CN114348584B - Intelligent control system based on coal flow transportation - Google Patents
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Abstract
The invention relates to an intelligent control system based on coal stream transportation, which comprises: the coal flow conveying unit comprises a crusher, a rubber belt conveyor and a raw coal bin; the detection unit is connected with the coal flow transportation unit and comprises a coal flow detection device which is arranged on the belt conveyor and used for detecting the coal flow of the completed transportation process, a belt speed detection device which is arranged on the belt conveyor and used for detecting the linear speed of a belt, and a coal bin detection device which is arranged in the raw coal bin and used for detecting the coal storage amount in the raw coal bin; and the central control unit is connected with each component in the detection unit. The intelligent control system has the beneficial effects that the intelligent control system has complex transportation process, multiple devices and other complex characteristics on the coal flow system, is applied to the coal flow transportation system in the aspects of main transportation belts, coal feeders, coal bunker storage and video monitoring, and realizes the remote one-key start-stop unattended operation of the belts and the coal feeders on the ground by researching intelligent control technology, sensor technology and informatization technology.
Description
Technical Field
The invention relates to the field of control systems, in particular to an intelligent control system based on coal flow transportation.
Background
The rubber belt conveyor can overcome the inertia of the whole rubber belt conveyor system according to the expected speed of people under the full-load working condition to realize stable and safe starting and stopping, namely the soft starting and stopping of the rubber belt conveyor system. At present, the control of the adhesive tape transport system is more and more perfect, the control of the adhesive tape transport system adopts a very mature field bus to carry out networking, and the communication is realized on the network. The centralized control of the adhesive tape conveying system can realize remote soft start and brake of the adhesive tape conveying system, automatic monitoring of a driving device, monitoring of the belt speed of an adhesive tape conveyor, remote monitoring of a protecting device, control of on-load speed regulation and the like.
Chinese patent publication No. CN111663959B discloses an intelligent speed regulation system and method for coal flow transportation of a fully mechanized caving face in a coal mine, which are used for controlling the operation frequencies of a front scraper conveyor, a rear scraper conveyor and a reversed loader of a fully mechanized caving face transportation device of a coal mining machine.
Therefore, the intelligent speed regulation system and method for coal flow transportation of the underground fully mechanized caving face of the coal mine have the following problems:
the system is not provided with a mature and complete coal flow monitoring system, the detection system can not judge the specific position of the fault, and the belt speed of the conveyor can not be regulated in real time.
In the existing methods for monitoring the real-time traffic volume of the conveyer belt, an electronic belt scale is arranged, but a plurality of groups of weighing sensors are required to be installed, the installation steps are complicated, and the accuracy is low; the non-contact laser scanner is convenient to install, but the calculation accuracy is greatly influenced by external factors and is unstable.
In coal mine transportation engineering, a conveyor is used for conveying coal in a continuous mode through a plurality of conveying belts. At present, most multi-stage conveyor starts all conveyors in sequence from the last stage of the conveyors, and after all conveyors are stable, the system starts blanking on the conveyor belt, which is also called reverse sequence start. This approach not only results in long idle operation, but also entails unnecessary energy waste.
In the coal production process, a dispatching room needs to know the height of coal level in a coal bin in real time. If the coal level is not monitored, when the coal level in the coal bunker exceeds the highest point, the coal bunker is full, the coal flow conveyor is forced to stop running immediately, the production of a working face is affected, and accidents occur; when the coal level is lower than a certain position, empty bins can appear, and the coal feeder under the bins can be damaged, the lump coal rate can be reduced, and the like.
Disclosure of Invention
Therefore, the invention provides an intelligent control system based on coal flow transportation, which is used for solving the problem that the belt speed of a belt cannot be adjusted in real time according to data detected by a coal flow monitoring system in the prior art.
In order to achieve the above object, the present invention provides an intelligent control system based on coal stream transportation, comprising:
The coal flow conveying unit comprises a crusher for crushing raw coal, an adhesive tape conveying unit for conveying the crushed raw coal and a raw coal bin for storing the crushed raw coal, wherein the input end of the adhesive tape conveying unit is connected with the crusher, and the output end of the adhesive tape conveying unit is connected with the raw coal bin and is used for conveying the crushed raw coal processed by the crusher to the raw coal bin; the adhesive tape conveyor unit comprises a plurality of conveyors which are connected end to end in sequence;
The detection units are respectively arranged in corresponding parts in the coal flow transportation unit and comprise a crusher detection device, a plurality of coal flow detection devices, a plurality of belt speed detection devices and a plurality of coal bin detection devices; the crusher detection devices are arranged in the crushers and used for detecting whether the running state of the crushers is normal or not, and the coal flow detection devices are respectively arranged at the corresponding positions of the conveyors and used for respectively detecting the coal flow conveyed by the conveyors; each belt speed detection device is respectively arranged at a corresponding position of each conveyor and used for respectively detecting the moving speed of the conveyor belt in each conveyor; each coal bin detection device is respectively arranged at a corresponding position of each raw coal bin and is used for respectively detecting the coal storage amount in each raw coal bin;
The central control unit is respectively connected with each rubber belt conveyor unit and each device in the detection unit and is used for controlling the detection unit to detect the coal flow of the rubber belt conveyor step by step when the system operates and judging whether the system operates normally or not according to the actual coal flow of the conveyor step by step and determining the specific position of the conveyor with faults according to the coal flow of each conveyor and the belt moving speed when the system is judged to operate abnormally, when the central control unit finishes determining the specific position of the conveyor with faults, the central control unit adjusts the corresponding working parameters of the conveyor to the corresponding values, and when the central control unit finishes adjusting the corresponding working parameters of the conveyor, if the coal flow of the conveyor does not meet the standard yet, the central control unit further judges the specific reasons that the coal flow of the conveyor does not meet the standard according to the actual operation parameters of the conveyor and the environmental parameters around the conveyor.
For a single coal flow detection device, the device is an ultrasonic sensor which is arranged at the corresponding conveyor and close to the output end; for a conveyor arranged at the output end of the crusher, the coal flow detection device is arranged at the input end of the conveyor, when the crusher conveys crushed raw coal to the conveyor, the coal flow detection device arranged on the conveyor marks the measured initial coal flow which is not conveyed as Q0, the central control unit marks Q0 as the preset initial coal flow, starts the conveyor which receives the crushed raw coal according to the preset coal flow Q0, sets the moving speed of a belt in the conveyor as the preset initial belt speed V0, and respectively determines the preset time length required for the raw coal to pass through each conveyor according to the preset initial belt speed V0 and the whole length of each conveyor; for a single conveyor which is not arranged at the output end of the crusher, when the conveyor at the upper stage of the conveyor is started and the running time reaches the corresponding preset time, the central control unit starts the conveyor to convey raw coal output by the conveyor at the upper stage of the conveyor and set the moving speed of a belt in the conveyor to be V0.
For a single said conveyor, comprising: the motor is used for providing drive for the conveyor and driving the roller to rotate; the roller is connected with the motor and is used for receiving power transmitted by the motor and driving the belt to run; the belt is tightly wrapped outside the roller, and the roller is driven to continuously run by virtue of friction force between the belt and the roller;
When the system operates, the central control unit respectively controls the coal flow detection devices to detect the flow of raw coal on the conveyor belt in each conveyor, and for a single conveyor, the coal flow detection device arranged on the conveyor marks the detected coal flow on the conveyor belt as Q, and the central control unit compares Q and Q0 and judges whether the system operates normally or not and primarily judges the cause of faults in the device when the system is judged to operate abnormally according to the comparison result;
if q=q0, the central control unit determines that the system is operating normally;
If Q is more than Q0, the central control unit preliminarily judges that the coal flow rate in the unit time in the conveyor is too high and judges whether to adjust the belt speed of the belt according to whether the belt speed of the belt exceeds a maximum critical value;
if Q is less than Q0, the central control unit preliminarily judges that the coal flow output by the conveyor does not meet the standard, and judges the specific reason that the coal flow output by the conveyor does not meet the standard according to whether the belt speed of the belt exceeds the maximum critical belt speed.
