Automatic loading and unloading system for mine car transportation box warehouse and control method thereof
Technical Field
The invention relates to the field of automatic transportation and loading and unloading of mine materials, in particular to an automatic loading and unloading system of a mine car transportation box warehouse and a control method thereof.
Background
At present, a manual or semi-manual loading and unloading mode is generally adopted for material transportation in mine and warehouse scenes, so that the outstanding problems of low operation efficiency, high manpower resource consumption, insufficient intrinsic safety and the like exist, and particularly, the problem that different material types such as minerals, various materials, equipment accessories and the like are difficult to adapt to different loading requirements of multiple material types due to structural limitations is solved, so that the space utilization rate is low, an intelligent coordination mechanism is lacking in a dispatching system, the phenomenon of transportation capacity waste is easy to occur during the coordination operation of multiple vehicles, meanwhile, complicated geological conditions and severe environments also bring great challenges to the operation of workers, the material transportation always cannot form an integral full-automatic operation flow, and the automatic loading and unloading difficulty is high by means of the existing loading system.
Disclosure of Invention
The invention provides an automatic loading and unloading system for a mine car transportation box warehouse and a control method thereof, which realize full-flow automatic loading and unloading of a multi-configuration transportation box in a mining scene through an intelligent framework of highly modularized hardware design, multi-sensor sensing and identification and cooperative control of a mechanical arm. The system takes multi-sensor depth fusion as a core, combines the operation technology of the mechanical arm dynamic posture adjustment and locking device, and effectively solves the problems of high manual dependency, insufficient precision, poor adaptability and the like in the traditional loading and unloading operation.
The system is composed of six parts of a lifting appliance module, an overhead travelling crane module, a mechanical arm module, a box body module, a flat car module and a sensor module, wherein the modules are integrated into the whole system to cooperatively operate. The box module is designed into various configurations such as a cover-free type, a double-door type, a side-unloading type, a column type, a canning type and the like according to physical characteristics and loading and unloading requirements of materials, all the configurations follow the unified external dimension standard, and high-strength steel corner pieces are welded at four corners of the top and the bottom and fixedly matched with locking mechanisms of the lifting tool module and the flat car module. The flat car module is provided with wheel pairs matched with the rails, lifting twist lock devices are arranged at four corners of the frame, the lock heads can vertically rise into corner pieces after the box body is placed on the flat car and then rotate to complete locking, the lock heads can be unlocked by reversely rotating, and the lock heads can be lowered below the surface of the flat car. The lifting appliance module is connected with the overhead traveling crane lifting hook through four groups of high-strength ropes, the four corners of the lifting appliance frame are provided with locking devices, the middle is provided with rotating shafts, the locking devices are rotatable lock heads through connecting rods, the two crank block mechanisms are integrally connected in series, when the overhead traveling crane lifting hook drives the middle rotating shaft to rotate, the rotating shafts transmit power to the four groups of lock heads, locking heads synchronously rotate to clamp angle pieces to complete locking and fixing, and unlocking and separating are realized when the lock heads rotate anticlockwise. And positioning baffles are arranged on the outer sides of the four corners, so that the matching accuracy of the lifting tool module and the box body module can be improved.
The sensor module is used as a sensing and identifying module of the system, and integrates a UWB (ultra wide band) positioning unit, an IMU (inertial measurement unit) and a plurality of groups of depth cameras to form a multi-mode sensing network covering a loading and unloading full scene. The UWB base station calculates three-dimensional space coordinates of the lifting tool module and the box body module in real time by a time difference ranging method, has higher positioning precision, can monitor the change of the attitude angle of the box body by the built-in three-axis gyroscope and the accelerometer of the IMU, can accurately identify millimeter-level outline characteristics of box body corner fittings, flat car twist locks and peripheral obstacles under complex illumination conditions by adopting a binocular stereoscopic vision and structured light fusion technology by the multi-depth camera, and provides path points for dynamically adjusting the box body attitude and operating the twist locks by the mechanical arm module. The crown block module is provided with an industrial man-machine interaction terminal, the position, the attitude Euler angle, the locking state and the movement track of the mechanical arm of the box body transmitted by the sensor module are displayed in real time, and an operator can switch a full-automatic mode or manually intervene fine adjustment through a touch interface.
