A hydraulic oil quantity monitoring method for a rotary drum unloader

Abstract

The present application relates to a kind of rotor dumper hydraulic oil quantity monitoring method, comprising: initial position monitoring, first segment overturn monitoring, second segment overturn monitoring, third segment overturn monitoring, fourth segment overturn monitoring and the like steps.The rotor dumper hydraulic oil quantity monitoring method provided by the present application realizes the liquid level monitoring of the liquid level of the hydraulic oil tank on the rotor dumper body during the operation of the equipment, timely discovers the problem of hydraulic oil reduction caused by hydraulic system pipe burst and the like faults, and guarantees the safety of system operation.Solves the technical difficulties of rotor dumper monitoring, improves the management level of remote state monitoring of equipment, reduces the labor intensity of workers, and creates conditions for unmanned operation of dumper.Also avoids the problems of system complexity, large pressure loss and low operation stability caused by moving the hydraulic station of dumper to the ground.

Description

TECHNICAL FIELD

[0001] The application relates to a rotor dumper hydraulic oil quantity monitoring method and belongs to the technical field of mechanical equipment. BACKGROUND

[0002] A dumper is a large mechanical equipment for dumping railway open car bulk materials. The dumper is a loading and unloading machine for overturning or tilting a railway vehicle to unload materials, and is suitable for ports and industrial departments such as metallurgy, coal and thermal power. The dumper mainly has a rotor type and a side tilting type. The side tilting type dumper has the characteristics of large self-weight and large power consumption, and is less used. At present, the rotor type dumper is most used. The rotor type dumper has the characteristics of light self-weight and small size. After a loaded open car is pushed into a metal frame shaped like a cylinder and clamped by a car pressing beam and a car leaning plate, the dumper is rotated about 165 degrees by a driving device, and bulk materials in the car are unloaded into an underground bin under the action of self-weight.

[0003] The car pressing beam mechanism and the car leaning plate mechanism of the rotor dumper are both driven by hydraulic transmission. In order to ensure the reliability of the work, the hydraulic oil level is an important monitoring parameter. Since the dumper body needs to rotate about 165 degrees during operation, the oil tank of the hydraulic system installed on the dumper body also rotates, and the oil level is always changing, so effective monitoring cannot be achieved, and manual regular inspection and observation and disposal are often used. With the progress of dumper system technology, enterprises are promoting remote control or unmanned control of equipment, and therefore, monitoring of the oil level and other states of the hydraulic system of the equipment is more necessary.

[0004] In order to detect the oil level of the rotating hydraulic oil tank, industry professionals have made many explorations. It is found through relevant data retrieval that a dumper hydraulic transmission device with application number CN2201268516Y moves the hydraulic oil tank and pump station of the dumper body as a whole to the ground, connects the valve station of the rotor dumper through an ultra-long high-pressure rubber pipe at the end ring of the dumper, and solves the problem of the explosion of the high-pressure rubber pipe through the parallel connection of multiple small-diameter high-pressure rubber pipes. This method solves the technical problem of hydraulic oil level detection. However, the multiple high-pressure rubber pipes are prone to explosion during reciprocating rotation, and the number of faults increases obviously. In order to avoid the influence of the explosion of the high-pressure rubber pipe on the safety of the car pressing beam and other hydraulic circuits, safety facilities such as explosion-proof valves need to be added to the hydraulic circuit, the safety of the hydraulic system on the machine is not good, and the system becomes more complex. After moving to the ground, the oil supply pipeline is lengthened, the system resistance loss increases, and the power also increases. SUMMARY

[0005] The technical problem solved by the present application is to overcome the above technical defects, provide a method for monitoring the change of the oil quantity in the hydraulic tank by monitoring the change of the turning angle of the roll-over machine, using the change of the liquid level during the rolling-over and the angle feedback double monitoring mode matching algorithm model, so as to avoid the abnormal state of the equipment and ensure the normal operation of the large equipment.

[0006] To solve the above technical problems, the technical solution provided by the present application is a rotor roll-over machine hydraulic oil quantity monitoring method, comprising the following steps:

[0007] Step 1: When the roll-over machine is at a turning angle of 0, the reading h1 of the liquid level meter on one side of the roll-over machine and the reading h2 of the liquid level meter on the other side are obtained; the oil quantity V2 is calculated as L*W*h1, wherein L is the length of the oil tank of the roll-over machine, and W is the width of the oil tank of the roll-over machine; if the calculated oil quantity V2 is less than 70% of the standard oil quantity V1, the roll-over machine is prohibited from turning over;

[0008] Step 2: The roll-over machine starts to turn over, the reading h1 of the liquid level meter on one side of the roll-over machine gradually decreases with the turning over of the roll-over machine, and the reading h2 of the liquid level meter on the other side gradually increases with the turning over of the roll-over machine, until the reading h1 of the liquid level meter on one side is 0; in this process, the calculated oil quantity V2 is L*W*(h1+h2) / 2; if the calculated oil quantity V2 is less than 70% of the standard oil quantity V1, the roll-over machine is stopped from turning over;

