CN118259619A - Active interaction control system of mill - Google Patents
Active interaction control system of mill Download PDFInfo
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- CN118259619A CN118259619A CN202410351500.3A CN202410351500A CN118259619A CN 118259619 A CN118259619 A CN 118259619A CN 202410351500 A CN202410351500 A CN 202410351500A CN 118259619 A CN118259619 A CN 118259619A
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- 230000003993 interaction Effects 0.000 title claims abstract description 58
- 238000003745 diagnosis Methods 0.000 claims abstract description 53
- 238000002347 injection Methods 0.000 claims abstract description 21
- 239000007924 injection Substances 0.000 claims abstract description 21
- 230000007123 defense Effects 0.000 claims abstract description 15
- 230000005856 abnormality Effects 0.000 claims abstract description 13
- 238000001514 detection method Methods 0.000 claims abstract description 11
- 230000005284 excitation Effects 0.000 claims abstract description 10
- 238000012423 maintenance Methods 0.000 claims abstract description 9
- 238000005461 lubrication Methods 0.000 claims description 17
- 230000002159 abnormal effect Effects 0.000 claims description 14
- 238000000034 method Methods 0.000 claims description 14
- 230000002452 interceptive effect Effects 0.000 claims description 9
- 238000012544 monitoring process Methods 0.000 claims description 9
- 230000008569 process Effects 0.000 claims description 9
- 238000004088 simulation Methods 0.000 claims description 5
- 230000006870 function Effects 0.000 abstract description 24
- 230000004927 fusion Effects 0.000 abstract description 2
- 238000007689 inspection Methods 0.000 abstract description 2
- 238000012545 processing Methods 0.000 description 8
- 238000004458 analytical method Methods 0.000 description 6
- 238000003672 processing method Methods 0.000 description 4
- 238000004891 communication Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 230000000630 rising effect Effects 0.000 description 3
- 238000007790 scraping Methods 0.000 description 3
- 230000001133 acceleration Effects 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 238000011065 in-situ storage Methods 0.000 description 2
- 230000001050 lubricating effect Effects 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000003032 molecular docking Methods 0.000 description 2
- 230000008439 repair process Effects 0.000 description 2
- 101000604592 Homo sapiens Keratin-like protein KRT222 Proteins 0.000 description 1
- 102100038184 Keratin-like protein KRT222 Human genes 0.000 description 1
- 230000007488 abnormal function Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000009529 body temperature measurement Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000012937 correction Methods 0.000 description 1
- 238000010219 correlation analysis Methods 0.000 description 1
- 238000013500 data storage Methods 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 238000007726 management method Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 238000005457 optimization Methods 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 238000001931 thermography Methods 0.000 description 1
Classifications
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/054—Input/output
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/10—Plc systems
- G05B2219/11—Plc I-O input output
- G05B2219/1103—Special, intelligent I-O processor, also plc can only access via processor
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Testing And Monitoring For Control Systems (AREA)
Abstract
The invention provides an active interaction control system of a mill, which comprises AICS a host computer and AICS HMI, wherein the AICS host computer is connected with a remote SOS support, an excitation cabinet, a high-voltage cabinet, dry oil injection, a mill PLC cabinet and an off-line detection platform, the mill PLC cabinet is connected with a field instrument, a DCS and a slow drive, and the active interaction control system comprises conventional functions, abnormality diagnosis, automatic restarting diagnosis, error stopping interception, active defense, emergency treatment, digital inquiry diagnosis, system self-inspection and active interaction. The intelligent control system has the advantages that the electric faults of equipment can be conducted through fault diagnosis and interpretation matching with the active interaction mode, the maintenance of the mill is facilitated, the requirements on staff are low, meanwhile, the complexity of searching the drawing is greatly reduced, the time consumption is shortened through intelligent fusion of AICS HMI and the drawing, and the excitation cabinet, the high-voltage cabinet and the dry oil injection are subjected to integrated control, so that the active interaction system can accurately judge the mill.
Description
Technical Field
The invention relates to the technical field of mill control, and particularly discloses an active interaction control system of a mill.
Background
When the mill works, the working state of the mill needs to be monitored and controlled in real time through the control system, and the existing control system has the following problems: the components and the circuits are aged, so that the failure rate is increased; a series of problems caused by program loopholes, namely, the key protection is lost and the equipment is stopped without faults; the possible drawing is lost and the maintenance is difficult; the system is dispersed, and the DCS cannot monitor a high-voltage cabinet, an excitation cabinet, dry oil injection and the like; the monitoring information is limited; the touch screen HMI consults the information unchanged; the loopholes of the control program are more; and the active interaction capability of the control system is poor, and the operation of personnel is complicated.
