CN-121990386-A - Dual-mode stacking and automatic alignment control method and system for stacker-reclaimer

CN121990386ACN 121990386 ACN121990386 ACN 121990386ACN-121990386-A

Abstract

The invention relates to a dual-mode stacking and automatic alignment control method and system of a stacker-reclaimer, wherein the method comprises real-time sensing and modeling; intelligent mode decision, dynamic alignment calculation, track planning and execution, closed loop calibration and anti-collision control. The system comprises a three-dimensional sensing subsystem, an edge computing and controlling subsystem, a device driving subsystem and a cloud collaborative optimization platform, wherein the edge computing and controlling subsystem comprises a data fusion and modeling module, a mode decision module, an intelligent alignment computing module and a track planning and motion control module. The invention solves the problems of single control mode and dependence on fixed coordinates of alignment in the prior art, realizes intelligent decision, accurate dynamic alignment and closed-loop safety control, and remarkably improves the overall efficiency and quality of material piling and taking operation.

Inventors

LV CHONGXIAO
XU XIANKAI
Zou Xiangchao
JIANG YULONG
GAO GUANGHENG
LIU MIAO

Assignees

中交机电工程局有限公司

Dates

Publication Date: 20260508
Application Date: 20251230

Claims (10)

1. The dual-mode stacking and automatic alignment control method of the stacker-reclaimer is characterized by comprising the following steps of: s1, real-time sensing and modeling, namely acquiring a real-time three-dimensional point cloud model of an operation area and preset operation task parameters; s2, intelligent mode decision, namely, based on the three-dimensional point cloud model and the operation task parameters, carrying out self-adaptive selection in an efficiency priority mode and a regular priority mode, wherein, The efficiency priority mode takes the maximum material throughput in unit time as an optimization target; The method comprises the steps of (1) orderly forming a priority mode, wherein the orderly forming a material pile profile which is beneficial to the subsequent full-face material taking is an optimization target; S3, dynamic alignment calculation, namely calling an alignment algorithm corresponding to the selected target mode, analyzing the three-dimensional point cloud model, resolving in real time and outputting an optimal alignment point matched with the dynamic geometrical characteristics of the current stockpile and the operation target; S4, track planning and execution, namely planning the motion track of the cantilever of the stacker-reclaimer according to the optimal alignment point, and controlling the stacker-reclaimer to execute the stacking or reclaiming operation.
2. The dual-mode stacking and automatic alignment control method of a stacker-reclaimer as claimed in claim 1, wherein in step S1, a laser radar or a depth camera mounted on a cantilever of the stacker-reclaimer is used for performing rotary scanning on an operation area to obtain a real-time three-dimensional point cloud model, and the operation task parameters at least comprise a material type, a target stacking height and an operation emergency degree identifier.
3. The dual-mode stacking and automatic alignment control method of a stacker-reclaimer of claim 1, wherein the adaptive selection logic in step S2 comprises selecting an efficiency priority mode if the job task parameter indicates that the average stack height obtained by initializing stacking or three-dimensional point cloud model analysis is lower than a first threshold, and selecting a regularity priority mode if the job task parameter indicates that the stack-shaped arrangement or the average stack height is higher than a second threshold, wherein the second threshold is greater than or equal to the first threshold.
4. The dual-mode stacking and automatic alignment control method of a stacker-reclaimer as set forth in claim 1, wherein in step S3, when the job is stacking, the real-time resolving includes invoking a first alignment algorithm if the three-dimensional form of the selected mode and the current stack is an efficiency priority mode, invoking a second alignment algorithm if the three-dimensional form of the selected mode and the current stack is a regular priority mode, and simulating a material blanking motion through the corresponding alignment algorithm to determine a cantilever end blanking focal point capable of optimizing a new stack of materials to achieve a current mode target as an optimal alignment point.
5. The dual-mode stacking and automatic alignment control method of a stacker-reclaimer as set forth in claim 4, wherein the first alignment algorithm determines the blanking focus with minimized material roll-off distance and cantilever idle travel movement time as optimization targets, and the second alignment algorithm determines the blanking focus with a blanking sequence required for simulating a preset standard stack-shaped cross section as a primary target.
6. The dual-mode stacking and automatic alignment control method of a stacker-reclaimer as set forth in claim 1, wherein in step S3, when the job is a reclaiming operation, the real-time resolving includes identifying a gradient and a contour of a reclaiming level based on a three-dimensional point cloud model, invoking a third alignment algorithm, and dynamically calculating a starting point and a cutting angle of a reclaiming device into a stockpile, which can achieve maximum reclaiming efficiency and avoid a risk of collapse of the stockpile, as an optimal alignment point.
7. The dual-mode stacker-reclaimer and automatic alignment control method of claim 1, further comprising: S5, closed loop calibration and anti-collision control are specifically carried out, wherein in the operation execution process, the step S1 is circularly carried out to update a three-dimensional point cloud model, the optimal opposite points and the motion track are adjusted in real time based on the updated model, meanwhile, the distances between the cantilever and the material taking device and the material pile and the surrounding facilities are monitored in the model, and if the distances are smaller than a safety threshold value, protective actions are triggered.
8. The dual-mode stacker-reclaimer and automatic alignment control system for implementing the dual-mode stacker-reclaimer and automatic alignment control method of any of claims 1-7, comprising: The three-dimensional sensing subsystem is fixedly arranged on the cantilever of the stacker-reclaimer and comprises at least one laser radar scanner and/or a depth camera and is used for periodically collecting original point cloud data of an operation area; The edge calculation and control subsystem is deployed in the stacker-reclaimer body control room and is in communication connection with the three-dimensional perception subsystem through an industrial Ethernet, and comprises: the data fusion and modeling module is used for carrying out filtering and registering processing on the original point cloud data to generate a real-time three-dimensional point cloud model; The mode decision module is embedded with dual-mode switching logic and is used for executing self-adaptive selection based on the three-dimensional point cloud model and externally input task parameters; the intelligent alignment calculation module is embedded with a first alignment algorithm and a second alignment algorithm which respectively correspond to the efficiency priority mode and the regular priority mode and is used for calculating an optimal alignment point based on the selected mode; The track planning and motion control module is used for generating driving instructions of all mechanisms according to the optimal alignment point and combining a stacker-reclaimer kinematic model; the equipment driving subsystem comprises a walking driving unit, a rotation driving unit, a pitching driving unit and a material taking device driving unit, and is used for receiving driving instructions and driving corresponding mechanisms to act.
9. The dual-mode stacker-reclaimer and automated alignment control system of claim 8, further comprising a cloud collaborative optimization platform, wherein the edge computing and control subsystem is connected to the cloud collaborative optimization platform via a wireless communication network, wherein the cloud collaborative optimization platform is configured to: converging historical operation data, a three-dimensional model and performance indexes of a plurality of devices; Based on big data analysis, performing global optimization on the switching logic in the mode decision module and the para algorithm parameters in the intelligent para calculation module; and sending the optimized algorithm model or parameter package to a corresponding edge computing and control subsystem for updating.
10. The dual-mode stacking and automatic alignment control system of the stacker-reclaimer as set forth in claim 8, wherein a knowledge base of material characteristics is integrated in the intelligent alignment calculation module, the knowledge base stores parameters of repose angles, densities and friction coefficients corresponding to different material types, and the first alignment algorithm and the second alignment algorithm call the characteristic parameters of the current material as physical constraint conditions when resolving.

