A grab automatic control system and method for realizing coke whole-process treatment

Abstract

The present application relates to a kind of automatic control system and method of realizing coke whole process treatment grab, including grab space positioning detection module, material distribution detection module, external feeding port blocking material detection and auxiliary positioning module, DCS control cabinet, remote operation HMI, control software, to realize grab space positioning with the combination of encoder and reference limit switch, to realize material distribution detection with the combination of 2D fan laser and millimeter wave sensor, to grid automatic coke processing sub software, intelligent multi-strategy automatic coke processing sub software, multiple grab collaborative sub software, automatic tray library sub software and the like mode, full remote automatic operation, make personnel away from the scene harmful environment, ensure personnel health, while one person multiple machines, save manpower and improve efficiency, realize the coke processing process of remote, safe, automatic, high efficiency, with very high application value.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of petroleum delayed coking, in particular to a grab automatic control system and method for realizing coke whole-process treatment in a water vapor environment in a coke pool. BACKGROUND

[0002] In the field of petrochemical industry, coke in a delayed coking device is discharged from a discharge port into a coke pool, and a grab crane is used to complete the treatment process of coke, such as unblocking the discharge port, stacking and filtering water, and feeding outside. The grab crane is arranged above the coke pool and is one or more, and the driver observes and manually operates in the on-site cab of the grab crane.

[0003] Due to the temperature difference of the environment, a large amount of water vapor is transpired in the coke pool and diffused above the coke pool, which interferes with and hinders the observation of the driver to the material below, especially in the coke pool with a closed shed, because the air circulation is slow, the water vapor accumulates to form thick water mist, the visibility is less than 3 meters, and the water mist cannot be dispersed for a long time, so the driver cannot observe the coke below, which leads to the forced stop of production, and the grab operation can be resumed after the water vapor dissipates. The water vapor diffusion accounts for 40% of the production cycle, which seriously affects the production stability.

[0004] Due to the manual operation, the driver needs to operate in the grab cab above the coke pool for more than 7 hours a day. The coke emits toxic and harmful gases such as methane and hydrogen sulfide and distributes in the coke pool and above, which continuously endangers the personal health of the grab driver.

[0005] Generally, multiple grab cranes are arranged above the coke pool to operate simultaneously, and due to the manual operation, only one person can operate one machine, and it is impossible to realize one person operating multiple machines, so the unit value output of the employees is low.

[0006] As shown above, the current manual operation of the grab crane to treat the coke in the coke pool has the characteristics of being easily interfered by water vapor, limited operation or even unable to operate, continuous harm of the harmful environment on site to the health of the personnel, too many employees occupied by one-person-one-machine operation, and low unit value output of the employees, which cannot meet the development needs of modern chemical enterprises in health, safety, automation and high efficiency. SUMMARY

[0007] In view of the defects of the prior art, the purpose of the present application is to provide a grab automatic control system and control method for realizing coke whole-process treatment, which can safely, automatically and efficiently treat coke in a water vapor environment in a coke pool.

[0008] In order to achieve the above purpose, the technical solution adopted by the present application is:

[0009] The automatic control system of the grab bucket for coke full-process treatment comprises a grab bucket space positioning detection module, a material distribution detection module, a material blocking detection and auxiliary positioning module for the external feeding port, a DCS control cabinet, a remote operation HMI and control software; the grab bucket space positioning detection module comprises a displacement encoder and a reference limit switch; the material distribution detection module comprises a millimeter wave sensor and a 2D fan-shaped laser sensor; the material blocking detection and auxiliary positioning module for the external feeding port comprises a material blocking detection switch and a feeding port grab bucket auxiliary positioning module; the control software comprises a grid coke automatic processing sub-software, an intelligent multi-strategy coke automatic processing sub-software, a multi-grab bucket cooperation sub-software and an automatic stockyard sub-software; the DCS control cabinet is installed in a ground control room, and the remote operation HMI is installed in a ground operation room and used for displaying information and providing an operation interface to an operator; the control system uses the reference limit switch and the displacement encoder to realize accurate grab bucket space positioning, uses the millimeter wave sensor and the 2D fan-shaped laser sensor to realize material distribution detection in a water vapor environment, uses the feeding port grab bucket auxiliary positioning module to realize accurate alignment of the grab bucket to the center of the external feeding port, and realizes coke full-process treatment in a coke pool in combination with the control software.

[0010] Further, the displacement encoders are respectively installed on the shafts of the cart wheels, the trolley wheels and the grab bucket lifting drum; the reference limit switches are respectively installed at the starting end, the middle position and the terminal end of the cart guide rail and at the starting end, the middle position and the terminal end of the trolley guide rail, and the reference limit switches correct the values of the displacement encoders.

[0011] Further, the material distribution detection module uses a two-sensor switching mode to realize distribution detection of the coke in the coke pool in a water vapor environment; the millimeter wave sensor is installed above the discharge port and used for penetrating the water mist to detect the coke accumulation height below the discharge port; the millimeter wave sensor is installed on the trolley beam of the grab bucket crane and arranged at a certain interval and vertically downward to penetrate the water mist to detect the distributed coke height in the coke pool; the 2D fan-shaped laser sensor is installed on the trolley beam on each side of the grab bucket crane and vertically downward emits a plurality of laser beams to downward detect the distributed coke height in the coke pool and generate a three-dimensional coke distribution model.

