WO2019232937A1 - 一种四绳抓斗抓取渣料的系统及方法 - Google Patents

一种四绳抓斗抓取渣料的系统及方法 Download PDF

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Publication number
WO2019232937A1
WO2019232937A1 PCT/CN2018/102431 CN2018102431W WO2019232937A1 WO 2019232937 A1 WO2019232937 A1 WO 2019232937A1 CN 2018102431 W CN2018102431 W CN 2018102431W WO 2019232937 A1 WO2019232937 A1 WO 2019232937A1
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Prior art keywords
inverter
cart
grab
rope
lifting
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PCT/CN2018/102431
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English (en)
French (fr)
Inventor
孙茂杰
李福存
徐海宁
张楠
孙敬忠
魏敬忠
杨孟
Original Assignee
江苏金恒信息科技股份有限公司
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Publication of WO2019232937A1 publication Critical patent/WO2019232937A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B66—HOISTING; LIFTING; HAULING
    • B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
    • B66C13/00—Other constructional features or details
    • B66C13/18—Control systems or devices
    • B66C13/22—Control systems or devices for electric drives
    • B66C13/32—Control systems or devices for electric drives for operating grab bucket hoists by means of one or more electric motors used both for hosting and lowering the loads and for opening and closing the bucket jaws
    • B66C13/38—Systems controlling independent motors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B66—HOISTING; LIFTING; HAULING
    • B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
    • B66C13/00—Other constructional features or details
    • B66C13/04—Auxiliary devices for controlling movements of suspended loads, or preventing cable slack
    • B66C13/06—Auxiliary devices for controlling movements of suspended loads, or preventing cable slack for minimising or preventing longitudinal or transverse swinging of loads
    • B66C13/063—Auxiliary devices for controlling movements of suspended loads, or preventing cable slack for minimising or preventing longitudinal or transverse swinging of loads electrical
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B66—HOISTING; LIFTING; HAULING
    • B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
    • B66C13/00—Other constructional features or details
    • B66C13/16—Applications of indicating, registering, or weighing devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B66—HOISTING; LIFTING; HAULING
    • B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
    • B66C13/00—Other constructional features or details
    • B66C13/18—Control systems or devices
    • B66C13/48—Automatic control of crane drives for producing a single or repeated working cycle; Programme control
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B66—HOISTING; LIFTING; HAULING
    • B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
    • B66C15/00—Safety gear
    • B66C15/04—Safety gear for preventing collisions, e.g. between cranes or trolleys operating on the same track
    • B66C15/045—Safety gear for preventing collisions, e.g. between cranes or trolleys operating on the same track electrical
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B66—HOISTING; LIFTING; HAULING
    • B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
    • B66C15/00—Safety gear
    • B66C15/06—Arrangements or use of warning devices
    • B66C15/065—Arrangements or use of warning devices electrical

Definitions

  • the invention relates to the field of automation control, in particular to a system and method for grabbing slag by a four-rope grab.
  • the four-rope grab crane is controlled manually.
  • the mechanical part includes the traveling gear reducer, lifting drum and reducer, opening and closing drum, and reducer.
  • the electrical control part consists of contactor, stator resistance, walking motor, and lifting motor. ⁇ Overload limiter, limit cam and door limit.
  • the water vapor in the blast furnace slag pool is relatively large, which seriously affects the line of sight in winter. People work hard in severe environments and are prone to safety accidents.
  • the technical problem to be solved by the present invention is to overcome the defects of the prior art and provide a system capable of automatically grasping slag.
  • the system for grasping slag by a four-rope grab includes a computer, a PLC, a lifting inverter, an incremental encoder A, an open / close inverter, an incremental encoder B, and a cart.
  • the machine B is connected to the opening and closing drum; the lifting rope and the opening and closing rope are connected to the grab bucket respectively; the lifting rope is wound on the lifting drum and the opening and closing rope is wound on the opening and closing drum; the limit cam is fixed on the lifting drum ;
  • the computer, hoisting inverter, opening / closing inverter, cart positioning device, overload limiter, cart travel motor and cart travel motor are respectively connected to the PLC; the PLC and the computer can use wired or wireless communication to achieve data exchange;
  • the hoisting motor and the incremental encoder A are respectively connected to the hoisting inverter, and the on-off motor and the incremental encoder B are respectively connected to the on-off inverter.
  • the on-off motor and lifting motor adopt the master-slave mode and torque control mode.
  • the inverter acts as a slave, and the torque of the open and close inverter is sent to the lifting inverter through communication.
  • the lifting inverter runs at a certain percentage, keeping the lifting rope and the opening and closing rope at the same time, and the lifting speed is consistent, so as to achieve uniform force. And do not scatter slag.
  • the hoisting inverter and the opening and closing inverter both have current output.
  • the opening and closing inverter has current output.
  • the PLC lifts the inverter and opens and closes the inverter by collecting.
  • the current output is archived and recorded in the computer.
  • the programmer analyzes the current value of the recorded current to obtain the current value interval of normal operation, and writes a program in PCL. If the actual current value is out of normal in these steps
  • the current value interval of the operation can judge that the state of the rope of the hoisting rope and the opening and closing rope is abnormal. In the program, the operation will be suspended and an alarm will occur. The operator will check the cause.