Disclosure of Invention
In view of the above-mentioned drawbacks or shortcomings in the prior art, the present application aims to provide an active interaction control system for a mill, which comprises AICS main units and AICS HMI, wherein the AICS main units are connected with remote SOS support, an excitation cabinet, a high-voltage cabinet, dry oil injection, a mill PLC cabinet and an offline detection platform, the mill PLC cabinet is connected with a field instrument, a DCS and a slow drive, and the active interaction control system comprises conventional functions, abnormality diagnosis, automatic restarting diagnosis, false stopping interception, active defense, emergency treatment, digital inquiry diagnosis, system self-inspection and active interaction.
Preferably, the conventional functions include automation control, process monitoring, parameter setting, fault and alarm, data logging, remote control, safety control and equipment operation timing.
Preferably, the abnormality diagnosis and treatment comprises equipment theft and stop diagnosis and treatment, automatic restarting diagnosis and treatment, non-stop diagnosis and treatment and remote SOS emergency rescue.
Preferably, the false stop interception is realized through a PLC control cabinet and a PLC program.
Preferably, the active defense not only can perform threshold protection on the mill, but also can perform active defense on key parts of mill active identification equipment, and also performs fault prediction on the equipment, so that the active defense on the mill is realized, and the active defense comprises mill main bearing fault prediction, a pinion shaft group, a pneumatic clutch, a large gear and a main motor.
Preferably, the emergency treatment comprises dry oil injection fault treatment and oil pump switching function shielding, and the dry oil injection fault treatment and the oil pump switching function shielding are realized through AICS HMI and a PLC program together.
Preferably, the digital interrogation includes fault diagnosis and fault interpretation, the fault diagnosis including electrical fault diagnosis, hydraulic fault diagnosis and mechanical fault diagnosis.
Preferably, the self-checking of the system adopts AICS system to realize the self-checking of the PLC program by sending the simulation signal.
Preferably, the active interaction comprises equipment start-up guidance interaction and abnormal state interaction, the equipment start-up guidance interaction comprises lubrication station start-up interaction, main motor start-up interaction, mill start-up interaction and maintenance work interaction, and the abnormal state interaction comprises mill unknown cause shutdown frequency statistics and reminding, oil tank heater function abnormality reminding, controller module and IO channel damage and fault relay abnormality reminding.
The beneficial effects are that:
1. According to the active interaction control system of the grinding machine, the user can be guided to rapidly process the electrical faults of the equipment through fault diagnosis and interpretation and the active interaction mode, so that the grinding machine is convenient to maintain and the requirements on staff are low, and meanwhile, through intelligent fusion of AICS HMI and drawings, the complexity of searching the drawings is greatly reduced, and the time consumption is shortened.
2. According to the active interaction control system of the mill, the excitation cabinet, the high-voltage cabinet and the dry oil injection are subjected to integrated control, so that the active interaction system can accurately judge the mill.
3. According to the active interaction control system of the mill, through carrying out data communication on the AICS host computer, the mill PLC, the dry oil injection, the excitation cabinet, the high-voltage cabinet and the mill PLC cabinet body, the PLC channel self-switching function can be realized, the channel fault processing time is greatly reduced, and various communication protocols are supported, so that the active interaction control system is strong in active interaction.
4. The active interaction control system of the grinding machine can accurately alarm through intelligent alarm management, improves alarm information and reduces false alarm.
Drawings
Other features, objects and advantages of the present application will become more apparent upon reading of the detailed description of non-limiting embodiments, made with reference to the accompanying drawings in which:
FIG. 1 is a system block diagram of the architecture of the present invention;
FIG. 2 is a functional block diagram of a system of the architecture of the present invention;
Fig. 3 is a system block diagram illustrating the conventional functions of the present invention.
Detailed Description
The application is described in further detail below with reference to the drawings and examples. It is to be understood that the specific embodiments described herein are merely illustrative of the application and are not limiting of the application. It should be noted that, for convenience of description, only the portions related to the application are shown in the drawings.
The drawings in the embodiments of the invention: the different kinds of cross-sectional lines in the drawings are not marked according to national standards, and the material of the elements is not required, so that the cross-sectional views of the elements in the drawings are distinguished.
