Coke oven vehicle anti-collision system and method based on ultrasonic technology

Abstract

The present application relates to a kind of coke oven vehicle anti-collision systems and methods based on ultrasonic technology, including electric locomotive, coke quenching vehicle, vehicle PLC control system, also including signal acquisition unit and signal analysis processing unit, signal acquisition unit and signal analysis processing unit are wirelessly connected, signal acquisition unit is set on coke quenching vehicle, signal analysis processing unit is set on electric locomotive, vehicle PLC control system is connected with signal analysis processing unit.The present application has the advantages that: wired connection between coke quenching vehicle and electric locomotive is transformed into wireless connection, the workload of coke quenching vehicle replacement maintenance is reduced, and the risk of system failure caused by cable breakage is also eliminated;Ultrasonic range finder and signal transmitter are arranged on coke quenching vehicle, which reduces the debugging difficulty and debugging workload;Touch screen is used to facilitate coking production and system maintenance, and operating personnel can check real-time distance information with adjacent coke quenching vehicle at any time.

Description

Technical Field

[0001] The present invention relates to a coke oven vehicle anti-collision system in the coking industry, and in particular to a coke oven vehicle anti-collision system and method based on ultrasonic technology. Background Art

[0002] Safety issues in coking operations are receiving increasing attention. The "four coking cars"—coal loading cars, coke pushers, coke blocking cars, and coke quenching cars—are crucial equipment in coking operations. Collisions between vehicles on the same track are common due to factors such as inclement weather, driver misoperation, and management issues. Severe collisions can cause casualties, property damage, and even halt coke oven production. In recent years, numerous solutions have been developed to address the issue of coke oven vehicle collision avoidance. Among these, ultrasonic-based coke oven vehicle collision avoidance systems have been implemented in numerous technical upgrades and new coke oven projects within the coking industry.

[0003] The existing coke oven vehicle anti-collision system based on ultrasonic technology utilizes the characteristics of ultrasonic waves that have strong anti-interference capabilities under harsh working conditions such as dust, electromagnetic fields, and steam, and still has good target capture capabilities in unfavorable environments such as vehicle shaking and local uneven track surfaces; at the same time, the system also has the advantages of low operating costs and easy maintenance.

[0004] However, in the application case of anti-collision of coke quenching cars (or coke tank cars), it was found that this technical solution still has certain disadvantages in the following aspects and needs further improvement and perfection.

[0005] 1) The existing solution places the ultrasonic rangefinder and reflector at the front of the outermost quenching car, with the control box located in the locomotive cab. To facilitate quenching car maintenance, the dedicated cables between the cars are connected via aviation plugs. In practice, this approach not only increases the workload of replacing the quenching cars but also makes it easy for the cables to be torn due to operator error, causing system failure.

[0006] 2) The existing technical solution sets the control box (including the signal transmitter) in the locomotive cab to facilitate debugging. However, for the debugging of the coke quenching car, since the coke quenching car must be disassembled and replaced, it actually increases the difficulty and workload of debugging.

[0007] 3) The existing technical solution has no human-machine interactive interface, and the process of system parameter setting and status confirmation is complicated, which is not conducive to daily maintenance. Summary of the Invention

[0008] In order to overcome the shortcomings of the existing technology, the purpose of the present invention is to provide a coke oven vehicle anti-collision system and method based on ultrasonic technology, in which a signal acquisition unit is arranged on the coke quenching vehicle, a signal analysis and processing unit is arranged on the electric locomotive, and the signal acquisition unit and the signal analysis and processing unit are wirelessly connected.

[0009] To achieve the above object, the present invention is implemented through the following technical solutions:

[0010] A coke oven vehicle anti-collision system based on ultrasonic technology includes an electric locomotive, a coke quenching vehicle, an on-board PLC control system, and also includes a signal acquisition unit and a signal analysis and processing unit. The signal acquisition unit and the signal analysis and processing unit are wirelessly connected. The signal acquisition unit is arranged on the coke quenching vehicle, the signal analysis and processing unit is arranged on the electric locomotive, and the on-board PLC control system is connected to the signal analysis and processing unit.

[0011] The signal acquisition unit includes an ultrasonic rangefinder, a reflector, a signal transmitter, and a transmitting controller of a wireless analog quantity acquisition module. The ultrasonic rangefinder and the signal transmitter are connected through a port, and the signal transmitter and the transmitting controller of the wireless analog quantity acquisition module are connected through a port.

[0012] The signal analysis and processing unit includes a receiving controller of the wireless analog quantity acquisition module, a touch screen, an alarm device, and a PLC controller. The receiving controller and the touch screen of the wireless analog quantity acquisition module are respectively connected to the PLC controller through a communication port, and the alarm device is connected to the PLC controller through a port.

