WO2019010728A1

WO2019010728A1 - Intelligent sandstone aggregate production line

Info

Publication number: WO2019010728A1
Application number: PCT/CN2017/094791
Authority: WO
Inventors: 周建龙; 吴波; 于剑锋; 毛嘉; 王功建; 王迺芳; 张志豪
Original assignee: 上海云统创申智能科技有限公司
Priority date: 2017-07-12
Filing date: 2017-07-28
Publication date: 2019-01-17
Also published as: CN107153410B; CN107153410A

Abstract

An intelligent sandstone aggregate production line, which relates to the technical field of sandstone aggregate production. The intelligent sandstone aggregate production line comprises an intelligent jaw type crusher, an intelligent impact type crusher, a vibrating screen, a vibrating feeder, a material bin, a hopper, a belt conveyor, a control-related network type integrated electric control system, a distributed control system, and an intelligent internet-of-things monitoring cloud platform. A variety of sensors are additionally mounted on the basis of an original crushing screening production line. Sensor information is transmitted to the distributed control system through the network type integrated electric control system, so that automatic regulation and control on the production process is achieved, and then, the sensor information is transmitted to the intelligent internet-of-things monitoring cloud platform; and by means of cloud computation, production data storage and safety are managed in a unified manner on the basis of classification and combing. The intelligent sandstone aggregate production line has a fault early-warning function and a real-time alarm function, and quickly increases the response speed; the internet-of-things intelligent control and remote monitoring are introduced, the production process is automatically regulated and control, operation is performed with optimal load, the yield is increased, and the downtime maintenance is reduced.

Description

Intelligent sandstone aggregate production line

Technical field

The invention relates to the technical field of sand and gravel aggregate production, in particular to an intelligent sandstone aggregate production line.

Background technique

Infrastructure construction is the foundation and pillar industry of national economic development. Sand and gravel aggregate is the most important basic raw material for sandstone used in infrastructure construction. According to the statistics of China Sand and Stone Association, in 2015, the world's aggregate output of sandstone is 40 billion. Tons, the manufacturing industry and transportation costs, including the production of complete sets of equipment, the annual output value of sand and gravel aggregates is 2 trillion yuan, which is a very large industry. The complete set of sand and gravel aggregate production is an important part of China's manufacturing industry. As a traditional industrial product, its basic mechanical power, capacity and characteristics can meet the needs of the domestic and international markets, and the gap with foreign advanced level is small, but advanced. Control, intelligent technology and the gap with developed countries, the lack of information and intelligent technology formation and accumulation.

At present, the development status of domestic sand and gravel aggregate production equipment mainly shows: single machine intelligence and low degree of informationization; insufficient state monitoring and fault diagnosis research; lack of data accumulation and application services.

Summary of the invention

The technical problem to be solved by the present invention is to provide an intelligent sandstone aggregate production line by introducing the intelligent control and remote monitoring of the Internet of Things, and realize automatic adjustment control of the production process to operate at an optimal load. Increase production, reduce downtime maintenance, and effectively improve fault handling and production efficiency.

In order to solve the above technical problems, the technical solution adopted by the present invention is: an intelligent sandstone aggregate production line, comprising intelligent single machine equipment, network integrated electronic control system, distributed control system and intelligent chemical network monitoring cloud platform;

The intelligent single-machine equipment is equipped with various sensors on the basis of the single-machine equipment of the original crushing and screening production line, which is used for real-time monitoring of the operating parameters of each single-machine equipment in the production process, realizing the real-time collection of the status of each single-machine equipment. And transmitting the collected data to the corresponding networked integrated electronic control system in real time through the signal transmission line;

Each stand-alone device has a corresponding network-type integrated electronic control system. The network-based integrated electronic control system includes a PLC main control unit, a human-machine interface HMI, a sensor communication module, a distributed control system communication module, and an electrical control loop of the corresponding single-machine device; The network integrated electronic control system panel is provided with a local control button for controlling the corresponding equipment when the equipment is being maintained and maintained, and is separated from the distributed control system;

The PLC main control unit communicates with the sensor on the single device through the sensor communication module, acquires the data collected by each sensor, and displays it on the HMI after analysis; the electrical control loop of the network integrated electronic control system is used according to the PLC The output result of the main control unit controls the running state of the corresponding single equipment; the distributed control system communication module is used for communication with the distributed control system; the distributed control system includes an industrial control computer, a local communication module, a mobile communication network or an Ethernet communication device;

The industrial control computer of the distributed control system is used to evaluate whether the crushing equipment at all levels is operating at the optimal load, whether the ideal working efficiency is achieved, and at the same time, the automatic adjustment control of the production process is realized;

The local communication module is used for communication between the distributed control system and the communication module of the distributed control system of the network integrated electronic control system, and obtains information of various sensors and information of the network integrated electronic control system;

The mobile communication network or the Ethernet communication device is used in the distributed control system to upload all the data on the production site to the intelligent IoT monitoring cloud platform;

The intelligent compound network monitoring cloud platform is used for unified management of production data storage and security on the basis of classification and combing according to equipment parameters sent by the distributed control system, and real-time monitoring of the operation status of the single equipment at any time and any place. Feedback and historical analysis, through data analysis and positioning equipment operating conditions and production process parameters, prompting operators to deal with and troubleshoot in a timely manner, and can display the on-site production situation in real time on the mobile phone or computer through the network for remote monitoring.

Further, the intelligent stand-alone equipment includes an intelligent jaw crusher, an intelligent impact crusher, a vibrating screen, a vibrating feeder, a silo, a hopper and a belt conveyor; the intelligent jaw crusher and The intelligent impact crusher is equipped with corresponding wear sensor, temperature sensor, speed sensor and vibration sensor in the corresponding position of the original crusher; each sensor on the crusher is used to monitor the working load and discharge port of the two crushers in real time. Dimensions, bearing temperature, spindle speed and main engine vibration; a material level sensor is installed on the silo for real-time monitoring of the silo material level; the belt conveyor is equipped with a transmission speed sensor, a weighing measuring sensor, a deviation switch and The rope speed switch, the transmission speed sensor and the weighing metering sensor are respectively used for real-time monitoring of the speed and instantaneous output of the belt conveyor, and the cumulative production information; each of the sensors is connected to the distributed control system through a network integrated electronic control system, and further Connected to the intelligent IoT monitoring cloud platform for networking functions of stand-alone devices. Stand-alone device with intelligent distributed control systems and intelligent network monitoring cloud platform was interactive, real-time remote monitoring.

