CN115959442A - Intelligent control method and system for constant material flow of electric hopper of coal wharf - Google Patents
Intelligent control method and system for constant material flow of electric hopper of coal wharf Download PDFInfo
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- CN115959442A CN115959442A CN202310040844.8A CN202310040844A CN115959442A CN 115959442 A CN115959442 A CN 115959442A CN 202310040844 A CN202310040844 A CN 202310040844A CN 115959442 A CN115959442 A CN 115959442A
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- 239000003245 coal Substances 0.000 title claims abstract description 30
- 238000007599 discharging Methods 0.000 claims abstract description 9
- 238000004891 communication Methods 0.000 claims description 38
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Abstract
The invention relates to the technical field of automatic control of material flow of a coal wharf, and particularly discloses an intelligent control method and system for material flow constancy of an electric hopper of a coal wharf, wherein the method comprises the following steps of S100, initialization setting, wherein feeding is performed, the weight sensor is reset to the hopper in a zero-load condition of the hopper, and then the material blanking speed is preset; step S200, calibrating and collecting data, collecting weight sensor information at regular time and sending the information to a server when the hopper discharges materials, collecting video information above the hopper and at the discharging hole in real time and sending the video information to the server, and waiting for the content; the invention can automatically control the blanking flow by drawing the data change curve according to the information collected by the weight sensor and the level sensor and combining the control of the output instruction of the server, so that the blanking flow can be kept relatively stable and output.
Description
Technical Field
The invention relates to the technical field of automatic control of material flow of a coal wharf, in particular to an intelligent control method and system for constant material flow of an electric hopper of a coal wharf.
Background
At present, most coal wharfs are low in automation, intellectualization and informatization level, the electric hopper control mode of the belt conveyor process mostly adopts a manual operation mode, a field operation worker needs to be arranged near each door machine hopper, and a central control room operator communicates with the field operation worker through an interphone to adjust the opening of the hopper door of the manual control hopper according to the field video monitoring condition; there are many problems with this manual control method: for example, the field devices have high noise and the interphone has low communication efficiency; the opening of the hopper is manually controlled, so that the problems of uneven discharging and large flow fluctuation exist; the labor cost is high, and certain potential safety hazards exist in the field unmanned monitoring operation workers.
The invention discloses a constant intelligent control system for material flow of an electric hopper of a coal wharf, which comprises a wireless communication network, a hopper door motor, a weighing sensor, a data acquisition industrial personal computer, two wireless monitoring cameras, a pull rope displacement sensor, a central control room server and a PLC (programmable logic controller) control system, wherein the hopper door motor is installed on the electric hopper and used for adjusting the angle of a hopper door, the weighing sensor is installed inside the electric hopper and used for monitoring the weight of materials in the hopper in real time, the data acquisition industrial personal computer is used for receiving signals and transmitting signals, the two wireless monitoring cameras are installed on a door machine above the hopper and are respectively used for monitoring the opening degree of the hopper door and the material storage condition in the hopper, the pull rope displacement sensor is installed on a push rod of the hopper door and is used for detecting the opening degree of the hopper door, the central control room server is used for receiving data and calculating and analyzing, and the PLC control system is used for driving the hopper door motor. The intelligent control method can avoid the problems of uneven discharging and larger flow fluctuation caused by manual control of the opening of the hopper, and can also avoid the problems of low communication efficiency of the interphone and influence on timely regulation and control of the opening of the hopper caused by large noise of field equipment. However, the blanking opening designed by the method only has three gears, the blanking speed is influenced due to different coal material qualities in actual use, the blanking opening cannot be controlled in real time according to the blanking condition, and manual operation still needs to be matched.
In order to solve the problems, the invention provides an intelligent control method and system for constant material flow of an electric hopper of a coal wharf.
Disclosure of Invention
The invention aims to provide a method and a system for intelligently controlling the constant material flow of an electric hopper of a coal wharf.
