Fully automated control system for ship unloaders

An industrial-grade Intelligent operating system centered on three-dimensional real-time perception, multi-axle collaborative control, and a full‑link safety closed loop. By integrating LiDAR vision, anti-sway algorithms, and redundant positioning into a technical closed loop, it not only achieves operational efficiency surpassing that of skilled drivers (≥960 t/h) but also provides proactive safety protection across the entire Procedure, offering bulk‑cargo ports an efficient, precise, and reliable unmanned ship‑unloading solution.

Core System Architecture
3D visual perception system : High-speed multi-line LiDAR + Intelligent imaging algorithms, enabling real-time scanning of ship hatchways and onboard material piles, constructing a three-dimensional operational scene, and supporting automatic point selection and collision-avoidance sensing.
Intelligent Anti-Sway Control System: Electronic anti-sway model + real-time feedback control: by calculating the grab’s motion state through a mathematical model, it achieves smooth tracking and precise positioning.
High-Precision Positioning System: Incremental + absolute encoder + RFID-assisted positioning, enabling centimeter-level positioning of the Trolley, the Small Car, and the grab, while supporting automatic path planning.

Automation-based material-grabbing strategy: Fixed-point material grabbing + automatic material grabbing dual mode, supporting driver‑interactive point selection and system‑intelligent decision‑making, adapting to various operational scenarios.
Full closed-loop security mechanism: Dual hardware-and-software collision avoidance, coupled with real-time monitoring, ensures the safety of equipment, vessels, and personnel, enabling zero-tolerance operations.
Key Features
Intelligent 3D Modeling and Recognition
·Lidar performs millisecond‑level scanning to construct real‑time 3D models of the chute and material pile, enabling automatic edge‑following entry into the chute and optimal grab‑point calculation.

Dual-mode automation material handling
Fixed-point material collection: The operator selects a point on the 3D map via the touchscreen, and the system automatically executes the sequence‑based picking operation.
Automatic material grabbing: The system Intelligent calculates the optimal material-grabbing point and coordinates with the PLC in real time to achieve fully automated cyclical 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 “overhead flight unloading.”

High-Precision Positioning and Cooperative Control
The encoder + RFID multi-positioning mechanism ensures synchronization of the Trolley, the Small Car, and the grab, supporting automatic cabin switching and continuous operation.
End-to-end security closed loop
Three-dimensional collision prevention + electrical interlocking + real-time monitoring ensure end-to-end security from perception to execution.

Performance Metrics
Grab pose recognition speed ≤ 100 ms, far exceeding human eye reaction time.

The grab’s positioning and hatch recognition accuracy is ≤20 cm, supporting edge‑aligned entry into the compartment, comparable to manual operations.
The positioning accuracy of the large vehicle is ≤3 cm, which exceeds that of conventional encoders.
The grab rotation angle recognition accuracy is ≤3°, enabling precise attitude control.
In-cabin drop‑bucket control accuracy is ≤40 cm, enhancing picking efficiency and minimizing spillage.
Unloading efficiency (taking the 800‑t class as an example) ≥ 960 t/h, surpassing the average level of manual operations and reaching the proficiency of a skilled operator.
Operational adaptability, enabling near‑all‑weather operations and minimizing the impact of weather and human factors.