[0012] Further, the material blocking detection switch is installed below the feeding port channel, and the feeding port grab bucket auxiliary positioning module comprises four proximity switches, wherein two proximity switches are installed in the X direction of the feeding port to detect that the cart moves above the feeding port; two proximity switches are installed in the Y direction of the feeding port to detect that the trolley moves above the feeding port; when the two proximity switches in the X direction and the Y direction both detect signals, it is represented that the grab bucket is located above the center of the feeding port.

[0013] Further, the grid coke automatic processing sub-software divides the XY plane of the coke pool bottom into several squares in the coordinate system of the coke pool, numbers each square to form a grid, and the size of each square should be equal to the opening area of the grab bucket; the numbering of the grid is sorted on the remote operation HMI, the system automatically controls the grab bucket, and the coke in the grid is sequentially grabbed according to the numbering arrangement order; when the numbering is not sorted, the system defaults to sequentially grab the materials in each grid according to 1, 2, 3... n.

[0014] Further, the intelligent multi-strategy coke automatic processing sub-software includes a high-point-first coke grabbing strategy, a coke grabbing strategy according to the priority of the region, a coke piling strategy according to the coke quality, and a coke feeding strategy according to the storage time of the coke, which fully meets the processing needs of the coke in the coke pool.

[0015] Further, the multi-grab bucket coordination sub-software assigns different priorities to the multiple grab bucket cranes; when working in the same region, the system preferentially controls the "high-priority grab bucket" to perform the work, and the "low-priority grab bucket" waits; when the high-priority grab bucket leaves the work region, the low-priority grab bucket starts and enters the work region to start working; when the high-priority grab bucket needs to enter the work region, the low-priority grab bucket in the work region stops the current work and avoids.

[0016] Further, the automatic stockyard sub-software divides the three-dimensional shape of the coke pile into N 100cm*100cm*H cubic columns by the control software, where H is the average value of the 100cm*100cm area at the top of the cubic column, the system calculates the volume of each cubic column, sums the volumes of all N cubic columns to calculate the overall volume of the coke pile, and then multiplies the coke density to obtain the weight of the coke pile, and then displays the volume and weight information on the remote operation HMI.

[0017] A grab bucket automatic control method for realizing coke whole-process processing using the control system, comprising the following working steps:

[0018] S1: The system automatically detects and dredges the discharge port; after the cutting of coke starts, the system detects the coke accumulation height in front of the discharge port through the millimeter wave sensor installed above the discharge port and penetrates the water mist;

[0019] When the system detects that the "actual coke accumulation height" reaches the "preset accumulation overheight alarm value", the system automatically controls the grab bucket crane to move above the discharge port, grabs and transports the coke in front of the discharge port to the stockyard area until the coke height value of the discharge port is lower than the "accumulation less unobstructed value", and the system automatically stops the grab bucket crane;

[0020] S2: The system automatically completes the detection of the distribution of coke in the coke pool; after cutting coke, the system starts the material distribution detection module, uses two sensors, a 2D fan-shaped laser sensor and a millimeter wave sensor, and overcomes the interference of water vapor in the coke pool to complete the detection of the material in the coke pool;

[0021] The system drives the trolley of the grab crane along the X-axis direction, i.e., the direction of the trolley guide rail, from the starting point to the end, and detects the material distribution value Y and the height Z at different X coordinates. The system combines the X coordinate and the material distribution height values Y and Z in the control software to form a three-dimensional model.

[0022] S3: The system controls the grab crane to automatically grab and stack coke in the coke pool; the system can use a coke grabbing strategy including "grid-based automatic coke handling, high-point-first coke grabbing strategy, coke grabbing strategy according to regional priority, coke stacking strategy according to coke quality, and feeding strategy according to coke storage time", automatically controls the grab crane to move above the coke, automatically performs the opening-lowering-closing-raising action of the grab, drives the trolley to move to the stacking target point, opens the grab to release the material, and then the system controls the grab crane to return above the coke, automatically performs the opening-lowering-closing-raising action of the grab to grab the material, and repeats the cycle until all the coke in the coke pool is moved to the stacking point. The system automatically stops the grab crane and returns to the parking position.

[0023] S4: The system automatically completes the inventory of the material in the coke pool; after stacking, the system starts the "automatic inventory sub-software", drives the grab crane to pass above the material pile, uses the material distribution detection module to detect the material pile, generates a three-dimensional graph of the material pile, and then the system uses the "automatic inventory sub-software" to calculate the overall volume of the material pile, multiplies the coke density to obtain the weight of the coke pile, and displays the information on the remote operation HMI.

[0024] S5: The system automatically completes the external feeding; after the material pile is filtered, the system detects the state of the feeding port, and when the blockage detection switch does not send a blockage signal, the system automatically controls the grab crane to grab the material from the material pile, controls the grab crane to move above the feeding port, relies on the grab auxiliary positioning module of the feeding port to make the grab accurately stop above the feeding port, opens the grab to unload, and then returns to the material pile to grab the material, and repeats the cycle until the external feeding amount reaches the demand.

