A method for early warning and judgment of external signal failure of dry quenching hoist automatic operation

Abstract

The present application relates to a kind of dry quenching hoist automatic operation external signal fault early warning determination method, the method includes the following steps: step 1: dry quenching hoist runs in automatic state by hoist PLC 16 acquisition hoist entire process in external limit signal;Step 2: with hoist is in the hook opening limit signal 3 signal loss trigger as PLC 16 in logic limit counting once effective as counting start bit;Step 3: by PLC 16 logic, limit trigger in whole process is judged in the process of rising trigger effective or in the process of falling effective, to carry out corresponding limit in PLC 16 logic counting once effective, etc., the scheme is triggered by the number of times of the external limit switch signal equipment in the whole lifting process involved in the dry quenching hoist control system in a group of processes as judgment, and then realize the rapid troubleshooting of dry quenching hoist fault and the deterioration early warning of external signal equipment, facilitate maintenance troubleshooting, reduce operation and maintenance cost.

Description

Technical Field

[0001] This invention relates to a judgment method, specifically a method for judging external signal faults during automatic operation of a dry quenching coke elevator, belonging to the field of dry quenching coke elevator control technology. Background Technology

[0002] The dry quenching elevator control system involves as many as 16 external limit switch signal devices throughout the lifting process, such as the elevator hook open limit, hook open limit, hook acceleration / deceleration limit, standby limit one, standby limit two, lifting acceleration / deceleration limit, lifting upper limit, and lifting extreme limit. Currently, these numerous limits are generally handled by Pepperl+Fuchs SJ30 U-shaped proximity switches from Germany. The typical way the dry quenching elevator control system displays these switches directly on the top of the screen. However, due to the crowded display, operators cannot easily locate the fault when a malfunction occurs. Furthermore, the status of these external limit switch signals cannot be determined until a fault occurs, making it impossible to assess the actual deterioration of the equipment. Therefore, it is essential to address the direct assessment of external signals during automatic operation of the dry quenching elevator and to accurately monitor the deterioration of external limit switches. Summary of the Invention

[0003] This invention addresses the problems existing in the prior art by providing a method for early warning and judgment of external signal faults during the automatic operation of a dry quenching coke elevator. This technical solution involves counting external limit signals acquired in the PLC control system of the dry quenching coke elevator, and displaying and comparing the count values ​​on a screen. This provides monitoring personnel with a convenient method for fault diagnosis and control of the status of external limit signals.

[0004] To achieve the above objectives, the technical solution of the present invention is as follows: a method for judging external signal faults during automatic operation of a dry quenching coke elevator, characterized in that the method includes the following steps:

[0005] Step 1: When the dry quenching elevator is running in automatic mode, the external limit signals of the elevator throughout the entire process are collected by the elevator PLC;

[0006] Step 2: The loss of the hook open limit signal of the hoist triggers the logic limit count in the PLC to be valid once, which is the count start bit;

[0007] Step 3: Determine whether the limit switch trigger is valid during the upward or downward process through PLC logic, and then perform the corresponding limit switch logic count in the PLC to ensure that each trigger is valid.

[0008] Step 4: The PLC logic determines that the loss of the standby position limit signal, the lifting upper limit signal, the hoist cooling position positioning signal, and the hoist cooling position positioning signal triggers the corresponding limit count in the PLC logic to be valid once.

[0009] Step 5: Ensure that the number of limit switches in the PLC should move consistently throughout the entire lifting-coke unloading process;

[0010] Step 6: The PLC performs logical judgment based on the fact that the limit switch count is the same in each lifting process. When the data is inconsistent, the inconsistent limit switch names are output and displayed on the screen.

[0011] Step 7: Notify the electrical maintenance department to conduct a spot check—a comprehensive judgment of the maintenance cycle and equipment lifespan, in order to realize the function of predicting the deterioration of the limit switch.

[0012] Step 8: When a limit switch fault occurs, the PLC outputs a different limit switch value through logical operation of the limit switch counter value, thus performing a fault limit switch judgment function.

