CN110683378A - Method and system for controlling expected divergence amount of clinker and aggregate - Google Patents
Method and system for controlling expected divergence amount of clinker and aggregate Download PDFInfo
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- CN110683378A CN110683378A CN201910967092.3A CN201910967092A CN110683378A CN 110683378 A CN110683378 A CN 110683378A CN 201910967092 A CN201910967092 A CN 201910967092A CN 110683378 A CN110683378 A CN 110683378A
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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
- B65G67/00—Loading or unloading vehicles
- B65G67/02—Loading or unloading land vehicles
- B65G67/04—Loading land vehicles
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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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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/054—Input/output
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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
- B65G2201/00—Indexing codes relating to handling devices, e.g. conveyors, characterised by the type of product or load being conveyed or handled
- B65G2201/04—Bulk
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- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
- Aviation & Aerospace Engineering (AREA)
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- Weight Measurement For Supplying Or Discharging Of Specified Amounts Of Material (AREA)
- Filling Or Emptying Of Bunkers, Hoppers, And Tanks (AREA)
Abstract
The invention discloses a method and a system for controlling the expected divergence amount of clinker and aggregate, wherein the method comprises the following steps: the PLC judges whether the variety of the pre-loaded material of the vehicle is the same as that of the pre-loaded lane, and if so, the constant feeder starts to load the material to the vehicle; the weighing sensor is used for weighing the material weight of the weighing section of the constant feeder; a speed measuring encoder measures a speed pulse signal of a tail wheel of the constant feeder; the PLC determines the accumulated loading amount according to the material weight and the speed pulse signal of the weighing section; comparing the accumulated loading amount with the pre-installation buffer amount, and when the accumulated loading amount reaches the pre-installation buffer amount, controlling a speed regulating motor by a PLC (programmable logic controller) to reduce the rotation frequency of a driving wheel of the constant feeder; and when the accumulated loading amount reaches the pre-loading amount, stopping loading by the constant feeder. The invention avoids the conditions of wrong loading, less loading and more loading, and improves the accuracy of loading measurement and the loading efficiency.
Description
Technical Field
The invention relates to the technical field of loading of clinker and aggregate, in particular to a method and a system for controlling the expected divergence amount of the clinker and the aggregate.
Background
At present, the capture of the automobile overload from the source has great influence on cement, clinker of mine enterprises and aggregate loading. The prior art is that a flow valve is installed at the bottom of a material warehouse, and an operator manually controls the flow valve, so that the phenomena of misloading, less loading and more loading of materials exist, the misloaded materials need to be unloaded, the less loading needs to be supplemented, the more loading needs to be unloaded, and the phenomena occur very frequently, so that the environmental pollution is caused, and the production efficiency of cement and mine enterprises is greatly influenced.
Disclosure of Invention
The invention aims to provide a method and a system for controlling the divergence expected amount of clinker and aggregate, which avoid the situations of misloading, less loading and more loading of clinker and aggregate and improve the accuracy of loading and metering.
In order to achieve the purpose, the invention provides the following scheme:
the invention discloses a method for controlling the expected divergence amount of clinker and aggregate, which comprises the following steps:
the method comprises the following steps that a vehicle swipes a card on a card reader through an all-purpose card, a PLC acquires a pre-installed material variety of the vehicle from an all-purpose card server through the card reader, the PLC is in communication connection with the card reader, and a pre-installed lane is configured with the PLC;
the PLC judges whether the pre-loading material variety of the vehicle is the same as the material variety of the pre-loading lane or not, the PLC stores the material variety of the pre-loading lane, if not, the PLC outputs a loading forbidding signal, and if the pre-loading material variety of the vehicle is the same as the material variety of the pre-loading lane, the PLC obtains the pre-loading amount of the vehicle from an one-card server through the card reader and controls a quantitative feeder to start loading materials for the vehicle;
a weighing sensor arranged on the constant feeder weighs the material weight of the weighing section of the constant feeder; a speed measuring encoder arranged on the constant feeder measures a speed pulse signal of a tail wheel of the constant feeder; the PLC controller determines the accumulated loading amount of the constant feeder according to the material weight of the weighing section and the speed pulse signal;
the PLC compares the accumulated loading amount with a pre-installed buffer amount, and when the accumulated loading amount reaches the pre-installed buffer amount, the PLC controls a speed regulating motor arranged on the constant feeder to reduce the rotation frequency of a driving wheel of the constant feeder;
and when the accumulated loading amount reaches the pre-loading amount, stopping loading by the constant feeder.
Optionally, the method further includes: the operation state of the constant feeder is controlled through a handheld remote controller, the operation state comprises loading starting, loading suspending and loading stopping, and the handheld remote controller is in communication connection with the PLC through a wireless transceiver.
