Communication controller with automatic spraying function

Abstract

A communication controller with an automatic spraying function belongs to the technical field of coal mine spraying, and input terminal strip wires DC24V-and I2.0 of a PLC (Programmable Logic Controller) in the communication controller are connected with a magnet type sensor. And a 127V connecting wire of the PLC is connected with a power supply binding post of the electric ball valve and a normally open connecting wire C end of the relay. And a Q0.5 terminal of the PLC is connected with a Q0.5 terminal of the relay. And the normally open terminal G of the relay is connected with the other power binding post of the electric ball valve. The magnet type speed sensor is arranged above the belt conveyor, and the magnet is hung below the magnet type speed sensor. An original outsourcing main control box of an automatic spraying device is omitted, a PLC in a communication controller used for controlling the rubber belt conveyor is used for controlling, meanwhile, an original electronic touch sensor is changed into a magnet type speed sensor to achieve the automatic spraying function, the equipment failure rate is reduced, the control reliability is improved, funds are saved, and safe operation of equipment is guaranteed.

Description

Technical Field

[0001] The utility model belongs to the technical field of coal mine spraying, in particular to a communication controller with an automatic spraying function. Background Art

[0002] Belt conveyors are mainly used for underground coal transportation in coal mines. When coal falls at each transfer and dropping point, there is a lot of coal dust. If the amount of coal dust is not controlled, firstly, the coal dust exceeds the standard and easily causes coal dust explosion when encountering open flames; secondly, the workers inhale a large amount of dust, which affects their health and causes pneumoconiosis. According to the safety regulations of coal mines, spray dust reduction equipment is required.

[0003] With the intelligent construction of coal mines, all coal mines have adopted communication controllers to realize the remote intelligent operation of belt conveyors. Each remote intelligent operation belt conveyor must purchase an automatic spray device for spray dust reduction. The purchased automatic spray device adopts single-chip control technology. During use, the automatic spray device control failure, host crash, sensor damage, and electric ball valve damage often occur, which makes the coal dust seriously exceed the standard, increases safety risks, and is extremely unfavorable to safe production. In this case, the only solution to the problem is to purchase a new automatic spray device for replacement, which wastes money and increases the workload of maintenance personnel. Therefore, it is urgent to develop a safe, stable and reliable automatic spray control system to improve the stability of the automatic spray system and ensure safe production in coal mines.

[0004] After an in-depth study of the working principle and internal composition of the communication controller, it was found that although the communication controllers used to control underground belt conveyors in various coal mines are manufactured by different manufacturers, the basic principles and structures are basically the same. At present, the communication controllers have control start, start signal feedback, communication, emergency stop of belt conveyors, speed, coal stacking, deviation, over-temperature, smoke, tension, call and alarm functions, but none of them have automatic spraying and watering functions. In this case, the developed automatic spraying device uses the advanced PLC function of the communication controller to download the self-written automatic spraying program to the communication controller PLC program. Without purchasing any equipment, the automatic spraying and watering function of the belt conveyor centralized control system can be realized. It has strong practicality and promotion in the coal system. Utility Model Content

[0005] The communication controller with automatic spray function can realize the automatic spray function by using the communication controller of the belt conveyor in combination with the magnetic speed sensor.

[0006] The technical solution adopted is:

[0007] The communication controller with automatic spray function includes a PLC, a magnetic speed sensor, an iron chain and an electric ball valve built into the communication controller.

[0008] The PLC input terminal block terminals DC24V- and I2.0 are connected to the two control wires of the magnetic sensor respectively.

[0009] The two 127V terminals of the PLC are respectively connected to a power terminal of the electric ball valve and the normally open terminal C of the relay.

[0010] The Q0.5 terminal of the PLC is connected to the Q0.5 terminal of the relay.

[0011] The normally open terminal G of the relay is connected to another power terminal of the electric ball valve.

[0012] The magnetic speed sensor is arranged above the belt conveyor, and the magnet is suspended below the magnetic speed sensor through an iron chain.

[0013] The communication controller model is KTC169.1 mining explosion-proof and intrinsically safe communication controller.

[0014] Its advantages are:

[0015] The original outsourced automatic spray device includes: a main control box (automatic control part, using single-chip microcomputer technology), an electronic touch sensor and an electric ball valve. The core of this technical solution is to cancel the original main control box. The functions of the main control box are written into the communication controller used to control the belt conveyor after self-programming. At the same time, the original electronic touch sensor is replaced by a magnetic speed sensor to realize the automatic spray function, which can reduce the equipment failure rate, improve control reliability and ensure the safe operation of the equipment.