In order to achieve the purpose, the invention provides the following technical scheme: an intelligent control method for constant material flow of an electric hopper of a coal wharf comprises the following steps:
s100, initializing, setting, namely, carrying out zero clearing on a hopper to calibrate a weight sensor under the condition that the hopper is unloaded by feeding, and then presetting the material discharging speed;
step S200, calibrating and collecting data, collecting weight sensor information at regular time and sending the information to a server when a hopper discharges materials, collecting video information above the hopper and at a discharging port in real time and sending the video information to the server, and synchronously collecting position information in the hopper and sending the position information to the server;
step S300, processing data, namely, judging whether the current blanking speed meets a preset requirement or not according to the acquired data by a server, continuing blanking operation if the current blanking speed meets the preset requirement, outputting a calculation result and performing the next operation if the current blanking speed does not meet the preset requirement, and simultaneously drawing a data change curve for information acquired by a weight sensor and a level sensor by the server, wherein the change curves of material weight, level height and material flow are respectively drawn by taking time as an abscissa, a material weight value, the level height and the material flow as an ordinate, and establishing a model;
step S400, adjusting blanking and analyzing whether the blanking is blocked, outputting an adjusting instruction according to a model, if the blanking speed is higher than a preset speed, outputting an instruction of reducing the opening degree of a blanking port by a server, if the blanking speed is lower than the preset speed, outputting an instruction of increasing the opening degree of the blanking port by the server, if the opening degree of the blanking port is increased, judging whether the current material is blocked or not according to regularly acquired material level information and video information, and if the material is blocked, performing the next step;
and S500, assisting in blanking, wherein the blanking control module vibrates and smashes the materials in the hopper through auxiliary equipment to dredge the materials, and synchronously feeds parameters such as video information and blanking data back to remote equipment for early warning.
As a preferred embodiment of the present invention, in the step S100, the preset feeding speed is not greater than the maximum feeding speed of the hopper.
As a preferred embodiment of the present invention, in step S200, each time the front weight sensor and the level sensor of the hopper need to collect data, data is collected again after the feeding is finished.
In a preferred embodiment of the present invention, in step S300, at each time of feeding the hopper, the weight and level information of the hopper before and after each feeding needs to be corrected, and the instruction is output again according to the data after each feeding.
As a preferred embodiment of the present invention, the method further includes a step S600 of remote operation, and the staff can remotely and manually control the opening and closing angle of the hopper feeding opening according to the information received by the remote device.
In a preferred embodiment of the present invention, the opening sensor is a linear displacement sensor for detecting data of the opening of the door.
As a preferred embodiment of the present invention, in step S300, a formula for calculating the blanking speed is as follows:
wherein Q is the current blanking speed m n Weight of material in hopper, m n-1 The weight of the material in the hopper in the previous time, and t is the time difference of two measurements.
The utility model provides a invariable intelligent control system of coal pier electronic hopper material flow, the system includes:
the information acquisition system comprises a weight sensor for measuring the loading capacity of the electric hopper, a timing module for providing time reference, an acquisition communication module for transmitting information, a video acquisition module for acquiring blanking video information of the hopper, a material level sensor arranged above the hopper for acquiring the material level distance of the hopper and an opening sensor arranged at a blanking port of the hopper;
the server comprises a data processing module for processing information acquired by the information acquisition system, a service communication module for communicating with the information acquisition system, the blanking control module and the remote equipment, a storage module for storing a blanking control algorithm and acquired data, and an execution module for issuing a blanking control instruction;
the blanking control module comprises a blanking communication module for receiving server information, auxiliary equipment for assisting blanking during the time of pause, and an opening motor for starting the blanking hopper;
the remote equipment is carried by a worker, and comprises an early warning module for early warning when the material is blocked and abnormal conditions occur, a remote communication module for server communication and a control module for issuing instructions.
In a preferred embodiment of the present invention, the video capture modules are provided in two sets and respectively correspond to the upper part of the hopper and the feed opening of the hopper, and the level sensor is provided directly above the hopper and provided with a plurality of level sensors.
As a preferred embodiment of the present invention, the collection communication module, the service communication module and the blanking communication module are connected and communicated through an optical cable, and the remote communication module and the service communication module are communicated in an internet connection manner.
