WO2018149087A1 - Intelligent and fully automatic stacker-reclaimer control apparatus - Google Patents

Intelligent and fully automatic stacker-reclaimer control apparatus Download PDF

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Publication number
WO2018149087A1
WO2018149087A1 PCT/CN2017/092730 CN2017092730W WO2018149087A1 WO 2018149087 A1 WO2018149087 A1 WO 2018149087A1 CN 2017092730 W CN2017092730 W CN 2017092730W WO 2018149087 A1 WO2018149087 A1 WO 2018149087A1
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Prior art keywords
reclaimer
stacker
plc system
control device
central processing
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PCT/CN2017/092730
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French (fr)
Chinese (zh)
Inventor
刘春晓
于沛东
师开革
胡朝友
张海龙
修立杰
陈永
丁建兵
牛长玻
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京能（锡林郭勒）发电有限公司
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Publication of WO2018149087A1 publication Critical patent/WO2018149087A1/en

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    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
    • G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
    • G05B19/054—Input/output
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/10—Plc systems
    • G05B2219/11—Plc I-O input output
    • G05B2219/1103—Special, intelligent I-O processor, also plc can only access via processor

Definitions

  • the invention relates to an intelligent automatic stacker and reclaimer, belonging to the technical field of bulk material transportation and the field of automation technology.
  • the invention aims at the deficiencies of the above prior art, and provides an intelligent automatic stacker and reclaimer control device, which has a typical stacking and reclaiming intelligent model function, a pile shape recognition function, a self position recognition function, automatic detection and protection. Features and complete central control functions.
  • an intelligent automatic stacker and reclaimer control device comprising: a central processing server, a central control remote PLC system, a stacker reclaimer PLC system, a human machine HMI operation interface, and a laser a scanning system, wherein the central control remote PLC system is connected to the central processing server, and the stacker reclaimer PLC system is respectively connected to the central processing server and the central control remote PLC system, and the human machine An HMI operation interface is respectively connected to the central processing server, the central control remote PLC system, and the stacker reclaimer PLC system, and the laser scanning system is connected to the central processing server; the intelligent automatic heap
  • the connections in the reclaimer control are all via intelligent telecom networks, including industrial fieldbus networks, industrial Ethernet and/or industrial television networks.
  • the present invention can also be improved as follows.
  • the central processing server comprises a data server and an image server.
  • a central control anti-collision system is installed in the data server to ensure collision of the stacker and reclaimer in the case of simultaneous operation of multiple stackers and reclaimers.
  • a three-dimensional image processing system is installed in the image server, and the data collected by the laser scanning system is integrated and calculated, and converted into a three-dimensional image of the pile and a pile count data.
  • the laser scanning system comprises a plurality of laser scanners for scanning a work pile, scanning a current work pile and collecting data; the laser scanner is connected and transmits data to the image server, Then, it is fed back to the man-machine HMI operation interface, and provides three-dimensional scanning pile shape and material pile inventory data of the stockyard.
  • the laser scanner is arranged on a stacker and reclaimer.
  • the laser scanner is arranged on a rack or building other than the stacker.
  • a video surveillance system is further included, the video surveillance system includes: a plurality of cameras mounted on the stacker and reclaimer, a video frequency divider connected to the camera, and a video display connected to the video frequency divider and a video operation keyboard; the video display is also connected to the human machine HMI Operation interface.
  • a remote operating handle coupled to the central remote PLC system to control the stacker reclaimer PLC system is also included.
  • the available modes are: classic stack mode, empty field stack mode, patch mode, and reclaim mode.
  • Specialized section setting stack height model reduces the dust pollution environment caused by the large drop of accumulated raw materials. When the rainy season comes, the stacking height can be appropriately reduced to reduce the pile collapse;
  • the classic stacking and reclaiming model reduces the unnecessary energy consumption caused by the large-speed adjustment of the boom pitch angle, walking and changing layers, and prolongs the service life of the equipment and maximizes the benefits;
  • the central control remote PLC system grants the operator special operation in an emergency situation, avoiding the loss caused by the time loss of the site inspection when the situation occurs;
  • the central control anti-collision system avoids the occurrence of serious safety accidents such as collision of stacker and reclaimer;
  • FIG. 1 is a schematic structural view of an intelligent automatic stacker and reclaimer control device according to the present invention
  • Figure 2a is a first embodiment of the fixed point pitch deposition process of the present invention
  • Figure 2b is a second embodiment of the fixed point pitching process of the present invention.
  • FIG. 3 is a schematic view of a method of segmented stack height according to the present invention.
  • Figure 4 is a rotating layered reclaiming process diagram of the present invention.
  • FIG. 1 is a schematic structural view of the intelligent automatic stacker and reclaimer control device of the present invention.
  • the intelligent automatic stacker and reclaimer control device comprises: a central processing server 101, a central control remote PLC system 102, a stacker reclaimer PLC system 103, a human machine HMI operation interface 104, and a laser scanning system, wherein
  • the central control remote PLC system 102 is connected to the central processing server 101, and the stacker reclaimer PLC system 103 is respectively connected to the central processing server 101 and the central control remote PLC system 102, and the human machine
  • the HMI operation interface 104 is respectively connected to the central processing server 101, the central control remote PLC system 102, and the stacker reclaimer PLC system 103, and the laser scanning system is connected to the central processing server 101;
  • all connections are through an intelligent remote communication network, including Industrial fieldbus networks, industrial Ethernet and industrial TV networks to meet the needs of different data communications.