[0025] In step S2, the two sensor switching cooperation is that the system first uses the 2D fan-shaped laser sensor to detect the coke distribution in the coke pool; when the laser sensor detects that the distance between more than 50% of the total material range and the laser sensor itself is greater than 5 meters, the system automatically determines that "the on-site environment is less disturbed by water vapor, and the detection can be normally carried out", and the system continues to use the 2D fan-shaped laser sensor to detect and complete the material detection; when the laser sensor detects that the distance between more than 50% of the total material range and the laser sensor itself is less than 5 meters, the system automatically determines that "the on-site environment is too much water vapor, and the laser detection is disturbed"; the system automatically switches the detection mode to the millimeter wave sensor, and uses the millimeter wave sensor to detect and complete the material detection.

[0026] Beneficial effects: 1. In the application: the method for detecting the discharge port coke accumulation height using the millimeter wave sensor overcomes the hindering effect of a large amount of water vapor transpired from the discharge port on the line of sight, penetrates the water vapor to accurately detect the material accumulation height of the discharge port, discovers the material overmuch condition in time, and the system automatically controls the grab crane to remove the coke overmuch at the discharge port, ensures the smoothness of the discharge port, avoids the situation that the coke is accumulated too much to block the production due to the blocked line of sight during manual operation, and reduces the production loss of the enterprise.

[0027] 2. In the application, the method for detecting the coke distribution in the coke pool using the laser sensor and the millimeter wave sensor solves the congenital defect that the laser cannot penetrate the water vapor, and overcomes the influence of the water vapor in the coke pool on the material detection. The laser sensor cannot be used for detection in the water vapor environment, and the production is forced to stop, which causes loss. In comparison, the combination of the two detection methods and the automatic switching method can realize the detection of the material in the water vapor environment, realize the whole process treatment of the coke, effectively ensure the stability of the production, and avoid the loss caused by the stop of the production.

[0028] 3. In the application, the displacement detection method combining the reference limit and the encoder effectively eliminates errors and provides higher accuracy for automatic control.

[0029] 4. In the application, the auxiliary positioning setting used in the feeding port in combination with the encoder effectively ensures that the grab accurately stops above the feeding port, eliminates the position control error, makes the material fall more smoothly, and also avoids the material scattering outside the feeding port due to the misalignment of the grab and the feeding port.

[0030] 5、In the present application, the coke distribution is detected by using the instrument sensor instead of the visual observation of the artificial eyes, and the remote control technology is used, so that all operations are realized on the remote operation HMI, and the operators are away from the dangerous, toxic and harmful environment, so that the personal safety and health of the operators are effectively ensured.

[0031] 6、In the present application, the coke is automatically processed in the whole process from the first link of discharging cooperating with dredging to the intermediate link of grabbing coke and stacking and filtering water to the last link of feeding, so that the labor intensity of the operators is reduced, and the coke in the coke pool is provided with the inventory statistics, so that the artificial rough observation statistics are replaced, and the accurate statistical information is provided to facilitate the production management.

[0032] 7、In the present application, the system can control one grab bucket crane to remotely and automatically work, and can also control multiple grab bucket cranes to cooperatively and remotely work in the same coke pool, so that one operator can operate multiple machines, the work efficiency is improved, and the customers are helped to save the human resources. BRIEF DESCRIPTION OF DRAWINGS

[0033] Figure 1 The system composition diagram of the present application;

[0034] Figure 2 The coke pool and the grab bucket crane of the present application;

[0035] Figure 3 The position diagram of each part of the present application;

[0036] Figure 4 The 2D laser detection principle diagram of the material distribution detection module of the present application;

[0037] Figure 5 The millimeter wave detection principle diagram of the material distribution detection module of the present application;

[0038] Figure 6 The grid working diagram in the grid coke automatic processing sub-software of the present application;

[0039] Figure 7 The strategy working diagram in the intelligent multi-strategy coke automatic processing sub-software of the present application;

[0040] Figure 8 The working diagram of the automatic inventory sub-software of the present application;

[0041] Marked in the figure: 1, grab crane, 2, grab space positioning detection module, 3, material distribution detection module, 4, external feeding port blocking detection and auxiliary positioning module, 5, DCS control cabinet, 6, remote operation HMI, 7, control software, 8, grid coke automatic processing sub-software, 9, intelligent multi-strategy coke automatic processing sub-software, 10, multi-grab cooperative sub-software, 11, automatic inventory sub-software, 12, reference limit switch, 13, displacement encoder, 14, 2D fan-shaped laser sensor, 15, millimeter wave sensor, 16, blocking detection switch, 17, feeding port grab auxiliary positioning module; 18, coke pool, 19, coke, 20, discharge port, 21, external feeding port, 22, cart guide rail, 23, cart, 24, cart wheel, 25, cart beam, 26, trolley, 27, trolley wheel, 28, lifting drum, 29, cable or optical fiber, 30, motor control cabinet; 31, radar wave, 32, laser beam; 33, grid, 34, coke pile height point, 35, coke pile low point, 36, high-quality coke pile, 37, low-quality coke pile, 38, coke pile with long storage time, 39, coke pile with short storage time, 40, cubic column. DETAILED DESCRIPTION

[0042] The specific embodiments are given below to further clearly, completely and specifically describe the technical solutions of the present application. It should be noted that the directions or positional relationships of the terms "X-axis direction", "Y-axis direction", "Z-axis direction" and the like in the present application indicate the directions or positional relationships based on the directions or positional relationships shown in the drawings, which are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular direction, be constructed and operated in a particular direction, and cannot be understood as a limitation on the present application.

