CN116222689A - Real-time metering system and method for loading amount of surface mine hydraulic shovel - Google Patents
Real-time metering system and method for loading amount of surface mine hydraulic shovel Download PDFInfo
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- CN116222689A CN116222689A CN202310335412.XA CN202310335412A CN116222689A CN 116222689 A CN116222689 A CN 116222689A CN 202310335412 A CN202310335412 A CN 202310335412A CN 116222689 A CN116222689 A CN 116222689A
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15B—SYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
- F15B19/00—Testing; Calibrating; Fault detection or monitoring; Simulation or modelling of fluid-pressure systems or apparatus not otherwise provided for
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15B—SYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
- F15B15/00—Fluid-actuated devices for displacing a member from one position to another; Gearing associated therewith
- F15B15/20—Other details, e.g. assembly with regulating devices
- F15B15/28—Means for indicating the position, e.g. end of stroke
- F15B15/2815—Position sensing, i.e. means for continuous measurement of position, e.g. LVDT
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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
- G01B21/02—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 length, width, or thickness
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F22/00—Methods or apparatus for measuring volume of fluids or fluent solid material, not otherwise provided for
- G01F22/02—Methods or apparatus for measuring volume of fluids or fluent solid material, not otherwise provided for involving measurement of pressure
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Abstract
The application discloses real-time metering system and method of open-pit mine hydraulic shovel ore loading volume, first piston rod length of arm pneumatic cylinder is acquireed through arm pneumatic cylinder sensor of acting as go-between, the arm pneumatic cylinder sensor of acting as go-between acquires the second piston rod length of arm pneumatic cylinder, pressure sensor acquires the pressure data of arm pneumatic cylinder, data processing apparatus carries out data processing to the geometric information of preset hydraulic shovel, first piston rod length, second piston rod length and pressure data, thereby correspond the single bucket ore loading volume of confirm hydraulic shovel in the ore loading in-process, and then realize acquireing the real-time ore loading volume of whole open-pit mine, in order to carry out work efficiency management to the ore loading condition.
Description
Technical Field
The invention relates to the technical field of mine hydraulic shovel work efficiency management, in particular to a real-time metering system and method for the loading quantity of a surface mine hydraulic shovel.
Background
The large hydraulic shovel is an integral part of the production of the surface mine and is an important component of the shovel loading link. 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 amount data 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 loading of an open-pit mine hydraulic shovel, which are used for solving the problem that in the prior art, when the loading condition of an open-pit mine is subjected to work efficiency management, the loading data cannot be acquired in real time.
In order to solve the problems, the invention provides a real-time metering system for loading of a surface mine hydraulic shovel, which comprises:
the bucket rod hydraulic cylinder stay wire sensor is used for acquiring the length of a first piston rod of the bucket rod hydraulic cylinder;
the movable arm hydraulic cylinder stay wire sensor is used for acquiring the length of a second piston rod of the movable arm hydraulic cylinder;
the pressure sensor is used for acquiring pressure data of the bucket rod hydraulic cylinder;
the data processing device is respectively connected with the bucket rod hydraulic cylinder stay wire sensor, the movable arm hydraulic cylinder stay wire sensor and the pressure sensor in a signal manner and is used for determining the ore loading quantity of the hydraulic shovel based on the preset geometric information of the hydraulic shovel, the length of the first piston rod, the length of the second piston rod and the pressure data.
Further, the geometric information includes a cylinder diameter of the hydraulic cylinder, a distance between the first hinge center and the second hinge center, a distance between the first hinge center and the third hinge center, a distance between a line of the first hinge center and the third hinge center and an intersection point of the arm, a distance between the fourth hinge center and the fifth hinge center, a distance between the sixth hinge center and the seventh hinge center, a boom cylinder fixing angle, a cylinder diameter of the hydraulic cylinder, and an arm mass;
the first hinging center refers to the hinging center of the movable arm and the bucket rod; the second hinge center is the hinge center of the bucket rod hydraulic cylinder and the forklift; the third hinging center is the hinging center of the bucket rod hydraulic cylinder and the bucket rod; the fourth hinging center is the hinging center of the big arm and the bucket rod; the fifth hinging center is the hinging center of the bucket rod and the bucket; the sixth hinging center is the hinging center of the movable arm hydraulic cylinder and the movable arm; the seventh articulation center refers to the articulation center of the boom cylinder with the forklift.
Further, the hydraulic shovel further comprises a positioning device for acquiring position information of the hydraulic shovel; and the data processing device 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 hydraulic 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 hydraulic shovel; wherein, positioner sets up in the enclosure space.
In order to solve the problems, the invention also provides a method for self-measuring the ore loading amount of the hydraulic shovel, which is applied to the real-time metering system of the ore loading amount of the hydraulic shovel of the surface mine, and comprises the following steps:
acquiring a first piston rod length bucket rod based on a bucket rod hydraulic cylinder stay wire sensor;
acquiring the length of a second piston rod based on a movable arm hydraulic cylinder stay wire sensor;
acquiring pressure data of the hydraulic shovel based on a pressure sensor;
the data processing device determines the ore loading amount of the hydraulic shovel based on the geometric information of the hydraulic shovel, the length of the first piston rod, the length of the second piston rod and the pressure data.
