CN116222477A - Real-time metering system and method for loading amount of large electric shovel of surface mine - Google Patents
Real-time metering system and method for loading amount of large electric shovel of surface mine Download PDFInfo
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- CN116222477A CN116222477A CN202310315573.2A CN202310315573A CN116222477A CN 116222477 A CN116222477 A CN 116222477A CN 202310315573 A CN202310315573 A CN 202310315573A CN 116222477 A CN116222477 A CN 116222477A
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02F—DREDGING; SOIL-SHIFTING
- E02F3/00—Dredgers; Soil-shifting machines
- E02F3/04—Dredgers; Soil-shifting machines mechanically-driven
- E02F3/46—Dredgers; Soil-shifting machines mechanically-driven with reciprocating digging or scraping elements moved by cables or hoisting ropes ; Drives or control devices therefor
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02F—DREDGING; SOIL-SHIFTING
- E02F3/00—Dredgers; Soil-shifting machines
- E02F3/04—Dredgers; Soil-shifting machines mechanically-driven
- E02F3/46—Dredgers; Soil-shifting machines mechanically-driven with reciprocating digging or scraping elements moved by cables or hoisting ropes ; Drives or control devices therefor
- E02F3/58—Component parts
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02F—DREDGING; SOIL-SHIFTING
- E02F9/00—Component parts of dredgers or soil-shifting machines, not restricted to one of the kinds covered by groups E02F3/00 - E02F7/00
- E02F9/26—Indicating devices
- E02F9/264—Sensors and their calibration for indicating the position of the work tool
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B21/00—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant
- G01B21/16—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring distance of clearance between spaced objects
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B21/00—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant
- G01B21/22—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring angles or tapers; for testing the alignment of axes
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01G—WEIGHING
- G01G19/00—Weighing apparatus or methods adapted for special purposes not provided for in the preceding groups
- G01G19/08—Weighing apparatus or methods adapted for special purposes not provided for in the preceding groups for incorporation in vehicles
- G01G19/12—Weighing apparatus or methods adapted for special purposes not provided for in the preceding groups for incorporation in vehicles having electrical weight-sensitive devices
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R19/00—Arrangements for measuring currents or voltages or for indicating presence or sign thereof
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R21/00—Arrangements for measuring electric power or power factor
- G01R21/06—Arrangements for measuring electric power or power factor by measuring current and voltage
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- Mechanical Engineering (AREA)
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Abstract
The application discloses real-time metering system and method of large-scale electric shovel ore loading of surface mine obtains first distance through bucket rod pull line sensing, and inclination sensor obtains first contained angle, and current transformer obtains the electric shovel's electric current, and voltage transformer obtains the voltage of electric shovel, and data processing module carries out data processing to preset electric shovel's operating parameter to and first distance, first contained angle, electric current and voltage, thereby corresponds the single bucket ore loading of determining electric shovel at ore loading in-process, and then realizes obtaining the real-time ore loading of whole mine to carry out work efficiency management to the ore loading condition.
Description
Technical Field
The invention relates to the technical field of mine electric shovel work efficiency management, in particular to a real-time metering system and method for the loading quantity of a large-scale electric shovel of an open pit mine.
Background
The large electric shovel is an integral part of the production of surface mines and is an important component of shovel loading links. In the shovel loading process, the working condition is complex, the full bucket rate of the bucket is low due to different levels of operators, and corresponding real-time monitoring equipment is not available, so that the shovel loading working efficiency is low, and the ore loading quantity cannot be obtained in time.
At present, in order to obtain the current ore loading condition, the task quantity and the vehicle number of the pulling vehicle are counted manually, and the current existing ore quantity is roughly determined through data accumulation, so that the subsequent work efficiency management is conducted according to the ore quantity. However, the current way of relying on manual statistics has serious hysteresis, which results in the inability to timely and efficient work management of the loading situation.
Therefore, in the prior art, when the mining conditions of the surface mine are subjected to work efficiency management, the problem that the mining quantity data of the electric shovel cannot be obtained in real time exists.
Disclosure of Invention
In view of the foregoing, it is necessary to provide a real-time metering system and method for the loading of a large electric shovel of a surface mine, so as to solve the problem that in the prior art, when the loading condition of the surface mine is subjected to work efficiency management, the loading data of the electric shovel cannot be obtained in real time.
In order to solve the problems, the invention provides a real-time metering system for loading ore quantity of a large electric shovel of a surface mine, which is applied to the metering of the loading ore quantity of the electric shovel and comprises the following components:
the distance measuring sensor is used for acquiring a first distance;
the inclination sensor is used for acquiring a first included angle;
the current transformer is used for acquiring the current of the electric shovel;
the voltage transformer is used for acquiring the voltage of the electric shovel;
the data processing module is respectively connected with the ranging sensor, the inclination sensor, the current transformer and the voltage transformer in a signal manner and is used for determining the ore loading quantity of the electric shovel based on the preset working parameters of the electric shovel, the first distance, the first included angle, the current and the voltage;
the first distance is the distance between the ranging sensor and the tail end of the bucket rod of the electric shovel;
the first included angle is the included angle between the bucket rod and the big arm.