  • the central processing server 101 includes a data server 1011 and an image server 1012, and is responsible for important tasks such as data communication, signal receiving and transmission, and parameter calculation correction, and establishes a complete internal communication network of the system;
  • a central control anti-collision system is installed in the data server 1011, and the central control anti-collision system ensures that serious safety accidents such as collision of the stacker and the reclaimer are avoided in the case of synchronous operation of multiple stackers and reclaimers;
  • the anti-collision calculation of the central control anti-collision system immediately informs the stacker and reclaimer PLC system 103 when the stacker and reclaimer may collide, and timely modifies and limits the operation movement of the stacker and reclaimer to prevent collision accidents. happened;
  • a three-dimensional image processing system is installed in the image server 1012, and the three-dimensional image processing system integrates and calculates a series of pile scan data collected by the laser scanning system, and converts the data into a three-dimensional image of the pile. Visually presented to provide control pile count data;
  • the central control remote PLC system 102 is responsible for coordinating the control of all the stacking and reclaiming machines of each operating unit, and granting the operator special operation in an emergency situation; the central remote PLC system 102 requests the three-dimensional image processing system to calculate the relevant data. And obtaining the calculation result, and then sending it to the stacker and reclaimer PLC system for real-time control, and the central control remote PLC system 102 also sends the job status and the like to the three-dimensional image processing system;
  • a stacker reclaimer PLC system 103 which obtains control commands and data parameters from the central processing server 101 and the central control remote PLC system 102, and issues commands to the traveling mechanism, the slewing mechanism, the tilting mechanism, and the wheel of the stacker and reclaimer Bucket mechanism, tail car mechanism, on-board belt mechanism, etc.;
  • the material machine PLC system 103 feeds back various working parameters and operating condition information of the field work to the human machine HMI operation interface 104 in real time;
  • the man-machine HMI operation interface 104 includes various parameter display for the job stacker and the specific button for controlling and modifying the actual work flow; and the job instruction is issued and modified on the man-machine HMI operation interface 104. And the data parameters are distributed to the stacker and reclaimer PLC system 103 through the integration and calculation of the central processing server 101 and the central control remote PLC system 102, so that the work stacker and the reclaimer operate according to specific instructions;
  • the laser scanning system comprises a plurality of laser scanners 105 for scanning the working material pile, which can scan the current working material pile in real time and clearly, and quickly and accurately collect and sort the working material pile scanning data;
  • the scan data is sent to the image server 1012, and the three-dimensional image processing system then performs data filtering and formula calculation, and then converts into a three-dimensional image mode that can be visually displayed, and feeds back to the human-machine HMI operation interface 104;
  • the laser scanner 105 can be disposed on the stacker and reclaimer, or can be disposed on a rack or a building other than the stacker and reclaimer;
  • the intelligent automatic stacker and reclaimer control device further comprises a video monitoring system, comprising: a plurality of cameras 106 mounted on the stacker and reclaimer, a video frequency divider 107 connected to the camera 106, and a connection
  • the video display 108 of the video divider 107 and the video operation keyboard 109 are also connected to the human-machine HMI operation interface 104; thereby, the video surveillance system can real-time the real scene of the job site.
  • the image is transmitted to the video display 108 and also displayed on the human-machine HMI operation interface 104, so that the operator can monitor the live scene in real time and assist in making accurate judgments;
  • the intelligent fully automated stacker and reclaimer control device further includes a remote operating handle 110 coupled to the central remote PLC system 102 for controlling the stacker and reclaimer PLC system 103 via an industrial fieldbus network.
  • the position of the blanking point is determined according to the width of the stacking pile, and the position of the blanking point is the middle position of the stacking width, and the CD line of Fig. 2a is the center line of the yard width;
  • the pitch angle of the boom is determined to ensure that the blanking position is on the CD line as shown in Fig. 2a;
  • Automatic stacking operation process After receiving the operation plan including the operation type and the planned operation quantity, the central control system finds the corresponding pile weight and accumulation angle information in the basic information base according to the operation type, and then determines the accumulation mode; Analyze the current state of use of the stockyard, determine the working machinery, stacking address, and stack height; use the above information as the work instruction to automatically deliver the corresponding stacker and reclaimer through the industrial network; and send the “stock preparation” command to the ground belt process.
  • the stacker and reclaimer automatically calculate the stacking according to the operation plan and perform automatic alignment.
  • the “fixed point stacking method” function is realized by the PLC on the stacker and reclaimer.
  • the stacker and reclaimer are in accordance with the central control command. Start the cantilever belt and the intermediate belt, and the ground belt conveyor starts to run according to the process sequence.
  • the stacker and reclaimer wait for the material to pass at the starting address according to the stacking requirements. Adjust the inching distance and the rotation angle of the cart according to the predetermined stacking principle. After that, the stack height is automatically adjusted, and the second layer of fixed point coverage is replenished until the predetermined height is completed. A pile of piles. When the first pile reaches the specified height and width, the stacker and reclaimer automatically moves to the second stacking point, and the stacking is repeated in the order of the first stacking point until the end of the operation.
  • the automatic stacking operation process is as follows:
  • the main server receives the stacking operation plan issued by the human-computer interaction interface
  • the central control screen displays the stacking operation control command and performs parameter correction (including shape, swing and pitch values);
  • the large machine receives the stacking operation instruction and performs the adjustment work before the official operation;
  • coal pile scan data is analyzed and saved.
  • the stack only needs to determine the stacking start address and the end address.
  • the system calculates the unloading volume according to the coal unloading amount and coal type, and then combines the stacking method to simulate the stacking effect at the site.
  • the operator Pre-judgment can be carried out.
  • the pile material first needs to determine the existing defect type, determine the start address and end address of the stockpiling, and the system calculates the coal unloading volume according to the coal unloading amount and coal type, and then combines the stacking method to simulate The stowage effect exhibited on the existing stock site, the operator thus performs the pre-judgment and selects the appropriate site.
  • the classic model is shown in Figure 4.
  • the stacker and reclaimer are operated.
  • the rotating and tilting device places the whole machine on the top position of the top of the pile, and then starts to take the material by the rotation control.
  • the running mechanism is slightly moved.
  • the layer changing operation is performed.
  • the rotation angle of each layer is determined by the angle of repose and the number of layers of the material; the pitch height is set by the number of layers, and the walking distance is determined by the feed rate. .