[0013] In step 1, the external limit signals include the hook opening limit signal, hook acceleration / deceleration limit signal, standby position limit signal, standby position acceleration / deceleration signal, lifting acceleration / deceleration limit signal, cooling tower lower limit signal, lifting upper limit signal, lifting upper limit signal, first lifting position positioning signal, second lifting position positioning signal, hoist lifting position acceleration / deceleration signal, hoist cooling position acceleration / deceleration signal, first hoist cooling position positioning signal, and second hoist cooling position positioning signal.

[0014] The first lifting position positioning signal and the second lifting position positioning signal are two sets of limit signals that ensure the same lifting position. The first hoist cooling position positioning signal and the second hoist cooling position positioning signal are two sets of limit signals that ensure the same cooling position.

[0015] The hoist PLC performs logical judgments by collecting the count values ​​of limit switches that should be consistent after being triggered in the same process. When limit switch deterioration occurs, abnormal actions or no actions will result in inconsistent count values, enabling the output of an early warning judgment of limit switch deterioration. When the equipment stops, it can also use inconsistent limit switch count values ​​during the operation process to diagnose PLC logic faults and then output fault limit switches.

[0016] This process demonstrates that the number of actions of each limit switch should be the same in the same direction and process. Based on this method, the PLC16 of the hoist counts each limit switch signal to achieve a method for limit switch fault warning and judgment under automatic operation. By adopting the external signal fault warning and judgment method of this invention for the automatic operation of the dry quenching hoist, the number of times the external limit switch signal devices involved in the entire hoisting process in the dry quenching hoist control system are triggered in a set of processes is counted as the judgment point. A set of arranged limit signal counting screens is used for display. When a fault occurs, the problem can be directly identified through different values. When the dry quenching hoist is running automatically, the comparison of the counts determines a certain abnormally triggered limit switch and provides an alert, providing a method for understanding the status of external signals. Because non-contact proximity switch limit sensors used in dry quenching generally employ inductive sensors, their detection coils, oscillation circuits, and amplification circuits may sometimes engage and output multiple times during a single triggering process when the equipment deteriorates. Therefore, the millisecond-level scanning method of the PLC can be used to count the limit triggers. By comparing the number of limit triggers in more than a dozen sets throughout the entire process, it can be determined that the equipment with multiple triggers may be deteriorating.

[0017] Compared with the prior art, the present invention has the following advantages: 1) This method provides a new approach for peripheral equipment, especially signal devices such as limit switches whose status cannot be directly controlled. It enables the control of equipment status through a more intuitive numerical method. This method can be applied to machine tool motion devices, lifting equipment, etc. in similar processes, adding another method to control equipment status; 2) This method makes the fault judgment of dry quenching more intuitive. During a shutdown process in a process, it is possible to find out whether it is a limit switch fault or which set of limit switches is faulty directly through automatic comparison. The fault judgment tends to be simple and intuitive. Even novices who are not familiar with the operation process can know the cause of a fault by seeing different values ​​or output alarms. Attached Figure Description

[0018] Figure 1 : Diagram of the lifting limit components of the control system for the dry quenching coke elevator;

[0019] Figure 2 Flowchart of the counting-based state control judgment method;

[0020] Figure 3 HMI screen limit display diagram.

[0021] Wherein: 1- Hoist coke tank; 2- Cooling tower; 3- Hook open limit signal; 4- Hook open acceleration / deceleration limit signal; 5- Standby position limit signal; 6- Standby position acceleration / deceleration limit signal; 7- Hoisting acceleration / deceleration limit signal; 8- Cooling tower lower limit signal; 9- Hoisting upper limit signal; 10- First hoisting position positioning signal; 11- Second hoisting position positioning signal; 12- Hoisting position traveling acceleration / deceleration limit signal; 13- Cooling tower position traveling acceleration / deceleration limit signal; 14- First hoisting cooling position positioning signal; 15- Second hoisting cooling position positioning signal; 16- Hoisting PLC; 17- Hoisting upper limit signal. Detailed Implementation

[0022] To enhance understanding of the present invention, the embodiments will be described in detail below with reference to the accompanying drawings.

[0023] Example 1: See Figure 1 A method for judging external signal faults during automatic operation of a dry quenching coke elevator, the method comprising the following steps:

[0024] Step 1: When the dry quenching elevator is running in automatic mode, the external limit signals of the elevator throughout the entire process are collected by the elevator PLC16;

[0025] Step 2: The count starts when the limit switch signal 3 is lost and triggered in the hoist, which is the logic limit counter in PLC16.

