阅读说明：本技术 一种自动对位装车系统 (Automatic alignment loading system ) 是由 毛继瑶 陈丽 于 2021-08-23 设计创作，主要内容包括：本发明公开了一种自动对位装车系统,包括对位模块、装车模块和安全保护模块,所述对位装车模块包括运动执行模块、位置检测模块和控制模块,所述运动执行模块包括行走小车,桁架轨道,升降气缸、电磁阀控制组件、限位开关,所述升降气缸上连接有鹤管,所述升降气缸固定连接所述行走小车上,所述位置检测模块包括视觉相机,激光检测仪和编码器,所述视觉相机固定于所述桁架轨道上,所述激光检测仪器和位置传感器固定连接在所述行走小车上,所述控制模块包括PLC主控模块、通讯模块和HMI显示模块以及键盘模块,所述装车模块包括装车控制模块和现场仪表模块。(The invention discloses an automatic alignment loading system, which comprises an alignment module, a loading module and a safety protection module, the alignment loading module comprises a motion execution module, a position detection module and a control module, the motion execution module comprises a walking trolley, a truss track, a lifting cylinder, an electromagnetic valve control assembly and a limit switch, the lifting cylinder is connected with a crane pipe and is fixedly connected with the walking trolley, the position detection module comprises a visual camera, a laser detector and an encoder, the visual camera is fixed on the truss track, the laser detection instrument and the position sensor are fixedly connected to the walking trolley, the control module comprises a PLC main control module, a communication module, an HMI display module and a keyboard module, and the loading module comprises a loading control module and a field instrument module.)

1. The utility model provides an automatic alignment loading system which characterized in that: including counterpoint module, loading module and safety protection module, the counterpoint module includes motion execution module, position detection module and control module, motion execution module includes the walking dolly, the truss track, lift cylinder, solenoid valve control assembly and limit switch, be connected with the oil filling riser on the lift cylinder, lift cylinder fixed connection on the walking dolly, the loading module includes loading control module and on-the-spot instrument module, position detection module includes vision camera, laser detector and encoder, the vision camera is fixed in on the truss track, laser detector and position sensor fixed connection be in on the walking dolly, control module includes PLC host system, communication module and HMI display module and keyboard module.

2. The automatic alignment loading system of claim 1, wherein: the communication module is connected with the Ethernet, the analog quantity and the pulse in a communication mode, receives equipment position and state information, and carries out operation control through the PLC main control module, and the HMI display module is used for text picture control and data exchange.

3. The automatic alignment loading system of claim 1, wherein: the loading control module comprises a programmable control PLC module, a display module, a keyboard operation module and an isolation execution module, wherein the keyboard operation module inputs an operation command and sends the operation command to the programmable control PLC module.

4. The automatic alignment loading system of claim 3, wherein: the programmable control PLC module processes the operation command and then sends control data to the isolation execution module for execution, and the display module displays the operation command and the operation state.

5. The automatic alignment loading system of claim 1, wherein: the field instrument module comprises a valve, a flowmeter, a pressure transmitter and a temperature transmitter, and the field instrument modules are all installed on a field pipeline.

6. The automatic alignment loading system of claim 1, wherein: the safety protection module comprises a human body static electricity releasing instrument, a vehicle key management box, an overflow static electricity controller, a toxic gas/combustible gas detector, a loading arm homing detector and a pipeline gas phase flow detector.

Technical Field

The invention belongs to the field of railway loading, and particularly relates to an automatic alignment loading system.

Background

The Chinese patent names: automatic aligning device of fluid canning oil filling riser, the bulletin number of authorizing: CN104445034B, date of authorized announcement: in 2017, 2, 15, the patent only mentions the control of alignment, but only one action, and the important work after alignment is loading, so that the two systems of alignment and loading cannot be fused together; the alignment work in the comparison file is to carry out position measurement through laser, the laser position measurement can cause scanning to be carried out only in the left-right direction, three-dimensional or two-dimensional position judgment cannot be carried out, laser scanning is carried out to the outside, positioning errors are caused, the situation that a loading system scans the correct position can be judged by mistake, a drop pipe falls off, the danger of vehicle crashing can be caused, the scanning efficiency in the comparison file is low, one-dimensional scanning is carried out in the past, the left side of the filling opening is scanned to the right side, the diameter of the filling opening is calculated, and the center of the filling opening is found out through the position difference; this results in the position scanning being completed without the loading arm being at the center of the nozzle, but rather stopped at the rightmost (or leftmost) position of the nozzle as a result of the laser scanning, thus requiring a secondary positioning (forward or backward) of the loading arm. The efficiency of contraposition is low; in terms of the whole system, the comparison file is only used for positioning the train, when the system is operated on site, the operation is carried out on the system for positioning the train, and then the operator needs to go to the loading system to carry out the loading action, so that the operator can alternately operate in the two systems, the efficiency is low, the operation is complicated, and the error is easy to occur; meanwhile, the train trestle is small, two sets of equipment are arranged on the trestle, a lot of area is occupied, the workload of operators is increased, and therefore an automatic alignment loading system needs to be designed.