[0043] As shown in Figures 1-8 A grab automatic control system for realizing coke whole-process processing in a coke pool under a water vapor environment, based on a grab crane 1, includes a grab space positioning detection module 2, a material distribution detection module 3, an external feeding port blocking detection and auxiliary positioning module 4, a DCS control cabinet 5, a remote operation HMI 6, and a control software 7. Among them, in the coke pool, the spatial coordinate system inside the coke pool is established with the cart movement direction (X direction) of the grab crane 1, the trolley movement direction (Y direction), and the grab movement direction (Z direction) as the reference, the grab crane 1 is located above the coke pool, and contains necessary general components such as the cart 23, the trolley 26, the grab, and the motor control cabinet 30, and the motor control cabinet is connected with the grab crane through the cable or optical fiber 29.

[0044] The grab space positioning detection module 2 comprises a reference limit switch 12 and a displacement encoder 13; the reference limit switch 12 is installed at the starting end, the middle position and the terminal end of the cart guide rail 22, and serves as the reference of the 0 value, the middle value and the maximum value of the X direction respectively; the reference limit switch 12 is also installed at the starting end, the middle position and the terminal end of the trolley guide rail, and serves as the reference of the 0 value, the middle value and the maximum value of the Y direction respectively; the reference limit switch 12 performs absolute correction on the value of the displacement encoder 13, and the two detection modes are matched to eliminate the displacement detection error caused by wheel skidding and realize the effect of accurate positioning of the grab.

[0045] Further, when the cart 23 passes through the reference limit switch 12 at the starting point, the middle position and the terminal position of the cart guide rail 22, the X-axis value of the grab is corrected to 0 value, 1 / 2 value and full-scale value respectively to eliminate the encoder detection error caused by wheel skidding and realize the effect of accurate positioning; the working principle of the reference limit switch of the trolley 26 is the same as that of the cart.

[0046] The displacement encoder 13 is installed on the shaft of the cart wheel 24, rotates with the wheel and detects the coordinate value of the grab in the X direction; the displacement encoder 13 is installed on the shaft of the trolley wheel 27, rotates with the wheel and detects the coordinate value of the grab in the Y direction; the displacement encoder 13 is installed on the shaft of the lifting drum 28, rotates with the drum and detects the coordinate value of the grab in the Z direction; the spatial position coordinates of the grab in the focus pool coordinate system are determined through the XYZ coordinate values.

[0047] The material distribution detection module 3 comprises a 2D fan-shaped laser sensor 14 and a millimeter wave sensor 15; as shown in Figure 4 The 2D fan-shaped laser sensor 14 is installed on the cart beam 25 on both sides of the grab crane 1, vertically emits a plurality of laser beams 32 downward, detects the height of the coke distributed in the focus pool downward, and generates a three-dimensional model of the coke distribution; as shown in Figure 5 The millimeter wave sensor 15 is installed above the discharge port 20, vertically emits radar waves 31 downward, detects the coke accumulation condition of the discharge port 20 downward; the millimeter wave sensor 15 is also installed below the cart beam 25 of the grab crane 1, is arranged in a certain interval and is installed in a plurality of ways, vertically emits radar waves 31 downward, detects the coke distribution condition at the bottom of the focus pool downward, and generates a three-dimensional model of the coke distribution.

[0048] Furthermore, the 2D fan-shaped laser sensor 14 calculates the distance from the sensor to the material by multiplying the time difference between emitting the laser beam and receiving the returned laser beam by the speed of light; the 2D fan-shaped laser sensor 14 emits a number of laser beams 32 in a fan-shaped plane, the fan-shaped plane is parallel to the YZ plane, the laser beams are emitted in the Z-axis direction, and the range of the laser beams emitted in the fan-shaped plane covers the width of the coke pool (Y direction).

[0049] Furthermore, the millimeter-wave sensor 15 emits radar waves 31 with a beam angle of less than 6° to detect downwards, and calculates the distance from the sensor to the material based on the time difference between the emitted wave and the echo; the millimeter-wave sensor 15 operates at a frequency of 3-30GHz and a wavelength of 1-10mm, and has good penetration capabilities for fog, smoke, and dust, and can penetrate water vapor in the coke pool to detect the material in the coke pool.

[0050] The system uses two sensor switching methods to detect the distribution of coke in the coking pool under water vapor conditions. First, the system uses a 2D fan-shaped laser sensor 14 to detect the coke in the coking pool. When the 2D fan-shaped laser sensor 14 detects that "more than 50% of the material is more than 5 meters away from the laser itself," the system automatically determines that "there is little water vapor interference in the environment, and detection can proceed normally," and the system continues to use the 2D fan-shaped laser sensor 14 to complete the coke material detection. When the 2D fan-shaped laser sensor 14 detects that "more than 50% of the material is less than or equal to 5 meters away from the laser itself," the system automatically determines that "there is too much water vapor in the environment, interfering with laser detection," and the system automatically switches to a millimeter-wave sensor 15, which penetrates the water vapor, to continue and complete the coke material detection.