The central control unit is also provided with a preset maximum critical belt speed Vmax, the Vmax is set to be larger than V0, when the central control unit judges that the coal flow rate in the unit time in the current conveyor is too high, the central control unit controls the belt speed detection device in the conveyor to measure the actual belt speed V of the belt in the conveyor, compares V with V0, judges whether the conveyor operates normally or not according to the comparison result, and preliminarily judges the position of a fault in the device when judging that the conveyor operates abnormally;
If V is less than or equal to V0, the central control unit judges that the coal flow rate output by a conveyor positioned at the upper stage of the conveyor is higher than a preset coal flow rate Q0;
If V is larger than V0, the central control unit preliminarily judges that the reason that the coal flow output by the conveyor is too high is that the belt speed of the conveyor is too high, V is compared with Vmax, if V is smaller than or equal to Vmax, the central control unit judges that the conveyor operates normally and judges that the belt speed of the conveyor is not required to be regulated, if V is larger than Vmax, the central control unit judges that the belt speed of the conveyor is required to be regulated, calculates the difference DeltaQ between Q0 and Q, and reduces the belt speed of the conveyor to a corresponding value according to the difference DeltaQ of the coal flow; after the adjustment is completed, the central control unit marks the coal flow output by the conveyor as Q 'and compares the Q' with Q0, if the Q 'is more than or equal to Q0, the central control unit judges that the current conveyor is qualified, detects the motor temperature of the current conveyor to monitor the safety of the current conveyor, and if the Q' is less than Q0, the central control unit preliminarily judges that the coal flow output by the conveyor does not accord with the standard and judges the specific reason that the coal flow output by the conveyor does not accord with the standard according to whether the belt speed of the belt exceeds the maximum critical belt speed Vmax.
The detection unit is also provided with temperature measuring sensors which are respectively arranged on the single conveyor, and the central control unit is also provided with a preset motor temperature T0; when the central control unit completes the regulation of the belt speed and the coal flow Q' output by the conveyor after the regulation is more than or equal to Q0, the central control unit controls a temperature measuring sensor to measure the temperature T of a motor in the conveyor, and the central control unit compares the temperature T with the temperature T0 respectively;
If T is less than or equal to T0, the central control unit judges that the running temperature of the conveyor is qualified and the working state is normal;
If T is more than T0, the central control unit judges that the temperature of the conveyor is abnormal, the central control unit sends a temperature abnormality alarm, and when the time length of the central control unit sending the abnormality alarm reaches a preset value, the central control unit controls the system to stop running.
When the central control unit judges that the coal flow rate in the unit time of the current conveyor is too low, the central control unit controls the single belt speed detection device to detect the belt speed again, the actual belt running speeds V1 of the single conveyor are respectively measured, the central control unit compares the V1 with the V0, judges whether the conveyor runs normally or not according to the comparison result, and carries out preliminary judgment on the position of a fault in the device when the conveyor runs abnormally;
If V1 is more than or equal to V0, the central control unit judges that the conveyor runs abnormally, the belt speed of the conveyor is too high, the failure reasons include low running efficiency of the crusher, coal in-situ immobility caused by friction reduction of the conveyor, leakage of the conveyor, or overflow of raw coal at a connecting port, and the central control unit further controls a crusher detection device in the detection unit and judges whether the crusher fails according to the measured running state of the crusher.
If V1 is less than V0, the central control unit judges that the current conveyor runs abnormally, the central control unit judges that the coal flow measured by the detection unit is unreasonable due to the too slow moving speed of the current conveyor, the central control unit judges that the belt speed of the belt needs to be regulated, calculates the difference DeltaQ between Q0 and Q, and increases the belt speed of the belt to a corresponding value according to the difference DeltaQ of the coal flow;
When the central control unit judges that the coal flow of the conveyor does not meet the standard and the belt speed is too fast, the central control unit controls a crusher detection device in the detection unit and judges whether the crusher is in fault or not according to the measured running state of the crusher, the crusher detection device detects the efficiency of the crusher to be eta, and the central control unit is also provided with preset crusher efficiency eta 0;
if eta is more than or equal to eta 0, the central control unit judges that the crusher operates normally, the central control unit judges that the friction of the conveyor is reduced, so that coal is not moved in situ or the conveyor leaks, and a conveyor fault alarm is sent;
And if eta is less than eta 0, the central control unit judges that the crusher is abnormal in operation and sends out a crusher fault alarm.
When the central control unit judges that the belt speed of the belt needs to be regulated, the central control unit calculates a coal flow difference DeltaQ and regulates the belt speed to a corresponding value according to DeltaQ, and DeltaQ= |Q-Q0|;
The central control unit is also provided with a first preset coal flow difference DeltaQ 1, a second preset coal flow difference DeltaQ 2, a third preset coal flow difference DeltaQ 3, a first preset motor rotating speed regulating coefficient alpha 1, a second preset motor rotating speed regulating coefficient alpha 2 and a third preset motor rotating speed regulating coefficient alpha 3, wherein DeltaQ 1 < DeltaQ2 < DeltaQ3, 1 < alpha 2 < alpha 3 < 1.5;
If the delta Q is less than or equal to delta Q1, the central control unit judges that the belt abrasion of the i-level conveyor is within an allowable error range, and the central control unit does not regulate the rotating speed of the motor;
If DeltaQ 1 < DeltaQis less than or equal to DeltaQ 2, the central control unit uses alpha 1 to regulate the rotating speed of the motor;
if DeltaQ 2 < DeltaQis less than or equal to DeltaQ 3, the central control unit uses alpha 2 to regulate the rotating speed of the motor;
if the delta Q is more than or equal to delta Q3, the central control unit uses alpha 3 to regulate the rotating speed of the motor;
When the central control unit increases the belt speed of the belt by using alpha j, setting j=1, 2 and 3, and setting V '=V×alpha j after the increased belt speed is denoted as V'; when the central control unit reduces the belt speed of the belt by using alpha j, the reduced belt speed is denoted as V ', and V' =V× (2-alpha j);
When the central control unit finishes the adjustment of the motor rotating speed, the central control unit controls the belt speed detection device to re-detect the running speed V ' of the belt, if V ' is not less than V, the central control unit judges that the adjustment of the motor rotating speed is finished, and if V ' is less than V, the central control unit re-adjusts the rotating speed of the motor.
The raw coal bin in the coal flow transportation unit comprises a first raw coal bin and a second raw coal bin, the rubber belt conveyor in the coal flow transportation unit also comprises a first bin matching conveyor and a second bin matching conveyor, and the central control unit is also provided with a splitter connected with the output end of the rubber belt conveyor and the bin matching conveyor and used for controlling the proportion of the rubber belt conveyor transmitted to the first bin matching conveyor and the second bin matching conveyor;
The central control device controls the coal bin monitoring device to measure that the percentage of the coal storage quantity of the first raw coal bin is B1 and the percentage of the coal storage quantity of the second raw coal bin is B2, the central control unit is internally provided with a preset highest coal storage percentage Bmax and a preset lowest coal storage percentage Bmin,
When B1 is larger than Bmax, the central control unit judges that the coal level of the first raw coal bin exceeds the highest point, controls the diverter to change the proportion of the first bin conveyor and the second bin conveyor, stops distributing raw coal to the first bin conveyor, and when B2 is larger than Bmax, the central control unit judges that the coal level of the second raw coal bin exceeds the highest point, controls the diverter to change the proportion of the first bin conveyor and the second bin conveyor, and stops distributing raw coal to the second bin conveyor;
when B1 is smaller than Bmin, the central control unit judges that the coal level of the first raw coal bin is lower than the empty bin guard line, the coal feeder under the bin is possibly damaged, the lump coal rate is reduced, the central control unit controls the diverter to change the proportion of the first bin conveyor and the second bin conveyor, the proportion of the raw coal distributed by the first bin conveyor is improved, when B2 is smaller than Bmin, the central control unit judges that the coal level of the second raw coal bin is lower than the empty bin guard line, the coal feeder under the bin is possibly damaged, the lump coal rate is possibly reduced, the central control unit controls the diverter to change the proportion of the first bin conveyor and the second bin conveyor, and the proportion of the raw coal distributed by the second bin conveyor is improved.
The coal bin detection device is a coal bin coal storage position estimation method based on multi-source data fusion analysis, and comprises a radar level gauge and a capacitance level gauge;
The radar level gauge transmits a group of detection pulses through an antenna, the detection pulses propagate in space at the speed of light, after encountering the surface of the raw coal level, part of energy is reflected back, the detection pulses are received by the antenna, the distance between the level gauge and the raw coal level can be deduced by calculating the time interval between the transmission of the detection pulses and the reception of the reflected pulses, the radar level gauge control circuit carries out filtering processing and calculation on the transmission pulses and the reception pulses to obtain an actual distance value, and the distance value is converted into a current signal and then is output to the central control unit;
The capacitance type level meter consists of a capacitance type level sensor and a circuit for detecting capacitance, the level sensor converts the level into capacitance change, then the capacitance measuring method is used for finding the level value, and the result is output to the central control unit.
