Anti-interference conveying method for common rail operation of stacker and reclaimer

Abstract

The present invention relates to the technical field of common rail conveying for stacking and reclaiming materials, and specifically to an anti-interference conveying method for common rail operation of stacking and reclaiming materials, which breaks the traditional design concept that the upstream belt line must be shut down when the downstream belt line fails, and realizes intelligent and precise shutdown control of the belt line; uses two accumulated values ​​of the same belt scale at different time points to calculate the material quantity in real time, and solves the problem of accuracy deviation of different belt scales; uses the corresponding relationship between "spatial position" and "accumulated value of the belt scale" on the belt line as the key principle to solve the problem, and when the buffer bin high-level alarm occurs, based on the recorded total material amount data, uses the two total material amounts on the same belt scale at different time points to accurately calculate the residual material amount on the current belt line, and then judges whether it is necessary to stop the belt line, thereby avoiding unnecessary interruption of the stacking operation process and delaying the unloading progress.

Description

Technical Field

[0001] The present invention relates to the technical field of common rail conveying for stackers and reclaimers, and in particular to an anti-interference conveying method for common rail operation of stackers and reclaimers. Background Art

[0002] In order to meet the increasing demand for train port clearance business, new reclaimers R3 and R4 are added to the existing BD2 and BD3 belt lines, sharing the track and belt line with the original stackers S2 and S3 respectively. The layout is as follows: Figure 7 As shown in the figure, this arrangement can fully utilize the storage yard while reducing the construction investment in infrastructure such as the belt line and dam foundation for the reclaimer operation. However, it also brings a problem: when the stacking operation and the reclaiming operation are operated on the same track, if the buffer bin in the reclaiming loading station is full, the belt line will stop to avoid bursting. The belt line shutdown will directly affect the reclaimer operation process and cause the unloading process to be interrupted.

[0003] To ensure the continuity of ship unloading operations, the BD belt line shared by stacking and reclaiming operations must not be shut down unless necessary. Our technical staff, through research based on actual production conditions, have found that when a high material level fault alarm is triggered in the buffer bin at the loading station, if the total amount of residual material on the belt line during the reclaiming operation is less than the remaining capacity of the belt line head hopper and buffer bin, even if the belt line continues to run, it will not cause any faults or equipment damage. Therefore, real-time and accurate calculation of the total amount of residual material on the belt line used for reclaiming operations and the distribution of the residual material on the belt line becomes the key to determining whether the belt line can continue to operate.

[0004] Faced with this problem, our company's initial solution was to add a belt scale near the head hopper at the head of the belt line to weigh the total amount of material leaving the belt line. The total amount of material leaving the belt line was then subtracted from the total amount of material taken by the reclaimer cantilever belt scale to obtain the total amount of residual material on the belt line. This solution was simple, but required the addition of an additional belt scale. However, weighing equipment such as belt scales is expensive, and the measurement accuracy of the newly added belt scale and the reclaimer cantilever belt scale could not be completely consistent, resulting in errors in the calculation results that could not be eliminated. In addition, the belt scale required a certain amount of installation space, and the complex on-site environment made smooth installation impossible. Summary of the Invention

[0005] In response to the above problems, an embodiment of the present invention provides an interference-proof conveying method for stacker-reclaimer common rail operations.

[0006] One aspect of the present invention provides an anti-interference conveying method for stacker and reclaimer common rail operations, which is applied to an anti-interference conveying system. The anti-interference conveying system includes: a belt line, a reclaimer cantilever belt scale, an OPC server, a host computer, and a central control PLC controller; wherein the reclaimer cantilever belt scale is communicatively connected to the central control PLC controller, the central control PLC controller is communicatively connected to the OPC server, the central control PLC controller is electrically connected to the belt line, and the OPC server is communicatively connected to the host computer;

[0007] The host computer determines the distance between the head unloading port of the belt line and the unloading port of the reclaimer. Using the determined distance and the belt speed of the belt line, it calculates the running time of the belt line from the unloading port of the reclaimer to the head unloading port.

[0008] After the belt line is started, the cantilever belt scale of the reclaimer weighs the total amount of material taken at the reclaimer's material outlet in real time, and forwards the real-time weighed total amount of material taken to the host computer through the OPC server;

[0009] After receiving the total amount of material taken measured in real time, the host computer records the total amount of material taken in real time; and when receiving the buffer bin high-level alarm signal, it determines the first total amount of material taken received at the current time T1 based on the recorded total amount of material taken data, and determines the second total amount of material taken corresponding to the previous time T2 of the running time before the current time T1;

[0010] The upper computer calculates the amount of residual material on the belt line using the total amount of the first and second materials taken; when the upper computer determines that the amount of residual material is less than the preset threshold value, it sends an instruction to keep the belt line running to the central control PLC controller through the OPC server, and the central control PLC controller keeps the belt line running; when the upper computer confirms that the amount of residual material is not less than the preset threshold value, it sends an instruction to stop the belt line to the central control PLC controller through the OPC server, and the central control PLC controller stops the belt line.