[0051] The aforementioned external feed port blockage detection and auxiliary positioning module 4 includes a blockage detection switch 16 and a feed port grab auxiliary positioning module 17; as follows Figure 3 As shown, the blockage detection switch 16 is installed below the feeding port channel. When the feeding port is blocked and the material cannot fall, a blockage signal is issued, and the system controls the grab crane to stop feeding material into the feeding port. The feeding port grab auxiliary positioning module 17 includes four proximity switches. Two are installed along the edge of the feeding port in the X direction, with the spacing between them equal to the width of the trolley and the center point of the spacing equal to the center point of the feeding port. Two are installed in the Y direction of the feeding port, with the spacing between them equal to the width of the trolley and the center point of the spacing equal to the center point of the feeding port. When two proximity switches in the X direction detect a signal simultaneously, it means that the trolley 23 has been aligned with the center of the feeding port. When two proximity switches in the Y direction detect a signal simultaneously, it means that the trolley 26 has been aligned with the center of the feeding port. At this time, it means that the grab is located above the center of the feeding port.

[0052] The DCS control cabinet 5 is installed in the ground control room, and contains a controller, a signal module, and a network element, which is used to receive the grab position signal on site, receive the signal of the material distribution detection on site, and display on the remote operation HMI, and simultaneously, the grab automatic control software 7 is built-in, and the control command is output to drive the grab crane to automatically complete the whole process of handling the coke in the coke pool in a remote mode.

[0053] The remote operation HMI 6 is installed in the ground operation room, and displays information to the operator and provides an operation interface.

[0054] The control software 7 contains a grid coke automatic handling sub-software 8, an intelligent multi-strategy coke automatic handling sub-software 9, a multi-grab cooperative sub-software 10, and an automatic inventory sub-software 11.

[0055] The grid coke automatic handling sub-software 8 realizes the method that the XY plane of the bottom of the coke pool is divided into a plurality of grids in the coordinate system of the coke pool, and each grid is numbered; the size of the grid is equal to the area of the grab opening, the grid automatic coke handling function is activated on the remote operation HMI 6, the system automatically controls the grab to grab the material in the grid one by one until the whole coke grabbing is completed.

[0056] As shown in Figure 6 The grid coke automatic handling sub-software 8 can sort the selected grid 33 number on the remote operation HMI 6, and the system automatically controls the grab to grab the coke in the grid 33 in the order of the number arrangement; the grid coke automatic handling sub-software 8 can select the range of the grid on the remote operation HMI 6, and the system automatically controls the grab to grab the coke in the selected grid 33, and the coke in the unselected grid 33 is not handled.

[0057] As shown in Figure 7 The intelligent multi-strategy coke automatic handling sub-software 9 realizes the method that the "high-point-first coke grabbing strategy, the coke grabbing strategy according to the priority of the area, the coke stacking strategy according to the coke quality, and the coke feeding strategy according to the storage time of the coke" are set in the control software, and the processing demand of the coke in the coke pool is fully met.

[0058] Further, the "high-point-first coke grabbing strategy" is that, in the three-dimensional coke distribution model in the coke pool, the coke distribution is divided into a plurality of grids 33 according to the projection area of the grab as the minimum unit, each grid 33 is uniquely numbered, then the control software filters the average height data of the coke in each grid 33, sorts the grid according to from high to low, and then grabs and transports the coke according to the order from high to low, Figure 7 In the figure, 34 represents the high point of the coke pile, and 35 represents the low point of the coke pile.

[0059] Further, the "regional priority grabbing strategy" is that in the coke distribution area (bottom XY plane), a certain area is selected and marked with priority on the remote operation HMI 6 by mouse dragging and dropping or inputting area coordinate values. The system automatically controls the grab bucket crane according to the number of selected areas and the priority number, first performs the grabbing and conveying operation of the high-priority area, and then performs the grabbing and conveying operation of the low-priority area until the coke in the selected area is processed.

[0060] Further, the "coke stacking strategy according to coke quality" is that two coke stacking areas are selected in the coke 19 distribution range (bottom XY plane) by operating the remote operation HMI 6, and the attributes are marked as high-quality coke stack 36 and low-quality coke stack 37, respectively. When the cut coke 19 is high-quality coke, the high-quality coke stacking operation is activated on the remote operation HMI 6, and the system controls the grab bucket crane to automatically grab the coke in front of the discharge port and stack it in the high-quality coke stack 36 stacking area. The stacking of coke of other qualities is the same as above.

[0061] Further, the "coke feeding strategy according to storage time" is that the system detects the shape of the stored material pile in the coke pool by the millimeter wave sensor 15 and the 2D fan-shaped laser sensor 14, numbers the material pile, records the starting time of the material pile, calculates the storage time, and displays it on the remote operation HMI 6. The operator can select which material pile to feed out according to the time length on the remote operation HMI 6, and the system controls the grab bucket crane 1 to grab the material from the pile for external feeding. When other material piles are not selected, no external feeding is performed. Figure 7 The reference sign 38 refers to a coke pile with long storage time, and 39 refers to a coke pile with short storage time.

