CN109132592B - Bucket wheel machine unattended operation control method based on PLC data partition storage - Google Patents
Bucket wheel machine unattended operation control method based on PLC data partition storage Download PDFInfo
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- CN109132592B CN109132592B CN201810652433.3A CN201810652433A CN109132592B CN 109132592 B CN109132592 B CN 109132592B CN 201810652433 A CN201810652433 A CN 201810652433A CN 109132592 B CN109132592 B CN 109132592B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G65/00—Loading or unloading
- B65G65/28—Piling or unpiling loose materials in bulk, e.g. coal, manure, timber, not otherwise provided for
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
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Abstract
An unattended bucket wheel machine control method based on PLC data partition storage comprises the following steps: 1. the method comprises the following steps of (1) manually dividing a coal yard into coal yard areas, 2) when a bucket wheel machine performs coal yard area selection operation, reading boundary data of the area by a PLC (programmable logic controller), comparing the boundary data with position data of the bucket wheel machine, if the bucket wheel machine is not in the area currently, enabling the bucket wheel machine to perform walking action, 3) when the bucket wheel machine enters the area for the first time, establishing initial data of the bucket wheel machine in the area and storing the initial data into the PLC, 4) generating historical data of the area after the bucket wheel machine finishes operation, respectively storing the position data when the bucket wheel machine finishes stacking and the position data when the material taking is finished, 5 performing automatic stacking operation of the bucket wheel machine, and 6 performing automatic material taking operation of the bucket wheel machine, wherein the method has the advantages that: the bucket wheel machine can be used for positioning the coal yard without a laser scanner, and the data of the coal yard area is compared with the data of the current position of the bucket wheel machine, so that the bucket wheel machine is used for positioning the coal yard.
Description
Technical Field
The invention relates to a cantilever bucket-wheel stacker-reclaimer for stacking or extracting and removing solid particle bulk materials, in particular to a bucket-wheel unattended control method based on PLC data partition storage.
Background
The cantilever bucket-wheel stacker-reclaimer consists of twenty-few components such as a walking mechanism, a slewing mechanism, a belt conveyor, a tail car, a pitching component, a water-spraying dedusting component, a cable drum, a counterweight, a door seat and the like (figure 1). As a continuous and efficient bulk material loading and unloading transportation device, the device has strong regularity and is easy to realize automation. Is widely applied to large-scale thermal power plants, industrial and mining enterprises and port bulk material storage yards.
The operation modes of the existing bucket wheel machine are roughly divided into three types:
firstly, manual control in situ: the method refers to that an operator carries out field operation on a single device in a bucket wheel machine cab, complex interlocking requirements of a system cannot be met, and the bucket wheel machine operates independently. Workers in a main control room of the coal conveying system do not know the working condition of field equipment and the operation parameters of the equipment, and alarm signals and relevant numbers of the equipment do not exist in the control room, so that the mode is gradually eliminated.
Secondly, semi-automatic control: the normal operation of bucket wheel machine all relies on manual operation, but the host computer of centralized control room also has certain control authority, and the staff in the centralized control room can direct control opening of bucket wheel, the motion of cart etc.. These operations can be performed without the permission of a driver in the bucket wheel machine control room, which should be done for small scale operations.
Thirdly, automatic control: the automatic control means that the bucket wheel machine realizes an unmanned control mode, and workers can carry out material piling and taking and various controls on the bucket wheel machine in a remote control room. The working condition of the bucket wheel machine can be monitored by a worker in a remote control room through a monitoring system, an operation condition graphic representation reflecting the working position and the working condition of the bucket wheel machine is arranged on a monitoring screen in the remote control room, an automatic alarm system is arranged, and various operation parameters of the bucket wheel machine can be known through a computer and required data can be obtained through a printer.