Further, the operating parameters include boost motor power, boost motor boost efficiency, boost motor rated speed, boost motor operating voltage, boost motor operating current, spool radius, and spool speed.
Further, the electric shovel further comprises a positioning device for acquiring position information of the electric shovel; and the data processing module is also used for classifying the ore loading amount based on the position information to obtain the ore loading amounts of different mining areas.
Further, the electric shovel also comprises a waterproof and shockproof protective shell, and a closed space is formed between the waterproof and shockproof protective shell and the top of a machine room of the electric shovel; wherein, positioner sets up in the enclosure space.
In order to solve the problems, the invention also provides a method for self-testing the ore loading amount of the electric shovel, which comprises the following steps:
acquiring a first distance based on a ranging sensor;
acquiring a first included angle based on the inclination sensor;
acquiring the current of the electric shovel based on a current transformer;
acquiring the voltage of an electric shovel based on a voltage transformer;
the data processing module determines ore loading quantity of the electric shovel based on preset working parameters of the electric shovel, a first distance, a first included angle, current and voltage;
the first distance is the distance between the ranging sensor and the tail end of the bucket rod of the electric shovel;
the first included angle is the included angle between the bucket rod and the big arm.
Further, the electric shovel also comprises a positioning device; based on preset working parameters of the electric shovel, and a first distance, a first included angle, current and voltage, determining the ore loading amount of the electric shovel comprises the following steps:
setting a first included angle comparison range and a second included angle comparison range of the first included angle, and a distance fluctuation range of the first distance;
when the first included angle is in the first included angle comparison range, activating the current transformer and the voltage transformer;
when the included angle change value of the first included angle is in the second included angle comparison range and the distance change value of the first distance is in the distance fluctuation range, closing the current transformer and the voltage transformer to obtain the current and the voltage of the electric shovel;
determining each single bucket ore loading amount of the electric shovel according to the working parameters, the first distance, the first included angle, the current and the voltage corresponding to the position information of the electric shovel, and determining the total ore loading amount based on the position information;
the first included angle comparison range is from a minimum included angle to a maximum included angle;
the minimum included angle is the included angle between the bucket rod and the large arm when the bucket of the electric shovel reaches the highest unloading height;
the maximum included angle is the included angle between the bucket rod and the large arm when the bucket of the electric shovel reaches the lowest unloading height;
the second included angle comparison range is from the minimum fluctuation value to the maximum fluctuation value of the included angle change value when the electric shovel runs stably.
Further, when the included angle change value of the first included angle is in the second included angle comparison range, and the distance change value of the first distance is in the distance fluctuation range, the current transformer and the voltage transformer are turned off to obtain the current and the voltage of the electric shovel, and the electric shovel comprises:
continuously differencing the first included angles of two adjacent moments to obtain an included angle change value;
continuously differencing the first distances between two adjacent moments to obtain a distance variation value;
when the included angle change value is in the second included angle comparison range and the distance change value is in the distance fluctuation range, closing the current transformer and the voltage transformer, and obtaining a current data set, a voltage data set, a first included angle data set and a first distance data set corresponding to a stable period;
averaging the current data set to obtain current;
and carrying out an averaging operation on the voltage data set to obtain the voltage.
Further, according to the working parameter, the first distance, the first included angle, the current and the voltage, determining the ore loading of each single bucket of the electric shovel, and determining the total ore loading based on the position information, including:
obtaining a first included angle change value and a stable duration according to the first included angle data;
determining the overall quality of a single bucket of the electric shovel based on a bucket overall quality calculation formula according to the working parameters, the first distance, the first included angle change value, the stable duration, the current and the voltage;
acquiring the total mass of a single bucket of the electric shovel when the electric shovel is empty, and determining the total mass of the empty bucket;
acquiring the total mass of a single bucket of the electric shovel during working, and determining the total mass of the working bucket;
the overall quality of the working bucket and the overall quality of the empty bucket are subjected to difference to obtain the ore loading quantity of each single bucket of the electric shovel;
and carrying out accumulated summation on each single hopper ore loading amount corresponding to the position information, and determining the total ore loading amount based on the position information.
Further, the overall mass calculation formula of the bucket is:
α＝β-φ
wherein M is the total mass of the single bucket, U is voltage, I is current, eta is the lifting efficiency of the lifting motor, deltat is the stable duration, L is the length of the bucket rod, the bucket rod is a uniform rod, L 1 The first distance is phi, the first included angle is delta alpha, delta alpha is a first included angle change value, r is the radius of a head sheave of the electric shovel, and beta and g are fixed values.
Further, the calculation formula of the ore loading of each single bucket of the electric shovel is as follows: w=m Work of -M Empty space
W is the ore loading quantity of a single hopper, M Work of For the total mass of the single bucket when the electric shovel operates, M Empty space The total mass of the single bucket when the electric shovel is empty.