Further, the wear sensor on the intelligent jaw crusher is installed on the fixed jaw plate and the movable jaw of the jaw crusher for real-time monitoring of the wear amount of the fixed jaw plate and the movable jaw plate, and the measured motor is passed. The working current judges the working load of the jaw crusher, adjusts the feeding amount and releases the replacement reminder in time; automatically detects the discharge port size of the jaw crusher through the original discharge port size and the feedback values of the two jaw wear sensors;

The wear sensor on the intelligent impact crusher is mounted on the first counterattack plate and the second counterattack plate for monitoring the wear amount of the first counterattack plate and the second counterattack plate in real time, and judging the counterattack by the measured working current of the motor The working load of the crusher is timely released and the replacement reminder; the speed sensor is arranged on the counter-shocking outer bearing seat to monitor the shaft speed in real time; when the machine is stopped, the wear amount of the plate hammer is calculated, and the wear amount of the counter-plate is used, and the hammer is used. The amount of wear and the size of the discharge port initially set, calculate the discharge port size of the impact crusher at the time of shutdown.

Further, a configuration software module is integrated in the industrial control computer, and the configuration software module includes system management Module, device monitoring module, fault alarm module and database storage and retrieval module; the system management module is used for basic setting and management of the distributed control system itself, including operator authority and working group formulation module, system parameter configuration module, The device parameter configuration module, the operation mode switching module, and the operation group permission automatic distinguishing module; the device monitoring module is configured to perform state monitoring and operation control on each single device on the production line, including a device running state monitoring module and a stand-alone device control module. The production line automatic control module; the fault alarm module is configured to perform related processing on various faults occurring in the production line operation, including a fault interlocking control module and an alarm module; and the database storage and retrieval module is configured to monitor The obtained key production data and alarm information of various production lines are stored in the database, and various retrieval and data extraction operations are performed on the database when needed;

Operator authority and work group development module, which is used to divide the operator into three levels, and assign different permissions and login passwords, and classify different levels of operators into different workgroups; three levels of operators respectively For: the first level is the operator, has the lowest authority, can only perform the corresponding device control operation function; the second level is the system administrator, in addition to the operator's authority, it also has the function of changing the system configuration; The level is an engineer, with all the functions of system configuration, management, and maintenance, and can also read and store the original documents of the system;

The system parameter configuration module is configured to configure two operation parameters of language switching and time calibration of the entire distributed control system, and the language switching configuration is used in countries and regions of different language environments, and the time calibration configuration is used for unnecessary Switch to the Windows operating system environment to calibrate the time, avoiding the uncertainty of the production line control by exiting the distributed control system;

The device parameter configuration module is configured to configure the initial state of the device and the alarm threshold parameter of the entire production line. The alarm threshold parameter includes the upper and lower thresholds of various monitoring device status parameters reaching different alarm levels, and the start and stop of each single device in the automatic mode. time interval;

The operation mode switching module is used for switching the maintenance/operation status of the production line and the operation mode for device control. The operation mode includes local operation, centralized operation and automatic operation; in the case of local operation, the control of the single device is controlled by the network integrated electronic control. The local control button on the system panel is used to control the on-site maintenance personnel to check the maintenance effect when the equipment is in the state of inspection; the centralized operation is to use all the control of the single-machine equipment in the operation instruction interface of the industrial control computer of the distributed control system. Virtual control button to control; automatic operation is automatically controlled by the automatic control part of the network integrated electronic control system for all the single equipment of the entire crushing and screening production line;

The operation group authority automatic distinguishing module is used to display different contents according to the different levels of the registered operators in the equipment parameter configuration interface of the industrial control computer of the distributed control system or the intelligent chemical network monitoring cloud platform, according to the operator, the system administrator and the engineer. Automatically display the content that can be modified by the operator at this level, without the need for artificial zone grouping;

The equipment running condition monitoring module is configured to monitor the running state of the field device during the running of the device, and display the main control interface of the industrial control computer of the distributed control system or the intelligent chemical network monitoring cloud platform; the running state of the single device is The main control interface is displayed in the form of a color light. The green light indicates that the corresponding single device is operating normally. The yellow light indicates that the corresponding single device is in a normal shutdown state, and the red light indicates that the corresponding single device is in a fault state.

The stand-alone device control module is used to automatically control each single device in the production line, and all virtual buttons and virtual drag bars for single device control are centralized in the operation instruction interface, and each virtual button and virtual drag bar are operated to control each The operation of the stand-alone device; the virtual button and the virtual drag bar are effectively arranged and combined according to the operating habits and comfort of the operator to reduce the possibility of misoperation;

The production line automatic control module is used to set the sequence and time of the automatic start of each single equipment from the back to the front, and the sequence and time of the stop and stop of each single equipment from front to back, and one key is started in the automatic operation mode. stop;

The fault linkage control module is configured to interlock the operation relationship of each single equipment according to the operating state of the network integrated electronic control system, and when the single equipment of the interlocked single equipment has a fault shutdown, the faulty equipment is associated with the faulty equipment. Other stand-alone equipment of the company also performs alarm shutdown to ensure equipment safety and production safety;

The alarm module is used for corresponding alarms on various abnormal states occurring in the production process, and the alarm information is popped up and displayed on the alarm information interface of the industrial control computer or the intelligent compound network monitoring cloud platform of the distributed control system; the alarm mode includes the alarm information. The display reminder of the interface, the local voice alarm and the voice alarm of the whole production line, and different alarm modes are used for alarm according to different alarm levels. The low-level alarm only has the corresponding number of alarms on the alarm information interface, which will be displayed after the personnel need to turn it on; the high-level alarm will display the alarm of the control room at the same time as the interface display; the higher-level alarm has a high level. In addition to the alarm function, there will be a tweeter alarm function for the entire production line.