  • the rotation speed of the boom should be determined as a function relationship with the rotation angle of the boom, and feedback based on the current of the driving motor can be realized to realize the algorithm of rotating layered equal-feeding.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Automation & Control Theory (AREA)
  • Control Of Position, Course, Altitude, Or Attitude Of Moving Bodies (AREA)
  • Warehouses Or Storage Devices (AREA)

Abstract

An intelligent and fully automatic stacker-reclaimer control apparatus, comprising: a central processing server (101), a central control remote PLC system (102), a stacker-reclaimer PLC system (103), a human-machine HMI operation interface (104) and a laser scanning system, wherein the central control remote PLC system (102) is connected to the central processing server (101); the stacker-reclaimer PLC system (103) is respectively connected to the central processing server (101) and the central control remote PLC system (102); the human-machine HMI operation interface (104) is respectively connected to the central processing server (101), the central control remote PLC system (102) and the stacker-reclaimer PLC system (103); and the laser scanning system is connected to the central processing server (101). The connections of the intelligent and fully automatic stacker-reclaimer control apparatus are all realised by means of intelligent remote communication networks, comprising an industrial field bus network, an industrial Ethernet and/or an industrial television network. The intelligent and fully automatic stacker-reclaimer control apparatus not only improves working efficiency and saves on the cost of manpower, but also improves the working environment of a driver.

Description

一种智能化全自动堆取料机控制装置Intelligent automatic stacker and reclaimer control device 技术领域Technical field
本发明涉及一种智能化全自动堆取料机，属于散状物料输送技术领域和自动化技术领域。The invention relates to an intelligent automatic stacker and reclaimer, belonging to the technical field of bulk material transportation and the field of automation technology.
背景技术Background technique
自20世纪50年代开始，国外就采用连续堆取料工艺取代抓斗、铲车等低效率设备，堆取料机开始在散货搬运工作中起着重要作用。1966年大连工矿车辆厂设计了中国第一台堆取料机，并于1968年在攀枝花钢厂投入使用。20世纪80年代，中国开始改革开放，引进国外先进技术，合作制造，这是堆取料机的繁荣时期，在这时期，积累了经验，设计、制造与检验水平有了很大进步。20世纪90年代末，我国已具备了自主设计开发大型堆取料机的能力。进入21世纪，国内的堆取料机设计制造能力已经与国外发达国家相当，基本满足国内用户的要求，完全可以取代国外进口的同类产品。Since the 1950s, foreign countries have used continuous stacking and reclaiming technology to replace inefficient equipment such as grabs and forklifts. The stacker and reclaimer have begun to play an important role in bulk handling. In 1966, Dalian Industrial and Mining Vehicle Factory designed China's first stacker and reclaimer, which was put into use in Panzhihua Steel Plant in 1968. In the 1980s, China began to reform and open up, introducing advanced foreign technology and co-manufacturing. This is the boom period of stacker and reclaimer. During this period, experience has accumulated and the level of design, manufacturing and inspection has made great progress. In the late 1990s, China had the ability to independently design and develop large-scale stacker and reclaimer. In the 21st century, the domestic design and manufacturing capacity of the stacker and reclaimer has been comparable to that of foreign developed countries, basically meeting the requirements of domestic users, and can completely replace similar products imported from abroad.
然而，堆取料机实现自动化的难度非常大！如果堆取料机能够实现全自动化，则整个料场***的自动化就很容易实现，就可提高生产效率、减少污染、降低成本、减少故障率，保证整个电厂的高效运行。However, it is very difficult to automate the stacker and reclaimer! If the stacker and reclaimer can be fully automated, the automation of the entire yard system can be easily achieved, which can increase production efficiency, reduce pollution, reduce costs, reduce failure rates, and ensure efficient operation of the entire plant.
发明内容Summary of the invention
本发明针对上述现有技术存在的不足，提供一种智能化全自动堆取料机控制装置，其具有典型堆取料智能模型功能、料堆形状识别功能、自身位置识别功能、自动检测和保护功能以及完备的中控功能。 The invention aims at the deficiencies of the above prior art, and provides an intelligent automatic stacker and reclaimer control device, which has a typical stacking and reclaiming intelligent model function, a pile shape recognition function, a self position recognition function, automatic detection and protection. Features and complete central control functions.
本发明解决上述技术问题的技术方案如下：一种智能化全自动堆取料机控制装置，包括：中央处理服务器、中控远程PLC***、堆取料机PLC***、人机HMI操作界面以及激光扫描***，其中，所述中控远程PLC***与所述中央处理服务器相连接，所述堆取料机PLC***与所述中央处理服务器、所述中控远程PLC***分别连接，所述人机HMI操作界面与所述中央处理服务器、所述中控远程PLC***、所述堆取料机PLC***分别连接，所述激光扫描***与所述中央处理服务器相连接；所述智能化全自动堆取料机控制装置中的连接皆是通过智能化远程通讯网络，包括工业现场总线网络、工业以太网和/或工业电视网络。The technical solution to solve the above technical problem is as follows: an intelligent automatic stacker and reclaimer control device, comprising: a central processing server, a central control remote PLC system, a stacker reclaimer PLC system, a human machine HMI operation interface, and a laser a scanning system, wherein the central control remote PLC system is connected to the central processing server, and the stacker reclaimer PLC system is respectively connected to the central processing server and the central control remote PLC system, and the human machine An HMI operation interface is respectively connected to the central processing server, the central control remote PLC system, and the stacker reclaimer PLC system, and the laser scanning system is connected to the central processing server; the intelligent automatic heap The connections in the reclaimer control are all via intelligent telecom networks, including industrial fieldbus networks, industrial Ethernet and/or industrial television networks.
在上述技术方案的基础上，本发明还可以做如下改进。Based on the above technical solutions, the present invention can also be improved as follows.
优选地，所述中央处理服务器包括数据服务器和图像服务器。Preferably, the central processing server comprises a data server and an image server.
优选地，在所述数据服务器中安装有中控防碰撞***，保证在多台堆取料机同步作业的情况下，避免堆取料机碰撞。Preferably, a central control anti-collision system is installed in the data server to ensure collision of the stacker and reclaimer in the case of simultaneous operation of multiple stackers and reclaimers.
优选地，在所述图像服务器中安装有三维图像处理***，将所述激光扫描***所采集的数据进行整合和计算，转化为料堆三维图像与料堆盘点数据。Preferably, a three-dimensional image processing system is installed in the image server, and the data collected by the laser scanning system is integrated and calculated, and converted into a three-dimensional image of the pile and a pile count data.