The beneficial effects of adopting above-mentioned technical scheme are: the invention provides a real-time metering system and method for the ore loading of a large electric shovel of an open pit mine, wherein a first distance is acquired through a bucket rod wire pulling sensor, a first included angle is acquired by an inclination angle sensor, a current transformer acquires the current of the electric shovel, a voltage transformer acquires the voltage of the electric shovel, and a data processing module carries out data processing on the preset working parameters of the electric shovel, the first distance, the first included angle, the current and the voltage, so that the ore loading of a single bucket of the electric shovel in the ore loading process is correspondingly determined, and the real-time ore loading of the whole ore field is acquired, so that the work efficiency management on the ore loading condition is facilitated.
Drawings
FIG. 1 is a schematic diagram of an embodiment of a real-time metering system for loading of a large electric shovel of an open pit mine;
FIG. 2 is a schematic diagram of another embodiment of a real-time metering system for loading of large electric shovel in surface mine;
FIG. 3 is a schematic flow chart of an embodiment of a method for self-testing loading of an electric shovel according to the present invention;
FIG. 4 is a schematic flow chart of an embodiment of a method for self-testing the loading of an electric shovel according to the present invention;
FIG. 5 is a schematic flow chart of an embodiment of obtaining current and voltage of an electric shovel according to the present invention;
FIG. 6 is a schematic flow chart of an embodiment of determining a total mine loading according to the present invention;
FIG. 7 is a schematic view of an embodiment of an electric shovel model according to the present invention;
fig. 8 is a schematic structural diagram of an embodiment of the information label corresponding to fig. 7.
Detailed Description
Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, which form a part hereof, and together with the description serve to explain the principles of the invention, and are not intended to limit the scope of the invention.
Before the embodiments are set forth, an electric shovel is described:
an electric shovel, also called a rope shovel and a steel cable shovel, namely a mechanical electric excavator, is a single bucket excavator which utilizes transmission parts such as gears, chains, steel cable pulley blocks and the like to transmit power.
The electric shovel is one of ten millions of ton class surface mine main mining equipment, has high productivity, high operation rate and low operation cost, and is a recognized model in mining industry. The electric shovel consists of a walking device, a rotating device, a working device, a lubricating system and an air supply system. The bucket is a main component of the electric shovel, directly bears the acting force of the excavated ore, so that abrasion is large, the bucket rod is one of the main components in the excavating process of the electric shovel, the bucket rod is used for connecting and supporting the bucket, pushing and pressing actions are transmitted to the bucket, and the bucket can finish the action of excavating soil under the combined action of the pushing and pressing forces and the lifting forces.
At present, in order to acquire the working condition of an electric shovel, the current ore loading condition is determined, mainly by manually counting the task quantity and the number of vehicles of a pulling car, and the current existing ore quantity is roughly determined through data accumulation, so that the subsequent work efficiency management is conveniently carried out according to the ore quantity. However, the current way of relying on manual statistics has serious hysteresis, which results in the inability to timely and efficient work management of the loading situation.
Therefore, in the prior art, when the mining conditions of the electric shovel of the surface mine are subjected to work efficiency management, the problem that the mining quantity data of the electric shovel cannot be obtained in real time exists.
In order to solve the problems, the invention provides a real-time metering system and method for the loading amount of a large electric shovel of an open pit mine, and the system and the method are respectively described in detail below.
As shown in fig. 1, fig. 1 is a schematic structural diagram of an embodiment of a real-time metering system for a large-scale electric shovel of an open pit mine, where the real-time metering system 100 for a large-scale electric shovel of an open pit mine includes:
a ranging sensor 101 for acquiring a first distance;
the inclination sensor 102 is used for acquiring a first included angle;
a current transformer 103 for obtaining the current of the electric shovel;
a voltage transformer 104 for acquiring the voltage of the electric shovel;
the data processing module 105 is respectively connected with the ranging sensor 101, the inclination sensor 102, the current transformer 103 and the voltage transformer 104 in a signal manner and is used for determining the ore loading amount of the electric shovel based on the preset working parameters of the electric shovel, the first distance, the first included angle, the current and the voltage;
the first distance is the distance between the ranging sensor 101 and the large arm of the electric shovel, which is close to one side of the ranging sensor 101;
the first included angle is an included angle between the bucket rod and the big arm.
In this embodiment, the first distance is acquired through the ranging sensor 101, the first included angle is acquired through the inclination sensor 102, the current of the electric shovel is acquired through the current transformer 103, the voltage of the electric shovel is acquired through the voltage transformer 104, and the data processing module 105 performs data processing on the preset working parameters of the electric shovel, the first distance, the first included angle, the current and the voltage, so that the single bucket ore loading amount of the electric shovel in the ore loading process is correspondingly determined, and the real-time ore loading amount of the whole ore field is acquired, so that the work efficiency management is performed on the ore loading condition.
As a preferred embodiment, the distance measuring sensor 101 may be a pull wire sensor or, alternatively, a laser distance measuring device.
The distance measuring sensor 101 is arranged at the top end of the bucket rod, and the distance between the distance measuring sensor 101 and the large arm of the electric shovel, which is close to one side of the distance measuring sensor 101, namely, the first distance can be obtained in real time.
As a preferred embodiment, the inclination sensor 102 is disposed at a corner of the armrest sleeve near the arm, so that the first included angle, that is, the included angle between the arm and the boom, can be obtained in real time.
