A communication monitoring system, control system and method for a multi-point driven belt conveyor

Abstract

The present invention discloses a communication monitoring system, control system and method for a multi-point driven belt conveyor, wherein the control system is composed of a head control main station and a machine control substation; the head control main station and the machine control substation interact with each other through a communication optical cable, and the communication monitoring system is arranged on the control main station controller and the control substation controller. By adding a communication monitoring device to the control main station and the control substation, the scheme can ensure the communication disconnection monitoring between the master and slave controllers, eliminate the communication disconnection fault, improve the reliability of the communication of the multi-control system, and avoid the safety accidents of personnel and equipment.

Description

Technical Field

[0001] The invention relates to the field of mechanical control, and in particular to a multi-point driven belt conveyor control system and a communication monitoring device and method. Background Art

[0002] With the development of the national economy, belt conveyors, as the main bulk material transportation device, are developing towards large-volume and long-distance transportation. Multi-point drive belt conveyors have become a mainstream model, and multi-point drive necessarily requires multi-point control. If the optical fiber, the communication medium between the controllers of a multi-point control system, is disconnected, the main controller shuts down due to an external fault, while the slave controller does not receive the "shutdown" signal from the main controller and continues to operate; or vice versa, both may pose a safety hazard to on-site equipment or personnel.

[0003] It can be seen that how to eliminate the communication disconnection failure and ensure normal communication between the master and slave controllers is a problem that needs to be solved in this field. Summary of the invention

[0004] In view of the problem of communication disconnection monitoring between master and slave controllers in existing belt conveyors, the purpose of the present invention is to provide a multi-point driven belt conveyor communication monitoring system, and based on this, provide a multi-point driven belt conveyor control system and a corresponding control method, which effectively solves the problems existing in the prior art.

[0005] In order to achieve the above-mentioned purpose, the multi-point driven belt conveyor communication listening system provided by the present invention mainly includes a master control communication module and a slave control communication module; the master control communication module is connected to the slave control communication module; the master control communication module is connected to a first communication listening unit; the slave control communication module is connected to a second communication listening unit; the first communication listening unit exchanges data with the second communication listening unit.

[0006] The first communication monitoring unit is composed of a first input variable module, a first intermediate variable module and a first output variable module, which are connected in sequence.

[0007] The second communication monitoring unit is composed of a second input variable module, a second intermediate variable module and a second output variable module, which are connected in sequence.

[0008] Furthermore, the master control communication module and the slave control communication module establish an accumulator based on the same interval frequency, with the controller CPU clock frequency as the reference frequency and the reference frequency multiple as the same interval frequency. When the interval time meets the conditions, the accumulator value is increased by 1, and the master control communication module and the slave control communication module simultaneously send the accumulated value as a signal to the input variable module of the other party. After receiving the signal, it is compared with the value of the intermediate variable module. If the value is still equal within n interval frequencies, the output variable module issues a communication disconnection fault indication and shuts down.

[0009] Furthermore, the master control communication module and the slave control communication module are connected via a communication optical cable and exchange commands and data with each other.

[0010] Furthermore, the interval frequency number n is 3-10.

[0011] Furthermore, the interval frequency is 0.5 ms to 2 ms.

[0012] In order to achieve the above-mentioned purpose, the multi-point driven belt conveyor control system provided by the present invention includes a head control main station, an in-machine control substation and a communication optical cable; the head control main station and the in-machine control substation are connected by a communication optical cable, and communication data exchange is carried out through any one of the communication monitoring systems described in claims 1-4.

[0013] Furthermore, the machine head control main station and the machine mid-control substation both use PLC as the core controller.

[0014] Furthermore, the number of the control main station is 1; the number of the control substations is multiple.