Further, determining a loading of the hydraulic shovel based on the geometry information of the hydraulic shovel, and the first piston rod length, the second piston rod length, and the pressure data, includes:
determining an included angle between the movable arm and the bucket rod hydraulic cylinder according to the length of the first piston rod, the length of the second piston rod and the geometric information;
when the fluctuation range of the included angle is within a preset angle range, activating a pressure sensor, and acquiring pressure data of the bucket rod hydraulic cylinder based on the pressure sensor;
and determining the ore loading amount of each single bucket of the hydraulic shovel according to the pressure data, the length of the first piston rod, the length of the second piston rod and the geometric information, and determining the total ore loading amount based on the position information.
Further, the calculation formula of the included angle is:
wherein alpha is the included angle between the movable arm and the bucket rod hydraulic cylinder, and beta 4 Fixed angle for boom cylinder, (L) 1 +L 4 ) Distance L between second hinge center and third hinge center when empty 7 L is the distance between the first hinge center and the second hinge center 8 Is the distance between the first hinge center and the third hinge center.
Further, the first piston rod length comprises a first empty bucket piston rod length and a first working piston rod length, and the second piston rod length comprises a second empty bucket piston rod length and a second working piston rod length; according to the pressure data, the first piston rod length, the second piston rod length and the geometric information, determining the ore loading of each single bucket of the hydraulic shovel, and determining the total ore loading based on the position information, wherein the method comprises the following steps of:
determining the bucket mass of the hydraulic shovel according to the pressure data, the length of the first empty bucket piston rod, the length of the second empty bucket piston rod and the geometric information;
determining the single bucket mining mass of the hydraulic shovel according to the pressure data, the length of the first operation piston rod, the length of the second operation piston rod and the geometric information;
making a difference between the bucket mass and the single bucket belt mineral mass to obtain each single bucket mineral loading of the hydraulic 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 calculation formula of the bucket mass is:
wherein mg is bucket mass, F is bucket pressure data, (L) 1 +L 4 ) Distance L between second hinge center and third hinge center when empty 7 L is the distance between the first hinge center and the second hinge center 8 L is the distance between the first hinge center and the third hinge center 9 L is the distance between the fourth hinge center and the fifth hinge center 14 Gamma is the distance between the first hinging center and the third hinging center along the line and the intersection point of the bucket rod 2 Is the bending angle of the bucket rod of the empty bucket, gamma 3 The bending angle of the bucket is the bending angle of the bucket;
wherein, empty bucket arm bending angle equals with empty bucket bending angle, and empty bucket arm bending angle's calculation formula is:
wherein, (L) 2 +L 3 ) Distance between the sixth hinge center and the seventh hinge center when the bucket is empty, L 5 L is the distance between the eighth hinge center and the seventh hinge center 6 Beta is the distance between the sixth hinge center and the eighth hinge center 1 、β 2 、β 3 And beta 5 All are fixed values.
Further, the calculation formula of the single bucket belt ore quality is as follows:
wherein Mg is single bucket with ore quality, F' is operation pressure data, (L) 1 ′+L 4 ) Gamma is the distance between the second hinging center and the third hinging center during operation 2 ' is the bending angle of the working arm, gamma 3 ' is the work bucket bend angle;
wherein, the bending angle of the working arm is equal to the bending angle of the working bucket, and the calculation formula of the bending angle of the working arm is as follows:
wherein, (L) 2 ′+L 3 ) Is the distance between the sixth hinging center and the seventh hinging center during operation.
The beneficial effects of adopting above-mentioned technical scheme are: the invention provides a real-time metering system and a real-time metering method for the loading capacity of a hydraulic shovel of an open-pit mine.
Drawings
FIG. 1 is a schematic diagram of an embodiment of a real-time metering system for loading of an open pit hydraulic shovel;
FIG. 2 is a schematic diagram of an embodiment of a pressure sensor according to the present invention;
FIG. 3 is a schematic diagram of another embodiment of a real-time metering system for loading of an open pit hydraulic shovel;
FIG. 4 is a schematic view of an embodiment of a hydraulic shovel model according to the present invention;
FIG. 5 is a schematic diagram of an embodiment of the length information label corresponding to FIG. 4;
FIG. 6 is a schematic diagram illustrating an embodiment of the angle information label corresponding to FIG. 4;
FIG. 7 is a schematic flow chart of an embodiment of a method for self-measuring loading of a hydraulic shovel according to the present invention;
FIG. 8 is a schematic flow chart of an embodiment of a method for self-measuring loading of a hydraulic shovel according to the present invention;
fig. 9 is a schematic flow chart of an embodiment of determining a total ore loading according to the present invention.
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, a hydraulic shovel is described:
the hydraulic shovel, namely the hydraulic excavator, is a multifunctional machine, is widely applied to the mechanical construction of hydraulic engineering, transportation, electric power engineering, mine mining and the like, and plays an important role in relieving heavy physical labor, ensuring engineering quality, accelerating construction speed and improving labor productivity.