[0009] Step 3: The roll-over machine continues to turn over; until the reading h2 of the liquid level meter on the other side reaches the maximum range;

[0010] Step 4: The roll-over machine continues to turn over; until the reading h1 of the liquid level meter on one side and the reading h2 of the liquid level meter on the other side are both between 0 and the maximum range;

[0011] Step 5: The roll-over machine continues to turn over; until the maximum turning angle is reached, in this process, the calculated oil quantity V2 is L*W*[ (maximum range-h1) + (maximum range-h2) ] / 2; if the calculated oil quantity V2 is less than 70% of the standard oil quantity V1, the roll-over machine is stopped from turning over.

[0012] The further improvement of the above-mentioned scheme is that in the step 4, if the turning angle is greater than 120 degrees and the reading h1 of the liquid level meter on one side is 0, the roll-over machine is stopped from turning over.

[0013] The further improvement of the above-mentioned scheme is that in the step 4, if the turning angle is greater than 120 degrees and the reading h1 of the liquid level meter on one side is 0, an alarm is sent to let the operator check the roll-over machine.

[0014] The further improvement of the scheme is that the liquid level meters on the one side and the other side of the dumper are the buoyancy magnetic overturning plate liquid level meters.

[0015] The further improvement of the scheme is that after the step 5, the dumper is reversely rotated to reset.

[0016] The further improvement of the scheme is that in the step 1, the step 2 and the step 5, if the calculated oil volume V2 is less than 70% of the standard oil volume V1, an alarm is sent to let the operator check the dumper.

[0017] The further improvement of the scheme is that the standard oil volume V1 is 80% of the total capacity of the oil tank of the dumper.

[0018] The rotor dumper hydraulic oil volume monitoring method provided by the application realizes the liquid level monitoring of the hydraulic oil tank on the rotor dumper body during the operation of the equipment, discovers in time the problem of hydraulic oil reduction caused by the pipe explosion of the hydraulic system and guarantees the safety of the system operation. The technical difficulty of the rotor dumper monitoring is solved, the management level of the remote state monitoring of the equipment is improved, the labor intensity of workers is reduced and the conditions for the unmanned operation of the dumper are created. The problem of the complexity of the system, the large pressure loss and the low operation stability caused by the moving of the hydraulic station of the dumper to the ground is also avoided. DETAILED DESCRIPTION EMBODIMENT

[0019] The rotor dumper hydraulic oil volume monitoring method of the embodiment involves specific control devices including a PLC control system, an HMI picture program, a magnetic overturning plate liquid level meter, a rotary positioning device (absolute value encoder), network data interaction equipment and a high-performance industrial computer, wherein the rotary positioning device includes measurement positions respectively installed at the low-speed end of the rotating shaft of the dumper body.

[0020] It is found from the field survey that the oil tank of the dumper is a cuboid structure. An algorithm model is established according to the readings h1 and h2 of the liquid level meters on the two sides and the dumper rotation angle a to calculate the actual oil volume. Then, the actual oil volume is compared with the initial oil volume to determine whether the oil tank and the hydraulic pipe are leaking or the pipeline is not smooth. If the actual oil volume is less than 70% of the initial oil volume, the dumper is prohibited from moving according to the interlocking relationship of the PLC program to play a role in protecting the equipment.

[0021] Let the measurement value of the left liquid level meter be h1, the measurement value of the right liquid level meter be h2, the length, width and height of the oil tank be L, W and H respectively, the first oil volume added into the oil tank be V1 (80% of the total volume), the real-time calculated oil volume be V2 and the rotation angle of the dumper be a.

[0022] Specifically, the method includes the following steps:

[0023] Step 1: When the turnover machine is at a turnover angle of 0, the PLC collects the liquid level data for 3 minutes (the turnover interval is greater than 3 minutes) when it is stationary, according to the readings h1 of the left liquid level meter and h2 of the right liquid level meter of the turnover machine; the oil volume V2 = L*W*h1 is calculated, where L is the length of the oil tank of the turnover machine and W is the width of the oil tank of the turnover machine; if the calculated oil volume V2 is less than 70% of the standard oil volume V1, the turnover machine is prohibited from turning over; if the data is valid, the turnover machine can be turned over;

[0024] Step 2: The turnover machine starts to turn over to the right, the reading h1 of the left liquid level meter of the turnover machine gradually decreases with the turning over of the turnover machine, and the reading h2 of the right liquid level meter gradually increases with the turning over of the turnover machine, until the reading h1 of the left liquid level meter is 0 (the value of a is 85 degrees according to experience); in this process, the PLC collects real-time liquid level data and calculates the oil volume V2 = L*W*(h1+h2) / 2; if the calculated oil volume V2 is less than 70% of the standard oil volume V1, or a < 70° when h1 has become zero, the turnover machine stops turning over; if the data is valid, the turnover continues;