[0013] The transmitting controller of the wireless analog quantity acquisition module is wirelessly connected to the signal analysis and processing unit.

[0014] The ultrasonic rangefinder consists of a horn-shaped radiation chamber, a piezoelectric ceramic ring, a conical wave receiver and a terminal chamber. The conical wave receiver is fixed in the horn-shaped radiation chamber through a slot on the top of the horn-shaped radiation chamber. The conical wave receiver has a hollow structure and is filled with sound-absorbing material. A piezoelectric ceramic ring is provided on the outside of the conical wave receiver, and the bottom of the piezoelectric ceramic ring extends to the middle and lower part of the horn-shaped radiation chamber. A terminal chamber is provided on the top of the horn-shaped radiation chamber, and a soft gasket for damping is provided between the connecting surfaces of the two. A terminal board is provided in the terminal chamber, and the positive and negative poles of the piezoelectric ceramic ring are respectively connected to the terminal and connected to the signal transmitter through a cable.

[0015] The output end of the ultrasonic rangefinder outputs a 4-20mA analog signal.

[0016] A coke oven vehicle anti-collision method based on ultrasonic technology, wherein each quenching car is provided with a signal acquisition unit, which is arranged at the forward end of each quenching car. If a spare quenching car is also used as a spare for a vehicle group in the opposite direction, the spare quenching car needs to be equipped with two signal acquisition units, which are respectively arranged at the front and rear ends of the quenching car. An ultrasonic rangefinder and a reflector are arranged at the outermost sides of the quenching car, and the reflector and the ultrasonic rangefinder are located on the same horizontal plane. The ultrasonic rangefinder is used to collect distance information between adjacent quenching cars and transmit the distance information to a PLC controller via a transmitting controller of a wireless analog quantity acquisition module and a receiving controller of the wireless analog quantity acquisition module. The PLC controller compares the distance information between adjacent quenching cars in real time according to a preset alarm interval. When the adjacent quenching car enters the alarm interval, the alarm device is activated and notifies the on-board PLC control system to control the quenching car to slow down or stop.

[0017] The receiving controller of the wireless analog quantity acquisition module on the electric locomotive transmits the analog quantity signal of the ultrasonic rangefinder collected by the transmitting controller of the wireless analog quantity acquisition module on each quenching car to the PLC controller through a point-to-multipoint pairing method.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] 1. The wired connection between the quenching car and the electric locomotive was converted to a wireless connection, which reduced the workload of replacing and repairing the quenching car and eliminated the risk of system failure due to cable breakage;

[0020] 2. The ultrasonic rangefinder and signal transmitter are both installed on the coke quenching car, which reduces the difficulty and workload of debugging;

[0021] 3. The touch screen is used to facilitate coking production and system maintenance, and operators can check the real-time distance information to adjacent quenching cars at any time. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of the coke oven vehicle anti-collision system based on ultrasonic technology.

[0023] In the figure: 1-ultrasonic rangefinder 2-signal analysis and processing unit 3-touch screen 4-PLC controller 5-alarm device 6-on-board PLC control system 7-transmitting controller of wireless analog quantity acquisition module 8-receiving controller of wireless analog quantity acquisition module. DETAILED DESCRIPTION

[0024] The present invention will be described in detail below with reference to the accompanying drawings, but it should be noted that the implementation of the present invention is not limited to the following embodiments.

[0025] The following examples are implemented under the premise of the technical solution of the present invention, and provide detailed implementation methods and specific operating processes, but the scope of protection of the present invention is not limited to the following examples. The methods used in the following examples are conventional methods unless otherwise specified.

[0026] [Example 1]

[0027] See Figure 1 A quenching car is a piece of coke oven production equipment specifically designed to receive mature coke at approximately 1000°C, ejected from the coke oven's carbonization chamber. Wet quenching involves pulling the car by an electric locomotive to a quenching tower for quenching; dry quenching involves pulling the car by an electric locomotive to a dry quenching station for quenching. Currently, large coking plants primarily utilize dry quenching. A common example of quenching car collision avoidance involves four coke ovens sharing a single track, with two dry quenching stations located between the ovens. Conventional dry quenching designs typically employ one electric locomotive and three quenching cars (two for production and one for standby) for every two coke ovens. In actual production, to shorten tank change times and the locomotive's operating cycle, the locomotive is typically located at one end of the two quenching cars, away from the dry quenching station. Because quenching cars are replaced and overhauled based on production needs, the outermost quenching car is not fixed.