Description

Dual-mode stacking and automatic alignment control method and system for stacker-reclaimer Technical Field The invention relates to the technical field of bulk cargo wharf and yard material processing automation, in particular to a dual-mode stacking and automatic alignment control method and system of a stacker-reclaimer. Background The stacker-reclaimer is used as key equipment of bulk storage yard, and the automation and intellectualization level directly affects the operation efficiency and safety. Currently, automatic control of stacker-reclaimers is mainly deployed around path presets and sensor feedback. For example, chinese patent publication No. CN113830569B discloses a stacking control method and a stacking system. According to the scheme, stacking position information (such as height and weight) is acquired through photographing equipment, a height sensor and a pressure sensor which are arranged on the ground, a PLC system judges whether stacking conditions are met or not, and a stacker is controlled to sequentially complete stacking operation of each stacking position. The technology represents the current mainstream automation thought, and realizes the transition from manual to automatic. However, such prior art, analyzed, still has the following limitations: 1. The control mode is single, namely, a fixed and sequential stacking logic is adopted, and the self-adaptive switching strategy cannot be adopted according to the operation stage (such as rapid stacking and post shaping) or the final target (such as preparation for subsequent efficient material taking), so that the overall operation chain efficiency is difficult to consider. 2. The sensing and alignment mode is discrete, namely single-point or two-dimensional judgment is carried out by depending on a plurality of discrete sensors (if the preset height is not reached), and continuous and accurate sensing of the overall three-dimensional geometric form of the material pile is lacked. The alignment in the technical scheme essentially means that the driving equipment moves to a preset fixed space coordinate, and the dynamic and intelligent space alignment is not carried out according to the real-time stockpile form. 3. The decision dimension is insufficient, the control decision is based on limited local state information (such as whether a single stack is full) and is not combined with material characteristics, global operation tasks (such as emergency degree) and better stacking target depth, and the intelligent level is limited. Therefore, the prior art is difficult to realize the collaborative optimization of the stacking and taking operation in terms of efficiency, quality and safety, and especially the core problem of how to intelligently decide and accurately align according to the real-time three-dimensional stacking form and the global task target cannot be solved. Disclosure of Invention The invention aims to solve the defects of the prior art and provides a dual-mode stacking and automatic alignment control method and system of a stacker-reclaimer. The invention adopts the following technical scheme to realize the aim: The dual-mode stacking and automatic alignment control method of the stacker-reclaimer comprises the following steps: s1, real-time sensing and modeling, namely acquiring a real-time three-dimensional point cloud model of an operation area and preset operation task parameters; s2, intelligent mode decision, namely, based on the three-dimensional point cloud model and the operation task parameters, carrying out self-adaptive selection in an efficiency priority mode and a regular priority mode, wherein, The efficiency priority mode takes the maximum material throughput in unit time as an optimization target; The method comprises the steps of (1) orderly forming a priority mode, wherein the orderly forming a material pile profile which is beneficial to the subsequent full-face material taking is an optimization target; S3, dynamic alignment calculation, namely calling an alignment algorithm corresponding to the selected target mode, analyzing the three-dimensional point cloud model, resolving in real time and outputting an optimal alignment point matched with the dynamic geometrical characteristics of the current stockpile and the operation target; S4, track planning and execution, namely planning the motion track of the cantilever of the stacker-reclaimer according to the optimal alignment point, and controlling the stacker-reclaimer to execute the stacking or reclaiming operation. In particular, in step S1, a laser radar or a depth camera mounted on a cantilever of the stacker-reclaimer is used to perform rotational scanning on a working area to obtain a real-time three-dimensional point cloud model, where working task parameters at least include a material type, a target stacking height, and a working emergency identifier. Specifically, the adaptive selection logic in step S2 includes selecting an efficiency priorit