CN115848943A - Optimized operation control method for belt conveyor - Google Patents
Optimized operation control method for belt conveyor Download PDFInfo
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- CN115848943A CN115848943A CN202211621294.0A CN202211621294A CN115848943A CN 115848943 A CN115848943 A CN 115848943A CN 202211621294 A CN202211621294 A CN 202211621294A CN 115848943 A CN115848943 A CN 115848943A
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Abstract
The invention discloses an optimized operation control method of a belt conveyor, which realizes transparent perception of the coal quantity of the belt conveyor through load calculation of the belt conveyor; on the basis, according to the mechanical characteristics of the belt conveyor, the self-adaptive speed regulation, start-stop control and tension self-adaptive adjustment of the belt conveyor based on load distribution are realized, the invalid energy consumption and equipment abrasion are reduced, the service life of the belt conveyor is prolonged, and the running optimization of the belt conveyor is further achieved.
Description
Technical Field
The invention relates to the technical field of electronic information, in particular to efficient operation control of a belt conveyor in the field of coal mine production.
Background
The belt conveyor is an important device for coal production, but due to the imbalance of coal mining, the belt conveyor is often in a non-optimal running state of a large horse-drawn trolley, so that not only is electric energy wasted, but also the transmission system, the rotating parts and the conveying belt of the belt conveyor are subjected to ineffective wear, the service life of the equipment is shortened, and the intelligent running of the belt conveyor is realized, so that the development direction of the current belt conveyor technology is provided.
In recent years, belt conveyors for coal mines have been largely driven by variable frequency driving, and there is a trend toward gradual change of belt conveyors driven by fluid coupling into variable frequency driving. Meanwhile, the material detection technology of the belt conveyor and the equipment management level of coal mine enterprises are continuously improved, and the basic conditions for optimizing the operation of the belt conveyor are met. Self-adaptive speed regulation is realized according to the load distribution condition of the belt conveyor, so that equipment abrasion can be effectively reduced and electric energy can be saved; the start-stop process of the belt conveyor is optimized, so that the mechanical impact on the transmission equipment in the start-stop process can be effectively reduced; the problems that a gate way belt conveyor is shortened along with the advancing of a coal face, the tension force is kept constant, the abrasion of a rubber belt and a roller is increased and the like are solved. Therefore, the research on improving the operating efficiency of the belt conveyor and analyzing the energy-saving and consumption-reducing effects are very significant.
The development of the optimization control technology of the existing belt conveyor is relatively lagged, and in order to ensure safe production, the operation control of the belt conveyor is usually started in advance only when coal exists and stopped when no coal exists; the load distribution condition of the belt conveyor is unclear, so that the belt conveyor runs at full speed in the running process; the starting time is fixed and the vehicle is freely stopped in the starting and stopping process; the crossheading belt conveyor is continuously shortened along with the advancing of the coal face, and the tension force is kept constant. The prior optimization control technology aiming at the belt conveyor is also applied experimentally in coal mine enterprises, particularly automatic speed regulation according to load is realized, but the optimization control technology is not popularized and normally operated, mainly the technology is not mature, the failure rate is high, and the maintenance workload of workers is increased; meanwhile, the effects of energy conservation, consumption reduction and personnel reduction are not obvious, so that the working efficiency of the conveyor optimization control system is greatly reduced.
Therefore, an efficient optimized control system for a conveyor is urgently needed.
Disclosure of Invention
Aiming at the technical problem of low efficiency of an optimized control system of a conveyor, the invention aims to provide an optimized operation control method of a belt conveyor, which can reduce ineffective energy consumption and equipment abrasion, prolong the service life of the belt conveyor and further achieve the optimization of the operation of the belt conveyor,
in order to achieve the above object, the present invention provides a method for controlling an optimized operation of a belt conveyor, including:
a control method for calculating the real-time coal amount of the belt conveyor through the load distribution of the belt conveyor;
through mechanical characteristics, the belt conveyor is based on a control method of speed regulation, automatic start-stop control and tension adjustment of the belt conveyor under load distribution.
Further, the real-time coal quantity control method is that the belt speed and the coal flow detected by the sensor on the conveyor are transmitted to the load distribution unit in the main control system to form a calculation module.
Further, the calculation module is formed satisfying the following formula:
coal flow = calculation coefficient conveyor belt speed coal flow detection volume.
Further, the self-adaptive adjustment of the belt tension calculates the actual required tension by taking the length change of the belt conveyor (gate way) as an example.