  • the overload limiter can detect the net weight of the grab when it is in the air. When the grab is lowered to contact the surface of the slag, the weight of the grab detected by the overload limiter will gradually become zero. In the program, if the detected grab is set, When the bucket weight becomes zero, the maximum amount of slag can be caught. If the detection weight of the bucket becomes half of the net weight, the amount of slag will be reduced. Through this principle, the amount of slag can be controlled. Regardless of whether there is water in the slag tank, the actual height of the grapple calculated by the incremental encoder A and the grapple weight detected by the overload limiter can be used to calculate the grapple in the grapple. The amount of slag taken is not more than half of the load. The slag in the bucket will be placed at the next target position, and then they will be taken together to mimic the function of artificial sand.
  • the cart positioning device includes a cart address coding generator, Gray bus A, antenna A, cart address decoder, cart address decoder, Gray bus B, cart address coding generator, and antenna B; cart
  • the address coding generator and antenna B are fixed on the trolley; antenna A is fixed on the driving beam; antenna A is connected to the PLC through the trolley address decoder, and Gray bus B is connected to the PLC through the trolley address decoder; the trolley address coding occurs
  • the device is connected to Gray bus A.
  • Gray bus A is encoded by the cart address coding generator.
  • the antenna A at the end of the driving beam receives the signal of Gray bus A and transmits it to the cart address decoder for decoding.
  • the cart address decoder transmits the location address to the PLC.
  • the car address code generator sends the code through the antenna B, installs the Gray bus B on the track beam that the car moves, receives the code, and then transmits it to the car address decoder for decoding, and then the location address
  • the real-time position information Y of the trolley is transmitted to the PLC through communication.
  • the safe distance between the trolley and the track terminal is set by the PLC program through the trolley positioning device. It is also passed between the trolley and another trolley on the same track. The program sets a safety distance and increases safety precautions.
  • the system also includes a car traveling inverter, a car traveling inverter; a car traveling inverter is added between the car traveling motor and the PLC, and a car traveling inverter is added between the car traveling motor and the PLC;
  • a car traveling inverter is added between the car traveling motor and the PLC;
  • the trolley traveling inverters all have integrated control models to adjust the output frequency, adjust the starting and stopping speeds of the trolley traveling motor and the trolley traveling motor to prevent grab swing.
  • the system also includes a twisted rope detection device connected to the PCL;
  • the twisted rope detection device includes a laser sensor and a reflective plate;
  • the laser sensor is fixed at the bottom of the trolley, and the reflective plate is fixed at the top of the grapple; the installation position of the laser sensor
  • the laser sensor can receive the reflected signal. If it cannot receive the signal, it indicates that the grab bucket has rotated. The PLC will suspend the operation of the vehicle, and an alarm will occur, and the operator will check the reason.
  • an infrared anti-collision device is installed on each side of the carriage's beam.
  • the outer side serves as the second protection for the collision between the carriage and the terminal of the track, and the inner side serves as an anti-collision between the carriage and another carriage on the same track.
  • the second protection; the infrared anti-collision device is connected to the PLC.
  • the present invention also provides a method based on the above system, including the following steps:
  • each slag pool is the area just grabbed by the grab, and calibrate the X-axis and Y-axis coordinate values of each area.
  • the set route starts to be captured in turn. All the areas in the pool are captured in a loop as a cycle. After the last area of the cycle is captured, the next cycle is resumed according to the set route.
  • the PLC When preparing to grab the target area, compare the target addresses of the X and Y axes with the actual addresses of the traveling beam and the traveling trolley to obtain whether the traveling motor of the trolley and the traveling motor of the traveling vehicle are running forward or reverse ; According to the difference between the target address and the actual address, the PLC outputs different frequencies to the inverter to control the running speed of the vehicle;
  • the grab bucket starts to drop from the high position to grab the material in the pool, and then rises to the high position after the grab, which belongs to a lifting cycle; in this process, the actual height of the grab bucket is calculated by the pulse value of the incremental encoder A and transmitted to the large Inverter for car travel, Inverter for car travel, Inverter for car travel, Inverter for car travel Adjust the output frequency to eliminate the swing amplitude of the grab; In each cycle, the limit cam will be triggered once to calibrate the grab height Check and correct to eliminate the cumulative error of incremental encoder A;
  • the switching motor and lifting motor adopt the master-slave mode and torque control mode.
  • the switching frequency converter is used as the master and the lifting frequency converter is used as the slave.
  • the torque of the switching frequency converter is sent to the lifting frequency converter through communication to improve the frequency conversion.
  • the device runs at a certain percentage, keeping the hoisting rope and the opening and closing rope at the same time, and the lifting speed is consistent; the grab bucket is lowered.
  • the limiter still detects the weight, indicating that there will be no slag in this area after grabbing this bucket. Mark the short position.
  • the next cycle will skip the area; the grab bucket will drop to the set low and low position and overload the limiter. Weight was still detected, indicating that there was very little slag in the area, not enough for half a bucket, and triggering the spit function.
  • the present invention is a system and method for grabbing slag by a four-rope grab.
  • the form of the slag is fine sand.
  • the slag in the blast furnace and the pulverized coal in the dry coal shed belong to the type of fine sand, and both of these systems and methods can be applied to realize automatic operation.
