Starting and stopping method for mine production line equipment

Abstract

The invention discloses a starting and stopping method for mine production line equipment. The starting and stopping method comprises the following steps: performing interlocking control and protection on electrical equipment from coarse crushing to finished product stacking and bulk packaging according to a reverse-sequence starting and sequential stopping principle; the material level is monitored through a material level sensor installed on the ore storage bin; fault shutdown and interlocking protection are implemented, and real-time state monitoring is carried out on each device; an in-situ starting cabinet or an in-situ control box is arranged beside each device, and a remote / in-situ control change-over switch is arranged; the operation condition of the equipment is monitored through a special liquid crystal display or an HMI (Human Machine Interface) of a PLC control level; the centralized control platform displays pictures, performs online monitoring on equipment data, monitors the temperature, the load and the rotating speed of the equipment, and triggers an alarm for the equipment of which the monitoring data exceed a normal range. The invention aims to realize automatic start-stop control of mine production line equipment so as to improve the efficiency, safety and reliability of mine production.

Description

Technical Field

[0001] The invention belongs to the technical field of automatic control of mining production equipment and relates to a start-stop method for mining production line equipment. Background Art

[0002] The mining production line is a complex system involving various types of equipment, such as crushers, conveyors, feeders, etc. The coordinated operation of these equipment is crucial for efficient production in mines. The start and stop control of equipment directly affects production efficiency, equipment life, energy consumption, production safety and other aspects.

[0003] However, there are many problems in the start-up and shutdown process of traditional mining production line equipment. First, the lack of an effective interlocking control mechanism leads to confusion in the start-up and shutdown sequence of equipment, which easily causes material blockage, equipment overload and other faults. Secondly, the control of material level is not precise enough, and material accumulation or empty warehouse often occurs, affecting the continuity and efficiency of production. Furthermore, the fault monitoring and processing capabilities are insufficient, and the equipment cannot be shut down in time when an abnormality occurs, which is easy to cause more serious damage, and the chain shutdown strategy after the fault occurs is not perfect, which may lead to the paralysis of the entire production line. In addition, the combination of local control and remote control is not flexible enough, and the operation is not convenient enough, which affects the efficiency of equipment debugging and fault handling. In terms of centralized control, the information display is not comprehensive and timely enough, and it is impossible to provide operators with accurate decision-making basis, making it difficult to achieve refined management of the production line.

[0004] The current methods mainly include adopting complex control systems, increasing the number of sensors to improve detection accuracy, and introducing intelligent algorithms for optimization. These methods have solved some problems to a certain extent, but they also have some disadvantages. Complex control systems increase maintenance difficulty and cost; too many sensors may lead to data redundancy and processing difficulties; the application of intelligent algorithms may be limited by actual working conditions and the effect may be unstable.

[0005] After comprehensive analysis of these solutions, the present invention uses interlocking control principles, precise material level control logic, comprehensive fault monitoring and processing strategies, flexible control methods, and a powerful centralized control platform to comprehensively solve various problems in the start-up and shutdown process of mine production line equipment, improve production efficiency, ensure equipment safety, reduce energy consumption, and realize intelligent and optimized management of mine production. Summary of the invention

[0006] The present invention provides a start-stop method for mining production line equipment, which realizes the automatic start-stop control of mining production line equipment, ensures the reverse start-up and sequential stop of the equipment, and achieves the effect of no material accumulation and no full warehouse. At the same time, it has a complete fault handling mechanism and flexible control authority management, and provides a comprehensive production process monitoring function to improve the efficiency, safety and reliability of mining production.

[0007] In order to solve the above problems, the technical solution adopted by the invention is:

[0008] A start-stop method for mining production line equipment comprises the following steps:

[0009] S01 interlocking control, based on the reverse start-up and sequential stop principle, interlocking control and protection of electrical equipment from coarse crushing to finished product stacking and bulk loading;

[0010] The equipment set is E = {E1, E2, E3, ..., E n}, where n is the total number of devices and the startup order is E n , E N-1 ,…,E1, the parking order is E1, E2, E3,…,E n ;

[0011] The above start and stop sequence is realized by hardware loop interlocking and interlocking through configuration programming of PLC control system;

[0012] For device E i The startup time delay is calculated by the following formula: T starti =i×T delaystart , where i represents the sequential position of the equipment in the reverse flow direction, T delaystart The unit start delay time;

[0013] For device E i The parking time delay is calculated by the following formula: T stop =i×T delaystop , where i represents the sequential position of the equipment in the direction of the material flow, T delaystop is the unit parking delay time;

[0014] S02 does not accumulate material and does not fill the warehouse. The material level is monitored by the material level sensor installed in the ore warehouse. The material level height detected by the material level sensor is H, and the preset maximum material level height is H max and the minimum material level height is H min ;

[0015] When H>H max When the feed rate is less than 100%, the no-feed control logic is activated to reduce the feed rate of the feeding equipment. The feed rate can be adjusted according to the formula Q adjust= k1×(h - h max ) is calculated, where k1 is the feed rate adjustment coefficient and can be determined through experiments;

[0016] When H < H min , the under-full bin control logic is activated to increase the feed rate of the feeding equipment. The adjustment amount of the feed rate can be calculated according to the formula Q adjust = k 12 ×(H mjn - H), where k2 is the feed rate adjustment coefficient and can be determined through experiments;

[0017] For the implementation of S03 fault shutdown and interlock protection, real-time status monitoring is carried out for each device E i , including but not limited to vibration frequency, amplitude, vibration direction, motor oil temperature, conveyor pressure monitoring, the rotational speed of the crusher rotor, the working current of the motor, line circuit, active power, reactive power, humidity and particle size of the ore. The set of monitored parameters is P i = {A, B, C, D, E, F, G, H, I, J, K, L};

[0018] When any parameter of device E i exceeds the normal range, that is, A > A max or A < A min , B > B max B < B min , C > C max or C < C min , D > D max or D < D min , G > G max or G < G min H > H max or I < I min , J > J or J < J min , K > K max or K < K min , L > L max or L < L min , where the range is A min , A max , B min , B max , …, L min , L max , a fault shutdown signal is triggered;

[0019] When the device fails to shut down or is emergently shut down, for cases other than the failure or emergency shutdown of the receiving equipment under the crusher, all devices E K in the incoming material direction (where k < i) are immediately shut down;

[0020] When the receiving equipment E under the crusher mIn case of failure or emergency shutdown, first stop the feeding device E above the crusher. m+1 , and allow Crusher E m+2 The machine will be shut down after the unprocessed materials are crushed. The time it takes for the crusher to process the materials can be calculated based on the crusher's processing capacity Z and the amount of remaining materials M. The formula is T process = Z / C;

[0021] S04 local control, a local start cabinet or local control box is set up next to each device, and equipped with a "remote / local" control conversion switch; when the conversion switch is set to "local", the single machine start and stop control of the equipment is realized through the local start cabinet or local control box, and this control authority has the highest priority;

[0022] The local control is mainly used for debugging and emergency shutdown of on-site faults. Press the stop button on the local control box and the equipment will stop immediately.