And further, the tension adjusting database is solidified in the main control system, when the belt conveyor runs, the main control system tracks the length, the gradient and the continuous load in real time through the detector, transmits the detected data to the main control system to be compared with the tension adjusting database, and forms a control command of the actually required tension to be sent to the tensioning device for adjustment after comparison.
Further, the adaptive control of start control in start-stop control should form a control logic based on the following formula:
m L ＝[2q B +q G +K 1 (q RO +q RU )]LKg；
three values of mL, mD and a can be obtained by the above formula, and the inertia force FA of the conveyor can be obtained by the three values:
F A ＝±(m L +m D )a，
f in the formula A The total inertia force of each moving body of the conveyor;
m L converting the moving body of the conveyor into the equivalent mass of linear motion on the conveyor belt;
m D the equivalent mass for the linear motion on the conveyor is converted into the rotating component of the conveyor;
K 1 the conversion coefficient is used for converting the mass of the rotating part of the carrier roller into the equivalent mass of linear motion;
n is the number of the driving units of the conveyer;
J iD the moment of inertia of the ith rotating part of the driving unit;
I i the transmission ratio of the ith rotating component of the driving unit to the transmission roller;
r is the radius of the transmission roller;
J i the moment of inertia of the ith roller;
r i the drum radius of the ith drum;
P M1 the power sum of the driving motors is actually selected by the conveyor;
P M positive power required for the conveyor;
F U the total inertia force of each moving body of the conveyor;
q B mass per meter of conveyor belt;
q G mass of material per meter on the conveyor belt;
q RO the belt conveyor bears the weight of the rotating part of the branch carrier roller per meter of machine length;
q RU the return branch of the belt conveyor has the mass of the rotating part of the carrier roller per meter of the machine length.
Further, the adaptive control of stop control in start-stop control should form a control logic based on the following formula:
a, average increasing (decreasing) speed of a conveyer belt;
F U the total inertia force of each moving body of the conveyor;
m L converting the moving body of the conveyor into the equivalent mass of linear motion on the conveyor belt;
m D the equivalent mass of the linear motion on the conveyor belt is converted to the rotating component of the conveyor.
Further, the control method for optimizing the operation of the belt conveyor also comprises a control method for saving energy and reducing consumption of the belt conveyor, and the control method for saving energy and reducing consumption of the belt conveyor forms a control logic based on the following formula:
the power calculation of the belt conveyor is the product of the running resistance and the speed of the belt conveyor:
N＝Fv
wherein N is the energy consumption rate; qav refers to average loading; l refers to the transport distance.
This formula is the energy consumed by the belt conveyor per 1 km of distance to transport 1 ton of material.
According to the belt conveyor optimal operation control method provided by the scheme, the transparent sensing of the coal quantity of the belt conveyor is realized through the load calculation of the belt conveyor; on the basis, the self-adaptive speed regulation, start-stop control and tension self-adaptive adjustment of the belt conveyor based on load distribution are realized according to the mechanical characteristics of the belt conveyor, the ineffective energy consumption and equipment abrasion are reduced, the service life of the belt conveyor is prolonged, the running optimization of the belt conveyor is further achieved,
drawings
The invention is further described below in conjunction with the appended drawings and the detailed description.
FIG. 1 is a schematic parameter diagram of a belt conveyor roadway;
fig. 2 is a schematic view of the structure of the tension-only device of the belt conveyor.
Detailed Description
In order to make the technical means, the creation characteristics, the achievement purposes and the effects of the invention easy to understand, the invention is further explained below by combining the specific drawings.
Aiming at the technical problem that an optimized control system of a belt conveyor is low in efficiency, the invention provides an optimized operation control method of the belt conveyor based on the technical problem, which can achieve the optimization of the operation of the belt conveyor, reduce the ineffective energy consumption and the equipment abrasion and prolong the service life of the belt conveyor.
According to the belt conveyor optimal operation control method provided by the scheme, the transparent sensing of the coal quantity of the belt conveyor is realized through the load calculation of the belt conveyor; on the basis, according to the mechanical characteristics of the belt conveyor, the self-adaptive speed regulation, start-stop control and tension self-adaptive adjustment of the belt conveyor based on load distribution are realized, the running optimization of the belt conveyor is achieved, the invalid energy consumption and equipment abrasion are reduced, and the service life of the belt conveyor is prolonged.