Optionally, the method further includes:
after the materials loaded by the vehicle reach the pre-loading amount, weighing the net weight of the materials by a weighbridge;
inputting the net weight of the material into the all-purpose card server through the all-purpose card, and sending the net weight of the material to the PLC by the all-purpose card server;
the PLC compares the pre-loading amount with the net weight to obtain an error, and if the errors of three continuous vehicles are not within a preset range, the PLC calculates a flow coefficient according to the pre-loading amount and the net weight of the three continuous vehicles;
and calibrating the flow of the constant feeder by using the flow coefficient.
Optionally, the weighing sensor includes 4 PW10A type weighing sensors, the 4 PW10A type weighing sensors support two weighing idlers of the quantitative feeder, and the 4 PW10A type weighing sensors form a rectangular surface.
Optionally, the PLC controller is connected to a display and input device, the display and input device is configured to display the pre-loading amount, the material type, the flow coefficient, and the loading prohibition signal, and the display and input device is further configured to modify the flow coefficient.
The invention also provides a system for controlling the expected amount of divergence of clinker and aggregate, which comprises:
the system comprises a material variety acquisition module, a PLC controller and a vehicle-mounted lane, wherein the material variety acquisition module is used for a vehicle to swipe a card through an all-purpose card on a card reader, the PLC controller acquires a pre-mounted material variety of the vehicle from an all-purpose card server through the card reader, the PLC controller is in communication connection with the card reader, and the pre-mounted lane is configured with the PLC controller;
the material type checking module is used for judging whether the pre-installed material type of the vehicle is the same as the material type of the pre-installed lane or not by the PLC controller, the material type of the pre-installed lane is stored in the PLC controller, if not, the PLC controller outputs a loading forbidding signal, and if the pre-installed material type of the vehicle is the same as the material type of the pre-installed lane, the PLC controller acquires the pre-installed quantity of the vehicle from an one-card server through the card reader and controls a constant feeder to start loading the material for the vehicle;
the loading quantity accumulation module is used for weighing the material weight of the weighing section of the constant feeder by a weighing sensor arranged on the constant feeder; a speed measuring encoder arranged on the constant feeder measures a speed pulse signal of a tail wheel of the constant feeder; the PLC controller determines the accumulated loading amount of the constant feeder according to the material weight of the weighing section and the speed pulse signal;
the frequency adjusting module is used for comparing the accumulated loading amount with a pre-installed buffer amount by the PLC, and when the accumulated loading amount reaches the pre-installed buffer amount, the PLC controls a speed regulating motor arranged on the constant feeder to reduce the rotation frequency of a driving wheel of the constant feeder;
and the stopping module is used for stopping loading the quantitative feeder when the accumulated loading amount reaches the pre-loading amount.
Optionally, the running state of the constant feeder is controlled through a handheld remote controller, the running state comprises loading starting, loading suspending and loading stopping, and the handheld remote controller is in communication connection with the PLC through a wireless transceiver.
Optionally, the system further includes a flow coefficient calibration module: the weighing machine is used for weighing the net weight of the materials by a weighbridge after the materials loaded by the vehicle by the constant feeder reach the pre-loading amount; inputting the net weight of the material into the all-purpose card server through the all-purpose card, and sending the net weight of the material to the PLC by the all-purpose card server; the PLC compares the pre-loading amount with the net weight to obtain an error, and if the errors of three continuous vehicles are not within a preset range, the PLC calculates an error coefficient according to the pre-loading amount and the net weight of the three continuous vehicles; and calibrating the flow of the constant feeder by using the flow coefficient.
Optionally, the weighing sensor includes 4 PW10A type weighing sensors, the 4 PW10A type weighing sensors support two weighing idlers of the quantitative feeder, and the 4 PW10A type weighing sensors form a rectangular surface.
Optionally, the PLC controller is connected to a display and input device, the display and input device is configured to display the pre-loading amount, the material type, the flow coefficient, and the loading prohibition signal, and the display and input device is further configured to modify the flow coefficient.
According to the invention content provided by the invention, the invention discloses the following technical effects:
the invention discloses a method and a system for controlling the expected amount of divergence of clinker and aggregate, wherein a vehicle is provided with an all-purpose card, a PLC (programmable logic controller) is provided with a card reader, the PLC acquires the variety of materials pre-installed on the vehicle in an all-purpose card server through the card reader and checks the variety of the materials of a pre-installed lane stored in the PLC, and the quantitative feeder is controlled to load the materials into the vehicle after the check is passed, so that the accuracy of the materials loaded on the vehicle is ensured; the quantitative feeder determines the accumulated loading amount through the weighing sensor and the speed measuring encoder, compares the accumulated loading amount with the pre-installed buffer amount, and reduces the rotation frequency of the quantitative feeder through the speed regulating motor when the pre-installed buffer amount is reached, namely, adjusts the loading speed of the quantitative feeder, so that the excessive loading and the insufficient loading of materials are avoided, and the metering accuracy of the loading is improved; in addition, the invention also improves the accuracy of the metering of loading by calibrating the flow coefficient on line.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.