[0023] S05 operation station control, through the PLC control level dedicated LCD display or HMI monitoring equipment operating conditions; in full manual control mode, according to the power size sequence to open the crusher, crusher set Y = {Y1, Y2, Y3, ..., Y P}, the power set is P = {P(Y1), P(Y2), …, P(Y P )}, start the crushers in ascending order of power, which satisfies P(Y1) <P(Y2)<…<P(Y P ), after the crusher reaches a stable operating state, start the remaining equipment one by one in the reverse direction of the material flow; in the automatic control mode, start the crusher first, and after the crusher reaches a stable operating state, press the automatic start button, and the remaining equipment will automatically start one by one in the reverse direction of the material flow. The start time interval is based on T in S01 start Formula calculation;

[0024] When the system is shut down, it is carried out in the reverse order of the startup sequence, and the shutdown time interval is based on T in S01. stop Calculate using the formula and confirm that all aggregate on the equipment has been unloaded before shutting down;

[0025] There is a fault emergency stop button. When pressed, the whole system will stop immediately. The fault emergency stop button has a self-holding function and must be reset manually after being pressed;

[0026] S06 centralized control, the centralized control platform displays the following screen:

[0027] The main process flow screen of the whole plant shows the overall process flow and equipment layout of the mining production line;

[0028] Equipment operation preparation monitoring screen displays the equipment preparation status information before startup;

[0029] The equipment operation status monitoring screen displays the real-time operation status of the equipment, including the equipment's running, stopping, and standby status;

[0030] Equipment fault status monitoring screen, showing the faulty equipment and its fault information;

[0031] The process selection, setting and operation review screen can be used to select and operate the process and display the corresponding operation information;

[0032] The valve status and ore tank material level display screen displays the valve switch status and ore tank material level information. The material level information is displayed based on the detection results of the material level sensor;

[0033] Operation records, alarm records, fault records and other display screens record operation information, alarm information and fault information for subsequent analysis and tracing;

[0034] The finished product silo position screen and silo capacity display shows the position and capacity of the finished product silo. The silo capacity is obtained through the material level sensor and corresponding calculations. The silo capacity calculation formula is V = S × H, where V is the cross-sectional area of ​​the silo and H is the material level height.

[0035] Record and analyze the energy consumption of each energy-consuming equipment in the factory, record the energy consumption information of the equipment, and the energy consumption can be calculated by power integration. The formula is

[0036]

[0037] Where P(T) is the power of the device at time t, and t1 and t2 are time intervals;

[0038] Online monitoring of equipment data, including the temperature, load and speed of the equipment, will trigger an alarm for equipment whose monitoring data exceeds the normal range.

[0039] The principle of this scheme is:

[0040] Interlocking control follows the principle of reverse start-up and sequential stop, and uses hardware loop interlocking and PLC configuration programming to ensure that the equipment starts and stops in a specific order. It also calculates and reasonably sets the time delay for start and stop to ensure smooth processes and equipment safety.

[0041] The control of no material accumulation and not full silo uses the material level sensor to monitor the material level. According to the comparison between the material level height and the preset value, the feed amount is adjusted through a specific formula to maintain the material level in the silo within a reasonable range.

[0042] The implementation of fault shutdown and interlocking protection is through real-time monitoring of multiple parameters of the equipment. Once an abnormality occurs, a fault shutdown signal is triggered, and corresponding interlocking shutdown strategies are adopted according to different fault conditions to ensure the safety of the equipment and the entire production line.

[0043] On-site control provides a direct, highest priority control method for debugging and emergency situations, ensuring rapid shutdown on site. The operator station control provides manual and automatic modes. In manual mode, the crusher is started and stopped in order of power size. In automatic mode, automatic start and stop are achieved in the reverse direction of material flow. The emergency stop button is used to ensure shutdown of the entire system in an emergency.

[0044] The centralized control platform integrates comprehensive information display and monitoring functions, including process flow, equipment status, fault information, material level, energy consumption, etc., to achieve centralized management and decision support for the entire production line.

[0045] The beneficial effects of this program:

[0046] Through interlocking control, electrical equipment is controlled and protected according to the principle of reverse start-up and sequential stop. This not only ensures the orderliness of equipment startup and shutdown, avoids failures and safety hazards that may be caused by chaotic operation, but also improves the operating efficiency of the entire production line. Through the calculated start-up and shutdown time delays, the coordination between various equipment is closer, reducing material accumulation or production interruptions caused by time incoordination.

[0047] The control strategy of no material accumulation and no full silo effectively maintains a reasonable level of material level in the ore silo, which can not only avoid overflow and waste caused by too high material level, but also prevent the material level from being too low and affecting the continuity of subsequent production. By adjusting the feed amount through real-time monitoring and precise calculation, the stability of the production process is guaranteed and the utilization efficiency of resources is improved.

[0048] The implementation of fault shutdown and interlocking protection monitors multiple parameters of the equipment in real time, and can promptly detect and handle abnormal conditions of the equipment. This timely response mechanism greatly reduces the scope and severity of equipment failures, reduces maintenance costs and production losses, and at the same time, based on targeted shutdown strategies for different fault conditions, the overall safety and stability of the production line is maintained to the greatest extent.

[0049] The local control setting enables on-site personnel to respond quickly in emergency situations, ensures the timeliness and flexibility of debugging and troubleshooting, and enhances the safety of the production line.

