WO2005012072A1

WO2005012072A1 - Coal cleaning robot system and method thereof

Info

Publication number: WO2005012072A1
Application number: PCT/KR2003/002908
Authority: WO
Inventors: Haengsoon Yoon; Hoki Nam; Sukbu Jong; Moonchang Ji
Original assignee: Korea South-East Power Co., Ltd.
Priority date: 2003-08-04
Filing date: 2003-12-31
Publication date: 2005-02-10
Also published as: AU2003289578A1; KR100545733B1; KR20050016927A

Abstract

A residual coal removing robot system in accordance with the present invention for use in removing residual coal in a collier comprises a cabin, an input controller, a crane arm, a crane controller, an excavator arm, an excavator controller, an RF receiver, a remote controller, a dozer arm, a dozer controller, a sweeper arm, a sweeper controller, an upper rotational part, a lower cruising part and a main controller.

Description

COAL CLEANING ROBOT SYSTEM AND METHOD THEREOF

Technical Field The present invention relates to a coal cleaning robot system and method thereof; and, more particularly, to a coal cleaning robot system, for use with a collier to unload coals to a power plant, for automatically collecting and removing coal residues through a manual/remote control and a coal cleaning method of the coal cleaning robot system.

Background Art

A thermoelectric power plant widely uses coals as fuel for generating electric power and is usually located at a seaside in order to facilitate the transportation of the coals as fuel. Since the coals used as fuel in domestic thermoelectric power plant are generally imported, the coals may be transported with a collier by sea. If the collier reaches an exclusive quay located to the seaside, heaped coals are unloaded from the collier by using a continuous ship unloader (CSϋ) . Fig. 1A describes a work of unloading the coals by using the CSU. Referring to Fig. 1A, the work of unloading the coals are performed with a CSU 100, a collier 110, hatches 120, a screw 130 and an outlet 140. The collier 110 typically includes about nine hatches

120 each accommodating coals therein. The coals heaped in the collier 110 are shifted through the CSU 100 to a conveyor belt, and are transferred through the conveyor into a coal storage yard. If one collier 110 berths at a quay, the coals are conventionally unloaded by using two CSUs 100, as shown in Fig. 1A. Each of two CSUs 100 performs the unloading of coals sequentially from outermost hatches 120 toward inner hatches 120 in order, so as to maintain a balance of the collier 110. Fig. IB describes the work of unloading the coals from the collier through the CSU onto the conveyor belt. The coals heaped in the hatches 120 of the collier 110 are lifted up from the hatches 120 by using the screw 130 provided in the CSU 100 and are transferred to the outlet

140 connected to the conveyor belt. In general, the unloading work is divided into three steps. The first step is to stevedore the coals heaped in the hatch 120 by using the CSU 100 only. By the time the coals in the hatch 120 are discharged to a certain extent, for example, the coals in the hatch 120 are left with a height of about 2 to 3 m from the bottom of the hatch 120, it becomes difficult to stevedore the coals by using the CSU 100 alone, so that an additional equipment may be required to continue to unload the coals. In the second step, a shovel truck or a palyloader is used for performing shoveling, lifting and discharging works to assist the coal unloading work of the CSU 100. That is, after a considerable amount of coals are discharged from the collier 110, the payloader is put into the hatch 120 to collect coal residues near the screw 130 of the CSU 100, thereby facilitating the automatic unloading of coals by the CSU 100. When the coals are left with a height of about 1 to 2 from the bottom of the hatch 102, the third step is begun. In the third step, the CSU 100 is withdrawn from the hatch 120 of the collier 110, and workers enter the hatch 120, so that, in cooperation with the payloader, the workers collects the coal residues in, for example, a bag, to discharge it outside and cleans the hatch 120. The coals unloading work in the collier 110 as described above is described in Table 1. Table 1

While the first step involving the CSU 100 only can be performed conveniently because the CSU 100 can be controlled by using a wired or a wireless control mechanism, the second and the third step require workers for operating the payloader and for removing the coal residues to stay inside the hatch 120, which is problematic in that working environment in the hatch 120 is very poor due to dust of coals, noise, and the like. Further, since workers should work along with the payloader in the third step, there is a high likelihood that the workers get injured. Particularly, since the thermoelectric power plant continuously runs 24 hours a day, the stevedoring work of coals must sometimes be continued even at night. Accordingly, it is problematic the increased fatigue of the workers due to the night shift work may in turn increase the possibility of accident. However, in order to solve the above problem, extra workers may be added to be stationed in three shifts. The input of extra workers, however, may exact more labor expense and exposes more workers to accidents, thereby resulting in an increase of the expense of the coal unloading. Accordingly, in order to collect the coals and to remove the coal residues in the collier 110, an equipment has been required for removing coal residues in the hatch 120 without exacting extra workers force, in addition to simple functions for shoveling, lifting and discharging conventionally provided by a payloader, but such equipment has not been developed. Further, since the work conditions inside the hatch 120 are very poor, such equipment should be remotely controlled and is preferably capable of being boarded by an operator for manually manipulating the equipment, if necessary, but there has been developed no equipment satisfying all' these requirements. Meanwhile, at colleges and laboratories, automation technologies for the heavy machinery among ^' the conventional industrial control system have been actively studied and developed, but such technologies have been mainly focused on a stationary robot for manufacturing the automobile in automobile manufacturer, a building automation robot or a human-like robot. Furthermore, mass production of the specific heavy machinery has not been achieved due to its inherent characteristics and, therefore, the heavy machinery has to be tailor-made to satisfy particular objects and performances required in each field. Since, however, the domestic market size is still small and the automation and robot system for the heavy machinery is not widely required, an equipment for automatically collecting and removing coal residues in a collier 110 has not been developed.