Compared with the prior art, the intelligent control system has the beneficial effects that the intelligent control system has the complex characteristics of complex transportation process, multiple devices and the like for the coal flow system, is applied to the coal flow transportation system in the aspects of main transportation belts, coal feeders, coal bunker storage and video monitoring, and realizes the remote one-key start-stop unattended operation of the main transportation belts and the coal feeders on the ground by researching the intelligent control technology, the sensor technology and the informatization technology.
According to the invention, the central control unit controls the detection unit to detect the coal flow of the rubber belt conveyor step by step when the system runs, judges whether the system runs normally or not according to the actual coal flow of the conveyor step by step, determines the specific position of the failed conveyor according to the coal flow of each conveyor and the belt moving speed when the system is judged to run abnormally, and adjusts the corresponding working parameters of the conveyor to the corresponding values when the determination of the specific position of the failed conveyor is completed, so that the unattended operation of the coal flow conveying system is realized.
Further, the belt detection device comprises an incremental grating encoder, the accurate positioning technology of the belt vulcanization joint of the coal flow system based on the incremental grating encoder and the position correction sensor can accurately measure and display the instantaneous position of the belt vulcanization joint, the running mileage and the accumulated running mileage of the belt conveyor in real time, zero point calibration is automatically carried out, the measurement accuracy is ensured, meanwhile, the belt detection device also has the functions of breach tracking, fixed point belt stopping and the like, the maintenance time is greatly saved, the method for calculating the arctangent by combining four-time frequency subdivision with A/D conversion is provided, the angular displacement of the encoder is measured, the resolution of the incremental grating encoder is further improved, and therefore the higher angular displacement measurement accuracy is obtained.
Further, in the coal mine transportation engineering, the belt conveyor is used for conveying coal in a continuous mode through a plurality of conveying belts. At present, most multi-stage belt conveyors are started by starting all conveyors in sequence from the last stage of the conveyor, and after all conveyors are stable, the system starts blanking on the conveyor belt, which is also called reverse sequence starting. This approach not only results in long idle operation, but also entails unnecessary energy waste. The invention adopts an intelligent speed control multi-stage belt conveyor sequential starting method, thereby greatly reducing the no-load operation rate of the system and reducing the pure no-load operation loss.
Furthermore, the conveyor disclosed by the invention adopts the belt conveyor, and the belt conveyor is the most ideal high-efficiency connection conveying equipment for coal mines, and has the advantages of long conveying distance, large conveying capacity, continuous conveying and the like. With the improvement of the requirements of high-yield and high-efficiency mines in China, the belt conveyor becomes key equipment for coal high-efficiency mining and mechanical-electrical integration technology.
Further, the preset maximum critical belt speed Vmax is arranged in the central control unit, the V and the Vmax are compared, whether the operation of the conveyor is normal or not is judged according to the comparison result, the position of the fault in the device is preliminarily judged when the abnormal operation of the conveyor is judged, the influence of inertia on the belt speed is effectively considered, the judgment precision of the intelligent control system on the fault is improved, and the operation safety of the coal flow conveying system is further ensured.
Further, the invention realizes the self-adaptive energy-saving control of the belt conveyor through a neural network and a genetic algorithm, calculates the optimal matching of the coal flow and the belt speed of the belt conveyor, then establishes a BP neural network model of the coal flow, the belt speed and the motor power consumption of the belt conveyor by applying Matlab software according to field experimental data, optimizes the established BP model parameters by combining the genetic algorithm, obtains an optimal matching relation diagram of the coal flow and the belt speed, finally applies a fuzzy control algorithm, designs a fuzzy controller according to the obtained optimal matching result, and realizes the fuzzy control by a PLC to complete the self-adaptive energy-saving control of the belt conveyor.
Furthermore, the invention calculates the real-time accurate coal flow on the belt through the ultrasonic sensor, and in order to accurately calculate the coal flow, the existing methods for monitoring the real-time coal flow of the conveyor belt are provided with the electronic belt scale, but a plurality of groups of weighing sensors are required to be installed, so that the installation steps are complicated and the accuracy is lower; the non-contact laser scanner is convenient to install, but the calculation accuracy is greatly influenced by external factors and is unstable. The multi-point measuring technology based on ultrasonic waves is adopted, so that the monitoring precision is further improved, and the operation is simple and feasible.
Further, a temperature measuring sensor is further arranged in the detection unit, and the temperature measuring sensor is used for monitoring the temperature of the motor of the conveyor in real time, so that when the motor overload operation or motor rotating shaft fault generates a condition that the temperature exceeds the preset temperature, the central control unit automatically stops the operation of the coal flow conveying system, and the operation safety of the coal flow conveying system is further ensured.
Furthermore, the detection unit is also provided with the crusher detection device, so that the crushing efficiency of the crusher is monitored, the condition of faults from the source is considered, and the operation condition of the conveyor is monitored, so that the fault position of the coal flow conveying system is accurately judged, and the operation safety of the coal flow conveying system is further ensured.
Further, in the coal production process, the dispatching room needs to know the height of the coal level in the coal bunker in real time. If the coal level is not monitored, when the coal level in the coal bunker exceeds the highest point, the coal bunker is full, the coal flow conveyor is forced to stop running immediately, the production of a working face is affected, and accidents occur; when the coal level is lower than a certain position, empty bins can appear, and the coal feeder under the bins can be damaged, the lump coal rate can be reduced, and the like. Therefore, the invention analyzes the estimation method of the coal storage coal level of the coal bunker through multi-source data fusion, and most data refer to the coal level data of the coal bunker, which is measured in real time by installing an inlet radar level gauge at the mouth of the coal bunker, the collected data of the capacitor level gauge, and the coal storage coal level data of the coal bunker, which is calculated through the coal storage amount, the belt coal conveying amount and the coal feeding amount of the coal feeder.
Further, as the application of the radar level gauge in the coal industry is almost blank, the radar level gauge applied to the ground industrial control industry is selected as a probe component of the radar level gauge through experiments and by combining the characteristics of the coal industry, the selected radar level gauge is subjected to mining modification, and the radar level gauge prototype at present has been subjected to underground and coal preparation plant coal bunker experiments, so that the expected effect is obtained, the measurement of the coal bunker coal level can be rapidly and accurately realized, and the radar level gauge has certain application.
Further, the capacitive coal level detection system works by utilizing the principle that the dielectric constant of materials is constant and the interelectrode capacitance is proportional to the material level, and generally uses the wall of a coal bin as one pole of the capacitance, a sensor probe is fixed in a detected object as the other pole, and the depth information of the coal level can be obtained by measuring the interelectrode capacitance, but the probe needs to contact the coal blocks in the coal bin, so that the sensor probe is easy to adhere and damage, and the measurement range is small. The invention adopts a novel capacitance coal bin level meter adopting a ring-wall type structure, 2 capacitance polar plates are respectively arranged at the left side and the right side of the coal bin wall, and a protective layer is arranged between the polar plates and the inner surface of the bin wall. With the change of the coal quantity, the inter-electrode dielectric constant can be changed, and the changed capacitance is converted into the changed current quantity output through the detection circuit, so that the coal level depth is obtained. The method can resist impact, ensure the stability and safety of equipment, is not interfered by dust and noise, has no strict requirements on various states of materials, and has strong anti-interference capability.
Furthermore, the invention provides a precise control method for the flashboard of the coal feeder in the coal flow system, wherein the manual reversing valve of the hydraulic station of the coal feeder is replaced by the electromagnetic reversing valve, an on-site control knob and a button are reserved, the flow control is carried out on the hydraulic oil way by using the proportional regulating valve, the fine adjustment with the accuracy of 0.5% can be carried out, so that the action speed of the oil cylinder of the feed opening is controlled, and meanwhile, the flashboard displacement detection sensor is matched, so that the slow and precise control of the flashboard of the coal feeder is realized, and the guarantee is provided for realizing the unattended operation of the coal feeder.
Furthermore, the invention obtains good social benefit, and realizes the following research based on the project: the intelligent level of the coal flow transportation system is improved, and the intelligent level responds to the call of the national technology instead of people; the intelligent control of each device is increased, and the personnel investment is greatly reduced; the probability of faults is reduced; further improves the intellectualization of the coal flow transportation system in China, and lays a foundation for the construction of intelligent mines. In addition, the project has realized visual operation, realizes ground one-key start-stop and remote centralized control, and realizes unmanned on-site manned patrol. The intelligent coal flow transportation system is one of the main directions of efficient management and operation development of the current coal mine, has important significance for energy conservation and consumption reduction and cost control of enterprises and better guarantees personal safety of staff, is an effective way for improving competitiveness of the enterprises, and generates great social benefit.