[0011] Compared with the prior art, the beneficial effect of the present invention lies in: using the correspondence between the "spatial position" on the belt line and the "accumulated value of the belt scale" as the key principle to solve the problem. When the buffer bin high-level alarm is sounded, based on the recorded total material collection data, the two total material collection amounts of the same belt scale at different time points are used to accurately calculate the amount of residual material on the current belt line, and then determine whether it is necessary to stop the belt line, thereby avoiding unnecessary interruption of the stacking operation process and delaying the unloading progress.

[0012] Optionally, when the host computer confirms that the amount of residual material is not less than a preset threshold value, it sends a command to stop the belt line to the central control PLC controller through the OPC server. The process of the central control PLC controller stopping the belt line includes:

[0013] When the upper computer confirms that the amount of residual material is not less than the preset threshold value, it determines the target total material amount between the current moment T1 and the previous moment T2, when the difference between the first and second total material amounts is greater than the preset threshold value, based on the recorded total material amount data. When the belt line position corresponding to the target total material amount runs to the unloading port at the head of the belt line, the upper computer sends a command to stop the belt line to the central control PLC controller through the OPC server, and the central control PLC controller stops the belt line operation.

[0014] Optionally, the process of determining the belt line position corresponding to the target total amount of material to be taken and running to the belt line head unloading port includes:

[0015] Determine the target time T for recording the target total amount of material taken m , using the target time T m , determine the distance between the belt line position corresponding to the target total material taking amount and the head unloading port at the previous moment T2 and the belt speed, and determine the belt line position corresponding to the target total material taking amount to run to the belt line head unloading port when the belt line continues to run the determined distance. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The drawings described herein are used to provide a further understanding of the present invention, constitute a part of this application, and do not constitute a limitation of the present invention. In the drawings:

[0017] Figure 1 A schematic flow chart of an anti-interference conveying method for stacker-reclaimer common rail operation provided by an embodiment of the present invention;

[0018] Figure 2 A graph showing a correspondence between spatial position and time on a belt line provided by an embodiment of the present invention;

[0019] Figure 3 A schematic diagram of using time difference to represent spatial position difference on a belt line provided by an embodiment of the present invention;

[0020] Figure 4 A graph showing the relationship between the total amount of material taken and time provided in an embodiment of the present invention;

[0021] Figure 5 A graph showing the corresponding relationship between the total amount of material taken and the spatial position on the belt line provided by an embodiment of the present invention;

[0022] Figure 6 A schematic structural diagram of an anti-interference conveying system provided by an embodiment of the present invention;

[0023] Figure 7 A schematic diagram of a common rail operation line provided by an embodiment of the present invention. DETAILED DESCRIPTION

[0024] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the embodiments and the accompanying drawings. Here, the exemplary embodiments of the present invention and their descriptions are used to explain the present invention, but are not intended to limit the present invention.

[0025] The embodiment of the present invention provides an anti-interference conveying method for common rail operation of stacking and reclaiming, which is applied to an anti-interference conveying system, such as Figure 6 The anti-interference conveying system shown includes: a belt line, a reclaimer cantilever belt scale, an OPC server, a host computer, and a central control PLC controller; wherein, the reclaimer cantilever belt scale is connected to the central control PLC controller in communication, the central control PLC controller is connected to the OPC server in communication, the central control PLC controller is connected to the belt line electronic control, and the OPC server is connected to the host computer in communication; see Figure 1 The method comprises:

[0026] S100, the host computer determines the distance between the head discharge port of the belt line and the discharge port of the reclaimer, and calculates the running time of the belt line from the discharge port of the reclaimer to the head discharge port using the determined distance and the belt speed of the belt line;

[0027] S110, after the belt line is started, the cantilever belt scale of the reclaimer weighs the total amount of reclaimed materials at the reclaimer's material outlet in real time, and forwards the real-time weighed total amount of reclaimed materials to the host computer through the OPC server;

[0028] S120, after receiving the total amount of material taken measured in real time, the host computer records the total amount of material taken in real time; and upon receiving a high-level alarm signal from the buffer bin, determines the first total amount of material taken received at the current time T1 based on the recorded total amount of material taken, and determines the second total amount of material taken corresponding to the previous time T2 of the running time before the current time T1;

[0029] S130, the upper computer calculates the amount of residual material on the belt line using the first total amount of material taken and the second total amount of material taken; when the upper computer determines that the amount of residual material is less than the preset threshold value, it sends an instruction to keep the belt line running to the central control PLC controller through the OPC server, and the central control PLC controller keeps the belt line running; when the upper computer confirms that the amount of residual material is not less than the preset threshold value, it sends an instruction to stop the belt line to the central control PLC controller through the OPC server, and the central control PLC controller stops the belt line.

