Design of a Hybrid ActivePassive Control Robotic System for Coupler Unhooking in Thermal Power Plant Wagon Tippers

NAVIGATE

Table of Contents

STATISTICS

Viewed6

Downloads16

Design of a Hybrid ActivePassive Control Robotic System for Coupler Unhooking in Thermal Power Plant Wagon Tippers

PDF下载 (16)

[1]QIU Yi,GUO Liubing,LIANG Jie.Design of a Hybrid ActivePassive Control Robotic System for Coupler Unhooking in Thermal Power Plant Wagon Tippers[J].Journal of Zhengzhou University (Engineering Science),2027,48(XX):1-9.[doi:10.13705/j.issn.1671-6833.2026.02.010]

Copy

Journal of Zhengzhou University (Engineering Science)[ISSN 1671-6833/CN 41-1339/T] Volume: 48 Number of periods: 2027 XX Page number: 1-9 Column: Public date: 2027-12-10

Title:: Design of a Hybrid ActivePassive Control Robotic System for Coupler Unhooking in Thermal Power Plant Wagon Tippers

Author(s):: QIU Yi, GUO Liubing, LIANG Jie; School of Mechanical and Power Engineering, Zhengzhou University, Zhengzhou 450001, China

Keywords:: hook-unloading robot; active-passive hybrid configuration; D-H method; line laser displacement sensor

CLC:: TP242.2；TP273

DOI:: 10.13705/j.issn.1671-6833.2026.02.010

Abstract:: To address the issues of harsh environmental conditions, high labor intensity, and safety risks in manual hook removal operations at thermal power plant tipper unloading systems, this paper proposed a tipping machine hook removal robot with a hybrid active-passive control configuration. First, the mechanical structure of the robot was designed, consisting of three active moving joints, one active rotating joint, one passive moving joint, and one passive rotating joint. The movement adaptability of the passive structure was analyzed using a graphical method, and the forward and inverse kinematic models of the entire system were established using the D-H method, providing a theoretical foundation for motion control. In terms of the control system, a hardware architecture was designed, and a hook handle recognition algorithm was proposed, based on measurement data from a linear laser displacement sensor. This algorithm was used to obtain the position information P_1(x_1,z_1) between the end effector and the hook handle, enabling precise positioning and gripping of the hook handle. A pilot test was conducted to verify the effectiveness of the proposed solution. The results showed that out of 50 hook removal operations, the robot achieved a 100% success rate, with all joint torques remaining within the rated limits. The average time for high-position hook removal was 25 seconds, while it was 30 seconds for low-position hooks, both meeting the production requirements. The maximum instantaneous torque at each joint was 62.1 N·m, which accounted for only 43.7% of the system’s limit, demonstrating sufficient safety margin. The experimental results reflected the robot’s adaptive ability to handle trajectory uncertainties of hooks, allowing it to accommodate deviations in the path of different models or variations of the same model. Furthermore, the precision of the proposed recognition algorithm was validated.

