Fully Automated Control System for Ship Unloader

An industrial-grade Intelligent Operation System centered on 3D real-time perception, multi-axle collaborative control, and a full-link safety closed loop. By leveraging a technological closed loop comprising LiDAR vision, anti-sway algorithms, and redundant positioning, it not only achieves operational efficiency surpassing that of skilled drivers (≥960 t/h) but also implements proactive safety protection across the entire Procedure, providing bulk cargo ports with an efficient, precise, and reliable unmanned ship-unloading solution.

Core System Architecture
3D visual perception system : High-speed multi-line LiDAR + Intelligent Imaging Algorithm, which scans the ship hatch and the material pile inside the cabin in real time, builds a 3D operation scene, and supports automatic point selection and collision avoidance perception.
Intelligent Anti-Sway Control System: Electronic anti-sway model + real-time feedback control: the motion state of the grab is calculated through a mathematical model, achieving smooth tracking and precise landing of the grab.
High-precision positioning system: Incremental + absolute encoder + RFID-assisted positioning, achieving centimeter-level positioning of the main Trolley, auxiliary Trolley, and grab, supporting automatic path planning.

Automation material-grabbing strategy: Fixed-point material grabbing + automatic material grabbing dual mode, supporting driver interaction for point selection and system intelligent decision-making, adapting to various operation scenarios.
Closed-loop security mechanism: Dual hardware-and-software collision avoidance combined with real-time monitoring ensures the safety of equipment, vessels, and personnel, enabling zero-tolerance operations.
Key Features
Intelligent 3D Modeling and Recognition
·Millisecond-level LiDAR scanning enables real-time construction of 3D models of hatch openings and material piles, supporting automatic edge-following entry into the bin and optimal grab-point calculation.

Dual-mode automation material handling
Fixed-point material grabbing: The operator selects points on the 3D map via the touchscreen, and the system automatically executes the sequence of captures.
Automatic material picking: The system Intelligent calculates the optimal material-grabbing point and coordinates with the PLC in real time to achieve fully automatic cyclic operation.
Grab Intelligent Anti-Sway and Trajectory Planning
An electronic anti-sway algorithm based on a kinematic model achieves smooth grab movement and precise landing, supporting “unloading while flying above the hopper”.

High-Precision Positioning and Cooperative Control
The encoder + RFID multi-positioning mechanism ensures the synchronization of the positions of the Trolley, the Grab, and the Cabin, supporting automatic cabin switching and continuous operation.
Full-Process Safety Closed Loop
Three-dimensional collision avoidance + electrical interlocking + real-time monitoring, realizing full-process security protection from perception to execution.

Performance Metrics
The pose recognition speed of the grab is ≤100 ms, which is much faster than human reaction time.

The positioning accuracy of the grab and the hatch recognition accuracy are ≤20 cm, supporting edge-adjacent cabin entry, comparable to manual operations.
The large vehicle positioning accuracy is ≤3 cm, which is higher than that of conventional encoders.
The recognition accuracy of the grab rotation angle is ≤3°, enabling precise attitude control.
In-cabin bucket-throwing control accuracy ≤ 40 cm, enhancing grab efficiency and reducing spillage.
Unloading efficiency (taking the 800-ton class as an example) is ≥960 t/h, surpassing the average level of manual operations and reaching the performance of a skilled operator.
Operational adaptability, enabling near-24/7 operations and reducing the impact of weather and human factors.