The hydraulic drive of an excavator is closely related, and its development is mainly based on the application of hydraulic technology. The structure of the excavator mainly comprises an engine, a hydraulic system, a working device, a running gear, an electric control and the like, and the excavator is complex in action required to be realized due to severe working conditions, so that the excavator has high requirements on the design of the hydraulic system, and the hydraulic system is the most complex hydraulic system of engineering machinery. Therefore, the analytical design of excavator hydraulic systems has become an important part of the push of the excavator. The hydraulic excavator with single bucket is one kind of mechanical equipment for periodic operation, and consists of three parts, including one work unit, one rotating unit and one walking unit. The working device comprises a movable arm, a bucket rod and various replaceable equipment according to working requirements, such as a front shovel, a back shovel, a loading bucket, a grab bucket and the like, and the typical working cycle is as follows: (1) When excavating in a hard soil city, the cutting angle is regulated by a bucket cylinder and the excavating is matched with the bucket cylinder which is mainly operated by a bucket rod; when digging and turning over in a soft soil slope, the action of a bucket cylinder is mainly taken; in the special requirement of the excavating action, the bucket cylinder, the bucket rod cylinder and the movable arm cylinder are combined to act so as to ensure that the bucket moves along a specific track. (2) After full bucket lifting and rotary excavating are finished, the bucket cylinder is pushed out, the movable Zhong Gang is lifted, and the full bucket is lifted; meanwhile, the rotary motor is started, and the rotary table rotates towards the soil unloading direction. (3) And the unloading turntable rotates to an unloading place, the turntable braking bucket rod cylinder adjusts the unloading radius, the bucket cylinder is retracted, and the rotating bucket is unloaded. When strict requirements are imposed on the unloading site worker and the height, the cooperation of the movable arm is also required. (4) After unloading is finished, the turntable reversely rotates, and meanwhile, the movable arm cylinder and the bucket rod cylinder cooperatively act, so that the empty bucket is lowered into a new digging position. The single bucket hydraulic excavator has very wide application in construction, transportation, water conservancy construction, open-pit mining and modern military engineering, and is an indispensable main mechanical device in various earth and stone construction.
At present, in order to acquire the working condition of the hydraulic shovel, the current ore loading condition is determined, mainly by manually counting the task quantity and the number of vehicles of the 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 surface mine are subjected to work efficiency management, the problem that the mining amount data cannot be obtained in real time exists.
In order to solve the problems, the invention provides a real-time metering system and a real-time metering method for loading quantities of a hydraulic shovel of an open pit mine, which 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 mine hydraulic shovel loading of an open pit, where the real-time metering system 100 for a mine hydraulic shovel loading of an open pit includes:
the bucket rod hydraulic cylinder stay wire sensor 101 is used for acquiring the length of a first piston rod of the bucket rod hydraulic cylinder;
a boom cylinder pull sensor 102 for acquiring a second piston rod length of the boom cylinder;
a pressure sensor 103 for acquiring pressure data of the arm cylinder;
the data processing device 104 is respectively connected with the positioning device, the bucket rod hydraulic cylinder stay wire sensor, the movable arm hydraulic cylinder stay wire sensor and the pressure sensor in a signal manner and is used for determining the ore loading amount of the hydraulic shovel based on the preset geometric information of the hydraulic shovel, the length of the first piston rod, the length of the second piston rod and the pressure data.
In this embodiment, the first piston rod length of the bucket rod hydraulic cylinder is acquired through the bucket rod hydraulic cylinder stay wire sensor 101, the second piston rod length of the movable arm hydraulic cylinder is acquired through the movable arm hydraulic cylinder stay wire sensor 102, the pressure data of the bucket rod hydraulic cylinder is acquired through the pressure sensor 103, and the data processing device 104 performs data processing on the geometric information, the first piston rod length, the second piston rod length and the pressure data of the preset hydraulic shovel, so that the single bucket ore loading amount of the hydraulic shovel in the ore loading process is correspondingly determined, and the real-time ore loading amount of the whole open-pit mine is acquired, so that the work efficiency management is convenient for the ore loading condition.
As a preferred embodiment, the boom cylinder wire sensor 101 is disposed at the top end of the boom cylinder, so that the first piston rod length of the boom cylinder can be obtained in real time.
The length of the first piston rod refers to the telescopic length of the piston rod of the bucket rod hydraulic cylinder.
As a preferred embodiment, the boom cylinder line sensor 102 is disposed at the top end of the boom cylinder, so that the second piston rod length of the boom cylinder can be obtained in real time.
The second piston rod length refers to the telescopic length of the piston rod of the movable arm hydraulic cylinder.
As a preferred embodiment, the pressure sensor 103 is disposed on an oil supply pipeline of the arm hydraulic cylinder, as shown in fig. 2, fig. 2 is a schematic structural diagram of an embodiment of the pressure sensor provided by the present invention, and the pressure sensor 103 is disposed on an oil supply pipeline 132 of the arm hydraulic cylinder 131, so that pressure data of the arm hydraulic cylinder can be obtained in real time.