优选地，所述激光扫描***包括多个用于扫描作业料堆的激光扫描仪，扫描当前作业料堆并进行数据的采集整理；所述激光扫描仪连接并将数据传输至所述图像服务器，进而反馈到所述人机HMI操作界面上，并提供料场三维扫描堆形与料堆盘点数据。Preferably, the laser scanning system comprises a plurality of laser scanners for scanning a work pile, scanning a current work pile and collecting data; the laser scanner is connected and transmits data to the image server, Then, it is fed back to the man-machine HMI operation interface, and provides three-dimensional scanning pile shape and material pile inventory data of the stockyard.
优选地，所述激光扫描仪配置在堆取料机上。Preferably, the laser scanner is arranged on a stacker and reclaimer.
优选地，所述激光扫描仪配置在堆取料机以外的机架或建筑物上。Preferably, the laser scanner is arranged on a rack or building other than the stacker.
优选地，还包括视频监视***，所述视频监视***包括：多个安装在堆取料机上的摄像头、与所述摄像头连接的视频分频器以及连接于所述视频分频器的视频显示器和视频操作键盘；所述视频显示器还连接至所述人机HMI 操作界面。Preferably, a video surveillance system is further included, the video surveillance system includes: a plurality of cameras mounted on the stacker and reclaimer, a video frequency divider connected to the camera, and a video display connected to the video frequency divider and a video operation keyboard; the video display is also connected to the human machine HMI Operation interface.
优选地，还包括连接至所述中控远程PLC***进而控制所述堆取料机PLC***的远程操作手柄。Preferably, a remote operating handle coupled to the central remote PLC system to control the stacker reclaimer PLC system is also included.
优选地，可供使用的模式有：经典堆料模式、空场堆垛模式、补垛模式以及取料模式。Preferably, the available modes are: classic stack mode, empty field stack mode, patch mode, and reclaim mode.
本发明的有益效果是：The beneficial effects of the invention are:
1、专门的分段设定堆积高度模型减少因堆积原料落差太大而产生扬尘污染环境，当在雨季来临时，也可以适当降低堆积高度，减少料堆塌方；1. Specialized section setting stack height model reduces the dust pollution environment caused by the large drop of accumulated raw materials. When the rainy season comes, the stacking height can be appropriately reduced to reduce the pile collapse;
2、专门的分层分段堆料模型避免因为只分段所造成的塌垛情形；2, the special layered section pile model avoids the collapse caused by only segmentation;
3、经典的堆取料模型减少了大车多次调整大臂俯仰角度、行走、换层造成的不必要的能耗，并延长了设备的使用寿命，效益最大化；3, the classic stacking and reclaiming model reduces the unnecessary energy consumption caused by the large-speed adjustment of the boom pitch angle, walking and changing layers, and prolongs the service life of the equipment and maximizes the benefits;
4、中控远程PLC***授予操作员在紧急情况下的特殊操作，避免了在发生状况时需通知现场点检的时间损耗而造成的损失；4. The central control remote PLC system grants the operator special operation in an emergency situation, avoiding the loss caused by the time loss of the site inspection when the situation occurs;
5、中控防碰撞***避免堆取料机碰撞等严重安全事故的发生；5. The central control anti-collision system avoids the occurrence of serious safety accidents such as collision of stacker and reclaimer;
6、设备的全自动化作业，实现料场管理、中央控制、堆取料机无人控制的一体化。6. The fully automated operation of the equipment realizes the integration of material yard management, central control and unmanned control of the stacker and reclaimer.
附图说明DRAWINGS
图1为本发明的智能化全自动堆取料机控制装置的结构示意图；1 is a schematic structural view of an intelligent automatic stacker and reclaimer control device according to the present invention;
图2a为本发明的定点俯仰堆积工艺图一；Figure 2a is a first embodiment of the fixed point pitch deposition process of the present invention;
图2b为本发明的定点俯仰堆积工艺图二；Figure 2b is a second embodiment of the fixed point pitching process of the present invention;
图3为本发明的分段堆积高度方法示意图；3 is a schematic view of a method of segmented stack height according to the present invention;
图4为本发明的旋转分层取料工艺图；Figure 4 is a rotating layered reclaiming process diagram of the present invention;
在附图中，各标号所表示的部件名称列表如下：In the drawings, the names of the parts indicated by the respective labels are as follows:
101               中央处理服务器 101 central processing server
1011            数据服务器1011 data server
1012            图像服务器1012 image server
102              中控远程PLC***102 central control remote PLC system
103              堆取料机PLC***103 stacker reclaimer PLC system
104             人机HMI操作界面104 Human Machine HMI Operation Interface
105              激光扫描仪105 laser scanner
106              摄像头106 camera
107              视频分频器107 video divider
108              视频显示器108 video display
109              视频操作键盘109 video operation keyboard
110              远程操作手柄110 remote operating handle
具体实施方式detailed description
以下结合附图对本发明的原理和特征进行描述，所举实例只用于解释本发明，并非用于限定本发明的范围。The principles and features of the present invention are described in the following with reference to the accompanying drawings.
请先参照图1所示，其为本发明的智能化全自动堆取料机控制装置的结构示意图。所述智能化全自动堆取料机控制装置包括：中央处理服务器101、中控远程PLC***102、堆取料机PLC***103、人机HMI操作界面104以及激光扫描***，其中，Please refer to FIG. 1 first, which is a schematic structural view of the intelligent automatic stacker and reclaimer control device of the present invention. The intelligent automatic stacker and reclaimer control device comprises: a central processing server 101, a central control remote PLC system 102, a stacker reclaimer PLC system 103, a human machine HMI operation interface 104, and a laser scanning system, wherein
所述中控远程PLC***102与所述中央处理服务器101相连接，所述堆取料机PLC***103与所述中央处理服务器101、所述中控远程PLC***102分别连接，所述人机HMI操作界面104与所述中央处理服务器101、所述中控远程PLC***102、所述堆取料机PLC***103分别连接，所述激光扫描***与所述中央处理服务器101相连接；在本发明的所述智能化全自动堆取料机控制装置中，所有的连接皆是通过智能化远程通讯网络，包括 工业现场总线网络、工业以太网和工业电视网络，以满足不同数据通讯的需要。The central control remote PLC system 102 is connected to the central processing server 101, and the stacker reclaimer PLC system 103 is respectively connected to the central processing server 101 and the central control remote PLC system 102, and the human machine The HMI operation interface 104 is respectively connected to the central processing server 101, the central control remote PLC system 102, and the stacker reclaimer PLC system 103, and the laser scanning system is connected to the central processing server 101; In the intelligent automatic stacker and reclaimer control device of the invention, all connections are through an intelligent remote communication network, including Industrial fieldbus networks, industrial Ethernet and industrial TV networks to meet the needs of different data communications.