Disclosure of the Invention

It is, therefore, an object of the present invention to provide a coal cleaning robot system, for use with a collier to unload coals to a power plant, for collecting and removing coal residues and a method thereof. In accordance with an embodiment of the present invention, there is provided a coal cleaning robot system for use in collecting and removing coal residues, the coal cleaning robot system being manually or remotely controlled by an operator comprising: a steering part for steering an operation of the coal cleaning robot system; an input controller for inputting data involving input command for use in a manipulation of the steering part; a crane arm for removing out coal residues; a crane controller for controlling an operation of the crane arm; an excavator arm for use in evacuating the coal residues; an excavator controller for controlling an operation of the excavator arm; a dozer arm for shoving and dipping up the coal residues; a dozer controller for controlling an operation of the dozer arm; a sweeper arm for collecting or suctioning the coal residues; a sweeper controller for controlling an operation of the sweeper arm; an upper rotational part for rotating the crane arm, the evacuator arm and the sweeper arm; a lower cruising part, hinge-connected to the upper rotational part to support the upper rotational part, for cruising the coal cleaning robot system back and forth and/or rightwards and leftwards; and a main controller for transferring a control signal to the crane controller, the excavator controller, the dozer controller and the sweeper controller by using a steering signal inputted from the steering part, and for controlling a rotation operation of the upper rotational part and a cruising operation of the lower cruising part. In accordance with another embodiment of the present invention, there is provided a method of cleaning coal residues by using a coal cleaning robot system for use in collecting and removing coal residues, wherein the system is manually or remotely controlled by an operator, the method comprising the steps of: (a) applying an electric power to ready the coal cleaning robot system for operation; (b) determining if a steering signal for operating an element of the coal cleaning robot system is received from a steering part; (c) transferring a compressed oil to a controller of the element to be operated by the -steering signal; and (d) controlling a fine operation of the element by means of the compressed oil. In accordance with still another embodiment of the present invention, there is provided a remote control transmitter for remotely controlling a coal cleaning robot system to input a command for collecting coals and removing a coal residues, the remote control transmitter comprising: a steering lever portion for outputting a manipulation command depending on an manipulation of an operator as an analog signal; a manipulation button portion provided with a plurality of buttons for inputting the operation command therewith; a key input processor for converting an analog- type manipulation signal inputted from the steering lever portion and command data inputted from the manipulation button portion into a corresponding analog-type command signal; a RF transmitter for converting the command and/or the manipulation signal inputted from the key input processor into a radio frequency signal and radio- transmitting the radio frequency signal through an antenna towards the air; and a power battery for providing a power required to operate the remote control transmitter.

Brief Description of the Drawings

The above and other objects and features of the present invention will become apparent from the following description of preferred embodiments given in conjunction with the accompanying drawings, in which: Fig. 1A illustrates a work of unloading coals by using a CSU; Fig. IB describes a work of unloading coals from the collier through the CSU to a conveyor belt; Fig. 2 is a schematic block diagram of a coal cleaning robot system for removing coal residues in accordance with a preferred embodiment of the present invention; Fig. 3 provides a schematic inner configuration of a RF control transmitter for controlling remotely the coal cleaning robot system in accordance with the preferred embodiment of the present invention; Fig. 4A shows a lateral view of the coal cleaning robot system in accordance with the preferred embodiment of the present invention; Fig. 4B offers a front view of the coal cleaning robot system in accordance with the preferred embodiment of the present invention; Fig. 5 is a schematic view of a manipulation panel of the remote control transmitter for manipulating the coal cleaning robot system remotely; Fig. 6 presents a flow chart for an operation control process of a crane arm in a coal cleaning method of the coal cleaning robot system in a preferred embodiment of the present invention; Fig. 7 illustrates a flow chart for an operation control process of an excavator arm of the coal cleaning robot system in accordance with the preferred embodiment of the present invention; and Fig. 8 depicts a flow chart for an operation control process of a dozer arm and a sweeper arm of the coal cleaning robot system in accordance with the preferred embodiment of the present invention.