FIG. 1 is a schematic flow chart of a method for controlling the expected divergence amount of clinker and aggregate according to an embodiment of the present invention;
FIG. 2 is a schematic structural diagram of a system for controlling the expected divergence of clinker and aggregate according to an embodiment of the present invention;
FIG. 3 is a detailed structural diagram of a clinker and aggregate divergence prediction control system according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The invention aims to provide a method and a system for controlling the divergence expected amount of clinker and aggregate, which avoid the situations of misloading, less loading and more loading of clinker and aggregate and improve the accuracy of loading and metering.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
As shown in figure 1, the invention discloses a method for controlling the expected amount of divergence of clinker and aggregate, which comprises the following steps:
step 101: the vehicle swipes a card on the card reader through the one-card, the PLC acquires the pre-installed material variety of the vehicle from the one-card server through the card reader, the PLC is in communication connection with the card reader, the material variety of a pre-installed lane is stored in the PLC, and the pre-installed lane is configured with the PLC.
The step 101 specifically includes configuring a one-card for each vehicle, inputting the information of the vehicle tare weight, the pre-loading amount, the required materials and the like into a one-card server (the function of the one-card system) and corresponding to the card number of the corresponding one-card, configuring a set of PLC controller for each pre-loading lane, connecting the PLC controllers with a handheld remote controller through wireless transceivers, and connecting the PLC controllers with a touch screen. After the vehicle arrives at the pre-installed lane, the card reader swipes the card by using the card of the all-purpose card, reads the card number of the all-purpose card and then transmits the card number to the PLC controller through MODBUS RTU communication, and the PLC controller is connected with the all-purpose card server through a PN/IE interface.
Step 102: the PLC judges whether the variety of the pre-installed material of the vehicle is the same as that of the pre-installed lane, if so, the step 103 is executed: the PLC controller obtains the pre-loading amount of the vehicle from the one-card server through the card reader and controls the constant feeder to start loading materials for the vehicle, and if the pre-loading amount is different from the pre-loading amount, the step 104 is executed: the PLC outputs a loading forbidding signal.
Step 102-; if the information is incorrect, the PLC outputs a loading forbidding signal to the quantitative feeder, and prompt information of material mismatching and loading forbidding is displayed on the touch screen and the handheld remote controller; if the information is correct, the PLC acquires the tare weight and the pre-load amount of the truck from the one-card server, outputs a loading signal to give the amount of the feeder and displays a prompt that the truck can be loaded on the touch screen and the handheld remote controller. A driver or an operator presses a 'start' button on the touch screen or the handheld remote controller, and the constant feeder starts loading.
The CPU of the PLC controller employs siemens S7-1200 with an integrated PN/IE interface (two RJ45 ports) and two MODBUS RTU interfaces extended.
Step 105: weighing the material weight of the weighing section of the constant feeder by a weighing sensor arranged on the constant feeder; a speed measuring encoder arranged on the constant feeder measures a speed pulse signal of a tail wheel of the constant feeder; and the PLC determines the accumulated loading amount of the constant feeder according to the material weight and the speed pulse signal of the weighing section.
Step 105 specifically comprises that the PLC is connected with the weighing and transmitting device through an MODBUS RTU interface 1; the PLC is connected with the wireless transceiver and the card reader through an MODBUS RTU interface 0; the PLC is connected with the touch screen through a PN/IE interface 0; the PLC controller is connected with the one-card server through a PN/IE interface 1.
Step 106: and the PLC compares the accumulated loading amount with the pre-installation buffer amount, and when the accumulated loading amount reaches the pre-installation buffer amount, the PLC controls a speed regulating motor arranged on the constant feeder to reduce the rotation frequency of a driving wheel of the constant feeder.