[0050] The manual and automatic modes provided by the operating station control meet different operating requirements. It can not only realize precise manual operation, but also run efficiently according to preset rules in automatic mode. The setting of the fault emergency stop button provides a fast and effective response to sudden emergencies.

[0051] The centralized control platform integrates a wealth of information and provides operators with a comprehensive and intuitive view of the production line status. Through real-time monitoring and analysis of various data, potential problems can be discovered in a timely manner, accurate decisions can be made, the production process can be optimized, and overall production efficiency can be improved.

[0052] Furthermore, in S01, the configuration programming of the PLC control system adopts a modular programming method, encapsulating the start-up and parking control logic of different devices in independent functional modules, each module corresponds to one or a group of devices with specific functions, and the functional modules transmit information and exchange interlocking signals through interfaces.

[0053] Furthermore, in S02, the material level sensor adopts a redundant design, including an ultrasonic material level sensor and a radar material level sensor, to perform redundant detection of the ore bin material level; when the difference between the detection results of the two types of sensors exceeds a preset threshold, an alarm is triggered and the detection result of the sensor with higher accuracy is used as the basis.

[0054] Furthermore, in S03, the real-time status monitoring of the equipment adopts a distributed monitoring system, and multiple monitoring nodes are distributed at the detection positions of the equipment. The monitoring nodes communicate through a field bus to achieve real-time transmission and centralized processing of monitoring data. The field bus adopts the industrial Ethernet protocol to ensure the real-time and reliability of data transmission.

[0055] Furthermore, the local starting cabinet or local control box is equipped with a human-machine interface, through which the real-time operating parameters of the equipment can be viewed, including but not limited to current, voltage, operating time and cumulative operating time, and local parameter settings can be made for the equipment. Local parameter settings are only valid in local control mode.

[0056] Furthermore, in the automatic control mode, the start and stop sequence and time interval of the equipment can be customized according to different production tasks. The user can input different equipment sequences and time delay parameters through the dedicated software of the operation station and store them as different production task templates. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] Figure 1 is a flow chart of the present invention; DETAILED DESCRIPTION

[0058] Embodiment 1 is basically as attached Figure 1 As shown, a method for starting and stopping equipment of a mine production line comprises the following steps:

[0059] S01 interlocking control, based on the reverse start-up and sequential stop principle, interlocking control and protection of electrical equipment from coarse crushing to finished product stacking and bulk loading;

[0060] The equipment set is E = {E1, E2, E3, ..., E n}, where n is the total number of devices and the startup order is E n , E N-1 ,…,E1, the parking order is E1, E2, E3,…,E n ;

[0061] The above start and stop sequence is realized by hardware loop interlocking and interlocking through configuration programming of PLC control system;

[0062] For device E i The startup time delay is calculated by the following formula: T starti =i×T delaystart , where i represents the sequential position of the equipment in the reverse flow direction, T delaystart The unit start delay time;

[0063] For device E i The parking time delay is calculated by the following formula: T stop =i×T delaystop , where i represents the sequential position of the equipment in the direction of the material flow, T delaystop is the unit parking delay time;

[0064] S02 does not accumulate material and does not fill the warehouse. The material level is monitored by the material level sensor installed in the ore warehouse. The material level height detected by the material level sensor is H, and the preset maximum material level height is H max and the minimum material level height is H min ;

[0065] When H>H max When the feed rate is less than 100%, the no-feed control logic is activated to reduce the feed rate of the feeding equipment. The feed rate can be adjusted according to the formula Q adjust =k1×(HH max ), where k1 is the feed rate adjustment coefficient, which can be determined by experiment;

[0066] When H <H min When the storage tank is full, the control logic of the full bin is started to increase the feeding amount of the feeding equipment. The adjustment amount of the feeding amount can be adjusted according to the formula Q adjust =k 12 ×(H min -H) calculation, where k2 is the feed rate adjustment coefficient, which can be determined by experiment;

[0067] S03 Fault parking and interlocking protection implementation, for each equipment E iConduct real-time status monitoring, including but not limited to vibration frequency, amplitude, vibration direction, motor oil temperature, conveyor pressure monitoring, the rotational speed of the crusher rotor, the operating current of the motor, line circuit, active power, reactive power, humidity and particle size of the ore. The set of monitored parameters is P i ={A, B, C, D, E, F, G, H, I, J, K, L};

[0068] When any parameter of equipment E i exceeds the normal range, that is, A > A max or A < A min , B > B max B < B min , C > C max or C < C min , D > D m3x or D < D min , G > G max or G < G min H > H max or I < I min , J > J or J < J min , K > K max or K < K min , L > L max or L < L min , where the range is A min , A max , B min , B max , …, L min , L max , a fault shutdown signal is triggered;

[0069] When the equipment fails to stop or is emergently shut down, for cases other than the failure or emergency shutdown of the receiving equipment under the crusher, all equipment E in the incoming material direction K (where k < i) stops immediately;

[0070] When the receiving equipment E under the crusher m fails or is emergently shut down, first stop the feeding equipment E above the crusher m+1 , and allow the crusher E m+2 to finish crushing the unprocessed materials before shutting down. The time for the crusher to process the materials can be calculated according to the processing capacity Z of the crusher and the remaining material quantity M. The formula is T process = Z / C;

[0071] S04 local control. Set up a local start cabinet or local control box beside each piece of equipment, and be equipped with a "remote / local" control switch; when the switch is placed in "local", realize the single-machine start and stop control of the equipment through the local start cabinet or local control box. This control authority has the highest priority;

[0072] The local control is mainly used for debugging and emergency shutdown of on-site faults. Press the stop button on the local control box and the equipment will stop immediately.