Best Mode for Carrying Out the Invention

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Here, like reference numerals represent like parts in various drawings. Further, it is notable that detailed description of known parts or functions will be omitted if there is a concern that the description of such parts or functions would render the technical essence of the present invention obscure. Fig. 2 is a block diagram for representing a schematic construction of a coal cleaning robot system 200 for removing coal residues in accordance with the present invention. The coal cleaning robot system 200 of the present invention includes a cabin 210, an input controller 212, a crane arm 220, a crane controller 222, an excavator arm 230, an excavator controller 232, a RF receiver 240, a remote controller 242, a dozer arm 250, a dozer controller 252, a sweeper arm 260, a sweeper controller 262, an upper rotational part 270, a lower cruising part 280, a main controller 290 and so on. In the coal cleaning robot system 200 constructed above, the crane arm 220, the excavator arm 230, the dozer arm 250 and the sweeper arm 260 are operated and controlled by means of a hydraulic pressure. The hydraulic pressure is adequate for providing a powerful force required by such elements. The hydraulic pressure provides the powerful force and, further, is suitable for a switching manipulation, i.e., a closing and opening manipulation, when involving hydraulic valves which are capable of easy control of the respective elements. Further, since each valve in a hydraulic system may be electrically controlled, a radio control thereof may be easily implemented. The cabin 210 includes a steering device for manually control the coal cleaning robot system 200 by an operator boarded on the cabin 210. The coal cleaning robot system 200 of the present invention may be not only manually but also remotely controlled. In case of manual control, the operator boards on the cabin 210 and controls steering levers and manipulation buttons (not shown) provided in the cabin 210 to operate respective functional elements. The input controller 212 is used to input an input command as data according to a manipulation of the steering levers and the manipulation buttons in the cabin 210. The input controller 212 inputs the input command from the steering levers to the main controller 290 as an analog signal and the input command from the manipulation buttons to the main controller 290 as digitally converted data. The crane arm 220 is used to remove the coal residues attached on a bottom and an inner wall of the hatch 120. Conventionally the coal residues attached on the bottom and the wall of the hatch 120 have been manually removed by workers with a brush attached on a long rod, while the crane arm of the present invention is used to easily remove the coal residues on the bottom and the wall of the hatch 120. The crane arm 220 includes a wall cleaning brush (not shown) and a water injection valve (not shown) which is used to inject water on the wall of the hatch 120 to remove the coal residues attached on the wall. If necessary, an air gun (not shown) may be provided therein so that a compressed air may be injected from the air gun to remove the coal residues attached on the wall of the hatch 120. The crane controller 222 controls an operation of the crane arm based on a control signal of the main controller 290. In other words, the crane controller 222 adjusts the height/length of the crane arm 220 as long as required to clean the wall of the hatch 120 or controls a rotational operation of the cleaning brush. The excavator arm 230 is an element used to dig or excavate the coals and is hinge-connected to the upper rotational part 270. The excavator controller 232 controls an operation of the excavator arm 230 based on the control signal of the main controller 290. The excavator controller 232 controls the excavator arm 230 either in a power mode or a work mode to facilitate a removing work. In the power mode, the excavator arm 230 is operated at a first speed mode, i.e., a light work engine output mode, in which a fuel efficiency is primarily considered, a second speed mode of a normal work engine output mode, and a third speed mode to perform a great deal of work in a short time. In the work mode, a part of work execution scheme is automated to facilitate the steering, and a horizontal work mode, an excavation work mode and a pivot priority work mode and so on may be divided. The horizontal work mode is a mode for horizontally moving the excavator arm 230 to perform an excavation work, the excavation work mode is a mode for performing a normal standard excavation work, and the pivot priority work mode is a mode for rotating the excavator arm 230 during the excavation work. The RF receiver 240 is a device for receiving a remote control signal generated by a remote control of the coal cleaning robot system 200 by an operator. The' remote controller 242 amplifies the remote control signal received to RF receiver 240, converts the amplified signal to digital data and transfers the digital data to the main controller 290. The excavator arm 230 may be operated by a manual control or a remote control. In the manual control, the operator manipulates the steering lever provided in the cabin 210 to operate the excavator arm 230. In other words, the manipulation of the steering lever causes a manipulation signal to be generated in the input controller 212 and to be applied to the main controller 290, so that the main controller 290 may apply a control signal corresponding to the manipulation signal to the excavator controller 232, which controls a hydraulic valve to operate the excavator arm 230. In the remote control of the excavator arm 230, a remote control signal generated by a remote manipulation of the operator is received to the RF receiver 240 and transferred through the remote controller 242 to the main controller 290. Therefore, the main controller 290 transfers the control signal to the excavator controller 232 so that the excavator controller 232 may operate the excavator arm 230 similarly as the manual control thereof. The dozer arm 250 is hinge-connected to the lower cruising part. The dozer arm 250 performs a work for shoving and dipping up the coals . The dozer controller 252 controls an operation of the dozer arm based on the control signal of the main controller 290. In other words, the dozer controller 252 controls the dozer arm 250 to be in contact with the coals to shove the coals thereby or controls the dozer arm 250 to be lifted up and down. The dozer arm 250 is operated by a manipulation of the steering lever provided in the cabin 210 similarly as the excavator arm 230. In case of the manual control, the operator manipulates a converting switch (not shown) provided in the cabin 210 so that the work of the excavator arm 230 is converted to a work of the dozer arm 250. In case of the remote control, the operator manipulates a manipulation panel (shown later) provided in the cabin 210 so that an excavation mode may be converted to a dozer mode. The remote control is performed by an electronic proportional control valve controlled by the main controller 290. The sweeper arm 260 is useful for removing the coal residues in the collier and includes a brush form for sweeping to collect the coal residues and a suction form for suctioning the coal residues. In other words, when the coal cleaning robot system 200 is cruises on the bottom of the hatch 120 to remove the coal residues remained on the bottom of the hatch 120, the sweeper arm 260 performs a work for sweeping and suctioning the coal residues from the outside of the sweeper arm 260 into the inside thereof. The sweeper controller 262 controls an operation of the sweeper arm 260 based on the control signal of the main controller 290. The upper rotational part 270 is connected to the crane arm 220, the excavator arm 230 and the sweeper arm 260 and is also connected to an upper portion of the lower cruising part 280 by a rotational bearing (not shown) . Further, the upper rotational part 270 includes an engine (not shown) for driving each of the elements including the lower cruising part 280, and preferably has the cabin 210 for the operator to ride on. The lower cruising part 280 causes the coal cleaning robot system 200 of the present invention to be capable of being moved back and forth and/or rightwards and leftwards, and the dozer arm 250 is located in front of the lower cruising part 280. Further, the lower cruising part 280 supports the upper rotational part 270 connected thereon. In the meantime, since the coal cleaning robot system 200 of a preferred embodiment of the present invention moves on the heaped coals, a caterpillar 410 is preferably selected as a cruising scheme of the lower cruising part 280 to prevent a cruising portion of the lower cruising part 280 from being embedded into the coals. However, the cruising scheme of the lower cruising part 280 of the present invention is not limited to the caterpillar, but a tire may be used as the cruising scheme, if required. The main controller 290 is a central control section for controlling overall operations of the coal cleaning robot system 200 in accordance with a preferred embodiment of the present invention. The main controller 290 receives the manipulation signal inputted from the cabin 210 or the remote control signal received through the RF receiver 240 in a form of digital data, and controls the crane controller 222, the excavator controller 232, the dozer controller 252 and the sweeper controller 262 so that the crane arm 220, the excavator arm 230, the dozer arm 250, the sweeper arm 260, the upper rotational part 270 and the lower cruising part 280 may be operated. The main controller 290, the crane controller 222, the crane controller 232, the dozer controller 252 and the sweeper controller 262 are controlled in a hydraulic scheme so that the respective elements may be operated by the switching manipulation, i.e., the closing/opening manipulation of hydraulic valves. The main controller 290 transfers the compressed oil to the crane controller 222, the excavator controller 232, the dozer controller 252 and the sweeper controller 262 in order to control each element. Fig. 3 shows a schematic inner construction for an RF control transmitter 300 for remotely controlling the coal cleaning robot system 200 of the present invention. The remote control transmitter 300 of the present invention includes a steering lever portion 310, a manipulation button portion 320, a key input processor 330, a RF transmitter 340, an antenna 342 and a power battery 350. The steering lever portion 310 outputs a manipulation command generated by a manipulation of the operator as an analog signal and, therefore, has a shape of a joy stick. The steering lever portion 310 with the shape of the joy stick is generally used to operate the excavator arm 230 and the dozer arm 250. The manipulation button portion 320 has a plurality of key input buttons for inputting the commands for the operations of the coal cleaning robot system of the present invention. The key input processor 330 converts the analog manipulation signal inputted from the steering lever portion 310 and the command data inputted from the manipulation button portion 320 to a command signal of an analog signal, and transfers the analog command signal to the RF transmitter 340. The RF transmitter 340 converts the command signal transferred from the key input processor 330 and/or the manipulation signal through the key input processor 330 from the steering lever portion 310 to a radio frequency signal with a radio frequency and transmits the radio frequency signal to the air. The power battery 350 provides a power required to operate the remote control transmitter 300. A disposable primary battery or a rechargeable secondary battery may be used as the power battery 350. Figs. 4a and 4b are a lateral view and a front view of the coal cleaning robot system 200 of a preferred embodiment of the present invention, respectively. As shown in Fig. 4a, in the coal cleaning robot system 200, the upper rotational part 270 is connected to an upper portion of the lower cruising part 280, and the crane arm 220, the excavator arm 230 and the sweeper arm 260 are connected to the upper rotational part 270. The upper rotational part 270 is connected to the upper portion of the lower cruising part 280 by the rotational bearing (not shown) to be capable of being rotated within 360 degrees. Further, the upper rotational part 270 includes an engine (not shown) to drive each of the elements including the lower cruising part 280, and has the cabin for the operator to ride on. In other words, the coal cleaning robot system 200 of the present invention is remotely controlled with a radio frequency through the remote control transmitter 300, but it is provided with the cabin 210 in order that it may be manually controlled by the operator boarded on the cabin 210, if necessary. The upper rotational part 270 is provided with a carriage box 430 for accumulating the coal residues swept and suctioned through the sweeper arm 260 during the removing process of the coal residues. The upper rotational part 270 is provided with a blower 420 for generating a suction power of the sweeper arm 260. The blower 420 has a fan (not shown) therein and is connected to the carriage box 430. The fan provided in the blower 420 is operated to exhaust the air in the carriage box 430 outwards so that the air pressure in the carriage box 430 may be lowered and the suction power may be generated in the sweeper arm 260 connected to the carriage box 430 by the same principle as an operation principle of a vacuum cleaner. Meanwhile, the lower cruising part 280 supports the upper cruising part 270 and includes the caterpillar for cruising back and forth and/or rightwards and leftwards, and the dozer arm 250 is situated in front of the lower cruising part 280. When the coal cleaning robot system 200 of the present invention is used to remove the coal residues in the hatch 120, the coal residues are usually dispersed to generate dust particles of coals. Further, moisture contained in the coals may cause the coals to be congealed on the bottom of the hatch 120 in order not to be easily removed. Accordingly, to solve the above problem, it is preferable that a water tank assembly (not shown) and an air tank assembly (not shown) are further provided in the sweeper arm 260. The water tank assembly has a water tank for reserving water and a water sprayer (not shown) for spraying water on the bottom of the hatch 120 to prevent the coal residues from being dispersed during the removing process of the coal residues. Further, the air tank assembly is used to compress the air and causes the compressed air to be injected on the bottom of the hatch 120. This approach may cause the coal residues attached on the bottom to be split from the bottom. If the coal residues suctioned through the sweeper arm 260 are heaped to the carriage box 430 over a predetermined amount, the coal residues heaped to the carriage box 430 must be exhausted outwards. The carriage box 430 is provided with a carriage box cylinder (not shown) to an end thereof. If a rod (not shown) of the carriage box cylinder is protruded, i.e., the length of the carriage box cylinder stretched out, the carriage box 430 is inclined to the front thereof. The carriage box 430 is provided on the front thereof with a carriage box gate and a carriage box gate cylinder, so that, if the stretch-out of the carriage box cylinder causes the carriage box 430 to be inclined to the front thereof, the operation of the carriage box gate cylinder may cause the carriage box gate to be open and, therefore, the coal residues heaped in the carriage box 430 may be exhausted outwards . Fig. 5 is a schematic diagram of a manipulation panel 500 of the remote control transmitter 300 for remotely manipulating the coal cleaning robot system 200 in accordance with the preferred embodiment of the present invention. The manipulation panel 500 of the remote control transmitter 300 shown in Fig. 5 is generally used to remotely control the coal cleaning robot system 200, but the same manipulation panel 500 may be used during the manual manipulation by the operator boarded on the cabin 210. Although manual manipulation levers in the cabin 210 are not shown separately, the manual manipulation levers provided in the cabin 210 performs the same functions as the manipulation lever portion which is served as the joy stick provided in the manipulation panel 500. The manipulation panel 500 shown in Fig. 5 includes a left main controller 502, a left cruising control stick 504, a right cruising control stick 506, a right main controller 508, an air gun button 510, a brush button 512, a first motor button 514, a second motor button 516, a third motor button 518, a blower button 520, a water pump button 522, a lift button 524, a power lamp 526, an emergency stop button 528, a RPM control button 530, a power mode selector 534, an element selector 536, a work mode selector 538. The left main controller 502 and the right main controller 508 are used to input operation commands of the crane arm 220 and the excavator arm 230, so that, in the crane arm 220 and the excavator arm 230, they may mainly control to lift up and down a boom, to lift up and down an arm and to stretch in and out a bucket. The crane arm 220 generally includes a boom, an arm and a bucket, while the excavator arm 230 includes a boom and an arm. The left cruising control stick 504 and the right cruising control stick 506 are used to input commands on cruising operations of the lower cruising part 280 back and forth and/or rightwards and leftwards. The air gun button 510 is used to input an execution command of the air gun. The brush button 512 is used to input an execution command of the brush. The first motor button 514 is used to input a command for operating the left brush provided in the sweeper arm 260, the second motor button 516 is used to input a command for operating the second brush, and the third button 518 is used to input a command for operating a roller brush (not shown) . The blower button 520 is used to input a command for operating the blower 420, the water pump button 522 is used to input a command for operating the water pump 522, and the lift button 524 is used to input a command for lifting up and down the brush device provided in the sweeper arm 260. The power lamp 526 is allowed to light on when a power is applied to the coal cleaning robot system 200, and the emergency stop button 528 is used to input a command for stopping all operations of the coal cleaning robot system 200 at a time upon an initiation of an emergency state, i.e., under a sudden failure. The RPM button 530 is used to input a command for increasing and decreasing the rotational speed of the engine (not shown) provided in the coal cleaning robot system 200, and the power mode selector 534 is used to input a command for controlling an operation of the excavator arm 230. The element selector 536 is used to select an operation mode of the excavator arm 230 or the dozer arm 250, and the work mode selector 538 is used to select a horizontal or a pivot operation of the excavator arm 230. Hereinafter, a preferable operation of the coal cleaning robot system 200 constructed above will be described. Fig. 6 is a flow chart for an operational control process of the crane arm 220 in a coal cleaning method of the coal cleaning robot system in accordance with the preferred embodiment of the present invention. The operator may use the remote control transmitter