  • the present invention solves the problem of anti-swaying of the grapple: during the start or stop of the traveling motor of the trolley and the traveling motor of the trolley, due to the inertia of the grapple, the pendulum has a pendulum effect relative to the traveling beam or the traveling trolley, which will produce a swing ;
  • the cart walking inverter and the cart walking inverter have integrated control models to adjust the output frequency, adjust the start and stop speed of the cart walking motor and the cart walking motor to prevent swing;
  • the present invention solves the problem of cooperation between the hoisting rope and the opening and closing rope; if the hoisting rope is stressed and the opening and closing rope is not stressed, the slag in the grapple will be scattered from the bottom; if the hoisting rope is stressed, the lifting When the rope is under no force, the opening and closing rope load is too large and easy to break. When manually grasping the material, it needs to be adjusted from time to time. The workload is large and the effect is poor.
  • the opening and closing motor and the lifting motor adopt master-slave mode and torque control. Mode, using the open / close frequency converter as the master and the lifting frequency converter as the slave. The torque of the open / close frequency converter is sent to the lifting frequency converter by wire or wirelessly.
  • the lifting frequency converter operates at a certain percentage, keeping the lifting rope and open The closed rope is stressed at the same time and the lifting speed is consistent, so that the force is uniform and the slag is not scattered;
  • the invention realizes the real-time detection of the driving position;
  • the Gray bus A installed on the rail fence traveled by the walking motor of the cart is encoded by the address coding generator, and the antenna A receives the signal of the Gray bus A and transmits it.
  • Go to the cart address decoder to decode the cart address decoder transmits the location address to the PLC, and obtains the real-time position information X of the driving beam;
  • the cart address code generator sends the code through the antenna B, and the gray bus B receives the code, and then sends it to The car address decoder decodes it, and then transmits the location address to the PLC wirelessly to obtain the real-time location information Y of the car;
  • the present invention realizes the detection of the broken rope of the grab steel wire rope; in the grab rising and falling steps, the hoisting inverter and the opening and closing inverter both have current output, and in the grasping and unloading steps, the inverter is opened and closed There is current output.
  • PLC collects and raises the inverter, opens and closes the inverter's current output, and sends it to the computer for archival records in the computer.
  • the programmer analyzes the current value of the recorded current to obtain the normal running current value. Interval, and then write a program in the PLC.
  • FIG. 1 is a process flowchart of the present invention
  • FIG. 2 is a schematic diagram of a system structure of the present invention
  • FIG. 3 is a schematic structural diagram of a twisted rope detection device of the present invention.
  • FIG. 4 is a schematic structural diagram of an internal crane structure of a trolley according to the present invention.
  • FIG. 5 is a schematic structural diagram of a positioning system device according to the present invention.
  • the four-rope grab slag material system includes a computer 1, a PLC 2, a hoisting inverter 3, an incremental encoder A5, an opening and closing inverter 6, and an incremental encoder.
  • B8 trolley travel inverter 9, trolley travel inverter 10, trolley positioning device 11, strand detection device 12, overload limiter 13, trolley travel motor 14, trolley travel motor 15, traveling beam 16, traveling trolley 17, Grab 21;
  • the traveling cart 17 is slidably connected to the traveling frame 16; the traveling cart 17 is provided with a lifting motor 4, an opening / closing motor 7, a lifting rope 22, an opening / closing rope 23, a lifting drum 24, a limit cam 25, and an opening / closing drum 26, Reducer A27 and reducer B36; lift motor 4 is connected to reducer A27, reducer A27 is connected to lift drum 24; on-off motor 7 is connected to reducer B36, reducer B36 is connected to open-close drum 26; lifting rope 22.
  • the opening and closing rope 23 is connected to the grab bucket 21 respectively; the lifting rope 22 is wound on the lifting drum 24, and the opening and closing rope 23 is wound on the opening and closing drum 26; the limit cam 25 is fixed on the lifting drum 24; Motor 4, the incremental encoder A5 is connected to the lifting inverter 3 respectively, and the open / close motor 7, the incremental encoder B8 is connected to the open / close inverter 6, respectively;
  • the cart positioning device 11 includes a cart address coding generator 28, a gray bus A29, an antenna A30, a cart address decoder 31, a cart address decoder 32, a gray bus B33, a cart address coding generator 34, and an antenna B35; the cart The address code generator 34 and antenna B35 are fixed on the carriage 17; the antenna A30 is fixed on the carriage beam 16; the antenna A30 is connected to PLC2 through the carriage address decoder 31, and the Gray bus B33 is connected to PLC2 through the carriage address decoder 32; The cart address code generator 28 is connected to Gray bus A29;
  • the twisted rope detection device 12 includes a laser sensor 18 and a reflective plate 20; the laser sensor 18 is fixed at the bottom of the trolley 17, the laser sensor 18 is connected to the PLC2, and the reflective plate 20 is fixed on the top of the grapple 21; the installation position should ensure that the laser light can be irradiated On the reflector 20 fixed on the top side of the grapple 21; when the grapple 21 rises to a set interval, the laser sensor 18 can receive a reflection signal. If the signal is not received, it indicates that the grapple 21 has been rotated. PLC2 will suspend the operation of the vehicle, and an alarm will occur, and the operator will check the reason; infrared laser anti-collision devices are set on both sides of the driving beam 16 and connected to PLC2.
  • the opening and closing motor 7 and the lifting motor 4 adopt a master-slave mode and a torque control mode.
  • the opening and closing inverter 6 is used as the master, and the lifting inverter 3 is used as the slave.
  • the torque of the opening and closing inverter 6 is wired.