[0062] Further, the multi-grab bucket cooperative sub-software 10 is that when the control object includes multiple grab bucket cranes 1 working together in one coke pool 18, the system assigns each grab bucket with a priority. When multiple grab bucket cranes enter a working area at the same time, the system controls the "high-priority grab bucket" to perform the grabbing action, and the "low-priority grab bucket" waits. When the high-priority grab bucket leaves the working area, the low-priority grab bucket starts and enters the working area to perform the grabbing action. When the low-priority grab bucket is working in the working area, the high-priority grab bucket needs to enter the working area, the low-priority grab bucket stops the current work and avoids, and after the high-priority grab bucket leaves the working area, the low-priority grab bucket starts and enters the working area to perform the grabbing action.

[0063] Further, the automatic stockyard sub-software 11 is that the system detects the shape of each stockpile in the coke pool through the millimeter wave sensor 15 and the 2D fan-shaped laser sensor 14, the system divides the stockpile into a plurality of 100cm*100cm*H cubic columns 40, wherein H is the average value of the 100cm*100cm area at the top of the cubic column 40, the system calculates the volume of each cubic column 40, and sums all the cubic columns 40 to calculate the overall volume of the stockpile, multiplies the coke density to obtain the weight of the coke stockpile, and then displays the volume and weight information on the remote operation HMI 6.

[0064] A grab automatic control system for realizing the whole process treatment of coke in a water vapor environment in the coke pool can automatically complete the whole treatment process of coke from the first link "starting to discharge from the discharge port, cooperating with dredging", to the intermediate link "grabbing coke stockpile, filtering water", to the last link "feeding outside", and the working steps of the whole process treatment are as follows:

[0065] S1: The system automatically detects and dredges the discharge port 20. After the cutting of coke starts, the operator activates the control software 7 of the system on the HMI, and the system detects the height of the coke accumulation in front of the discharge port 20 through the millimeter wave sensor 15 installed above the discharge port 20.

[0066] The system compares the detected real-time data with the system preset "accumulation overheight alarm value" and "accumulation less smoothness value", when the height of the coke accumulation reaches the preset accumulation overheight alarm value, the system automatically starts the grab crane 1 to move above the discharge port 20, opens the grab to descend and grab the material, and transports the coke to the stockpile area, then the system automatically controls the grab to return to the discharge port 20 above, continues to grab the coke and transports it to the stockpile area, and circulates repeatedly until the coke height value of the discharge port 20 is lower than the "accumulation less smoothness value", the system automatically stops the grab crane and returns it to the parking position.

[0067] S2: The system automatically completes the distribution detection of coke in the coke pool. After cutting coke, the discharge port 20 no longer discharges, and the coke is irregularly distributed in the coke pool. The system starts the material distribution detection module 3, and uses two kinds of sensors to switch and cooperate to complete the detection of the material in the coke pool; the system first drives the grab crane 1 along the X-axis direction (the trolley guide rail) from the starting point to the end, and detects the material distribution value (Y) and height (Z) at different X coordinates, and the system combines the X coordinate and the material distribution height value (Y and Z) in the control software to form a three-dimensional model.

[0068] Further, in step S2, the two sensor switching cooperation is that the system first uses the 2D fan-shaped laser sensor 14 to detect the coke distribution in the focus pool. When the material (more than 50% of the total material range) detected by the 2D fan-shaped laser sensor 14 is more than 5 meters away from the 2D fan-shaped laser sensor 14 itself, the system automatically determines that "the on-site environment has less water vapor interference, and the detection can be normally carried out", and the system continues to use the 2D fan-shaped laser sensor 14 to complete the material detection. When the material (more than 50% of the total material range) detected by the 2D fan-shaped laser sensor 14 is less than 5 meters away from the laser itself, the system automatically determines that "the on-site environment has too much water vapor, and the laser detection is disturbed", and the system automatically switches the detection mode to the millimeter wave sensor 15. The millimeter wave sensor 15 is used to complete the material detection.

[0069] S3: The system controls the grab crane to automatically grab and stack the coke distributed in the focus pool. According to the different grab coke conveying modes preset on the remote operation HMI 6, the system uses "grid automatic coke processing, high point priority grab coke strategy, priority grab coke strategy according to area, coke quality stacking strategy, and coke storage time feeding strategy" to control the grab crane to move above the coke, automatically execute the opening-lowering-closing-raising action of the grab, drive the trolley to move to the stacking target point, open the grab to release the material, and then the system controls the grab crane to return to the top of the coke, automatically executes the opening-lowering-closing-raising action of the grab to grab the material, and repeats the cycle until all the coke in the focus pool is moved to the stacking point. The system automatically stops the grab crane and returns to the parking position.