References:: [1] 中能传媒研究院. 中国能源大数据报告[EB/OL]. (2023-06-20)[2024-07-20]. https://news.bjx.com.cn/html/20230620/1313822.shtml. China Energy Media Research Institute. China Energy Big Data Report (2023)[EB/OL]. (2023-06-20)[2024-07-20]. https://news.bjx.com.cn/html/20230620/1313822.shtml.
[2] Sun Wenqiao, Ye Fei, Xin Shuli. Connotations and paths of intelligent transformation of railway marshalling stations[J]. Railway Transport and Economy, 2023, 45(8): 75-80. [孙文桥, 叶飞, 辛姝丽. 铁路编组站智能化转型发展内涵及路径探讨[J]. 铁道运输与经济, 2023, 45(8): 75-80.]
[3] Zhang Yuanbo. Design of railway automatic unhook robot and visual inspection of couplers[D]. Shenyang: Shenyang University of Technology, 2020. [张渊博. 铁路自动摘钩机器人设计及车钩视觉检测[D]. 沈阳: 沈阳工业大学, 2020.]
[4] Nold M, Corman F. Dynamic train uncoupling and decoupling at cruising speed: systematic classification, operational potentials, and research agenda[J]. Journal of Rail Transport Planning & Management, 2021, 18: 100241.
[5] Zhang Suobin. The design and manufacture of automatic uncoupling robot model[D]. Chengdu: Southwest Jiaotong University, 2017. [张所斌. 自动摘钩机器人模型的设计与制作[D]. 成都: 西南交通大学, 2017.]
[6] Feng Yu. Research on automatic train disassemble system of hump marshalling station[D]. Shijiazhuang: Shijiazhuang Tiedao University, 2020. [冯宇. 驼峰编组站列车自动分解系统研究[D]. 石家庄: 石家庄铁道大学, 2020.]
[7] Li Jidong. Key technologies research on automatic uncoupling system of hump pushing[D]. Beijing: China Academy of Railway Sciences, 2022. [李继东. 驼峰推峰自动摘钩系统关键技术研究[D]. 北京: 中国铁道科学研究院, 2022.]
[8] Sun Cheng. The visual tracking and control for a train uncoupling robot[D]. Harbin: Harbin Engineering University, 2018. [孙程. 火车摘钩机器人的视觉跟踪及控制[D]. 哈尔滨: 哈尔滨工程大学, 2018.]
[9] Guo Renjie. System design and key technology research of train uncoupling robot[D]. Beijing: University of Chinese Academy of Sciences, 2023. [郭仁杰. 火车摘钩机器人系统设计与关键技术研究[D]. 北京: 中国科学院大学, 2023.]
[10] Laroca R, Boslooper A C, Menotti D. Automatic counting and identification of train wagons based on computer vision and deep learning[PP/OL]. (2020-10-30)[2025-06-08]. https://doi.org/10.48550/arXiv.2010.16307.[10] Laroca R, Boslooper A C, Menotti D. Automatic counting and identification of train wagons based on computer vision and deep learning[PP/OL]. V1. arXiv (2020-10-30)[2025-06-08]. https://doi.org/10.48550/arXiv.2010.16307.
[11] Wu Jinhui, Tao Yourui. Review on research status of positioning accuracy reliability of industrial robots[J]. China Mechanical Engineering, 2020, 31(18): 2180-2188. [吴锦辉, 陶友瑞. 工业机器人定位精度可靠性研究现状综述[J]. 中国机械工程, 2020, 31(18): 2180-2188.]
[12] Cao Wenwei. Research on the application of automatic unhooking manipulator for railway train marshalling hump station based on ROS[D]. Shenyang: Northeastern University, 2021. [曹文伟. 基于ROS的铁路列车编组驼峰工位自动摘钩机器人应用研究[D]. 沈阳: 东北大学, 2021.]
[13] Luan Dejie, Feng Jun, Yang Huachang, et al. Path planning algorithm for automatic hump uncoupling robot based on improved RRT[J]. Railway Transport and Economy, 2023, 45(1): 30-38. [栾德杰, 冯军, 杨华昌, 等. 基于改进RRT的驼峰自动摘钩机器人路径规划算法[J]. 铁道运输与经济, 2023, 45(1): 30-38.]