The structure of the constant feeder in steps 105 and 106 is a short belt conveyor, and the functions of the constant feeder are material conveying and dynamic metering. The weighing and transmitter weighs the materials on the weighing section of the constant feeder, converts the materials into digital quantity signals, and transmits the digital quantity signals to the PLC through MODBUS RTU interface 1 in a communication manner; the speed measuring encoder is arranged on a tail wheel of the quantitative feeder, a speed measuring encoder shaft and the tail wheel synchronously rotate, and the measured speed pulse signal is transmitted to a high-speed input port of the PLC controller; the speed regulating motor is arranged on a driving wheel of the constant feeder, and the speed of the equipment 4, namely the speed regulating motor, is regulated by changing the frequency of a frequency converter in the PLC. The PLC controller automatically calculates instantaneous flow and accumulated loading amount according to sampled material weight and speed pulse signals, compares the accumulated loading amount with a pre-installed buffer amount, controls the frequency converter to operate at a fast frequency when the pre-installed buffer amount is not reached, and operates at a slow frequency after the pre-installed buffer amount is reached, so that the functions of accurate and stable loading are realized.
The running state of the constant feeder is controlled through the handheld remote controller, and the running state comprises loading starting, loading suspending and loading stopping.
The weighing sensor comprises 4 PW10A type weighing sensors, the 4 PW10A type weighing sensors support two weighing carrier rollers of the quantitative feeder, and the 4 PW10A type weighing sensors form a rectangular surface.
Step 107: and when the accumulated loading amount reaches the pre-loading amount, stopping loading by the constant feeder.
The method further comprises the following steps:
after the material loaded by the vehicle reaches the pre-loading amount, the net weight of the material is weighed by a weighbridge.
The net weight of the material is input into the all-purpose card server through the all-purpose card, and the all-purpose card server sends the net weight of the material to the PLC.
The PLC compares the pre-loading amount with the net weight to obtain an error, if the error is within a preset range, the PLC gives a qualified signal, otherwise, the PLC gives an unqualified signal, and if the errors of three continuous vehicles are not within the preset range, the PLC calculates a flow coefficient according to the pre-loading amount and the net weight of the three continuous vehicles; and calibrating the flow of the constant feeder by using the flow coefficient, namely updating the flow coefficient in the PLC 6 by using the flow coefficient, and displaying the net weight, the flow coefficient and the error on the touch screen.
The PLC sends signals such as pre-loading amount, loading in the vehicle, loading suspension and the like to the wireless transceiver, the PLC and the wireless remote control system realize handheld mobile remote control operation and monitoring functions in an online mode, the wireless transceiver displays the signals on the handheld remote controller through wireless transmission, the handheld remote controller is provided with 1 four-row liquid crystal display, the first row displays wireless signal strength, channel numbers and battery amount, the second row displays the pre-loading amount, the third row displays the loading amount, and the fourth row displays loading states such as loading in the vehicle, loading suspension and the like. The hand-held remote controller is provided with 15 operation keys: "power", "pause/continue", "start", "stop", "alarm", "up", "down", "auxiliary start", "auxiliary stop", "left shift", "right shift", "+", "", "menu", and "confirm".
(1) Modify the pre-load amount by "move left", "move right", "+", "-" and "confirm" keys;
(2) starting loading by a start key and a confirm key;
(3) stopping loading the car through a stop key and a confirmation key;
(4) the loading is suspended through a 'suspension' key;
(5) the bulk head is controlled to ascend and descend by the ascending and descending keys;
(6) the on-site audible and visual alarm is controlled through an alarm bell key;
(7) the start and stop of an auxiliary machine (such as a dust collector) are controlled by an auxiliary machine start key and an auxiliary machine stop key;
(8) the channel is modified by the "menu", "+", "-" and "confirm" keys.
The handheld remote controller can modify operation commands such as 'preassembly', 'start', 'stop', 'pause', 'rise', 'fall' and the like and wirelessly transmits the operation commands to the wireless transceiver, and the wireless transceiver transmits the operation commands to the PLC controller through MODBUS RTU communication, so that the function of remote control operation is achieved.
In addition, the touch screen is programmed separately, and the following three functions are realized: 1. a parameter setting function: setting and modifying parameters such as a flow coefficient, a weight zero point, a weight range, a weight coefficient, a speed coefficient, a weighing segment length, a small flow signal, a loading buffer amount, a loading operation control mode and the like; 2. zero calibration and calibration: carrying out weight zero calibration and weight calibration; 3. running operation and data monitoring: the monitoring data includes: a) one-card data (license plate number, tare weight, material variety, pre-loading amount, permission/prohibition and the like), b) loading data (pre-loading amount, real-time loading amount, final loading amount, loading state, pause state and the like), and c) constant feeder operation data (flow, weight, speed, accumulated amount, drive, operation, fault and the like).
In the loading process, if a certain condition (such as the vehicle amount is full) is met and the pre-loading amount is not reached, the loading is required to be stopped, and the stop button can be pressed on the handheld remote controller to finish the loading.