As a preferred embodiment, the current transformer 103 and the voltage transformer 104 are respectively arranged in the circuit of the electric shovel lifter, so that the current and the voltage of the electric shovel can be obtained in real time.
As a preferred embodiment, the operating parameters include boost motor power, boost motor boost efficiency, boost motor rated speed, boost motor operating voltage, boost motor operating current, spool radius, and spool speed.
As a preferred embodiment, the real-time measuring system 100 for the mine loading of the large-scale electric shovel of the surface mine further comprises a positioning device 106, as shown in fig. 2, fig. 2 is a schematic structural diagram of another embodiment of the real-time measuring system for the mine loading of the large-scale electric shovel of the surface mine, where the positioning device 106 is used for obtaining the position information of the electric shovel; the data processing module 105 is further configured to classify the loading amounts based on the location information, so as to obtain loading amounts of different mining areas.
As a preferred embodiment, the positioning device 106 is disposed at the top of the machine room of the electric shovel, so that the position of the electric shovel can be well positioned, and the safety of the positioning device 106 can be well ensured because the machine room of the electric shovel belongs to a key protection area.
In other embodiments, the setting position of the positioning device 106 may be adaptively adjusted according to actual needs.
In this embodiment, the ore loading amounts and the position information are in one-to-one correspondence, so that the ore loading amounts in real time can be obtained for the ore sites at different positions, so that the ore loading amount data can be classified and managed.
As a preferred embodiment, the positioning device 106 is a device capable of determining its own position in real time.
In a specific embodiment, the positioning device 106 includes at least one of a GPS positioning device, a Beidou satellite positioning device, a base station positioning device, a wifi positioning device, and a bluetooth positioning device.
Further, since the electric shovel is mostly operated in an open air environment during the working process, the positioning device 106 needs to be protected in order to ensure the normal operation of the positioning device 106.
In a specific embodiment, the real-time metering system 100 for the loading of the large electric shovel of the surface mine further comprises a waterproof and shockproof protective casing, wherein the waterproof and shockproof protective casing and the top of the machine room of the electric shovel form a closed space, and the positioning device 106 is arranged in the closed space.
In this embodiment, by adding the waterproof and shockproof protective housing to the positioning device 106, the positioning device 106 can avoid the problems of failure and the like caused by external environmental factors in the running process.
In order to solve the above problems, the present invention further provides a method for self-testing ore loading of an electric shovel, where the method is applied to the electric shovel according to any one of the above technical solutions, as shown in fig. 3, fig. 3 is a schematic flow chart of an embodiment of the method for self-testing ore loading of an electric shovel according to the present invention, and includes:
step S101: acquiring a first distance based on a ranging sensor;
step S102: acquiring a first included angle based on the inclination sensor;
step S103: acquiring the current of the electric shovel based on a current transformer;
step S104: acquiring the voltage of an electric shovel based on a voltage transformer;
step S105: the data processing module determines ore loading quantity of the electric shovel based on preset working parameters of the electric shovel, a first distance, a first included angle, current and voltage;
the first distance is the distance between the ranging sensor and the tail end of the bucket rod of the electric shovel;
the first included angle is the included angle between the bucket rod and the big arm.
In the embodiment, first, a first distance is acquired based on a ranging sensor, a first included angle is acquired based on an inclination sensor, current of an electric shovel is acquired based on a current transformer, and voltage of the electric shovel is acquired based on a voltage transformer; then, the data processing module determines the ore loading amount of the electric shovel based on the preset working parameters of the electric shovel, the first distance, the first included angle, the current and the voltage.
In the embodiment, the first distance, the first included angle, the current and the voltage are acquired in real time; then, according to the preset working parameters, the first distance, the first included angle, the current and the voltage of the electric shovel, determining the ore loading quantity of each single bucket of the electric shovel, and accordingly determining the total ore loading quantity, acquiring ore loading quantity data in real time, and facilitating work efficiency management on ore loading conditions.
As a preferred embodiment, in step S105, the data processing module not only acquires the preset operating parameters of the electric shovel, but also performs data processing and calculation on the acquired dynamic information according to a preset algorithm, so as to determine the target amount.
As a preferred embodiment, in step S105, the electric shovel further includes a positioning device, and in order to determine the ore loading of the electric shovel, as shown in fig. 4, fig. 4 is a schematic flow chart of an embodiment of a method for self-testing the ore loading of the electric shovel according to the present invention, which includes:
step S151: setting a first included angle comparison range and a second included angle comparison range of the first included angle, and a distance fluctuation range of the first distance;
step S152: when the first included angle is in the first included angle comparison range, activating the current transformer and the voltage transformer;
step S153: when the included angle change value of the first included angle is in the second included angle comparison range and the distance change value of the first distance is in the distance fluctuation range, closing the current transformer and the voltage transformer to obtain the current and the voltage of the electric shovel;
step S154: determining each single bucket ore loading amount of the electric shovel according to the working parameters, the first distance, the first included angle, the current and the voltage corresponding to the position information of the electric shovel, and determining the total ore loading amount based on the position information;
the first included angle comparison range is from a minimum included angle to a maximum included angle;
the minimum included angle is the included angle between the bucket rod and the large arm when the bucket of the electric shovel reaches the highest unloading height;
the maximum included angle is the included angle between the bucket rod and the large arm when the bucket of the electric shovel reaches the lowest unloading height;
the second included angle comparison range is from the minimum fluctuation value to the maximum fluctuation value of the included angle change value when the electric shovel runs stably.