At present, the automatic control mode (unattended operation) of the bucket wheel machine is mainly realized in the form of fig. 2, and the process flow is roughly as follows: 1. and carrying out sector scanning on the whole stockpile of the stock ground through a laser scanner. 2. And the bucket wheel machine positioning system determines the stroke, rotation and pitching angle data of the stacker-reclaimer. 3. The data communication transmits the position parameters of the positioned bucket wheel machine and the boundary data of the material pile to the operation terminal. 4. The image processing software processes the laser scanner, the positioning data and the like, converts the data into a visual three-dimensional image of the stockpile and provides coordinate parameters of important boundary points of the stockpile. 5. And a controller establishes an operation plan according to an actual operation task, initializes model parameters and then issues an operation instruction, and controls the automatic operation of the bucket wheel machine by using the material pile model and the PLC module. However, the unattended system depending on the positioning of the laser scanner is high in cost, errors exist from laser measurement to data processing, and in addition, most of the installation positions of the existing laser scanner are installed on a cantilever which is often in a moving state, so that the scanning accuracy of the laser scanner is indirectly influenced.
Disclosure of Invention
The invention aims to provide an unattended bucket wheel machine control method based on PLC data partition storage, which is used for bucket wheel machine data partition storage and realizes the bucket wheel machine to position coal yards in different areas, thereby achieving the full-automatic unattended function of the bucket wheel machine and overcoming the defects of the prior art.
The technical scheme of the invention is realized in such a way that the unattended operation control system of the bucket wheel machine specifically comprises the following steps:
step S1: the coal yard is divided into coal yard areas manually, and boundary data of each divided coal yard area is stored into the PLC in a subarea mode according to the number of the coal yard areas and serves as a condition for storing data stored by bucket wheels in each coal yard area in a subarea mode;
step S2: storing the coal yard area divided in the step S1 into the configuration software of the industrial personal computer, setting a coal yard area selection button, reading boundary data of the area by the PLC when the bucket wheel machine performs coal yard area selection operation, comparing the boundary data with position data of the bucket wheel machine, and performing walking action by the bucket wheel machine if the bucket wheel machine is not in the area currently;
step S3: when the bucket wheel machine enters the area for the first time, establishing initial data of the bucket wheel machine in the area and storing the initial data into the PLC, wherein if the coal yard is an empty coal yard, the initial data of the bucket wheel machine is set to be a certain fixed position of the coal yard to start operation; if materials exist in the coal yard area, the bucket wheel machine is manually driven to a position needing operation through a remote operation platform, and then an operation mode is selected according to the actual situation;
step S4: after the operation of the bucket wheel machine is finished, historical data of the area is generated, the PLC stores position data of the bucket wheel machine at the end of material stacking and position data of the bucket wheel machine at the end of material taking respectively according to the operation mode of the bucket wheel machine, when the bucket wheel machine receives an operation command formula again, the PLC triggers the historical position data of the bucket wheel machine in the area in the memory, and the historical data of the bucket wheel machine at the area of material stacking or material taking is called according to the current operation command and the operation area;
step S5: comparing historical data of the bucket wheel machine in the area with current bucket wheel machine position data, automatically positioning a last working point by the bucket wheel machine on the premise of ensuring the safety of the operation track of the bucket wheel machine, namely positioning the coal yard area, and performing automatic coal piling and taking operation after the bucket wheel machine reaches a preset position;
step S6: when the bucket wheel machine is in automatic stacking operation, a material level meter at the head of the bucket wheel machine is utilized, when the stacking reaches a set height, the bucket wheel machine carries out the next stacking action, so that the automatic stacking of the bucket wheel machine is realized, and the safe and stable operation of the bucket wheel machine is ensured by combining a protection limit and a high-definition video monitoring system on the bucket wheel machine;
step S7: when the bucket wheel machine automatically takes materials, the belt weigher or the laser material flow sensor is matched with the bucket wheel machine rotating angle, when the bucket wheel machine rotates to reach a historical angle and the material flow value of the belt weigher or the laser material flow sensor is smaller than a certain value, the bucket wheel machine is judged to take the materials to the edge of a coal pile, then the bucket wheel machine moves forwards, after the bucket wheel machine moves forwards, the bucket wheel machine rotates in the opposite direction, and the reciprocating action in the same way is realized to automatically take the materials.
The invention has the advantages and positive effects that:
1. the bucket wheel machine can position the coal yard without a laser scanner, the coal yard is positioned by the bucket wheel machine by dividing the coal yard area and comparing the data of the coal yard area with the current position data of the bucket wheel machine, the bucket wheel machine enters the coal yard area to be used as a PLC (programmable logic controller) for reading various data of the bucket wheel machine stored in the coal yard area to be used as a basis for automatically positioning the coal yard by the bucket wheel machine, and after the bucket wheel machine starts to operate, various data of the coal yard are continuously updated according to the state of the bucket wheel machine until the bucket wheel machine stops operating.