Furthermore, the invention has good economic benefit, can save the wage expense of the operator; after the invention is applied, the coal flow along the coal flow conveying system is started, the one-key starting equipment is realized, the light load operation rate of the main coal flow conveying system is effectively reduced, the equipment abrasion is greatly reduced, and the service life of the equipment is prolonged.
Drawings
FIG. 1 is a schematic diagram of a coal flow transportation-based intelligent control system according to the present invention;
FIG. 2 is a schematic view of the structure of an ultrasonic sensor according to the present invention;
Fig. 3 is a schematic structural view of the adhesive tape conveyor according to the present invention.
Detailed Description
In order that the objects and advantages of the invention will become more apparent, the invention will be further described with reference to the following examples; it should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.
Preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are merely for explaining the technical principles of the present invention, and are not intended to limit the scope of the present invention.
It should be noted that, in the description of the present invention, terms such as "upper," "lower," "left," "right," "inner," "outer," and the like indicate directions or positional relationships based on the directions or positional relationships shown in the drawings, which are merely for convenience of description, and do not indicate or imply that the apparatus or elements must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as limiting the present invention.
Furthermore, it should be noted that, in the description of the present invention, unless explicitly specified and limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be either fixedly connected, detachably connected, or integrally connected, for example; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention can be understood by those skilled in the art according to the specific circumstances.
Referring to fig. 1, which is a schematic structural diagram of an intelligent control system based on coal flow transportation according to the present invention, the invention provides an intelligent control system based on coal flow transportation, comprising:
The coal flow transportation unit comprises a crusher 1 for crushing raw coal, a rubber belt conveyor 2 group for conveying the crushed raw coal and a raw coal bin for storing the crushed raw coal, wherein the input end of the rubber belt conveyor 2 group is connected with the crusher 1, the output end of the rubber belt conveyor 2 group is connected with the raw coal bin, and the rubber belt conveyor is used for conveying the crushed raw coal processed by the crusher 1 to the raw coal bin; the adhesive tape conveyor 2 group comprises a plurality of conveyors which are connected end to end in sequence;
the detection units are respectively arranged in corresponding parts in the coal flow transportation unit and comprise a crusher detection device, a plurality of coal flow detection devices, a plurality of belt speed detection devices and a plurality of coal bin detection devices; the crusher detection devices are arranged in the crusher 1 and used for detecting whether the running state of the crusher 1 is normal or not, and the coal flow detection devices are respectively arranged at the corresponding positions of the conveyors and used for respectively detecting the coal flow rate conveyed by the conveyors; each belt speed detection device is respectively arranged at a corresponding position of each conveyor and used for respectively detecting the moving speed of the conveyor belt in each conveyor; each coal bin detection device is respectively arranged at a corresponding position of each raw coal bin and is used for respectively detecting the coal storage amount in each raw coal bin;
The central control unit is respectively connected with each rubber belt conveyor 2 group and each device in the detection unit, and is used for controlling the detection unit to detect the coal flow of the rubber belt conveyor 2 step by step when the system is in operation, judging whether the system is in normal operation or not step by step according to the actual coal flow of the conveyor, determining the specific position of the conveyor with faults according to the coal flow of each conveyor and the moving speed of the belt 23 when the system is judged to be abnormal, adjusting the corresponding working parameters of the conveyor to the corresponding values when the central control unit finishes determining the specific position of the conveyor with faults, and further judging the specific reasons that the coal flow of the conveyor is not in accordance with the standards according to the actual operation parameters of the conveyor and the environmental parameters around the conveyor when the central control unit finishes adjusting the corresponding working parameters of the conveyor.
Specifically, when the system is running, the underground crusher 1 in the coal flow transportation unit processes the bulk raw coal, then places the bulk raw coal on the rubber belt conveyor 2, and then transports the raw coal to the raw coal bin 3 after passing through each stage of conveyor step by step to wait for further processing of the raw coal by the coal preparation plant; the detection unit is used for respectively monitoring the operation conditions of all the components in the coal flow transportation unit, uploading the monitoring results to the central control unit, and carrying out feedback adjustment on equipment in the coal flow transportation unit according to the operation results by the central control unit.
According to the invention, the central control unit controls the detection unit to detect the coal flow of the rubber belt conveyor step by step when the system runs, judges whether the system runs normally or not according to the actual coal flow of the conveyor step by step, determines the specific position of the failed conveyor according to the coal flow of each conveyor and the belt moving speed when the system is judged to run abnormally, and adjusts the corresponding working parameters of the conveyor to the corresponding values when the determination of the specific position of the failed conveyor is completed, so that the unattended operation of the coal flow conveying system is realized.
The belt detection device comprises an incremental grating encoder, the invention can accurately measure and display the instantaneous position of the belt vulcanizing joint, the running mileage and the accumulated running mileage of the belt conveyor in real time through the accurate positioning technology of the belt vulcanizing joint based on the incremental grating encoder and the position correction sensor, and automatically perform zero point calibration, thereby ensuring the measurement accuracy, simultaneously having the functions of breach tracking, fixed point belt stopping and the like, greatly saving the maintenance time, providing a method for calculating the arctangent by combining four-time frequency subdivision with A/D conversion, measuring the angular displacement rotated by the encoder, further improving the resolution of the incremental grating encoder, and further obtaining higher angular displacement measurement accuracy.
The grating encoder is a digital detection device integrating light, mechanical and electrical, is a sensor for converting the angular displacement of a motor rotor into digital quantity through photoelectric conversion, has the advantages of high resolution, high precision, good reliability, wide measurement range, long service life and the like, and is widely applied to various fields of aerospace, automatic assembly lines, high-precision speed measuring systems and the like. The grating encoder is further divided into an absolute grating encoder and an incremental grating encoder according to its measurement principle. The absolute grating encoder obtains absolute position information through the encoded value corresponding to the angular position of the motor shaft, and does not need to measure zero position, but is relatively expensive in comparison with other modes. The incremental grating encoder directly outputs rectangular wave pulse signals by utilizing the photoelectric conversion principle, and has the advantages of simple structure, long mechanical average life, high reliability, strong anti-interference capability and long transmission distance; the disadvantage is the relative position information that only the output shaft can rotate.
Based on the common incremental grating encoder in the motion control system, a high-precision angular displacement detection method research is performed. The current common zero detection circuit adopts a single-limit voltage comparator, and has the problem of poor anti-interference capability. By adopting the hysteresis voltage comparator, the anti-interference capability of the encoder zero signal detection circuit is improved. The common encoder signal processing adopts a quadruple frequency mode, and can only improve the resolution of the encoder by 4 times; the four-frequency subdivision is combined with the A/D sampling mode, four-frequency subdivision and phase discrimination are carried out on sine and cosine signals which are output by the encoder and have 90 degrees of phase difference, meanwhile, A/D conversion is carried out on the output signals of the encoder, an arctangent function is constructed, subdivision calculation is further carried out, and the angular displacement measurement accuracy of the encoder is greatly improved.
For a single coal flow detection device, the device is an ultrasonic sensor which is arranged at the corresponding conveyor and close to the output end; for the conveyor arranged at the output end of the crusher 1, the coal flow detection device is arranged at the input end of the conveyor, when the crusher 1 conveys crushed raw coal to the conveyor, the coal flow detection device arranged on the conveyor marks the measured initial coal flow which is not conveyed as Q0, the central control unit marks Q0 as the preset initial coal flow, starts the conveyor which receives the crushed raw coal according to the preset coal flow Q0, sets the moving speed of a belt 23 in the conveyor as the preset initial belt speed V0, and respectively determines the preset duration required by the raw coal passing through each conveyor according to the preset initial belt speed V0 and the whole length of each conveyor; for a single conveyor which is not arranged at the output end of the crusher 1, when the conveyor at the upper stage of the conveyor is started and the running time reaches the corresponding preset time, the central control unit starts the conveyor to convey the raw coal output by the conveyor at the upper stage of the conveyor and set the moving speed of the belt 23 in the conveyor to V0.