[0015] In order to achieve the above object, the multi-point drive belt conveyor control method provided by the present invention comprises the following steps:

[0016] (1) The master control communication module and the slave control communication module establish a communication connection;

[0017] (2) The controller communication modules each increase the frequency by 1 after each interval period and send it to the input variable module of the other controller;

[0018] (3) storing the input variable module data of each interval frequency period into the intermediate variable module;

[0019] (4) The input variable module data of the current interval frequency cycle is compared with the intermediate variable module data of the previous interval frequency cycle. If they are equal, the offline count is increased by 1;

[0020] (5) If the offline count reaches 5, the controller considers that the communication is offline and shuts down due to a fault.

[0021] The multi-point driven belt conveyor control scheme provided by the present invention can ensure normal communication between the master and slave controllers and improve the reliability of multi-controller system communication by directly adding communication monitoring devices to the control master controller and the control slave controller. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments.

[0023] Figure 1 A schematic diagram of the overall structure of the control system provided by the present invention;

[0024] Figure 2 A schematic diagram of the local structure of the control system provided by the present invention;

[0025] Figure 3 This is a schematic diagram of the principles of the communication monitoring system in the control system provided by the present invention. DETAILED DESCRIPTION

[0026] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further explained below with reference to specific diagrams.

[0027] See also Figure 1-Figure 2 , which is a schematic diagram of the control system structure. As can be seen from the figure, it includes a belt conveyor head 1, a belt conveyor middle 2, a belt conveyor tail 3, a head control main station 4, a middle drive control substation 5, a communication medium optical cable 6, a two-way pull rope switch 7, a loudspeaker 8a-8c, a deviation switch 9a-9d, a smoke sensor 10, a speed sensor 11, a tear sensor 12, a material quantity scanner 13, a wire rope 14, a control speaker 15, a main controller 16, and a slave controller 17.

[0028] The head control main station 4 and the main controller 16 are arranged on the belt conveyor head 1, and the above components cooperate to form the head control main station. The main controller 16 is the control center of the head control main station.

[0029] The middle drive control substation 5 and the slave controller 17 are arranged in the belt conveyor machine 2, and the above components cooperate to form the middle drive control substation. The slave controller 17 is the control center of the middle drive control substation.

[0030] The distance between the head control main station and the in-machine control substation is more than 1000 meters, and they are generally connected and data exchanged through a communication optical cable 6. The length of a single multi-point driven belt conveyor is relatively long, generally more than 3 kilometers, and even up to more than 20 kilometers, so as a preferred embodiment, the communication optical cable 6 here is an optical fiber, which is made of glass or plastic fibers, easy to damage, but has a long communication distance.

[0031] Both the locomotive control main station and the in-locomotive control substation use PLC as the core controller. The number of locomotive control main station 4 is one, and the number of in-locomotive control substations 5 is multiple.

[0032] It should be noted here that the installation position of the drive device is not limited and can be arranged at the front, middle or rear of the machine.

[0033] Furthermore, the present solution is provided with three two-way pull-rope switches 7, which are spaced a certain distance apart and are connected in sequence by steel wire ropes 14;

[0034] Furthermore, three two-way pull cord switches 7 are respectively arranged on three loudspeakers, namely loudspeaker 8a, loudspeaker 8b, and loudspeaker 8c. One connector of loudspeaker 8a is connected to the control speaker; two interfaces are respectively connected to deviation switch 9a and deviation switch 9b; and the other interface is connected to the interface of loudspeaker 8b.

[0035] The deviation switch 9a is located above the belt conveyor head, and the deviation switch 9b is arranged on the belt conveyor head.

[0036] Furthermore, the loudspeaker phone 8b is connected to a connector on the loudspeaker phone 8c.

[0037] Furthermore, the other four interfaces of the loudspeaker phone 8c are respectively connected to the deviation switch 9c, the deviation switch 9d, the material quantity scanner 13 and the tear sensor 12.

[0038] The deviation switch 9c is located above the tail 3 of the belt conveyor; the deviation switch 9d, the tear sensor 12 and the material quantity scanner 13 are arranged on the tail 3 of the belt conveyor.