As a preferred embodiment, the pressure sensor 103 may further include a plurality of sub-pressure sensors, where the plurality of sub-pressure sensors are arranged in an array on the oil supply line 132 of the arm cylinder 131 and are connected to the data processing device 104 by signals, and the reliability of the pressure data of the arm cylinder obtained by the plurality of sub-pressure sensors is improved by performing an averaging operation on the pressure data of the arm cylinders obtained by the plurality of sub-pressure sensors.
As a preferred embodiment, the real-time metering system 100 for the mine hydraulic shovel loading capacity of the surface mine further comprises a positioning device 105, as shown in fig. 3, fig. 3 is a schematic structural diagram of another embodiment of the real-time metering system for the mine hydraulic shovel loading capacity of the surface mine provided by the invention, and the positioning device 105 is used for acquiring position information of the hydraulic shovel; the data processing device 104 is further configured to classify the ore loading amounts based on the location information, so as to obtain the ore loading amounts of different mining areas.
As a preferred embodiment, the positioning device 105 is disposed at the top of the machine room of the hydraulic shovel, so that not only can the position of the hydraulic shovel be well positioned, but also the safety of the positioning device 105 can be well ensured because the machine room of the hydraulic shovel belongs to a key protection area.
As a preferred embodiment, the positioning device 105 is a device capable of determining its own positioning in real time.
In a specific embodiment, the positioning device 105 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 hydraulic shovel mostly works in an open air environment during the working process, the positioning device 105 needs to be protected in order to ensure the normal operation of the positioning device 105.
In a specific embodiment, the real-time metering system 100 for the loading of the surface mine hydraulic shovel further comprises a waterproof and shockproof protective shell, wherein the waterproof and shockproof protective shell and the top of the machine room of the hydraulic shovel form a closed space, and the positioning device 105 is arranged in the closed space.
In this embodiment, by adding the waterproof and shockproof protective housing to the positioning device 105, the positioning device 105 can avoid the problems of failure and the like caused by external environmental factors in the running process.
In other embodiments, the setting position of the positioning device 105 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 real-time metering system 100 for the loading of the surface mine hydraulic shovel further comprises a memory, and the memory is in signal connection with the data processing device 104 and is used for storing position information of the hydraulic shovel, the length of the first piston rod, the length of the second piston rod, pressure data, geometric information, an included angle between the movable arm and the bucket rod hydraulic cylinder and the loading of the mine hydraulic shovel.
In summary, through the real-time metering system 100 for the mine loading of the surface mine hydraulic shovel in the scheme, not only the current position of the hydraulic shovel can be obtained, but also the loading data can be obtained in real time, so that the single bucket loading of the hydraulic shovel in the loading process is correspondingly determined, and further the real-time loading of the whole surface mine is obtained, so that the loading condition is conveniently and effectively managed.
As the parameters of different hydraulic shovels may be different, the data processing device 104 needs to acquire the parameters of the hydraulic shovel, namely, the geometric information, in order to implement fine management of the hydraulic shovel.
Preferably, in order to simplify the model of the hydraulic shovel, the positions corresponding to the geometric information are clearly described, as shown in fig. 4, fig. 4 is a schematic structural diagram of an embodiment of the hydraulic shovel model provided by the present invention, in addition, as shown in fig. 5, fig. 5 is a schematic structural diagram of an embodiment of the length information label corresponding to fig. 4, as shown in fig. 6, and fig. 6 is a schematic structural diagram of an embodiment of the angle information label corresponding to fig. 4.
Wherein KE is the distance between the second hinge center and the third hinge center, denoted (L 1 +L 4 ) AH is the distance between the sixth hinge center and the seventh hinge center, and is denoted as (L 2 +L 3 ) GH is the distance between the eighth hinge center and the seventh hinge center, denoted as L 5 AG is the distance between the sixth hinge center and the eighth hinge center, denoted as L 6 BK is the distance between the first and second hinge centers, denoted as L 7 The distance between the fourth hinge center and the third hinge center of BE is denoted as L 8 BD is the distance between the fourth hinge center and the fifth hinge center, denoted as L 9 DE is the hinge center of the fifth hinge center and the third hinge center, denoted as L 10 AK is the distance between the bucket rod hydraulic cylinder and the hinge center and the second hinge center of the movable arm, and is marked as L 11 AB is the distance between the sixth hinge center and the fourth hinge center, denoted as L 12 KG is the distance between the second hinging center and the eighth hinging center, and is marked as L 13 BC is the distance between the first hinging center and the third hinging center along the line and the intersection point of the bucket rod, and is marked as L 14 ；
The first hinging center refers to the hinging center of the movable arm and the bucket rod; the second hinge center is the hinge center of the bucket rod hydraulic cylinder and the forklift; the third hinging center is the hinging center of the bucket rod hydraulic cylinder and the bucket rod; the fourth hinging center is the hinging center of the big arm and the bucket rod; the fifth hinging center is the hinging center of the bucket rod and the bucket; the sixth hinging center is the hinging center of the movable arm hydraulic cylinder and the movable arm; the seventh hinging center refers to the hinging center of the movable arm hydraulic cylinder and the forklift; the eighth hinging center refers to the hinging center of the movable arm and the forklift; the ninth hinge center refers to the hinge center of the arm hydraulic cylinder and the movable arm.
