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CN-122009709-A - Intelligent control system of anode carbon block automatic stereoscopic warehouse

CN122009709ACN 122009709 ACN122009709 ACN 122009709ACN-122009709-A

Abstract

The invention belongs to the technical field of stereoscopic warehouses, and particularly relates to an intelligent control system of an automatic stereoscopic warehouse for anode carbon blocks, which comprises a machine vision sensing module, a multi-sensor fusion positioning module, an intelligent scheduling engine and an intelligent scheduling engine, wherein the machine vision sensing module is used for acquiring information of a bin position state, a carbon block position, a transportation equipment position and a personnel position in real time through an industrial camera to generate three-dimensional space coordinate data, the multi-sensor fusion positioning module is used for integrating a laser range finder, an encoder and an RFID tag to perform millimeter-level positioning on a stacker, a conveyor and the carbon block, the error range is less than or equal to +/-2 mm, the intelligent scheduling engine is used for generating high-density point cloud data through a top surface by adopting INTEL REALSENSE D and 455, and the side view deployment of 2 Basler bluze-101 is used for fusing the top surface data through an ICP algorithm to construct a complete outline of the carbon block, and monitoring the personnel position through the wide-angle camera to realize millisecond-level accurate recognition of the carbon block position and the attitude in the stacking process, so that stacking failure caused by tilting is avoided, and personnel safety is ensured.

Inventors

  • LI YAJUAN

Assignees

  • 上海品蓝信息科技有限公司

Dates

Publication Date
20260512
Application Date
20260227

Claims (10)

  1. 1. An intelligent control system of an anode carbon block automatic stereoscopic warehouse comprises the following steps: the machine vision perception module is used for acquiring the position state of the warehouse, the position of the carbon block, the position of the transportation equipment and the position information of personnel in real time through the industrial camera and generating three-dimensional space coordinate data; The multi-sensor fusion positioning module integrates a laser range finder, an encoder and an RFID tag, performs millimeter-level positioning on a stacker, a conveyor and a carbon block, and has an error range of less than or equal to +/-2 mm; The intelligent scheduling engine dynamically distributes operation tasks to the stacker, the AGV and the conveying system based on a multi-equipment multi-task coordination model, optimizes path planning and reduces equipment idle rate by more than or equal to 30 percent; the three-dimensional modeling and quality detection module is used for constructing a carbon block three-dimensional model by utilizing at least three groups of line lasers and an area array camera, and comparing the carbon block three-dimensional model with a standard model to automatically identify defects such as cracks, deformation and the like, wherein the detection accuracy rate is more than or equal to 99.5%; The self-adaptive stacking control module dynamically adjusts the clamping force and stacking height of the fork according to the size of the carbon block, supports the maximum stacking height of 12m, and has a single-layer bearing of more than or equal to 5 tons; the safety anti-collision system monitors the running area of equipment in real time through an ultrasonic sensor and a laser radar, and triggers the emergency braking response time to be less than or equal to 0.2 seconds; The inventory dynamic management module is used for updating the time, the position and the batch information of the carbon block in-out warehouse in real time, generating a visual report and supporting inventory turnover rate analysis; The 5G wireless communication module is used for realizing low-delay data interaction of the machine vision system, the carrying equipment and the dispatching management system, wherein the communication delay is less than or equal to 10ms; The fault self-diagnosis module monitors the operation parameters of equipment, predicts the service lives of key components such as a motor, a speed reducer and the like, and early warns about potential faults 72 hours in advance; And the remote operation and maintenance module realizes multi-warehouse centralized monitoring through a cloud platform, supports remote parameter adjustment and firmware upgrading, and reduces the field maintenance frequency by more than or equal to 50 percent.
  2. 2. The intelligent control system of claim 1, wherein the machine vision perception module comprises a top surface depth camera and a side view depth camera, which are respectively arranged above and beside the stacker, and synchronously acquire image data of the top surface and the side surface of the carbon block to construct a complete three-dimensional profile.
  3. 3. The intelligent control system of claim 1, wherein the intelligent scheduling engine generates the optimal task sequence using a genetic algorithm-based multi-objective optimization model with operating efficiency, energy consumption, and equipment wear as optimization objectives.
  4. 4. The intelligent control system according to claim 1, wherein in the three-dimensional modeling and quality detection module, the scanning frequency of the line laser is more than or equal to 10kHz, the resolution of the area array camera is more than or equal to 1200 ten thousand pixels, and the real-time modeling of the dynamic object is supported.
  5. 5. The intelligent control system of claim 1, wherein the adaptive stacking control module comprises a cylinder lifting adjustment mechanism and an electric push rod transverse adjustment mechanism, wherein the cylinder travel range is 0-500mm, and the electric push rod displacement precision is +/-0.1 mm.
  6. 6. The intelligent control system of claim 1, wherein the safety anti-collision system further comprises terminal limit protection, chain breakage protection and cargo rope breakage protection devices, any of which, when triggered, immediately shuts off the equipment power source.
  7. 7. The intelligent control system according to claim 1, wherein the inventory dynamic management module supports seamless interfacing with the ERP system, automatically synchronizes production planning and purchase orders, and achieves inventory upper and lower limit early warning and automatic replenishment.
  8. 8. The intelligent control system of claim 1, wherein the 5G wireless communication module employs a TSN time sensitive network protocol to ensure deterministic transmission of critical control commands.
  9. 9. The intelligent control system of claim 1, wherein the fault self-diagnostic module collects device operation data via a vibration sensor, a temperature sensor, and a current sensor, predicts a remaining useful life based on an LSTM neural network model.
  10. 10. The intelligent control system of claim 1, wherein the remote operation and maintenance module supports VR/AR remote assistance, and wherein an expert can mark equipment fault points through a virtual interface to guide field personnel to complete maintenance operations.