In the embodiment, the overall processing is performed on the data information of the electric shovel in the ore loading process, so that the single bucket ore loading amount at any moment is determined, and then the total ore loading amount based on the position information is obtained in real time based on the data processing.
In the embodiment, through carrying out fine study on the motion states of the large arm and the bucket rod of the electric shovel in the ore loading process, the distance between any fixed point of the large arm and the bucket rod is found to be in a stable state when the electric shovel is in a full bucket state after ore loading is finished; on the other hand, the included angle between the bucket rod and the big arm is in a stable state. In order to facilitate measurement, a ranging sensor is provided in this embodiment, and is installed at the apex of the stick. That is, in the present embodiment, when the electric shovel is in the full bucket state at the end of mining, L 1 In steady state, α is also in steady state.
In other embodiments, the position of the ranging sensor may also be adaptively adjusted as desired.
In a preferred embodiment, in step S151, the first angle comparison range is from the minimum angle to the maximum angle. The minimum included angle is the included angle between the bucket rod and the large arm when the bucket of the electric shovel reaches the highest unloading height; the maximum included angle is the included angle between the bucket rod and the large arm when the bucket of the electric shovel reaches the lowest unloading height.
As a preferred embodiment, in step S152, when the first included angle is within the first included angle comparison range, it is indicated that the electric shovel is in an operation state, so that the current transformer and the voltage transformer need to be activated to acquire current data and voltage data of the electric shovel in real time.
However, because the electric shovel inevitably shakes in the running process, in order to better judge whether the electric shovel is in a stable state, an included angle change value of the first included angle and a distance change value of the first distance need to be acquired in real time, and a second included angle comparison range and a distance fluctuation range are preset. In step S153, in order to obtain reliable current and voltage of the electric shovel, as shown in fig. 5, fig. 5 is a schematic flow chart of an embodiment of obtaining current and voltage of the electric shovel according to the present invention, including:
step S1531: continuously differencing the first included angles of two adjacent moments to obtain an included angle change value;
step S1532: continuously differencing the first distances between two adjacent moments to obtain a distance variation value;
step S1533: when the included angle change value is in the second included angle comparison range and the distance change value is in the distance fluctuation range, closing the current transformer and the voltage transformer, and obtaining a current data set, a voltage data set, a first included angle data set and a first distance data set corresponding to a stable period;
step S1534: averaging the current data set to obtain current;
step S1535: and carrying out an averaging operation on the voltage data set to obtain the voltage.
In this embodiment, through carrying out real-time management and control to the change condition of first contained angle and first distance, realize accurate judgement electric shovel whether be in the operation stage after the mining is accomplished to obtain reliable stable period corresponding electric current dataset, voltage dataset, first contained angle dataset and first distance dataset, with the stable electric current and the voltage of confirm electric shovel at operation period.
In step S1533, the second angle comparison range is set to (-X, X) in order to ensure the reliability of the angles, and in a preferred embodiment, the second angle comparison range is set to (-X, X), and the model parameters of different electric shovels, especially the accuracy, are different, so that the value of X can be adjusted according to the actual needs by different electric shovels.
In a specific embodiment, the value of X is 0.5 °, that is, when the variation range of the angle variation value is between-0.5 ° and 0.5 °, it is determined that the angle between the arm and the boom is in a stable state.
Correspondingly, the range of the distance fluctuation is also required to be described, and as a preferred embodiment, the range of the distance fluctuation is set to (-Y, Y), and as model parameters, particularly accuracy, of different electric shovels are different, the value of Y can be adjusted according to actual needs by the different electric shovels.
In a specific embodiment, Y takes a value of 5mm, i.e. when the range of the distance change value is between-5 mm and 5mm, it is determined that the distance between the boom and the ranging sensor is in a stable state.
As a preferred embodiment, in step S154, after determining the current data set, the voltage data set, the first included angle data set, and the first distance data set corresponding to the electric shovel tending to stabilize period, in order to determine each single bucket ore loading amount of the electric shovel, thereby determining the total ore loading amount based on the position information, as shown in fig. 6, fig. 6 is a schematic flow chart of an embodiment of determining the total ore loading amount provided by the present invention, including:
step S1541: obtaining a first included angle change value and a stable duration according to the first included angle data;
step S1542: determining the overall quality of a single bucket of the electric shovel based on a bucket overall quality calculation formula according to the working parameters, the first distance, the first included angle change value, the stable duration, the current and the voltage;
step S1543: acquiring the total mass of a single bucket of the electric shovel when the electric shovel is empty, and determining the total mass of the empty bucket;
step S1544: acquiring the total mass of a single bucket of the electric shovel during working, and determining the total mass of the working bucket;
step S1545: the overall quality of the working bucket and the overall quality of the empty bucket are subjected to difference to obtain the ore loading quantity of each single bucket of the electric shovel;
step S1546: and carrying out accumulated summation on each single hopper ore loading amount corresponding to the position information, and determining the total ore loading amount based on the position information.