Disclosure of Invention

The invention aims to provide an automatic alignment loading system which can solve the problems.

The technical scheme adopted by the invention is as follows: the utility model provides an automatic alignment loading system, includes counterpoint module, loading module and safety protection module, counterpoint loading module includes motion execution module, position detection module and control module, motion execution module includes the walking dolly, the truss track, lift cylinder, solenoid valve control assembly, limit switch. The device comprises a motion execution device, a solenoid valve control component, a motion control device, a limit switch, a lifting cylinder, a position detection module, a laser detector and a coder, wherein the solenoid valve control component is connected with a power interface of the motion execution device to realize motion control, the limit switch limits the motion of each component within a safety range, the lifting cylinder is connected with a crane pipe, the lifting cylinder is fixedly connected with the walking trolley, the walking trolley is responsible for sending the lifting cylinder to the tank opening position of the tank car, the lifting cylinder is responsible for sending the crane pipe to the tank opening of the tank car, the position detection module comprises a vision camera, a laser detector and a coder, the vision camera is fixed on the truss track, the laser detector and a position sensor are fixedly connected on the walking trolley, the vision camera is responsible for capturing the tank opening position of the tank car and establishing a working coordinate system, the laser detector is responsible for dynamically scanning the tank opening position, the position sensor is responsible for feeding back the actual position of the trolley, and transmits data to the control system through Ethernet, analog quantity information and pulse communication modes, the system judges whether the trolley reaches the end point by comparing the sent position command with the current position fed back by the trolley, the control module comprises a PLC (programmable logic controller) main control module, a communication module, an HMI (human machine interface) display module and a keyboard module, and the loading module comprises a loading control module and a field instrument module.

The invention is further improved in that: the communication module receives the position and state information of the equipment through communication modes such as Ethernet, analog quantity, pulse and the like, the operation control is carried out through the PLC main control module, and the HMI display module is used for controlling text pictures and exchanging data, displaying the travelling state of the trolley, the position information, the loading process flow information, the field instrument information, detecting picture numbers, and logically judging the loading password and the card swiping verification condition.

The invention is further improved in that: the loading control module comprises a programmable control PLC module, a display module, a keyboard operation module and an isolation execution module, and the keyboard operation module inputs an operation command and sends the operation command to the programmable control PLC module.

The invention is further improved in that: the programmable control PLC module processes the operation command and then sends control data to the isolation execution module for execution, and the display module displays the operation command and the operation state.

The invention is further improved in that: the field instrument module comprises a valve, a flowmeter, a pressure transmitter and a temperature transmitter, and the field instrument module is arranged on a field pipeline.

The invention is further improved in that: the safety protection module comprises a human body static electricity releasing instrument, a vehicle key management box, an overflow static electricity controller, a toxic gas/combustible gas detector, a loading arm homing detector and a pipeline gas phase flow detector, an alarm signal is sent to the control system through a signal cable, and the safety protection module detects the conditions of site environment, equipment state, personnel operation and the like so as to detect or judge dangerous information and inform the system to take emergency measures.

Has the advantages that:

the invention provides an automatic alignment loading system, which adopts a pneumatic or hydraulic actuating mechanism, utilizes a vision and laser dual positioning mode to directly capture the position of a filling opening, positions the filling opening at one time and can carry out positioning self-checking control. And constant current control is carried out, real-time detection loading flow rate, logic valve control is carried out, logic pump control, safety interlock control, the problem that the existing technology can only realize single quantitative loading or single counterpoint function is solved, the operation flow is optimized, the potential safety hazard problem of manual misoperation is solved, the operation efficiency is improved, comparison and verification through a visual algorithm and a laser algorithm are realized, the problems that the traditional positioning mode is single, the external environment is easily influenced and the positioning problem that the position can not be verified is solved, and the accuracy and the stability of position detection are greatly improved.