The mechanical arm module is composed of four six-degree-of-freedom cooperative mechanical arms, and is symmetrically arranged on two sides of the flat car module, and the tail end of the mechanical arm module is provided with a multifunctional clamping jaw. In the loading and unloading process, the mechanical arm performs multi-task cooperation according to multi-sensor fusion data, namely when the box body is lifted to the upper part of the flat car from the crown block, the mechanical arm dynamically adjusts the tail end clamping force through an impedance control algorithm to offset pose deviation caused by shaking of the lifting appliance, and in the box body lowering process, the multi-depth camera captures the space coordinates of the corner fitting and the lock hole in real time to guide the clamping jaw of the mechanical arm to operate the twist lock to finish lifting and screwing operation. The system has the functions of fault self-diagnosis and redundant fault tolerance, and when a single mechanical arm is down due to unexpected power failure or communication interruption, the rest mechanical arms automatically redistribute task weights, and the continuity of the loading and unloading flow is maintained by increasing the clamping force and adjusting the movement track.
The core of the control method is to construct a closed-loop control architecture of 'sensing-decision-execution-feedback'. After loading and unloading operation is started, UWB and IMU real-time fusion data are generated to estimate the initial pose of the box, and the overhead travelling crane module lifts the box to a target area above the flat car according to a path planning algorithm. At this stage, the multi-depth camera synchronously scans the surface of the flatbed, identifies the spatial coordinates of the locking device by a feature matching algorithm, and inputs the data into the robotic arm motion planner. When the box body enters a hovering state, the tail end clamping jaw of the mechanical arm accurately grabs the automatic twist lock at the bottom of the box body based on visual guidance, and fine adjustment moment in the horizontal plane is applied to the box body through a force-position hybrid control strategy, so that pose deviation caused by hoisting inertia is eliminated. After the box body is lowered to the flat car module, the multi-depth camera rapidly recognizes space coordinates of lock holes at four corners of the flat car, the multi-mechanical arm plans a clamping point position path according to visual guidance, the clamping jaw mechanism realizes locking through pushing and rotating combined movement, reverse operation is performed during unloading, the mechanical arm module positions characteristic points of locking devices at four corners of the bearing platform under the guidance of the multi-depth camera, and the clamping jaw realizes reverse rotation unlocking of the locking handle through reverse rotation action.
The invention has the advantages that the double-lifting of the material transportation loading and unloading efficiency and the safety is realized through the modularized design, the locking structure of the box body with uniform specification and the universal flat car is integrally adopted, the multi-configuration material transportation requirement is adapted, the transport capacity waste is reduced, and the loading and unloading efficiency is improved. The sensor fusion technology (UWB/IMU/depth vision) is used for constructing a centimeter-level positioning network, and the four mechanical arms are combined to cooperatively adjust the gesture and control the fault tolerance, so that the hoisting shaking error is dynamically eliminated, and the accurate butt joint of the box body and the flat car module is ensured. The locking device of the flat car is matched with the vision guide system to realize automatic locking and unlocking operation of the mechanical arm, and high-risk operation of manual intervention is avoided. The overhead travelling crane monitoring and pedestrian early warning system forms three-dimensional protection, man-machine cooperation and full-automatic mode seamless switching are realized through a visual interface, operation safety is guaranteed, and meanwhile, the system can continuously optimize an operation flow through reinforcement learning, so that an intelligent loading and unloading system with a high-efficiency closed loop is formed.
Drawings
FIG. 1 is a schematic diagram of an automated loading and unloading system for a warehouse of a transportation box for mine cars according to an embodiment of the present invention;
FIG. 2 is an enlarged view of a partial structure at A in FIG. 1;
FIG. 3 is a schematic diagram of a truck platform box locking system for an automated loading and unloading system for a transportation box warehouse of a mine car according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of key components of a flatbed module of an automated loading and unloading system for a transportation box warehouse of a mine car according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of a hoist box lock of an automated loading and unloading system for a transportation box warehouse of a mine car according to an embodiment of the present invention;
FIG. 6 is a schematic diagram of a mechanical arm module of an automated loading and unloading system for a warehouse of a transportation box of a mine car according to an embodiment of the present invention;
fig. 7 is a schematic diagram of a control frame of an automated loading and unloading system for a warehouse of a transportation box for mine cars according to an embodiment of the present invention.
