此，本装箱装置设置翻转仓库4，用于放置空集装箱，并将集装箱翻转至箱门向上。装箱过程结束后，使用场站专有设备恢复至水平状态。
如图2所示，感应引导通道5的一端连接翻转仓库4，另一端连接装箱通道6，用于将待装集装箱由翻转仓库4引导至装箱通道6上。感应引导通道5包括第一传送带和第一重量传感器。第一传送带用以承载和传送待装集装箱。感应引导通道5靠近装箱通道6的一端设有警示区52，其余区域为等待区51。当第一重量传感器感知到第一个待装集装箱通过警示区52后，待装封闭通道2和皮带机3开始启动。在一个装箱过程中，当前一批次的集装箱在装箱通道6处装运散货时，后一批次的待装集装箱在感应引导通道5处的等待区51依次等待。
装箱通道6上设有第二传送带，用于承载并传送集装箱。装箱通道6上包括若干装配区61，每个装配区61设于皮带机3末端的下方，每个装配区61都包括一个第二重量传感器63。当同一批次的待装集装箱都到达装配区61时，皮带机3上的散货被运送至集装箱内；当第二重量传感器63测得的重量达到满箱重量时，该批次的集装箱装配完成，第二传送带将该批次的集装箱运出；同时，将下一批次的待装集装箱传送到装配区61。在本例中，每个装配区61还包括一个位置传感器62，以监测空集装箱是否运送到位。位置传感器62可以是光敏传感器、红外传感器等。在不设有位置传感器62的实施例中，第二重量传感器63能够起到监测空集装箱是否运送到位的作用。当第二重量传感器63测得的重量为0时，待装集装箱未运送到位，当第二重量传感器63测得的重量为空集装箱的重量时，待装集装箱运送到位。
为确定每装箱一轮最小长度，可利用如下方法。从装箱通道6开始工作时，采集瞬时速度V，通过计算可以得到一段微小时间内的距离，因此将时间作如下处理：以100ms为基本单位，在每个100ms开始时采集瞬时速度V i， 并计算出每个区域间隔距离S i：
Figure PCTCN2021097732-appb-000001
瞬时速度的计算公式为V＝N×S×π×d；其中，N为电机每分钟转速，S为减速机变速比，d为电机直径；工作一次需要最小总距离为L＝S 1+S 2+…+S n。
如图3所示，本发明还提供了一种散改集自动化装箱系统，包括：
数据采集系统，采集所述第一传感器、第二传感器和第三传感器将所述的重量信号，并转化为电信号；采集所述单元门的开关信号，并转化为电信号；
数据处理系统，接收数据采集系统的电信号，根据电信号，判断装箱过程的运行状态，下发指令；
机械控制系统，接收数据处理系统的指令，控制第一传送带、第二传送带和第三传送带的运行；
所述数据采集系统、数据处理系统和机械控制系统之间电连接。三个子系统之间均通过无线传输方式发出控制指令，且以串联工作模式相连，构成全自动数字化信息系统，各系统间不可越级进行，且整个装箱过程停止前，均循环操作之前装箱过程。
如图4所示，本发明的一个装箱过程包括如下步骤：
1)装箱过程启动：
打开待装封闭通道2的单元门，装箱过程开启；
待装集装箱在翻转仓库4内由箱门在侧面翻转至箱门向上，并由运载车从翻转仓库4中运至感应引导通道5上，此时感应引导通道5的第一传送带的速度为v 1；
运有待装集装箱的运载车，被感应引导通道5上的第一传送带运至警示区52时，待装封闭通道2和皮带机3启动；
运有待装集装箱的运载车全部运送至装箱通道6上的装配区61后，皮带机3将散货运送至集装箱中。
2)装箱过程中：
感应引导通道5的第一传送带的速度为v 2，v 2接近于0；
第二重量传感器63测得的重量达到满箱重量时，该批次的集装箱装配完 成：
a)若感应引导通道5的等待区51的重量不为0，说明仍有待装集装箱还未装箱，此时待装封闭通道2的第三传送带低速工作，皮带机3暂停工作，由装箱通道6的第二传送带将已装满的集装箱运出装箱通道6，再由运载车运送集装箱驶离；之后，感应引导通道5的第二传送带的速度变为v 1，将待装集装箱运送至装箱通道6的装配区61上，皮带机3将散货运送至集装箱中；
b)若感应引导通道5的等待区51域重量为0，进一步判断等待时间，等待时间指的是从待装集装箱运送到装配区61，至该待装集装箱装满的时间，该时间由人为提前设定：
i.若实际的等待时间低于设定的等待时间，说明翻转仓库4中的翻箱过程延迟，此时待装封闭通道2的第三传送带低速工作，皮带机3暂停工作，等待翻转仓库4继续完成翻箱；
ii.若实际等待时间大于等于设定的等待时间，说明所有待装集装箱均已完成装箱；
3)装箱结束：
所有待装集装箱均完成装箱后，皮带机3停止工作；
若待装封闭通道2上第三重量传感器测得的重量大于0，说明待装封闭通道2内还有残余散货，则待装封闭通道2的第三传送带逆向运行，将残余散货运回陆上散装堆场1；
若待装封闭通道2上第三重量传感器测得的重量等于0，说明待装封闭通道2内的散货已运尽，关闭待装封闭通道2的单元门，装箱过程结束。