Referring to fig. 1-3, an active interaction control system of a mill includes a AICS host and a AICS HMI, the AICS host is connected with remote SOS support, an excitation cabinet, a high-voltage cabinet, dry oil injection, a mill PLC cabinet and an off-line detection platform, vibration analysis can be performed through the off-line detection platform, obtained data is transmitted to the AICS host as reference elements of mill operation parameters, the mill PLC cabinet is connected with a site instrument, DCS and a slow drive, the AICS host is a control center and a data storage center of the system, data communication is performed through the control center and the data storage center of the system, the AICS host realizes data storage and processing, the line of sight of each function on the AICS host is realized in a mode of a single algorithm module, AICS HMI accesses and reads and writes data on the AICS host, and AICS HMI images adopt a mode of Web access for building software/platform of a monitoring system, and SCADA software with higher openness is adopted, and the higher openness is required in order to meet the requirements of site modification images, and the active interaction control system includes conventional functions, abnormal control, automatic interception, automatic control, emergency stop, active interaction, digital interaction, diagnosis and digital interaction.
The conventional functions comprise automatic control, process monitoring, parameter setting, fault and alarm, data recording, remote control, safety control and equipment operation timing, the conventional functions are realized through a mill PLC, the automatic control can automatically execute a program through the PLC, and each part of the mill is monitored and controlled, wherein the automatic control comprises an automatic control lubrication system, a main motor, a heater start, a cooling fan, dry oil injection, speed regulation (with a high-voltage frequency converter) and the like; the running state of the mill, including parameters such as temperature, pressure, speed and the like, can be monitored through the PLC in the process monitoring, and can be adjusted according to the needs, the parameter setting can set key parameters of equipment and fault alarm values according to the actual conditions on site, the fault and alarm can detect the fault or abnormal condition of the mill through the PLC, and an alarm or report can be generated, so that operators or maintenance personnel can take measures rapidly; the data record can record the running data of the mill through the PLC, is used for production report and maintenance analysis, and helps to improve production efficiency and equipment reliability; the remote control is connected with the upper computer to realize remote monitoring and start-stop of the mill, so that a remote operator can intervene and manage equipment in real time; safety control can implement safety functions such as emergency shutdown, prevention of dangerous situations and the like through the PLC so as to ensure the safety of operators and equipment, equipment running time can record mill running time including current running time, last running time and accumulated running time, and record mill fault shutdown time, shutdown time caused by the fault and accumulated shutdown time caused by the fault.
The abnormal diagnosis and treatment comprises equipment theft and stop diagnosis and treatment, automatic restarting and diagnosis and treatment, non-stop diagnosis and treatment and remote SOS emergency rescue, wherein the equipment theft and stop diagnosis and treatment is realized through a mill PLC (programmable logic controller) cabinet aiming at the unknown reasons of a mill, wherein the equipment theft and stop diagnosis and treatment comprises the following steps:
a) And (3) tracking the shutdown reason of the mill: through mill PLC and AICS HMI realization, display the reason of shutting down after the mill shut down, the reason of shutting down includes:
1. Manually stopping in situ;
2. Stopping rapidly in situ;
3. Remotely stopping the machine manually;
4. Remotely stopping suddenly;
5. Fault shutdown (auxiliary equipment such as high-voltage cabinet faults, excitation cabinet faults and the like);
6. equipment scrapings (including clutch scrapings and main motor scrapings);
7. Network fluctuations: the central control stop signal receives interference.
B) And (3) signal processing:
S1, performing short-time filtering processing on all stop signals, wherein the stop button is disconnected for more than 100ms (the specific time can be adjusted), and then sending out a stop signal by the system;
S2, if the system displays manual shutdown on the premise of no manual shutdown, the system prompts a user to check a stop button loop possibly caused by loosening of a stop button wire;
s3, if the PLC monitors that the clutch is disconnected, the main motor stops (the high-voltage cabinet is disconnected), the signal of the total stop button of the lubrication system is 0 for a long time, an alarm signal of button signal disconnection is sent, and a user is reminded to check a loop;
s4, a button signal line of a grinding machine stop (clutch brake opening) is unchanged, a signal is always 1, and a clutch is tripped, so that the system sends out a clutch stop due to loosening of a cable of a clutch electromagnetic valve control loop, and the clutch control loop wiring is checked;
S5, the button signal line of the 'high-voltage cabinet brake-separating (main motor stopping)' is unchanged, the signal is always 1, no high-voltage cabinet fault signal exists, the high-voltage cabinet trips, the high-voltage cabinet side is very likely to be high-voltage cabinet side or abnormality occurs, and the system sends out 'high-voltage cabinet brake-out', please check the signal line from the high-voltage cabinet and the PLC cabinet to the high-voltage cabinet.