  • the communication method is sent to the hoisting inverter 3, and the hoisting inverter 3 runs at a certain percentage, keeping the hoisting rope 22 and the opening and closing rope 23 simultaneously stressed, and the hoisting speed is the same, so that the force is uniform and the slag is not scattered.
  • the gray bus A29 installed on the railing rail of the cart walking motor 14 is encoded by the address coding generator 28.
  • the antenna A30 installed at the end of the driving beam 16 receives the signal of the gray bus A29 and transmits it to the cart address decoder. 31 to decode, the car address decoder 31 transmits the location address to PLC2, and obtains the real-time position information X of the driving beam 16; the car address code generator 34 installed on the driving car 17, sends the code through the antenna B35, and transmits the code to the driving car
  • the gray bus B33 installed on the moving track beam 17 receives the code, and then transmits it to the car address decoder 32 for decoding, and then transmits the location address to PLC2 through communication to obtain the real-time position information Y of the car 17.
  • the method for grabbing slag by a four-rope grab includes the following steps:
  • each slag pool is the area just grabbed by the grab bucket 21, and the X-axis and Y-axis coordinate values of each area are calibrated. Start to grab in turn according to the set route. All the areas in the pool will grab a bucket as a cycle. After the last area of the cycle is captured, continue to the next cycle according to the set route.
  • Open / close motor 7 and lift motor 4 use master-slave mode and torque control mode, with open / close frequency converter 6 as the master, lift frequency converter 3 as the slave, and the torque of open / close frequency converter 6 is sent to the lift through communication.
  • Inverter 3 lifting Inverter 3 runs at a certain percentage, keeping the lifting rope 22 and the opening and closing rope 23 at the same time, and the lifting speed is the same; the overload limiter 13 is used to detect the net weight of the grapple 21 when it is in the air. When 21 drops but does not touch the slag surface, the detection weight does not change.
  • the weight of the grapple 21 detected by the overload limiter 13 will gradually become zero, and it can be known that the grapple 21 has contacted.