本发明能够提高自动化装箱工艺的效率。相较于传统散货装箱流程的装箱过程，做如下假设：假设W为散货船上待卸载散货的总重量，w表示单个集装箱装载的重量，T cs表示散货从散货船到存储区，再经过皮带机3的总工作时间，规定散货开始从散货船上卸货为开始计时时刻，皮带机3停止工作为计时终止时刻；T S表示当前集装箱装货结束至下一个连续空集装箱到达的时间，也为自动卡口一次工作时间，T S1表示传统的换箱时间，T S2表示自动化 装箱条形带的换箱时间；T 0表示货物一次装箱时间；L表示当前正在装载的集装箱几何中心与下一个连续空集装箱几何中心在装箱条形带上投射的实际距离，即装箱条形带工作一次前进的距离。因此可以计算得到传统散货装箱作业总时间为：
Figure PCTCN2021097732-appb-000002
以及所设计的自动化装箱作业总时间：
Figure PCTCN2021097732-appb-000003
其中
Figure PCTCN2021097732-appb-000004
因此，相比较传统的装箱作业，自动化装箱过程的效率在装箱效率上有：
Figure PCTCN2021097732-appb-000005
联立上式①②③④可得
Figure PCTCN2021097732-appb-000006
其中传统换箱时间T S1、货物装箱时间T 0、散货从船到离开皮带机3的总时间T cs以及待卸货的散货总重量W为完成一次装箱任务后实际测得的量，集装箱之间的距离L、单个集装箱最大装载重量w、装箱条形带运行平均速度
Figure PCTCN2021097732-appb-000007
均为已知量。以宁波某散货码头为例，一艘装载5000吨煤炭的散货船，用最大载重量为20吨的20英寸集装箱运输，煤炭从散货船通过带抓斗的工具以及皮带机3到达装箱点的时间约为5分钟，装箱时间约为20分钟，此外优化前待装集装箱之间的间隔大约为3分钟，假设设计时采用充足的间距，取8m(L必须大于运载集装箱AGV的宽度)，装箱条形带的平均运行速度为0.4m/s，此时优化后提升的效率至少为9.54％。(即一次装箱任务需要24小时的话，采用该自动化装箱工艺可以节省至少2.39个小时)。
尽管本发明的内容已经通过上述优选实施例作了详细介绍，但应当认识到上述的描述不应被认为是对本发明的限制。在本领域技术人员阅读了上述 内容后，对于本发明的多种修改和替代都将是显而易见的。因此，本发明的保护范围应由所附的权利要求来限定。

Claims (9)

  1. 一种散改集自动化装箱装置，其特征在于，包括：
    陆上散装堆场，用于堆放及存储散货；
    若干皮带机，用于将散货由所述陆上散装堆场传送至集装箱内，其末端向上倾斜；
    翻转仓库，用于放置空集装箱，并将集装箱翻转至箱门向上；
    感应引导通道，其一端连接所述翻转仓库，用于将集装箱从所述翻转仓库中运出；及
    装箱通道，与所述感应引导通道的另一端相连；
    集装箱由所述翻转仓库经所述感应引导通道，运至所述装箱通道上，使每个集装箱的箱门对准所述皮带机的末端；装箱完成后，集装箱沿所述装箱通道被运出所述装箱装置。
  2. 如权利要求1所述的装箱装置，其特征在于，所述感应引导通道包括：
    第一传送带，用于承载并传送集装箱；
    警示区，位于所述感应引导通道靠近所述装箱通道的一端；
    等待区，除所述警示区外的区域均为等待区；及
    第一重量传感器。
  3. 如权利要求1所述的装箱装置，其特征在于，所述装箱通道包括：
    第二传送带，用于承载并传送集装箱；
    若干装配区，每个所述装配区设于所述皮带机末端的下方，每个所述装配区包括第二重量传感器。
  4. 如权利要求3所述的装箱装置，其特征在于，每个所述装配区还包括位置传感器，用于监测空集装箱是否运送到位。
  5. 如权利要求1所述的装箱装置，其特征在于，还包括若干待装封闭通道，其一端连接陆上散装堆场，用于将散货从陆上散装堆场中运出，另一端连接所述皮带机的始端。
  6. 如权利要求5所述的装箱装置，其特征在于，所述待装封闭通道包括：
    单元门，其设于所述待装封闭通道与陆上散装堆场连接的一端；
    第三传送带，用于承载并传送散货；及
    第三重量传感器。
  7. 如权利要求6所述的装箱装置，其特征在于，所述待装封闭通道还包括控制器，用于控制单元门的开关。
  8. 如权利要求6所述的装箱装置，其特征在于，所述第三传送带为可逆向转动。
  9. 一种散改集自动化装箱系统，用于如权利要求1-8所述的装箱装置，其特征在于，所述的系统包括：
    数据采集系统，采集所述第一传感器、第二传感器和第三传感器将所述的重量信号，并转化为电信号；采集所述单元门的开关信号，并转化为电信号；
    数据处理系统，接收数据采集系统的电信号，根据电信号，判断装箱过程的运行状态，下发指令；
    机械控制系统，接收数据处理系统的指令，控制第一传送带、第二传送带和第三传送带的运行；
    所述数据采集系统、数据处理系统和机械控制系统之间电连接。
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