[14] Liu Zhiquan, Wei Leilei, Ni Wenbo, et al. Design and experiment of train uncoupling robot[J]. Machine Tool & Hydraulics, 2024, 52(21): 14-19. [刘治权, 韦蕾蕾, 倪文波, 等. 列车摘钩机器人的设计与试验[J]. 机床与液压, 2024, 52(21): 14-19.]
[15] Yuan Quan, Ma Dong, Liang Jianquan. Scheme design and device research on automatic decoupling of railway freight cars[J]. China Plant Engineering, 2023(19): 131-133. [袁泉, 马冬, 梁建全. 铁路货车自动脱钩方案设计及装置研究[J]. 中国设备工程, 2023(19): 131-133.]
[16] Jiang Yuanhua, Shao Zezhan, Xu Zhanying, et al. General framework design and key technologies of intelligent marshalling station[J]. China Railway, 2024(11): 118-127. [蒋元华, 邵泽展, 许展瑛, 等. 智能编组站总体框架设计及关键技术[J]. 中国铁路, 2024(11): 118-127.]
[17] Liu Lei, Wang Ye, Tian Changhe, et al. Train connection handle recognition method based on YOLOv5 and its application in automatic unhook machine[J]. Science Technology and Engineering, 2025, 25(4): 1563-1572. [刘雷, 王野, 田长河, 等. 基于YOLOv5的火车连接手柄识别方法及在自动摘钩机器的应用[J]. 科学技术与工程, 2025, 25(4): 1563-1572.]
[18] Liao Zixuan, Wu Jianhua, Zhou Tieliang, et al. Compliance control in automatic uncoupling robot system[J]. Science Technology and Engineering, 2023, 23(18): 7838-7843. [廖梓轩, 吴建华, 周铁梁, 等. 机器人自动摘钩系统中柔顺控制方法研究[J]. 科学技术与工程, 2023, 23(18): 7838-7843.]
[19] Tu Qing, Liu Qingyou, Ren Tao, et al. Obstacle crossing and traction performance of active and passive screw pipeline robots[J]. Journal of Mechanical Science and Technology, 2019, 33(5): 2417-2427.
[20] Yan Daliang. Research on dynamic parameter identification and trajectory tracking control of heavy-duty robot[D]. Nanjing: Nanjing University of Aeronautics and Astronautics, 2021. [严大亮. 重载机器人动力学参数辨识与轨迹跟踪控制研究[D]. 南京: 南京航空航天大学, 2021.]
[21] Peng Jinzhu, Zhang Jianxin, Zeng Qingshan. Inverse kinematic parameters calibration of 3-RPS parallel robot based on modified differential evolution[J]. Journal of Zhengzhou University (Engineering Science), 2022, 43(5): 1-7. [彭金柱, 张建新, 曾庆山. 基于改进差分进化的3-RPS机器人逆运动学参数标定[J]. 郑州大学学报(工学版), 2022, 43(5): 1-7.]
[22] Yang Sibo, Luo Lincong, Law W C, et al. Design and evaluation of a compact 3D end-effector assistive robot for adaptive arm support[J]. IEEE Transactions on Robotics, 2024, 40(3): 123-135.
[23] Yuan Peixin, Cai Da, Cao Wenwei, et al. Train target recognition and ranging technology based on binocular stereoscopic vision[J]. Journal of Northeastern University (Natural Science), 2022, 43(3): 335-343. [原培新, 蔡妲, 曹文伟, 等. 基于双目立体视觉的列车目标识别和测距技术[J]. 东北大学学报(自然科学版), 2022, 43(3): 335-343.]
[24] Zhao Hongnan, Jiang Wensong, Yang Li, et al. Correction method for edge deviation of line laser sensor[J]. Infrared and Laser Engineering, 2022, 51(4): 324-330. [赵洪楠, 江文松, 杨力, 等. 线激光传感器的边缘偏差修正方法[J]. 红外与激光工程, 2022, 51(4): 324-330.]
[25] Luo Fuwen, Wang Xuemei, Ni Wenbo, et al. Visual detection system of uncoupling manipulator in hump marshalling yards[J]. Journal of Railway Science and Engineering, 2025, 22(9): 4145-4159. [罗涪文, 王雪梅, 倪文波, 等. 驼峰编组站摘钩机械臂视觉检测系统研究[J]. 铁道科学与工程学报, 2025, 22(9): 4145-4159.]
[26] Cao Jinqi, Han Xuesong. Review of research methods for industrial robot trajectory planning[J]. Information and Control, 2024, 53(4): 471-486. [曹锦旗, 韩雪松. 工业机器人轨迹规划的研究方法综述[J]. 信息与控制, 2024, 53(4): 471-486.]

Similar References:

Memo

Last Update: 2026-05-08