Further, the intelligent IoT monitoring cloud platform includes a device working condition monitoring module, a fault alarm monitoring module, a production line comprehensive briefing module, and a full line video monitoring module;

The equipment condition monitoring module is used to monitor the working status of each single equipment in real time, including the working load of the crusher, the host current, the bearing temperature, the tank temperature, the lining wear, the material level of the silo, the vibration of the main engine, the spindle speed; the feeder Instantaneous load, feed frequency; instantaneous load and vibration current of vibrating screen; speed of belt conveyor, instantaneous output, cumulative production information;

The fault alarm monitoring module is used for real-time monitoring of the type, time, cause and solution information of each equipment fault alarm;

The production line comprehensive briefing module is used to comprehensively display various types of production information, including instantaneous production output, cumulative output, equipment start-up time, production line load, current month output, current month start-up time, average load and product grain analysis report;

The full-line video monitoring module is used to upload pictures and videos collected by the on-site video monitoring system to the cloud platform to realize real-time remote visual monitoring of the field conditions.

Further, the intelligent IoT monitoring cloud platform further includes a smart warehouse monitoring module, an automatic loading monitoring module, and a statistical analysis query module;

The intelligent warehousing monitoring module is used to monitor the daily feeding amount, the discharging amount, the inventory amount, and the unloading trolley including the finished product silos. Working state

The automatic loading monitoring module is used to monitor the status of the arc door switch of each silo, the inventory status of each finished silo, and the loading vehicle through the RFID chip pre-installed on each vehicle and the load cell on the loading floor and the weighbridge. Type, time, tonnage, transaction amount information;

The statistical analysis query module is used for querying and statistical analysis of various historical data, as well as comprehensive scores of production line operation efficiency and health status.

Further, the intelligent IoT monitoring cloud platform further has a reserved interface for providing service access for a third party or a future platform, and can read various production data monitored by the intelligent IoT monitoring cloud platform through the reserved interface. .

It can be seen from the above technical solutions that the invention has the advantages that the intelligent sand and gravel aggregate production line provided by the invention realizes the automatic adjustment control of the production process and the automation level of the crushing equipment by introducing the intelligent control and remote monitoring of the Internet of Things. Reduce manpower waste and reduce the work intensity of on-site operators; effectively increase the effective load rate of equipment, operate at optimal load, increase equipment capacity per unit time, increase equipment life cycle, reduce energy consumption per unit of output, increase output And can reduce downtime maintenance, effectively improve fault handling and production efficiency compared to traditional production lines. The operator can monitor and control the production quality through the large screen. The owner can use the mobile phone and the computer to stay in the house and know the production situation in real time, which greatly facilitates the remote control of the site by the owner.

DRAWINGS

1 is a flow chart of an arrangement of a production line device according to an embodiment of the present invention;

2 is a structural block diagram of an intelligent sandstone aggregate production line according to an embodiment of the present invention;

3 is a partial structural schematic view of an intelligent jaw crusher according to an embodiment of the present invention;

Figure 4 is a cross-sectional view taken along line C-C of the side of the fixed plate of Figure 2;

Figure 5 is a cross-sectional view taken along line D-D of the movable jaw plate of Figure 2;

6 is a partial structural schematic view of an intelligent impact crusher according to an embodiment of the present invention;

7 is a schematic structural diagram of a hardware network of a production line distribution control system according to an embodiment of the present invention;

FIG. 8 is a schematic diagram of a control interface of a production line distribution control system according to an embodiment of the present invention; FIG.

FIG. 9 is a schematic diagram of a network control structure of an intelligent compound network monitoring cloud platform according to an embodiment of the present invention;

FIG. 10 is a schematic diagram of a history query function of a report statistics interface according to an embodiment of the present invention.

In the figure: 1. Wear sensor on the jaw crusher of the jaw crusher; 2. Wear sensor on the jaw crusher motorized jaw; 3. Wear sensor of the impact crusher; 4. Hydraulic adjustment mechanism; 5. Counter hammer .

Detailed ways

The specific embodiments of the present invention are further described in detail below with reference to the drawings and embodiments. The following examples are intended to illustrate the invention but are not intended to limit the scope of the invention.

In this embodiment, the production process of the aggregate of sand and gravel is as shown in Fig. 1. The material is unloaded from the truck, and the gravel aggregate production line is started from the large hopper, and is transported to the intelligent jaw crusher through the vibrating feeder. The coarse crushing treatment is then transported to the intermediate silo by the belt conveyor, dropped from the intermediate silo, and then transported to the intelligent impact crusher through the vibrating feeder for medium-fine crushing treatment, and finally through the belt conveyor and the two vibrating screens. According to the procedure, four kinds of finished sandstone aggregates with different specifications are obtained.

An intelligent sand and gravel aggregate production line includes intelligent single machine equipment, network integrated electronic control system, distributed control system and intelligent chemical network monitoring cloud platform. As shown in FIG. 2, it is a structural block diagram of the production line of the embodiment, and the specific structure is as follows.

In this embodiment, the intelligent stand-alone equipment selected for the production line includes an intelligent jaw crusher, an intelligent impact crusher, a vibrating feeder, a vibrating screen, a silo, a hopper and a belt conveyor. A series of sensors are installed on the single machine. For example, the jaw crusher is equipped with wear sensor, temperature sensor, speed sensor and vibration sensor. The impact crusher is equipped with wear sensor, temperature sensor, speed sensor and vibration sensor. There is a level gauge, and the belt conveyor is equipped with a weighing measuring sensor, a speed sensor, a deviation switch, and a rope switch. These sensors can collect real-time crusher workload, host current, bearing temperature, liner wear, discharge port size, silo material level, main engine vibration, spindle speed, belt conveyor speed, instantaneous output, and equipment conditions. Cumulative production information. The deviation switch is installed on both sides of the belt conveyor. When the belt runs off, the deviation switch is subjected to pressure, and the system pressure feedback signal is used to determine whether it is necessary to stop the recalibration of the belt; the rope switch is essentially an emergency stop switch, the belt conveyor A long drawstring is arranged on the side. When an emergency occurs, pulling the rope at any position on the side of the belt conveyor can stop the machine. The feeding frequency is adjusted by adjusting the frequency of the feeder motor through the frequency converter. The frequency converter will display the frequency. The working current is measured by the current transformer and can be displayed by the ammeter. The mechanical load is proportional to the working current. The rated current ratio is calculated. Each sensor is connected to the distributed control system through a corresponding networked integrated electronic control system, and the distributed control system is further connected with the intelligent IoT monitoring cloud platform for realizing the networking function of the single device, so that the intelligent stand-alone device and the distributed control system and the intelligent The IoT monitoring cloud platform realizes interaction and remote real-time monitoring of the running status of each stand-alone device. The accumulated historical big data can be used for backtracking analysis and process optimization.