In the loading process, if certain conditions (such as no material in a warehouse) are met, the loading is suspended, a 'pause/continue' button can be pressed on a hand-held remote controller, the loading is suspended, and the constant feeder stops (the hand-held remote controller displays 'loading' and 'suspending'); and after the conditions are processed, pressing a pause/continue button, starting and operating the constant feeder, and continuously accumulating the loading amount and the data before pause until the loading amount reaches the pre-loading amount.
As shown in fig. 2-3, the invention discloses a system for controlling the expected amount of clinker and aggregate divergence, which comprises:
the material type obtaining module 201 is used for swiping a card on a card reader through an all-purpose card by a vehicle, the PLC obtains a pre-installed material type of the vehicle from an all-purpose card server through the card reader, the PLC is in communication connection with the card reader, and the PLC stores the material type of a pre-installed lane.
The material variety obtaining module 201 specifically comprises that each vehicle is provided with an all-purpose card, information such as vehicle tare weight, pre-loading amount and required materials is input into an all-purpose card server (functions of an all-purpose card system) and corresponds to a corresponding all-purpose card number, each pre-loading lane is provided with a set of PLC controller, the PLC controllers are connected with a handheld remote controller 9 through a wireless transceiver 8, and the PLC controllers are connected with a touch screen 7. After the vehicle arrives at the pre-installed lane, the card reader 10 swipes the card by using the one-card, and after reading the card number of the one-card, the card reader 10 transmits the card number to the PLC through MODBUS RTU communication.
The material type checking module 202 is used for judging whether the pre-installed material type of the vehicle is the same as the material type of the pre-installed lane by the PLC controller, if not, the PLC controller outputs a vehicle loading forbidding signal, and if so, the PLC controller acquires the pre-installed quantity of the vehicle from an all-purpose card server through the card reader and controls a quantitative feeder to start loading the material for the vehicle;
the material variety checking module 202 specifically includes: the PLC controller is connected with the one-card server through a PN/IE interface, finds the information of the vehicle corresponding to the card number in the one-card server through the card number, compares the information with the information of the pre-installed lane stored in the PLC controller, and judges whether the material of the pre-installed lane is the material which needs to be installed and taken by the vehicle; if the information is incorrect, the PLC outputs a loading forbidding signal to the quantitative feeder 1, and prompt information of material mismatching and loading forbidding is displayed on the touch screen 7 and the handheld remote controller 9; if the information is correct, the PLC acquires the tare weight and the pre-load amount of the truck from the one-card server, outputs a loading allowing signal to give the amount feeder 1 and displays a prompt that the truck can be loaded on the touch screen 7 and the handheld remote controller 9. A driver or an operator presses a 'start' button on the touch screen 7 or the hand-held remote controller 9, and the constant feeder 1 starts loading.
The CPU of the PLC controller employs siemens S7-1200 with an integrated PN/IE interface (two RJ45 ports) and two MODBUS RTU interfaces extended.
The loading amount accumulation module 203 is used for weighing the material weight of the weighing section of the constant feeder 1 by the weighing sensor 2 arranged on the constant feeder 1; a speed measuring encoder 3 arranged on the quantitative feeder 1 measures a speed pulse signal of a tail wheel of the quantitative feeder 1; and the PLC determines the accumulated loading amount of the constant feeder 1 according to the material weight and the speed pulse signal of the weighing section.
The load cell 2 in the loading amount accumulation module 203 comprises 4 PW10A type load cells, the loading amount accumulation module 203 further comprises an FDQ-3 type weight transmitter, the 4 PW10A type load cells support two weighing carrier rollers of the constant feeder 1, and the 4 PW10A type load cells form a rectangular surface. PW10A type weighing sensor is middle square groove structure, and weighing idler both ends are square, and 2 PW10A type weighing sensor support a weighing idler, and the weighing sensor signal converts into digital signal through FDQ-3 type weight transmitter, transmits for PLC control system through MODBUS RTU communication. The PW10A model load cell is a model PW10AC3-200kg load cell manufactured by HBM.
The PLC is connected with the weighing sensor through an MODBUS RTU interface 1; the PLC is connected with the wireless transceiver 8 and the card reader 10 through an MODBUS RTU interface 0; the PLC controller is connected with the touch screen 7 through a PN/IE interface 0; the PLC controller is connected with the one-card server through a PN/IE interface 1.
