CN111429026B - Method for evaluating performance of electric shovel of strip mine - Google Patents
Method for evaluating performance of electric shovel of strip mine Download PDFInfo
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- CN111429026B CN111429026B CN202010292124.7A CN202010292124A CN111429026B CN 111429026 B CN111429026 B CN 111429026B CN 202010292124 A CN202010292124 A CN 202010292124A CN 111429026 B CN111429026 B CN 111429026B
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Abstract
The invention discloses a method for evaluating the performance of an electric shovel of an open pit mine, which can obtain the electric shovel performance indexes such as the yield, the energy consumption, the cycle operation time, the percentage of full ladles, the rotation of an excavating belt, the motor stalling and the like by analyzing the state parameters of the electric shovel and processing the state parameters, and comprehensively evaluate the performance, the economy and the operation level of a driver of the electric shovel through the performance indexes.
Description
Technical Field
The invention belongs to the energy industry, and particularly relates to a method for evaluating the performance of an electric shovel of a strip mine, which is suitable for analyzing the performance of the electric shovel of the strip mine, analyzing the economy of the electric shovel of the strip mine and analyzing the operation level of a driver of the electric shovel of the strip mine.
Background
With the advance of industry 4.0, scientific evaluation on the operation performance of important equipment is urgently needed in an open pit mine, an open pit mine electric shovel is important equipment influencing open pit mine production, a scientific evaluation method does not exist at present, and how to utilize real-time state data of the open pit mine electric shovel equipment and scientifically evaluate the performance of the electric shovel after processing treatment becomes a technical difficulty in the industry.
Disclosure of Invention
The invention aims to provide a method for evaluating the performance of an open-pit electric shovel, which is characterized in that a model for evaluating the performance of the open-pit electric shovel is obtained through processing and analysis according to real-time state parameters of the open-pit electric shovel, so that the performance index of the open-pit electric shovel can be calculated on line conveniently, and the performance analysis, the economic analysis and the on-line evaluation of the operation level of an electric shovel driver are carried out on the electric shovel.
In order to achieve the purpose, the invention adopts the technical scheme that:
a method for evaluating the performance of an electric shovel of a strip mine comprises the following steps:
1) Collecting real-time data of electric shovel operation
Collecting real-time data of the operation of the electric shovel, wherein the real-time data comprise lifting current TSDL, pushing current TYDL, fighting action KDDZ, lifting power TSGL, pushing power TYGL, rotary power HZGL, lifting given TSGD, pushing given TYGD, rotary given HZGD, lifting torque TSZJ, pushing torque TYZJ and lifting drum encoder TSJTBMQ real-time data;
2) Processing real-time data
Obtaining the electric shovel yield CL, energy consumption NH, cycle operation time XHZYSJ, fill percentage MDBFB, excavation belt rotation WJDHZ and motor stalling DJDZ electric shovel performance indexes through the real-time data of the secondary processing electric shovel;
3) Establishing a radar chart for evaluating the performance of the electric shovel
Performing radar map analysis on electric shovel performance indexes such as electric shovel yield, energy consumption, cycle operation time, percentage of full bucket, rotation of an excavating belt, motor stalling and the like to obtain an electric shovel performance evaluation system;
4) Evaluating shovel performance and shovel driver operating level
And (4) scoring in real time according to the electric shovel performance radar chart, and evaluating the electric shovel performance and the operation level of a driver.