Compared with the prior art, the invention has the beneficial effects that: the invention can automatically control the blanking flow by acquiring the blanking weight information and the material level information in stages, drawing the data change curve by acquiring the information of the weight sensor and the material level sensor and combining the output instruction control of the server, so that the blanking flow can be kept in relatively stable output.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the embodiments or the description of the prior art will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention.
FIG. 1 is a flow chart of an intelligent control method for constant material flow of an electric hopper of a coal wharf;
FIG. 2 is a block diagram of an intelligent control system for constant material flow of an electric hopper of a coal wharf, provided by the invention;
FIG. 3 is an information acquisition module of the intelligent control system for the constant material flow of the electric hopper of the coal wharf;
FIG. 4 is a service structure diagram of the intelligent control system for constant material flow of the electric hopper of the coal wharf;
FIG. 5 is a diagram of a blanking control module of the intelligent control system for controlling constant material flow of the electric hopper of the coal wharf;
fig. 6 is a structure diagram of a remote device of the intelligent control system for constant material flow of the electric hopper of the coal wharf.
Detailed Description
In order to make the technical problems, technical solutions and advantageous effects of the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Example one
Referring to fig. 1-6, the invention provides an intelligent control system for constant material flow of an electric hopper of a coal wharf, comprising:
the information acquisition system comprises a weight sensor for measuring the loading capacity of the electric hopper, a timing module for providing time reference, an acquisition communication module for transmitting information, a video acquisition module for acquiring blanking video information of the hopper, a material level sensor arranged above the hopper for acquiring the material level distance of the hopper and an opening sensor arranged at a blanking port of the hopper;
the weight sensor adopts a high-precision digital-to-analog conversion technology and a single chip microcomputer control technology, carries out intelligent processing on the resistance strain type weighing sensor, calculates the weight of the material in real time, and can adopt the existing equipment for measurement; in addition, the weighing sensor system has the advantages of automatically correcting and calibrating the error of the material and stably outputting a control signal; the video sensors are provided with two groups and respectively correspond to the video information of the top of the hopper and the video information of the feed opening of the hopper, and the plurality of level sensors are used for monitoring the level information in real time and making up the defects of a video acquisition method; further, information acquired by the weight sensor, the opening sensor and the level sensor needs to acquire time information of the timing module synchronously.
The server comprises a data processing module for processing information acquired by the information acquisition system, a service communication module for communicating with the information acquisition system, the blanking control module and the remote equipment, a storage module for storing a blanking control algorithm and acquiring data, and an execution module for issuing a blanking control instruction;
in this embodiment, the server is connected to the internet, and the remote communication device communicates with the server through the internet;
the blanking control module comprises a blanking communication module for receiving server information, auxiliary equipment for assisting blanking during the time of blocking, and an opening motor for starting the blanking hopper;
in this embodiment, the feed opening module mainly comprises an opening motor and a remote communication module, wherein the opening motor and the remote communication module are installed at the feed opening and connected with a feed opening switch;
the remote equipment is carried by a worker, comprises an early warning module for early warning when the material is blocked and abnormal conditions occur, a remote communication module for server communication and a control module for issuing instructions.
Furthermore, the video acquisition module is provided with two sets of and corresponds hopper top and hopper feed opening respectively, level sensor sets up directly over the hopper and is provided with a plurality ofly, is favorable to multi-angle control information collection.
Furthermore, the acquisition communication module, the service communication module and the blanking communication module are connected and communicated through optical cables, and the remote communication module is communicated with the service communication module in an internet connection mode.
Example two
Referring to fig. 1-3, the present invention provides a method for intelligently controlling the material flow rate of an electric hopper of a coal wharf in a constant manner, wherein the method comprises the following steps:
step S100, initializing, setting, firstly resetting the hopper to calibrate the weight sensor under the condition that the hopper is unloaded by feeding, and then presetting the material discharging speed Q 0 ；
In this step, the system automatically initializes the data to reduce errors.