In the embodiment, the first included angle data is processed to determine a first included angle change value and a stable duration, and then the overall quality of a single bucket of the electric shovel is determined based on a bucket overall quality calculation formula according to the working parameters, the first distance, the first included angle change value, the stable duration, the current and the voltage, so that the overall quality of the single bucket of the electric shovel is obtained in real time; further, in order to obtain the ore loading amount independently, the electric shovel is required to be operated by the empty bucket, the total mass of the empty bucket is obtained, and then the total mass of the empty bucket is removed by making a difference in the subsequent operation process, so that each single bucket ore loading amount of the electric shovel is obtained.
As a preferred embodiment, in step S1541, in order to improve the stability of the first angle data set, thereby improving the accuracy of the overall quality of the resulting single bucket, the first angle data set needs to be screened, that is, the first angle data set of a certain preferred period before the current transformer and the voltage transformer are turned off and the first distance data set, the stable duration, the current data set and the voltage data set of the corresponding period thereof are selected.
In a specific embodiment, the preferred time period is selected to be a time period T, and an end point of the time period is a time point when the current transformer and the voltage transformer are turned off, wherein the value of T is 10ms.
In other embodiments, the preferred time period may be selected based on other criteria, and T may take other values.
As a preferred embodiment, in step S1542, in order to describe a process of processing acquired data to obtain a lifting force of the lifting wire rope according to an operation parameter of the electric shovel, a derivation process is described in this embodiment, wherein the formula involved includes:
P＝UI (3)
from equations (1) (2) (3) (4):
because v 1 ＝v 2 From equations (5) (6):
substituting equation (8) into equation (7) yields:
wherein F is the pulling force of the hoisting steel wire rope; t is the torque of the winding drum; p is the boost motor power; η is the lifting efficiency and is generally 0.8 to 0.9; i is the transmission ratio of the transmission mechanism; n is n j The rotational speed of the winding drum; n is n e To increase the rated rotation speed of the motor; r is the radius of the reel; v 1 Is the linear velocity of the winding drum; v 2 The linear speed of the bucket rod during lifting is set; r is the rotation radius (L-L) of the bucket rod when the bucket is empty 1 ) The method comprises the steps of carrying out a first treatment on the surface of the Delta alpha is the angle variation of delta t before the included angle between the bucket rod and the big arm is unchanged; u is the working voltage of the lifting motor; i is the boost motor operating current.
Further, in order to simplify the model of the electric shovel, the positions corresponding to the working parameters are clearly described, as shown in fig. 7, fig. 7 is a schematic structural diagram of an embodiment of the electric shovel model provided by the invention, and in addition, as shown in fig. 8, fig. 8 is a schematic structural diagram of an embodiment of the information label corresponding to fig. 7.
α＝β-φ
Wherein L is 1 Is a first distance; phi is a first included angle; beta is the included angle between the big arm and the horizontal plane, and beta is a fixed value; l is the length of the bucket rod, and the bucket rod is a uniform rod.
In DeltaBAC, AB is the distance between the arm large arm connecting bolt button and the large arm head sheave connecting bolt button, and is marked as l 3 And l 3 Is a fixed value; angle bac= angle α, ac=l-L 1 According to the cosine theorem:
BC 2 ＝AB 2 +AC 2 -2AB·AC cos∠BAC
according to sine theorem:
the simplification can be obtained:
in delta BDC, the angle BDC is the included angle between the large arm and the horizontal plane and is recorded as beta; the internal triangle angle and formula are:
∠BCD＝π-∠BDC-∠DBC
in Δdac, Δdac=pi- < bac=pi- α, which is obtained from the triangle interior angle sum formula:
∠ACD＝α-β
in Δbce, BE is the radius r of the head sheave, be+.ce, obtained by sine theorem:
the balance principle of the moment arm can be obtained by:
wherein: ac=l-L 1 ；AH＝L 1 ；∠ECA＝∠BCE+∠BCD-∠ACD；
γ 1 ＝γ 2 ＝γ 3 = angle ACD; m is the total mass of the single bucket; m is m 1 The rear end mass of the bucket rod; m is m 2 The bucket rod is close to the bucket end; m is m 3 Is the mass of the bucket rod.
In summary, it is possible to obtain:
and (3) finishing to obtain:
wherein:
α＝β-φ
wherein M is the total mass of the single bucket, U is voltage, I is current, eta is the lifting efficiency of the lifting motor, deltat is the stable duration, L is the length of the bucket rod, the bucket rod is a uniform rod, L 1 For the first distance, Δα is a first angle change value, and g is a constant number.
By the method, the overall quality of the single bucket at any moment can be obtained, and during operation, the quality of the single bucket can be corrected according to the need, preferably in a fixed period, in order to reduce the influence of the sundries in the electric shovel bucket on the ore loading quantity counting process.
In other embodiments, the conditions for correcting the empty bucket mass may also be adjusted as desired.