[0073] S05 operation station control, through the PLC control level dedicated LCD display or HMI monitoring equipment operating conditions; in full manual control mode, according to the power size sequence to open the crusher, crusher set Y = {Y1, Y2, Y3, ..., Y P}, the power set is P = {P(Y1), P(Y2), …, P(Y P )}, start the crushers in ascending order of power, which satisfies P(Y1) <P(Y2)<…<P(Y P ), after the crusher reaches a stable operating state, start the remaining equipment one by one in the reverse direction of the material flow; in the automatic control mode, start the crusher first, and after the crusher reaches a stable operating state, press the automatic start button, and the remaining equipment will automatically start one by one in the reverse direction of the material flow. The start time is strictly in accordance with T in S01 start Formula calculation;

[0074] When the system is shut down, it is carried out in the reverse order of the startup sequence, and the shutdown time is strictly in accordance with T in S01. stop Calculate using the formula and confirm that all aggregate on the equipment has been unloaded before shutting down;

[0075] There is a fault emergency stop button. When pressed, the whole system will stop immediately. The fault emergency stop button has a self-holding function and must be reset manually after being pressed;

[0076] S06 centralized control, the centralized control platform displays the following screen:

[0077] The main process flow screen of the whole plant shows the overall process flow and equipment layout of the mining production line;

[0078] Equipment operation preparation monitoring screen displays the equipment preparation status information before startup;

[0079] The equipment operation status monitoring screen displays the real-time operation status of the equipment, including the equipment's running, stopping, and standby status;

[0080] Equipment fault status monitoring screen, showing the faulty equipment and its fault information;

[0081] The process selection, setting and operation review screen can be used to select and operate the process and display the corresponding operation information;

[0082] The valve status and ore tank material level display screen displays the valve switch status and ore tank material level information. The material level information is displayed based on the detection results of the material level sensor;

[0083] Operation records, alarm records, fault records and other display screens record operation information, alarm information and fault information for subsequent analysis and tracing;

[0084] The finished product silo position screen and silo capacity display shows the position and capacity of the finished product silo. The silo capacity is obtained through the material level sensor and corresponding calculations. The silo capacity calculation formula is V = S × H, where V is the cross-sectional area of ​​the silo and H is the material level height.

[0085] Record and analyze the energy consumption of each energy-consuming equipment in the factory, record the energy consumption information of the equipment, and the energy consumption can be calculated by power integration. The formula is

[0086]

[0087] Where P(T) is the power of the device at time t, and t1 and t2 are time intervals;

[0088] Online monitoring of equipment data, including the temperature, load and speed of the equipment, will trigger an alarm for equipment whose monitoring data exceeds the normal range.

[0089] The lock control follows the principle of reverse start-up and sequential stop, and uses hardware loop interlocking and PLC configuration programming to ensure that the equipment starts and stops in a specific order. It also calculates and reasonably sets the time delay for start and stop to ensure smooth processes and equipment safety.

[0090] The control of no material accumulation and not full silo uses the material level sensor to monitor the material level. According to the comparison between the material level height and the preset value, the feed amount is adjusted through a specific formula to maintain the material level in the silo within a reasonable range.

[0091] The implementation of fault shutdown and interlocking protection is through real-time monitoring of multiple parameters of the equipment. Once an abnormality occurs, a fault shutdown signal is triggered, and corresponding interlocking shutdown strategies are adopted according to different fault conditions to ensure the safety of the equipment and the entire production line.

[0092] On-site control provides a direct, highest priority control method for debugging and emergency situations, ensuring rapid shutdown on site. The operator station control provides manual and automatic modes. In manual mode, the crusher is started and stopped in order of power size. In automatic mode, automatic start and stop are achieved in the reverse direction of material flow. The emergency stop button is used to ensure shutdown of the entire system in an emergency.

[0093] The centralized control platform integrates comprehensive information display and monitoring functions, including process flow, equipment status, fault information, material level, energy consumption, etc., to achieve centralized management and decision support for the entire production line.

[0094] Through interlocking control, electrical equipment is controlled and protected according to the principle of reverse start-up and sequential stop. This not only ensures the orderliness of equipment startup and shutdown, avoids failures and safety hazards that may be caused by chaotic operation, but also improves the operating efficiency of the entire production line. Through the calculated start-up and shutdown time delays, the coordination between various equipment is closer, reducing material accumulation or production interruptions caused by time incoordination.

[0095] The control strategy of no material accumulation and no full silo effectively maintains a reasonable level of material level in the ore silo, which can not only avoid overflow and waste caused by too high material level, but also prevent the material level from being too low and affecting the continuity of subsequent production. By adjusting the feed amount through real-time monitoring and precise calculation, the stability of the production process is guaranteed and the utilization efficiency of resources is improved.

[0096] The implementation of fault shutdown and interlocking protection monitors multiple parameters of the equipment in real time, and can promptly detect and handle abnormal conditions of the equipment. This timely response mechanism greatly reduces the scope and severity of equipment failures, reduces maintenance costs and production losses, and at the same time, based on targeted shutdown strategies for different fault conditions, the overall safety and stability of the production line is maintained to the greatest extent.

[0097] The local control setting enables on-site personnel to respond quickly in emergency situations, ensures the timeliness and flexibility of debugging and troubleshooting, and enhances the safety of the production line.

[0098] The manual and automatic modes provided by the operating station control meet different operating requirements. It can not only realize precise manual operation, but also run efficiently according to preset rules in automatic mode. The setting of the fault emergency stop button provides a fast and effective response to sudden emergencies.

[0099] The centralized control platform integrates a wealth of information and provides operators with a comprehensive and intuitive view of the production line status. Through real-time monitoring and analysis of various data, potential problems can be discovered in a timely manner, accurate decisions can be made, the production process can be optimized, and overall production efficiency can be improved.

[0100] In S01, the configuration programming of the PLC control system adopts a modular programming method, and the start-up and parking control logics of different devices are encapsulated in independent functional modules. Each module corresponds to one or a group of devices with specific functions, and the functional modules transmit information and exchange interlocking signals through interfaces. Each functional module focuses on the control logic of a specific device, so that programmers can develop and optimize each module more centrally and deeply, reducing the complexity of the code and the possibility of errors. When a device needs to modify or upgrade the control logic, only the corresponding functional module needs to be adjusted without affecting the normal operation of other modules. For new devices, new functional modules can also be easily created and connected to the system, reducing the difficulty and cost of system upgrades and expansions.

[0101] In S02, the material level sensor adopts a redundant design, including an ultrasonic material level sensor and a radar material level sensor, to perform redundant detection of the ore bin material level; when the difference between the detection results of the two types of sensors exceeds a preset threshold, an alarm is triggered and the detection result of the sensor with higher accuracy is used as the basis. By having two sensors working on different principles work simultaneously, the risk of material level detection errors caused by a single sensor failure is reduced, the accuracy and stability of the material level information are ensured, and a reliable data basis is provided for the control of no material accumulation and full silo. Even if one of the sensors has a temporary abnormality or failure, the other sensor can continue to provide material level data, so that the system can maintain normal operation to a certain extent and reduce production interruptions caused by sensor failures.