Step S200, calibrating and collecting data, collecting weight sensor information at regular time and sending the information to a server when a hopper discharges materials, collecting video information above the hopper and at a discharging port in real time and sending the video information to the server, synchronously collecting position information in the hopper and sending the position information to the server, wherein the weight sensor collects information in a format that: (m) n ,t),m n The current material weight is adopted, t is the measurement time, and the information acquisition format of the material level sensor is as follows: (h) a n ,t),h n The current material height is obtained, and t is the measuring time;
step S300, data processing, namely, the server judges whether the current blanking speed meets a preset requirement according to the acquired data, if so, the blanking operation is continued, if not, a calculation result is output, the next operation is performed, and meanwhile, the server draws a data change curve for the information acquired by the weight sensor and the level sensor; respectively drawing change curves of the material weight, the material level height and the material flow by taking time as an abscissa, the material weight value, the material level height and the material flow as an ordinate, and establishing a model;
when the model is built in the step, if the problem of material blockage occurs, the drawn and built model data is only reserved and is not referred to.
Step S400, adjusting blanking and analyzing whether the blanking is blocked, outputting an adjusting instruction according to a model, if the blanking speed is higher than a preset speed, outputting an instruction of reducing the opening degree of a blanking port by a server, if the blanking speed is lower than the preset speed, outputting an instruction of increasing the opening degree of the blanking port by the server, if the opening degree of the blanking port is increased, judging whether the current material is blocked or not according to regularly acquired material level information and video information, and if the material is blocked, performing the next step;
and S500, assisting in blanking, wherein the blanking control module vibrates and smashes the materials in the hopper through auxiliary equipment to dredge the materials, and synchronously feeds parameters such as video information and blanking data back to remote equipment for early warning.
Further, the preset feeding speed in the step S100 is not greater than the maximum feeding speed of the hopper.
Further, in the step S200, each time the front weight sensor and the level sensor of the hopper need to collect data, the data is collected again after the feeding is finished.
Further, in step S300, during each feeding of the hopper, the weight and the material level information of the hopper before and after each feeding need to be combined for correction, and the command is output again according to the data after the feeding, specifically, the control command is output according to the opening and closing angle corresponding to the blanking speed in the established model curve.
Further, the method also comprises the step S600 of remote operation, and a worker can remotely and manually control the opening and closing angle of the hopper feed opening according to the information received by the remote equipment.
Furthermore, the opening sensor adopts a linear displacement sensor and is used for detecting the opening data of the hopper door, and the model is SH23-GWH-10ZK.
Further, in the step S300, a formula for calculating the blanking speed is as follows:
wherein Q is the current blanking speed m n Weight of material in hopper, m n-1 The weight of the material in the hopper in the previous time, and t is the time difference of two measurements.
In conclusion, the invention can automatically control the blanking flow to keep the blanking flow in relatively stable output by acquiring the blanking weight information and the material level information in stages, drawing the data change curve by acquiring the information of the weight sensor and the material level sensor and combining the output instruction control of the server, and can also carry out remote control, so that the blanking speed of the material amount can be intuitively judged by combining the material level sensor in the remote control.
It should be noted that, in this document, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrases "comprising a component of' 8230; \8230;" does not exclude the presence of another like element in a process, method, article, or apparatus that comprises the element.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention, and all equivalent structures or equivalent processes performed by the present invention or directly or indirectly applied to other related technical fields are also included in the scope of the present invention.