In addition, the geometric information also comprises the cylinder diameter of the hydraulic cylinder and the fixed angle beta of the movable arm hydraulic cylinder 4 。
In order to solve the above problems, the present invention further provides a method for self-measuring a loading amount of a hydraulic shovel, wherein the method is applied to the hydraulic shovel according to any one of the above technical solutions, as shown in fig. 7, fig. 7 is a schematic flow chart of an embodiment of the method for self-measuring a loading amount of a hydraulic shovel according to the present invention, and the method includes:
step S101: acquiring the length of a first piston rod based on a pull wire sensor of a bucket rod hydraulic cylinder;
step S102: acquiring the length of a second piston rod based on a movable arm hydraulic cylinder stay wire sensor;
step S103: acquiring pressure data of the hydraulic shovel based on a pressure sensor;
step S104: the data processing device determines the ore loading amount of the hydraulic shovel based on the geometric information of the hydraulic shovel, the length of the first piston rod, the length of the second piston rod and the pressure data.
In the embodiment, first, the length of a first piston rod is acquired based on a bucket rod hydraulic cylinder stay wire sensor, the length of a second piston rod is acquired based on a movable arm hydraulic cylinder stay wire sensor, and pressure data of a hydraulic shovel is acquired based on a pressure sensor; the data processing device then determines the loading of the hydraulic shovel based on the geometry information of the hydraulic shovel, and the first piston rod length, the second piston rod length, and the pressure data.
In the embodiment, the first piston rod length, the second piston rod length and the pressure data are acquired in real time; and then, determining the ore loading quantity of each single bucket of the hydraulic shovel according to the pressure data, the length of the first piston rod, the length of the second piston rod and the geometric information, so as to determine the total ore loading quantity, and acquiring the ore loading quantity data in real time to facilitate the work efficiency management of the ore loading condition.
As a preferred embodiment, in step S101, the first piston rod length corresponds to L in fig. 4 1 。
As a preferred embodiment, in step S102, the second piston rod length corresponds to L in fig. 4 2 。
As a preferred embodiment, in step S104, the data processing device not only acquires the preset geometric information of the hydraulic shovel, but also performs data processing and calculation on the acquired dynamic information according to a preset algorithm, thereby determining the target amount.
As a preferred embodiment, in step S104, the hydraulic shovel further includes a positioning device, and in order to determine the ore loading of the hydraulic shovel, as shown in fig. 8, fig. 8 is a schematic flow chart of an embodiment of a method for self-measuring the ore loading of the hydraulic shovel according to the present invention, which includes:
step S141: determining an included angle between the movable arm and the bucket rod hydraulic cylinder according to the length of the first piston rod, the length of the second piston rod and the geometric information;
step S142: when the fluctuation range of the included angle is within a preset angle range, activating a pressure sensor, and acquiring pressure data of the bucket rod hydraulic cylinder based on the pressure sensor;
step S143: and determining the ore loading amount of each single bucket of the hydraulic shovel according to the pressure data, the length of the first piston rod, the length of the second piston rod and the geometric information, and determining the total ore loading amount based on the position information.
In this embodiment, through carrying out the fine study to the contained angle between the movable arm and the arm pneumatic cylinder of hydraulic shovel in the ore loading process, found that when hydraulic shovel is excavated the ore and is ended and be in full fill state, have two quantities to be in steady state, first is that the contained angle between movable arm and the arm pneumatic cylinder can be in steady state in a period of time, and second is that first piston rod length is the constant value.
However, since the hydraulic shovel inevitably shakes during operation, a predetermined angle range needs to be set, that is, when the fluctuation range of the included angle is within the predetermined angle range, the included angle is determined to be in a stable state.
In summary, on the one hand, when the fluctuation range of the included angle between the boom and the arm cylinder is within the preset angle range, on the other hand, the first piston rod length is in a stable and non-telescopic state, that is, the first piston rod length is a fixed value, the hydraulic shovel is considered to be in a full bucket moving state.
In order to ensure the reliability of the included angle, a preset angle range needs to be described, and as a preferred embodiment, the preset angle range is set to (-X, X), and because model parameters, especially accuracy, of different hydraulic shovels are different, the value of X can be adjusted according to actual needs by different hydraulic shovels.
In a specific embodiment, the value of X is 0.5 °, that is, when the variation range of the angle between the boom and the arm cylinder of the hydraulic shovel is between-0.5 ° and 0.5 °, it is determined that the angle between the boom and the arm cylinder is in a stable state.
As a preferred embodiment, in order to determine the angle between the boom and the arm cylinder, first, geometric information of the hydraulic shovel itself needs to be determined, wherein the geometric information includes a cylinder diameter of the cylinder, distances of a first hinge center and a second hinge center of the hydraulic shovel, distances of the first hinge center and a third hinge center, distances of a fourth hinge center and a fifth hinge center, distances of a line of the first hinge center and the third hinge center, intersections of the boom cylinder, distances of the fourth hinge center and the fifth hinge center, distances of a line of the first hinge center and the third hinge center, intersections of the boom, a cylinder diameter of the cylinder, a mass of the arm, a sixth hinge center, and distances of a seventh hinge center, in step S141.