[0102] In S03, the real-time status monitoring of the equipment adopts a distributed monitoring system, and multiple monitoring nodes are distributed at the detection positions of the equipment. The monitoring nodes communicate through a field bus to achieve real-time transmission and centralized processing of monitoring data. The field bus adopts the industrial Ethernet protocol to ensure the real-time and reliability of data transmission.

[0103] The local starting cabinet or local control box is equipped with a human-machine interface, through which the real-time operating parameters of the equipment can be viewed, including but not limited to current, voltage, operating time and cumulative operating time, and local parameter settings can be made for the equipment. Local parameter settings are only valid in the local control mode. On-site staff can directly obtain key parameters such as current, voltage, operating time and cumulative operating time through the human-machine interface on-site, without relying on a remote monitoring system or going to a central control room, so that they can grasp the working conditions of the equipment more timely and intuitively, make judgments and decisions, and allow local parameter settings in the local control mode, so that on-site personnel can make immediate adjustments to the equipment according to actual conditions. During equipment debugging, troubleshooting or special working conditions, they can quickly optimize the equipment operating parameters to meet specific needs on site and improve the adaptability and work efficiency of the equipment.

[0104] In the automatic control mode, the start and stop sequence and time interval of the equipment can be customized according to different production tasks. Users can input different equipment sequences and time delay parameters through the dedicated software of the operation station and store them as different production task templates, thereby improving the flexibility and adaptability of production. Different production tasks often have different requirements for the operation sequence and time of the equipment. Through customized configuration, various specific production needs can be accurately met, so that the production line can be quickly switched and adjusted to adapt to diverse production tasks, thereby improving production efficiency and response speed. Specific embodiment 2

[0106] 1. Implementation Preparation

[0107] Equipment and system configuration

[0108] Determine that the total number of equipment in the production line is 20 (i.e. n = 20), starting with the coarse crushing equipment numbered E1, and so on to the finished product storage shed and bulk equipment E 20 According to the function of the equipment and the material flow, the startup sequence is E 20 、E 19 , E1, the parking order is E1, E2, E 20 .

[0109] A PLC control system with sufficient input and output interfaces and computing power is selected. Its configuration programming adopts modular programming. Independent functional modules are created for each device, such as crusher module, conveyor module, feeder module, etc. Each module realizes information transmission and interlocking signal exchange through the interface to ensure coordinated control between devices. For example, after receiving the start signal, the crusher module will send a ready signal to the downstream conveyor module. After the conveyor is started and runs stably, the crusher will be officially started to ensure smooth transportation of materials.

[0110] Install ultrasonic material level sensors and radar material level sensors in the ore bin to perform redundant detection of the material level and set the maximum material level height H max The minimum material level height is 8 meters. min The feed adjustment coefficients k1=0.5 and k2=0.8 are preliminarily determined based on experience, and can be further optimized based on actual production conditions.

[0111] A distributed monitoring system is built, and monitoring nodes are installed at key locations of each equipment, such as motors, bearings, transmission devices, etc., with a total of 50 monitoring nodes. The monitoring nodes use high-precision sensors that can accurately measure the equipment's vibration frequency, amplitude, vibration direction, motor oil temperature, conveyor pressure, crusher rotor speed, motor operating current, line circuit, active power, reactive power, ore humidity, particle size and other parameters. The monitoring nodes communicate with each other through the field bus of the industrial Ethernet protocol to ensure that the data can be transmitted to the central monitoring room in real time.

[0112] A local starting cabinet or local control box is set up next to each device and equipped with a "remote / local" control conversion switch. The local starting cabinet or local control box is equipped with a human-machine interface, which can display the real-time operating parameters of the equipment, such as the current range of 0-200A, the voltage range of 380-660V, the operating time accurate to seconds and the cumulative operating time, etc., and the local parameters of the equipment can be set in the local control mode, such as adjusting the starting frequency of the motor, the operating speed of the conveyor, etc.

[0113] A dedicated LCD display and HMI are configured at the operation station to monitor the equipment operating status, and dedicated software for the operation station is installed to customize the equipment startup and shutdown sequence and time intervals in automatic control mode.

[0114] Build a centralized control platform, whose software system has the function of displaying the following screens:

[0115] The main process flow screen of the whole plant: the overall process flow of the mining production line is displayed with an intuitive graphical interface, including the whole process from ore mining to crushing, transportation, screening and finished product stacking, as well as the layout position and connection relationship of each equipment in the process.

[0116] Equipment operation preparation monitoring screen: Real-time display of key preparation status information of each device before startup, such as whether the electrical connection of the equipment is normal, whether the lubrication system is ready, whether the initial position of each component is correct, etc.

[0117] Equipment operation status monitoring screen: Displays the equipment's running, stopping, and standby status, as well as key operating parameters such as the equipment's operating speed and load rate, through dynamic icons and real-time data.

[0118] Equipment fault status monitoring screen: Once a device fails, the location and name of the faulty device will be highlighted on this screen, and the fault information will be listed in detail, such as the fault type (mechanical failure, electrical failure, etc.), the time when the fault occurred, and the abnormal values ​​of related parameters.

[0119] Process selection, setting and operation review screen: Operators can select and operate different production processes on this screen, such as switching the screening particle size of ore, adjusting the stacking method of finished products, etc., and the corresponding operation information and operation results are displayed in real time.

[0120] Valve status and ore trough material level display screen: clearly display the switch status of each valve in the production line, as well as the material level information of the ore trough. The material level data is updated in real time according to the detection results of the material level sensor, and is intuitively presented in the form of numbers and liquid level diagrams.

[0121] Operation record, alarm record, fault record and other display screens: automatically record each operation information of the operator, the alarm information and fault information of the equipment, including operation time, operation content, alarm time, alarm reason, fault time, fault location and treatment measures, etc., for subsequent analysis and tracing.

[0122] Finished product silo position and capacity: The material level of the finished product silo is detected by the material level sensor, and combined with the cross-sectional area of ​​the silo, the position and capacity of the finished product silo are calculated and displayed in real time according to the formula V=S×H, providing accurate data support for production scheduling.