  • the surface of the slag is now calculated by calculating the distance from the bottom of the pond through the height of the grapple 21 recorded by the incremental encoder A5. At this time, you can determine how much slag is left in this area and whether you need to go to this area for slag catching in the next cycle; In the computer 1, if the weight of the detected grapple 21 is set to zero, the maximum amount of slag can be captured.
  • the weight of the grapple 21 is set to a certain percentage of 0-100% of the net weight, Grab, the amount of slag to be grabbed will Less.
  • the amount of slag that each grab 21 can be controlled to prevent overload; the grab 21 is lowered, and when the grab 21 is lowered to contact the slag surface, it starts to grab the material; if the grab 21 is lowered to a set low position , The overload limiter 13 still detects the weight, indicating that there will be no slag in this area after grabbing the bucket, mark the empty position, the next cycle will skip the area; grab 21 drops to the set low and low However, the overload limiter 13 still detected a weight, indicating that there was very little slag in the area, which was not enough for half a bucket to trigger the function of sand.

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  • Mechanical Engineering (AREA)
  • Automation & Control Theory (AREA)
  • Control And Safety Of Cranes (AREA)

Abstract

一种四绳抓斗抓取渣料的系统及其控制方法，抓取系统包括计算机（1）、PLC（2）、提升变频器（3）、增量编码器A（5）、开闭变频器（6）、增量编码器B（8）、大车小车定位装置（11）、绞绳检测装置（12）、超载限制器（13）、大车行走电机（14）、小车行走电机（15）、行车大梁（16）、行车小车（17）及抓斗（21），行车小车（17）与行车大梁（16）滑动连接，PLC（2）与计算机（1）间可采用有线或无线的通讯方式实现数据交换。与现有人工操作相比，本发明可在大雾、水蒸汽影响视线等情况下，仍能安全作业，减少安全隐患，避免人员在含硫水蒸汽下作业，减少健康危害。

Description

一种四绳抓斗抓取渣料的系统及方法 技术领域
本发明涉及自动化控制领域，具体是一种四绳抓斗抓取渣料的系统及方法。
背景技术
目前四绳抓斗行车由人工控制，机械部分有大小车行走减速机、提升转筒及减速机、开闭转筒及减速机，电气控制部分由接触器、定子电阻、行走电机、起重电机、超载限制器，限位凸轮及门限位构成。高炉渣池水蒸汽较大，在冬季严重影响视线，人员在恶劣环境下高强度工作，也容易发生安全事故。
随着经济和科技的发展，在工业生产中自动化设备的运用越来越广泛，如何完成一些需要定位的自动化项目，需要检测装备将位置信息测量出来传给系统。
发明内容
本发明所要解决的技术问题在于克服现有技术缺陷，提供一种能自动化抓取渣料的系统。
为了解决上述技术问题，本发明提供的四绳抓斗抓取渣料的系统，包括计算机、PLC、提升变频器、增量编码器A、开闭变频器、增量编码器B、大车小车定位装置、超载限制器、大车行走电机、小车行走电机、行车大梁、行车小车及抓斗；行车小车与行车大梁滑动连接；行车小车上设有提升电机、开闭电机、提升绳、开闭绳、提升转筒、限位凸轮、开闭转筒、减速机A及减速机B；提升电机与减速机A连接，减速机A与提升转筒连接；开闭电机与减速机B连接，减速机B与开闭转筒连接；提升绳、开闭绳分别与抓斗连接；提升绳缠绕在提升转筒上，开闭绳缠绕在开闭转筒上；限位凸轮固定在提升转筒上；
计算机、提升变频器、开闭变频器、大车小车定位装置、超载限制器、大车行走电机及小车行走电机分别与PLC连接；PLC与计算机间可采用有线或无线的通讯方式实现数据交换；提升电机、增量编码器A分别与提升变频器连接，开闭电机、增量编码器B分别与开闭变频器连接。
在实践过程中，若提升绳受力，开闭绳不受力，则抓斗内渣料会从底部撒落；若开闭绳受力，提升绳不受力，则开闭绳负载过大易断裂，在人工抓料时需要时时进行调节，工作量大、效果差；在自动控制中，开闭电机和提升电机采用主从方式和力矩控制模式，将开闭变频器做为主机，提升变频器做为从机，开闭变频器的力矩通过通讯发送给提升变频器，提升变频器以一定的百分比运行，保持提升绳和开闭绳同时受力，提升速度一致，从而达到 受力均匀且不撒落渣料。
在抓斗上升、下降步骤中，提升变频器、开闭变频器均有电流输出，在抓料、放料步骤中，开闭变频器有电流输出，PLC通过采集提升变频器、开闭变频器电流输出，并在计算机中做归档记录，程序员通过对记录电流的电流值规律进行分析，得出正常运行的电流值区间，在PCL中编写程序，若在这些步骤中实际电流值偏出正常运行的电流值区间，即可判断提升绳、开闭绳的钢丝绳状态不正常，在程序中将会暂停作业运行，并发生报警，操作工查看原因。