The frequency adjusting module 204 is used for comparing the accumulated loading amount with the pre-installed buffer amount by the PLC 6, and when the accumulated loading amount reaches the pre-installed buffer amount, the PLC 6 controls a speed regulating motor arranged on the constant feeder 1 to reduce the rotation frequency of a driving wheel of the constant feeder 1;
the structure of the constant feeder 1 in the loading amount accumulation module 203 and the frequency adjustment module 204 is a short belt conveyor, and the functions of the short belt conveyor are material conveying and dynamic metering. The weighing and transmitter weighs the materials on the weighing section of the constant feeder 1, converts the materials into digital quantity signals, and transmits the digital quantity signals to the PLC 6 through MODBUS RTU interface 1 in a communication way; the speed measuring encoder 3 is arranged on a tail wheel of the quantitative feeder 1, a shaft of the speed measuring encoder 3 and the tail wheel synchronously rotate, and the measured speed pulse signal is transmitted to a high-speed input port of the PLC 6; the adjustable speed motor 4 is installed on the action wheel of the constant feeder 1, the speed of the adjustable speed motor 4 is adjusted by changing the frequency of the frequency converter 5 in the PLC controller 6, the DQ control in the PLC controller 6 indicates the control of the on-off switching value, and the DQ on-off output of the PLC controller 6 controls the on-off of the frequency converter 5. The PLC 6 automatically calculates instantaneous flow and accumulated loading amount according to sampled material weight and speed pulse signals by a program, the PLC 6 compares the accumulated loading amount with a pre-installed buffer amount, the PLC 6 controls the frequency converter 5 to operate at a high frequency when the accumulated loading amount is not reached to the pre-installed buffer amount, and the frequency converter 5 operates at a low frequency after the pre-installed buffer amount is reached, so that the functions of accurate and stable loading are realized.
And the stopping module 205 is configured to stop the loading of the constant feeder 1 when the accumulated loading amount reaches the pre-loading amount.
The running state of the constant feeder 1 is controlled through the handheld remote controller 9, the running state comprises starting loading, suspending loading and stopping loading, and the handheld remote controller 9 is in communication connection with the PLC controller 6 through the wireless transceiver 8.
The system also comprises a flow coefficient calibration module, which is used for weighing the net weight of the material by a weighbridge after the material loaded by the vehicle reaches the pre-loading amount by the constant feeder 1; the net weight of the material is recorded into the all-purpose card server through the all-purpose card, and the all-purpose card server sends the net weight of the material to the PLC 6; the PLC 6 compares the pre-loading amount with the net weight to obtain an error, if the errors of the three continuous vehicles are not in a preset range, the PLC 6 calculates a flow coefficient according to the pre-loading amount and the net weight of the three continuous vehicles, wherein the error is (net weight-pre-loading amount)/net weight multiplied by 100%; and calibrating the instantaneous flow of the constant feeder by using a flow coefficient, wherein the flow coefficient is net weight/pre-loading amount multiplied by an original flow coefficient, namely, the flow coefficient in the PLC 6 is updated by using the flow coefficient to realize the function of online scale calibration.
The PLC 6 is connected with a display and input device, the display and input device is used for displaying the pre-loading amount, the material variety, the flow coefficient and the loading forbidding signal, and the display and input device is also used for modifying the flow coefficient.
The display and input devices are a hand-held remote control 9 and a touch screen 7.
The PLC controller 6 sends signals such as the pre-loading amount, the loading in the process of loading, the loading pause and the like to the wireless transceiver 8, the wireless transceiver 8 displays the signals on the handheld remote controller 9 through wireless transmission, the handheld remote controller 9 is provided with 1 four-line liquid crystal display, the first line displays the wireless signal strength, the channel number and the battery amount, the second line displays the pre-loading amount, the third line displays the loading amount, and the fourth line displays the loading states such as the loading in the process of loading, the loading pause and the like. The hand-held remote controller 9 is provided with 15 operation keys: "power", "pause/continue", "start", "stop", "alarm", "up", "down", "auxiliary start", "auxiliary stop", "left shift", "right shift", "+", "", "menu", and "confirm".
(1) Modify the pre-load amount by "move left", "move right", "+", "-" and "confirm" keys;
(2) starting loading by a start key and a confirm key;
(3) stopping loading the car through a stop key and a confirmation key;
(4) the loading is suspended through a 'suspension' key;
(5) the bulk head is controlled to ascend and descend by the ascending and descending keys;
(6) the on-site audible and visual alarm is controlled through an alarm bell key;
(7) the start and stop of an auxiliary machine (such as a dust collector) are controlled by an auxiliary machine start key and an auxiliary machine stop key;
(8) the channel is modified by the "menu", "+", "-" and "confirm" keys.
The hand-held remote controller 9 can modify the operation commands of 'preassembly', 'start', 'stop', 'pause', 'rise', 'fall' and the like and send the operation commands to the wireless transceiver 8 in a wireless way, and the wireless transceiver 8 transmits the signal commands to the PLC controller 6 through MODBUS RTU communication, thereby achieving the function of remote control operation.
