Full automation control system for bucket-wheel excavators

The fully autonomous operation system for bucket-wheel stacker-reclaimers, based on multi-sensor fusion positioning, real-time 3D dynamic modeling, and adaptive control algorithms, achieves unmanned, precision operations throughout the entire stacking and reclaiming process through high-precision integrated positioning, multiple redundancy safeguards, and real-time environmental perception. It supports multi-mode adaptive operations and remote visual intervention, adapts to complex and harsh industrial environments, and provides a highly reliable, high-efficiency bulk material handling solution for smart ports.

Core System Composition: High-Precision Positioning System

Large‑carriage mechanism: dual calibration using RFID and an absolute encoder
Rotary mechanism: multi-turn absolute encoder + inductive proximity switch for calibration
Pitch mechanism: absolute encoder + redundant angle sensor
Beidou RTK-GNSS: Centimeter-Level 3D Positioning

Intelligent Anti-Collision and Monitoring System

Heavy Vehicle Collision Avoidance: Laser Scanning Combined with Visual/Ultrasonic Redundant Sensing
Boom collision prevention: dual-side laser scanners
Level Measurement: High-Frequency Radar Level Meter with Vertical Adaptive Detection

Real-time Modeling and Monitoring System

Real-time 3D modeling using laser-scanned point clouds and pose data
14-channel HD video surveillance, providing full coverage of key operational points.

Fully Automatic Operation Control System

Supports multiple modes, including large flat-tier material retrieval, segmented retrieval, bottom-push material retrieval, and rotary/linear fixed-point stacking.
Seamless manual–automatic switchover, with support for remote intervention.

Key Features: Fully Automatic Positioning and Path Tracking

Automatically calculates workstations based on the material stack model and supports “forced positioning” for rapid resumption of operations.

Multi-mode adaptive material retrieval
Various material-retrieval strategies, such as large flat tiers, segmentation, and bottom-layer pushing, adapt to different Stack yard operating conditions.

Intelligent Stacking Control
Various stacking modes, such as rotary fixed-point and traveling fixed-point layering, as well as single-pass material stacking, ensure neat and controllable stack configurations.

Real-time 3D Modeling and Updating
Laser scanning combined with Beidou positioning enables dynamic modeling of material stacks and inventory counting.

Multi-layered security protection
Laser, vision, and ultrasonic multi-sensor collision avoidance with real-time alerts and shutdown protection.

Remote Visual Control
Full HD video coverage, with support for remote manual intervention and monitoring.

Performance Metric: Positioning Accuracy

Large vehicle ±5mm
Rotation ±0.1°
Pitch ±0.05°

Beidou positioning accuracy
Plane ±2 cm
Elevation accuracy: ±3 cm (in RTK differential mode)
Material level detection accuracy: ±2 cm

System response time
From command issuance to execution ≤ 500 ms