超载限制器能检测抓斗在空中时的净重量，当抓斗下降到接触水渣表面的过程中，超载限制器检测的抓斗重量会逐渐变为零；在程序中，若设置检测的抓斗重量变为零时抓取，则能抓取最大的渣量，若设置检测的抓斗重量变为净重量一半时抓取，则抓取的渣量会减少。通过此种原理，可控制抓取渣量；不论渣池内是否有水，通过增量编码器A计算的抓斗实际高度与超载限制器检测的抓斗重量相结合，能计算出抓斗内抓取的渣量，抓取渣料不超过荷载量的一半，会将该抓斗里的渣子放在下一个目标位，然后一起抓取，模仿了人工的并沙功能。
作为改进，所述大车小车定位装置包括大车地址编码发生器、格雷母线A、天线A、大车地址解码器、小车地址解码器、格雷母线B、小车地址编码发生器及天线B；小车地址编码发生器、天线B固定在行车小车上；天线A固定在行车大梁上；天线A通过大车地址解码器与PLC连接，格雷母线B通过小车地址解码器与PLC连接；大车地址编码发生器与格雷母线A连接。
格雷母线A通过大车地址编码发生器进行编码，在行车大梁的端头的天线A接收格雷母线A的信号，传送到大车地址解码器进行解码，大车地址解码器将位置地址传给PLC，得到行车大梁的实时位置信息X；小车地址编码发生器通过天线B发送编码，在行车小车移动的轨道梁安装格雷母线B，接收编码，再传送到小车地址解码器进行解码，然后将位置地址通过通讯传给PLC，得到行车小车的实时位置信息Y；通过大车小车定位装置，通过PLC程序设置该行车与轨道终端的安全距离，在该行车和同一轨道的另外一台行车之间也通过程序设置安全距离，增加安全防范措施。
作为改进，该系统还包括大车行走变频器、小车行走变频器；大车行走变频器增设在大车行走电机与PLC之间，小车行车变频器增设在小车行走电机与PLC之间；大车走电机和小车行走电机启动或停止的过程中，抓斗由于有惯性，相对于行车大梁或行车小车有一个钟摆效应，会产生摇摆；为达到消除摇摆，根据物理原理，大车行走变频器、小车行走变频 器均集成控制模型，调整输出频率，调节大车走电机、小车行走电机的启动和停止速度来进行防止抓斗摇摆。
作为改进，该系统还包括与PCL连接的绞绳检测装置；绞绳检测装置包括激光传感器、反光板；激光传感器固定在行车小车底部，反光板固定在抓斗顶部；安装激光传感器的安装的位置要保证激光能够照射在固定在抓斗顶部一侧的反光板上，当抓斗上升到设定的区间，激光传感器就能接受到反射信号，若接受不到信号，则表明抓斗已经旋转，PLC将会暂停行车的运行，并发生报警，操作工查看原因。
作为改进，在行车的大梁两侧分别安装一个红外防撞装置，外侧的作为该行车与轨道终端防撞的第二重保护，内侧的作为该行车和同一轨道的另外一台行车之间防撞的第二重保护；红外防撞装置与PLC连接。
本发明还提供一种基于以上系统的方法，包括以下步骤：
1)将每个渣池进行分解成多个区域，每个区域为抓斗刚好抓取的面积，并标定每个区域的X轴、Y轴坐标值，行车开始自动作业后，在渣池内按设定路线开始依次抓取，池内所有区域都抓取一斗为一个循环，该循环最后一个区域抓取完毕后重新按设定路线继续下一循环；
2)当准备抓取目标区域时，将该X、Y轴的目标地址与行车大梁、行车小车的实际地址进行比较，从而得出大车行走电机、行车小车行走电机是正向运行还是反向运行；根据目标地址与实际地址的差值大小，PLC输出给变频器不同的频率，控制行车的运行速度；
3)抓斗从高位开始下降到池内抓料，抓料后再上升到高位，属于一个升降周期；在这个过程中，通过增量编码器A的脉冲值计算抓斗的实际高度，传送给大车行走变频器、小车行走变频器，大车行走变频器、小车行走变频器调整输出频率，消除抓斗摆动幅度；在每个周期内，限位凸轮会被触发一次，对抓斗高度进行校验，矫正消除增量编码器A的累计误差；
4)开闭电机和提升电机采用主从方式和力矩控制模式，将开闭变频器做为主机，提升变频器做为从机，开闭变频器的力矩通过通讯发送给提升变频器，提升变频器以一定的百分比运行，保持提升绳和开闭绳同时受力，提升速度一致；抓斗下降，当抓斗下降到接触渣面后，开始抓料；若抓斗下降到设定低位，超载限制器仍然检测到有重量，表明该区域抓完这一斗后，将没有渣子了，做空位标记，下一循环，将跳过该区域；抓斗下降到设定的低低位，超载限制器仍然检测到有重量，表明该区域的渣子很少，不够半斗，触发并沙功能。
有益效果：本发明是一种四绳抓斗抓取渣料的系统及方法，渣料的形式是细沙。高炉的水渣、干煤棚的煤粉均属于细沙类型，都可以应用此系统及方法实现自动作业。
(1)本发明解决了抓斗的防摇摆问题：大车行走电机、小车行走电机启动或停止的 过程中，抓斗由于有惯性，相对于行车大梁或行车小车有一个钟摆效应，会产生摇摆；为达到消除摇摆，根据物理原理，大车行走变频器、小车行走变频器均集成控制模型，调整输出频率，调节大车走电机、小车行走电机的启动和停止速度来进行防摇摆；
(2)本发明解决了提升绳和开闭绳的配合问题；若提升绳受力，开闭绳不受力，则抓斗内渣料会从底部撒落；若开闭绳受力，提升绳不受力，则开闭绳负载过大易断裂，在人工抓料时需要时时进行调节，工作量大、效果差；在自动控制中，开闭电机和提升电机采用主从方式和力矩控制模式，将开闭变频器做为主机，提升变频器做为从机，开闭变频器的力矩通过有线或无线方式发送给提升变频器，提升变频器以一定的百分比运行，保持提升绳和开闭绳同时受力，提升速度一致，从而达到受力均匀且不撒落渣料；
(3)本发明实现了对行车位置的实时信息的检测；在大车行走电机行走的轨道护栏上安装的格雷母线A，通过地址编码发生器进行编码，天线A接收格雷母线A的信号，传送到大车地址解码器进行解码，大车地址解码器将位置地址传给PLC，得到行车大梁的实时位置信息X；小车地址编码发生器通过天线B发送编码，格雷母线B接收编码，再传送到小车地址解码器进行解码，然后将位置地址通过无线传给PLC，得到行车小车的实时位置信息Y；