In addition, the touch screen 7 is programmed separately to implement the following three functions: 1. a parameter setting function: setting and modifying parameters such as a flow coefficient, a weight zero point, a weight range, a weight coefficient, a speed coefficient, a weighing segment length, a small flow signal, a loading buffer amount, a loading operation control mode and the like; 2. zero calibration and calibration: carrying out weight zero calibration and weight calibration; 3. running operation and data monitoring: the monitoring data includes: a) one-card data (license plate number, tare weight, material variety, pre-loading amount, permission/prohibition, etc.), b) loading data (pre-loading amount, real-time loading amount, final loading amount, loading state, suspension state, etc.), and c) operation data (flow, weight, speed, accumulated amount, drive, operation, fault, etc.) of the constant feeder 1.
In the loading process, if a certain condition (such as the vehicle amount is full) is met and the pre-loading amount is not reached, the loading is required to be stopped, and the stop button can be pressed on the handheld remote controller 9 to stop the loading.
In the loading process, if certain conditions (such as no material in a warehouse) are met, the loading is suspended, the 'pause/continue' button can be pressed on the hand-held remote controller 9, the loading is suspended, and the quantitative feeder 1 stops (the 'loading is being carried out' and the 'suspension' is displayed on the hand-held remote controller 9); and after the conditions are processed, pressing a pause/continue button, starting the constant feeder 1 to operate, and continuously accumulating the loading amount and the data before pause until the loading amount reaches the preset amount.
The PLC controller mainly realizes the following three functions: firstly, connecting with a constant feeder to realize the functions of automatic metering and quantitative loading; secondly, the system is connected with an all-purpose card system to realize the functions of automatic management and automatic on-line scale correction; and thirdly, the wireless remote control system is connected to realize the functions of handheld mobile remote control operation and monitoring.
The invention relates to a method and a system for controlling the expected divergence amount of clinker and aggregate, which achieve the technical effects that:
the loading efficiency is high. The main reasons are: a) the information is automatically checked on line with the one-card system, and compared with the information manually checked, the information is accurate and quick; b) the wireless remote control operation is simple, flexible and convenient, and one remote controller can simultaneously operate several PLC control systems. c) The operation is stable, the metering accuracy is high, the phenomena of filling and multi-loading and unloading are avoided, and the loading efficiency is greatly improved.
The metering precision is high, and the error is less than 0.5%. The main reasons are: a) weighing with 4 load cells: compared with the weighing of one load sensor and two load sensors, the four load sensors support two weighing carrier rollers to form a rectangular surface, so that the influence of material unbalance loading and belt deviation on weighing is effectively prevented; b) the weight signal is converted into a digital signal on site and transmitted through the MODBUS, so that the influence of attenuation and interference of signal transmission on the weight is effectively prevented; c) the speed of the tail wheel of the encoder is measured, the resolution of the encoder is 2500rpm, the detection precision of the number of speed pulses is high, and meanwhile, the speed measurement of the tail wheel is compared with the speed measurement of a motor and the speed measurement of a head wheel, so that the false speed caused by belt slippage, shaking, stalling and the like is prevented. d) The frequency converter controls the speed, so that errors caused by inertia when the quantitative feeder is started and stopped are greatly reduced; e) and the system is connected with the all-purpose card system, has an online calibration function and corrects errors in real time.
The embodiments in the present description are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other. For the system disclosed by the embodiment, the description is relatively simple because the system corresponds to the method disclosed by the embodiment, and the relevant points can be referred to the method part for description.
The principles and embodiments of the present invention have been described herein using specific examples, which are provided only to help understand the method and the core concept of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.
Claims (10)
1. A method for controlling the expected amount of clinker and aggregate divergence, which is characterized by comprising the following steps:
the method comprises the following steps that a vehicle swipes a card on a card reader through an all-purpose card, a PLC acquires a pre-installed material variety of the vehicle from an all-purpose card server through the card reader, the PLC is in communication connection with the card reader, and a pre-installed lane is configured with the PLC;
the PLC judges whether the pre-loading material variety of the vehicle is the same as the material variety of the pre-loading lane or not, the PLC stores the material variety of the pre-loading lane, if not, the PLC outputs a loading forbidding signal, and if the pre-loading material variety of the vehicle is the same as the material variety of the pre-loading lane, the PLC obtains the pre-loading amount of the vehicle from an one-card server through the card reader and controls a quantitative feeder to start loading materials for the vehicle;
a weighing sensor arranged on the constant feeder weighs the material weight of the weighing section of the constant feeder; a speed measuring encoder arranged on the constant feeder measures a speed pulse signal of a tail wheel of the constant feeder; the PLC controller determines the accumulated loading amount of the constant feeder according to the material weight of the weighing section and the speed pulse signal;
the PLC compares the accumulated loading amount with a pre-installed buffer amount, and when the accumulated loading amount reaches the pre-installed buffer amount, the PLC controls a speed regulating motor arranged on the constant feeder to reduce the rotation frequency of a driving wheel of the constant feeder;
and when the accumulated loading amount reaches the pre-loading amount, stopping loading by the constant feeder.