[0016] At present, most of the belt conveyors in the coal mines of Tiefa Energy Company use communication controllers for centralized control, and all of them use purchased spray devices, which reduces the utilization rate of advanced equipment. The company's annual procurement and maintenance costs are extremely high, which greatly increases the production costs of coal mining enterprises, which is not conducive to the high-yield and high-quality development of enterprises. The automatic spray system developed using a built-in communication controller and an ordinary magnetic speed sensor to realize the automatic spraying of the belt conveyor can save capital investment, reduce the workload of maintenance personnel, improve the stability of equipment operation, and prevent coal dust explosion accidents caused by excessive coal dust caused by equipment failure, ensuring safe production in coal mines. According to rough estimates, there are about 120 belt conveyors in the company. If all of them are switched to communication controllers to realize the automatic spray system, the company can save about 3 million yuan in economic benefits each year, which has great promotion and application value. At the same time, it provides reliable technical basis, technical support and guarantee for coal mining enterprises to promote the mechanization, automation, intelligence and information construction. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 Design diagram for the program.

[0018] Figure 2 The schematic diagram of the circuit of this device.

[0019] Figure 3 It is a structural schematic diagram of the device.

[0020] Communication controller 1, belt conveyor 2, coal bunker 3, magnetic speed sensor 4, control cable 5, iron chain 6, coal 7, electric ball valve 8, high-pressure water pipe 9, underground coal mine water supply pipeline 10, relay 11, spray nozzle 12. DETAILED DESCRIPTION

[0021] Xiaoqing Coal Mine uses the KTC169.1 mine-use flameproof and intrinsically safe communication controller produced by Anhui Hengtai Electric Technology Co., Ltd. It decided to utilize the advanced PLC function inside the KTC169.1 mine-use flameproof and intrinsically safe communication controller to realize the automatic spray dust reduction function of the belt conveyor centralized control system. According to the instructions, the communication controller with PLC used by other belt conveyors in this industry can also implement this technical solution.

[0022] The core control part of KTC169.1 mine flameproof and intrinsically safe communication controller is Siemens S7-200SMARTPLC series CPU, which has programming software function. Use computer to connect with PLC of KTC169.1 mine flameproof and intrinsically safe communication controller with network cable, and write automatic spray program into PLC program. Automatic spray program is designed and written according to the requirement of coal mine that automatic spray dust reduction must be realized when the underground centralized control belt conveyor is running. The program design diagram is as follows: Figure 1 Those skilled in the art can also write programs by themselves according to the instructions.

[0023] symbol address Notes ALWays-On SM0.0 Always connected I2.0 I2.0 Automatic spray trigger Q0.5 Q0.5 Automatic spray watering Delay 2 T241

[0024] The communication controller with automatic spraying function comprises a PLC built into the communication controller 1, a magnetic speed sensor 4, an iron chain 6 and an electric ball valve 8.

[0025] The PLC input terminal block terminals DC24V- and I2.0 are respectively connected to the two control wires of the magnetic sensor 4.

[0026] The two 127V terminals of the PLC are respectively connected to a power terminal of the electric ball valve 8 and the normally open terminal C of the relay 11.

[0027] The Q0.5 terminal of the PLC is connected to the Q0.5 terminal of relay 11.

[0028] The normally open terminal G of the relay 11 is connected to another power terminal of the electric ball valve 8 .

[0029] The magnetic speed sensor 4 (this is a known product on the market) can be arranged above the belt conveyor 2 through a bracket, the magnet is fixed to the lower end of the iron chain 6, and the upper end of the iron chain 6 can be fixed to the housing of the magnetic speed sensor 4.

[0030] The inlet of the electric ball valve 8 is connected to the underground water supply pipeline 10 of the coal mine through the high-pressure water pipe 9.

[0031] The outlet of the electric ball valve 8 is connected to the spray nozzle 12 .

[0032] Relay 11 is a K6 relay on the relay board circuit of the existing belt conveyor.

[0033] The PLC is connected to the magnetic speed sensor 4 via a control cable 5 .

[0034] The magnetic speed sensor 4, magnet, iron chain 6 and spray nozzle 12 are arranged above the belt conveyor 2. The magnet is on the surface of the belt. When the belt is running and coal 7 flows through and is transported to the coal bunker 3, it will touch the magnet. The magnet is upward and in close contact with the fixed magnetic sensor 4. The spring piece in the magnetic speed sensor 4 is turned on (SM0.0 is turned on) under the action of magnetic force. The PLC input terminal (DC24V- and I2.0 are turned on) The spring piece in the magnetic speed sensor 4 is turned on (SM0.0 is turned on) under the action of magnetic force. The PLC input terminal (DC24V- and I2.0) is connected, giving an input sampling connection signal to the PLC internal input image area. The PLC starts to execute the downloaded automatic spray program, and the internal instructions start driving. The control output sampling area sends a start signal (DC24V- and Q0.5 are connected) to trigger the output image area to output a start signal (Q0.5 is connected). The control relay 11 of the 1# relay board is energized to close the normally open contacts (G and C), and the electric ball valve 8 is energized to work, controlling the water valve core to rotate, and the spray nozzle 12 sprays water.