(4)本发明实现了对抓斗钢丝绳断绳检测；在抓斗上升、下降步骤中，提升变频器、开闭变频器均有电流输出，在抓料、放料步骤中，开闭变频器有电流输出，PLC通过采集提升变频器、开闭变频器电流输出，并传送给计算机，在计算机中做归档记录，程序员通过对记录电流的电流值规律进行分析，得出正常运行的电流值区间，再在PLC中编写程序，若在这些步骤中实际电流值偏出正常运行的电流值区间，即可判断提升绳、开闭绳的钢丝绳状态不正常，PLC程序将会自动暂停作业运行，并发生报警，操作工查看原因。
附图说明
图1为本发明的工艺流程图；
图2为本发明的系统结构示意图；
图3为本发明的绞绳检测装置的结构示意图；
图4为本发明行车小车内部起重机构的结构示意图；
图5为本发明的定位系统装置的结构示意图；
图中：1、计算机，2、PLC，3、提升变频器，4、提升电机，5、增量编码器A，6、开闭变频器，7、开闭电机，8、增量编码器B，9、大车行走变频器，10、小车行走变频器，11、大车小车定位装置，12、绞绳检测装置，13、超载限制器，14、大车行走电机，15、小车行走电机，16、行车大梁，17、行车小车，18、激光传感器，19、激光光线示意，20、反光板， 21、抓斗，22、提升绳，23、开闭绳，24、提升转筒，25、限位凸轮，26、开闭转筒，27、减速机A，28、大车地址编码发生器，29、格雷母线A，30、天线A，31、大车地址解码器，32、小车地址解码器，33、格雷母线B，34、小车地址编码发生器，35、天线B，36、减速机B。
具体实施方式
如附图2-5所示，本发明提供的四绳抓斗抓取渣料系统，包括计算机1、PLC2、提升变频器3、增量编码器A5、开闭变频器6、增量编码器B8、大车行走变频器9、小车行走变频器10、大车小车定位装置11、绞绳检测装置12、超载限制器13、大车行走电机14、小车行走电机15、行车大梁16、行车小车17、抓斗21；
行车小车17与行车大梁16滑动连接；行车小车17上设有提升电机4、开闭电机7、提升绳22、开闭绳23、提升转筒24、限位凸轮25、开闭转筒26、减速机A27及减速机B36；提升电机4与减速机A27连接，减速机A27与提升转筒24连接；开闭电机7与减速机B36连接，减速机B36与开闭转筒26连接；提升绳22、开闭绳23分别与抓斗21连接；提升绳22缠绕在提升转筒24上，开闭绳23缠绕在开闭转筒26上；限位凸轮25固定在提升转筒24上；提升电机4、增量编码器A5分别与提升变频器3连接，开闭电机7、增量编码器B8分别与开闭变频器6连接；
计算机1、提升变频器3、开闭变频器6、绞绳检测装置12、超载限制器13、大车行走变频器9及小车行车变频器10分别与PLC2连接；大车行走电机14与大车行走变频器9连接，小车行走电机15与小车行车变频器10连接；大车行走变频器9、小车行走变频器10均集成控制模型，通过调整输出频率，调节大车走电机14、小车行走电机15的启动和停止速度来进行防摇摆；
大车小车定位装置11包括大车地址编码发生器28、格雷母线A29、天线A30、大车地址解码器31、小车地址解码器32、格雷母线B33、小车地址编码发生器34及天线B35；小车地址编码发生器34、天线B35固定在行车小车17上；天线A30固定在行车大梁上16；天线A30通过大车地址解码器31与PLC2连接，格雷母线B33通过小车地址解码器32与PLC2连接；大车地址编码发生器28与格雷母线A29连接；
绞绳检测装置12包括激光传感器18、反光板20；激光传感器18固定在行车小车17底部，激光传感器18与PLC2连接，反光板20固定在抓斗21顶部；安装的位置要保证激光光线能够照射在固定在抓斗21顶部一侧的反光板20上；当抓斗21上升到设定的区间，激光传感器18就能接受到反射信号，若接受不到信号，则表明抓斗21已经旋转，PLC2将会暂停 行车的运行，并发生报警，操作工查看原因；红外激光防撞装置设置于行车大梁16的两侧，与PLC2连接。
在自动控制中，开闭电机7和提升电机4采用主从方式和力矩控制模式，将开闭变频器6做为主机，提升变频器3做为从机，开闭变频器6的力矩通过有线通讯方式发送给提升变频器3，提升变频器3以一定的百分比运行，保持提升绳22和开闭绳23同时受力，提升速度一致，从而达到受力均匀且不撒落渣料。
在大车行走电机14行走的轨道护栏上安装的格雷母线A29通过地址编码发生器28进行编码，在行车大梁16的端头安装的天线A30接收格雷母线A29的信号，传送到大车地址解码器31进行解码，大车地址解码器31将位置地址传给PLC2，得到行车大梁16的实时位置信息X；在行车小车17上安装的小车地址编码发生器34，通过天线B35发送编码，在行车小车17移动的轨道梁安装的格雷母线B33，接收编码，再传送到小车地址解码器32进行解码，然后将位置地址通过通讯传给PLC2，得到行车小车17的实时位置信息Y。
如图1所示，本发明提供的四绳抓斗抓取渣料的方法包括以下步骤：
1)将每个渣池进行分解成多个区域，每个区域为抓斗21刚好抓取的面积，并标定每个区域的X轴、Y轴坐标值，行车开始自动作业后，在渣池内按设定路线开始依次抓取，池内所有区域都抓取一斗为一个循环，该循环最后一个区域抓取完毕后重新按设定路线继续下一循环；
2)当准备抓取目标区域时，将该X、Y轴的目标地址与行车大梁16、行车小车17的实际地址进行比较，从而得出大车行走电机14、行车小车行走电机15是正向运行还是反向运行；根据目标地址与实际地址的差值大小，PLC2输出给变频器不同的频率，控制行车的运行速度；
3)抓斗21从高位开始下降到池内抓料，抓料后再上升到高位，属于一个升降周期；在这个过程中，通过增量编码器A5的脉冲值计算抓斗21的实际高度，传送给大车行走变频器9、小车行走变频器10，大车行走变频器9、小车行走变频器10调整输出频率，消除抓斗21摆动幅度；在每个周期内，限位凸轮25会被触发一次，对抓斗21高度进行校验矫正；