2. The bucket wheel machine unattended control system based on PLC data partition storage breaks through the traditional mode of sensor positioning, realizes positioning of a bucket wheel machine on a coal yard operation point through data partition storage, not only reduces the cost of the bucket wheel machine automatic positioning system, but also greatly reduces errors caused by sensor measurement and complex calculation, and combines the technologies of PLC control, video monitoring, detection elements, an upper computer and the like to realize the functions of one-key start-stop, intelligent coal blending and unattended operation of the bucket wheel machine, save human resources, improve the production efficiency and reduce the occurrence probability of site personal accidents.
Drawings
FIG. 1 is a schematic view of a bucket wheel machine configuration of the prior art.
Fig. 2 is a flow chart of the present invention.
Fig. 3 is a control flow diagram of the present invention.
Fig. 4 is a schematic flow diagram of the present invention.
Detailed Description
According to the invention, position data of the bucket wheel machine when the bucket wheel machine finishes working in each area of the coal yard is stored through the PLC, then different conditions when the bucket wheel machine works in the area next time trigger reading of historical data of the bucket wheel machine in the area, the bucket wheel machine can automatically find the position of the bucket wheel machine in the last time operation so as to realize positioning of the bucket wheel machine on the coal yard, and the bucket wheel machine unattended operation is realized by combining with an automatic operation process of the bucket wheel machine.
Referring to fig. 3, the present embodiment specifically includes the following steps:
step S1: manually dividing coal yard areas I, II, III and IV for the coal yard, and respectively storing the boundary data of the divided coal yard areas I, II, III and IV into a PLC (programmable logic controller) as the conditions for storing data by bucket turbines in the coal yard areas I, II, III and IV;
step S2: storing the coal yard areas I, II, III and IV divided in the step S1 into configuration software of an industrial personal computer, setting coal yard area selection buttons I, II, III and IV, reading boundary data of the coal yard area I by a PLC (programmable logic controller) when the bucket wheel machine selects the coal yard area I, comparing the boundary data with position data of the bucket wheel machine, and if the bucket wheel machine is not in the coal yard area I currently, enabling the bucket wheel machine to move to enter a specified position in the coal yard area I;
step S3: when the bucket wheel machine firstly enters a coal yard area I, establishing initial data of the bucket wheel machine in the coal yard area I and storing the initial data into the coal yard area I divided by the PLC, wherein if the coal yard area I is an empty coal yard, the initial data of the bucket wheel machine is set to be a certain fixed position of the coal yard area I to start operation; if the coal yard area I has materials, an operator needs to manually drive the bucket wheel machine to a position needing operation through a remote operation platform, and then selects an operation mode according to actual conditions;
step S4: after the operation of the bucket wheel machine is finished, historical data of a coal yard area I are generated, the PLC respectively stores position data of the bucket wheel machine at the end of material stacking and position data of the bucket wheel machine at the end of material taking according to different operation modes of the bucket wheel machine, when the bucket wheel machine receives an operation command formula again, the historical position data of the bucket wheel machine of the coal yard area I in the PLC memory is triggered, and the historical data of the bucket wheel machine at the coal yard area I for material stacking or material taking is called according to the current operation command and the operation area;
step S5: comparing historical data of a bucket wheel machine in a coal yard area I with current bucket wheel machine position data, automatically positioning a last working point by the bucket wheel machine on the premise of ensuring the safety of a bucket wheel machine running track, namely positioning the coal yard area, and performing automatic coal piling and taking operation after the bucket wheel machine reaches a preset position;
calling historical data of a bucket wheel machine, calling the historical data of a coal yard area I by the bucket wheel machine when the bucket wheel machine enters a set coal yard area I, and calling historical (stacking or taking) position data of the coal yard area I according to a current operation command (stacking or taking) of the bucket wheel machine, wherein the method comprises the following steps:
if the operation is stacking, the last position data of the bucket wheel machine in the coal yard area I is the position data of the stacking, and the bucket wheel machine directly calls the data;
if the operation is stacking, the last position data of the bucket wheel machine in the coal yard area I is the position data of material taking, and the amplitude variation height in the historical data of the material taking is lower than the set stacking height, the position data of the stacking is the fixed stacking preset data in the area; and if the amplitude variation height of the historical material taking data is greater than or equal to the set stacking height, the position data of the stacking is the position data of the last material taking.