In a preferred embodiment, in step S1543, after determining the bucket total mass calculation formula, in order to determine the total mass of the empty bucket, the electric shovel is subjected to a dumping operation, so as to determine the total mass of the empty bucket, denoted as M Empty space 。
As a preferred embodiment, in step S1544, the overall mass of the work bucket, denoted as M, for each bucket of the electric shovel during operation can also be determined according to the bucket overall mass calculation formula.
As a preferred embodiment, in step S1545, the formula for determining the ore loading of each single bucket of the electric shovel is:
W＝M work of -M Empty space
W is the ore loading quantity of a single hopper, M Work of For the total mass of the single bucket when the electric shovel operates, M Empty space The total mass of the single bucket when the electric shovel is empty.
As a preferred embodiment, in step S1546, the single bucket loading amounts of the electric shovel are classified according to the position information, and then the single bucket loading amounts having the same positions are cumulatively summed, so that the corresponding total loading amounts of the electric shovel at each position are determined.
In summary, the position information of the electric shovel is obtained through the positioning device, so that the area where the electric shovel is positioned is determined in real time, and accordingly, the material of a mine field and the optimal single-bucket ore loading amount are determined conveniently; the method comprises the steps that a first distance is obtained through bucket rod wire drawing sensing, a first included angle is obtained through an inclination angle sensor, current of an electric shovel is obtained through a current transformer, voltage of the electric shovel is obtained through a voltage transformer, a data processing module carries out data processing on preset working parameters of the electric shovel and the first distance, the first included angle, the current and the voltage, so that single bucket ore loading amount of the electric shovel in the ore loading process is correspondingly determined, real-time ore loading amount of the whole ore field is obtained, and work efficiency management is carried out on ore loading conditions conveniently.
It should be noted that, in some embodiments, the memory in the present application may be an internal storage unit of the computer device, for example, a hard disk or a memory of the computer device. In other embodiments, the external storage device of the computer device may be, for example, a plug-in hard disk, a Smart Media Card (SMC), a Secure Digital (SD) Card, a Flash Card (Flash Card) or the like. Further, the memory may also include both internal storage units and external storage devices of the computer device. The memory is used for storing application software installed on the computer device and various data, such as program codes for installing the computer device. The data storage module may also be used to temporarily store data that has been output or is to be output.
The data processing module may in some embodiments be a central processing unit (Central Processing Unit, CPU), microprocessor or other data processing chip for executing program code or processing data stored in the data storage module, such as executing algorithmic instructions or the like.
Those skilled in the art will appreciate that implementing all or part of the above described methods may be accomplished by way of a computer program stored on a non-transitory computer readable storage medium, which when executed, may comprise the steps of the embodiments of the methods described above. Any reference to memory, storage, database, or other medium used in the various embodiments provided herein may include non-volatile and/or volatile memory. The nonvolatile memory can include Read Only Memory (ROM), programmable ROM (PROM), electrically Programmable ROM (EPROM), electrically Erasable Programmable ROM (EEPROM), or flash memory. Volatile memory can include Random Access Memory (RAM) or external cache memory. By way of illustration and not limitation, RAM is available in a variety of forms such as Static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double Data Rate SDRAM (DDRSDRAM), enhanced SDRAM (ESDRAM), synchronous Link DRAM (SLDRAM), memory bus direct RAM (RDRAM), direct memory bus dynamic RAM (DRDRAM), and memory bus dynamic RAM (RDRAM), among others.
The present invention is not limited to the above-mentioned embodiments, and any changes or substitutions that can be easily understood by those skilled in the art within the technical scope of the present invention are intended to be included in the scope of the present invention.
Claims (10)
1. The utility model provides a large-scale electric shovel ore loading volume real-time measurement system in surface mine, is applied to electric shovel ore loading volume measurement, its characterized in that includes:
the distance measuring sensor is used for acquiring a first distance;
the inclination sensor is used for acquiring a first included angle;
the current transformer is used for acquiring the current of the electric shovel;
the voltage transformer is used for acquiring the voltage of the electric shovel;
the data processing module is respectively connected with the ranging sensor, the inclination sensor, the current transformer and the voltage transformer in a signal manner and is used for determining the ore loading amount of the electric shovel based on the preset working parameters of the electric shovel, the first distance, the first included angle, the current and the voltage;
the first distance is the distance between the distance measuring sensor and the tail end of the bucket rod of the electric shovel;
the first included angle is an included angle between the bucket rod and the big arm.
2. The real-time surface mine large electric shovel loading real-time metering system according to claim 1, wherein the operating parameters comprise boost motor power, boost motor boost efficiency, boost motor rated speed, boost motor operating voltage, boost motor operating current, spool radius and spool speed.
3. The real-time measuring system for the loading of the large electric shovel of the surface mine according to claim 1, wherein the electric shovel further comprises a positioning device for acquiring the position information of the electric shovel; and the data processing module is also used for classifying the ore loading amount based on the position information to obtain the ore loading amounts of different mining areas.
4. The real-time metering system for the loading of the large electric shovel of the surface mine according to claim 3, wherein the electric shovel further comprises a waterproof and shockproof protective shell, and a closed space is formed between the electric shovel and the top of a machine room of the electric shovel; wherein, positioner sets up in the enclosure space.