Further, in the actual use of the belt conveyor, because the opening degree of the coal feeder, the traveling progress of the coal mining machine, the speed of the conveyor and other factors can cause the material change on the conveyor, the material accumulation can occur on the local part of the conveyor, the belt can be pressed or the material can be scattered under the serious condition, the potential safety hazard exists in the operation process of the conveyor, and the safety operation of the equipment is not facilitated. In addition, the delivery system throughput varies over time, and if the conveyor is still running at the speed at which the maximum capacity is present, it results in wasted capacity and energy.
Therefore, according to the characteristics of the coal quantity detection data, the belt speed and the designed transportation quantity parameters of the belt conveyor are combined and transmitted to the main control system, the main control system establishes a belt conveyor load distribution unit according to the belt speed and the designed transportation quantity, and the real-time coal quantity of the belt conveyor is calculated through a calculation module in the load distribution unit, so that the transparent display of the belt conveyor load distribution is realized.
The real-time coal quantity of the belt conveyor is calculated through load distribution, and the calculation of the real-time coal quantity of the belt conveyor meets the following formula:
coal flow = calculated coefficient belt speed detection volume
Further, the coal flow rate of the preceding belt conveyor is based on the following formula:
Q1＝K1*V1*M：
q1, the coal flow rate (t/s) of the front-stage belt conveyor; v1 belt speed (m/s) of a front-stage belt conveyor; volume of M coal (M) 3 ) (ii) a And the K1 preceding-stage belt conveyor coal flow calculation coefficient is related to the bandwidth.
Likewise, the coal flow rate of the belt conveyor of this stage is based on the following formula:
Q2＝K2*V2*M
q2, the coal flow rate (t/s) of the front-stage belt conveyor; v2 belt speed (m/s) of a front-stage belt conveyor; volume of M coal (M) 3 ) (ii) a And the K2 preceding-stage belt conveyor coal flow calculation coefficient is related to the bandwidth.
The belt speeds V of the preceding-stage belt conveyor and the current-stage belt conveyor are detected by speed sensors arranged on two sides of the preceding-stage belt conveyor and the current-stage belt conveyor, and the detected belt speeds are transmitted to a calculation module in the load distribution unit for calculation.
The coal volume M on the front-stage belt conveyor and the current-stage belt conveyor is detected by coal flow detection sensors arranged on the front-stage belt conveyor and the current-stage belt conveyor, and the detected coal volume data is transmitted to a calculation module in the load distribution unit for calculation.
Furthermore, the belt conveyor needs a certain tension force to ensure that the conveyor belt does not slip in the normal operation process and the sag of the conveyor belt between the carrier rollers is kept within a certain range when the conveyor belt is loaded, the calculation and model selection of the tensioning device at the present stage all meet the tension magnitude of the belt conveyor under the maximum and worst working conditions, the use process of the tensioning device is simply set in three states of starting, running and stopping of the belt conveyor, and in practice, the tension magnitude required by the running of the belt conveyor is directly related to the load, the length and the gradient of a roadway.
The gate-trough belt conveyor is continuously shortened along with the advancing of mining, the required tension force is reduced, and the service lives of the rack, the rubber belt and the tensioning roller bearing are greatly prolonged only by running according to the actually required tension force under the condition that the length of the belt conveyor is changed.
Therefore, the scheme provides an adaptive adjustment method of the tension of the belt conveyor based on load distribution, and the actual required tension is calculated by taking the length change of the belt conveyor (gate way) as an example, as shown in table 1, and relevant parameters of the belt conveyor are shown in fig. 1-2.
TABLE 1 tensing force with transport length variation Table
From the data analysis of table 1 above, it can be seen that the operation at the actual required tension force under the condition of the belt conveyor length change greatly improves the service life of the frame, the belt and the tensioning roller bearing; therefore, in order to ensure the safe, reliable and efficient operation of the belt conveyor, a series of different tension force data obtained according to the length, the gradient of a roadway and the change of load are required to be processed.
Firstly, a tension adjustment database is solidified in a main control system, when a belt conveyor runs, the main control system tracks the length, the gradient and the continuous load in real time through a detector, transmits the detected data to the main control system to be compared with the tension adjustment database, and forms a control command of the actually required tension to be sent to a tensioning device for adjustment after comparison.
The belt conveyor is large-inertia low-damping equipment, a smooth starting (stopping) and increasing (decreasing) speed curve of the belt conveyor can be stably carried out, the inertia force and impact force generated in the starting (stopping) process of the belt conveyor are reduced to the maximum extent, the impact of starting current on a power grid is reduced, and meanwhile, the mechanical vibration of starting torque on a load can be reduced, so that the load born by the conveyor is reduced, and the service life is prolonged.