[0123] Record and analyze the energy consumption of each energy-consuming equipment in the factory: monitor and record the energy consumption of each equipment in real time, and calculate the energy consumption of the equipment in different time periods through power integration. The formula is:

[0124]

[0125] The energy consumption trend and energy consumption ratio of the equipment are displayed in charts to help enterprises analyze energy utilization efficiency and formulate energy-saving measures.

[0126] Online monitoring of equipment data: Continuously monitor key data such as temperature, load, speed, etc. of the equipment. For equipment data that exceeds the normal range, an alarm is immediately triggered and the alarm information is highlighted on the corresponding monitoring screen to remind the operator to handle it in time.

[0127] 2. Implementation process

[0128] When starting the equipment, follow the reverse order principle, starting with crusher E 10 For example, its sequence position in the reverse flow direction is i=11, assuming that the unit start delay time is T delaystart = 5 seconds, then E 10 The start-up time delay T start10 =11×5=55 seconds. When the start signal is issued, the PLC control system starts the downstream related equipment, such as the conveyor, through hardware loop interlocking and interlocking as well as configuration programming. After the conveyor runs stably for 55 seconds, E 10It is started only after it is started to ensure smooth transmission of materials between equipment and avoid blockage.

[0129] When the equipment is stopped, the sequential stopping principle is followed. For feeder E5, the sequential position i=5 in the direction of the material flow, and the unit stop delay time T delaystop =3 seconds, then the stop time delay of E5 is Tstop5=5×3=15 seconds. When the stop command is issued, E5 will stop running after 15 seconds. At the same time, its upstream equipment will also delay stopping in sequence to ensure that the materials can be processed and prevent materials from accumulating in the equipment.

[0130] Control of no material accumulation and no full warehouse

[0131] During the production process, the material level sensor monitors the material level in the ore bin in real time. Assume that at a certain moment, the material level sensor detects a material level height of H = 9 meters, which is greater than the preset maximum material level height H max = 8 meters, at this time the system starts the non-accumulation control logic. According to the formula Q adjust =k1×(HH max ), calculate the adjustment amount of the feed amount. Taking k1 = 0.5 as an example, Q adjust =0.5×(9-8)=0.5 cubic meters / minute, that is, reducing the feeding amount of the feeding equipment by 0.5 cubic meters / minute to ensure that the material level gradually drops to a reasonable range.

[0132] If the material level height H = 1.5 meters, less than H min = 2 meters, the system starts the non-full warehouse control logic, according to the formula Q adjust =k 12 ×(H min -H), calculate Q adjust = = 0.8 × (2-1.5) = 0.4 cubic meters / minute, increase the feeding capacity of the feeding equipment by 0.4 cubic meters / minute to prevent the empty ore bin from affecting production continuity.

[0133] Fault parking and interlock protection

[0134] Distributed monitoring systems continuously monitor the operating parameters of the equipment. For example, crusher E 15 The motor working current suddenly exceeds the normal range (assuming the normal range is 80-120A, the detection current is 150A at this time), and the monitoring system immediately triggers a fault stop signal. At this time, except for the failure or emergency stop of the receiving equipment below the crusher, all the equipment in the incoming direction, such as the upstream conveyor E 14 , Feeder E 13 Shut down the machine immediately to prevent the fault from further expanding.

[0135] If the receiving device E16 below the crusher fails and stops, first stop the feeding device E above the crusher. 17, and allow Crusher E 15 Stop the machine after the unprocessed materials are crushed. Assuming that the processing capacity of crusher E15 is Z = 10 tons / hour and the amount of remaining materials is M = 5 tons, according to the formula T process =M / Z, the time it takes for the crusher to process the material is calculated to be T process =M / Z=5 / 10=0.5 hour=30 minutes. During these 30 minutes, the crusher continues to run until it stops automatically after the material is processed.

[0136] Local Control

[0137] During the equipment commissioning phase, set the "remote / local" control conversion switch to the "local" position. The commissioning personnel can view the real-time operating parameters of the equipment through the human-machine interface of the local starting cabinet or the local control box, such as the current of the E1 crusher is 100A, the voltage is 400V, the operating time is 10 minutes, and the cumulative operating time is 100 hours. If the equipment operating parameters are found to be abnormal, they can be directly operated on the local control box, such as adjusting the speed of the crusher or stopping the equipment. For example, when the crusher vibrates abnormally, the stop button can be pressed immediately, and the equipment will stop immediately, so that the commissioning personnel can troubleshoot and handle the fault.

[0138] During the production process, if an emergency occurs on site, such as equipment smoking or making abnormal noise, the on-site operator can quickly press the stop button on the local control box to stop the equipment immediately to ensure the safety of personnel and equipment.

[0139] Operator station control

[0140] In full manual control mode, the operator starts the crushers in order according to their power. Assuming that the power of crusher Y1 is P(Y1)=100kW, the power of Y2 is P(Y2)=120kW, and the power of Y3 is P(Y3)=80kW, the crushers are sorted from small to large as Y3, Y2, and Y1. The operator starts Y3 first, and after it reaches a stable operating state, the operator starts the remaining equipment one by one in the reverse direction of the material flow, such as conveyors, feeders, etc., and adjusts the operating parameters of the equipment according to the actual production situation.

[0141] In the automatic control mode, the operator can input different equipment sequences and time delay parameters through the dedicated software of the operation station to adapt to different production tasks. For example, for production task A, set the equipment startup sequence to E 20 、E 18 , E2, the parking order is E2, E4, E 20, the start time interval is 8 seconds, the stop time interval is 6 seconds, and this configuration is stored as a template for production task A. When production task A needs to be executed, just select the template at the operation station and press the automatic start button. The system will automatically start and stop the equipment in the preset order and time interval to achieve efficient production.

[0142] During system operation, if an emergency occurs, the operator can press the fault emergency stop button to shut down the entire system immediately. The fault emergency stop button has a self-holding function and must be manually reset after being pressed to ensure that the equipment will not be started by mistake before the fault is eliminated.

[0143] Centralized control

[0144] The centralized control platform displays the main process flow of the entire plant in real time, and the operator can clearly see the flow of ore between the various equipment, as well as the layout and connection relationship of the equipment. For example, the ore mined from the mine is transported to the coarse crushing equipment E1 by a transport vehicle, and the crushed ore is transported to the medium crushing equipment E3 by the conveyor E2.