5. A method for self-measuring ore loading of an electric shovel, which is characterized in that the method is applied to the real-time ore loading metering system of a large-scale electric shovel for an open pit mine according to any one of claims 1 to 4, and comprises the following steps:
acquiring a first distance based on a ranging sensor;
acquiring a first included angle based on the inclination sensor;
acquiring the current of the electric shovel based on a current transformer;
acquiring the voltage of the electric shovel based on a voltage transformer;
the data processing module determines the ore loading amount of the electric shovel based on the preset working parameters of the electric shovel, the first distance, the first included angle, the current and the voltage;
the first distance is the distance between the distance measuring sensor and the tail end of the bucket rod of the electric shovel;
the first included angle is an included angle between the bucket rod and the big arm.
6. The method of self-testing a loading of an electric shovel according to claim 5, wherein the electric shovel further comprises a positioning device; based on preset working parameters of the electric shovel, the first distance, the first included angle, the current and the voltage, determining the ore loading amount of the electric shovel comprises the following steps:
setting a first included angle comparison range and a second included angle comparison range of the first included angle, and a distance fluctuation range of the first distance;
activating the current transformer and the voltage transformer when the first included angle is in the first included angle comparison range;
when the included angle change value of the first included angle is in the second included angle comparison range and the distance change value of the first distance is in the distance fluctuation range, closing the current transformer and the voltage transformer to obtain the current and the voltage of the electric shovel;
determining each single bucket ore loading amount of the electric shovel according to the working parameters, the first distance, the first included angle, the current and the voltage corresponding to the position information of the electric shovel, and determining the total ore loading amount based on the position information;
wherein, the first included angle comparison range is from a minimum included angle to a maximum included angle;
the minimum included angle is the included angle between the bucket rod and the large arm when the bucket of the electric shovel reaches the highest unloading height;
the maximum included angle is the included angle between the bucket rod and the large arm when the bucket of the electric shovel reaches the lowest unloading height;
the second included angle comparison range is from the minimum fluctuation value to the maximum fluctuation value of the included angle change value when the electric shovel runs stably.
7. The method of self-testing ore loading of an electric shovel according to claim 6, wherein when the included angle change value of the first included angle is in the second included angle comparison range and the distance change value of the first distance is in the distance fluctuation range, closing the current transformer and the voltage transformer to obtain the current and the voltage of the electric shovel, comprising:
continuously differencing the first included angles at two adjacent moments to obtain an included angle change value;
continuously differencing the first distances between two adjacent moments to obtain a distance variation value;
when the included angle change value is in the second included angle comparison range and the distance change value is in the distance fluctuation range, closing the current transformer and the voltage transformer, and obtaining a current data set, a voltage data set, a first included angle data set and a first distance data set corresponding to a stable period;
averaging the current data set to obtain the current;
and carrying out averaging operation on the voltage data set to obtain the voltage.
8. The method of self-test loading of an electric shovel according to claim 7, wherein determining each single bucket loading of the electric shovel based on the operating parameter, the first distance, the first included angle, the current, and the voltage, and determining a total loading based on the positional information, comprises:
obtaining a first included angle change value and a stable duration according to the first included angle data;
determining the overall quality of a single bucket of the electric shovel based on a bucket overall quality calculation formula according to the working parameters, the first distance, the first included angle change value, the stable duration, the current and the voltage;
acquiring the total mass of the single bucket of the electric shovel when the electric shovel is empty, and determining the total mass of the empty bucket;
acquiring the total mass of the single bucket of the electric shovel during working, and determining the total mass of the working bucket;
performing difference on the total mass of the working bucket and the total mass of the empty bucket to obtain each single bucket ore loading amount of the electric shovel;
and carrying out accumulated summation on each single hopper ore loading corresponding to the position information, and determining the total ore loading based on the position information.
9. The method for self-testing the ore loading of the electric shovel according to claim 8, wherein the calculation formula of the total mass of the bucket is as follows:
α＝β-φ
wherein M is the total mass of the single bucket, U is the voltage, I is the current, eta is the lifting efficiency of the lifting motor, deltat is the stable duration, L is the length of the bucket rod, the bucket rod is a uniform rod, and L 1 And for the first distance, phi is the first included angle, delta alpha is the first included angle change value, r is the radius of the head sheave of the electric shovel, and beta and g are fixed values.
10. According to the weightsThe method for self-testing the ore loading of the electric shovel according to claim 8, wherein the calculation formula of each single bucket ore loading of the electric shovel is as follows: w=m Work of -M Empty space
W is the ore loading quantity of a single hopper, M Work of For the total mass of the single bucket when the electric shovel operates, M Empty space The total mass of the single bucket when the electric shovel is empty.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117449371A (en) * | 2023-12-25 | 2024-01-26 | 山西太重数智科技股份有限公司 | Intelligent electric shovel attitude adjusting control system and method |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117449371A (en) * | 2023-12-25 | 2024-01-26 | 山西太重数智科技股份有限公司 | Intelligent electric shovel attitude adjusting control system and method |
| CN117449371B (en) * | 2023-12-25 | 2024-03-19 | 山西太重数智科技股份有限公司 | Intelligent electric shovel attitude adjusting control system and method |
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