If the operation is material taking, the last position data of the bucket wheel machine in the area is the position data of the material taking, and the bucket wheel machine directly calls the data;
if the operation is material taking, the last position data of the bucket wheel machine in the region is the position data of the stockpile, and the bucket wheel machine is required to be reduced in a preset mode on the data of the amplitude-variable height after calling the data, because the height of the bucket wheel is preset through the level gauge when the material is stockpiled.
Step S6: bucket wheel machine is when automatic windrow operation, set for the windrow height, the windrow machine begins the windrow after arriving the windrow point, detect when the charge level indicator and reach preset windrow height, bucket wheel machine left turn windrow, after last gyration (the gyration scope can be preset in PLC, also can set up on the host computer), the charge level indicator acts once more, bucket wheel machine retreats, bucket wheel machine continues the windrow after the fallback, charge level indicator action bucket wheel machine is reverse gyration, the cart continues to retreat after the gyration, from this repeated operation.
Step S7: when the bucket wheel machine is in automatic material taking operation, the bucket wheel machine starts to take materials after reaching a material taking point, if the bucket wheel machine is used for taking materials for left turning for the last time, the operation is carried out if the materials are taken, when the bucket wheel machine reaches a preset position, the bucket wheel machine can continue to take the left turning operation, when the rotation reaches the range of the historical stacking edge, the analog quantity material flow of the belt scale is close to 0, the bucket wheel machine is determined to take the edge of the coal pile, meanwhile, the cart of the bucket wheel machine advances for a certain distance (the advancing distance is preset in the PLC), after the advance is finished, the rotation is carried out in a reverse direction, when the reverse angle reaches the stacking range, and meanwhile, when the analog quantity material flow of the belt scale is close to 0, the bucket wheel machine is determined to take the other edge of the coal pile, and.
The method is characterized in that the storage and operation of the taken materials are carried out on the data of the belt weigher, the data of the operation amount of the bucket wheel machine pile and the taken materials are stored and calculated, the accumulated coal amount of the belt weigher is calculated, the addition operation is carried out during the material piling, the subtraction operation is carried out on the taken materials, and the coal amount of the coal yard area I can be calculated, and the method is different from a rough algorithm of multiplying the laser scanning volume by the density.
The constant material flow system is used for realizing PID control of material taking of the bucket wheel machine by acquiring instantaneous flow signals of the belt weigher and combining rotary variable frequency speed analog quantity signals and programming, and achieves the effect of stable coal taking.
After the bucket wheel machine is positioned at an operation entry point, a pile/material taking operation mode is selected for the bucket wheel machine through a remote operation platform, and the bucket wheel machine carries out automatic pile material taking operation in a coal yard area I. When the bucket wheel machine enters an automatic operation state, the PLC does not read the coal yard data any more, but is used as a trigger condition for updating the coal yard data according to the operation state of the bucket wheel machine until the operation is finished or the completion command of unattended operation is realized by setting the workload, or manual intervention operation is carried out through a remote operation console when special conditions are met.
The field industrial personal computer is also provided with a handle operation table, the manual operation standby and the manual intervention fine adjustment function for the automatic operation of the bucket wheel machine are adopted in special conditions, and the handle operation table is communicated with the bucket wheel machine PLC master station in a field bus mode through a PLC remote slave station.
The bucket wheel machine unattended control system based on PLC data layered storage breaks through the traditional mode of sensor positioning, the bucket wheel machine is positioned on a coal yard operation point through data segmented storage, the cost of the bucket wheel machine automatic positioning system is reduced, errors caused by sensor measurement and complex calculation are greatly reduced, the bucket wheel machine 'one-key start-stop', intelligent coal blending and unattended functions are achieved by combining the technologies of PLC control, video monitoring, detection elements, an upper computer and the like, human resources are saved, production efficiency is improved, the occurrence probability of site personal accidents is reduced, the mode based on PLC data storage and depth algorithm can be applied to automatic positioning of the bucket wheel machine, and the automatic positioning of complex working conditions of large-scale equipment is also started and started.