[0028] Each quenching car is equipped with a signal acquisition unit, which is installed at the forward end of each quenching car (generally the side facing the dry quenching station). If the spare quenching car also serves as a backup for the train set in the opposite direction, the spare quenching car needs to be equipped with two signal acquisition units, one at the front and rear ends of the quenching car.

[0029] The ultrasonic rangefinder 1 and reflector are located at the outermost edge of the quenching car. The center of the ultrasonic probe's horn must be at the same height as the center of the reflector, with a minimum center-to-center distance of 1.5 meters. This improves the ultrasonic rangefinder's detection performance. The reflector is a 1000mm x 1000mm x 3mm carbon steel plate. The ultrasonic rangefinder 1 is connected to the analog input of the signal transmitter via a dedicated cable. The transmitter controller 7 of the wireless analog acquisition module is connected to the analog output of the signal transmitter. The wireless analog acquisition module uses a 100mW wireless power rating and a 4-20mA analog input.

[0030] The wireless analog quantity acquisition module's receiving controller 8, touch screen 3, alarm device 5, and PLC controller 4 are installed on the electric locomotive. These components are integrated into a single control box. The touch screen 3 can be installed on the control box or separately, depending on site requirements. The alarm device 5 can be an audible and visual alarm, or it can utilize the locomotive's built-in alarm device.

[0031] PLC controller 4 uses Siemens' S7-200SMART / CPUSR20. Since electric locomotives are still primarily operated by human operators, touch screen 3 uses Siemens' SIMATIC HMISMART1000IEV3 to facilitate driver observation. Wireless analog data acquisition modules use models LX-RAI02 / LX-RAO04. The locomotive driver and operator can use touch screen 3 to confirm the real-time location of adjacent vehicles.

[0032] A coke oven vehicle anti-collision system based on ultrasonic technology includes an electric locomotive, a coke quenching car, an on-board PLC control system 6, and also includes a signal acquisition unit and a signal analysis and processing unit 2. The signal acquisition unit and the signal analysis and processing unit 2 are wirelessly connected. The signal acquisition unit is set on the coke quenching car, the signal analysis and processing unit 2 is set on the electric locomotive, and the on-board PLC control system 6 is connected to the signal analysis and processing unit 2.

[0033] The signal acquisition unit includes an ultrasonic rangefinder 1, a reflector, a signal transmitter, and a transmitting controller 7 of a wireless analog quantity acquisition module. The ultrasonic rangefinder 1 and the signal transmitter are connected through a port, and the signal transmitter and the transmitting controller 7 of the wireless analog quantity acquisition module are connected through a port; the signal analysis and processing unit 2 includes a receiving controller 8 of the wireless analog quantity acquisition module, a touch screen 3, an alarm device 5, and a PLC controller 4. The receiving controller 8 and the touch screen 3 of the wireless analog quantity acquisition module are respectively connected to the PLC controller 4 through communication ports, and the alarm device 5 is connected to the PLC controller 4 through a port, and the alarm device 5 uses an audible and visual alarm; the wireless analog quantity acquisition module is an integrated transmitter and receiver, supports point-to-point and point-to-multipoint signal acquisition, includes a transmitting controller 7 of the wireless analog quantity acquisition module and a receiving controller 8 of the wireless analog quantity acquisition module, and the transmitting controller 7 of the wireless analog quantity acquisition module is wirelessly connected to the receiving controller 8 of the wireless analog quantity acquisition module.

[0034] The ultrasonic rangefinder 1 utilizes the "Ultrasonic Distance Measurement Ultrasonic Sensor with Publication No. CN106646478A." It consists of a horn-shaped radiation chamber, a piezoelectric ceramic ring, a conical receiver, and a terminal block. The conical receiver is secured within the horn-shaped radiation chamber via a slot at its top. The conical receiver is hollow and filled with sound-absorbing material. A piezoelectric ceramic ring is positioned outside the conical receiver, with its bottom extending to the lower middle portion of the horn-shaped radiation chamber. A terminal block is located on top of the horn-shaped radiation chamber, with a soft damping gasket placed between the two connecting surfaces. The terminal block houses a terminal board, with the positive and negative terminals of the piezoelectric ceramic ring connected to the terminals, which are then connected to a signal transmitter via a cable. The output of the ultrasonic rangefinder 1 outputs a 4-20mA analog signal.

[0035] In the ultrasonic-based coke oven vehicle collision avoidance method, an ultrasonic rangefinder 1 is used to collect distance information between adjacent quenching vehicles and transmit this information to a programmable logic controller 4 via a wireless analog acquisition module's transmitter controller 7 and receiver controller 8. The PLC controller 4 compares the distance information between adjacent quenching vehicles in real time based on a preset alarm interval. When an adjacent quenching vehicle enters the alarm interval, an alarm device 5 activates and notifies the onboard PLC control system 6 to control the quenching vehicle to slow down or stop. The receiver controller 8 of the wireless analog acquisition module on the electric locomotive transmits the analog signals from the ultrasonic rangefinder 1, collected by the transmitter controllers 7 of the wireless analog acquisition modules on each quenching vehicle, to the PLC controller 4 via a point-to-multipoint pairing method.