4)开闭电机7和提升电机4采用主从方式和力矩控制模式，将开闭变频器6做为主机，提升变频器3做为从机，开闭变频器6的力矩通过通讯发送给提升变频器3，提升变频器3以一定的百分比运行，保持提升绳22和开闭绳23同时受力，提升速度一致；利用超载限制器13检测抓斗21在空中时的净重量，当抓斗21下降但没接触渣面时，检测重量不发生变化，抓斗21接触水渣表面的过程中，超载限制器13检测的抓斗21重量会逐渐变为零，则可以 知道抓斗21已经接触渣面了；此时通过增量编码器A5记录的抓斗21高度计算离池底距离，就能判断该区域的渣子还剩余多少、在下一循环中是否还需要到该区域进行抓渣作业；在计算机1中，若设置检测的抓斗21重量变为零时抓取，则能抓取最大的渣量，若设置检测的抓斗21重量变为净重量的0-100％某一百分比时抓取，则抓取的渣量会减少。通过此种原理，可控制每次抓斗21抓取的渣量，防止超载；抓斗21下降，当抓斗21下降到接触渣面后，开始抓料；若抓斗21下降到设定低位，超载限制13器仍然检测到有重量，表明该区域抓完这一斗后，将没有渣子了，做空位标记，下一循环，将跳过该区域；抓斗21下降到设定的低低位，超载限制器13仍然检测到有重量，表明该区域的渣子很少，不够半斗，触发并沙功能。
以上所述的仅是本发明的一些实施方式。对于本领域的普通技术人员来说，在不脱离本发明创造构思的前提下，还可以做出若干变形和改进，这些都属于本发明的保护范围。

Claims (6)

  1. 一种四绳抓斗抓取渣料系统，其特征在于：包括计算机(1)、PLC(2)、提升变频器(3)、增量编码器A(5)、开闭变频器(6)、增量编码器B(8)、大车小车定位装置(11)、超载限制器(13)、大车行走电机(14)、小车行走电机(15)、行车大梁(16)、行车小车(17)及抓斗(21)；
    所述行车小车(17)与行车大梁(16)滑动连接，行车小车(17)上设有提升电机(4)、开闭电机(7)、提升绳(22)、开闭绳(23)、提升转筒(24)、限位凸轮(25)、开闭转筒(26)、减速机A(27)及减速机B(36)；所述提升电机(4)与减速机A(27)连接，减速机A(27)与提升转筒(24)连接；所述开闭电机(7)与减速机B(36)连接，减速机B(36)与开闭转筒(26)连接；所述提升绳(22)、开闭绳(23)分别与抓斗(21)连接；所述提升绳(22)缠绕在提升转筒(24)上，开闭绳(23)缠绕在开闭转筒(26)上；所述限位凸轮(25)固定在提升转筒(24)上；
    所述计算机(1)、提升变频器(3)、开闭变频器(6)、大车小车定位装置(11)、超载限制器(13)、大车行走电机(14)及小车行走电机(15)分别与PLC(2)连接；所述提升电机(4)、增量编码器A(5)分别与提升变频器(3)连接，开闭电机(7)、增量编码器B(8)分别与开闭变频器(6)连接。
  2. 根据权利要求1所述的四绳抓斗抓取渣料系统，其特征在于：所述大车小车定位装置(11)包括大车地址编码发生器(28)、格雷母线A(29)、天线A(30)、大车地址解码器(31)、小车地址解码器(32)、格雷母线B(33)、小车地址编码发生器(34)及天线B(35)；所述小车地址编码发生器(34)、天线B(35)固定在行车小车(17)上；所述天线A(30)固定在行车大梁上(16)，天线A(30)通过大车地址解码器(31)与PLC(2)连接，格雷母线B(33)通过小车地址解码器(32)与PLC(2)连接；所述大车地址编码发生器(28)与格雷母线A(29)连接。
  3. 根据权利要求1所述的四绳抓斗抓取渣料系统，其特征在于：该系统还包括大车行走变频器(9)、小车行走变频器(10)；所述大车行走变频器(9)增设在大车行走电机(14)与PLC(2)之间，小车行车变频器(10)增设在小车行走电机(15)与PLC(2)之间。
  4. 根据权利要求1所述的四绳抓斗抓取渣料系统，其特征在于：该系统还包括与PCL(2)连接的绞绳检测装置(12)；所述绞绳检测装置(12)包括激光传感器(18)、反光板(20)，激光传感器(18)固定在行车小车(17)底部，反光板(20)固定在抓斗(21)顶部。
  5. 根据权利要求1所述的四绳抓斗抓取渣料系统，其特征在于：该系统还包括与PLC(2)连接的红外激光防撞装置，红外激光防撞装置设置于行车大梁(16)的两侧。
  6. 一种基于权利要求3-5任一所述四绳抓斗抓取渣料系统的自动控制方法，其特征在于包括以下步骤：
    1)将每个渣池进行分解成多个区域，每个区域为抓斗(21)刚好抓取的面积，并标定每个区域的X轴、Y轴坐标值，行车开始自动作业后，在渣池内按设定路线开始依次抓取，池内所有区域都抓取一斗为一个循环，该循环最后一个区域抓取完毕后重新按设定路线继续下一循环；
    2)当准备抓取目标区域时，将该X、Y轴的目标地址与行车大梁(16)、行车小车(17)的实际地址进行比较，从而得出大车行走电机(14)、行车小车行走电机(15)是正向运行还是反向运行；根据目标地址与实际地址的差值大小，PLC(2)输出给变频器不同的频率，控制行车的运行速度；
    3)抓斗(21)从高位开始下降到池内抓料，抓料后再上升到高位，属于一个升降周期；在这个过程中，通过增量编码器A(5)的脉冲值计算抓斗(21)的实际高度，传送给大车行走变频器(9)、小车行走变频器(10)，大车行走变频器(9)、小车行走变频器(10)调整输出频率，消除抓斗(21)摆动幅度；在每个升降周期内，限位凸轮(25)会被触发一次，对抓斗(21)高度进行校验矫正；
    4)开闭电机(7)和提升电机(4)采用主从方式和力矩控制模式，将开闭变频器(6)做为主机，提升变频器(3)做为从机，开闭变频器(6)的力矩通过通讯发送给提升变频器(3)，提升变频器(3)以一定的百分比运行，保持提升绳(22)和开闭绳(23)同时受力，提升速度一致；抓斗(21)下降，当抓斗(21)下降到接触渣面后，开始抓料；若抓斗(21)下降到设定低位，超载限制器(13)仍然检测到有重量，表明该区域抓完这一斗后，将没有渣子了，做空位标记，下一循环，将跳过该区域；抓斗(21)下降到设定的低低位，超载限制器(13)仍然检测到有重量，表明该区域的渣子很少，不够半斗，触发并沙功能。
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