Then, according to the fixed angle of the movable arm hydraulic cylinder, the length of the first piston rod, the length of the second piston rod, the distance between the first hinging center and the second hinging center and the distance between the first hinging center and the third hinging center, determining the included angle between the movable arm and the bucket rod hydraulic cylinder through an included angle calculation formula;
wherein alpha is the included angle between the movable arm and the bucket rod hydraulic cylinder, and beta 4 Fixed angle for boom cylinder, (L) 1 +L 4 ) Distance L between second hinge center and third hinge center when empty 7 L is the distance between the first hinge center and the second hinge center 8 Is the distance between the first hinge center and the third hinge center.
As a preferred embodiment, in step S143, after determining the position information of the hydraulic shovel by the positioning device, the first piston rod length, the second piston rod length and the pressure data are acquired in real time; then, according to the pressure data, the length of the first piston rod, the length of the second piston rod and the geometric information, each single bucket ore loading amount of the hydraulic shovel is determined, and the total ore loading amount based on the position information is determined, so that the ore loading amount data are obtained in real time, and classified based on the position information, and more efficient and comprehensive data dependence is provided for carrying out work efficiency management according to the ore loading condition.
In addition, when the position of the hydraulic shovel changes or is restarted, the positioning device updates the position of the hydraulic shovel, and the subsequent information is counted and processed based on the new position information.
Further, after determining a criterion for determining whether the hydraulic shovel is in an ore excavation state or a full bucket movement state, firstly, acquiring a first empty bucket piston rod length, a first operation piston rod length, a second empty bucket piston rod length and a second operation piston rod length, namely, carrying out situation division processing on the hydraulic shovels in different states so as to determine the hydraulic shovel mass in the empty bucket and the hydraulic shovel mass in the full bucket; in order to determine the total loading based on the position information by determining each single bucket loading of the hydraulic shovel, as shown in fig. 9, fig. 9 is a schematic flow chart of an embodiment of determining the total loading according to the present invention, including:
step S1431: determining the bucket mass of the hydraulic shovel according to the pressure data, the length of the first empty bucket piston rod, the length of the second empty bucket piston rod and the geometric information;
step S1432: determining the single bucket mining mass of the hydraulic shovel according to the pressure data, the length of the first operation piston rod, the length of the second operation piston rod and the geometric information;
step S1433: making a difference between the bucket mass and the single bucket belt mineral mass to obtain each single bucket mineral loading of the hydraulic shovel;
step S1434: 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, firstly, determining the bucket mass of a hydraulic shovel according to pressure data, the length of a first empty bucket piston rod, the length of a second empty bucket piston rod and geometric information; secondly, determining the single bucket ore carrying quality of the hydraulic shovel according to the pressure data, the length of the first operation piston rod, the length of the second operation piston rod and the geometric information; then, making difference on the bucket quality and the single bucket belt mineral quality to obtain each single bucket mineral loading quantity of the hydraulic shovel; and finally, carrying out accumulated summation on each single bucket ore loading amount corresponding to the position information, and determining the total ore loading amount based on the position information.
In this embodiment, through carrying out situation discussion on the hydraulic shovel in different states, firstly, determining the bucket quality of the hydraulic shovel, then determining the single bucket belt mineral quality of the hydraulic shovel, finally, determining the single bucket mineral loading corresponding to each bucket of the hydraulic shovel through difference, and determining the total mineral loading based on data accumulation calculation, and adding the position information of the hydraulic shovel determined before, the total mineral loading based on the position information can be determined, thereby realizing real-time acquisition of mineral loading data and meeting the data requirement when carrying out work efficiency management on the mineral loading condition of an open-pit mine.
As a preferred embodiment, in step S1431, in order to determine the bucket mass of the hydraulic shovel, firstly, the geometric information to be acquired further includes the distance between the fourth hinge center and the fifth hinge center, the distance between the first hinge center and the third hinge center along the line and the intersection point of the arm, the cylinder diameter of the hydraulic cylinder, the arm mass, the distance between the sixth hinge center and the seventh hinge center, and then, the bucket mass of the hydraulic shovel is determined according to the pressure data, the first hollow bucket piston rod length, the second hollow bucket piston rod length, the distance between the first hinge center and the second hinge center, the distance between the first hinge center and the third hinge center, the distance between the fourth hinge center and the fifth hinge center, the distance between the first hinge center and the third hinge center along the line and the intersection point of the arm, the cylinder diameter of the hydraulic cylinder and the arm mass;
wherein, the calculation formula of empty bucket mass is:
wherein mg is bucket mass, F is bucket pressure data, (L) 1 +L 4 ) Distance L between second hinge center and third hinge center when empty 7 L is the distance between the first hinge center and the second hinge center 8 L is the distance between the first hinge center and the third hinge center 9 L is the distance between the fourth hinge center and the fifth hinge center 14 Gamma is the distance between the first hinging center and the third hinging center along the line and the intersection point of the bucket rod 2 Is the bending angle of the bucket rod of the empty bucket, gamma 3 The bending angle of the bucket is the bending angle of the bucket;
wherein, empty bucket arm bending angle equals with empty bucket bending angle, and empty bucket arm bending angle's calculation formula is:
wherein, (L) 2 +L 3 ) Distance between the sixth hinge center and the seventh hinge center when the bucket is empty, L 5 L is the distance between the eighth hinge center and the seventh hinge center 6 Beta is the distance between the sixth hinge center and the eighth hinge center 1 、β 2 、β 3 And beta 5 All are fixed values.