In the starting and braking processes of the belt conveyor, the belt conveyor is gradually accelerated from a static state to a rated belt speed or gradually decelerated from a dynamic state to a stop state, and the inertia of a motion system needs to be overcome, so that the dynamic load Fa must be considered, and the acceleration and deceleration speed during starting (stopping) can be ensured to ensure that the materials and the conveying belt do not slip under the most unfavorable working condition.
Therefore, the scheme provides a belt conveyor start-stop control method based on load distribution under the condition that the belt conveyor is based on load distribution:
(1) The start of the conveyor can realize the standard of starting and stopping the conveyor based on the following formula:
during the starting acceleration and deceleration stop of the conveyer, the conveyer belt is regarded as a rigid body, and the inertia force of the conveyer can be calculated by the following formula, wherein the inertia force satisfies the following formula:
F A ＝±(m L +m D )a，
m L ＝[2q B +q G +K 1 (q RO +q RU )]LKg；
FA in the formula is the total inertia force of all moving bodies of the conveyor;
mL is the equivalent mass of the linear motion converted from the moving body of the conveyor to the conveying belt;
mD is the equivalent mass of the linear motion converted from the rotating part of the conveyor to the conveying belt;
k1 is a conversion coefficient for converting the mass of the rotating part of the carrier roller into the equivalent mass of linear motion;
n is the number of the driving units of the conveyer;
JiD is the moment of inertia of the i-th rotating part of the drive unit;
ii is the transmission ratio from the ith rotating component of the driving unit to the transmission roller;
r is the radius of the transmission roller;
ji is the moment of inertia of the ith roller;
ri is the drum radius of the ith drum;
the PM1 is the sum of the power of the driving motors actually selected by the conveyor;
PM is positive power required by the conveyor;
the total inertia force of each moving body of the FU conveyor;
qB mass per meter of conveyor belt;
mass of material per meter on qG conveyor;
qRO belt conveyor bears the weight of a rotating part of a long carrier roller of each meter of branch;
qRU belt conveyer return branch every meter of long idler rotating part mass.
Since the inertial force of the rotating part involves many parts and the value is difficult to obtain in a sample, the starting coefficient Ka (1.3-1.7, which can be set by dynamic analysis when using a soft start device) or m is often used in engineering calculation L The ratio (0.2-0.3) of the inertia force of the linearly moving part is used to estimate and calculate m D The numerical value of (c).
Analytically, when the torque of the starting device is controllable, the above acceleration formula expresses the meaning that the actual starting acceleration value is the difference between the driving circumferential force given at the starting time and the circumferential driving force (the calculated circumferential driving force) for reducing the stable operation condition, and then the difference is divided by the conversion into the linear motionEquivalent mass (m) of L +m D )。
Further, the deceleration at which the conveyor is decelerated should satisfy the following equation:
the large-scale conveyer can adopt modes of free parking, force-reducing parking, inertia increasing (additionally provided with an inertia increasing flywheel), braking parking and the like according to performance and working condition parameters.
Wherein the free-stop deceleration can be adjusted
And (4) calculating.
a, average increasing (decreasing) speed of a conveyer belt;
the total inertia force of each moving body of the FU conveyor;
mL is the equivalent mass of the linear motion of the moving body of the conveyor converted to the conveying belt;
and mD is the equivalent mass of the linear motion converted from the rotating part of the conveyor to the conveying belt.
Under ideal conditions, the motor torque can be set to do work and all the work is converted into kinetic energy, and then W = E, W = Pt, E =1/2 (mv 2); can be pushed out
Then->
J＝mr 2 Is moment of inertia, is greater or less>
Is the rate of change of angular velocity. A practical form of the equation of motion is->
GD2=4gJ is called flywheel torque (N · m 2). Therein for teaching
The free-stop deceleration procedure is well known to those skilled in the art and will not be described in detail here.
Based on the formula, the standard setting of the starting and stopping of the conveyor can be formed, and the condition that the acceleration and deceleration speed during starting (stopping) can be ensured not to slip between the materials and the conveying belt under the most unfavorable working condition can be further ensured.