[0035] The intermittent coal flow will cause the automatic spray device to start frequently. In order to prevent damage to the equipment caused by frequent starting, the KTC169.1 mine flameproof and intrinsically safe communication controller automatic spray device developed can solve the problem of avoiding damage to the equipment caused by frequent starting. The PLC output image area receives the input sampling connection signal. For example, the control time of the electric ball valve 8 is 5 seconds per cycle. Within the 5-second action cycle, the PLC receives the input sampling connection signal again. The 5-second action cycle starts again. If the magnet is away from the magnetic speed sensor 4 within the 5-second action cycle, it means that no coal passes. The PLC does not receive the input connection signal, and the PLC outputs the start signal. The electric ball valve 8 loses power and stops working, and the automatic spray stops sprinkling water. Since the magnet is bolted to the iron chain 6 and will not leave, the above process will be repeated when the coal 7 flows next time, realizing automatic induction without manual intervention.

[0036] When the belt is running, coal flow passes by and touches the magnet, the spring sheet in the magnetic speed sensor 4 is turned on, the PLC input terminals DC24V- and I2.0 are closed, the CPU receives the trigger signal, and the control output terminals DC-24V and Q0.5 start to close, the relay 11 is energized, its normally open contacts G and C are closed, and the electric ball valve 8 starts to work and the automatic spray nozzle 12 starts to spray water.

[0037] Main innovations:

[0038] 1. By utilizing the PLC device in the communication controller of the existing operating equipment of the belt centralized control itself, automatic spraying of the centralized control belt can be realized without spending money to purchase automatic spraying devices.

[0039] 2. The main control part adopts PLC programming device, and the main control part of the purchased automatic spray device adopts single-chip microcomputer technology. The advantages of PLC compared with single-chip microcomputer are: high reliability, anti-interference ability, convenient programming and stronger adaptability to harsh industrial environment, so the probability of failure of homemade spray device is extremely low.

[0040] 3. The main components of the magnetic sensor are magnets and spring sheets. There are no electronic components, so it is not easy to be damaged and has a longer service life than purchased touch sensors.

[0041] 4. The homemade spray device uses the existing PLC programming device of the belt centralized control, while the purchased spray device adds more equipment, which increases the inspection and maintenance workload of the maintenance personnel.

[0042] 5. The start-up cycle time of the purchased spray device is fixed at 30S per gear. The start-up cycle of the PLC programming software can be added by every second and can be set according to the actual situation on site. It is flexible, convenient and practical.

[0043] 6. The electric ball valve and main control box of the purchased spray device are integrated. The electric ball valve is frequently started and the mechanism is easily damaged, so it is inconvenient to disassemble and repair due to the small space. The homemade spray device uses a single electric ball valve, which is not restricted by space and is more convenient to install, disassemble and repair.

[0044] Benefit Analysis:

[0045] Our mine uses ZP-127Z automatic spray device, which costs 7257 yuan per set (including ZP-127Z automatic spray main control box and touch sensor). The purchased automatic spray device has a high failure rate. Calculated based on about 8 failures per month, the maintenance personnel take about 2 hours to handle each failure.

[0046] Monthly troubleshooting time: 8×2=16 hours

[0047] The maintenance staff's salary is about 300 yuan per day. Calculated as 8 hours a day, the hourly wage is 37.5 yuan.

[0048] Annual maintenance cost: 37.5×16×12=7200 yuan

[0049] The purchased ZP-127Z automatic spray device costs 7257 yuan per set. Due to damage, it can only be replaced, 2 sets per year, 2×7257=14514 yuan.

[0050] At present, there are 15 centralized control belts in my mine, 15×14514=217710 yuan, the total cost is: 217710

[0051] +7200=224910 yuan.

[0052] The cost of the parts used in the homemade spray device: 315 yuan for the magnetic speed sensor.

[0053] Electric ball valve is 796 yuan.

[0054] Homemade spray cost: (796+315)×15 = 16,665 yuan

[0055] Annual cost savings: 224910-16665=208245 yuan.

Claims

1. A communication controller with automatic spray function, comprising a PLC, a magnetic speed sensor (4), an iron chain (6) and an electric ball valve (8) built into the communication controller (1); characterized in that: The PLC input terminal block terminals DC24V- and I2.0 are connected to two control wires of the magnetic sensor (4) respectively; The two 127V terminals of the PLC are respectively connected to a power terminal of the electric ball valve (8) and the normally open terminal C of the relay (11); The Q0.5 terminal of the PLC is connected to the Q0.5 terminal of the relay (11); The normally open terminal G of the relay (11) is connected to another power terminal of the electric ball valve (8); The magnetic speed sensor (4) is arranged above the belt conveyor (2), and the magnet is suspended below the magnetic speed sensor (4) through an iron chain (6).

2. The communication controller with automatic spray function according to claim 1, characterized in that: The upper end of the iron chain (6) is fixed on the housing of the magnetic speed sensor (4), and the magnet is fixed on the lower end of the iron chain (6).

3. The communication controller with automatic spray function according to claim 1, characterized in that: The communication controller (1) is of model KTC169.1, a flameproof and intrinsically safe communication controller for mining.

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