Drawings

Fig. 1 is a system flow diagram.

Fig. 2 is an overall structural view.

Fig. 3 is a detailed structural view.

The reference numbers: the system comprises a loading module, a safety protection module, a motion execution module, a 4-walking trolley, a 5-truss track, a 6-lifting cylinder, a 7-solenoid valve control assembly, an 8-tank car tank opening, a 9-vision camera, a 10-laser detector, an 11-position sensor and a 12-control module.

Detailed Description

In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments.

An automatic alignment loading system comprises an alignment module 1, a loading module 1 and a safety protection module 2, wherein the alignment loading module 1 comprises a motion execution module 3, a position detection module and a control module 12, the motion execution module 3 comprises a walking trolley 4, a truss track 5, a lifting cylinder 6, an electromagnetic valve control component 7 and a limit switch, the electromagnetic valve control component is connected with a power interface of motion execution equipment to realize motion control, the limit switch limits the motion of each component in a safety range, the lifting cylinder 6 is connected with a crane pipe 7, the lifting cylinder 6 is fixedly connected with the walking trolley 4, the walking trolley 4 is responsible for conveying the lifting cylinder 6 to a tank car opening position 8, the lifting cylinder 6 is responsible for conveying the crane pipe 7 to the tank car opening 8, the position detection module 5 comprises a visual camera 9, a laser detector 10 and an encoder, the visual camera 9 is fixed on the truss track 5, the laser detector 10 and the position sensor 11 are fixedly connected on the walking trolley 4, the visual camera 9 is responsible for capturing the position of the tank opening 8 of the tank car and establishing a working coordinate system, the system can be directly positioned to the center position of the tank opening, and the laser detector 10 is responsible for dynamically scanning the position of the tank opening and calculating the radius of the tank opening.

The position sensor 11 is responsible for feeding back the actual position of the trolley, transmitting data to the control system in an Ethernet, analog quantity information and pulse communication mode to form closed-loop control on the movement, judging whether the trolley reaches the end point or not by comparing a sent position command with the current position fed back by the trolley by the system, verifying whether the alignment of the loading arm is accurate or not by comparing laser calculated data and visual position data, the control module 12 comprises a PLC main control module, a communication module, an HMI (human machine interface) display module and a keyboard module, the loading module 1 comprises a loading control module and a field instrument module, the communication module receives equipment position and state information in the Ethernet, analog quantity and pulse communication mode, the PLC main control module performs operation control, the HMI display module performs text picture control and data exchange to display the travelling state of the trolley in real time, the method comprises the following steps of position information, loading process flow information, field instrument information, safety interlocking information, detection picture numbering and logic judgment of loading passwords and card swiping verification conditions.

The loading control module comprises a programmable control PLC module, a display module, a keyboard operation module and an isolation execution module, the keyboard operation module inputs an operation command and sends the operation command to the programmable control PLC module, the programmable control PLC module processes the operation command and then sends control data to the isolation execution module to execute, and the display module displays the operation command and the operation state.

The field instrument module includes valve, flowmeter, pressure transmitter, temperature transmitter, the field instrument module is all installed on the site pipe way, the safety protection module includes human static electricity discharge appearance, vehicle key management box, overflow electrostatic controller, toxic gas combustible gas detector, oil filling riser playback detection and gaseous phase pipeline flow detection, sends alarm signal to through the signal cable control system, safety protection module 2 detects situations such as site environment condition, equipment status, personnel's operation to detect or judge dangerous information, and the notice system takes emergency measures.

Through fixed 9 collection jar mouthful positions of vision camera and laser dynamic scanning jar mouthful positions, the form of laser with two kinds of modes sound and static combinations of vision compares the effect, greatly increased anti environmental interference ability. The HMI display module can display the validation data information and can set the error amount according to the actual situation of the tank opening so as to meet the operation requirements of tank cars with different specifications.

The programmable control PLC module carries out loading amount calculation, loading data entry and storage, touch screen text picture control and data exchange, data exchange with an upper computer and data exchange with a card reader;

the constant flow rate control is to control the opening of the valve according to the actual second flow data to keep the flow within the requirement of safe and constant flow rate. The specific implementation mode is as follows through a PID algorithm: output = proportional + integral + derivative.