Meanwhile, the scheme also provides a calculation method for energy conservation and consumption reduction of the belt conveyor, which meets the following formula:
the power calculation of the belt conveyor is the product of the running resistance and the speed of the belt conveyor:
N＝Fv
further, the air conditioner is provided with a fan,
wherein N is the energy consumption rate; qav refers to average loading; l refers to the transport distance.
The meaning of this equation is the energy consumed by the belt conveyor per 1 km of material transported 1 ton.
The optimized operation control method of the belt conveyor, which is formed by the scheme, can optimize the operation of the belt conveyor, reduce the ineffective energy consumption and the equipment abrasion and prolong the service life of the belt conveyor.
The foregoing shows and describes the general principles, essential features, and advantages of the invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (8)
1. A method for controlling the optimized operation of a belt conveyor is characterized by comprising the following steps:
a control method for calculating the real-time coal amount of the belt conveyor through the load distribution of the belt conveyor;
and the belt conveyor is based on the control method of speed regulation, automatic start-stop control and tension adjustment of the belt conveyor under the load distribution through mechanical characteristics.
2. The method for controlling the optimized operation of the belt conveyor as claimed in claim 1, wherein the real-time coal quantity control method is to form a calculation module by transmitting the belt speed and coal flow values detected by the sensors on the conveyor to the load distribution unit in the main control system.
3. The method of claim 2, wherein the calculation module is formed by satisfying the following equation:
coal flow = calculation coefficient coal flow detection volume.
4. The method for controlling the optimized operation of the belt conveyor as claimed in claim 1, wherein the adaptive adjustment of the belt tension calculates the actual required tension by taking the length change of the belt conveyor (gate way) as an example.
5. The optimized operation control method for the belt conveyor as claimed in claim 4, wherein the tension adjustment database is solidified in the main control system, when the belt conveyor runs, the main control system tracks the length, the gradient and the continuous load in real time through the detector, transmits the detected data to the main control system to be compared with the tension adjustment database, and forms a control command to the tensioning device to adjust the actual required tension after comparison.
6. The method for controlling the optimized operation of the belt conveyor according to claim 1, wherein the starting control adaptive adjustment in the start-stop control is formed by a control logic based on the following formula:
m L ＝[2q B +q G +K 1 (q RO +q RU )]LKg；
m can be obtained by the above formula L ，m D And a, from which the inertial force FA of the conveyor is derived:
F A ＝±(m L +m D )a，
f in the formula A The total inertia force of each moving body of the conveyor;
m L converting the moving body of the conveyor into the equivalent mass of linear motion on the conveyor belt;
m D the equivalent mass for the linear motion on the conveyor is converted into the rotating component of the conveyor;
K 1 the conversion coefficient is used for converting the mass of the rotating part of the carrier roller into the equivalent mass of linear motion;
n is the number of the driving units of the conveyer;
J iD the moment of inertia of the ith rotating part of the driving unit;
I i the transmission ratio of the ith rotating component of the driving unit to the transmission roller;
r is the radius of the transmission roller;
J i the moment of inertia of the ith roller;
r i the drum radius of the ith drum;
P M1 the conveyor actually selects the sum of the power of the driving motors;
P M positive power required for the conveyor;
F U the total inertia force of each moving body of the conveyor;
q B mass per meter of conveyor belt;
q G mass of material per meter on the conveyor belt;
q RO belt typeThe conveyor bears the weight of the rotating part of the branch carrier roller per meter of the machine length;
q RU the return branch of the belt conveyor has the mass of the rotating part of the carrier roller per meter of the machine length.
7. The method for controlling the optimized operation of the belt conveyor according to claim 1, wherein the self-adaptive adjustment of stop control in start-stop control is based on the following formula to form a control logic:
a, average increasing (decreasing) speed of a conveyer belt;
the total inertia force of each moving body of the FU conveyor;
mL is the equivalent mass of the linear motion of the moving body of the conveyor converted to the conveying belt;
and mD is the equivalent mass of the linear motion converted from the rotating part of the conveyor to the conveying belt.
8. The method for controlling the optimized operation of the belt conveyor according to claim 1, further comprising a method for controlling the energy saving and consumption reduction of the belt conveyor, wherein the method for controlling the energy saving and consumption reduction of the belt conveyor forms a control logic based on the following formula:
the power calculation of the belt conveyor is the product of the running resistance and the speed of the belt conveyor:
N＝Fv
wherein N is the energy consumption rate; qav refers to average loading; l refers to the transport distance;
this formula is the energy consumed by the belt conveyor per 1 km of distance to transport 1 ton of material.
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