[0036] The present invention transforms the wired connection between the quenching car and the electric locomotive into a wireless connection, reducing the workload of replacing and repairing the quenching car and eliminating the risk of system failure due to cable breakage; the ultrasonic rangefinder and signal transmitter are both arranged on the quenching car, reducing the difficulty and workload of debugging; the use of a touch screen facilitates coking production and system maintenance, and operators can view real-time distance information to adjacent quenching cars at any time.

Claims

1. A coke oven vehicle anti-collision system based on ultrasonic technology, comprising an electric locomotive, a coke quenching vehicle, and an on-board PLC control system, characterized in that: It also includes a signal acquisition unit and a signal analysis and processing unit, which are wirelessly connected. The signal acquisition unit is arranged on the coke quenching car, and the signal analysis and processing unit is arranged on the electric locomotive. The on-board PLC control system is connected to the signal analysis and processing unit. Each quenching car is provided with a signal acquisition unit, which is installed at the forward end of each quenching car. If the spare quenching car is also used as a spare for the train group in the opposite direction, the spare quenching car needs to be equipped with two sets of signal acquisition units, which are respectively installed at the front and rear ends of the quenching car. The ultrasonic rangefinder and the reflector are arranged at the outermost side of the quenching car, and the reflector and the ultrasonic rangefinder are located at the same horizontal plane. The ultrasonic rangefinder is used to collect distance information between adjacent quenching cars and transmit the distance information to the PLC controller through the transmitting controller of the wireless analog acquisition module and the receiving controller of the wireless analog acquisition module. The PLC controller compares the distance information between the adjacent quenching cars in real time according to the preset alarm interval. When the adjacent quenching car enters the alarm interval, the alarm device is activated and notifies the on-board PLC control system to control the quenching car to slow down or stop. The signal acquisition unit includes an ultrasonic rangefinder, a reflector, a signal transmitter, and a transmitting controller of a wireless analog quantity acquisition module; The signal analysis and processing unit includes a receiving controller of a wireless analog quantity acquisition module, a touch screen, an alarm device, and a PLC controller.

2. The ultrasonic technology-based coke oven vehicle anti-collision system according to claim 1, characterized in that: The ultrasonic rangefinder and the signal transmitter are connected through a port, and the signal transmitter and the transmitting controller of the wireless analog quantity acquisition module are connected through a port.

3. The ultrasonic technology-based coke oven vehicle anti-collision system according to claim 1, characterized in that: The receiving controller and the touch screen of the wireless analog quantity acquisition module are respectively connected to the PLC controller through the communication port, and the alarm device is connected to the PLC controller through the port.

4. The ultrasonic technology-based coke oven vehicle anti-collision system according to claim 2, characterized in that: The transmitting controller of the wireless analog quantity acquisition module is wirelessly connected to the signal analysis and processing unit.

5. The anti-collision system for coke oven vehicles based on ultrasonic technology according to claim 2, characterized in that: The ultrasonic rangefinder includes a horn-shaped radiation chamber, a piezoelectric ceramic ring, a conical wave receiver and a terminal chamber; the conical wave receiver is fixed in the horn-shaped radiation chamber through a slot on the top of the horn-shaped radiation chamber. The conical wave receiver has a hollow structure and is filled with sound-absorbing material. A piezoelectric ceramic ring is provided on the outside of the conical wave receiver, and the bottom of the piezoelectric ceramic ring extends to the middle and lower part of the horn-shaped radiation chamber; a terminal chamber is provided on the top of the horn-shaped radiation chamber, and a soft gasket with a damping effect is provided between the connecting surfaces of the two; a terminal board is provided in the terminal chamber, and the positive and negative poles of the piezoelectric ceramic ring are respectively connected to the terminal and connected to the signal transmitter through a cable.

6. The ultrasonic technology-based coke oven vehicle anti-collision system according to claim 5, characterized in that: The output end of the ultrasonic rangefinder outputs a 4-20mA analog signal.

7. The ultrasonic technology-based coke oven vehicle anti-collision system according to claim 1, characterized in that: The receiving controller of the wireless analog quantity acquisition module on the electric locomotive transmits the analog quantity signal of the ultrasonic rangefinder collected by the transmitting controller of the wireless analog quantity acquisition module on each quenching car to the PLC controller through a point-to-multipoint pairing method.

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