Reference numerals illustrate:
The lifting device comprises a lifting tool module (1), a crown block module (2), a mechanical arm module (3), a box module (4), a flat car module (5), a sensor module (6), corner fittings (7), a twist lock tapered end (8), a wheel set (9), a twist lock (10), a rotary tapered end (11) and a positioning baffle (12).
Detailed Description
In order that the above objects, features and advantages of the invention will be readily understood, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.
The automatic loading and unloading system for the mine car transportation box warehouse is characterized by comprising a lifting tool module (1), a crown block module (2), a mechanical arm module (3), a box module (4), a flat car module (5) and a sensor module (6), wherein the flat car module (5) is provided with a locking device, the box module (4) can be fixed and carried, materials are filled in the box module (4) and transported through the flat car module (5), the lifting tool module (1) is hung below the crown block module (2), the box module (4) can be lifted by the lifting tool module (1), loading and unloading of the box module (4) are achieved through movement of the crown block module (2), the box module (4) is provided with various configurations, different types of materials can be loaded, the mechanical arm module (3) is arranged around the flat car module (5), a series of automatic operations are achieved in the loading and unloading process of the box module (4), the automatic torsion lock is taken, the box module (4) is locked and unlocked, the sensor module (6) has sensing and sensing functions, and the position and the motion characteristics of the box module (4) can be provided.
The box module (4) is designed into various configurations according to the types of materials, the box module is divided into a cover-free type, a double-door type, a side-dump type, a column type and a canning type, each configuration has the same overall dimension, locking and separation can be respectively realized with the flat car module (5) and the lifting tool module (1), corner pieces (7) are arranged at the top and the bottom of the box, twist lock heads (8) and rotary lock heads (11) are respectively arranged at corresponding positions of the flat car module (5) and the lifting tool module (1), the two lock heads can rotate in the corner pieces (6) to realize locking or separation of the two modules, the flat car module (5) can move on rails, the flat car module (4) can be fixed and transported, the bottom of the flat car module (4) is provided with a wheel pair (9) structure, twist locks (10) are arranged on a frame according to the positions of the corner pieces (7) at the bottom of the box module (4), as shown in fig. 4, the twist lock heads (8) can be locked for each configuration of the box module (4), the twist lock heads (8) can rotate in opposite directions to enable the flat car (8) to rotate to be used as the flat car body (5) to rotate in opposite directions, and the flat car can rotate to the flat car (5) to be used as the general lock heads.
The lifting appliance module (1) can be mounted on the crown block module (2) to realize locking and separating functions with the box module (4), the lifting appliance module (1) is particularly characterized in that ear plate structures are arranged at four corners, the lifting appliance module (2) is pulled to lifting hooks by four ropes, rotary lock heads (11) are arranged at four corners of a frame according to the positions of angle pieces at the top of the box module (4), as shown in fig. 5, the rotary lock heads (11) are connected with middle rotating shafts through connecting rods, the lifting hooks drive the middle rotating shafts to rotate so as to drive the rotary lock heads (11) to synchronously rotate so as to realize locking or separating, shaking can exist in the lifting appliance moving process, positioning baffle plates (12) are also designed at the four corners, the crown block module (2) comprises a crown block, an upper computer and man-machine interaction monitoring software, the crown block can mount and move the lifting appliance module (1), the monitoring interfaces are arranged at the tops of the crown block, the monitoring interfaces can display monitoring pictures, pose data of the box and the current flow state in real time, and give an alarm to personnel entering a crown block working area, and the crown block module (2) can be automatically controlled or operated by personnel.