300 to remotely control the coal cleaning robot system 300 or may ride as the operator on the cabin 210 of the coal cleaning robot system 200 to directly control the coal cleaning work of the coal cleaning robot system 200. If the coal cleaning robot system 200 turns on, the engine (not shown) is operated so that a power required to operate the crane arm 220, the excavator arm 230, the dozer arm 250, the sweeper arm 260, the upper rotational part 270 and the lower cruising part 280 may be generated. The engine is used to operate a hydraulic pump (not shown) provided in each element to generate a hydraulic pressure with a compressed oil. The compressed oil is transferred from the main controller 290 to the corresponding controller provided in each element for controlling said each element. As described above, each of the main controller 290, the crane controller 222, the excavator controller 232, the dozer controller 252 and the sweeper controller 262 is used to control its corresponding element by using the switching operation of the hydraulic valves. Since, in general, a hydraulic valve receives a high level of pressure and requires a supply of a great amount of compressed oil when hydraulic pressure is used to deliver a great force as in heavy machinery, there is a limit in controlling such a large pressure or the opening/closing of the hydraulic valve directly in the manual mode. Accordingly, the opening/closing of the hydraulic pressure is carried out by a pilot control method using a pilot pressure, in general. The pilot pressure refers to a hydraulic pressure used to indicate a switching signal of a valve, and the pilot control method is defined as a control method for controlling the opening/closing of the hydraulic valve by way of controlling a pilot line on which the pilot pressure is exerted. By employing the pilot control method, the control of a greater force is enabled with a smaller force, making it easy to operate the heavy machinery. Thus, in case of manually controlling the coal cleaning robot system 200 of the present invention, the operator boarded on the cabin 260 is able to control the system 200 by using a plurality of manipulation buttons and the steering lever installed in the cabin 210. In the remote control mode, however, such manipulation by using the pilot control method cannot be carried out. When remote-controlling the system, it is preferable to use an electric proportional control valve. Generally, the electric proportional control valve refers to a valve capable of being controlled in proportion to an electric signal. As for the electric proportional control valve, though the opening and closing of the valve can be directly controlled by using a solenoid, there are many problems in practical aspect because a large capacity solenoid should be used, as in the case of the manual control mode. Thus, widely employed instead is a method for controlling the opening/closing of the electric proportional control valve by way of controlling a pilot pressure, i.e., a pilot line by means of the electric proportional control valve. In case of remote controlling the system 200 in accordance with the preferred embodiment of the present invention, the operation of the hydraulic circuit is controlled by controlling the pilot line through the use of the electric proportional control valve. The electric proportional control valve for use in the preferred embodiment of the present invention may be varied depending on the purpose of using it, so that an electric proportional decompression valve for reducing a pressure, an electric proportional flow rate control valve for controlling a flow rate and an electric proportional direction and flow rate control valve for controlling both a direction and a flow rate may be used. Meanwhile, it is noted that the electric proportional control valve can be used not only for the remote control mode but also for the manual control mode in order to facilitate the control of the system. After the coal cleaning robot system 200 turns on, it maintains to be a standby if there is no steering command at step S602. To operate the coal cleaning robot system 200 in the standby state, the operator manipulates the manipulation panel 500 provided in the cabin 210 or the remote control transmitter 300. The operator manipulates the left and the right cruising control stick 504 and 506 in the manipulation panel