The further improvement of the invention is that in the step 2), the calculation method of the electric shovel performance index is as follows:
electric shovel yield CL: and (3) comparing the lifting current value of one second before bucket opening as a reference value with the full bucket rated current value of the electric shovel, and judging whether the single ladle is full or not, wherein the calculation process is as follows:
when TSJTBMQ >4000 and KDDZ =1, calculating the real-time yield of the electric shovel, and the formula is as follows:
electric shovel yield = TSDL _1/600 x 30
Wherein TSDL _1 is a historical value of TSDL one second before the calculation time, 4000 is the vehicle height, 1 is in an on state, 600 is the rated lifting current, and 30 is the rated capacity of the electric shovel;
cycle operation time XHZYSJ: the calculation process of the time interval between two adjacent electric shovel loading processes is as follows:
when KDDZ =1, starting timing, and ending timing until the next KDDZ =1, and counting a cycle operation period, wherein the timing result in the period is the cycle operation time, and when the cycle operation time is less than 30 seconds or more than 2 minutes, the timing result is not output;
energy consumption NH: the ratio of the power consumption to the yield of the electric shovel in a cycle working period is calculated as follows:
when KDDZ =1, starting to accumulate the power consumption of the electric shovel until the next KDDZ =1, ending the accumulation, and realizing the accumulation of the accumulated power DCHDL through the total power DCZGL of the electric shovel and the calculation interval duration, wherein the formula is as follows:
energy consumption = DCHDL/CL
Wherein DCZGL = ZTGL + CTGL + TYGL + HZGL, ZTGL is main power, CTGL is auxiliary power, TYGL is pushing power, and HZGL is rotation power; KDDZ is the opening action; CL is the shovel output;
percentage of full fill MDBFB: the ratio of the full bucket unloading times of the electric shovel to the total unloading times is calculated as follows:
when KDDZ =1 and TSJTBMQ >4000, calculating to be one unloading, counting the total unloading times, simultaneously reading the historical value TDSL _1 of TSDL one second before the calculation time, and calculating to be one full bucket if TDSL _1>600, and counting the full bucket unloading times of the electric shovel;
percent fill = MDXZCS/ZXZCS
Wherein MDXZCS is the full bucket unloading times of the electric shovel, and ZXZCS is the total unloading times;
the digging belt is turned to alarm, and the alarm logic is as follows:
when TSZJ and TYZJ are larger than 90% of the respective rated torque, judging whether HZGD is larger than 10% or smaller than-10%, and if yes, alarming;
the motor locked-rotor alarm has the following alarm logics:
and when TSDL and TYDL are larger than respective locked-rotor currents, TSGD and TYGD are not reduced, the duration of the whole process is longer than 3 seconds, if yes, an alarm is given, and otherwise, the alarm is normal.
The invention has the following beneficial technical effects;
by analyzing the state parameters of the electric shovel, the electric shovel performance indexes such as the electric shovel yield, the energy consumption, the cycle operation time, the percentage of full ladles, the digging belt rotation, the motor stalling and the like can be obtained after the state parameters are processed, and the performance, the economy and the electric shovel driver operation level of the electric shovel are comprehensively evaluated through the performance indexes.
Drawings
FIG. 1 is a logic diagram of a full bucket current draw;
FIG. 2 is a logic diagram of a mining belt slewing alarm;
FIG. 3 is a motor stall warning logic diagram;
FIG. 4 is a radar chart for evaluating the performance of an electric shovel;
FIG. 5 is a graph of throughput;
FIG. 6 is a graph of energy consumption;
FIG. 7 is a graph of the number of times of full fill;
FIG. 8 is a graph of the number of times of opening the bucket;
FIG. 9 is a graph of cycle time;
fig. 10 is a safety index graph.
Detailed Description
The invention is further described below with reference to the following figures and examples.
The invention provides a method for evaluating the performance of an electric shovel of a strip mine, which comprises the following steps:
1. collecting real-time data of electric shovel operation
The real-time data of the electric shovel operation are collected and comprise lifting current TSDL, pushing current TYDL, fighting action KDDZ, lifting power TSGL, pushing power TYGL, rotary power HZGL, lifting given TSGD, pushing given TYGD, rotary given HZGD, lifting torque TSZJ, pushing torque TYZJ and lifting drum encoder TSJTBMQ real-time data.
2. Processing real-time data
Obtaining the performance indexes of the electric shovel, such as the yield CL, the energy consumption NH, the cycle operation time XHZYSJ, the fill percentage MDBFB, the excavation belt rotation WJDHZ and the motor stalling DJDDZ, through the real-time data of the secondary processing electric shovel, wherein the calculation method of the performance indexes comprises the following steps:
1) Electric shovel yield CL: and (3) comparing the lifting current value of one second before bucket opening as a reference value with the full bucket rated current value of the electric shovel, and judging whether the single ladle is full or not, wherein the calculation process is as follows:
when TSJTBMQ >4000 and KDDZ =1, calculating the real-time yield of the electric shovel, and the formula is as follows:
electric shovel yield = TSDL _1/600 x 30
TSDL _1 is a historical value of TSDL one second before the calculation time, 4000 is the vehicle height, 1 is in an on state, 600 is the rated lifting current, and 30 is the rated capacity of the electric shovel.