The automatic restarting diagnosis and treatment is realized by a mill PLC cabinet and a PLC program, and the automatic restarting diagnosis and treatment method comprises the following processing methods:
1. The high-voltage cabinet brake-separating and fault brake-separating relay adopts a normally closed point;
2, the PLC is powered on for 1min to send out stop signals to all the execution mechanisms (a high-voltage cabinet, a clutch, an oil pump, a heater and a fan);
3. all the devices ensure that after receiving a starting command, clutch operation signals are used for clutch driving and self-locking;
4. and the lubricating station oil pump is self-locked by using an oil pump operation signal.
The diagnosis and treatment of the incapable shutdown is realized through a PLC control cabinet and a PLC program, and the method comprises the following processing steps:
1. The high-voltage cabinet brake-separating and fault brake-separating relay adopts a normally closed point;
2. the clutch is opened, the main motor is stopped (the high-voltage cabinet is opened), and the wiring of a total stop button of the lubrication system adopts a normally closed point;
3. optimizing the PLC control program and strictly forbidding the SR trigger to be used in the equipment start-stop control program.
When the system is stopped for unknown reasons and equipment is started up involuntarily, the remote SOS emergency rescue automatically sends a remote rescue call AICS under the condition that the equipment cannot be stopped.
The false stopping interception is realized through a PLC control cabinet and a PLC program, and can actively intercept some non-manual intentional stopping accidents and unnecessary fault stopping, and is mainly embodied in the following aspects:
1. during the operation of the main motor, the selection switch (local/remote selection switch, manual/automatic selection switch) acts or wires are loosened, and the processing method comprises the following steps: alarming without stopping;
2. the slow-driving disconnection limit switch acts, and the processing method comprises the following steps: alarming without stopping;
3. The instrument and sensor lines are loose, and the processing method comprises the following steps: the alarm is not stopped (the conventional signal disconnection processing is firstly carried out, and after a new judging mode is developed in the later period, correction is considered);
to avoid downtime for these reasons, optimization on the mill PLC program is required.
The active defense can not only protect the threshold value of the mill, but also actively identify the key part of equipment of the mill to perform active defense, and also predict faults of the equipment to realize active defense of the mill, wherein the active defense comprises mill main bearing fault prediction, a pinion shaft group, a pneumatic clutch, a large gear and a main motor, and the mill main bearing fault prediction comprises:
(1) Protection of temperature rising trend: 6 bearing temperatures, wherein a certain temperature rises by 3 ℃ (modifiable) in any 30 seconds (modifiable) continuously to consider that the bearing bush of the mill fails (functions are ignored when the oil temperature of the lubrication station is higher than the temperature of the bearing bush), and a shutdown signal is sent out and an alarm is given; recording the normal working temperature trend of the mill, and automatically correcting the temperature rise protection set value;
(2) High-pressure oil flow and high-pressure oil pressure trend protection: when the oil pump operates, a certain oil pressure falls by 50% in any 10 seconds continuously to judge that the lubrication system fails, and a stop signal is sent out and an alarm is given; and recording the oil pressure and the oil flow trend of the mill during normal operation, and automatically correcting the falling protection set value.
A pinion shaft set based on AICS host and vibration diagnostic analysis platform, comprising:
(1) Protection of temperature rising trend: the temperature of the pinion 2 bearings rises by 3 ℃ in any continuous 30 seconds (modifiable), and the fault of the pinion bearing bush is considered, and a stop signal is sent out and an alarm is given; recording the normal working temperature trend of the pinion, and automatically correcting the temperature rise protection set value;
(2) And (3) temperature difference protection: when the temperature difference of the 2 bearings of the pinion is 10 ℃ more, an alarm is sent to prompt that the temperature deviation of the two ends of the bearing of the pinion is larger, and the bearing of the pinion is centered after the shutdown. ";
(3) Vibration measurement protection: it is considered that a set of acceleration vibration fault diagnosis platform is added, AICS needs to complete data docking with the vibration analysis platform, and if the vibration detection fault diagnosis platform is not available, the function is shielded.