Claims (10)
1. An intelligent control method for constant material flow of an electric hopper of a coal wharf is characterized by comprising the following steps:
s100, initializing, setting, namely, carrying out zero clearing on a hopper to calibrate a weight sensor under the condition that the hopper is unloaded by feeding, and then presetting the material discharging speed;
step S200, calibrating and collecting data, collecting weight sensor information at regular time and sending the information to a server when a hopper discharges materials, collecting video information above the hopper and at a discharging port in real time and sending the video information to the server, and synchronously collecting position information in the hopper and sending the position information to the server;
step S300, processing data, namely, judging whether the current blanking speed meets a preset requirement or not according to the acquired data by a server, continuing blanking operation if the current blanking speed meets the preset requirement, outputting a calculation result and performing the next operation if the current blanking speed does not meet the preset requirement, and simultaneously drawing a data change curve for information acquired by a weight sensor and a level sensor by the server, wherein the change curves of material weight, level height and material flow are respectively drawn by taking time as an abscissa, a material weight value, the level height and the material flow as an ordinate, and establishing a model;
step S400, adjusting blanking and analyzing whether the blanking is blocked, outputting an adjusting instruction according to a model, if the blanking speed is higher than a preset speed, outputting an instruction of reducing the opening degree of a blanking port by a server, if the blanking speed is lower than the preset speed, outputting an instruction of increasing the opening degree of the blanking port by the server, if the opening degree of the blanking port is increased, judging whether the current material is blocked or not according to regularly acquired material level information and video information, and if the material is blocked, performing the next step;
and S500, assisting in blanking, wherein the blanking control module vibrates and smashes the materials in the hopper through auxiliary equipment to dredge the materials, and synchronously feeds parameters such as video information and blanking data back to remote equipment for early warning.
2. The intelligent control method for the constant material flow of the electric hopper of the coal wharf as claimed in claim 1, wherein the preset blanking speed in the step S100 is not greater than the maximum blanking speed of the hopper.
3. The intelligent control method for the constant material flow of the electric hopper of the coal wharf according to claim 2, wherein in the step S200, data needs to be collected by both the front weight sensor and the level sensor during each hopper feeding, and data is collected again after the feeding is finished.
4. The method as claimed in claim 3, wherein in step S300, the weight and level information of the hopper before and after each charging is corrected, and the command is outputted again according to the data after charging.
5. The intelligent control method for the constant material flow of the electric hopper of the coal wharf according to claim 1, further comprising a step S600 of remote operation, wherein a worker can remotely and manually control the opening and closing angle of a feed opening of the hopper according to information received by a remote device.
6. The intelligent control method for the constant material flow of the electric hopper of the coal wharf according to claim 1, wherein the opening sensor adopts a linear displacement sensor and is used for detecting opening data of the hopper door.
7. The intelligent control method for the constant material flow of the electric hopper of the coal wharf according to claim 1, wherein in the step S300, a formula for calculating the blanking speed is as follows:
wherein Q is the current blanking speed m n Weight of material in hopper, m n-1 The weight of the material in the hopper in the previous time, and t is the time difference of the two measurements.
8. A coal wharf electric hopper material flow constant intelligent control system for implementing the method as claimed in claims 1 to 5, wherein the system comprises:
the information acquisition system comprises a weight sensor for measuring the loading capacity of the electric hopper, a timing module for providing time reference, an acquisition communication module for transmitting information, a video acquisition module for acquiring blanking video information of the hopper, a material level sensor arranged above the hopper for acquiring the material level distance of the hopper and an opening sensor arranged at a blanking port of the hopper;
the server comprises a data processing module for processing information acquired by the information acquisition system, a service communication module for communicating with the information acquisition system, the blanking control module and the remote equipment, a storage module for storing a blanking control algorithm and acquired data, and an execution module for issuing a blanking control instruction;
the blanking control module comprises a blanking communication module for receiving server information, auxiliary equipment for assisting blanking during the time of blocking, and an opening motor for starting the blanking hopper;
the remote equipment is carried by a worker, and comprises an early warning module for early warning when the material is blocked and abnormal conditions occur, a remote communication module for server communication and a control module for issuing instructions.
9. The intelligent control system for controlling the material flow rate of the electric hopper of the coal wharf to be constant according to claim 8, wherein the video acquisition modules are arranged in two groups and respectively correspond to an upper part of the hopper and a lower part of the hopper, and the level sensors are arranged right above the hopper and are provided with a plurality of level sensors.
10. The intelligent control method for material flow constancy in an electric hopper of a coal terminal as claimed in claim 8, wherein said acquisition communication module, said service communication module and said blanking communication module are in communication by optical cable connection, and said remote communication module is in communication with said service communication module by internet connection.
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Application publication date: 20230414 |