500 to input a cruising command for locating the coal cleaning robot system 200 near a heap of coals at step S604. The input from the cabin 210 is transferred to the main controller 290 by using the input controller 212, and a remote control signal transmitted from the remote control transmitter 300 is transferred to the main controller 290 by using the RF receiver 240 and the remote controller 242. If the main controller 290 determines the input signal as the cruising mode, the main controller 290 controls the lower cruising part 280 so that the coal cleaning robot system 200 may be cruised back and forth and/or rightwards and leftwards at step S606. Under the manual control of the lower cruising part 280, the left and the right steering lever (not shown) in the cabin 210 are manipulated. The left and the right steering lever in the cabin 210 has lever shapes which correspond to the left and the right cruising control stick 504 and 506 provided in the manipulation panel 500, respectively. If the left and the right steering lever in the cabin 210 are manipulated, the pilot pressure for controlling the left and the right cruising motor (not shown) are controlled so that the lower cruising part 280 is controlled to be cruised. Under the remote control of the lower cruising part 280, the electronic proportional control valve causes the pilot line (not shown) connected to the main controller 290 to be controlled to control the speed and the stop operation of the coal cleaning robot system 200. The left and the right cruising control stick 504 and 506 are controlled that the coal cleaning robot system 200 may be cruised back and forth and/or rightwards and leftwards. In this case, the thrust level of the left and the right cruising control stick 504 and 506 may be manipulated to control the output of the engine (not shown) . If the command for operating the crane arm 220 is inputted from the left and the right main controller 502 and 504 of the manipulation panel 500 by the manipulation of the operator so that the crane mode is determined at step S608, the main controller 290 transfers the compressed oil to the crane controller 222 to operate the crane arm 220 at step S610. Then, if a boom operation signal for lifting up and down the boom is inputted from the left main controller 502 of the manipulation panel 500 at step S612, the main controller 290 controls the crane controller 222 to operate the boom at step S614. If the command for operating the brush such as a side brush or a roller brush provided in the crane arm 220 is inputted from the left main controller 502 of the manipulation panel 500 at step S616, the main controller 290 controls the crane controller 222 to operate its corresponding brush at step S618. At step S612 and step S616 described above, the cruising mode for operating the lower cruising part 280 may be performed with the boom or the brush operated. At step S604 described above, if the lower cruising part 280 for cruising the coal cleaning robot system 200 is not operated while a command for operating the upper rotational part 270 is inputted so that the rotational mode is determined at step S620, the main controller 290 controls the rotational part 270 so that the rotational part 270 provided with the crane arm 220, the excavator arm 230 and the sweeper arm 260 thereon may be rotated within 360 degrees at step S622. Fig. 7 shows a flow chart for illustrating the operation control process of the excavator arm 230 in the coal cleaning method of the coal cleaning robot system in accordance with the present invention. Under the excavating mode in which the operation command for the excavator arm 230 is inputted from the manipulation panel 500 by the manipulation of the operator at step S702, the main controller 290 transfers the compressed oil to the excavator controller 232 at step S704. Accordingly, the excavator controller 232 is allowed to control the excavator arm 230 by using the compressed oil. If the command for operating the excavating boom is inputted from the manipulation panel 500 at step S706, the main controller 290 controls the excavator controller 232 to lift up and down the excavating boom at step S708. If the command for operating the excavating arm is inputted from the manipulation panel 500 at step S710, the main controller 290 controls the excavator controller 232 to stretch in and out the excavating arm at step S712. If the command for operating the excavating boom is not inputted at step S706 described above and if the command for operating the bucket is inputted at step S714, the main controller 290 controls the excavator controller 232 to stretch in and out the bucket at step S716. Fig. 8 is a flow chart for illustrating the operation control process of the dozer arm 250 and the sweeper arm 260 in the coal cleaning method of the coal cleaning robot system in accordance with the present invention. Under a dozer mode in which a command for operating the dozer arm 250 is inputted from the manipulation panel by the manipulation of the operator at step S802, the main controller 290 transfers the compressed oil to the dozer controller 252 at step S804. Then, if the command for a swing operation is inputted from the manipulation panel 500 by the operator at step S806, the main controller 290 controls the dozer controller 252 to perform the swing operation for moving the dozer arm 250 rightwards and leftwards at step S808. If the command for the tilt operation is inputted from the manipulation panel 500 at step S810, the main controller 290 controls the dozer controller 252 to lift up and down the dozer arm 250 vertically at step S812. Under the sweeper mode in which the command for operating the sweeper arm 260 is inputted from the manipulation panel 500 at step S814, the main controller 290 transfers the compressed oil to the sweeper controller 262 at step S816. Accordingly, the sweeper controller 262 may control the sweeper arm 260. If the command for operating the brush is inputted from the manipulation panel 500 at step S818, the main controller 290 controls the sweeper controller 262 to perform the operation for rotating the brush at step S820. When the sweeper arm 260 is operated, each brush is operated by using an operation motor (not shown) . Also, when the sweeper arm 260 is operated, each brush and a suction port (not shown) for suctioning the coal residues are lifted down and, after the operation of the brush and the suction port is completed, the brush and the suction port are lifted up. In accordance with the present invention described above, the coal cleaning robot system, for use in a collier to unload coals to a power plant, for collecting the coals and finely removing the coal residues through the manual/remote control and a coal cleaning method of the coal cleaning robot system are realized. Furthermore, the coal cleaning robot system of the present invention has advantages in that it can be used in a roadside trees maintenance work, a street cleaning work, etc., as well as in the work for unloading the coals. Particularly, if the present invention is used in a road maintenance work, excavation of road, maintenance of roadsi-de trees, cleaning of the road can be all performed efficiently. While the invention has been shown and described with respect to the preferred embodiments, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the present invention as defined in the following claims.

