CN-121990516-A - Laser radar-based full-automatic alignment loading monitoring system and method for oil filling riser

CN121990516ACN 121990516 ACN121990516 ACN 121990516ACN-121990516-A

Abstract

The invention discloses a full-automatic alignment loading monitoring system and method for a loading arm based on a laser radar, wherein the system comprises an industrial personal computer and a first network switch which are positioned in a central control room, the full-automatic loading arm, the laser radar, a driving motor which are positioned in a loading site, and a PLC (programmable logic controller) and a second network switch which are positioned in a site control cabinet.

Inventors

LIU JIE
YI JIAJING
LIU WEIRONG
SU WENBIN
ZHANG HAOCHEN

Assignees

兰州理工大学

Dates

Publication Date: 20260508
Application Date: 20260115

Claims (8)

1. A full-automatic alignment loading monitoring system of a loading arm based on a laser radar is characterized by comprising an industrial personal computer and a first network switch which are positioned in a central control room, a full-automatic loading arm, the laser radar and a driving motor which are positioned in a loading site, and a PLC (programmable logic controller) and a second network switch which are positioned in a site control cabinet; The full-automatic loading crane pipe is arranged on the upright post and is positioned above the tank truck to be loaded, the driving motor is arranged on the full-automatic loading crane pipe, the industrial personal computer is connected to the second network switch through the first network switch and then connected to the PLC, and the laser radar is fixed above the tank truck and is connected to the first network switch through the second network switch and then connected to the industrial personal computer; The industrial personal computer is connected with two displays, is respectively used for displaying the upper bit pattern interface and the remote monitoring interface, is configured to display the state information of the full-automatic loading crane, receives an externally input control command through the upper bit pattern interface and sends the control command to the PLC, and the PLC is used for responding to the control command and controlling the movement of the full-automatic loading crane so as to realize automatic alignment.
2. The laser radar-based full-automatic alignment loading monitoring system for a crane pipe according to claim 1, wherein, The intelligent double-layer switching network with the edge computing capability is formed by the first network switch and the second network switch, wherein a point cloud preprocessing unit, an instruction caching and retransmitting module and a device self-diagnosis module are arranged in the second network switch and are used for locally filtering, extracting features and calculating coordinates of point cloud data acquired by a laser radar, only uploading key coordinate information and abnormal identifiers to the first network switch, and the first network switch dynamically adjusts VLAN bandwidth allocation according to an operation stage and provides a dynamic priority lifting mechanism for real-time control instructions through an embedded industrial protocol analysis engine and a flow self-learning scheduling module.
3. The laser radar-based full-automatic alignment loading monitoring system for a crane pipe according to claim 2, wherein the first network switch can dynamically adjust VLAN bandwidth allocation according to an operation stage through a built-in industrial protocol analysis engine and a flow self-learning scheduling module, and specifically comprises: In the initial operation stage, collecting data traffic of each VLAN in different operation stages including alignment, filling and homing in real time, recording information such as time stamp, data packet size, data packet type, source and destination address and the like, and simultaneously recording the current operation stage identification; extracting flow characteristics for each operation stage, wherein the flow characteristics comprise average bandwidth occupancy rate, peak bandwidth occupancy rate, data packet inter-arrival time distribution, data packet size distribution and proportion of data packets with different priorities; clustering flow characteristics of each operation stage to form a typical flow mode of each stage, and establishing a flow template of each operation stage, wherein the flow template comprises the following steps: template phase = { VLAN10: expected bandwidth ratio, VLAN20: expected bandwidth ratio, VLAN30: expected bandwidth ratio, others: expected bandwidth ratio }; and monitoring the difference between the actual flow of each VLAN and the pre-allocated bandwidth in real time, and triggering dynamic adjustment and dynamically allocating the VLAN bandwidth if the flow of a certain VLAN continuously exceeds the threshold value of the pre-allocated bandwidth.
4. The laser radar-based full-automatic alignment loading monitoring system for loading arm according to claim 3, wherein the dynamic allocation of VLAN bandwidth comprises the following adjustment formula: new bandwidth = current bandwidth× (1+α× (actual traffic-pre-allocated bandwidth)/pre-allocated bandwidth); Wherein α is an adjustment coefficient.
5. The laser radar-based crane tube full-automatic alignment loading monitoring system according to claim 1, wherein the power consumption monitoring unit of the built-in equipment of the switch is used for monitoring the power consumption state of each access equipment in real time, and automatically executing power supply protection and reporting to the industrial personal computer when overload or abnormality occurs.
6. The laser radar-based crane tube full-automatic alignment loading monitoring system as claimed in claim 2, wherein the point cloud preprocessing unit comprises the following specific processing flows: Step 1, data receiving and buffering The laser radar sends original point cloud data to a point cloud preprocessing unit of the second network switch at a fixed frequency; the preprocessing unit opens up a buffer area and receives and temporarily stores the original point cloud data; Step 2, outlier filtering Calculating the average distance from each cloud point to all adjacent points by adopting a statistical outlier filtering algorithm, and removing points with the distance mean value exceeding the standard deviation sigma times on the assumption that the obtained distribution is Gaussian distribution; Step 3, removing ground points Fitting a ground plane by adopting a random sampling consistency algorithm, and removing ground points; Step 4, extracting edge characteristics of the tank opening Dividing the point cloud after the ground is removed into a plurality of clusters by adopting a Euclidean clustering algorithm, wherein each cluster represents a potential object, for each cluster, calculating a characteristic value by using principal component analysis, and judging that the tank opening is formed if the ratio of the maximum characteristic value to the next largest characteristic value is larger than a threshold value; And fitting a cylindrical model to the cluster determined to be the tank opening by adopting a least square method to obtain the direction of the central shaft of the tank opening, the coordinates of the central point and the radius. Step 5, data compression and uploading And (3) packaging the central coordinates (x, y, z) of the tank opening, the fitting radius r and the confidence as results into a data packet and uploading the data packet to the industrial personal computer.
7. The laser radar-based full-automatic alignment loading monitoring system for the oil filling riser of claim 1, wherein the industrial personal computer is provided with an upper monitoring interface for displaying oil filling riser state information, point cloud processing results, receiving control instructions and displaying alarm information.
8. A laser radar-based full-automatic alignment loading monitoring method for a crane pipe, which is characterized by being realized based on the system of any one of claims 1-7, and comprising the following steps: Driving the tank truck to be loaded to the area below the full-automatic loading crane pipe; Clicking an automatic alignment button, wherein the laser radar collects tank opening point cloud data, a point cloud preprocessing unit arranged in a second network switch performs local filtering, feature extraction and coordinate calculation, key coordinate information is only transmitted to the industrial personal computer through the first network switch, the industrial personal computer generates tank opening coordinate information based on the key coordinate information and transmits the tank opening coordinate information to the PLC, and the PLC calculates rotation angles of three driving motors according to the coordinate information to drive an inner arm, an outer arm and a vertical pipe of the full-automatic loading crane pipe to move so that the vertical pipe is accurately aligned to the lower part of the tank opening; after alignment is completed and safety is confirmed, a filling button is clicked, the system executes filling, the liquid level and the flow are monitored in real time through an anti-overflow controller, and filling is automatically stopped after the preset liquid level is reached; after filling, standing for a period of time, and then driving the crane tube to return.