2) Cycle time XHZYSJ: the calculation process of the time interval between two adjacent loading of the electric shovel (namely the time difference between two opening buckets) is as follows:
and when KDDZ =1, starting timing, ending timing until the next KDDZ =1, counting a cycle operation period, wherein the timing result in the period is the cycle operation time, and when the cycle operation time is less than 30 seconds or more than 2 minutes, the timing result is not output.
3) Energy consumption NH: the ratio of the power consumption to the yield of the electric shovel in a cycle of operation. The calculation process is as follows:
and when KDDZ =1, starting to accumulate the power consumption of the electric shovel until the next KDDZ =1, ending accumulation, and accumulating the accumulated power DCHDL through the total power DCZGL of the electric shovel and the calculation interval duration. The formula is as follows:
energy consumption = DCHDL/CL
Wherein DCZGL = ZTGL + CTGL + TYGL + HZGL, ZTGL is main power, CTGL is auxiliary power, TYGL is pushing power, and HZGL is rotation power; KDDZ is the fighting action; CL is shovel output.
4) Percentage of full fill MDBFB: the ratio of the times of full bucket unloading of the electric shovel to the total unloading times is calculated as follows:
when KDDZ =1 and TSJTBMQ >4000, counting the total unloading times for one unloading, simultaneously reading the historical value TDSL _1 of TSDL one second before the calculation time, and counting the full-bucket unloading times for the electric shovel if TDSL _1> 600.
Percent full fill = MDXZCS/ZXZCS
Wherein, MDXZCS is the full-bucket unloading times of the electric shovel, and ZXZCS is the total unloading times. The full bucket current extraction logic diagram is shown in FIG. 1:
5) Safety index
a) Digging belt rotary alarm
And alarm logic: and when TSZJ and TYZJ are larger than 90% of the rated torque of each, judging whether HZGD is larger than 10% or smaller than-10%, and if yes, alarming. Rated torques for electric shovels model WK-20 and WK-35 are shown in the following table:
the digging belt rotation alarm logic is shown in figure 2:
b) Motor stalling alarm
And alarm logic: when TSDL and TYDL are greater than the respective locked rotor current (locked rotor current = rated current x 1.2 and does not change over time), TSGD and TYGD do not decrease and the entire process duration is greater than 3 seconds, if true, an alarm is given, otherwise normal. Rated currents of the electric shovel model WK-20 and model WK-35 are shown in the following table:
the motor locked-rotor alarm logic is shown in fig. 3:
3. establishing a radar chart for evaluating the performance of the electric shovel
And (4) performing radar map analysis on the electric shovel performance indexes such as the electric shovel yield, the energy consumption, the cycle operation time, the percentage of full buckets, the digging belt rotation, the motor stalling and the like to obtain an electric shovel performance evaluation system.
The electric shovel data model is a radar map, and 5 coordinates of the radar map are yield, energy consumption, percentage of fill-up, cycle time and safety index respectively. The higher the yield is, the more full the radar map filling is, the lower the energy consumption is, the greater the full bucket percentage is, the more full the radar map filling is, the smaller the cycle time is, the more full the radar map filling is, and the smaller the safety index is, the more full the radar map filling is.
4. Evaluating shovel performance and driver operating level
And (4) scoring in real time according to the electric shovel performance radar chart, and evaluating the electric shovel performance and the operation level of a driver. And respectively drawing curves of the performance indexes, and analyzing the performance of the electric shovel and the operation level of an electric shovel driver through the curves.
As shown in fig. 5 and 6, the yield and energy consumption curves of the electric shovel driver on duty are plotted.
The percentage full-fill curves are plotted as open-time curves and full-time curves, respectively, as shown in fig. 7 and 8.