The wear sensor on the intelligent jaw crusher is installed on the fixed jaw and the movable jaw of the jaw crusher for real-time monitoring of the wear of the fixed jaw and the movable jaw, and judges the working current of the motor through the measured motor. The crusher's workload, adjust the feed amount and release replacement reminders in a timely manner. The structure of the intelligent jaw crusher is shown in Figure 3. The positions of the wear sensors on the fixed jaw and the movable jaw are shown in Figures 4 and 5, respectively. When the working load of the equipment is low, the feeding amount is automatically increased. When the equipment load is high, the feeding amount is automatically reduced, the intelligent control of the feeding amount is realized, the daily output of the equipment is effectively improved, and the overload blocking material is prevented. The size of the discharge port of the jaw crusher can be calculated by the original discharge port size plus the feedback value of the two jaw wear sensors. The size of the discharge port is automatically detected, and the hydraulic system and the wedge structure are automatically adjusted to ensure the discharge granularity. Stability. Temperature sensor is used to monitor bearing temperature in real time, find abnormal conditions in time, timely maintenance, and extend bearing life. Life. The speed sensor is used to monitor the spindle speed in real time, and the belt slips automatically to stop the alarm. The vibration sensor is used to monitor the vibration of the host in real time. When the equipment is over-iron, the hammer is broken, the rotor is unbalanced, and the loose bolt of the anchor bolt occurs, it will automatically stop and stop. Real-time monitoring of the main motor current is realized by the current transformer. When the equipment is over-iron, the host current will surge, and the amount of current collected by the system will be automatically judged, and then the alarm will be automatically stopped.

The wear sensor on the intelligent impact crusher is mounted on the plate hammer, the first counterattack plate and the second counterattack plate for real-time monitoring of the wear amount of the plate hammer, the first counterattack plate and the second counterattack plate, and the measured motor is passed. The working current is used to judge the workload of the impact crusher, and the replacement reminder is issued in time. Part of the structure of the intelligent impact crusher is shown in Figure 6. The temperature sensor is used to monitor the bearing temperature in real time, find abnormal conditions in time, maintain in time, and prolong the service life of the bearing. The speed sensor is installed on the counter-shock outer bearing housing for real-time monitoring of the spindle speed, and the belt slipper automatically stops and stops. The vibration sensor is used to monitor the vibration of the host in real time. When the equipment is over-iron, the hammer is broken, the rotor is unbalanced, and the loose bolt of the anchor bolt occurs, it will automatically stop and stop. When the machine is shut down, the wear amount of the plate hammer is calculated by the method described in the patent No. 2016107855014, and the stoppage can be calculated by the wear amount of the counter plate, the wear amount of the plate hammer, and the size of the discharge port initially set. The size of the discharge port of the impact crusher is matched with the hydraulic system to adjust the position of the first counterattack plate and the second counterattack plate. When the discharge port is too large, the counter-attack frame is rotated by countering the hydraulic system above, thereby adjusting The discharge particle size ensures the stability of the discharge particle size.

In the actual production process, when the seesaw or counterattack plate is worn to the preset value of the system, the wear sensor feeds back the signal to the distributed control system, promptly warning or alarming, reminding the site manager to replace the seesaw or counterattack, and adjust the discharge. The size of the mouth ensures the stability of the discharge granularity; when the jaw crusher or the impact crusher has the belt slip belt, the speed sensor feeds the signal back to the distributed control system, promptly alarms, reminds the site manager to arrange the personnel to view or Maintenance; when the bearing temperature is too high, the vibration amplitude of the main engine is too large, and the material level of the silo is too high, the distributed control system will collect key parameter information, timely warning or alarm shutdown to prevent abnormal shutdown of the production line. Even the device is damaged. At the same time, the distributed control system and the Internet of Things monitoring cloud platform store all types of faults, time, causes and solutions that occur on the site. On the one hand, they can respond quickly, reduce the number of actual faults on the site through early warning and shutdown, and improve the fault. Solving speed and reducing production waiting time, on the other hand, the accumulation of production data can provide new ideas and methods for equipment manufacturer structure optimization.

Each stand-alone device has a corresponding network-type integrated electronic control system. The network-based integrated electronic control system includes a PLC main control unit, a human-machine interface HMI, a sensor communication module, a distributed control system communication module, and an electrical control loop of the corresponding single-machine device. The network integrated electronic control system panel is provided with local control buttons for controlling the corresponding equipment when the equipment is being maintained and maintained.

The PLC main control unit communicates with the sensors on the stand-alone device through the sensor communication module, and acquires the data collected by each sensor, and displays it on the HMI after analysis. The electrical control loop of the network integrated electronic control system is used according to the PLC master The output of the control unit controls the operating status of the corresponding stand-alone device. The distributed control system communication module is used to communicate with the distributed control system.

The distributed control system is used to accurately evaluate whether the crushing equipment at all levels is operating at the optimal load and achieve the desired working efficiency according to the equipment parameters collected in real time, and realize the automatic adjustment control of the production process; the distributed control system integrates all equipment parameters and transmits through the wireless communication network. Upload all the data on the production site to the intelligent IoT monitoring cloud platform. It can realize centralized operation control of the whole aggregate equipment of sand and gravel aggregate production line, as well as real-time monitoring and alarm processing of production parameters of various equipment on the production line.

The distributed control system includes an industrial control computer, a local communication module, a mobile communication network, or an Ethernet communication device. The industrial control computer of the distributed control system is used to evaluate whether the crushing equipment at all levels is operating at the optimal load, whether it achieves the ideal working efficiency, and at the same time realizes the automatic adjustment control of the production process. The local communication module is used for communication between the distributed control system and the distributed control system communication module of the network integrated electronic control system, and obtains information of various sensors and information of the network integrated electronic control system. The mobile communication network or Ethernet communication equipment is used in the distributed control system to upload all the data on the production site to the intelligent IoT monitoring cloud platform. Each industrial control computer is assigned a unique logical address to control one or more stand-alone devices (eg jaw crushers, impact crushers), independent and related. The structure of the distributed control system is shown in Figure 7, and the display interface of the distributed control system is shown in Figure 8.