In coal mine transportation engineering, a belt conveyor is used for conveying coal in a continuous mode through a plurality of conveying belts. At present, most multi-stage belt conveyors are started by starting all conveyors in sequence from the last stage of the conveyor, and after all conveyors are stable, the system starts blanking on the conveyor belt, which is also called reverse sequence starting. This approach not only results in long idle operation, but also entails unnecessary energy waste. The invention adopts an intelligent speed control multi-stage belt conveyor sequential starting method, thereby greatly reducing the no-load operation rate of the system and reducing the pure no-load operation loss.
Please refer to fig. 2, which is a schematic structural diagram of the ultrasonic sensor according to the present invention, wherein the ultrasonic sensor obtains height data of materials on a conveyor belt according to a signal acquired by the ultrasonic sensor, and calculates real-time accurate coal flow on the belt 23 according to real-time belt speed information of the conveyor belt obtained by the speed sensor acquired by the speed sensor;
Specifically, the ultrasonic sensor transmits ultrasonic pulses to the coal pile every a period of time, the ultrasonic pulses are reflected and reflected to the receiver and then processed into useful electric signals, and the central control unit calculates the coal flow according to the known signal time interval. The calculation formula is q=avp, wherein: v is the belt speed, P is the unit time, A is the cross-sectional area of the coal pile,
The approximate calculation formula of a is a= (l+ Htan θ) H, where: l is the length of the bottom edge, θ is the angle, and H is the height of the coal pile.
In the method, the real-time accurate coal flow on the belt 23 is calculated through the ultrasonic sensor, and in order to accurately calculate the coal flow, the existing methods for monitoring the real-time coal flow of the conveyor belt are provided with the electronic belt scales, but a plurality of groups of weighing sensors are required to be installed, so that the installation steps are complicated and the accuracy is lower; the non-contact laser scanner is convenient to install, but the calculation accuracy is greatly influenced by external factors and is unstable. The multi-point measuring technology based on ultrasonic waves is adopted, so that the monitoring precision is further improved, and the operation is simple and feasible.
Referring to fig. 3, which is a schematic structural diagram of the adhesive tape conveyor 2 according to the present invention, for a single conveyor, the adhesive tape conveyor comprises: a motor 21 for driving the conveyor to drive the roller 22 to rotate; the roller 22 is connected with the motor 21 and is used for receiving power transmitted by the motor 21 and driving the belt 23 to run; the belt 23 is tightly wrapped outside the roller 22, and the roller 22 is driven to continuously run by virtue of friction force between the belt 23 and the roller 22;
Specifically, when the system is in operation, the central control unit controls the coal flow rate detection devices to detect the flow rate of raw coal on the conveyor belt in each conveyor respectively, and for a single conveyor, the coal flow rate detection device arranged on the conveyor marks the detected coal flow rate on the conveyor belt 23 as Q, and the central control unit compares Q and Q0 and judges whether the system is in operation normally or not according to the comparison result and primarily judges the cause of faults in the device when the system is judged to be in abnormal operation;
if q=q0, the central control unit determines that the system is operating normally;
If Q is more than Q0, the central control unit preliminarily judges that the coal flow rate in the conveyor in unit time is too high and judges whether to adjust the belt speed of the belt 23 according to whether the belt speed of the belt 23 exceeds a maximum critical value;
If Q < Q0, the central control unit preliminarily judges that the coal flow output by the conveyor does not meet the standard and judges the specific reason that the coal flow output by the conveyor does not meet the standard according to whether the belt speed of the belt 23 exceeds the maximum critical belt speed.
In coal mine transportation engineering, a belt conveyor is used for conveying coal in a continuous mode through a plurality of conveying belts. At present, most multi-stage belt conveyors are started by starting all conveyors in sequence from the last stage of the conveyor, and after all conveyors are stable, the system starts blanking on the conveyor belt, which is also called reverse sequence starting. This approach not only results in long idle operation, but also entails unnecessary energy waste. The invention adopts an intelligent speed control multi-stage belt conveyor sequential starting method, thereby greatly reducing the no-load operation rate of the system and reducing the pure no-load operation loss.
The belt conveyor 2 adopts a belt conveyor, is the most ideal high-efficiency connection conveying equipment for coal mines, and has the advantages of long conveying distance, large conveying capacity, continuous conveying and the like. With the improvement of the requirements of high-yield and high-efficiency mines in China, the belt conveyor becomes key equipment for coal high-efficiency mining and mechanical-electrical integration technology.
The central control unit is also provided with a preset maximum critical belt speed Vmax, the Vmax is set to be larger than V0, when the central control unit judges that the coal flow rate in the unit time in the current conveyor is too high, the central control unit controls the belt speed detection device in the conveyor to measure the actual belt speed V of the belt 23 in the conveyor, compares V with V0, judges whether the conveyor operates normally or not according to the comparison result, and preliminarily judges the position of a fault in the device when judging that the conveyor operates abnormally;
If V is less than or equal to V0, the central control unit judges that the coal flow rate output by a conveyor positioned at the upper stage of the conveyor is higher than a preset coal flow rate Q0;
If V is larger than V0, the central control unit preliminarily judges that the reason that the coal flow output by the conveyor is too high is that the belt speed of the belt 23 in the conveyor is too high, compares V with Vmax, if V is smaller than or equal to Vmax, the central control unit judges that the conveyor normally operates and judges that the belt speed of the belt 23 in the conveyor is not required to be regulated, if V is larger than Vmax, the central control unit judges that the belt speed of the belt 23 is required to be regulated, calculates the difference DeltaQ of Q0 and Q, and reduces the belt speed of the belt 23 to a corresponding value according to the difference DeltaQ of the coal flow; after the adjustment is completed, the central control unit marks the coal flow output by the conveyor as Q 'and compares the Q' with Q0, if the Q 'is more than or equal to Q0, the central control unit judges that the current conveyor is qualified, detects the temperature of a motor 21 of the current conveyor to monitor the safety of the current conveyor, and if the Q' is less than Q0, the central control unit preliminarily judges that the coal flow output by the conveyor does not meet the standard and judges the specific reason that the coal flow output by the conveyor does not meet the standard according to whether the belt speed of the belt 23 exceeds the maximum critical belt speed Vmax.
The invention compares V with Vmax and judges whether the conveyor operates normally or not according to the comparison result, and initially judges the position of the fault in the device when judging that the conveyor operates abnormally, effectively considers the influence of inertia on the belt speed, improves the judging precision of the intelligent control system on the fault, and further ensures the operation safety of the coal flow conveying system.
The detection unit is also provided with temperature measuring sensors which are respectively arranged on the single conveyor, and the central control unit is also provided with a preset motor 21 temperature T0; when the central control unit completes the regulation of the belt speed of the belt 23 and the coal flow Q' output by the conveyor after the regulation is more than or equal to Q0, the central control unit controls a temperature measuring sensor to measure the temperature T of a motor 21 in the conveyor, and the central control unit compares the T with the T0 respectively;
If T is less than or equal to T0, the central control unit judges that the running temperature of the conveyor is qualified and the working state is normal;
If T is more than T0, the central control unit judges that the temperature of the conveyor is abnormal, the central control unit sends a temperature abnormality alarm, and when the time length of the central control unit sending the abnormality alarm reaches a preset value, the central control unit controls the system to stop running.
According to the invention, the temperature of the motor of the conveyor is monitored in real time through the temperature measuring sensor, and when the motor overload operation or motor rotating shaft fault generates a temperature exceeding a preset temperature, the central control unit automatically stops the operation of the coal flow conveying system, so that the operation safety of the coal flow conveying system is further ensured.
When the central control unit judges that the coal flow rate in the unit time of the current conveyor is too low, the central control unit controls the single belt speed detection device to detect the belt speed again, the actual running speeds V1 of the belts 23 of the single conveyor are respectively measured, the central control unit compares the V1 with the V0, judges whether the conveyor runs normally or not according to the comparison result, and carries out preliminary judgment on the position of a fault in the device when the conveyor runs abnormally;
If V1 is more than or equal to V0, the central control unit judges that the conveyor runs abnormally, the belt 23 of the conveyor runs too fast, and the fault reasons include low running efficiency of the crusher 1, coal in-situ immobility caused by friction reduction of the conveyor, leakage of the conveyor, or overflow of raw coal at a connecting port, and the central control unit further controls a crusher detection device in the detection unit and judges whether the crusher 1 is faulty according to the measured running state of the crusher 1.
