Fully automated control system for ship loaders

This system is a multimodal perception and digital twin–based collaborative control platform designed for large-scale bulk cargo loading operations. Leveraging a fused perception architecture integrating millimeter-wave radar and LiDAR, it constructs a real-time, three-dimensional dynamic model of the cargo hold and employs a digital twin simulation decision-making system to achieve fully automated planning and control of the loading process. In response to challenging operating conditions in port loading—such as heavy dust, high humidity, and vessel motion—the system has been robustly engineered, incorporating a machine vision perception system, an anti-collision system, and a comprehensive safety protection framework, thereby realizing end-to-end automation across the entire Procedure, from perception and modeling to decision-making and safety safeguards.

Core System Architecture
Fusion Perception Tier: dual 3D millimeter-wave radars + a 16-line rotating LiDAR, enabling in-cabin material modeling, hull and hatch recognition, pitch and roll angle detection, and all-weather anti-interference perception.
Decision Simulation Tier: Digital Twin Real-Time Simulation Platform + Intelligent Control Algorithms, including task path planning, collision avoidance decision-making, dynamic calculation of load balance, and system rehearsal and optimization.
Execution Control Tier: Fully Automatic Control System + Collaborative Communication Interface, enabling automatic cabin switching, seamless integration with stacker-reclaimers and the Procedure system, 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 protection, visual supervision of the operation process, and multi-layered safety redundancy—product features.

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

Intelligent Balance Control
Automatically calculates and adjusts the balance between the ship’s port and starboard sides and its stern, ensuring loading safety and navigational Stability.
All-weather environmental adaptability
Sensors and algorithms are optimized for high-dust and high-humidity conditions, ensuring continuous, stable operation in complex environments.
Human–Machine Collaboration and Safety Closed Loop
By integrating digital twin simulation with CCTV surveillance, we achieve end-to-end security and controllability across the entire chain—perception, decision-making, execution, and oversight.

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

Crash protection range:
Three-dimensional full‑coverage, with no blind spots in monitoring.
Supports interoperation with the stacker-reclaimer and the Procedure control system.
Environmental adaptability:
Suitable for dusty environments, humid conditions, nighttime operations, and low-visibility scenarios.