Industrial Applicability

In accordance with the present invention described above, various works can be performed by using a single equipment in stevedoring coals from a hatch of a collier, rendering the stevedoring work time safe and efficient in the economic point of view. Further, by using the coal cleaning robot system in accordance with the present invention, the unloading of the coals from the hatch can be sufficiently performed, and the removal of the coal residues from the hatch and the cleaning of the hatch can also be carried out without adding extra workers into the hatch so that an avoidable accident may be effectively blocked. Moreover, since the coal cleaning robot system of the present invention can be remote controlled, it becomes possible to operate the system without the operator having to ride in a cabin. Furthermore, the system of the present invention has advantages in that it can be used in a roadside trees maintenance work, a street cleaning work, etc., as well as in the work for unloading the coals. Particularly, if the present invention is used in a road maintenance work, excavation of road, maintenance of roadside trees, cleaning of the road can be all performed efficiently.

Claims

What is claimed:

1. A coal cleaning robot system for use in collecting and removing coal residues, the coal cleaning robot system being manually or remotely controlled by an operator comprising: a steering part for steering an operation of the coal cleaning robot system; an input controller for inputting data involving input command for use in a manipulation of the steering part; a crane arm for removing out coal residues; a crane controller for controlling an operation of the crane arm; an excavator arm for use in evacuating the coal residues; an excavator controller for controlling an operation of the excavator arm; a dozer arm for shoving and dipping up the coal residues; a dozer controller for controlling an operation of the dozer arm; a sweeper arm for collecting or suctioning the coal residues; a sweeper controller for controlling an operation of the sweeper arm; an upper rotational part for rotating the crane arm, the evacuator arm and the sweeper arm; a lower cruising part, hinge-connected to the upper rotational part to support the upper rotational part, for cruising the coal cleaning robot system back and forth and/or rightwards and leftwards; and a main controller for transferring a control signal to the crane controller, the excavator controller, the dozer controller and the sweeper controller by using a steering signal inputted from the steering part, and for controlling a rotation operation of the upper rotational part and a cruising operation of the lower cruising part.

