Full Automation Control System for Bucket Wheel Stacker-Reclaimer

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 and precise operations throughout the entire stacking and reclaiming process through high-precision integrated positioning, multiple redundancy protections, 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 and efficient bulk material handling solution for smart ports.

Core System Components: High-Precision Positioning System

Large Vehicle Mechanism: Dual Calibration with RFID and Absolute Encoder
Rotary mechanism: multi-turn absolute encoder + inductive proximity switch for calibration
Pitch and Yaw Mechanism: Absolute Encoder + Redundant Angle Sensor
Beidou RTK-GNSS: Centimeter-Level 3D Spatial Positioning

Intelligent Anti-collision and Monitoring System

Heavy Vehicle Collision Avoidance: Laser Scanning with Vision/Ultrasonic Redundant Detection
Boom collision avoidance: dual-side laser scanners
Level Detection: High-Frequency Radar Level Meter with Vertical Adaptive Detection

Real-Time Modeling and Monitoring System

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

Fully Automated Operation Control System

Supports various modes such as large-flat-tier material retrieval, segmented material retrieval, bottom-push material retrieval, and rotary/traveling fixed-point stacking.
Seamless manual-to-automatic switchover with remote intervention support.

Key Feature: 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 flat-layer, sectional, and bottom-push approaches, are available to suit different Stack yard operating conditions.

Intelligent Stacking Control
Various stacking modes such as rotary fixed-point stacking, traveling fixed-point layered stacking, and single-pass material stacking, with neat and controllable stack patterns.

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

Multiple Security Protections
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)
Level detection accuracy: ±2 cm

System response time
From command issuance to execution ≤500 ms