If V1 is less than V0, the central control unit judges that the current conveyor runs abnormally, the central control unit judges that the coal flow measured by the detection unit is unreasonable due to the too slow moving speed of the current conveyor, the central control unit judges that the belt speed of the belt 23 needs to be regulated, calculates the difference DeltaQ between Q0 and Q, and increases the belt speed of the belt 23 to a corresponding value according to the difference DeltaQ of the coal flow;
When the central control unit judges that the coal flow of the conveyor does not meet the standard and the belt 23 is excessively fast, the central control unit controls a crusher detection device in the detection unit and judges whether the crusher 1 is in fault or not according to the measured running state of the crusher 1, the crusher detection device detects that the efficiency of the crusher 1 is eta, and the central control unit is also provided with preset crusher 1 efficiency eta 0;
If eta is more than or equal to eta 0, the central control unit judges that the crusher 1 operates normally, the central control unit judges that the friction of the conveyor is reduced, so that coal is not moved in situ or the conveyor leaks, and a conveyor fault alarm is sent;
If eta < eta 0, the central control unit judges that the crusher 1 is abnormally operated and sends a fault alarm to the crusher 1.
According to the invention, the crushing efficiency of the crusher is monitored, the condition of faults from the source is considered, and the operation condition of the conveyor is monitored, so that the fault position of the coal flow conveying system is accurately judged, and the operation safety of the coal flow conveying system is further ensured.
When the central control unit judges that the belt speed of the belt 23 needs to be regulated, the central control unit calculates a coal flow difference DeltaQ and regulates the belt speed to a corresponding value according to DeltaQ, and DeltaQ= |Q-Q0|;
The central control unit is also provided with a first preset coal flow difference DeltaQ 1, a second preset coal flow difference DeltaQ 2, a third preset coal flow difference DeltaQ 3, a first preset motor 21 rotating speed regulating coefficient alpha 1, a second preset motor 21 rotating speed regulating coefficient alpha 2 and a third preset motor 21 rotating speed regulating coefficient alpha 3, wherein DeltaQ 1 < DeltaQ2 < DeltaQ3, 1 < alpha 2< alpha 3 < 1.5;
if DeltaQ is less than or equal to DeltaQ 1, the central control unit judges that the abrasion of the belt 23 of the i-level conveyor is within an allowable error range, and the central control unit does not regulate the rotating speed of the motor 21;
If DeltaQ 1 < DeltaQis less than or equal to DeltaQ 2, the central control unit uses alpha 1 to regulate the rotating speed of the motor 21;
if DeltaQ 2 < DeltaQis less than or equal to DeltaQ 3, the central control unit uses alpha 2 to regulate the rotating speed of the motor 21;
If DeltaQ is not less than DeltaQ 3, the central control unit uses alpha 3 to regulate the rotating speed of the motor 21;
When the central control unit increases the belt speed of the belt 23 using αj, j=1, 2,3 is set, the increased belt speed of the belt 23 is denoted as V ', and V' =v×αj is set; when the central control unit decreases the belt speed of the belt 23 using αj, the decreased belt speed of the belt 23 is denoted as V ', and V' =v× (2- αj);
when the central control unit completes the adjustment of the rotation speed of the motor 21, the central control unit controls the belt speed detection device to re-detect the running speed V ' of the belt 23, if V ' is not less than V, the central control unit determines that the adjustment of the rotation speed of the motor 21 is completed, and if V ' is less than V, the central control unit re-adjusts the rotation speed of the motor 21.
The invention designs a belt speed control method according to the energy-saving feasibility analysis of a belt conveyor, and provides a coal flow monitoring method based on an ultrasonic technology for monitoring the instantaneous carrying capacity on a conveyor belt. By analyzing the blanking form, the reference speed of the belt speed of the conveyer belt under the rated transportation capacity is given. Meanwhile, in order to save energy efficiency, a coal flow starting method is provided.
According to the invention, self-adaptive energy-saving control of the belt conveyor is realized through a neural network and a genetic algorithm, the optimal matching of the coal flow and the belt speed of the belt conveyor is calculated, then a BP neural network model of the coal flow, the speed of the belt 23 and the power consumption of a motor of the belt conveyor is established by applying Matlab software according to field experimental data, the established BP model parameters are optimized by combining the genetic algorithm, an optimal matching relation diagram of the coal flow and the belt speed is obtained, finally a fuzzy control algorithm is applied, a fuzzy controller is designed according to the obtained optimal matching result, and the fuzzy control is realized by a PLC, so that the self-adaptive energy-saving control of the belt conveyor is completed.
The raw coal bin in the coal flow transportation unit comprises a first raw coal bin 31 and a second raw coal bin 32, the rubber belt conveyor 2 in the coal flow transportation unit further comprises a first cabin matching conveyor 231 and a second cabin matching conveyor 232, and the central control unit is further provided with a diverter connected with the output end of the rubber belt conveyor 2 and the cabin matching conveyor for controlling the proportion of the rubber belt conveyor 2 transmitted to the first cabin matching conveyor 231 and the second cabin matching conveyor 232;
the central control device controls the coal bin monitoring device to measure that the percentage of the coal storage quantity of the first raw coal bin 31 is B1 and the percentage of the coal storage quantity of the second raw coal bin 32 is B2, the central control unit is internally provided with a preset highest coal storage percentage Bmax and a preset lowest coal storage percentage Bmin,
When B1 is larger than Bmax, the central control unit judges that the coal level of the first raw coal bin 31 exceeds the highest point, controls the flow divider to change the proportion of the first bin conveyor 231 and the second bin conveyor 232, stops distributing raw coal to the first bin conveyor 231, and when B2 is larger than Bmax, the central control unit judges that the coal level of the second raw coal bin 32 exceeds the highest point, controls the flow divider to change the proportion of the first bin conveyor 231 and the second bin conveyor 232, and stops distributing raw coal to the second bin conveyor 232;
When B1 is smaller than Bmin, the central control unit judges that the coal level of the first raw coal bin 31 is lower than the empty bin warning line, the coal level under the bin is possibly damaged, the lump coal rate is possibly reduced, the central control unit controls the diverter to change the proportion of the first bin conveyor 231 and the second bin conveyor 232, the proportion of the raw coal distributed by the first bin conveyor 231 is improved, when B2 is smaller than Bmin, the central control unit judges that the coal level of the second raw coal bin 32 is lower than the empty bin warning line, the coal level under the bin is possibly damaged, the lump coal rate is possibly reduced, the central control unit controls the diverter to change the proportion of the first bin conveyor 231 and the second bin conveyor 232, and the proportion of the raw coal distributed by the second bin conveyor 232 is improved.
In the coal production process, a dispatching room needs to know the height of coal level in a coal bin in real time. If the coal level is not monitored, when the coal level in the coal bunker exceeds the highest point, the coal bunker is full, the coal flow conveyor is forced to stop running immediately, the production of a working face is affected, and accidents occur; when the coal level is lower than a certain position, empty bins can appear, and the coal feeder under the bins can be damaged, the lump coal rate can be reduced, and the like. Therefore, the invention analyzes the estimation method of the coal storage coal level of the coal bunker through multi-source data fusion, and most data refer to the coal level data of the coal bunker, which is measured in real time by installing an inlet radar level gauge at the coal bunker opening, the collected data of the capacitor level gauge, and the coal storage coal level data of the coal bunker, which is calculated through the coal storage coal amount, the belt 23 coal conveying amount and the coal feeding and discharging amount of the coal feeder.
The coal bin detection device is a coal bin coal storage position estimation method based on multi-source data fusion analysis, and comprises a radar level gauge and a capacitance level gauge;
The radar level gauge transmits a group of detection pulses through an antenna, the detection pulses propagate in space at the speed of light, after encountering the surface of the raw coal level, part of energy is reflected back, the detection pulses are received by the antenna, the distance between the level gauge and the raw coal level can be deduced by calculating the time interval between the transmission of the detection pulses and the reception of the reflected pulses, the radar level gauge control circuit carries out filtering processing and calculation on the transmission pulses and the reception pulses to obtain an actual distance value, and the distance value is converted into a current signal and then is output to the central control unit;
The capacitance type level meter consists of a capacitance type level sensor and a circuit for detecting capacitance, the level sensor converts the level into capacitance change, then the capacitance measuring method is used for finding the level value, and the result is output to the central control unit.
The radar level gauge is almost blank in application in the coal industry, the radar level gauge applied to the ground industrial control industry is selected as a probe component of the radar level gauge by experiments and by combining with the characteristics of the coal industry, the selected radar level gauge is subjected to mining modification, and the radar level gauge model machine at present has been subjected to underground and coal preparation plant coal bunker experiments, so that the expected effect is obtained, the measurement of coal bunker coal level can be rapidly and accurately realized, and the radar level gauge has certain application.