The pneumatic clutch predicts the phenomena of non-opening and non-locking of the pneumatic clutch by using the pressure of the air bag and the air tank, the closing time, the opening time, the current of the main motor and the closing times, protects equipment in time, and is provided with two pressure sensors: the air bag pressure P1 and the air tank pressure P2 collect main motor current from a high-voltage cabinet or an excitation cabinet, and the method comprises the following steps of:
(1) Basic control: p1 and P2 are used for mill starting interlocking through a mill PLC, when the P1 pressure value is smaller than 5ps (set value L), the clutch air bag is free of residual pressure, and the main motor is allowed to start at the moment; p2 is higher than 100psi (set point N), indicating sufficient pressure in the tank to allow the clutch to close; if P2 is smaller than 90psi after the mill is started, the clutch is disconnected, and a 'low pressure fault of a clutch gas tank' is alarmed;
(2) Judging locking and releasing: by AICS the host machine, the time T1 (usually 7 seconds) which is usually required from the start of the band-type brake to the complete locking of the clutch and the trend curves of the process P1 and P2 in the secondary process are monitored; the trend of the main motor current in the secondary course is monitored for the duration P1 and P2 of the clutch from the start of opening to the time T2 of complete disengagement (typically 200 ms).
Locking judgment: if P1 does not reach the set value N (usually 100 psi) in the time of T1, the clutch brake is considered to be failed, a clutch brake separating command is sent out, and failure information of clutch air bag pressure abnormality and clutch slipping is reported;
judging that the vehicle is not separated: after the time T2 is up, the current of the main motor does not decrease to the idle current of the motor according to the conventional trend, and the clutch release failure (possibly mechanical failure and exhaust failure) is judged, and a 'clutch release failure' is sent out;
Judging excessive load slipping: in the running process of the mill, the clutch is always in a band-type brake state, the P1 is also maintained above the set value N, but the current of the main motor is not obviously reduced (the current is temporarily reduced to 70% of normal running), the mill is considered to be too large in load, so that the clutch is slipped, and fault information of too large mill load and slipping of the clutch is reported.
All the parameters can be determined whether to need to be corrected according to the actual requirements of the mill.
The gear adopts infrared temperature measurement, thermal imaging and vibration measurement to predict the conditions of pitting, fracture and the like of the tooth surface of the gear.
The main motor includes:
(1) Protection of temperature rising trend: the temperature of the main motor 2 bearings rises by 3 ℃ in any continuous 30 seconds (modifiable), and the main motor bearing bush is considered to be faulty, a shutdown signal is sent out and an alarm is given; recording the normal working temperature trend of the main motor, and automatically correcting the temperature rise protection set value;
(2) Predicting current harmonic faults;
(3) Vibration measurement protection: the acceleration vibration fault diagnosis platform is added, the AICS host needs to complete data docking with the vibration analysis platform, and if the vibration detection fault diagnosis platform is not available, the function is shielded.
The emergency treatment comprises dry oil injection fault treatment and oil pump switching function shielding, and the dry oil injection fault treatment and the oil pump switching function shielding are realized together through AICS HMI and a PLC program, so that a user can delay or shield the dry oil injection fault after the dry oil injection fault is about to be full of 2 hours, when the dry oil injection fault occurs, the PLC starts to count two hours (the specific time is based on the PLC internal program), fault stop countdown is displayed on AICS HMI, an interface of dry oil injection fault operation is performed on a AICS HMI interface, and the dry oil injection stop time or the dry oil injection fault shielding can be prolonged; the oil pump switching function shielding is realized by reserving an oil pump switching shielding interface in part of the program through the mill PLC program at the oil pump switching function, and setting a low-pressure pump switching shielding button, a high-pressure pump switching shielding button and a return function button through AICS HMI, wherein the interface is used for simultaneously displaying which low-pressure pump and which high-pressure pump are selected as a main pump.
