Fully Automated Control System for Ship Loaders

This system is a multimodal perception and digital twin collaborative control platform for large-scale bulk cargo loading operations. Based on a millimeter-wave radar plus LiDAR fusion perception architecture, it constructs a real-time 3D dynamic model of the cargo hold and uses a digital twin simulation decision-making system to achieve fully automated planning and control of the loading process. In response to the complex operating conditions in port loading operations—such as heavy dust, high humidity, and ship motion—the system has been robustly designed, with the establishment of a machine vision perception system, an anti-collision system, and a safety protection framework, thereby realizing end-to-end automation spanning perception, modeling, decision-making, and safety protection.

Core System Architecture
Fusion perception tier: dual 3D millimeter-wave radar + 16-line rotary LiDAR, cabin material modeling, hull and hatch recognition, longitudinal and transverse tilt angle detection, all-weather anti-interference perception
Decision-making simulation tier: digital twin real-time simulation platform + Intelligent control algorithms, including task path planning, collision avoidance decision-making, dynamic calculation of loading balance, and system rehearsal and optimization.
Execution Control Tier: Fully Automatic Control System + Collaborative Communication Interface, enabling automatic cabin switching, interoperation with stacker-reclaimers and Procedure systems, and precise execution of loading commands.
Safety protection tier: 1D/2D millimeter-wave radar three-dimensional envelope collision avoidance + CCTV real-time monitoring, fully closed-loop collision avoidance protection, visible supervision of the operation process, and multi-layer safety redundancy product features.

Key Features
High-Precision 3D Recognition and Modeling
By integrating millimeter-wave radar with LiDAR, the system achieves a hatch boundary detection accuracy of ±6 cm and supports real-time measurement of a vessel’s longitudinal and transverse trim as well as its heading angle.
Fully automated Procedure
Supports automatic whole-cell scanning, automatic cell switching, in-cell material matching, and coordinated optimization of operation takt with upstream equipment.

Intelligent Balance Control
It automatically calculates and adjusts the balance between the ship’s port and starboard sides and the stern to ensure loading safety and航行稳定性.
All-weather environmental adaptability
Sensors and algorithms are optimized for high-dust and high-humidity conditions, ensuring continuous and stable operation in complex environments.
Human-Machine Collaboration and Safety Closed Loop
By integrating digital twin simulation with CCTV surveillance, end-to-end security and controllability are achieved across the entire “perception–decision–execution–monitoring” loop.

Performance Metrics
Hatch recognition accuracy: ±6 cm
Shipping efficiency improved by 8% to 10%.
Real-time modeling and recognition, with support for dynamic tracking.

Crash protection range:
Three-dimensional full-envelope monitoring with no blind spots.
Supports interlocking with stacker-reclaimers and Procedure Control Systems.
Environmental adaptability:
Suitable for dusty, humid, nighttime, and low-visibility conditions.