The capacitive coal level detection system works by utilizing the principle that the interelectrode capacitance is proportional to the material level when the dielectric constant of the material is constant, and generally uses the bin wall of the coal bin as one pole of the capacitance, the sensor probe is fixed in a measured object as the other pole, and the depth information of the coal level can be obtained by measuring the interelectrode capacitance, but the probe needs to contact the coal in the coal bin, so that the sensor probe is easy to adhere and damage, and the measurement range is smaller. The invention adopts a novel capacitance coal bin level meter adopting a ring-wall type structure, 2 capacitance polar plates are respectively arranged at the left side and the right side of the coal bin wall, and a protective layer is arranged between the polar plates and the inner surface of the bin wall. With the change of the coal quantity, the inter-electrode dielectric constant can be changed, and the changed capacitance is converted into the changed current quantity output through the detection circuit, so that the coal level depth is obtained. The method can resist impact, ensure the stability and safety of equipment, is not interfered by dust and noise, has no strict requirements on various states of materials, and has strong anti-interference capability.
The invention provides a precise control method for a flashboard of a coal feeder in a coal flow system, wherein a manual reversing valve of a hydraulic station of the coal feeder is replaced by an electromagnetic reversing valve, an on-site control knob and a button are reserved, a proportional control valve is used for controlling the flow of a hydraulic oil way, fine adjustment with 0.5% precision can be performed so as to control the action speed of an oil cylinder of a feed opening, and meanwhile, a flashboard displacement detection sensor is matched, so that the flashboard of the coal feeder is slowly and precisely controlled, and a guarantee is provided for realizing unattended operation of the coal feeder.
The invention obtains good social benefit, and realizes the following research based on the project: the intelligent level of the coal flow transportation system is improved, and the intelligent level responds to the call of the national technology instead of people; the intelligent control of each device is increased, and the personnel investment is greatly reduced; the probability of faults is reduced; further improves the intellectualization of the coal flow transportation system in China, and lays a foundation for the construction of intelligent mines. In addition, the project has realized visual operation, realizes ground one-key start-stop and remote centralized control, and realizes unmanned on-site manned patrol. The intelligent coal flow transportation system is one of the main directions of efficient management and operation development of the current coal mine, has important significance for energy conservation and consumption reduction and cost control of enterprises and better guarantees personal safety of staff, is an effective way for improving competitiveness of the enterprises, and generates great social benefit.
The invention has good economic benefit, and the annual personnel expenditure can be saved by 115 ten thousand yuan; after the invention is applied, the coal flow along the coal flow conveying system is started, the one-key starting equipment is realized, the light load operation rate of the main coal flow conveying system is effectively reduced, the equipment abrasion is greatly reduced, and the service life of the equipment is prolonged. The total benefit saved by the invention is 415 ten thousand yuan.
Thus far, the technical solution of the present invention has been described in connection with the preferred embodiments shown in the drawings, but it is easily understood by those skilled in the art that the scope of protection of the present invention is not limited to these specific embodiments. Equivalent modifications and substitutions for related technical features may be made by those skilled in the art without departing from the principles of the present invention, and such modifications and substitutions will be within the scope of the present invention.
The foregoing description is only of the preferred embodiments of the invention and is not intended to limit the invention; various modifications and variations of the present invention will be apparent to those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (7)
1. An intelligent control system based on coal stream transportation, which is characterized by comprising:
The coal flow conveying unit comprises a crusher for crushing raw coal, an adhesive tape conveying unit for conveying the crushed raw coal and a raw coal bin for storing the crushed raw coal, wherein the input end of the adhesive tape conveying unit is connected with the crusher, and the output end of the adhesive tape conveying unit is connected with the raw coal bin and is used for conveying the crushed raw coal processed by the crusher to the raw coal bin; the adhesive tape conveyor unit comprises a plurality of conveyors which are connected end to end in sequence;
The detection units are respectively arranged in corresponding parts in the coal flow transportation unit and comprise a crusher detection device, a plurality of coal flow detection devices, a plurality of belt speed detection devices and a plurality of coal bin detection devices; the crusher detection devices are arranged in the crushers and used for detecting whether the running state of the crushers is normal or not, and the coal flow detection devices are respectively arranged at the corresponding positions of the conveyors and used for respectively detecting the coal flow conveyed by the conveyors; each belt speed detection device is respectively arranged at a corresponding position of each conveyor and used for respectively detecting the moving speed of the conveyor belt in each conveyor; each coal bin detection device is respectively arranged at a corresponding position of each raw coal bin and is used for respectively detecting the coal storage amount in each raw coal bin;
The central control unit is respectively connected with each rubber belt conveyor unit and each device in the detection unit and is used for controlling the detection unit to detect the coal flow of the rubber belt conveyor step by step when the system is in operation, judging whether the system is in normal operation or not step by step according to the actual coal flow of the conveyor, determining the specific position of the conveyor with faults according to the coal flow of each conveyor and the belt moving speed when the system is judged to be in abnormal operation, adjusting the corresponding working parameters of the conveyor to the corresponding values when the central control unit finishes determining the specific position of the conveyor with faults, and further judging the specific reasons that the coal flow of the conveyor is not in accordance with the standards according to the actual operation parameters of the conveyor and the environmental parameters around the conveyor when the central control unit finishes adjusting the corresponding working parameters of the conveyor; for a single coal flow detection device, the device is an ultrasonic sensor which is arranged at the corresponding conveyor and close to the output end; for a conveyor arranged at the output end of the crusher, the coal flow detection device is arranged at the input end of the conveyor, when the crusher conveys crushed raw coal to the conveyor, the coal flow detection device arranged on the conveyor marks the measured initial coal flow which is not conveyed as Q0, the central control unit marks Q0 as the preset initial coal flow, starts the conveyor which receives the crushed raw coal according to the preset coal flow Q0, sets the moving speed of a belt in the conveyor as the preset initial belt speed V0, and respectively determines the preset time length required for the raw coal to pass through each conveyor according to the preset initial belt speed V0 and the whole length of each conveyor; for a single conveyor which is not arranged at the output end of the crusher, when the conveyor at the upper stage of the conveyor is started and the running time reaches the corresponding preset time, the central control unit starts the conveyor to convey raw coal output by the conveyor at the upper stage of the conveyor and set the moving speed of a belt in the conveyor to be V0; for a single said conveyor, comprising: the motor is used for providing drive for the conveyor and driving the roller to rotate; the roller is connected with the motor and is used for receiving power transmitted by the motor and driving the belt to run; the belt is tightly wrapped outside the roller, and the roller is driven to continuously run by virtue of friction force between the belt and the roller;
When the system operates, the central control unit respectively controls the coal flow detection devices to detect the flow of raw coal on the conveyor belt in each conveyor, and for a single conveyor, the coal flow detection device arranged on the conveyor marks the detected coal flow on the conveyor belt as Q, and the central control unit compares Q and Q0 and judges whether the system operates normally or not and primarily judges the cause of faults in the device when the system is judged to operate abnormally according to the comparison result;
if q=q0, the central control unit determines that the system is operating normally;
If Q is more than Q0, the central control unit preliminarily judges that the coal flow rate in the unit time in the conveyor is too high and judges whether to adjust the belt speed of the belt according to whether the belt speed of the belt exceeds a maximum critical value;
If Q is less than Q0, the central control unit preliminarily judges that the coal flow output by the conveyor does not meet the standard and judges the specific reason that the coal flow output by the conveyor does not meet the standard according to whether the belt speed of the belt exceeds the maximum critical belt speed; the central control unit is also provided with a preset maximum critical belt speed Vmax, the Vmax is set to be larger than V0, when the central control unit judges that the coal flow rate in the unit time in the current conveyor is too high, the central control unit controls the belt speed detection device in the conveyor to measure the actual belt speed V of the belt in the conveyor, compares V with V0, judges whether the conveyor operates normally or not according to the comparison result, and carries out preliminary judgment on the position of a fault in the device when judging that the conveyor operates abnormally;
If V is less than or equal to V0, the central control unit judges that the coal flow rate output by a conveyor positioned at the upper stage of the conveyor is higher than a preset coal flow rate Q0;
If V is larger than V0, the central control unit preliminarily judges that the reason that the coal flow output by the conveyor is too high is that the belt speed of the conveyor is too high, V is compared with Vmax, if V is smaller than or equal to Vmax, the central control unit judges that the conveyor operates normally and judges that the belt speed of the conveyor is not required to be regulated, if V is larger than Vmax, the central control unit judges that the belt speed of the conveyor is required to be regulated, calculates the difference DeltaQ between Q0 and Q, and reduces the belt speed of the conveyor to a corresponding value according to the difference DeltaQ of the coal flow; after the adjustment is completed, the central control unit marks the coal flow output by the conveyor as Q 'and compares the Q' with Q0, if the Q 'is more than or equal to Q0, the central control unit judges that the current conveyor is qualified, detects the motor temperature of the current conveyor to monitor the safety of the current conveyor, and if the Q' is less than Q0, the central control unit preliminarily judges that the coal flow output by the conveyor does not accord with the standard and judges the specific reason that the coal flow output by the conveyor does not accord with the standard according to whether the belt speed of the belt exceeds the maximum critical belt speed Vmax.