2. The coal cleaning robot system of claim 1, wherein the steering part includes a plurality of manipulation buttons and steering levers for steering the coal cleaning robot system.

3. The coal cleaning robot system of claim 1, wherein the steering part includes a cabin on which the operator rides to manually manipulate the coal cleaning robot system; or a remote control transmitter for remotely controlling at least one operation of the coal cleaning robot system.

4. The coal cleaning robot system of claim 1, wherein the crane arm includes a cleaning brush, a water injection valve and an air gun, the crane controller causes water to be injected to the coal residues attached to a wall to remove the coal residues, and a compressed air injected from the air gun is used to remove the coal residues attached to the wall ,

5. The coal cleaning robot system of claim 1, wherein the excavator controller controls the excavator arm into operating in a power mode or in a work mode, in the power mode, the excavator arm is operated in any one of a first, a second and a third speed mode, the first speed mode being a light work engine output mode in which a fuel efficiency is primarily considered, the second speed mode being a normal work engine output mode, and the third speed mode being a heavy work engine output mode for performing a good deal of work in a short time, and in the work mode, a part of work execution scheme is automated to facilitate the steering of the coal cleaning robot system, the work mode including a horizontal work mode, an excavation work mode and a pivot priority work mode.

6. The coal cleaning robot system of claim 5, wherein the horizontal work mode is a mode for causing the excavator arm to be horizontally moved to perform an excavation work, the excavation work mode is a mode for performing a normal excavation work, and the pivot priority work mode is a mode for rotating the excavator arm during the excavation work.

7. The coal cleaning robot system of claim 1, wherein the control of the crane arm by the crane controller, the control of the excavator arm by the excavator controller, the control of the dozer arm by the dozer controller and the control of the sweeper arm by the sweeper controller are performed by using hydraulic valves.

8. The coal cleaning robot system of claim 1, wherein the sweeper arm includes a brush for sweeping to collect the coal residues, a suction port for suctioning the coal residues, and a carriage box for accumulating the suctioned coal residues thereon.

9. The coal cleaning robot system of claim 1, further comprising: a RF receiver for receiving a remote control signal to remotely control the coal cleaning robot system by the operator; and a remote controller for amplifying the remote control signal received by the RF receiver and converting the amplified remote control signal into a digital data to be transmitted to the main controller.

10. The coal cleaning robot system of claim 9, wherein the main controller causes an electromagnetic proportion control valve to control the crane controller, the excavator controller, the dozer controller and the sweeper controller, if the remote control signal is inputted through the RF receiver and the remote controller.

11. The coal cleaning robot system of claim 1, wherein the lower cruising part is provided with a caterpillar or a tire as a cruising scheme for preventing a cruising portion from being embedded into the coal residues.

12. The coal cleaning robot system of claim 3, wherein the remote control transmitter has: a steering lever portion for outputting manipulation command depending on an manipulation of the operator as an analog signal; a manipulation button portion provided with a plurality of buttons for use in inputting the operation command therewith; a key input processor for converting an analog-type manipulation signal inputted from the steering lever portion and command data inputted from the manipulation button portion into a corresponding analog-type command signal; a RF transmitter for converting the command and/or the manipulation signal inputted from the key input processor into a radio frequency signal and radio-transmitting the radio frequency signal through an antenna towards the air; and a power battery for providing a power required to operate the remote control transmitter.

13. The coal cleaning robot system of claim 3 or claim 12, wherein the cabin or the remote control transmitter has a manipulation panel for generating the manipulation and/or the command signal.

14. The coal cleaning robot system of claim 13, wherein the manipulation panel has: a right and a left main steering portion used to input an operation command of the crane arm and the excavator arm; a right and a left cruising steering stick for inputting a cruising operation command of the lower cruising part back and forth and/or rightwards and leftwards; an air gun button for inputting an execution command of the air gun; a brush button for inputting an execution command of the brush; a first motor button for inputting a command to operate a left brush provided in the sweeper arm; a second motor button for inputting a command to operate a right brush; a third motor button for inputting a command to operate a roller brush; a blower button for inputting a command to operate a blower; a water pump button for inputting a command to operate a water pump; a lift button for inputting a command to lift up and down a brush device provided in the sweeper arm; an emergency stop button for a command to stop all operations of the coal cleaning robot system at a time upon an initiation of an emergency state; a RPM button for inputting a command to increase or decrease a rotational speed of an engine during the operation of the coal cleaning robot system; a power mode selector for inputting a command to control an operation of the excavator arm; an element selector for selecting an operation mode of the excavator arm or the dozer arm; and a work mode selector for selecting a horizontal or a pivot operation of the excavator arm.

15. The coal cleaning robot system of claim 14, wherein the right and the left main steering portion is used in the crane arm and the excavator arm to input commands for lifting up and down a boom, lifting up and lowering down an arm and stretching in and out of a bucket.

16. The coal cleaning robot system of claim 1, wherein the main controller, the crane controller, the excavator controller, the dozer controller and the sweeper controller are controlled by means of a hydraulic pressure in which each respective element is controlled with the switching manipulation of hydraulic valves.

17. A method of cleaning coal residues by using a coal cleaning robot system for use in collecting and removing coal residues, wherein the system is manually or remotely controlled by an operator, the method comprising the steps of: (a) applying an electric power to ready the coal cleaning robot system for operation; (b) determining if a steering signal for operating an element of the coal cleaning robot system is received from a steering part; (c) transferring a compressed oil to a controller of the element to be operated by the steering signal; and (d) controlling a fine operation of the element by means of the compressed oil.