需要进行说明的是：由于本发明中设备繁多，为使附图简洁，省略了一些连接线，本领域技术人员应理解的是，关于本发明的连接关系，以文字描述为准。It should be noted that, due to the numerous devices in the present invention, in order to simplify the drawing, some connecting lines are omitted, and those skilled in the art should understand that the connection relationship of the present invention is subject to the text description.
中央处理服务器101，其包括数据服务器1011和图像服务器1012，负责数据通讯、信号接收发送和参数计算修正等重要工作并建立一套完整的***内部通讯网络；The central processing server 101 includes a data server 1011 and an image server 1012, and is responsible for important tasks such as data communication, signal receiving and transmission, and parameter calculation correction, and establishes a complete internal communication network of the system;
在所述数据服务器1011中安装有中控防碰撞***，所述中控防碰撞***保证在多台堆取料机同步作业的情况下，避免堆取料机碰撞等严重安全事故的发生；当所述中控防碰撞***的防碰撞演算得出堆取料机可能发生碰撞时，立即通知所述堆取料机PLC***103，及时修改和限定作业堆取料机的运行动作，防止碰撞事故的发生；A central control anti-collision system is installed in the data server 1011, and the central control anti-collision system ensures that serious safety accidents such as collision of the stacker and the reclaimer are avoided in the case of synchronous operation of multiple stackers and reclaimers; The anti-collision calculation of the central control anti-collision system immediately informs the stacker and reclaimer PLC system 103 when the stacker and reclaimer may collide, and timely modifies and limits the operation movement of the stacker and reclaimer to prevent collision accidents. happened;
在所述图像服务器1012中安装有三维图像处理***，所述三维图像处理***将所述激光扫描***所采集的一系列料堆扫描数据进行整合和计算，将这些数据转化为料堆三维图像的直观呈现，以提供控制用的料堆盘点数据；A three-dimensional image processing system is installed in the image server 1012, and the three-dimensional image processing system integrates and calculates a series of pile scan data collected by the laser scanning system, and converts the data into a three-dimensional image of the pile. Visually presented to provide control pile count data;
中控远程PLC***102，其负责协调各操作单元对所有堆取料机的控制，授予操作员在紧急情况下的特殊操作；所述中控远程PLC***102向三维图像处理***请求计算相关数据并获得计算结果，然后发送给堆取料机PLC***进行实时控制，所述中控远程PLC***102亦向三维图像处理***发送作业状态等信息；The central control remote PLC system 102 is responsible for coordinating the control of all the stacking and reclaiming machines of each operating unit, and granting the operator special operation in an emergency situation; the central remote PLC system 102 requests the three-dimensional image processing system to calculate the relevant data. And obtaining the calculation result, and then sending it to the stacker and reclaimer PLC system for real-time control, and the central control remote PLC system 102 also sends the job status and the like to the three-dimensional image processing system;
堆取料机PLC***103，其从所述中央处理服务器101和所述中控远程PLC***102获得控制指令和数据参数，下达命令给堆取料机的行走机构、回转机构、俯仰机构、轮斗机构、尾车机构以及机上皮带机构等；所述堆取 料机PLC***103实时将现场作业的各种作业参数和运作状况信息反馈给所述人机HMI操作界面104；a stacker reclaimer PLC system 103, which obtains control commands and data parameters from the central processing server 101 and the central control remote PLC system 102, and issues commands to the traveling mechanism, the slewing mechanism, the tilting mechanism, and the wheel of the stacker and reclaimer Bucket mechanism, tail car mechanism, on-board belt mechanism, etc.; The material machine PLC system 103 feeds back various working parameters and operating condition information of the field work to the human machine HMI operation interface 104 in real time;
人机HMI操作界面104，其包含了针对作业堆取料机的各项参数显示以及可控制和修改实际作业流程的具体按键；在所述人机HMI操作界面104上，下发和修改作业指令和数据参数，通过所述中央处理服务器101和所述中控远程PLC***102的整合和计算，下发给所述堆取料机PLC***103，使作业堆取料机按照具体指令进行运作；The man-machine HMI operation interface 104 includes various parameter display for the job stacker and the specific button for controlling and modifying the actual work flow; and the job instruction is issued and modified on the man-machine HMI operation interface 104. And the data parameters are distributed to the stacker and reclaimer PLC system 103 through the integration and calculation of the central processing server 101 and the central control remote PLC system 102, so that the work stacker and the reclaimer operate according to specific instructions;
激光扫描***，其包括多个用于扫描作业料堆的激光扫描仪105，能实时和清晰地对当前作业料堆进行扇形扫描，快速准确地对作业料堆扫描数据进行采集和整理；然后，将扫描数据发送给所述图像服务器1012，三维图像处理***随即将数据进行数据筛选和公式计算，进而转化成可以直观显示的三维图像模式，反馈到所述人机HMI操作界面104上；多个激光扫描仪105可配置在堆取料机上，也可配置在堆取料机以外的机架或建筑物上；The laser scanning system comprises a plurality of laser scanners 105 for scanning the working material pile, which can scan the current working material pile in real time and clearly, and quickly and accurately collect and sort the working material pile scanning data; The scan data is sent to the image server 1012, and the three-dimensional image processing system then performs data filtering and formula calculation, and then converts into a three-dimensional image mode that can be visually displayed, and feeds back to the human-machine HMI operation interface 104; The laser scanner 105 can be disposed on the stacker and reclaimer, or can be disposed on a rack or a building other than the stacker and reclaimer;
优选地，所述智能化全自动堆取料机控制装置还包括视频监视***，其包括：多个安装在堆取料机上的摄像头106、与所述摄像头106连接的视频分频器107、连接于所述视频分频器107的视频显示器108和视频操作键盘109，所述视频显示器108还连接至所述人机HMI操作界面104；由此，所述视频监视***实时将作业现场的真实画面传输到所述视频显示器108上，同时亦显示在所述人机HMI操作界面104上，方便操作员对现场作业场景进行实时的监视，并协助做出准确的判断；Preferably, the intelligent automatic stacker and reclaimer control device further comprises a video monitoring system, comprising: a plurality of cameras 106 mounted on the stacker and reclaimer, a video frequency divider 107 connected to the camera 106, and a connection The video display 108 of the video divider 107 and the video operation keyboard 109 are also connected to the human-machine HMI operation interface 104; thereby, the video surveillance system can real-time the real scene of the job site. The image is transmitted to the video display 108 and also displayed on the human-machine HMI operation interface 104, so that the operator can monitor the live scene in real time and assist in making accurate judgments;
优选地，所述智能化全自动堆取料机控制装置还包括远程操作手柄110，其连接至所述中控远程PLC***102，通过工业现场总线网络控制所述堆取料机PLC***103。Preferably, the intelligent fully automated stacker and reclaimer control device further includes a remote operating handle 110 coupled to the central remote PLC system 102 for controlling the stacker and reclaimer PLC system 103 via an industrial fieldbus network.
