CN112474018A - Coal crusher monitoring system and monitoring method based on PLC - Google Patents
Coal crusher monitoring system and monitoring method based on PLC Download PDFInfo
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- CN112474018A CN112474018A CN202011161552.2A CN202011161552A CN112474018A CN 112474018 A CN112474018 A CN 112474018A CN 202011161552 A CN202011161552 A CN 202011161552A CN 112474018 A CN112474018 A CN 112474018A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C25/00—Control arrangements specially adapted for crushing or disintegrating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C23/00—Auxiliary methods or auxiliary devices or accessories specially adapted for crushing or disintegrating not provided for in preceding groups or not specially adapted to apparatus covered by a single preceding group
- B02C23/04—Safety devices
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- Crushing And Grinding (AREA)
- Disintegrating Or Milling (AREA)
Abstract
The invention discloses a coal crusher monitoring system and a monitoring method based on a PLC, and relates to the field of monitoring of operation of coal crushers. The system comprises a data acquisition module, a data conversion module and a data processing module, wherein the data acquisition module comprises a temperature sensor and a vibration sensor, the data conversion module comprises a signal conditioner and an A/D converter, and the data processing module comprises a computer and a PLC control unit; the data measured by the temperature sensor and the vibration sensor are processed by the signal conditioner and the A/D converter and then respectively transmitted to the PLC control unit and the computer. The invention solves the problem that the original system can not monitor a plurality of coal crushers, the processed data of each coal crusher is also input into a computer, and the computer is also internally provided with spectrum analysis software. The invention saves a large amount of cost, has simple maintenance process, adopts the spectrum analysis software, can accurately position the fault point and provides a basis for the equipment fault analysis and diagnosis.
Description
Technical Field
The invention relates to the field of monitoring of operation of coal crushers, in particular to a coal crusher monitoring system and a coal crusher monitoring method based on a PLC.
Background
The coal crusher is a key large-scale device in a transportation system of a power plant and a coal washing plant, and the operation working state of the coal crusher has important influence on production. Raw coal is fed into a coal crusher through a belt, a rotor shaft drives a ring hammer to rotate and impact coal blocks, and the crushed coal is made into coal powder through a coal mill. Because the power and the load of the coal crusher are large, the vibration, the noise and the dust pollution of the working site are serious, and the operating personnel can hardly monitor the working state of the coal crusher for a long time.
During the operation of a coal breaker of a coal conveying system of a coal mine, generally, due to mechanical abrasion, faults of large rotor vibration, high bearing temperature and the like often occur, an original coal breaker monitoring system adopts a single chip microcomputer technology, the anti-interference capability is poor, the service time is long, the fault rate is high, the real-time monitoring on the vibration and temperature conditions of the coal breaker cannot be implemented, equipment can only be measured by a temperature detector and a vibration meter on site by equipment maintenance personnel, the measurement cannot be automated, the manual measurement is realized, the frequency cannot reach the standard, so that the vibration spectrum is convenient to analyze, the first-hand fault diagnosis data on site is provided, and the improvement on the coal breaker monitoring system is necessary.
Disclosure of Invention
The invention provides a coal crusher monitoring system and a monitoring method based on a PLC (programmable logic controller) in order to solve various problems of an original coal crusher monitoring system.