[0030] During implementation, the preset threshold value can be determined based on the remaining capacity of the belt line head hopper and the buffer bin, and should not be greater than the sum of the two. When the host computer confirms that the amount of residual material is not less than the preset threshold value, it sends a stop belt line instruction to the central control PLC controller through the OPC server. The process of the central control PLC controller stopping the belt line includes:

[0031] When the upper computer confirms that the amount of residual material is not less than the preset threshold value, it determines the target total material amount between the current time T1 and the previous time T2, when the difference between the first and second total material amounts is greater than the preset threshold value, based on the recorded total material amount data. When the belt line position corresponding to the target total material amount runs to the unloading port at the head of the belt line, the upper computer sends a command to stop the belt line through the OPC server to the central control PLC controller, and the central control PLC controller stops the belt line operation; and before stopping the belt line, if the high-level alarm signal of the buffer bin is released, there is no need to stop the belt line, creating conditions for the upstream equipment not to stop.

[0032] The process of determining the belt line position corresponding to the target total amount of material to be taken and running to the belt line head unloading port includes: determining the target time T for recording the target total amount of material to be taken m , using the target time T m , determine the distance between the belt line position corresponding to the target total material taking amount and the head unloading port at the previous moment T2 and the belt speed, and determine the belt line position corresponding to the target total material taking amount to run to the belt line head unloading port when the belt line continues to run the determined distance.

[0033] The anti-interference conveying system also includes an SQL database. The upper computer is connected to the SQL database for communication and can store the total amount of material taken received from real-time weighing in the SQL database for standby use.

[0034] During the operation, the belt line runs continuously and at a uniform speed, which provides the basis for the design idea of ​​this application. Taking the position of the material discharge port of the reclaimer as the timing starting point, after Δt1, Δt2 and Δt3 respectively, the running distance of the belt line is Δs1, Δs2, and Δs3 respectively; according to the uniform motion physics formula "s=vt", it can be known that the spatial position s is a monotonically increasing function of the time t, and the slope of the function is constant, which is equal to the running speed of the belt line; then, a coordinate system can be established with the material discharge port of the reclaimer as the origin, which represents the correspondence between the distance and time between any point on the current belt line and the origin, as shown in the following figure: Figure 2 、 Figure 3 As shown; this makes it possible to use "time difference" to represent "spatial position difference", and then establish the first important correspondence, that is, the correspondence between "time difference" and "spatial position difference".

[0035] This application can establish a corresponding relationship between "time difference and" "belt scale cumulative value" for the continuously increasing time points and their corresponding cumulative values ​​of the reclaimer cantilever belt scale (total amount of material taken) at a frequency of 1 per second. Specifically, the current moment is defined as time 0, a time axis is established, and the corresponding relationship is established with the belt scale cumulative value w corresponding to a certain moment as the function axis. Figure 4 As shown;

[0036] At the same time, the point on the current belt line that is directly below the material discharge port of the reclaimer is defined as the spatial position zero point, and the "spatial position horizontal axis" is established. Time can be expressed as the ratio of distance to speed, so the corresponding relationship between the "belt scale cumulative value" and the "spatial position" can be established, such as Figure 5 As shown, based on this correspondence, it can be deduced that there is a one-to-one correspondence between the "conveyor scale cumulative value" and the "spatial position on the belt line". It can be seen that there is a one-to-one correspondence between the spatial position on the belt line and the cumulative value of the belt scale. Any two points on the belt line each correspond to a belt scale cumulative value. Subtracting the two can determine the amount of material between the two points. This confirms the feasibility of the design idea of ​​this application.

[0037] As shown in Table 1, after the technical solution of this application was put into use on the two belt lines BD2 and BD3, the number of common rail shutdowns and downtimes during stacking operations during common rail operations were significantly reduced, which is of great promotion value.

[0038] years Common rail shutdown times Downtime (minutes) 2020 384 8832 2021 144 3312 2022 13 229

[0039] Table 1. Common rail shutdown times and downtime in the past three years

[0040] From the perspective of economic benefits: before the technical solution of this application was put into use, the downtime of the common rail operation in 2020 was: 8832 ÷ 60 = 147.2 hours; the average unloading efficiency in the affected stockpiling operation was 4500 tons / hour. After it was put into use, the number of interruptions of the stockpiling operation due to the common rail operation was reduced to 144 times by 2021, and the downtime was: 3312 ÷ 60 = 55.2 hours, which is equivalent to an increase of (147.2-55.2) hours × 4500 tons / hour = 414,000 tons in the unloading operation in 2021 relative to 2020; calculated based on a profit margin of 13 yuan / ton, the additional profit in 2021 relative to before commissioning was 414,000 tons × 13 yuan / ton = 5,382,000 yuan, an increase of approximately 5.38 million yuan in revenue;