Description

Laser radar-based full-automatic alignment loading monitoring system and method for oil filling riser Technical Field The invention relates to the technical field of petrochemical industry, in particular to a full-automatic alignment loading monitoring system and method for a loading arm based on a laser radar. Background The crane pipe is used as special equipment for liquid loading and unloading in petrochemical industry, and is mainly applied to liquid transferring process of storage tank or transport vehicle (such as tank car, train or ship), and its structure generally includes upright post, inner arm, outer arm, vertical pipe and hydraulic driving system to realize flexible positioning and sealing connection. In the prior art, in order to improve loading and unloading efficiency and security, some oil filling riser devices have introduced long-range visual management function, for example through the visible light camera that installs on the vertical tube combines small-size lamp holder, carries out real-time observation to loading and unloading box inside to the operating personnel remote monitoring liquid flow state of being convenient for avoids overflow or leakage risk. For example, chinese patent No. CN218579639U (application number: 202221765065.1) discloses a crane tube with remote visual management function, which comprises a column, a liquid connection port, an inner arm, an outer arm, a vertical tube and a sealing block, wherein the outer arm is driven by a telescopic hydraulic cylinder, a monitoring structure is arranged below the sealing block, and the monitoring structure comprises a visible light camera on a mounting ring and a lamp cap in a fixing block, and is used for improving the light in the box body and realizing video detection. The device emphasizes that the working efficiency is improved by passively observing the inside of the box body in the loading and unloading process, but the monitoring is limited to two-dimensional images, is greatly influenced by environmental factors such as illumination, fog and dust, and cannot provide three-dimensional space data to support accurate positioning. Similarly, chinese patent CN111994865B (application No. 202010983689. X) describes a video alignment system for a crane, in which visual auxiliary alignment of the crane with the tank opening of the tank truck is implemented by a remote control device and a camera system, but the monitoring function still depends on the basic camera system, only for two-dimensional video feedback, and the movement control of the crane still needs to be performed by a worker on the remote control device with reference to the image returned by the camera system. Although the video alignment technology is introduced to assist in positioning, the monitoring mode is limited to visible light video, is easy to be disturbed by weather, and does not integrate the 3D scanning technology, so that the alignment precision depends on manual adjustment, and potential safety hazards exist. The prior art has a certain development in the aspects of mechanical structure and remote video monitoring, but has the obvious defects that firstly, a monitoring relies on a visible light camera to provide only two-dimensional images, the accuracy is insufficient to realize millimeter-level automatic alignment of a crane pipe and an opening of a tank car, and especially, error or overflow accidents are easily caused under low light or severe weather conditions, secondly, three-dimensional sensing equipment such as a laser radar and the like is lacking, autonomous navigation and real-time calibration of point cloud data cannot be generated, manual intervention is still needed in a loading process, the efficiency is low, the safety risk is high, thirdly, the network architecture is simple, the connection of a single-layer switch is usually not supported, the parallel and fault isolation of multiple equipment cannot be supported, the data transmission delay is large, and the large-scale industrial application is not facilitated. These problems restrict the level of intellectualization and automation of the loading system of the crane tube, and a full-automatic crane tube alignment monitoring system capable of realizing high precision, high efficiency, safety and reliability is needed to realize high-precision three-dimensional positioning, real-time data fusion and reliable transmission, thereby improving loading and unloading efficiency and safety. Disclosure of Invention In view of the above, the invention provides a laser radar-based crane tube full-automatic alignment loading monitoring system and method, which are used for solving at least part of technical problems in the background art. In order to achieve the above purpose, the present invention adopts the following technical scheme: The full-automatic alignment loading monitoring system comprises an industrial personal computer and a first network switch which are positioned in a c