Description

Intelligent control system of anode carbon block automatic stereoscopic warehouse Technical Field The invention relates to the technical field of stereoscopic warehouses, in particular to an intelligent control system of an automatic stereoscopic warehouse for anode carbon blocks. Background In the electrolytic aluminum industry, anode carbon blocks are used as core production raw materials, and storage management directly influences production continuity and cost control. The following technical problems generally exist in the traditional anode carbon block warehouse, and the intelligent upgrading of the industry is seriously restricted: The traditional stacker relies on manual positioning and operation, in a high-shelf scene with the thickness of more than 12m, the stacking error of the carbon blocks often exceeds +/-5 mm, so that the bearing of the shelf is uneven, collapse risks exist, the empty rate is up to 45%, the daily work load is less than 200 tons, manual scheduling is easily influenced by factors such as fatigue and experience, the continuous feeding requirement of an electrolytic tank for 24 hours cannot be met, the single-layer bearing of the carbon blocks is up to 5 tons, the manual clamping force is improperly controlled, the breakage is easily caused, the breakage rate is up to 3%, and the annual direct economic loss exceeds millions of yuan. The electrolytic aluminum enterprises need to put a large amount of manpower to carry out repeated carrying operation, the manual operation efficiency fluctuates greatly, and large-scale and standardized management is difficult to realize. The traditional warehouse lacks multi-level safety protection, only depends on a basic anti-collision strip and a limit switch, has response time exceeding 1 second, cannot cope with sudden collision when the stacker runs at high speed (more than or equal to 120 m/min), lacks state monitoring of key components (such as a transmission chain and a motor), relies on periodic inspection for fault prediction, causes unplanned downtime to be 8 hours/times and seriously affects production rhythm, and has safety level which only accords with ISO 13849-1 PLc standard, and cannot effectively prevent equipment from falling or goods from dumping under extreme working conditions such as fork overload, chain breakage and the like. Disclosure of Invention In order to solve the problems, the invention provides an intelligent control system of an automatic stereoscopic warehouse for anode carbon blocks, so as to solve the problems in the background art more exactly. The invention is realized by the following technical scheme: the invention provides an intelligent control system of an automatic stereoscopic warehouse of anode carbon blocks, which comprises a machine vision sensing module, a control module and a control module, wherein the machine vision sensing module is used for acquiring the state of a warehouse position, the position of a carbon block, the position of a transportation device and the position information of personnel in real time through an industrial camera to generate three-dimensional space coordinate data; the intelligent scheduling engine dynamically distributes operation tasks to the stacker, the AGV and the conveying system based on a multi-equipment multi-task coordination model, optimizes path planning and reduces equipment empty rate by more than or equal to 30 percent, the three-dimensional modeling and quality detection module utilizes at least three groups of line lasers and an area array camera to construct a three-dimensional model of the carbon block, compares the three-dimensional model with a standard model, automatically identifies defects such as cracks and deformation, has detection accuracy rate of more than or equal to 99.5 percent, dynamically adjusts fork clamping force and stacking height according to the size of the carbon block, supports the maximum stacking height of 12m, has single-layer bearing of more than or equal to 5 tons, and the safe anti-collision system triggers emergency braking response time to be less than or equal to 0.2 seconds by monitoring the equipment operation area through an ultrasonic sensor and the laser radar, and the inventory dynamic management module updates the time, the position and the batch information of the carbon block in and out of the warehouse in real time to generate a visual report, and supports inventory turnover rate analysis; The system comprises a 5G wireless communication module, a fault self-diagnosis module, a remote operation and maintenance module, a cloud platform and a remote control module, wherein the low-delay data interaction of a machine vision system, carrying equipment and a dispatching management system is realized, the communication delay is less than or equal to 10ms, the fault self-diagnosis module monitors equipment operation parameters, predicts the service lives of key components such as a motor and a speed reducer, early w