18. The method of claim 17, the element includes: a crane arm for removing the coal residues; a excavator arm used to excavate the coal residues; a dozer arm for shoving and dipping up the coal residues; a sweeper arm for sweeping or suctioning the coal residues; an upper rotational part for rotating the crane arm, the excavator arm and the sweeper arm; and a lower cruising part, hinge-connected with the upper rotational part to support the upper rotational part, for cruising the coal cleaning robot system back and forth and/or rightwards and leftwards.

19. The method of claim 17, wherein the controller of the element includes : a crane controller for controlling an operation of the crane arm; an excavator controller for controlling an operation of the excavator arm; a dozer controller for controlling an operation of the dozer arm; and a sweeper controller for controlling an operation of the sweeper arm.

20. The method of claim 17, wherein the steering part includes a plurality of manipulation buttons and a steering lever for steering the coal cleaning robot system.

21. The method of claim 17, wherein the steering part includes a cabin on which the operator rides to manipulate manually the coal cleaning robot system or a remote control transmitter for remotely controlling at least one operation of the coal cleaning robot system.

22. The method of claim 19, wherein the crane controller causes water to be injected to the coal residues attached to a wall to remove the coal residues, and a compressed air injected from an air gun is used to remove the coal residues attached to the wall, if the steering signal is a steering signal for operating the crane arm.

23. The method of claim 19, wherein the excavator controller controls the excavator arm into operating in a power mode or in a work mode, in the power mode, the excavator arm is operated in any one of a first, a second and a third speed mode, the first speed mode being a light work engine output mode in which a fuel efficiency is primarily considered, the second speed mode being a normal work engine output mode, and the third speed mode being a heavy work engine output mode for performing a good deal of work in a short time, and in the work mode, a part of work execution scheme is automated to facilitate the steering of the coal cleaning robot system, the work mode including a horizontal work mode, an excavation work mode and a pivot priority work mode.

24. The method of claim 23, wherein the horizontal work mode is a mode for causing the excavator arm to be horizontally moved to perform an excavation work, the excavation work mode is a mode for performing a normal excavation work, and the pivot priority work mode is a mode for rotating the excavator arm during the excavation work.

25. The method of claim 17, wherein, at step (b) , the steering part including: a RF receiver for receiving a remote control signal to remotely control the coal cleaning robot system by the operator; and a remote controller for amplifying the remote control signal received by the RF receiver and converting the amplified remote control signal to be a digital data to be transmitted to the main controller.

26. The method of claim 25, wherein, if the remote control signal is inputted through the RF receiver and the remote controller, the main controller causes an electromagnetic proportion control valve to control the crane controller, the excavator controller, the dozer controller and the sweeper controller

27. The method of claim 18, wherein the sweeper arm includes a brush for sweeping to collect the coal residues, a suction port for suctioning the coal residues, and a carriage box for accumulating the suctioned coal residues thereon.

28. The method of claim 18, wherein the lower cruising part is provided with a caterpillar or a tire as a cruising scheme for preventing a cruising portion from being embedded into the coal residues.

29. The method of claim 19, wherein the main controller, the crane controller, the excavator controller, the dozer controller and the sweeper controller are controlled with a hydraulic pressure in which their respective elements are controlled with the switching manipulation of hydraulic valves.

30. The method of claim 21, wherein the remote control transmitter has: a steering lever portion for outputting a manipulation command depending on an manipulation of the operator as an analog signal; a manipulation button portion provided with a plurality of buttons for inputting the operation command therewith; a key input processor for converting an analog-type manipulation signal inputted from the steering lever portion and command data inputted from the manipulation button portion into a corresponding analog-type command signal; a RF transmitter for converting the command and/or the manipulation signal inputted from the key input processor to a radio frequency signal and radio-transmitting the radio frequency signal through an antenna towards the air; and a power battery for providing a power required to operate the remote control transmitter.

31. A remote control transmitter for remotely controlling a coal cleaning robot system to input a command for collecting coals and removing a coal residues, the remote control transmitter comprising: a steering lever portion for outputting a manipulation command depending on an manipulation of an operator as an analog signal; a manipulation button portion provided with a plurality of buttons for inputting the operation command therewith; a key input processor for converting an analog-type manipulation signal inputted from the steering lever portion and command data inputted from the manipulation button portion into a corresponding analog-type command signal; a RF transmitter for converting the command and/or the manipulation signal inputted from the key input processor into a radio frequency signal and radio-transmitting the radio frequency signal through an antenna towards the air; and a power battery for providing a power required to operate the remote control transmitter.

32. The remote control transmitter of claim 31, wherein the remote control transmitter has a manipulation panel for generating the manipulation and/or the command signal.

33. The remote control transmitter of claim 32, wherein the manipulation panel has: a right and a left main steering portion used to input an operation command of the crane arm and the excavator arm; a right and a left cruising steering stick for inputting a cruising operation command of the lower cruising part back and forth and/or rightwards and leftwards; an air gun button for inputting an execution command to inject an air from the coal cleaning robot system; a brush button for inputting an execution command of the brush in the coal cleaning robot system; a first motor button for inputting a command to operate a left brush provided in the coal cleaning robot system; a second motor button for inputting a command to operate a right brush in the coal cleaning robot system; a third motor button for inputting a command to operate a roller brush in the coal cleaning robot system; a blower button for inputting a command to operate a blower so that an air is suctioned in the coal cleaning robot system; a water pump button for inputting a command to operate a water pump in the coal cleaning robot system; a lift button for inputting a command to lift up and down a brush device provided in the coal cleaning robot system; an emergency stop button for a command to stop all operations of the coal cleaning robot system at a time upon an initiation of an emergency state; a RPM button for inputting a command to increase or decrease a rotational speed of an engine during the operation of the coal cleaning robot system; a power mode selector for inputting a command to control an excavating operation of the coal cleaning robot system; an element selector for selecting the excavating operation or a dozer operation in the coal cleaning robot system; and a work mode selector for selecting a horizontal or a pivot operation of the excavating operation in the coal cleaning robot system.

34. The remote control transmitter of claim 33, wherein the right and the left main steering portion is generally used in a crane operation and the excavating operation to input commands for lifting up and down a boom, lifting up and down an arm and stretching in and out a bucket .