Views: 0 Author: Site Editor Publish Time: 2026-07-16 Origin: Site
A bulk cargo port operates multiple stacker-reclaimers for handling iron ore, coal, and other materials. Accurate travel position and slew angle detection are essential for automated equipment operation.
Before the upgrade, travel position relied on encoders combined with limit switches. Over time, these accumulated errors and required regular manual recalibration. Slew angle was also measured by encoders, which suffered from the same drift issues. Worse, the dusty, vibrating environment caused frequent encoder failures. Operators had to rely on experience to judge equipment position, which limited both accuracy and productivity.
The project goal was to achieve precise, reliable travel positioning and slew angle measurement as the foundation for future unmanned operation.
The project uses Gray code busbar positioning technology to detect both travel position and slew angle. Think of the Gray code busbar as a precision electronic ruler laid along the track. An antenna box mounted on the equipment reads its position through non-contact感应, with no mechanical wear and no accumulated error.
The Gray code busbar runs the full length of the stockyard track. The antenna box is mounted on the stacker-reclaimer itself. As the machine moves, the system instantly knows its exact position on the track, and the control room can see it at any time.
The Gray code cable is arranged in a circular loop that rotates with the boom, while the antenna box stays fixed on the main frame. The system reads the boom's rotation angle the moment it moves.
Data from both position sensors is transmitted back to the central control room via wireless network in real time, interfacing with the PLC control system to support remote monitoring and automated operations.
After commissioning, travel positioning accuracy reached 1 millimeter with no cumulative drift, eliminating the need for periodic manual recalibration. Slew angle measurement became stable and precise, no longer affected by encoder wear or vibration. From the control room, operators can now see the exact position and attitude of the stacker-reclaimer at any moment, providing a solid foundation for remote control and automated operation. Maintenance requirements dropped significantly, and the Gray code busbar itself carries a service life of over 10 years.