[0026] Step 3: Determine whether the limit switch trigger in the overall process is valid during the upward or downward process through the PLC16 logic, and then perform the corresponding limit switch logic count in the PLC16 to count once valid.

[0027] Step 4: The loss of the standby position limit signal 5, the upper limit signal 9, the elevator cooling position positioning signal 14, and the elevator cooling position positioning signal 15 is determined by the PLC16 logic. The corresponding limit count in the PLC logic is valid once.

[0028] Step 5: Ensure that the limit switches in PLC16 operate consistently throughout the entire lifting-coking process;

[0029] Step 6: The PLC16 performs logical judgment based on the fact that the limit switch count is the same in each lifting process. When the data is inconsistent, the inconsistent limit switch names are output and displayed on the screen.

[0030] Step 7: Notify the electrical maintenance department to conduct a spot check—a comprehensive judgment of the maintenance cycle and equipment lifespan, in order to realize the function of predicting the deterioration of the limit switch.

[0031] Step 8: When a limit switch fault occurs, the PLC outputs a different limit switch value through logical operation of the limit switch counter value, thus performing a fault limit switch judgment function.

[0032] In step 1, the external limit signals include hook opening limit signal 3, hook acceleration / deceleration limit signal 4, standby position limit signal 5, standby position acceleration / deceleration signal 6, lifting acceleration / deceleration limit signal 7, cooling tower lower limit signal 8, lifting upper limit signal 9, lifting upper limit signal 17, first lifting position positioning signal 10, second lifting position positioning signal 11, hoist lifting position acceleration / deceleration signal 12, hoist cooling position acceleration / deceleration signal 13, hoist cooling position positioning signal 14, and hoist cooling position positioning signal 15.

[0033] The first lifting position positioning signal 10 and the second lifting position positioning signal 11 are two sets of limit signals to ensure the same lifting position. The first hoist cooling position positioning signal 14 and the second hoist cooling position positioning signal 15 are two sets of limit signals to ensure the same cooling position.

[0034] The hoist PLC16 performs logical judgment by collecting the count values ​​of limit switches that should be consistent after being triggered in the same process. When limit switch deterioration occurs, abnormal actions or no actions will result in inconsistent count values, enabling the output of an early warning judgment of limit switch deterioration. When the equipment stops, it can also use inconsistent limit switch count values ​​during the operation process to judge the PLC logic fault and then output a fault limit switch.

[0035] This process demonstrates that the number of times each limit switch operates in the same direction and within the same flow should be the same. Based on this method, the hoist PLC16 counts each limit switch signal to achieve a method for early warning and judgment of limit switch faults under automatic conditions.

[0036] This improvement addresses the issue of unpredictable limit switch action counts during manual lifting. The system counts actions during automatic operation, and immediately stops and maintains the count when switching to manual operation, allowing time for troubleshooting. To ensure consistent counts for each limit switch group within the same process during automatic operation, different limit switches are grouped. For example, when the hook open limit switch 3 is engaged during the lifting action, the proximity switch triggers and de-energizes; that is, it increments the counter when the hook open signal is de-energized during the lifting process. Similarly, when the coke tank 1 descends to the hook open position, the hook open limit switch 3 is activated from zero; during the descent, the counter increments by 1 as the hook open position is activated again. Likewise, each limit switch group is divided into lifting and lowering actions, and the limit switch count is incremented by 1 in the PLC logic counter. The increase in the number of limit switch actions during the forward and backward movement of the lifting mechanism is counted in the same way as during the up and down movement, thus ensuring that all limit switch count values ​​are consistent throughout the entire process. This allows the invention to diagnose faults and assess limit switch degradation by analyzing inconsistencies in count values. The PLC6 logic then identifies limit switches with different count values ​​and displays the results via color changes on the screen. The specific implementation logic is as follows. Figure 2 As shown.

[0037] By collecting data internally from the PLC16 of the hoist and counting the number of limit switches for each group, consistency in the number of limit switch actions within the same process is achieved. This is then implemented via screen-based limit switching, allowing the operator to monitor and diagnose faults. See below. Figure 3 As shown, a new set of count displays has been added to the HMI screen, showing the count values ​​from hook opening limit 3 to cooling tower positioning limit 15. These displays are arranged in a consistent manner from top to bottom, making it easier to identify the count values ​​at each different limit and quickly detect discrepancies. A reset button has also been added, allowing for resetting the count after handling a fault or identifying and fixing equipment degradation, facilitating subsequent monitoring and troubleshooting.