The digital inquiry comprises fault diagnosis and fault interpretation, wherein the fault diagnosis comprises electric fault diagnosis, hydraulic fault diagnosis and mechanical fault diagnosis, when the mill gives an alarm, the system not only displays alarm information, but also can judge the reason for giving an alarm to the mill through data correlation analysis, and gives a processing suggestion; the electrical fault diagnosis comprises instrument sensor faults, PLC faults (a PLC fault memory can be directly read), line faults and isolator faults (an isolator with self fault monitoring can be examined), the hydraulic fault diagnosis uses data correlation for analysis and judgment, and the mechanical fault diagnosis uses signals such as vibration, temperature, coaxiality and the like for judgment; fault interpretation is a fault diagnosis and fault resolution function in a system, which aims at monitoring, detecting and identifying problems and faults in a control system, interpreting the faults, so as to timely propose suggestions of repair measures, performing text explanation on the faults occurring in a mill system, providing suggestions or suggestions on how to solve the faults, including repair steps or maintenance guidelines, and performing problem processing by operators or maintainers according to the content of the explanation.
The self-checking of the system adopts AICS system to realize self-checking of the PLC program by sending simulation signals, after all alarm information or fault information related to PLC control is sent to AICS host computer, AICS host computer sends simulation signals to PLC one by one, see AICS host computer can receive alarm information sent by PLC, and if the received alarm information is consistent with the sent simulation signals, monitor comprehensive alarm information and comprehensive fault information sent by PLC at the same time, and when the program self-checking is required, mill is in shutdown state, after self-checking process is started, AICS HMI is required to display self-checking state (self-checking is being carried out, detection is completed, etc.) and item, after self-checking is completed, detected abnormal content is displayed.
Wherein, the active interaction includes a device start-up guidance interaction and an abnormal state interaction, the device start-up guidance interaction includes a lubrication station start-up interaction, a main motor start-up interaction, a mill start-up interaction, and a maintenance work interaction, the lubrication station start-up interaction is performed after the system monitors that the "lubrication system total start-up" button is pressed, but if the lubrication system start-up condition is not provided at this time, AICS HMI active popup prompt query "is about to start up the mill lubrication system? The text box for starting the lubrication system is displayed at the same time, all conditions required by starting the lubrication system are attached below the text box, after a negative button is clicked, the popup window is closed, an operator does not select any item within 5 seconds, and the popup window is closed; main motor start interaction after the system monitors that the main motor start button is pressed, but if the lubrication system start condition is not met at this time, AICS HMI active popup prompt asks "do it want to start main motor? Displaying a text box for starting the main motor under the conditions that the main motor needs to meet, closing the pop-up window after clicking a negative button, and closing the pop-up window when an operator does not select any in 5 seconds; mill start interaction after the system detects that the "mill start" ("clutch on") button is pressed, but if the lubrication system start condition is not present at this time, AICS HMI active popup prompt asks "do it want to start mill? The character box of the following conditions required for starting the mill is displayed at the same time, all the conditions required for starting the mill are attached to the lower part of the character box, after a negative button is clicked, the popup window is closed, an operator does not select any item within 5 seconds, and the popup window is closed; maintenance work interaction is performed in a prompt area at the right lower corner on an electric control main interface of the mill, a dialog box is directly popped up, and a small card prompts: "lubricating station heater was on for 30 minutes, but no change in temperature was detected. Please check 1. If the heater main loop is loose, the breaker QM3, contactor KM3, outlet terminal position JX1:13, 14,15.2. Whether oil tank temperature sensor breaks or damages, isolator BT3, oil tank temperature binding post position ", abnormal state is interactive including mill unknown reason shut down number of times statistics and warning, oil tank heater function abnormality warning, controller module damage and the unusual warning of fault relay, wherein:
Counting and reminding the number of times of shutdown of the mill for unknown reasons: the system detects the times that the mill is stopped if the unknown reasons appear in a certain period of time recently (default 14 days), and the popup window reminds that the mill is stopped if the unknown reasons appear n times recently, and the most likely stopping reason is as follows: … …. Please check the following lines: … …. ";
The abnormal function of the oil tank heater is reminded: after the mill lubrication station heater is started for 30 minutes, the temperature of the oil tank does not change obviously, a system popup window prompts that the oil tank heater is started for 30 minutes, the oil temperature of the oil tank is not obviously increased, a heater loop possibly fails, whether a main loop of the heater is open or is in phase failure is checked, whether an oil temperature sensor of the oil tank is normal or not is checked, and the popup window is also attached with information such as the number of a heater breaker, the number of a contactor, the number of a terminal and the like;
the controller module and IO channel damage include:
PLC module damage alert: after detecting the conditions of damage, power failure, signal loss and the like of the PLC module, the system sends out a prompt, and the method for detecting the damage of the module is not only hardware detection, but also software algorithm detection;
2. Hardware performance is detected by methods such as hardware fault diagnosis and the like;
3. Detection of software: if all analog quantity of a certain module is detected to be broken, judging that the module is abnormal or power supply is abnormal; when the analog quantity of an AI module remains unchanged for a certain time (default 3 s), it is determined that the AI module is abnormal.