[0145] The equipment operation preparation monitoring screen displays the preparation status information of each device before starting. For example, at a certain moment, if the lubrication system pressure of the E5 feeder is insufficient, it will be displayed on the screen with a red warning sign and specific fault information "E5 feeder lubrication system pressure is low, please check", reminding the operator to deal with it in time to ensure that the equipment can start normally.

[0146] The equipment operation status monitoring screen dynamically updates the equipment's running, stopping, standby status and key operating parameters. Operators can check the operating status of each device at any time, such as E 10 The real-time speed of the crusher is 1000 rpm, the load rate is 80%, etc., so as to timely detect abnormal operating conditions of the equipment.

[0147] The device fault status monitoring screen quickly displays the faulty device and its fault information when a fault occurs. 18 The conveyor motor temperature is too high, and E will be highlighted on the screen. 18 The location of the conveyor and the detailed fault information "E 18 The temperature of the conveyor motor is 120℃, which is beyond the normal range of 80-100℃. Please check the cooling system or motor failure." This helps maintenance personnel quickly locate the cause of the failure and improve maintenance efficiency.

[0148] The process selection, setting and operation monitoring screen allows operators to select and operate processes and displays corresponding operation information. For example, if the operator selects "high-grade ore screening process", the screen will display "high-grade ore screening process has been selected and is being executed...", and also displays the operating parameters and operation steps of each equipment under the process to ensure the accuracy and consistency of the operation.

[0149] The valve status and ore trough material level display screen displays the valve switch status and ore trough material level information in real time. For example, the material level of ore trough 1 is 6 meters, valve 1 is in the open state, valve 2 is in the closed state, etc., providing an accurate basis for material allocation in the production process.

[0150] The operation record, alarm record, fault record and other display screens fully record the operation information, alarm information and fault information. For example, within a certain period of time, if the operator adjusts the parameters of the equipment, it will be recorded as "[time] operator [name] adjusts the speed parameter of the E3 equipment from 800 rpm to 900 rpm"; at the same time, if the E7 equipment has an overcurrent alarm, it will be recorded as "[time] the E7 equipment has an overcurrent alarm, the alarm value is 130A, and the duration is 5 seconds"; if the E 12 When a device fails and stops, it is recorded as “[time]E 12 The equipment shut down due to a motor failure. The cause of the failure was a short circuit in the motor winding. Maintenance personnel [name] performed maintenance at [maintenance time]. After the motor winding was replaced, the equipment resumed normal operation." These records provide important reference for subsequent production analysis, equipment maintenance and troubleshooting.

[0151] The finished product silo position and capacity are calculated and displayed based on the detection results of the material level sensor and the cross-sectional area of ​​the silo. For example, the material level height H of the finished product silo is 4 meters, and the cross-sectional area S is 50 square meters. According to the formula V = S × H, the calculated silo capacity is 200 cubic meters. At the same time, the change trend of the silo position is displayed in the form of a chart to help production managers arrange production and delivery plans reasonably.

[0152] Record and analyze the energy consumption of each energy-consuming equipment in the plant area. The energy consumption of the equipment is calculated by power integration, and the energy consumption trend and energy consumption proportion are displayed in the form of charts. For example, in the past week, the energy consumption of crusher E1 accounted for 30% of the total energy consumption, and the energy consumption of conveyor E2 accounted for 20%. By analyzing the energy consumption data, the company can find the equipment and links with high energy consumption and take corresponding energy-saving measures, such as optimizing equipment operating parameters, improving process flow, etc., to reduce production costs.

[0153] Online monitoring of equipment data continuously monitors the temperature, load, speed and other data of the equipment, and triggers alarms for equipment that exceeds the normal range. 1∫If the bearing temperature of the crusher suddenly rises to 80℃ (normal range is 60-70℃), the centralized control platform will immediately send out an alarm signal and display the alarm message "E 15 The crusher bearing temperature is too high, the current temperature is 80℃, please check the lubrication and cooling system", reminding the operator to deal with it in time to prevent equipment damage.

[0154] The above are only embodiments of the present invention. Common knowledge such as the known specific structures and characteristics in the scheme is not described in detail here. Ordinary technicians in the relevant field are aware of all the common technical knowledge in the technical field to which the invention belongs before the application date or priority date, can obtain all the existing technologies in the field, and have the ability to apply conventional experimental means before that date. Ordinary technicians in the relevant field can improve and implement this scheme in combination with their own abilities under the enlightenment given by this application. Some typical known structures or known methods should not become obstacles for ordinary technicians in the relevant field to implement this application. It should be pointed out that for those skilled in the art, several deformations and improvements can be made without departing from the structure of the present invention, which should also be regarded as the scope of protection of the present invention, and these will not affect the effect of the implementation of the present invention and the practicality of the patent. The scope of protection required by this application shall be based on the content of its claims, and the specific implementation methods and other records in the specification can be used to interpret the content of the claims.