Claims (1)
1. A bucket wheel machine unattended control method based on PLC data partition storage is characterized by comprising the following steps:
step S1: the method comprises the steps of manually dividing coal yard areas of a coal yard, storing boundary data of each divided coal yard area into a PLC in a regional mode according to the number of the coal yard areas, and using the boundary data as conditions for storing data of bucket wheel machines in each coal yard area in a regional mode;
step S2: storing the coal yard area divided in the step S1 into the configuration software of the industrial personal computer, setting a coal yard area selection button, reading boundary data of the area by the PLC when the bucket wheel machine performs coal yard area selection operation, comparing the boundary data with position data of the bucket wheel machine, and performing walking action by the bucket wheel machine if the bucket wheel machine is not in the area currently;
step S3: when the bucket wheel machine enters the area for the first time, establishing initial data of the bucket wheel machine in the area and storing the initial data into the PLC, wherein if the coal yard is an empty coal yard, the initial data of the bucket wheel machine is set to be a certain fixed position of the coal yard to start operation; if materials exist in the coal yard area, the bucket wheel machine is manually driven to a position needing operation through a remote operation platform, and then an operation mode is selected according to the actual situation;
step S4: the method comprises the steps that after the operation of a bucket wheel machine is finished, historical data of the area are generated, a PLC stores position data of the bucket wheel machine when the material stacking is finished and position data of the bucket wheel machine when the material taking is finished respectively according to the operation mode of the bucket wheel machine, when the bucket wheel machine receives an operation command again, the historical position data of the bucket wheel machine of the area in a PLC memory is triggered, and the historical data of the bucket wheel machine stacking or material taking of the area is called according to the current operation command and the operation area, wherein the position data of the bucket wheel machine when the bucket wheel machine finishes the operation in each area of a coal yard are stored through the PLC, and then the historical data of the bucket wheel machine in the area are triggered and read under different conditions when the bucket wheel machine operates in the coal;
step S5: comparing historical data of the bucket wheel machine in the area with current bucket wheel machine position data, automatically positioning a last working point by the bucket wheel machine on the premise of ensuring the safety of the operation track of the bucket wheel machine, namely positioning the coal yard area, and performing automatic coal piling and taking operation after the bucket wheel machine reaches a preset position;
step S6: when the bucket wheel machine is in automatic stacking operation, a material level meter at the head of the bucket wheel machine is utilized, when the stacking reaches a set height, the bucket wheel machine carries out the next stacking action, so that the automatic stacking of the bucket wheel machine is realized, and the safe and stable operation of the bucket wheel machine is ensured by combining a protection limit and a high-definition video monitoring system on the bucket wheel machine;
step S7: when the bucket wheel machine automatically takes materials, the belt weigher or the laser material flow sensor is matched with the bucket wheel machine rotating angle, when the bucket wheel machine rotates to reach a historical angle and the material flow value of the belt weigher or the laser material flow sensor is smaller than a certain value, the bucket wheel machine is judged to take the materials to the edge of a coal pile, then the bucket wheel machine moves forwards, after the bucket wheel machine moves forwards, the bucket wheel machine rotates in the opposite direction, and the reciprocating action in the same way is realized to automatically take the materials.
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| CN109740944A (en) * | 2019-01-07 | 2019-05-10 | 阜阳华润电力有限公司 | Data managing method and data administrator |
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| CN112110220A (en) * | 2020-10-13 | 2020-12-22 | 中国大唐集团科技工程有限公司 | Unmanned operation system for material stacking and taking of bucket wheel machine |
| CN113320995A (en) * | 2021-05-25 | 2021-08-31 | 中冶南方工程技术有限公司 | Unmanned control system for stockyard stacker-reclaimer |
| CN113284114B (en) * | 2021-05-28 | 2022-12-16 | 华能聊城热电有限公司 | Bucket wheel machine rotation angle measurement and coal flow equalization method based on image processing |
| CN113885422A (en) * | 2021-08-23 | 2022-01-04 | 河北邯峰发电有限责任公司 | Unmanned intelligent system of bucket wheel machine |
| CN114803391B (en) * | 2022-05-12 | 2023-11-03 | 北京华能新锐控制技术有限公司 | Unmanned automatic material taking method for bucket wheel machine of intelligent fuel system |
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