[0025] Step 3: The turnover machine continues to turn over; until the reading h2 of the right liquid level meter reaches the maximum range;

[0026] Step 4: The turnover machine continues to turn over; until the reading h1 of the left liquid level meter and the reading h2 of the right liquid level meter of the turnover machine are both between 0 and the maximum range;

[0027] In the process of step 3 and step 4, the change process of a from h1 = 0 to h1 ≠ 0 is recorded, which is matched with the empirical value (86-110°); if a > 120° (empirical value) and h1 = 0, the turnover machine stops turning over at this time; if the data is valid, the turnover continues;

[0028] Step 5: The turnover machine continues to turn over; until it reaches the maximum turning angle, the maximum turning angle of the turnover machine in this embodiment is 165°; in this process, since the oil tank is turned over, the readings of the liquid level meters are not the actual oil volume, therefore, it is necessary to process it. That is, the maximum range is subtracted from the reading to obtain the true data, and the oil volume V2 = L*W*[ (maximum range-h1) + (maximum range-h2)] / 2 is calculated; in actual operation, the measured data is first processed by the PLC, and the data given by the liquid level meter is inverted in binary format to obtain the true data; if the calculated oil volume V2 is less than 70% of the standard oil volume V1, the turnover machine stops turning over; if the data is valid, the turnover is ended and the turnover machine returns to the 0° position.

[0029] When the rollover calculation is V2 < V1 * 70%, the rollover is immediately stopped, and the HMI screen will prompt an alarm, allowing maintenance personnel to go to the site to check and analyze. The experience value is the result of multiple measurements under constant oil volume V1, with an error of not more than 2%. When the oil volume in step 3 cannot be calculated, the angle value, liquid level value, and experience value are used to determine the oil volume monitoring during the entire rollover process.

[0030] The present application is not limited to the above embodiments. Any technical solution formed by equivalent replacement falls within the scope of protection required by the present application.

Claims

1. A method of monitoring hydraulic oil quantity of a rotary dump body, characterized by, The method comprises the following steps: Step 1: When the turnover machine is at a turnover angle of 0, the oil quantity V2=L*W*h1 is calculated according to the reading h1 of the liquid level meter on one side of the turnover machine and the reading h2 of the liquid level meter on the other side, wherein L is the length of the oil tank of the turnover machine, and W is the width of the oil tank of the turnover machine; if the calculated oil quantity V2 is less than 70% of the standard oil quantity V1, the turnover machine is prohibited from turning over; Step 2: The turnover machine starts to turn over, the reading h1 of the liquid level meter on one side of the turnover machine gradually decreases with the turning over of the turnover machine, and the reading h2 of the liquid level meter on the other side gradually increases with the turning over of the turnover machine until the reading h1 of the liquid level meter on one side is 0; in this process, the calculated oil quantity V2=L*W*(h1+h2) / 2 is calculated; if the calculated oil quantity V2 is less than 70% of the standard oil quantity V1, the turning over of the turnover machine is stopped; Step 3: The turnover machine continues to turn over until the reading h2 of the liquid level meter on the other side reaches the maximum range; Step 4: The turnover machine continues to turn over until the reading h1 of the liquid level meter on one side and the reading h2 of the liquid level meter on the other side are both between 0 and the maximum range; Step 5: The turnover machine continues to turn over until the maximum turnover angle is reached, and in this process, the calculated oil quantity V2=L*W*[ (maximum range-h1) + (maximum range-h2) ] / 2 is calculated; if the calculated oil quantity V2 is less than 70% of the standard oil quantity V1, the turning over of the turnover machine is stopped.

2. The hydraulic oil quantity monitoring method for a rotodumper according to claim 1, characterized in that: In the step 4, if the reading h1 of the liquid level meter on one side is 0 when the turnover angle is greater than 120 degrees, the turning over of the turnover machine is stopped.

3. The hydraulic oil quantity monitoring method for a rotodumper according to claim 2, characterized in that: In the step 4, if the reading h1 of the liquid level meter on one side is 0 when the turnover angle is greater than 120 degrees, an alarm is sent to let the operator check the turnover machine.

4. The hydraulic oil quantity monitoring method for a rotocaster according to claim 1, characterized by: The liquid level meter on one side and the liquid level meter on the other side of the turnover machine are float magnetic flap liquid level meters.

5. The hydraulic oil quantity monitoring method for a rotocaster according to claim 1, characterized by: After the step 5, the turnover machine is reversely rotated to reset.

6. The hydraulic oil quantity monitoring method for a rotocaster according to claim 1, characterized by: In the steps 1, 2 and 5, if the calculated oil quantity V2 is less than 70% of the standard oil quantity V1, an alarm is sent to let the operator check the turnover machine.

7. The hydraulic oil quantity monitoring method for a rotocaster according to claim 1, characterized by: The standard oil quantity V1 is 80% of the total capacity of the oil tank of the turnover machine.