Further, in step S1432, in order to determine the single bucket belt quality of the hydraulic shovel, the single bucket belt quality of the hydraulic shovel is determined according to the pressure data, the first working piston rod length, the second working piston rod length, the distance between the first hinge center and the second hinge center, the distance between the first hinge center and the third hinge center, the distance between the fourth hinge center and the fifth hinge center, the distance between the first hinge center and the third hinge center along the intersection with the arm, the cylinder diameter of the hydraulic cylinder, and the arm quality;
the calculation formula of the single bucket belt ore quality is as follows:
wherein Mg is single bucket with ore quality, F' is operation pressure data, (L) 1 ′+L 4 ) To be used asDistance between second hinge center and third hinge center in industry, gamma 2 ' is the bending angle of the working arm, gamma 3 ' is the work bucket bend angle;
wherein, the bending angle of the working arm is equal to the bending angle of the working bucket, and the calculation formula of the bending angle of the working arm is as follows:
wherein, (L) 2 ′+L 3 ) Is the distance between the sixth hinging center and the seventh hinging center during operation.
Next, in step S1433, in order to determine each single bucket loading amount of the hydraulic shovel, each single bucket loading amount of the hydraulic shovel is determined by a calculation formula of the single bucket loading amount according to the bucket mass and the single bucket belt mass.
Wherein, the calculation formula of single fill ore loading is:
wherein Q is 1 The ore loading amount is single bucket.
Finally, in step S1434, the data processing device classifies the single bucket loading of the hydraulic shovel according to the position information, and then performs cumulative summation on the single bucket loading with the same position, so as to determine the corresponding total loading of the hydraulic shovel at each position.
In summary, the position information of the hydraulic shovel is obtained through the positioning device, so that the area where the hydraulic shovel is located 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 the first piston rod length of the bucket rod hydraulic cylinder is obtained through the bucket rod hydraulic cylinder stay wire sensor, the second piston rod length of the movable arm hydraulic cylinder is obtained through the movable arm hydraulic cylinder stay wire sensor, the pressure data of the bucket rod hydraulic cylinder is obtained through the pressure sensor, the geometric information of the hydraulic shovel is obtained through the data processing device, the geometric information, the first piston rod length, the second piston rod length and the pressure data are subjected to data processing through the data processing device, so that the single bucket ore loading amount of the hydraulic shovel in the ore loading process is correspondingly determined, and the real-time ore loading amount of the whole open-air mine is obtained, so that the ore loading condition is subjected to work efficiency management.
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 means 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 real-time metering system of open pit mine hydraulic shovel loading volume which characterized in that includes:
the bucket rod hydraulic cylinder stay wire sensor is used for acquiring the length of a first piston rod of the bucket rod hydraulic cylinder;
the movable arm hydraulic cylinder stay wire sensor is used for acquiring the length of a second piston rod of the movable arm hydraulic cylinder;
the pressure sensor is used for acquiring pressure data of the bucket rod hydraulic cylinder;
the data processing device is respectively connected with the bucket rod hydraulic cylinder stay wire sensor, the movable arm hydraulic cylinder stay wire sensor and the pressure sensor in a signal manner and is used for determining the ore loading amount of the hydraulic shovel based on preset geometric information of the hydraulic shovel, the length of the first piston rod, the length of the second piston rod and the pressure data.
2. The real-time surface mine hydraulic shovel loading amount metering system according to claim 1, wherein the geometric information comprises a cylinder diameter of a hydraulic cylinder, a distance between a first hinge center and a second hinge center, a distance between the first hinge center and a third hinge center, a distance between a line of the first hinge center and the third hinge center and an intersection point of the arm, a distance between a fourth hinge center and a fifth hinge center, a distance between a sixth hinge center and a seventh hinge center, a distance between an eighth hinge center and the seventh hinge center, a distance between the sixth hinge center and the eighth hinge center, a boom cylinder fixing angle, a cylinder diameter of the hydraulic cylinder, and an arm mass;
wherein the first hinge center is a hinge center of the movable arm and the bucket rod; the second hinging center is the hinging center of the bucket rod hydraulic cylinder and the forklift; the third hinging center is the hinging center of the bucket rod hydraulic cylinder and the bucket rod; the fourth hinging center is the hinging center of the big arm and the bucket rod; the fifth hinging center is the hinging center of the bucket rod and the bucket; the sixth hinging center is the hinging center of the movable arm hydraulic cylinder and the movable arm; the seventh hinging center is the hinging center of the movable arm hydraulic cylinder and the forklift; the eighth hinging center refers to the hinging center of the movable arm and the forklift; the ninth hinging center is the hinging center of the bucket rod hydraulic cylinder and the movable arm.