Claims

1. A method for starting and stopping equipment in a mine production line, characterized in that: The steps include: S01 interlocking control, based on the reverse start-up and sequential stop principle, interlocking control and protection of electrical equipment from coarse crushing to finished product stacking and bulk loading; The equipment set is E = {E1, E2, E3, ..., E n }, where n is the total number of devices and the startup order is E n , E N-1 ,…,E1, the parking order is E1, E2, E3,…,E n ; The above start and stop sequence is realized by hardware loop interlocking and interlocking through configuration programming of PLC control system; For device E i The startup time delay is calculated by the following formula: T starti =i×T delaystart , where i represents the sequential position of the equipment in the reverse flow direction, T delaystart The unit start delay time; For device E i The parking time delay is calculated by the following formula: T stop =i×T delaystop , where i represents the sequential position of the equipment in the direction of the material flow, T delaystop is the unit parking delay time; S02 does not accumulate material and does not fill the warehouse. The material level is monitored by the material level sensor installed in the ore warehouse. The material level height detected by the material level sensor is H, and the preset maximum material level height is H max and the minimum material level height is H min ; When H>H max When the feed rate is less than 100%, the no-feed control logic is activated to reduce the feed rate of the feeding equipment. The feed rate can be adjusted according to the formula Q adjust =k1×(HH max ), where k1 is the feed rate adjustment coefficient, which can be determined by experiment; When H <H min When the storage tank is full, the control logic of the full bin is started to increase the feeding amount of the feeding equipment. The adjustment amount of the feeding amount can be adjusted according to the formula Q adjust =k 12 ×(H min -H) calculation, where k2 is the feed rate adjustment coefficient, which can be determined by experiment; S03 fault parking and interlocking protection implementation control, for each equipment E i Real-time status monitoring is performed, including but not limited to vibration frequency, amplitude, vibration direction, motor oil temperature, conveyor pressure monitoring, crusher rotor speed, motor working current, line circuit, active power, reactive power, ore humidity, particle size, and the monitored parameter set is P i ={A,B,C,D,E,F,G,H,I,J,K,L}; When device E i Any parameter of exceeds the normal range, that is, A>A max or A min , B>B max B min , C>C max or C <C min , D>D m3x or D <D min , G>G max or G <G min H>H max or I min , J>J or J <J min , K>K max or K <K min , L>L max or L <L min , where the range is A min ,A max ,B min ,B max ,…,L min ,L max , triggering a fault stop signal;​​​ When the equipment fails and stops or makes an emergency stop, for situations other than the failure or emergency stop of the receiving equipment below the crusher, all equipment E in the incoming material direction K (where k < i) immediately stops; When the receiving equipment E below the crusher m In case of failure or emergency shutdown, first stop the feeding device E above the crusher. m+1 , and allow Crusher E m+2 The machine will be shut down after the unprocessed materials are crushed. The time it takes for the crusher to process the materials can be calculated based on the crusher's processing capacity Z and the amount of remaining materials M. The formula is T process = Z / C; S04 local control: a local starter cabinet or local control box is set up next to each device, and equipped with a "remote / local" control switch; when the switch is set to "local", the single-machine start and stop control of the equipment is realized through the local starter cabinet or local control box, and this control authority has the highest priority; The local control is mainly used for debugging and emergency shutdown of on-site faults. Press the stop button on the local control box and the equipment will stop immediately. S05 operation station control, through the PLC control level dedicated LCD display or HMI monitoring equipment operating conditions; in full manual control mode, according to the power size sequence to open the crusher, crusher set Y = {Y1, Y2, Y3, ..., Y P }, the power set is P = {P(Y1), P(Y2), …, P(Y P )}, start the crushers in ascending order of power, which satisfies P(Y1) <P(Y2)<…<P(Y P ), after the crusher reaches a stable operating state, start the remaining equipment one by one in the reverse direction of the material flow; in the automatic control mode, start the crusher first, and after the crusher reaches a stable operating state, press the automatic start button, and the remaining equipment will automatically start one by one in the reverse direction of the material flow. The start time interval is based on T in S01 start Formula calculation; When the system is shut down, it is carried out in the reverse order of the startup sequence, and the shutdown time interval is based on T in S01. stop Calculate using the formula and confirm that all aggregate on the equipment has been unloaded before shutting down; There is a fault emergency stop button. When pressed, the whole system will stop immediately. The fault emergency stop button has a self-holding function and must be reset manually after being pressed; S06 centralized control, the centralized control platform displays the following screen: The main process flow screen of the whole plant shows the overall process flow and equipment layout of the mining production line; Equipment operation preparation monitoring screen displays the preparation status information before the equipment starts; The equipment operation status monitoring screen displays the real-time operation status of the equipment, including the equipment's running, stopping, and standby status; Equipment fault status monitoring screen, showing the faulty equipment and its fault information; The process selection, setting and operation review screen can be used to select and operate the process and display the corresponding operation information; The valve status and ore tank material level display screen displays the valve switch status and ore tank material level information. The material level information is based on the detection results of the material level sensor; Operation record, alarm record, and fault record display screen record operation information, alarm information, and fault information for subsequent analysis and tracing; The finished product silo position screen and silo capacity display shows the position and capacity of the finished product silo. The silo capacity is obtained through the material level sensor and corresponding calculations. The silo capacity calculation formula is V = S × H, where V is the cross-sectional area of ​​the silo and H is the material level height. Record and analyze the energy consumption of each energy-consuming equipment in the factory, record the energy consumption information of the equipment, and the energy consumption can be calculated by power integration. The formula is Where P(T) is the power of the device at time t, and t1 and t2 are time intervals; Online monitoring of equipment data, including the temperature, load and speed of the equipment, will trigger an alarm for equipment whose monitoring data exceeds the normal range.

2. A method for starting and stopping mining production line equipment according to claim 1, characterized in that: In S01, the configuration programming of the PLC control system adopts a modular programming method, encapsulating the start and stop control logic of different devices in independent functional modules, each module corresponds to one or a group of devices with specific functions, and the functional modules transmit information and exchange interlocking signals through interfaces.

3. A method for starting and stopping mining production line equipment according to claim 1, characterized in that: In S02, the material level sensor adopts a redundant design, including an ultrasonic material level sensor and a radar material level sensor, to perform redundant detection of the ore bin material level; when the difference between the detection results of the two types of sensors exceeds a preset threshold, an alarm is triggered and the detection result of the sensor with higher accuracy is used as the basis.

4. A method for starting and stopping mining production line equipment according to claim 1, characterized in that: In S03, the real-time status monitoring of the equipment adopts a distributed monitoring system, and multiple monitoring nodes are distributed at the detection positions of the equipment. The monitoring nodes communicate through a field bus to achieve real-time transmission and centralized processing of monitoring data. The field bus adopts the industrial Ethernet protocol to ensure the real-time and reliability of data transmission.

5. The start-stop method for mining production line equipment according to claim 1, characterized in that: In S04, the local starting cabinet or local control box is equipped with a human-machine interface, through which the real-time operating parameters of the equipment can be viewed, including but not limited to current, voltage, operating time and cumulative operating time, and local parameter settings can be performed on the equipment. Local parameter settings are only valid in the local control mode.

6. The start-stop method for mining production line equipment according to claim 1, characterized in that: In S05, in the automatic control mode, the start and stop sequence and time interval of the equipment can be customized according to different production tasks. The user can input different equipment sequences and time delay parameters through the dedicated software of the operation station and store them as different production task templates.

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