The invention is realized by the following technical scheme: a coal breaker monitoring system based on a PLC comprises a data acquisition module, a data conversion module and a data processing module, wherein the data acquisition module comprises a temperature sensor and a vibration sensor, the data conversion module comprises a signal conditioner and an A/D converter, and the data processing module comprises a computer and a PLC control unit; setting n coal breakers, wherein the number of the temperature sensors for each coal breaker is two, and the temperature sensors are used for measuring the temperature of two bearings of the rotor in real time and transmitting data; the number of the vibration sensors is four, two of the vibration sensors are arranged at the horizontal position and the vertical position of the left bearing to measure horizontal end vibration value data and vertical end vibration value data, and the other two vibration sensors are arranged at the horizontal position and the vertical position of the right bearing to measure horizontal end vibration value data and vertical end vibration value data; the data measured by the temperature sensor and the vibration sensor are processed by the signal conditioner and the A/D converter and then are respectively transmitted to the PLC control unit and the computer; the PLC control unit comprises a multi-directional selection switch module, an IM (instant messaging) port, a start-stop input port, a PLC timer and 6 digital quantity input ports, wherein a start button and a stop button of each coal crusher are connected with the start-stop input port of the PLC control unit, the IM port is connected with the multi-directional selection switch module, and the multi-directional selection switch module is used for selecting a signal of which coal crusher is sampled; data acquired by two temperature sensors and four vibration sensors of each coal crusher are input into 6 digital quantity input ports of a PLC control unit after passing through a signal conditioner and an A/D converter, diodes are arranged on input lines of digital quantities of n-1 coal crushers, the direction of each diode is the digital quantity input port of the PLC control unit, and the digital quantity input ports of the PLC control unit are directly input into the input lines of the digital quantities of the remaining coal crushers without arranging the diodes; the processed data of each coal crusher is also input into a computer, and frequency spectrum analysis software is also installed in the computer.
The working principle of the coal breaker monitoring system based on the PLC is as follows: when a plurality of coal crushers work, a PLC control unit is adopted to control which coal crusher is sampled and sampling conversion frequency is adopted, then a temperature sensor and a vibration sensor acquire temperature and vibration data of the coal crusher and transmit the temperature and vibration data to the PLC control unit and a computer for data processing through a signal conditioner and an A/D converter, the PLC compares input data with a standard value and then executes an alarm and a stop instruction, meanwhile, after the A/D converter transmits the data to the computer, the computer stores the data and draws a frequency spectrum curve after the data is processed by corresponding digital signal processing software, and the frequency spectrum curve is compared with a normal frequency spectrum in a database to diagnose system faults; in order to avoid the problem of parasitic circuits possibly existing when a plurality of coal crushers transmit data, a grouping input method of diode isolation is adopted in a system input circuit, and diode isolation is added to the commodity of the A/D converter for outputting data of n-1 coal crushers. The monitoring method of the coal breaker monitoring system based on the PLC comprises the following steps: the method comprises the following steps:
starting n coal breakers, and inputting starting signals to an IM port of a PLC control unit;
setting a multi-directional switch conversion time interval t of the multi-directional selection switch module on the basis of meeting a time domain sampling theorem by a multi-directional selection switch module of the PLC control unit, wherein t is 0.02s, and carrying out sequential sampling on a plurality of coal breakers;
when the coal crusher is converted into any coal crusher, the temperature sensor collects temperature data of two bearings of a rotor of the coal crusher, and the temperature data is input into two digital quantity input ports of the PLC control unit after passing through the signal conditioner and the A/D converter; the vibration sensor collects the horizontal and vertical positions of the left and right bearings to measure the vibration value data of the horizontal and vertical ends, and the vibration value data is input into the rest four digital input ports of the PLC control unit after passing through the signal conditioner and the A/D converter; simultaneously, the data are also transmitted into the computer;
fourthly, the computer stores data, draws temperature and vibration frequency spectrum curves after being processed by corresponding digital frequency spectrum analysis software, compares the temperature and vibration frequency spectrum curves with normal frequency spectrums in the database and diagnoses system faults;
when the temperature data measurement exceeds 80 ℃, the PLC control unit marks and outputs alarm display, and stops the machine; when the vibration data exceeds 0.15mm, the PLC control unit marks and gives an alarm, and when the vibration data exceeds 0.25mm, the PLC control unit marks and stops the machine.