The sensor module (6) comprises UWB, IMU and multi-depth camera, the UWB and the IMU are respectively used for obtaining three-dimensional pose of the lifting tool module (1) and the box module (4), the multi-depth camera is used for identifying and sensing the features of the box module (4) and the flat car module (5) to obtain feature point pose, the feature point pose is specifically represented by dynamically adjusting the pose of the box module (4) obtained based on the UWB and the IMU through the mechanical arm module (3), the multi-depth camera is used for identifying the features of the box and the flat car to obtain depth information of the box and the flat car, reference is provided for motion control of the mechanical arm module (3), and real-time, rapidness and safety of measured data transmission are guaranteed; the mechanical arm module (3) comprises four groups of mechanical arms, as shown in fig. 6, the mechanical arms can realize the accurate loading and unloading of the box module (4) through cooperative control, the mechanical arms are arranged outside the locking device of the flat car module (5), the loading and unloading action flow of operators can be simulated based on the sensing feedback data of the sensor module (6) as shown in claim 1, the mechanical arms can automatically realize picking up the automatic twist lock, the box module (4) position and posture righting, locking and unlocking the twist lock (10) of the flat car module (5), the path is planned in real time, the obstacle avoidance function is realized, certain fault tolerance capability is realized, when a certain mechanical arm or a plurality of mechanical arms are down, the mechanical arms which can normally work still can finish the loading operation without influencing the normal work flow, and the reinforcement learning model can be built through storing and inquiring historical data, and performing reinforcement training according to the historical data, and optimizing the motion trail of the mechanical arm.
The intelligent control framework of closed loop feedback is constructed through the depth fusion of the sensor module (6) identification positioning technology and the mechanical arm module (3) cooperative control technology as shown in the claim 4, and as shown in fig. 7, the accurate positioning, dynamic pose adjustment and automatic locking operation of the flat car module (5) and the box module (4) of the box module (4) are realized as shown in the claim 2, and the intelligent control framework is specifically characterized in that based on the three-dimensional pose of the box module (4) obtained by the IMU and UWB in the sensor module (6), the visual identification of the box module (4) by combining a multi-depth camera is combined, the multi-mode sensing data is formed and transmitted to a visual interface in the crown block module (2), the box position, the pose angle and the surrounding environment are dynamically displayed, so that an operator can control the crown block in real time, and the preliminary lifting and positioning of the box module (4) are completed; simultaneously, the system calculates the target pose errors of the box body module (4) and the flat car module (5) in real time through a space coordinate transformation algorithm, inputs an error vector into the mechanical arm module (3), generates an articulation track instruction of the mechanical arm, drives the mechanical arm module (3) to synchronously execute the box body centralizing, fine tuning and dynamic balance compensating actions, continuously corrects the control parameters through an IMU and UWB feedback loop until the errors are converged to a preset threshold range, synchronously identifies the torsion lock (10) of the flat car module (5) and the hole position of a corner piece (7) at the bottom of the box body module (4) through a multi-depth camera in the process, the system supports man-machine cooperation and full-automatic mode switching, an operator in a manual mode controls a box body to be lifted to a target area through a crown block console and slowly lowered, multiple mechanical arms adjust the posture in real time to offset lifting disturbance and compensate tail end positioning errors through vision, the crown block in the full-automatic mode is taken over by a central controller, lifting and lowering are automatically completed based on a path planning algorithm, meanwhile, a mechanical arm module (3) can optimize a control strategy through reinforcement learning, high-precision dynamic alignment of the box body and a flat car is achieved, and the operator only needs to monitor abnormality through a safety interface.
The system comprises a UWB positioning system, a multi-depth camera identification system and an IMU inertial measurement unit in a sensor module (6), wherein a multi-source sensor network is built by combining a cooperative control technology of a mechanical arm module (3), when the system is used for loading, a transport box body moving track is monitored in real time by the UWB and the multi-depth camera, when the box body module (4) is identified to hover above a flat car module (5), the mechanical arm module (3) cooperatively completes automatic box bottom twist lock picking operation under the guidance of the sensor module (6), then a horizontal plane pose deviation of the box body and a bearing platform is calculated in real time by a pose resolving algorithm fused by the IMU and the multi-depth camera, a multi-mechanical arm cooperative motion track is generated, the box body is dynamically righted and adjusted by adopting a multi-point compliant control strategy, after the box body is lowered to the flat car module (5), the multi-depth camera rapidly identifies four corner space coordinates of the flat car, the multi-mechanical arm realizes locking according to visual guide clamping path, and clamping jaw opening, when the mechanical arm module (3) is pushed and rotated to realize combined motion, the box body is reversely positioned by the mechanical arm module (3), and the clamping jaw is reversely rotated to realize automatic clamping jaw positioning of the flat car (4), and the mechanical arm is reversely positioned at the bottom of the flat car (2), and the mechanical clamping jaw (3) is reversely positioned, and the mechanical clamping jaw is accurately locked, and the box is positioned, and the box body is positioned.