2. The intelligent control system based on coal stream transportation according to claim 1, wherein the detection unit is further provided with temperature measuring sensors which are respectively arranged on the single transportation machine, and the central control unit is further provided with a preset motor temperature T0; when the central control unit completes the regulation of the belt speed and the coal flow Q' output by the conveyor after the regulation is more than or equal to Q0, the central control unit controls a temperature measuring sensor to measure the temperature T of a motor in the conveyor, and the central control unit compares the temperature T with the temperature T0 respectively;
If T is less than or equal to T0, the central control unit judges that the running temperature of the conveyor is qualified and the working state is normal;
If T is more than T0, the central control unit judges that the temperature of the conveyor is abnormal, the central control unit sends a temperature abnormality alarm, and when the time length of the central control unit sending the abnormality alarm reaches a preset value, the central control unit controls the system to stop running.
3. The intelligent control system based on coal flow transportation according to claim 1, wherein when the central control unit judges that the coal flow rate in unit time in the current conveyor is too low, the central control unit controls the belt speed detection device to detect the belt speed again, the actual belt running speeds V1 of the single conveyor are respectively measured, the central control unit compares V1 with V0, judges whether the conveyor runs normally or not according to the comparison result, and carries out preliminary judgment on the position of a fault in the device when judging that the conveyor runs abnormally;
if V1 is more than or equal to V0, the central control unit judges that the conveyor runs abnormally, the belt speed of the conveyor is too high, the failure reasons include low running efficiency of the crusher, coal in situ is fixed due to reduction of friction force of the conveyor, the conveyor leaks, or raw coal at a connecting port overflows, the central control unit further controls a crusher detection device in the detection unit, and whether the crusher fails or not is judged according to the measured running state of the crusher;
if V1 is less than V0, the central control unit judges that the current conveyor runs abnormally, the central control unit judges that the coal flow measured by the detection unit is unreasonable due to the fact that the moving speed of the current conveyor is too slow, the central control unit judges that the belt speed of the belt needs to be adjusted, calculates the difference DeltaQ between Q0 and Q, and increases the belt speed of the belt to a corresponding value according to the difference DeltaQ of the coal flow.
4. The intelligent control system based on coal flow transportation according to claim 3, wherein when the central control unit judges that the coal flow rate of the conveyor does not meet the standard and the belt speed is too high, the central control unit controls a crusher detection device in the detection unit and judges whether the crusher is faulty according to the measured running state of the crusher, the crusher detection device detects the efficiency of the crusher as eta, and the central control unit is also provided with preset crusher efficiency eta 0;
if eta is more than or equal to eta 0, the central control unit judges that the crusher operates normally, the central control unit judges that the friction of the conveyor is reduced, so that coal is not moved in situ or the conveyor leaks, and a conveyor fault alarm is sent;
And if eta is less than eta 0, the central control unit judges that the crusher is abnormal in operation and sends out a crusher fault alarm.
5. The intelligent control system based on coal flow transportation according to claim 3, wherein when the central control unit determines that the belt speed of the belt needs to be adjusted, the central control unit calculates a coal flow difference value Δq and adjusts the belt speed to a corresponding value according to Δq, and Δq= |q-q0| is set;
The central control unit is also provided with a first preset coal flow difference DeltaQ 1, a second preset coal flow difference DeltaQ 2, a third preset coal flow difference DeltaQ 3, a first preset motor rotating speed regulating coefficient alpha 1, a second preset motor rotating speed regulating coefficient alpha 2 and a third preset motor rotating speed regulating coefficient alpha 3, wherein DeltaQ 1 < DeltaQ2 < DeltaQ3, 1 < alpha 2 < alpha 3 < 1.5;
If the delta Q is less than or equal to delta Q1, the central control unit judges that the belt abrasion of the conveyor is within an allowable error range, and the central control unit does not regulate the rotating speed of the motor;
If DeltaQ 1 < DeltaQis less than or equal to DeltaQ 2, the central control unit uses alpha 1 to regulate the rotating speed of the motor;
if DeltaQ 2 < DeltaQis less than or equal to DeltaQ 3, the central control unit uses alpha 2 to regulate the rotating speed of the motor;
if the delta Q is more than or equal to delta Q3, the central control unit uses alpha 3 to regulate the rotating speed of the motor;
When the central control unit increases the belt speed of the belt by using alpha j, setting j=1, 2 and 3, and setting V '=V×alpha j after the increased belt speed is denoted as V'; when the central control unit reduces the belt speed of the belt by using alpha j, the reduced belt speed is denoted as V ', and V' =V× (2-alpha j);
When the central control unit finishes the adjustment of the motor rotating speed, the central control unit controls the belt speed detection device to re-detect the running speed V ' of the belt, if V ' is not less than V, the central control unit judges that the adjustment of the motor rotating speed is finished, and if V ' is less than V, the central control unit re-adjusts the rotating speed of the motor.
6. The intelligent control system based on coal stream transportation according to claim 1, wherein,
The raw coal bin in the coal flow transportation unit comprises a first raw coal bin and a second raw coal bin, the rubber belt conveyor in the coal flow transportation unit also comprises a first bin matching conveyor and a second bin matching conveyor, and the central control unit is also provided with a splitter connected with the output end of the rubber belt conveyor and the bin matching conveyor and used for controlling the proportion of the rubber belt conveyor transmitted to the first bin matching conveyor and the second bin matching conveyor;
The central control unit controls the coal bin monitoring device to measure that the percentage of the coal storage quantity of the first raw coal bin is B1 and the percentage of the coal storage quantity of the second raw coal bin is B2, the central control unit is internally provided with a preset highest coal storage percentage Bmax and a preset lowest coal storage percentage Bmin,
When B1 is larger than Bmax, the central control unit judges that the coal level of the first raw coal bin exceeds the highest point, controls the diverter to change the proportion of the first bin conveyor and the second bin conveyor, stops distributing raw coal to the first bin conveyor, and when B2 is larger than Bmax, the central control unit judges that the coal level of the second raw coal bin exceeds the highest point, controls the diverter to change the proportion of the first bin conveyor and the second bin conveyor, and stops distributing raw coal to the second bin conveyor;
when B1 is less than Bmin, the central control unit judges that the coal level of the first raw coal bin is lower than the empty bin guard line, the central control unit controls the flow divider to change the proportion of the first bin conveyor and the second bin conveyor, the proportion of the raw coal distributed by the first bin conveyor is improved, when B2 is less than Bmin, the central control unit judges that the coal level of the second raw coal bin is lower than the empty bin guard line, the coal feeder under the bin is possibly damaged, the lump coal rate is possibly reduced, the central control unit controls the flow divider to change the proportion of the first bin conveyor and the second bin conveyor, and the proportion of the raw coal distributed by the second bin conveyor is improved.
7. The intelligent control system based on coal flow transportation according to claim 6, wherein the coal bin detection device is a method for estimating a coal level of a coal bin based on multi-source data fusion analysis, and comprises a radar level gauge and a capacitance level gauge;
The radar level gauge transmits a group of detection pulses through an antenna, the detection pulses propagate in space at the speed of light, after encountering the surface of the raw coal level, part of energy is reflected back, the detection pulses are received by the antenna, the distance between the level gauge and the raw coal level can be deduced by calculating the time interval between the transmission of the detection pulses and the reception of the reflected pulses, the radar level gauge control circuit carries out filtering processing and calculation on the transmission pulses and the reception pulses to obtain an actual distance value, and the distance value is converted into a current signal and then is output to the central control unit;
The capacitance type level meter consists of a capacitance type level sensor and a circuit for detecting capacitance, the level sensor converts the level into capacitance change, then the capacitance measuring method is used for finding the level value, and the result is output to the central control unit.
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