The industrial control computer integrates various functional modules corresponding to each single-machine device, and uses the configuration software to design. In the specific implementation, the calls of these configuration software modules are different according to the configuration of the production line. In this embodiment, The production line only has a jaw crusher and a counter crusher. The distributed control system only calls the control and communication modules corresponding to the jaw crusher and the impact crusher. In the specific implementation, the configuration of the production line is handled according to the owner's situation, and the system can be changed, and is not limited to the two stand-alone devices.

The configuration software module includes a system management module, a device monitoring module, a fault alarm module, and a database storage and retrieval module.

The system management module is used for the basic setting and management of the distributed control system itself, including the operator authority and working group formulating module, the system parameter configuration module, the device parameter configuration module, the operation mode switching module, and the operation group authority automatic distinguishing module.

Operator authority and work group development module, which is used to divide the operator into three levels and assign different permissions and login passwords to effectively prevent equipment loss and personal damage caused by misuse or other reasons, and at the same time, different levels of operators It is organized into different working groups to facilitate the management of the operators of the production line. The three levels of operators are: the first level is the operator, has the lowest authority, can only perform the corresponding device control operation function; the second level is the system administrator, in addition to the operator's authority, Change the function of the system configuration; the highest level is the engineer, which has all the functions of system configuration, management, and maintenance, and can also read and store the original documents of the system.

The system parameter configuration module is configured to configure two operation parameters of language switching and time calibration of the entire distributed control system, and the language switching configuration is used in countries and regions of different language environments, and the time calibration configuration is used for unnecessary Switching to the Windows operating system environment can calibrate the time and avoid the uncertainty of the production line control by exiting the distributed control system.

The device parameter configuration module is configured to configure the initial state of the device and the alarm threshold parameter of the entire production line. The alarm threshold parameter includes upper and lower thresholds of various monitoring device status parameters reaching different alarm levels, such as oil temperature and shaft temperature of the alarm. The upper and lower thresholds of speed, current, vibration amplitude, discharge port size, material level height, etc., and the start and stop time interval of each stand-alone device in automatic mode. The start-stop time interval means that when the production line is started by one button, each single-machine device is automatically started by the back-end to the front end according to the preset start-stop time interval; when the production line is shut down by one button, each single-machine device is pre-set The start and stop time interval is automatically shut down from the front end to the rear. The entire distributed control system monitors each operation data of the production line according to the configured value, and controls the operation/stop state of each single equipment. If a certain parameter in the operation exceeds the set limit, according to the corresponding setting Automatically perform alarm or alarm stop operation.

The operation mode switching module is used for switching the maintenance/operation status of the production line and the operation mode for device control. The operation mode includes local operation, centralized operation and automatic operation; in the case of local operation, the control of the single device is controlled by the network integrated electronic control. The local control button on the system panel is used for control, which is convenient for on-site maintenance personnel to detect the maintenance effect when the single-machine equipment is in the state of maintenance; centralized operation is to use all the control of the single-machine equipment as the operation instruction interface of the industrial control computer of the distributed control system. The virtual control button is used for control; the automatic operation is automatically controlled by the automatic control part of the network integrated electronic control system for all the single equipment of the entire crushing and screening production line.

The operation group authority automatic distinguishing module is configured to display different contents according to different levels of the registered operators in the device parameter configuration interface of the industrial control computer or the intelligent compound network monitoring cloud platform, and enter different according to the registered operator permission level. The control interface automatically displays the content that can be modified by the operator at the level according to the operator, system administrator and engineer, without the need for artificial zone grouping.

The equipment monitoring module is used for condition monitoring and operation control of each single equipment on the production line, including equipment operation status monitoring module, single equipment control module, and production line automatic control module.

The equipment running status monitoring module is configured to monitor the running status of the field device when the single device is running, and display the display on the main control interface of the industrial control computer or the intelligent chemical network monitoring cloud platform. The running status of the stand-alone device is displayed in the form of a color light on the main control interface. The green light indicates that the corresponding single device is operating normally, the yellow light indicates that the corresponding single device is in the normal stop state, and the red light indicates that the corresponding single device is in the fault. status. When the indicator light next to each single device on the main control interface turns red, it means that the corresponding single device has an alarm. When the indicator light turns red, it will pop up the window of the alarm information interface. The window contains information about the alarm, such as the device serial number. , equipment location, alarm cause, alarm parameters and alarm time.

The stand-alone device control module is used to automatically control each single device in the production line, and all virtual buttons and virtual drag bars for single device control are centralized in the operation instruction interface, and each virtual button and virtual drag bar are operated to control each The operation of a stand-alone device saves a lot of hardware structure. The virtual button refers to the machine opening key and the gear position key; the virtual drag bar is similar to the mobile phone brightness bar, and can be dragged as needed to control the frequency of the variable frequency motor. Virtual buttons and virtual drag bars are effectively arranged in accordance with the operator's operating habits and comfort to reduce the possibility of misuse.

The production line automatic control module is used to set the sequence and time of the automatic start of each single equipment from the back to the front, and the sequence and time of the stop and stop of each single equipment from front to back, and one key is started in the automatic operation mode. stop. Since the equipment of the whole crushing and screening production line can sometimes reach hundreds, it is not only a waste of manpower for so many equipments to be manually started, but also the equipment may be damaged due to the wrong sequence of starting, and the safe operation of the production line may be affected. . Set one-button start-stop function of the production line, the operator only needs to click the one-button start-stop button in the operation command interface. When starting, each single-machine device automatically starts from the back to the front according to the set sequence and time. Stop in order from the front to the back according to the set order and time.