3. The real-time metering system of the loading of the surface mine hydraulic shovel according to claim 1, wherein the hydraulic shovel further comprises a positioning device for acquiring the position information of the hydraulic shovel; the data processing device 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 mineral loading metering system of the surface mine hydraulic shovel according to claim 3, wherein the hydraulic shovel further comprises a waterproof and shockproof protective shell, and a closed space is formed between the hydraulic shovel and the top of a machine room of the hydraulic shovel; wherein, positioner sets up in the enclosure space.
5. A method for self-measuring the loading of a hydraulic shovel, which is applied to the real-time metering system of the loading of the hydraulic shovel for the surface mine according to any one of claims 1 to 4, and comprises the following steps:
acquiring a first piston rod length bucket rod based on a bucket rod hydraulic cylinder stay wire sensor;
acquiring the length of a second piston rod based on a movable arm hydraulic cylinder stay wire sensor;
acquiring pressure data of the hydraulic shovel based on a pressure sensor;
the data processing device determines the ore loading amount of the hydraulic shovel based on the geometric information of the hydraulic shovel, the length of the first piston rod, the length of the second piston rod and the pressure data.
6. The method of self-testing a loading amount of a hydraulic shovel according to claim 5, wherein the hydraulic shovel further comprises a positioning device; determining the loading of the hydraulic shovel based on the geometric information of the hydraulic shovel, the first piston rod length, the second piston rod length, and the pressure data, comprising:
determining an included angle between a movable arm and the bucket rod hydraulic cylinder according to the length of the first piston rod, the length of the second piston rod and the geometric information;
when the fluctuation range of the included angle is within a preset angle range, activating the pressure sensor, and acquiring pressure data of the bucket rod hydraulic cylinder based on the pressure sensor;
and determining each single bucket ore loading amount of the hydraulic shovel according to the pressure data, the first piston rod length, the second piston rod length and the geometric information, and determining the total ore loading amount based on the position information.
7. The method for self-measuring ore loading of the hydraulic shovel according to claim 6, wherein the calculation formula of the included angle is:
wherein alpha is the included angle between the movable arm and the bucket rod hydraulic cylinder, and beta is 4 Fixing an angle for the boom cylinder, (L) 1 +L 4 ) The distance L between the second hinging center and the third hinging center when the bucket is empty 7 L is the distance between the first hinge center and the second hinge center 8 Is the distance between the first hinge center and the third hinge center.
8. The method of self-testing a loading capacity of a hydraulic shovel of claim 6, wherein the first piston rod length comprises a first skip piston rod length and a first work piston rod length, and the second piston rod length comprises a second skip piston rod length and a second work piston rod length; determining each single bucket loading of the hydraulic shovel according to the pressure data, the first piston rod length, the second piston rod length and the geometric information, and determining a total loading based on the position information, wherein the determining comprises the following steps:
determining the bucket mass of the hydraulic shovel according to the pressure data, the length of the first empty bucket piston rod, the length of the second empty bucket piston rod and the geometric information;
determining the single bucket mining mass of the hydraulic shovel according to the pressure data, the length of the first operation piston rod, the length of the second operation piston rod and the geometric information;
making a difference between the bucket mass and the single bucket belt mineral mass to obtain each single bucket mineral loading of the hydraulic 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 hydraulic shovel according to claim 8, wherein the calculation formula of the bucket mass is:
wherein mg is bucket mass, F is bucket pressure data, (L) 1 +L 4 ) The distance L between the second hinging center and the third hinging center when the bucket is empty 7 For the first hinge center and the first hinge centerDistance of second hinge center, L 8 L is the distance between the first hinge center and the third hinge center 9 L is the distance between the fourth hinge center and the fifth hinge center 14 Gamma is the distance between the intersection point of the first hinging center and the third hinging center along the line and the bucket rod 2 Is the bending angle of the bucket rod of the empty bucket, gamma 3 The bending angle of the bucket is the bending angle of the bucket;
wherein, empty fill arm bending angle with empty fill bucket bending angle equals, empty fill arm bending angle's calculation formula is:
wherein, (L) 2 +L 3 ) Distance between the sixth hinge center and the seventh hinge center when the bucket is empty, L 5 L is the distance between the eighth hinge center and the seventh hinge center 6 Beta is the distance between the sixth hinge center and the eighth hinge center 1 、β 2 、β 3 And beta 5 And the eighth hinging center refers to the hinging center of the movable arm and the forklift.
10. The method for self-measuring ore loading of the hydraulic shovel according to claim 8, wherein the calculation formula of the single bucket belt ore mass is as follows:
wherein Mg is single bucket with ore mass, F ′ For working pressure data, (L) 1 ′ +L 4 ) Gamma is the distance between the second hinge center and the third hinge center during operation 2 ′ For working arm bending angle, gamma 3 ′ Bending angle for the working bucket;
wherein, the operation arm bending angle equals with the operation bucket bending angle, the operation arm bending angle's calculation formula is:
wherein, (L) 2 ′ +L 3 ) Is the distance between the sixth hinging center and the seventh hinging center during operation.
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