在本发明的智能化全自动堆取料机控制装置中，可供使用的模式有以下四种： In the intelligent automatic stacker and reclaimer control device of the present invention, there are four modes available:
1、经典堆料模式1, the classic stack mode
模型如图2a、2b和3所示，工艺如下：The model is shown in Figures 2a, 2b and 3, and the process is as follows:
首先，根据垛堆宽度来确定落料点位置，落料点位置为堆垛宽度的中间位置，图2a的CD线为堆场宽度中心线；Firstly, the position of the blanking point is determined according to the width of the stacking pile, and the position of the blanking point is the middle position of the stacking width, and the CD line of Fig. 2a is the center line of the yard width;
其次，根据堆存高度，来确定大臂的俯仰角度，保证落料位置为如图2a所示的CD线上；Secondly, according to the height of the stack, the pitch angle of the boom is determined to ensure that the blanking position is on the CD line as shown in Fig. 2a;
根据垛堆的长度S，煤种等信息，确定每次寸动的距离⊿S；According to the length S of the pile, coal type and other information, determine the distance 寸S of each inching;
具体堆法：将大机行驶至堆料开始点位置，确定了大臂的俯仰高度和寸动距离后，设定该值并保持大臂俯仰高度不变，然后开始堆料，利用煤料的自然重力进行滑动，形成如图2b所示的三角形截面；当堆至指定高度H后，料位计报警，则进行寸动走行⊿S距离，开始下一堆堆料，如此循环，直至寸动完料堆长度距离S，则堆料完成。作业中有时需要采用分段设定堆积高度的方法来减少扬尘。如图3所示，堆积高度分为三段，6m、9m、12.4m，对应的悬臂高度为8.4m、11.8m、14.5m，堆积高度由“料位检测器”进行控制。Concrete stacking method: After driving the large machine to the starting position of the stocking, determining the pitching height and the inching distance of the boom, setting the value and keeping the boom pitch height unchanged, then starting the stacking, using the coal material The natural gravity slides to form a triangular section as shown in Fig. 2b; when the pile reaches the specified height H, the level gauge alarms, then the distance of the inching ⊿S is started, the next pile of materials is started, and the cycle is continued until the movement When the length of the pile is completed, the pile is completed. In the work, it is sometimes necessary to use a method of setting the stack height to reduce the dust. As shown in Fig. 3, the stacking height is divided into three sections, 6m, 9m, and 12.4m, and the corresponding cantilever heights are 8.4m, 11.8m, and 14.5m, and the stacking height is controlled by the "level detector".
自动堆料操作工艺：中控***在收到包含作业货种、计划作业量的作业计划后，根据作业货种在基础信息库中查出对应堆比重、堆积角度信息，然后确定堆积方式；随后分析料场当前使用状态，确定作业机械、堆积地址、料堆堆高；将以上信息作为作业指令自动通过工业网络下发对应堆取料机；同时给地面皮带流程发送“堆料准备”指令。无人堆料过程中，堆取料机按照作业计划，自动进行堆料计算，并进行自动对位，“定点堆积法”功能由堆取料机上PLC实现，堆取料机按照中控指令先启动悬臂皮带、中间皮带，地面皮带机按流程顺序开始运转，堆取料机按照堆料要求在起始地址等待物料通过，参照预定堆积原则对大车寸动距离和旋回角度进行调整，堆积结束后，自动调整堆积高度，进行第二层定点覆盖补堆，直至预定高度，完成第 一料堆的堆积。当第一料堆达到规定高度、宽度时，堆取料机自动向第二堆积点移动，按照第一堆积点的作业顺序方式重复堆积，直至作业结束。Automatic stacking operation process: After receiving the operation plan including the operation type and the planned operation quantity, the central control system finds the corresponding pile weight and accumulation angle information in the basic information base according to the operation type, and then determines the accumulation mode; Analyze the current state of use of the stockyard, determine the working machinery, stacking address, and stack height; use the above information as the work instruction to automatically deliver the corresponding stacker and reclaimer through the industrial network; and send the “stock preparation” command to the ground belt process. During the unmanned stacking process, the stacker and reclaimer automatically calculate the stacking according to the operation plan and perform automatic alignment. The “fixed point stacking method” function is realized by the PLC on the stacker and reclaimer. The stacker and reclaimer are in accordance with the central control command. Start the cantilever belt and the intermediate belt, and the ground belt conveyor starts to run according to the process sequence. The stacker and reclaimer wait for the material to pass at the starting address according to the stacking requirements. Adjust the inching distance and the rotation angle of the cart according to the predetermined stacking principle. After that, the stack height is automatically adjusted, and the second layer of fixed point coverage is replenished until the predetermined height is completed. A pile of piles. When the first pile reaches the specified height and width, the stacker and reclaimer automatically moves to the second stacking point, and the stacking is repeated in the order of the first stacking point until the end of the operation.