[0039] Furthermore, the smoke sensor 10 is located above the belt conveyor head 1 ; the speed sensor 11 is arranged on the belt conveyor head 1 ; and both the smoke sensor 10 and the speed sensor 11 are connected to the control box 15 .

[0040] For example, when the two-way pull rope switch, deviation switch, and tear sensor are activated, the switch signal enters the loudspeaker, and the coal quantity scanner scans the contour of the belt material through laser, and sends an analog signal to the loudspeaker after calculation. The loudspeaker sends data including position and action signal data to the controller through CAN communication, and automatically stops the machine; the speed sensor monitors the slippage of the conveyor roller. The friction between the roller and the belt can easily generate smoke, which can cause fire in severe cases. The smoke sensor can send a signal to stop the machine.

[0041] like Figure 3, which is a schematic diagram of the principle of the communication interception system. As can be seen from the figure, it includes a master control communication module 16a arranged on the master controller 16, a slave control communication module 17a arranged on the slave controller 17, and a communication optical cable 6. The master control communication module 16a and the slave control communication module 17a are connected through the communication optical cable and perform data exchange.

[0042] Furthermore, the master control communication module 16a is connected to a first communication listening unit 18 located in the master controller; and the slave control communication module 17a is connected to a second communication listening unit 19 located in the slave controller.

[0043] The first communication intercepting unit 18 includes a first input variable module 18a, a first intermediate variable module 18b and a first output variable module 18c, which are connected in sequence.

[0044] The second communication intercepting unit 19 includes a second input variable module 19a, a first intermediate variable module 19b and a first output variable module 19c, which are connected in sequence.

[0045] Specifically, the master control communication module and the slave control communication module establish an accumulator based on the same interval frequency, with the controller CPU clock frequency as the reference frequency and the reference frequency multiple as the same interval frequency. When the interval time meets the conditions, the accumulator value is increased by 1. The master control communication module and the slave control communication module send the accumulated value as a signal to the other party's input variable module at the same time. After receiving the signal, it is compared with the value of the intermediate variable module. If the value is still equal within n interval frequencies, the output variable module issues a communication disconnection fault indication and shuts down.

[0046] As an example, the input module is the "heartbeat reception" signal and the "communication establishment" signal; the intermediate module is the "heartbeat comparison" signal, the "communication interruption" signal and the "disconnection count" signal; the output module is the "communication disconnection" signal. The main controller 16 and the slave controller 17 read each other's data respectively. Before the communication is established, the "communication establishment" of the input module is assigned a value of 0; after the communication is established, the "communication establishment" is assigned a value of 1. An accumulator based on the same interval frequency is established between the program segment of the main controller 16 and the program segment of the slave controller 17, and the accumulated value is sent as a "heartbeat signal" to the other party's "heartbeat reception" signal. The "heartbeat reception" signal is compared with the "heartbeat comparison" signal. As long as they are not equal, the "heartbeat reception" signal is assigned to the "heartbeat comparison" signal, and the "disconnection count" of the intermediate module is cleared to 0;

[0047] On the contrary, the values ​​of the "heartbeat reception" signal and the "heartbeat comparison" signal are equal, and the "communication established" is not 0 at this time, then the "offline count" is increased by 1, and the frequency is still equal at the next interval, and the "offline count" is increased by 1 again until the "offline count" value is greater than 5, "communication interruption" = 1, the system issues a fault prompt, and the output module "communication offline" = 1, then the control system shuts down.

[0048] Once the communication returns to normal, the "count drop" signal is cleared to 0 and the "communication drop" fault is reset.

[0049] The number of times in the above interval frequency is generally 3 to 10. Theoretically, the smaller the value, the stronger the real-time performance. The interval frequency is generally 0.5ms to 2ms. Theoretically, the smaller the interval frequency, the stronger the real-time performance.