Compared with the prior art, the invention has the following beneficial effects: according to the coal breaker monitoring system and the monitoring method based on the PLC, faults of the rotor and the hydraulic coupler are effectively monitored for many times in one year through the practical use of the monitoring system, so that the rotor and the hydraulic coupler are prevented from being seriously damaged, the maintenance cost is saved by more than 2 ten thousand yuan, and the indirect cost is more than 10 ten thousand yuan; the temperature sensor is replaced by a non-contact infrared sensor, the damage rate of the sensor is greatly reduced from 4 times per month to 1 time per month in the maintenance period, a large amount of cost is saved, the maintenance process is simple, and the sensor is reliably enhanced; meanwhile, a system modified by adopting a diode-isolated packet input method can control a plurality of coal crushers, so that the normal operation of the monitoring system is ensured; the adopted spectrum analysis software can record the monitoring data and draw a time-amplitude curve and a spectrum curve, can accurately position a fault point and provides a basis for equipment fault analysis and diagnosis.
Drawings
Fig. 1 is a connection diagram of the structural module of the present invention.
FIG. 2 is a diagram of an input circuit according to an embodiment of the present invention.
Fig. 3 is an input/output interface table of the PLC control unit according to an embodiment of the present invention.
Detailed Description
The present invention is further illustrated by the following specific examples.
A PLC-based coal pulverizer monitoring system, as shown in fig. 1 and 2: the system comprises a data acquisition module, a data conversion module and a data processing module, wherein the data acquisition module comprises a temperature sensor and a vibration sensor, the data conversion module comprises a signal conditioner and an A/D converter, and the data processing module comprises a computer and a PLC control unit; setting n coal breakers, wherein the number of the temperature sensors for each coal breaker is two, and the temperature sensors are used for measuring the temperature of two bearings of the rotor in real time and transmitting data; the number of the vibration sensors is four, two of the vibration sensors are arranged at the horizontal position and the vertical position of the left bearing to measure horizontal end vibration value data and vertical end vibration value data, and the other two vibration sensors are arranged at the horizontal position and the vertical position of the right bearing to measure horizontal end vibration value data and vertical end vibration value data; the data measured by the temperature sensor and the vibration sensor are processed by the signal conditioner and the A/D converter and then are respectively transmitted to the PLC control unit and the computer; the PLC control unit comprises a multi-directional selection switch module, an IM (instant messaging) port, a start-stop input port, a PLC timer and 6 digital quantity input ports, wherein a start button and a stop button of each coal crusher are connected with the start-stop input port of the PLC control unit, the IM port is connected with the multi-directional selection switch module, and the multi-directional selection switch module is used for selecting a signal of which coal crusher is sampled; data acquired by two temperature sensors and four vibration sensors of each coal crusher are input into 6 digital quantity input ports of a PLC control unit after passing through a signal conditioner and an A/D converter, diodes are arranged on input lines of digital quantities of n-1 coal crushers, the direction of each diode is the digital quantity input port of the PLC control unit, and the digital quantity input ports of the PLC control unit are directly input into the input lines of the digital quantities of the remaining coal crushers without arranging the diodes; the processed data of each coal crusher is also input into a computer, and frequency spectrum analysis software is also installed in the computer.
In this embodiment, the temperature sensor is a non-contact infrared temperature measurement sensor; the number of the coal breakers is two, and the multi-directional selection switch module is a bidirectional selection switch; the frequency spectrum analysis software is Labview; the A/D converter is an 8-channel 24-bit converter of ADS 1216; the PLC control unit is s7-200 and comprises 14 digital quantity inputs. The input and output signal interfaces in this embodiment are shown in the table of fig. 3.