自动堆料操作流程如下：The automatic stacking operation process is as follows:
1)主服务器接收人机交互界面下发的堆料作业计划；1) The main server receives the stacking operation plan issued by the human-computer interaction interface;
2)分析堆料作业计划内容，确定堆料模式，生成大机的堆料控制指令；2) Analyze the contents of the stacking operation plan, determine the stocking mode, and generate the stacking control command for the large machine;
3)中控画面显示堆料作业控制指令，进行参数修正(包括走形、回旋和俯仰值)；3) The central control screen displays the stacking operation control command and performs parameter correction (including shape, swing and pitch values);
4)堆料控制指令下发到大机PLC***；4) The stacking control instruction is sent to the large PLC system;
5)大机收到堆料作业指令，进行正式作业前的调整工作；5) The large machine receives the stacking operation instruction and performs the adjustment work before the official operation;
6)大机走行到计划堆料区域的起始地址，大机各机构作业准备完毕；6) The large machine travels to the starting address of the planned stocking area, and the operations of the large machine are completed.
7)地面流程启动，给料机与相应的输送机开始作业，大机开始自动堆料作业；7) The ground process starts, the feeder and the corresponding conveyor start the operation, and the large machine starts the automatic stacking operation;
8)自动堆料过程的控制；8) Control of the automatic stacking process;
9)大机未到达堆积终止地址(但给料机已停止给料)或堆料作业到达堆积终止地址，大机完成堆料作业的处理；9) The large machine does not reach the stacking termination address (but the feeder has stopped feeding) or the stacking operation reaches the stacking termination address, and the large machine completes the processing of the stacking operation;
10)堆料结束后，将煤堆扫描数据进行分析和保存。10) After the end of the pile, the coal pile scan data is analyzed and saved.
2、空场堆垛模式2, empty field stacking mode
此种情况下的堆料只需要确定堆垛起始地址和终止地址，***会根据卸煤量、煤种来计算卸煤体积，再结合堆垛方法来模拟在场地的堆存效果，操作人员可以进行堆存预判。In this case, the stack only needs to determine the stacking start address and the end address. The system calculates the unloading volume according to the coal unloading amount and coal type, and then combines the stacking method to simulate the stacking effect at the site. The operator Pre-judgment can be carried out.
空场堆垛方法：Empty field stacking method:
1)根据卸车量、煤种信息，计算出堆存体积；1) Calculate the storage volume according to the amount of unloading and coal type information;
2)确定堆料起始地址；2) Determine the starting address of the stockpiling;
3)选择堆垛方法；3) Select the stacking method;
4)将堆存体积结合堆垛方法，模拟仿真堆存效果图； 4) Combine the storage volume with the stacking method and simulate the simulation of the storage effect;
5)开始堆料；5) Start stacking;
6)堆料结束后，将煤堆扫描数据进行分析和保存。6) After the end of the pile, the coal pile scan data is analyzed and saved.
3、补垛模式3, supplement mode
此种情况下的堆料首先需要确定现有垛型的情况，确定堆存的起始地址和终止地址，***会根据卸煤量、煤种来计算卸煤体积，再结合堆垛方法来模拟在现有存量的场地上所展现的堆存效果，操作人员由此进行堆存预判和选择合适的场地。In this case, the pile material first needs to determine the existing defect type, determine the start address and end address of the stockpiling, and the system calculates the coal unloading volume according to the coal unloading amount and coal type, and then combines the stacking method to simulate The stowage effect exhibited on the existing stock site, the operator thus performs the pre-judgment and selects the appropriate site.
补垛方法：Supplementary method:
1)根据卸车量、煤种信息，计算出堆存体积；1) Calculate the storage volume according to the amount of unloading and coal type information;
2)确定堆料起始地址；2) Determine the starting address of the stockpiling;
3)选择堆垛方法；3) Select the stacking method;
4)扫描现有堆垛的数据，或者调用已保存的垛型数据；4) Scan the data of the existing stack or call the saved data of the type;
5)将堆存体积结合堆垛方法，在现有堆垛上进行扫描生成堆存效果图；5) Combine the storage volume with the stacking method, and scan the existing stack to generate a storage effect map;
6)开始堆料；6) Start stacking;
7)堆料结束后，将煤堆扫描数据进行分析和保存。7) After the end of the pile, the coal pile scan data is analyzed and saved.
4、取料模式4, reclaim mode
经典模型如图4，首先操作堆取料机行走，旋转、俯仰装置使整机置于料堆顶层作业开始点位置上，然后靠旋转控制开始取料，每达到旋转范围时行走机构微动一个设定距离即进给量，取完第一层后，进行换层操作，每层的旋转角度由物料的安息角及层数决定；俯仰高度由层数设定，行走距离由进给量决定。臂架旋转速度应与臂架回转角度成确定函数关系，并根据驱动电动机的电流进行反馈，实现旋转分层等量取料算法。The classic model is shown in Figure 4. First, the stacker and reclaimer are operated. The rotating and tilting device places the whole machine on the top position of the top of the pile, and then starts to take the material by the rotation control. When the rotation range is reached, the running mechanism is slightly moved. Set the distance, that is, the feed amount. After the first layer is taken, the layer changing operation is performed. The rotation angle of each layer is determined by the angle of repose and the number of layers of the material; the pitch height is set by the number of layers, and the walking distance is determined by the feed rate. . The rotation speed of the boom should be determined as a function relationship with the rotation angle of the boom, and feedback based on the current of the driving motor can be realized to realize the algorithm of rotating layered equal-feeding.