[0050] A communication monitoring method for a multi-point driven belt conveyor is to set a communication monitoring device on a control master station and a control slave station, and the communication monitoring function is completed by the device, which can be copied between controllers and has a simple structure and operation. In specific application, it includes the following steps:

[0051] (1) The master control communication module and the slave control communication module establish a communication connection;

[0052] (2) The controller communication modules each increase the frequency by 1 after each interval period and send it to the input variable module of the other controller;

[0053] (3) storing the input variable module data of each interval frequency period into the intermediate variable module;

[0054] (4) The input variable module data of the current interval frequency cycle is compared with the intermediate variable module data of the previous interval frequency cycle. If they are equal, the offline count is increased by 1;

[0055] (5) If the offline count reaches 5, the controller considers that the communication is offline and shuts down due to a fault.

[0056] The multi-point drive belt conveyor control scheme constructed according to the above scheme is simple in structure and strong in practicality by adding a communication monitoring system between the control master station controller and the control slave station controller. In specific applications, it can ensure the communication disconnection monitoring between the master and slave controllers, eliminate the communication disconnection fault, improve the reliability of multi-control system communication, and avoid causing safety accidents for personnel and equipment.

[0057] The above shows and describes the basic principles, main features and advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A multi-point driven belt conveyor communication monitoring system, characterized in that: It includes a master control communication module and a slave control communication module; the master control communication module is connected to the slave control communication module; the master control communication module is connected to a first communication listening unit; the slave control communication module is connected to a second communication listening unit; the first communication listening unit is connected to the second communication listening unit for data exchange; The first communication interception unit is composed of a first input variable module, a first intermediate variable module and a first output variable module, which are connected in sequence; The second communication interception unit is composed of a second input variable module, a second intermediate variable module and a second output variable module, which are connected in sequence; The master control communication module and the slave control communication module establish an accumulator based on the same interval frequency, with the controller CPU clock frequency as the reference frequency and the reference frequency multiple as the same interval frequency. When the interval time meets the conditions, the accumulator value is increased by 1. The master control communication module and the slave control communication module simultaneously send the accumulated value of the accumulator as a signal to the input variable module of the other party. After receiving the signal, it is compared with the value of the intermediate variable module. If the value is still equal within n interval frequencies, the output variable module issues a communication disconnection fault indication and shuts down.

2. A communication monitoring system for a multi-point driven belt conveyor according to claim 1, characterized in that: The master control communication module and the slave control communication module are connected via a communication optical cable and exchange commands and data with each other.

3. A communication monitoring system for a multi-point driven belt conveyor according to claim 1, characterized in that: The interval frequency number n is 3 to 10.

4. A communication monitoring system for a multi-point driven belt conveyor according to claim 1, characterized in that: The interval frequency is 0.5ms~2ms.

5. A multi-point drive belt conveyor control system, characterized in that: It includes a head control main station, an in-machine control substation and a communication optical cable; the head control main station and the in-machine control substation are connected through a communication optical cable, and communication data is exchanged through the communication interception system described in any one of claims 1-4.

6. A multi-point drive belt conveyor control system according to claim 5, characterized in that: The head control main station and the in-machine control substation both use PLC as the core controller.

7. A multi-point drive belt conveyor control system according to claim 5, characterized in that: The number of the control main station is 1; the number of the control substations is multiple.

8. A multi-point drive belt conveyor control method, characterized in that: It is implemented based on the communication monitoring system of the multi-point driven belt conveyor according to any one of claims 1 to 4 above, and the control method of the multi-point driven belt conveyor comprises the following steps: (1) The master control communication module and the slave control communication module establish a communication connection; (2) Each controller communication module adds 1 after each interval frequency cycle and sends it to the input variable module of the other controller; (3) Storing the input variable module data of each interval frequency period into the intermediate variable module; (4) The input variable module data of the current interval frequency cycle is compared with the intermediate variable module data of the previous interval frequency cycle. If they are equal, the offline count is increased by 1; (5) If the offline count reaches 5, the controller considers that the communication is offline and shuts down due to a fault.

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