[0038] Specific implementation method: Refer to Figure 1 — Figure 3 This example implements the technical method based on the dry quenching elevator system of Meigang coke oven. Combined with... Figure 1 , Figure 2Flow control diagram. The CPU of the PLC 1756-L73 series on the hoist body counts the acquired hoisting limit switches. The hoist's ascent and descent, and the hoisting trolley's forward and backward movement are used as judgment conditions. Counting is performed for each limit switch trigger (including two sets of processes: limit switch energization-de-energization and de-energization), ensuring that all limit switches on the upper part of the hoist structure have the same count value in the same process. This serves as the basis for subsequent logical fault diagnosis. The program is programmed internally within the CPU. Figure 3 The dry quenching screen is designed so that a row of count values ​​are compared together. When there are abnormally inconsistent count values, the limit text and graphic frame are highlighted in red to remind the maintenance operator to make a quick judgment and grasp the equipment deterioration. A one-click reset button is also set to ensure that the count is reset after each fault is handled or after each value is different. The reset condition is set to reset when the hook is lifted to the open position at the beginning of the same process and the power is lost, so as to ensure that all count values ​​are consistent.

[0039] It should be noted that the above embodiments are not intended to limit the scope of protection of the present invention. Equivalent transformations or substitutions made based on the above technical solutions all fall within the scope of protection of the claims of the present invention.

Claims

1. A method for judging external signal faults during automatic operation of a dry quenching coke elevator, characterized in that, The method includes the following steps: Step 1: When the dry quenching coke elevator is running in automatic mode, the elevator PLC (16) collects the external limit signals of the elevator throughout the entire process. The external limit signals include hook opening limit signal (3), hook acceleration and deceleration limit signal (4), standby position limit signal (5), standby position acceleration and deceleration signal (6), lifting acceleration and deceleration limit signal (7), cooling tower lower limit signal (8), lifting upper limit signal (9), lifting upper limit signal (17), first lifting position positioning signal (10), second lifting position positioning signal (11), elevator lifting position acceleration and deceleration signal (12), elevator cooling position acceleration and deceleration signal (13), first elevator cooling position positioning signal (14), and second elevator cooling position positioning signal (15). Step 2: The count starts when the hoist is in the hook open limit position and the signal (3) is lost, triggering the logic limit count in PLC (16) once. Step 3: Use the PLC (16) logic to determine whether the limit switch trigger is effective during the upward or downward process. Perform a corresponding limit switch logic count in the PLC (16) to confirm that each trigger is effective. Step 4: The PLC (16) logic determines that the loss of the standby position limit signal (5), the lifting upper limit signal (9), the first hoist cooling position positioning signal (14), and the second hoist cooling position positioning signal (15) triggers the corresponding limit count in the PLC logic to be valid once. Step 5: Ensure that all limit switches in the PLC (16) operate the same number of times throughout the entire process of lifting and releasing the coke. Step 6: The PLC (16) performs logical judgment based on the fact that the limit count is the same in each lifting process. When the data is inconsistent, the inconsistent limit name is output and displayed on the screen. Step 7: Notify the electrical maintenance department to conduct a comprehensive assessment of the inspection and maintenance cycle and equipment lifespan, so as to realize the function of predicting the deterioration of the limit switch. Step 8: When a limit switch fault occurs, the PLC outputs a different limit switch value through logical operation of the limit switch counter value, thus performing a fault limit switch judgment function.

2. The method for judging external signal faults during automatic operation of a dry quenching coke elevator according to claim 1, characterized in that: The hoist PLC (16) performs logical judgment by collecting the count values ​​of the limit switches in the same process after they should be triggered. When the limit switches deteriorate, the count values ​​of abnormal actions or no actions will be inconsistent. The PLC performs the function of predicting the deterioration of the limit switches in advance. When the equipment stops, it performs fault judgment of the PLC logic by the inconsistency of the limit switch count values ​​during the action process, and then outputs the fault limit switch.

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