In the specific implementation, through the equipment monitoring module, the vibration frequency of the vibrating feeder can be adjusted according to the load condition of the host, thereby changing the feeding amount of the main machine, increasing the effective load rate of the equipment, increasing the unit time capacity of the equipment, and being effective. Protect the device. Through the fuzzy load control algorithm and the control program, the front feeding speed of the crushing equipment is automatically matched according to the running load of the crushing equipment, and the manual operation can be completely eliminated, and the automatic adjustment speed of the system reaches the millisecond level. The worker can preset the crushing equipment load value according to the actual situation of the production line. When the system is running, it can automatically adjust the preset feeding load according to the current load condition by adjusting the front feeding frequency, so that the load of the crushing equipment is always constant at the preset. The value, so that the motor is always running under the condition of close to the rated load, saving electricity and reducing labor.

The fault alarm module is used for related processing of various faults occurring in the operation of the production line, including a fault interlocking control module and an alarm module. The faults that may occur in the specific implementation include mechanical faults, electrical faults, hydraulic faults, etc.; the fault handling modes are classified into fault warning, alarm, direct interlock shutdown, and the like.

The fault linkage control module is configured to interlock the operation relationship of each single equipment according to the operating state of the network integrated electronic control system, and when the single equipment of the interlocked single equipment has a fault shutdown, the faulty equipment is associated with the faulty equipment. Other stand-alone equipment of the company also performs alarm shutdown to ensure equipment safety and production safety. The operating status of all networked integrated electronic control systems is read by the configuration software, and the operating relationships of the stand-alone devices are linked in the configuration software. For example, if the conveyor of the feeder is stopped due to a failure, the feeder can be automatically stopped, thereby saving the time required for the operation or patrolling personnel to find the failure and ensuring the safety of the equipment.

The alarm module is used for corresponding alarms on various abnormal states occurring in the production process, and the alarm information is popped up and displayed on the alarm information interface of the industrial control computer or the intelligent compound network monitoring cloud platform. The alarm mode includes display reminder of the alarm information interface, local voice alarm and voice alarm of the whole production line, and different reports are adopted according to different alarm levels. The police mode is used to alarm. The alarm mode is preset, and the system sets different alarm modes according to the severity of the problem according to the possible situation. The low-level alarm only has the corresponding number of alarms on the alarm information interface, which will be displayed after the personnel need to turn it on; the high-level alarm will display the alarm of the control room at the same time as the interface display; the higher-level alarm has a high level. In addition to the alarm function, there will be a tweeter alarm function for the entire production line. The alarm information interface configures a large number of alarm information. If the current main interface is not on the alarm information interface, the alarm information is in pop-up mode. When there is no fault, the alarm will not pop up; once the field device has a fault alarm, it will be on any interface. A prompt will pop up for the operator to quickly interpret and handle the fault; if the current main interface is an alarm information interface, the alarm information is directly displayed. In the specific implementation, all the alarms of the crushing and screening production line include the single-machine and production line interlocking alarms, and perform different operations on different grouping alarms. If the upper limit is exceeded, only the alarm will alert the field personnel to pay attention, and exceed the upper limit. Then alarm and stop.

The database storage and retrieval module is configured to store various production data and alarm information of the monitored production line in a database, and perform various retrieval and data extraction operations on the database when needed. The stored data is mainly the key parameters in each time period, such as current size, feeder frequency, material level height, time period production, total output, number of alarms, and cause analysis. The system has a dedicated database on the industrial control computer, which can perform various operations on the database. The type of the database can be selected from the current mainstream Access, SQLserver, and Oracle. The database storage and retrieval module can provide the production status retrieval function of the production line, and automatically count the key data of the production for reference; through the report statistics interface of the industrial control computer, as shown in Figure 10, the instantaneous output and accumulation of the conveyor can be monitored in real time. Production information, and can query historical data, query production according to day, week and month; also have the function of query by class, automatically statistics the production of the team, to facilitate management personnel to assess the performance of production personnel; It can automatically count the alarm situation of the whole crushing and screening production line. Through the report statistics interface, the alarm information can be queried in real time according to the day, week and month; all the information queried on the report statistics interface can be printed.

The intelligent compound network monitoring cloud platform is used for real-time monitoring, feedback and historical analysis of the operation status of the single-machine equipment according to the equipment parameters sent by the distributed control system, and analyzing the operating conditions and production process parameters of the equipment through data analysis. It prompts the operator to deal with and eliminate the fault in time, and can display the on-site production situation in real time on the mobile phone or computer through the network for remote monitoring. The network control structure of the intelligent IoT monitoring cloud platform in this embodiment is shown in Figure 9. For the customization and diversification of sand and gravel aggregate production, cloud computing is used to manage production data storage and security on the basis of classification and combing. Provide data storage and service access functions through cluster application, grid technology or distributed file system technology. Specifically, it includes equipment condition monitoring module, fault alarm monitoring module, production line comprehensive briefing module, full line video monitoring module, intelligent warehouse monitoring module, automatic loading monitoring module and statistical analysis query module.

The equipment condition monitoring module is used to monitor the working status of each single equipment in real time, including the working load of the crusher, the host current, the bearing temperature, the tank temperature, the lining wear, the material level of the silo, the vibration of the main engine, the spindle speed; the feeder Instantaneous negative Load and feed frequency; instantaneous load and vibration current of vibrating screen; speed of belt conveyor, instantaneous output, cumulative production information.

The fault alarm monitoring module is used to monitor the type, time, cause and solution information of each single equipment fault alarm in real time.

The production line comprehensive briefing module is used to comprehensively display various types of production information, including instantaneous production, cumulative production, equipment start-up time, production line load, current month output, current month start-up time, average load and product grain analysis report.

The intelligent warehousing monitoring module is used for real-time monitoring of the feeding amount, the discharging amount, the inventory quantity and the working state of the unloading trolley of each finished silo by the material level sensor, and the data fed back by the material level sensor can control the feeding of the system. Position, to prevent the warehouse from overflowing or not in the warehouse.

The automatic loading monitoring module is used for monitoring real-time information including the status of the arc door switch of each silo, the inventory status of each finished silo, the type of loading vehicle, time, tonnage, and transaction amount; in specific implementation, pre-installed in each vehicle The RFID chip reads the vehicle information, and at the same time, through the comprehensive calculation of the load cell on the loading building and the weighbridge, it automatically recognizes the important parameters such as the type of material, the number of loading times and the weight of the loading of each vehicle.