当垛型较大较长时，有时需进行旋转分层分段取料，即按照设定的供料段的长度进行，取完当前层时自动进行换层，当取完最下一层后进行换段操作，置于第二段最顶层的作业开始点上，重复进行取料，直到取料完成。自 动取料操作流程如下：When the 垛 type is large and long, it is sometimes necessary to perform the rotating layered section feeding, that is, according to the length of the set feeding section, and automatically change the layer when the current layer is taken, when the bottom layer is taken The change operation is performed, and the work is started at the topmost work start point of the second stage until the take-up is completed. Self The operation process of the reclaiming operation is as follows:
1)实现料堆激光扫描三维成像并为自动取料控制提供数据依据，作业计划设定；1) Realize the three-dimensional imaging of the laser scanning of the material pile and provide data basis for the automatic material reclaiming control, and set the operation plan;
2)根据三维成像提供的分析数据，确定分层、寸动量、边界值等数据，以设定***自动取料的依据；2) According to the analysis data provided by the three-dimensional imaging, determine the stratification, the amount of momentum, the boundary value and other data to set the basis for the system to automatically withdraw the material;
3)在取同一层时，根据设定参数自动运行取料；3) When taking the same layer, automatically take the reclaim according to the set parameters;
4)当层取完后按照设定参数自动对位、开层、换层；4) After the layer is taken, it will automatically align, open and change layers according to the set parameters;
5)取料结束后，将煤堆扫描数据进行分析和保存。5) After the material is taken, the coal pile scan data is analyzed and saved.
以上所述仅为本发明的较佳实施例，并不用以限制本发明，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。 The above are only the preferred embodiments of the present invention, and are not intended to limit the present invention. Any modifications, equivalents, improvements, etc., which are within the spirit and scope of the present invention, should be included in the protection of the present invention. Within the scope.

Claims (10)

  1. 一种智能化全自动堆取料机控制装置，其特征在于，包括：中央处理服务器、中控远程PLC***、堆取料机PLC***、人机HMI操作界面以及激光扫描***，其中，The utility model relates to an intelligent automatic stacker and reclaimer control device, which comprises: a central processing server, a central control remote PLC system, a stacker reclaimer PLC system, a human machine HMI operation interface and a laser scanning system, wherein
    所述中控远程PLC***与所述中央处理服务器相连接，所述堆取料机PLC***与所述中央处理服务器、所述中控远程PLC***分别连接，所述人机HMI操作界面与所述中央处理服务器、所述中控远程PLC***、所述堆取料机PLC***分别连接，所述激光扫描***与所述中央处理服务器相连接；The central control remote PLC system is connected to the central processing server, and the stacker reclaimer PLC system is respectively connected to the central processing server and the central control remote PLC system, and the human machine HMI operation interface and the office The central processing server, the central remote PLC system, and the stacker reclaimer PLC system are respectively connected, and the laser scanning system is connected to the central processing server;
    所述智能化全自动堆取料机控制装置的连接皆是通过智能化远程通讯网络，包括工业现场总线网络、工业以太网和/或工业电视网络。The intelligent automatic stacker and reclaimer control device is connected through an intelligent remote communication network, including an industrial field bus network, an industrial Ethernet network, and/or an industrial television network.
  2. 根据权利要求1所述的控制装置，其特征在于，所述中央处理服务器包括数据服务器和图像服务器。The control device according to claim 1, wherein said central processing server comprises a data server and an image server.
  3. 根据权利要求2所述的控制装置，其特征在于，在所述数据服务器中安装有中控防碰撞***，保证在多台堆取料机同步作业的情况下，避免堆取料机碰撞。The control apparatus according to claim 2, wherein a centrally controlled anti-collision system is installed in said data server to ensure collision of the stacker and reclaimer in the case of simultaneous operation of a plurality of stackers and reclaimers.
  4. 根据权利要求2所述的控制装置，其特征在于，在所述图像服务器中安装有三维图像处理***，将所述激光扫描***所采集的数据进行整合和计算，转化为料堆三维图像与料堆盘点数据。The control device according to claim 2, wherein a three-dimensional image processing system is installed in the image server, and data collected by the laser scanning system is integrated and calculated, and converted into a three-dimensional image and material of the pile Stacking data.
  5. 根据权利要求2或4所述的控制装置，其特征在于，所述激光扫描***包括多个用于扫描作业料堆的激光扫描仪，扫描当前作业料堆并进行数据的采集整理；所述激光扫描仪连接并将数据传输至所述图像服务器，进而反馈到所述人机HMI操作界面上，并提供料场三维扫描堆形与料堆盘点数据。 The control device according to claim 2 or 4, wherein the laser scanning system comprises a plurality of laser scanners for scanning the working material pile, scanning the current working material pile and collecting and collating the data; The scanner connects and transmits the data to the image server, and then feeds back to the human-machine HMI operation interface, and provides the three-dimensional scanning pile shape and the pile count data of the stockyard.
  6. 根据权利要求5所述的控制装置，其特征在于，所述激光扫描仪配置在堆取料机上。The control device according to claim 5, wherein said laser scanner is disposed on a stacker and reclaimer.
  7. 根据权利要求5所述的控制装置，其特征在于，所述激光扫描仪配置在堆取料机以外的机架或建筑物上。The control device according to claim 5, wherein the laser scanner is disposed on a rack or a building other than the stacker and reclaimer.
  8. 根据权利要求1或2所述的控制装置，其特征在于，还包括视频监视***，所述视频监视***包括：多个安装在堆取料机上的摄像头、与所述摄像头连接的视频分频器以及连接于所述视频分频器的视频显示器和视频操作键盘；所述视频显示器还连接至所述人机HMI操作界面。The control device according to claim 1 or 2, further comprising a video monitoring system, the video monitoring system comprising: a plurality of cameras mounted on the stacker and reclaimer, and a video frequency divider connected to the camera And a video display and a video operation keyboard coupled to the video divider; the video display is also coupled to the human HMI operation interface.
  9. 根据权利要求1或2所述的控制装置，其特征在于，还包括连接至所述中控远程PLC***进而控制所述堆取料机PLC***的远程操作手柄。A control device according to claim 1 or 2, further comprising a remote operating handle coupled to said centrally controlled remote PLC system for controlling said stacker reclaimer PLC system.
  10. 根据权利要求1或2所述的控制装置，其特征在于，可供使用的模式有：经典堆料模式、空场堆垛模式、补垛模式以及取料模式。 The control device according to claim 1 or 2, wherein the available modes are: a classic stocking mode, an empty field stacking mode, a supplemental mode, and a reclaiming mode.
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