Fig. 2 shows a method for connecting a coal crusher a and a coal crusher B to a PLC control unit, where the method includes:
starting two coal crushers, and inputting starting signals to an IM (instant messaging) port of a PLC (programmable logic controller) control unit;
secondly, a multi-directional selection switch module of the PLC control unit, namely a bidirectional selection shape, sets a bidirectional switch conversion time interval t on the basis of meeting the time domain sampling theorem, wherein t is 0.02s, and carries out sequential sampling of two coal breakers: when the monitoring system monitors the vibration value of the bearing operation temperature of the coal breaker A, the bidirectional selector switch is controlled to be switched to the path A by the coal breaker starting signal A, and the bearing data is monitored when the coal breaker operates; monitoring the coal breaker B in the same way, wherein the starting signal of the coal breaker B controls the bidirectional selector switch to be switched to the path B for monitoring;
the temperature sensor collects temperature data of two bearings of the coal breaker rotor, and the temperature data is input into two digital quantity input ports of the PLC control unit after passing through the signal conditioner and the A/D converter; the vibration sensor collects the horizontal and vertical positions of the left and right bearings to measure the vibration value data of the horizontal and vertical ends, and the vibration value data is input into the rest four digital input ports of the PLC control unit after passing through the signal conditioner and the A/D converter; simultaneously, the data are also transmitted into the computer; the PLC is ensured to acquire temperature and vibration data of the coal pulverizer A, B at different time intervals, and programs are used for processing data of A, B two coal pulverizers; in the system, an input circuit A adopts a diode-isolated grouping input method, a switch SA is controlled by a timer to be respectively switched to A, B paths of input data, and the diode of the circuit has the function of avoiding generating a parasitic circuit and ensuring the correct input of signals; as shown in FIG. 2, the odd icons represent A-breakers and the even icons represent B-breakers;
fourthly, the computer stores data, draws temperature and vibration frequency spectrum curves after being processed by corresponding Labview software, compares the temperature and vibration frequency spectrum curves with normal frequency spectrums in the database and diagnoses system faults;
when the temperature data measurement exceeds 80 ℃, the PLC control unit marks and outputs alarm display, and stops the machine; when the vibration data exceeds 0.15mm, the PLC control unit marks and gives an alarm, and when the vibration data exceeds 0.25mm, the PLC control unit marks and stops the machine.
The scope of the invention is not limited to the above embodiments, and various modifications and changes may be made by those skilled in the art, and any modifications, improvements and equivalents within the spirit and principle of the invention should be included in the scope of the invention.
Claims (7)
1. The utility model provides a coal breaker monitoring system based on PLC which characterized in that: the system comprises a data acquisition module, a data conversion module and a data processing module, wherein the data acquisition module comprises a temperature sensor and a vibration sensor, the data conversion module comprises a signal conditioner and an A/D converter, and the data processing module comprises a computer and a PLC control unit; setting n coal breakers, wherein the number of the temperature sensors for each coal breaker is two, and the temperature sensors are used for measuring the temperature of two bearings of the rotor in real time and transmitting data; the number of the vibration sensors is four, two of the vibration sensors are arranged at the horizontal position and the vertical position of the left bearing to measure horizontal end vibration value data and vertical end vibration value data, and the other two vibration sensors are arranged at the horizontal position and the vertical position of the right bearing to measure horizontal end vibration value data and vertical end vibration value data; the data measured by the temperature sensor and the vibration sensor are processed by the signal conditioner and the A/D converter and then are respectively transmitted to the PLC control unit and the computer;
the PLC control unit comprises a multi-directional selection switch module, an IM (instant messaging) port, a start-stop input port, a PLC timer and 6 digital quantity input ports, wherein a start button and a stop button of each coal crusher are connected with the start-stop input port of the PLC control unit, the IM port is connected with the multi-directional selection switch module, and the multi-directional selection switch module is used for selecting a signal of which coal crusher is sampled; data acquired by two temperature sensors and four vibration sensors of each coal crusher are input into 6 digital quantity input ports of a PLC control unit after passing through a signal conditioner and an A/D converter, diodes are arranged on input lines of digital quantities of n-1 coal crushers, the direction of each diode is the digital quantity input port of the PLC control unit, and the digital quantity input ports of the PLC control unit are directly input into the input lines of the digital quantities of the remaining coal crushers without arranging the diodes;
the processed data of each coal crusher is also input into a computer, and frequency spectrum analysis software is also installed in the computer.