In addition, there are cycle time curves and safety index curves, as shown in fig. 9 and 10.
Claims (1)
1. A method for evaluating the performance of an electric shovel of a strip mine is characterized by comprising the following steps:
1) Collecting real-time data of electric shovel operation
Collecting real-time data of the operation of the electric shovel, wherein the real-time data comprise lifting current TSDL, pushing current TYDL, fighting action KDDZ, lifting power TSGL, pushing power TYGL, rotary power HZGL, lifting given TSGD, pushing given TYGD, rotary given HZGD, lifting torque TSZJ, pushing torque TYZJ and lifting drum encoder TSJTBMQ real-time data;
2) Processing real-time data
Obtaining the electric shovel yield CL, energy consumption NH, cycle operation time XHZYSJ, fill percentage MDBFB, excavation belt rotation WJDHZ and motor stalling DJDZ electric shovel performance indexes through the real-time data of the secondary processing electric shovel; the calculation method of the performance index of the electric shovel comprises the following steps:
electric shovel yield CL: and (3) comparing the lifting current value of one second before bucket opening as a reference value with the full bucket rated current value of the electric shovel, and judging whether the single bucket is full or not, wherein the calculation process is as follows:
when TSJTBMQ >4000 and KDDZ =1, calculating the real-time yield of the electric shovel, and the formula is as follows:
electric shovel yield = TSDL _1/600 × 30
Wherein TSDL _1 is a historical value of TSDL one second before the calculation time, 4000 is the vehicle height, 1 is in an on state, 600 is the rated lifting current, and 30 is the rated capacity of the electric shovel;
cycle time XHZYSJ: the calculation process of the time interval between two adjacent loading of the electric shovel is as follows:
when KDDZ =1, starting timing, and ending timing until the next KDDZ =1, and counting a cycle operation period, wherein the timing result in the period is the cycle operation time, and when the cycle operation time is less than 30 seconds or more than 2 minutes, the timing result is not output;
energy consumption NH: the ratio of the power consumption to the yield of the electric shovel in a cycle working period is calculated as follows:
when KDDZ =1, starting to accumulate the power consumption of the electric shovel until the next KDDZ =1, ending accumulation, and realizing the accumulated power DCHDL through accumulation of the total power DCZGL of the electric shovel and the calculation interval duration, wherein the formula is as follows:
energy consumption = DCHDL/CL
Wherein DCZGL = ZTGL + CTGL + TYGL + HZGL, ZTGL is main power, CTGL is auxiliary power, TYGL is pushing power, and HZGL is rotation power; KDDZ is the fighting action; CL is the shovel output;
percentage of full fill MDBFB: the ratio of the full bucket unloading times of the electric shovel to the total unloading times is calculated as follows:
when KDDZ =1 and TSJTBMQ >4000, calculating to be one unloading, counting the total unloading times, simultaneously reading the historical value TDSL _1 of TSDL one second before the calculation time, and calculating to be one full bucket if TDSL _1>600, and counting the full bucket unloading times of the electric shovel;
percent fill = MDXZCS/ZXZCS
Wherein MDXZCS is the full bucket unloading times of the electric shovel, and ZXZCS is the total unloading times;
the digging belt is turned to alarm, and the alarm logic is as follows:
when TSZJ and TYZJ are larger than 90% of the respective rated torque, judging whether HZGD is larger than 10% or smaller than-10%, and if yes, alarming;
the motor locked-rotor alarm has the following alarm logics:
when TSDL and TYDL are larger than respective locked rotor currents, TSGD and TYGD are not reduced, the duration time of the whole process is longer than 3 seconds, if yes, an alarm is given, and otherwise, the process is normal;
3) Establishing a radar chart for evaluating the performance of the electric shovel
Performing radar map analysis on electric shovel performance indexes such as electric shovel yield, energy consumption, cycle operation time, percentage of full bucket, rotation of an excavating belt, motor stalling and the like to obtain an electric shovel performance evaluation system;
4) Evaluating shovel performance and shovel driver operating level
And (4) scoring in real time according to the electric shovel performance radar chart, and evaluating the electric shovel performance and the operation level of a driver.
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