2. The clinker aggregate divergence prediction control method of claim 1, further comprising: the operation state of the constant feeder is controlled through a handheld remote controller, the operation state comprises loading starting, loading suspending and loading stopping, and the handheld remote controller is in communication connection with the PLC through a wireless transceiver.
3. The clinker aggregate divergence prediction control method of claim 1, further comprising:
after the materials loaded by the vehicle reach the pre-loading amount, weighing the net weight of the materials by a weighbridge;
inputting the net weight of the material into the all-purpose card server through the all-purpose card, and sending the net weight of the material to the PLC by the all-purpose card server;
the PLC compares the pre-loading amount with the net weight to obtain an error, and if the errors of three continuous vehicles are not within a preset range, the PLC calculates a flow coefficient according to the pre-loading amount and the net weight of the three continuous vehicles;
and calibrating the flow of the constant feeder by using the flow coefficient.
4. The method of claim 1, wherein the load cell comprises 4 PW10A type load cells, the 4 PW10A type load cells support two weighing idlers of the quantitative feeder, and the 4 PW10A type load cells form a rectangular surface.
5. The method of claim 1, wherein the PLC is connected to a display and input device for displaying the pre-load amount, the material type, the flow coefficient and the no-load signal, and for modifying the flow coefficient.
6. A clinker and aggregate divergence expected control system, the system comprising:
the system comprises a material variety acquisition module, a PLC controller and a vehicle-mounted lane, wherein the material variety acquisition module is used for a vehicle to swipe a card through an all-purpose card on a card reader, the PLC controller acquires a pre-mounted material variety of the vehicle from an all-purpose card server through the card reader, the PLC controller is in communication connection with the card reader, and the pre-mounted lane is configured with the PLC controller;
the material type checking module is used for judging whether the pre-installed material type of the vehicle is the same as the material type of the pre-installed lane or not by the PLC controller, the material type of the pre-installed lane is stored in the PLC controller, if not, the PLC controller outputs a loading forbidding signal, and if the pre-installed material type of the vehicle is the same as the material type of the pre-installed lane, the PLC controller acquires the pre-installed quantity of the vehicle from an one-card server through the card reader and controls a constant feeder to start loading the material for the vehicle;
the loading quantity accumulation module is used for weighing the material weight of the weighing section of the constant feeder by a weighing sensor arranged on the constant feeder; a speed measuring encoder arranged on the constant feeder measures a speed pulse signal of a tail wheel of the constant feeder; the PLC controller determines the accumulated loading amount of the constant feeder according to the material weight of the weighing section and the speed pulse signal;
the frequency adjusting module is used for comparing the accumulated loading amount with a pre-installed buffer amount by the PLC, and when the accumulated loading amount reaches the pre-installed buffer amount, the PLC controls a speed regulating motor arranged on the constant feeder to reduce the rotation frequency of a driving wheel of the constant feeder;
and the stopping module is used for stopping loading the quantitative feeder when the accumulated loading amount reaches the pre-loading amount.
7. The clinker aggregate divergence expected quantity control system of claim 6, wherein the operation state of the constant feeder is controlled through a hand-held remote controller, the operation state comprises loading starting, loading suspending and loading stopping, and the hand-held remote controller is in communication connection with the PLC through a wireless transceiver.
8. The clinker aggregate divergence expected control system of claim 6, further comprising a flow coefficient calibration module: the weighing machine is used for weighing the net weight of the materials by a weighbridge after the materials loaded by the vehicle by the constant feeder reach the pre-loading amount; inputting the net weight of the material into the all-purpose card server through the all-purpose card, and sending the net weight of the material to the PLC by the all-purpose card server; the PLC compares the pre-loading amount with the net weight to obtain an error, and if the errors of three continuous vehicles are not within a preset range, the PLC calculates a flow coefficient according to the pre-loading amount and the net weight of the three continuous vehicles; and calibrating the flow of the constant feeder by using the flow coefficient.
9. The clinker aggregate divergence expected control system of claim 6, wherein the load cell comprises 4 PW10A type load cells, 4 PW10A type load cells support two weighing idlers of the quantitative feeder, and 4 PW10A type load cells form a rectangular surface.
10. The clinker and aggregate divergence expected flow control system of claim 6, wherein the PLC is connected with a display and input device, the display and input device is used for displaying the pre-loading amount, the material variety, the flow coefficient and the loading prohibition signal, and the display and input device is also used for modifying the flow coefficient.
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