（M_(t)：<Loop output>，K_C：<Loop gain>，e：<Loop deviation>，M_initial： <Initial value of loop output>) (ii) a By setting the target value on the HMI,the instantaneous flow of the flow is a current value, and an instruction is output to adjust the opening of the valve, so that the closed-loop control of constant flow speed is ensured.

The loading amount calculation is to calculate the actual volume or mass according to the pulse number acquired by the high-speed counter, the volume can be accurately converted into the mass by the real-time temperature compensation of the temperature transmitter and the combination of the standard density value, the compensation coefficient can be set by process control, and the actual loading weight is finally calculated;

the equipment, the loading state and various parameters are in real-time butt joint with an upper computer, and the upper computer sends a loading set quantity command, loading parameters and a card swiping verification result command to the PLC according to the state; data exchange communication with the card reader: whether a card swiping event is generated is detected in real time on a card swiping interface, a card swiping verification result is fed back, so that correct loading information is ensured, the system is provided with a local loading password and a parameter setting password, the operation of corresponding authority personnel is met, and the operation safety is ensured.

The method comprises the following specific operation steps:

1. when the vehicle arrives in the appointed loading area, a driver extinguishes and gets off the vehicle, puts the vehicle key into the key management box, releases the human static electricity, and does not allow the loading operation if the system does not detect the key box signal or the human static electricity release signal.

2. And connecting the electrostatic clamp, inputting the loading amount in the system, or swiping the loading IC card, and recording the loading data by the system.

3. And (4) preparing loading preparation, and automatically checking whether a coordinate origin is established by the system, if the coordinate origin is not established, prompting the system to return to the origin, wherein the return to the origin is executed by a pneumatic motor.

4. After the system establishes the origin of coordinates, a start key is pressed, the visual sensor captures the coordinates of the position of the train tank opening and transmits the position information to the PLC system, the pneumatic motor starts to operate, and meanwhile, the laser sensor also starts to calculate the position. The system isomorphism receives the encoder signal, thereby the current position information of the pneumatic motor is collected in real time. When the pneumatic motor reaches the position above the train tank opening, the system compares the laser sensor data with the visual sensor data, if the error is within an allowable range, the positioning is judged to be successful, and if the error exceeds the allowable range, the positioning is judged to be unsuccessful, and the positioning operation needs to be carried out again.

5. After the positioning is successful, the oil filling riser is automatically placed into a train tank opening, the proximity sensor at the lower part of the sealing cap judges that the oil filling riser is placed in place, the system sends out an instruction, and the pump is opened to start loading. By collecting flow rate information of the flow meter and adjusting the opening of the valve in real time, the constant flow rate loading can be controlled. In the loading process, if overflow or electrostatic alarm occurs, the system stops loading, and after the operation personnel finishes processing, the system can choose to continue loading or finish loading.

6. When the system collects the oil loading amount to reach the set amount, the system stops the pump and closes the valve. The oil filling riser rises to return, and the return sensor sends the signal of returning to the position to the PLC module, and the loading system sends the pneumatic dolly of instruction and gets back to the original point. And the automatic alignment loading is completely finished.

Has the advantages that:

the position of the tank opening of the oil tank truck is searched by automatic calculation and subjected to position validation, then the oil filling riser is accurately fed into the tank opening, constant-current control is adopted, the loading flow rate is detected in real time, logic valve control is carried out, logic pump control and safety interlock protection are carried out, and the functions of automatic alignment and quantitative loading of the oil filling riser are realized.

(1) The system scans through three dimensions and two dimensions, the positioning speed is high, secondary positioning is not needed, the system can automatically compare, vision can be directly positioned, laser is used for verification, if the scanning positions of the two are consistent, the scanning positions are accurate, if the scanning positions are different, an alarm can be given, a worker can scan after confirming again, and safety accidents can be avoided from the source;

(2) the two systems are integrated into one and are connected seamlessly, so that the operation efficiency can be improved, the operation burden is reduced, the whole process system automatically runs only by operating on one system without manual intervention, the operation efficiency and safety are improved, and the error rate of operation is reduced;

(3) the structure of the invention which combines two into one can leave activity space for operators, save the use area of the site, has higher integration level of the site device, and can save the workload of the operators, so an automatic alignment loading system is needed to be designed to solve the problems.

The above are merely preferred embodiments of the present invention.