2. The PLC-based coal pulverizer monitoring system of claim 1, wherein: the temperature sensor is a non-contact infrared temperature measurement sensor.
3. The PLC-based coal pulverizer monitoring system of claim 1, wherein: the coal crusher is provided with two coal crushers, and the multi-directional selection switch module is a bidirectional selection switch.
4. The PLC-based coal pulverizer monitoring system of claim 1, wherein: the spectrum analysis software is Labview.
5. The PLC-based coal pulverizer monitoring system of claim 1, wherein: the A/D converter is selected from 8-channel 24-bit converter of ADS 1216.
6. The PLC-based coal pulverizer monitoring system of claim 1, wherein: the PLC control unit is s7-200 and comprises 14 digital quantity inputs.
7. The monitoring method of the PLC-based coal pulverizer monitoring system of claim 1, wherein: the method comprises the following steps:
starting n coal breakers, and inputting starting signals to an IM port of a PLC control unit;
setting a multi-directional switch conversion time interval t of the multi-directional selection switch module on the basis of meeting a time domain sampling theorem by a multi-directional selection switch module of the PLC control unit, wherein t is 0.02s, and carrying out sequential sampling on a plurality of coal breakers;
when the coal crusher is converted into any coal crusher, the temperature sensor collects temperature data of two bearings of a rotor of the coal crusher, and the temperature data is input into two digital quantity input ports of the PLC control unit after passing through the signal conditioner and the A/D converter; the vibration sensor collects the horizontal and vertical positions of the left and right bearings to measure the vibration value data of the horizontal and vertical ends, and the vibration value data is input into the rest four digital input ports of the PLC control unit after passing through the signal conditioner and the A/D converter; simultaneously, the data are also transmitted into the computer;
fourthly, the computer stores data, draws temperature and vibration frequency spectrum curves after being processed by corresponding digital frequency spectrum analysis software, compares the temperature and vibration frequency spectrum curves with normal frequency spectrums in the database and diagnoses system faults;
when the temperature data measurement exceeds 80 ℃, the PLC control unit marks and outputs alarm display, and stops the machine; when the vibration data exceeds 0.15mm, the PLC control unit marks and gives an alarm, and when the vibration data exceeds 0.25mm, the PLC control unit marks and stops the machine.
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| CN202011161552.2A CN112474018A (en) | 2020-10-27 | 2020-10-27 | Coal crusher monitoring system and monitoring method based on PLC |
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| CN202011161552.2A CN112474018A (en) | 2020-10-27 | 2020-10-27 | Coal crusher monitoring system and monitoring method based on PLC |
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| EP0222760A1 (en) * | 1984-07-26 | 1987-05-27 | Univ Queensland | Comminution of coal, ores and industrial minerals and rocks. |
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2020
- 2020-10-27 CN CN202011161552.2A patent/CN112474018A/en active Pending
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| EP0222760A1 (en) * | 1984-07-26 | 1987-05-27 | Univ Queensland | Comminution of coal, ores and industrial minerals and rocks. |
| CN2118586U (en) * | 1991-11-08 | 1992-10-14 | 沈阳电力机械研究所 | Control arrangement for crusher |
| CN202306287U (en) * | 2011-10-18 | 2012-07-04 | 上海重型机器厂有限公司 | Remote monitoring and fault diagnosis system for coal mill |
| CN207571518U (en) * | 2017-11-30 | 2018-07-03 | 江苏中矿创慧信息科技股份有限公司 | Mine ventilator monitoring device |
| CN108981785A (en) * | 2018-06-19 | 2018-12-11 | 江苏高远智能科技有限公司 | A kind of intelligent Detection of coal breaker equipment safety |
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Application publication date: 20210312 |