The intelligent IoT monitoring cloud platform also has a reserved interface for providing service access for third parties or future platforms, for example, connecting mobile terminal devices such as smart phone terminals, through which the intelligent IoT monitoring cloud can be read. The various production data monitored in the platform provide an extended design for the comprehensive management platform for building diversified terminal products in the future.

The intelligent sandstone aggregate production line provided by the embodiment enables the crushing equipment to increase the service life of the equipment by more than 20% under the same output, reduce the energy consumption by more than 15%, improve the automation level of the crushing equipment, and improve the effective load rate of the equipment. Increase the unit time capacity of the equipment, increase the life cycle of the equipment, and reduce the energy consumption per unit of output. At the same time, it effectively reduces manpower waste, reduces the work intensity of on-site operators, helps crushing sand and gravel aggregates, saves energy and reduces emissions, and improves production efficiency.

It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and are not limited thereto; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that The technical solutions described in the foregoing embodiments are modified, or some or all of the technical features are equivalently substituted; and the modifications or alternatives do not detract from the nature of the corresponding technical solutions.

Claims

An intelligent sandstone aggregate production line, comprising: intelligent single machine equipment, network integrated electronic control system, distributed control system and intelligent chemical network monitoring cloud platform;

The intelligent single-machine equipment is equipped with various sensors on the basis of the single-machine equipment of the original crushing and screening production line, which is used for real-time monitoring of the operating parameters of each single-machine equipment in the production process, realizing the real-time collection of the status of each single-machine equipment. And transmitting the collected data to the corresponding networked integrated electronic control system in real time through the signal transmission line;

Each stand-alone device has a corresponding network-type integrated electronic control system. The network-based integrated electronic control system includes a PLC main control unit, a human-machine interface HMI, a sensor communication module, a distributed control system communication module, and an electrical control loop of the corresponding single-machine device; The network integrated electronic control system panel is provided with a local control button for controlling the corresponding device when the device is being maintained and maintained, and the PLC main control unit communicates with the sensor on the single device through the sensor communication module. Obtaining data collected by each sensor and displaying it on the HMI after analysis; the electrical control loop of the network integrated electronic control system is configured to control the running state of the corresponding single device according to the output result of the PLC main control unit; the distributed control The system communication module is used for communication with the distributed control system; the distributed control system includes an industrial control computer, a local communication module, a mobile communication network or an Ethernet communication device;

The industrial control computer of the distributed control system is used to evaluate whether the crushing equipment at all levels is operating at the optimal load, whether it achieves the ideal working efficiency, and at the same time realizes the automatic adjustment control of the production process; the local communication module is used for the distributed control system and the network integrated electronic control system. The communication control module of the distributed control system communicates to obtain information of various sensors and information of the network-based integrated electronic control system; the mobile communication network or the Ethernet communication device is used for the distributed control system to upload all the data of the production site to the intelligent IoT monitoring cloud platform;

The intelligent compound network monitoring cloud platform is used for unified management of production data storage and security on the basis of classification and combing according to equipment parameters sent by the distributed control system, and real-time monitoring of the operation status of the single equipment at any time and any place. Feedback and historical analysis, through data analysis and positioning equipment operating conditions and production process parameters, prompting operators to deal with and troubleshoot in a timely manner, and can display the on-site production situation in real time on the mobile phone or computer through the network for remote monitoring.
The intelligent sandstone aggregate production line according to claim 1, wherein the intelligent stand-alone equipment comprises an intelligent jaw crusher, an intelligent impact crusher, a vibrating screen, a vibrating feeder, Silo, hopper and belt conveyor; the intelligent jaw crusher and intelligent impact crusher are equipped with corresponding wear sensors, temperature sensors, speed sensors and vibration sensors at the corresponding positions of the original crusher; Each sensor is used to monitor the working load, the discharge port size, the bearing temperature, the spindle speed and the host vibration of the two crushers in real time; the material level sensor is installed on the silo for real-time monitoring of the silo material level; The belt conveyor is equipped with a transmission speed sensor, a weighing metering sensor, a deviation switch and a rope switch, and the transmission speed sensor and the weighing meter are respectively used for real-time monitoring of the belt conveyor speed and instantaneous output, and cumulative production information; Each of the sensors is integrated with a networked electronic control system The distributed control system is connected, and then connected with the intelligent IoT monitoring cloud platform, which is used to realize the networking function of the single device, so that the intelligent stand-alone device interacts with the distributed control system and the intelligent IoT monitoring cloud platform for remote real-time monitoring.
The intelligent sand aggregate production line according to claim 2, wherein the wear sensor on the intelligent jaw crusher is mounted on the fixed jaw and the movable jaw of the jaw crusher for Real-time monitoring of the wear of the boring plate and the boring plate, judging the working load of the jaw crusher by the measured motor working current, adjusting the feed amount and issuing the replacement reminder in time; passing the original discharge port size and two 颚The feedback value of the plate wear sensor automatically detects the discharge port size of the jaw crusher;

The wear sensor on the intelligent impact crusher is mounted on the first counterattack plate and the second counterattack plate for monitoring the wear amount of the first counterattack plate and the second counterattack plate in real time, and judging the counterattack by the measured working current of the motor The working load of the crusher is timely released and the replacement reminder; the speed sensor is arranged on the counter-shocking outer bearing seat to monitor the shaft speed in real time; when the machine is stopped, the wear amount of the plate hammer is calculated, and the wear amount of the counter-plate is used, and the hammer is used. The amount of wear and the size of the discharge port initially set, calculate the discharge port size of the impact crusher at the time of shutdown.
The intelligent sandstone aggregate production line according to claim 3, wherein the industrial control computer integrates a configuration software module, and the configuration software module comprises a system management module, a device monitoring module, and a fault alarm. Module and database storage and retrieval module; the system management module is used for basic setting and management of the distributed control system itself, including operator authority and work group formulation module, system parameter configuration module, device parameter configuration module, operation mode switching The module and the operation group automatically distinguish the module; the device monitoring module is used for condition monitoring and operation control of each single device on the production line, including a device operation state monitoring module, a single device device control module, and a production line automatic control module; The fault alarm module is configured to perform related processing on various faults occurring in the operation of the production line, including a fault interlock control module and an alarm module; the database storage and retrieval module is used for key production of various production lines to be monitored. Data and alarm information statistics are stored in the database, and Perform various retrieval and data extraction operations on the database as needed;