[0070] S4: The system automatically completes the inventory statistics into the focus pool. After stacking is completed, the system automatically starts the "automatic inventory sub-software", drives the grab crane to pass above the material pile, uses the material distribution detection module 3 to detect the material pile, and generates a three-dimensional graph of the material pile. Then the system divides the three-dimensional shape of the material pile into a plurality of 100cm*100cm*H cubic columns 40 in the control software 7, wherein H is the average value of the 100cm*100cm area at the top of the cubic column. The system calculates the volume of each cubic column 40, sums all the cubic columns 40, calculates the overall volume of the material pile, multiplies the coke density to obtain the weight of the coke material pile, and the related information is displayed on the remote operation HMI 6.

[0071] S5: the system automatically completes the feeding to the outside. After the filter water of the material pile is completed, the system detects the feeding port 21. After the blockage detection switch 16 does not detect the blockage signal, the system automatically controls the grab crane to grab the material from the material pile, and controls the grab crane to move to the top of the feeding port and open the grab to unload. The position coordinates of the feeding port 21 are set in advance on the remote operation HMI. The system controls the grab crane to return to the material pile to continue to grab the material, move to the top of the feeding port 21, open the grab to unload, and so on, until the feeding to the outside reaches the demand.

[0072] The system of the present application realizes the automatic processing of the coke in the whole process from the first link of "starting to discharge from the discharge port and cooperating with dredging" to the intermediate link of "grabbing the coke pile and filtering water" to the last link of "feeding to the outside", reduces the labor intensity of the workers, and provides the statistics of the coke in the coke pool, replaces the rough observation and statistics of the workers, and provides accurate statistical information to facilitate the production management.

[0073] The control system of the present application can control one grab crane to remotely and automatically work, or can control multiple grab cranes to cooperatively and remotely work in the same coke pool, realizes the operation of one person and multiple machines, improves the work efficiency, and helps the customers to save the human resources and costs.

[0074] The above is only a specific embodiment of the present application, but the protection scope of the present application is not limited to this. Any deformation or replacement of the present application in the technical scope of the present application should be covered in the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. An automatic control system for grab buckets that realizes the entire process of coke processing, comprising a grab bucket spatial positioning detection module, a material distribution detection module, a blockage detection and auxiliary positioning module for the external feed port, a DCS control cabinet, a remote operation HMI, and control software; characterized in that, The grab bucket spatial positioning detection module includes a displacement encoder and a reference limit switch; the material distribution detection module includes a millimeter-wave sensor and a 2D sector laser sensor; the external feed port blockage detection and auxiliary positioning module includes a blockage detection switch and a feed port grab bucket auxiliary positioning module; the control software includes a gridded coke automatic processing sub-software, an intelligent multi-strategy coke automatic processing sub-software, a multi-grab bucket coordination sub-software, and an automatic inventory sub-software; the gridded coke automatic processing sub-software divides the XY plane at the bottom of the coke pool into several squares in the coordinate system of the coke pool, numbers each square to form a grid, and the size of a single square should be equal to the opening area of ​​the grab bucket; The grid numbers are sorted on the remote operation HMI, and the system automatically controls the grab bucket to grab the coke in the grid sequentially according to the numbering order. If the numbers are not sorted, the system defaults to grabbing the material in each grid one by one according to 1, 2, 3...n. The DCS control cabinet is installed in the ground control room, and the remote operation HMI is installed in the ground operation room to display information and provide an operation interface for operators. The control system uses reference limit switches and displacement encoders to achieve precise spatial positioning of the grab bucket, uses millimeter-wave sensors and 2D fan-shaped laser sensors to detect material distribution in a water vapor environment, and uses a feed port grab bucket auxiliary positioning module to ensure that the grab bucket is accurately aligned with the center of the external feed port. Combined with the control software, the entire process of coke processing in the coke pool is realized.

2. The grab bucket automatic control system for realizing the whole process of coke processing as described in claim 1, characterized in that: The displacement encoders are respectively installed on the axles of the main trolley wheels, the axles of the trolley wheels, and the axle of the grab bucket lifting drum; the reference limit switches are respectively installed at the starting end, intermediate position, and ending end of the main trolley guide rail, and at the starting end, intermediate position, and ending end of the trolley guide rail, and the reference limit switches correct the values ​​of the displacement encoders.

3. The grab bucket automatic control system for realizing the whole process of coke processing as described in claim 1, characterized in that: The material distribution detection module uses two sensor switching methods to detect the distribution of coke in the coke pool under a steam environment. The millimeter-wave sensor is installed above the discharge port to penetrate the water mist and detect the coke accumulation height below the discharge port. The millimeter-wave sensors are also installed on the beams of the grab crane, arranged at certain intervals, to penetrate the water mist vertically downwards and detect the height of the distributed coke in the coke pool. One 2D fan-shaped laser sensor is installed on each side of the grab crane's main beam, emitting several laser beams vertically downwards to detect the height of the distributed coke in the coke pool and generate a three-dimensional model of the coke distribution.

4. The grab bucket automatic control system for realizing the whole process of coke processing as described in claim 1, characterized in that: The aforementioned blockage detection switch is installed below the feed inlet channel. The feed inlet grab auxiliary positioning module includes four proximity switches: two along the X-axis edge of the feed inlet to detect when the trolley has moved above the feed inlet; and two along the Y-axis to detect when the trolley has moved above the feed inlet. When both the X-axis and Y-axis proximity switches detect a signal, it indicates that the grab is positioned above the center of the feed inlet.