Abnormality reminding of fault relay: after a contact loop of a fault relay (comprising a fault relay of a mill system and a high-voltage cabinet) is loosened, a pair of normally open electric shocks of the fault relay of the mill are connected to a PLC, if a relay driving signal is sent out, the fault opening relay KA21 of the high-voltage cabinet acts normally, and the fault relay counts the number of times of abnormal shutdown intercepted within a period of time (defaults 15 days).
It should be noted that, without conflict, the embodiments of the present application and features of the embodiments may be combined with each other. The application will be described in detail below with reference to the drawings in connection with embodiments.
The above description is only illustrative of the preferred embodiments of the application and the principles employed. It will be appreciated by persons skilled in the art that the scope of the application referred to in this application is not limited to the details of the specific combinations of features described above, but is intended to cover other arrangements of any combination of the features described above or their equivalents without departing from the spirit of the application. Such as those described above, are substituted for those disclosed herein that perform similar functions.
Claims (9)
1. The active interaction control system of the grinding machine comprises AICS main units and AICS HMI and is characterized in that: the AICS host is connected with a remote SOS support, an excitation cabinet, a high-voltage cabinet, dry oil injection, a mill PLC cabinet and an offline detection platform, the mill PLC cabinet is connected with a site instrument, a DCS and a slow drive, and the active interaction control system comprises a conventional function, an abnormality diagnosis and treatment, an automatic restarting diagnosis and treatment, a false stopping interception, an active defense, an emergency treatment, a digital inquiry diagnosis, a system self-check and active interaction.
2. The mill active interactive control system according to claim 1, wherein: including automation control, process monitoring, parameter settings, fault and alarm, data logging, remote control, safety control, and equipment operation timing.
3. The mill active interactive control system according to claim 1, wherein: the abnormality diagnosis and treatment comprises equipment halt diagnosis and treatment, automatic restarting diagnosis and treatment, non-stop diagnosis and treatment and remote SOS emergency rescue.
4. The mill active interactive control system according to claim 1, wherein: the false stopping interception is realized through a PLC control cabinet and a PLC program.
5. The mill active interactive control system according to claim 1, wherein: the active defense can not only protect the threshold value of the mill, but also actively identify key parts of equipment of the mill to perform active defense, and also predict faults of the equipment, so that the active defense of the mill is realized, and the active defense comprises the prediction of faults of the main bearing of the mill, a pinion shaft group, a pneumatic clutch, a large gear and a main motor.
6. The mill active interactive control system according to claim 1, wherein: the emergency treatment comprises dry oil injection fault treatment and oil pump switching function shielding, and the dry oil injection fault treatment and the oil pump switching function shielding are realized through AICS HMI and a PLC program together.
7. The mill active interactive control system according to claim 1, wherein: the digital interrogation includes fault diagnosis and fault interpretation, the fault diagnosis including electrical fault diagnosis, hydraulic fault diagnosis and mechanical fault diagnosis.
8. The mill active interactive control system according to claim 1, wherein: the self-checking of the system adopts AICS system to realize the self-checking of the PLC program by sending the simulation signal.
9. The mill active interactive control system according to claim 1, wherein: the active interaction comprises equipment starting guiding interaction and abnormal state interaction, the equipment starting guiding interaction comprises lubrication station starting interaction, main motor starting interaction, mill starting interaction and maintenance work interaction, and the abnormal state interaction comprises mill unknown cause shutdown frequency statistics and reminding, oil tank heater function abnormality reminding, controller module and IO channel damage and fault relay abnormality reminding.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202410351500.3A CN118259619A (en) | 2024-03-26 | 2024-03-26 | Active interaction control system of mill |
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| CN202410351500.3A CN118259619A (en) | 2024-03-26 | 2024-03-26 | Active interaction control system of mill |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN119458099A (en) * | 2024-12-03 | 2025-02-18 | 西安交通大学 | An electric rust removal device inside a pressure vessel and its control system |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN119458099A (en) * | 2024-12-03 | 2025-02-18 | 西安交通大学 | An electric rust removal device inside a pressure vessel and its control system |
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