Operator authority and work group development module, which is used to divide the operator into three levels, and assign different permissions and login passwords, and classify different levels of operators into different workgroups; three levels of operators respectively For: the first level is the operator, has the lowest authority, can only perform the corresponding device control operation function; the second level is the system administrator, in addition to the operator's authority, it also has the function of changing the system configuration; The level is an engineer, with all the functions of system configuration, management, and maintenance, and can also read and store the original documents of the system;

The system parameter configuration module is configured to configure two operation parameters of language switching and time calibration of the entire distributed control system, and the language switching configuration is used in countries and regions of different language environments, and the time calibration configuration is used for unnecessary Switch to the Windows operating system environment to calibrate the time, avoiding the uncertainty of the production line control by exiting the distributed control system;

The device parameter configuration module is configured to configure the initial state of the device and the alarm threshold parameter of the entire production line, and alarm The threshold parameter includes upper and lower thresholds of various monitoring device status parameters reaching different alarm levels, and starting and stopping time intervals of each single device in the automatic mode;

The operation mode switching module is used for switching the maintenance/operation status of the production line and the operation mode for device control. The operation mode includes local operation, centralized operation and automatic operation; in the case of local operation, the control of the single device is controlled by the network integrated electronic control. The local control button on the system panel is used to control the on-site maintenance personnel to check the maintenance effect when the equipment is in the state of inspection; the centralized operation is to use all the control of the single-machine equipment in the operation instruction interface of the industrial control computer of the distributed control system. Virtual control button to control; automatic operation is automatically controlled by the automatic control part of the network integrated electronic control system for all the single equipment of the entire crushing and screening production line;

The operation group authority automatic distinguishing module is used to display different contents according to the different levels of the registered operators in the equipment parameter configuration interface of the industrial control computer of the distributed control system or the intelligent chemical network monitoring cloud platform, according to the operator, the system administrator and the engineer. Automatically display the content that can be modified by the operator at this level, without the need for artificial zone grouping;

The equipment running condition monitoring module is configured to monitor the running state of the field device during the running of the device, and display the main control interface of the industrial control computer of the distributed control system or the intelligent chemical network monitoring cloud platform; the running state of the single device is in the main control interface The display is performed by means of a color light. The green light indicates that the corresponding single device is operating normally, the yellow light indicates that the corresponding single device is in a normal shutdown state, and the red light indicates that the corresponding single device is in a fault state;

The stand-alone device control module is used to automatically control each single device in the production line, and all virtual buttons and virtual drag bars for single device control are centralized in the operation instruction interface, and each virtual button and virtual drag bar are operated to control each The operation of the stand-alone device; the virtual button and the virtual drag bar are effectively arranged and combined according to the operating habits and comfort of the operator to reduce the possibility of misoperation;

The production line automatic control module is used to set the sequence and time of the automatic start of each single equipment from the back to the front, and the sequence and time of the stop and stop of each single equipment from front to back, and one key is started in the automatic operation mode. stop;

The fault linkage control module is configured to interlock the operation relationship of each single equipment according to the operating state of the network integrated electronic control system, and when the single equipment of the interlocked single equipment has a fault shutdown, the faulty equipment is associated with the faulty equipment. Other stand-alone equipment of the company also performs alarm shutdown to ensure equipment safety and production safety;

The alarm module is used for corresponding alarms on various abnormal states occurring in the production process, and the alarm information is popped up and displayed on the alarm information interface of the industrial control computer or the intelligent compound network monitoring cloud platform of the distributed control system; the alarm mode includes the alarm information. The display reminder of the interface, the local voice alarm and the voice alarm of the whole production line, and different alarm modes are used for alarm according to different alarm levels. The low-level alarm only has the corresponding number of alarms on the alarm information interface, which will be displayed after the personnel need to turn it on; the high-level alarm will display the alarm of the control room at the same time as the interface display; the higher-level alarm has a high level. In addition to the alarm function, there will be a tweeter alarm function for the entire production line.
The intelligent sandstone aggregate production line according to claim 4, characterized in that: intelligent chemical network monitoring The cloud platform includes a device condition monitoring module, a fault alarm monitoring module, a production line comprehensive briefing module, and a full line video monitoring module;

The equipment condition monitoring module is used to monitor the working status of each single equipment in real time, including the working load of the crusher, the host current, the bearing temperature, the tank temperature, the lining wear, the material level of the silo, the vibration of the main engine, the spindle speed; the feeder Instantaneous load, feed frequency; instantaneous load and vibration current of vibrating screen; speed of belt conveyor, instantaneous output, cumulative production information;

The fault alarm monitoring module is used for real-time monitoring of the type, time, cause and solution information of each equipment fault alarm;

The production line comprehensive briefing module is used to comprehensively display various types of production information, including instantaneous production output, cumulative output, equipment start-up time, production line load, current month output, current month start-up time, average load and product grain analysis report;

The full-line video monitoring module is used to upload pictures and videos collected by the on-site video monitoring system to the cloud platform to realize real-time remote visual monitoring of the field conditions.
The intelligent sandstone aggregate production line according to claim 5, wherein the intelligent chemical network monitoring cloud platform further comprises a smart warehouse monitoring module, an automatic loading monitoring module and a statistical analysis query module;

The intelligent warehousing monitoring module is used for monitoring the daily feeding amount, the discharging amount, the inventory amount and the working state of the unloading trolley including the finished product silos;

The automatic loading monitoring module is used to monitor the status of the arc door switch of each silo, the inventory status of each finished silo, and the loading vehicle through the RFID chip pre-installed on each vehicle and the load cell on the loading floor and the weighbridge. Type, time, tonnage, transaction amount information;

The statistical analysis query module is used for querying and statistical analysis of various historical data, as well as comprehensive scores of production line operation efficiency and health status.
The intelligent sandstone aggregate production line according to claim 5, wherein the intelligent IoT monitoring cloud platform further has a reserved interface for providing service access for a third party or a future platform, The reserved interface can read various production data monitored in the intelligent IoT monitoring cloud platform.