5. The grab bucket automatic control system for realizing the whole process of coke processing as described in claim 1, characterized in that: The intelligent multi-strategy coke automatic processing sub-software includes a high-point priority coke grabbing strategy, a region-based priority coke grabbing strategy, a coke-based high-low coke stacking strategy, and a coke-based feeding strategy, which fully meets the coke processing needs in the coke pool.

6. The grab bucket automatic control system for realizing the whole process of coke processing as described in claim 1, characterized in that: The aforementioned multi-grab bucket coordination sub-software assigns different priorities to multiple grab bucket cranes. When operating in the same area, the system prioritizes controlling the "high-priority grab bucket" to perform the operation, while the "low-priority grab bucket" waits. When the high-priority grab bucket leaves the operating area, the low-priority grab bucket starts and enters the operating area to begin its operation. When the high-priority grab bucket needs to enter the operating area, the low-priority grab buckets in the operating area stop their current work and give way.

7. The grab bucket automatic control system for realizing the whole process of coke processing as described in claim 1, characterized in that: The aforementioned automatic inventory software divides the three-dimensional shape of the coke pile into N 100cm*100cm*H cubic columns through control software, where H is the average value of the top 100cm*100cm area of ​​the cubic column. The system calculates the volume of each cubic column and sums the volumes of all N cubic columns to calculate the overall volume of the coke pile. Then, it multiplies the overall volume by the coke density to obtain the weight of the coke pile. Finally, the volume and weight information are displayed on the remote operation HMI.

8. A method for automatic control of a grab bucket for the entire process of coking using the control system described in any one of claims 1-7, characterized in that, The following steps are included: S1: The system automatically detects and clears the discharge port; after coke cutting begins, the system uses a millimeter-wave sensor installed above the discharge port to penetrate the water mist and detect the height of the coke accumulation in front of the discharge port. When the system detects that the "actual coke stacking height" reaches the "preset stacking height alarm value", the system automatically controls the grab crane to move above the discharge port, grab the coke in front of the discharge port and transport it to the stacking area until the coke height value at the discharge port is lower than the "stacking less unobstructed value", the system automatically stops the grab crane. S2: The system automatically completes the distribution detection of coke in the coke pool; after coke cutting, the system starts the material distribution detection module, using two types of sensors, a 2D fan-shaped laser sensor and a millimeter-wave sensor, to overcome the interference of water vapor in the coke pool and complete the detection of materials in the coke pool. The system drives the grab crane's trolley along the X-axis, i.e., the direction of the trolley guide rail, from the starting point to the end point. At different X coordinates, the material distribution value Y and height Z are detected respectively. In the control software, the system combines the X coordinates and the material distribution height values ​​Y and Z to form a three-dimensional model. S3: The system controls the grab crane to automatically grab and stack coke in the coke pool. The system can use grab strategies including "grid-based automatic coke processing, high-point priority grab strategy, area-based priority grab strategy, coke quality-based stacking strategy, and coke storage time-based feeding strategy". The system automatically controls the grab crane to move above the coke and automatically executes the grab opening-lowering-closing-rising action to drive the trolley to the stacking target point. The grab crane is opened to release the material. Then the system controls the grab crane to return to above the coke and automatically executes the grab opening-lowering-closing-rising action to grab material. This cycle is repeated until all the coke in the coke pool is moved to the stacking point. The system then automatically stops the grab crane and returns to the parking position. S4: The system automatically completes the inventory and statistics of materials in the coke pit; after the material is piled up, the system starts the "automatic inventory sub-software", drives the grab crane to pass over the material pile, uses the material distribution detection module to detect the material pile, generates a three-dimensional image of the material pile, and then the system uses the "automatic inventory sub-software" to calculate the overall volume of the material pile, multiplies it by the coke density to obtain the weight of the coke material pile, and displays the information on the remote operation HMI; S5: The system automatically completes external material feeding; after the material pile is filtered, the system detects the status of the feeding port. When the blockage detection switch does not send a blockage signal, the system automatically controls the grab crane to grab material from the material pile and controls the grab crane to move above the feeding port. Relying on the grab bucket auxiliary positioning module of the feeding port, the grab bucket is accurately stopped above the feeding port, opens the grab bucket to unload material, and then returns to the material pile to grab material. This cycle is repeated until the external material feeding volume reaches the requirement.

9. The automatic control method for grab buckets to realize the whole process of coke processing as described in claim 8, characterized in that, In step S2, the switching between the two sensors is as follows: First, the system uses a 2D fan-shaped laser sensor to detect the distribution of coke in the coke pool. When the laser sensor detects that more than 50% of the total material area is more than 5 meters away from the laser sensor itself, the system automatically determines that "there is little water vapor interference in the environment, and detection can be performed normally," and the system continues to use the 2D fan-shaped laser sensor to perform and complete the material detection. When the laser sensor detects that more than 50% of the total material area is less than 5 meters away from the laser sensor itself, the system automatically determines that "there is too much water vapor in the environment, and laser detection is interfered with." The system automatically switches the detection mode to a millimeter-wave sensor and uses the millimeter-wave sensor to perform and complete the material detection.

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