[0041] By 2022, the number of interruptions in stacking operations due to common rail operations will be reduced to 13 times, which is equivalent to an increase of (147.2-3.8) hours × 4,500 tons / hour = 645,300 tons in unloading operations in 2022 compared with 2020; calculated based on a profit margin of 13 yuan / ton, the additional profit in 2022 compared with before the commissioning will be 645,300 tons × 13 yuan / ton = 8,388,900 yuan, an increase of approximately 8.3 million yuan.

[0042] According to the actual production design annual operating days of 300 days and an operating rate of 80%, the reasonable actual increase in revenue in 2021 is 538×0.8=4.304 million yuan; the reasonable actual increase in revenue in 2022 is 830×0.8=6.64 million yuan, which brings huge economic benefits to the enterprise.

[0043] The anti-interference conveying method for common rail operation of stacking and reclaiming in this application breaks the traditional design concept that the upstream belt line must be shut down when the downstream belt line fails, and realizes intelligent and precise shutdown control of the belt line; uses the two cumulative values ​​of the same belt scale at different time points to calculate the material quantity in real time, solving the problem of accuracy deviation of different belt scales; uses the corresponding relationship between "spatial position" and "belt scale cumulative value" on the belt line as the key principle to solve the problem. When the buffer bin high-level alarm occurs, based on the recorded total material reclaiming data, the two total material reclaiming values ​​on the same belt scale at different time points are used to accurately calculate the current residual material quantity on the belt line, and then determine whether it is necessary to stop the belt line, thereby avoiding unnecessary interruption of the stacking operation process and delaying the unloading progress.

[0044] The above description is only a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention are included in the scope of protection of the present invention.

Claims

1. A method for preventing interference in common rail operation of stacker and reclaimer, characterized in that: Applied to anti-interference conveying system, which includes: belt line, reclaimer cantilever belt scale, OPC server, host computer and central control PLC controller; among them, the reclaimer cantilever belt scale is connected to the central control PLC controller, the central control PLC controller is connected to the OPC server, the central control PLC controller is connected to the belt line electronic control, and the OPC server is connected to the host computer; The host computer determines the distance between the head unloading port of the belt line and the unloading port of the reclaimer. Using the determined distance and the belt speed of the belt line, it calculates the running time of the belt line from the unloading port of the reclaimer to the head unloading port. After the belt line is started, the cantilever belt scale of the reclaimer weighs the total amount of material taken at the reclaimer's material outlet in real time, and forwards the real-time weighed total amount of material taken to the host computer through the OPC server; After receiving the total amount of material taken measured in real time, the host computer records the total amount of material taken in real time; and when receiving the buffer bin high-level alarm signal, it determines the first total amount of material taken received at the current time T1 based on the recorded total amount of material taken data, and determines the second total amount of material taken corresponding to the previous time T2 of the running time before the current time T1; The upper computer calculates the amount of residual material on the belt line using the total amount of the first and second materials taken; when the upper computer determines that the amount of residual material is less than the preset threshold value, it sends an instruction to keep the belt line running to the central control PLC controller through the OPC server, and the central control PLC controller keeps the belt line running; when the upper computer confirms that the amount of residual material is not less than the preset threshold value, it sends an instruction to stop the belt line to the central control PLC controller through the OPC server, and the central control PLC controller stops the belt line.

2. The anti-interference conveying method for stacker-reclaimer common rail operation according to claim 1, characterized in that: When the host computer confirms that the amount of residual material is not less than the preset threshold value, it sends a command to stop the belt line to the central control PLC controller through the OPC server. The process of the central control PLC controller stopping the belt line includes: When the upper computer confirms that the amount of residual material is not less than the preset threshold value, it determines the target total material amount between the current moment T1 and the previous moment T2, when the difference between the first and second total material amounts is greater than the preset threshold value, based on the recorded total material amount data. When the belt line position corresponding to the target total material amount runs to the unloading port at the head of the belt line, the upper computer sends a command to stop the belt line to the central control PLC controller through the OPC server, and the central control PLC controller stops the belt line operation.

3. The anti-interference conveying method for common rail operation of stacker and reclaimer according to claim 2, characterized in that: The process of determining the belt line position corresponding to the target total amount of material to be taken and running it to the belt line head unloading port includes: Determine the target time T for recording the target total amount of material taken m , using the target time T m , determine the distance between the belt line position corresponding to the target total material taking amount and the head unloading port at the previous moment T2 and the belt speed, and determine that the belt line position corresponding to the target total material taking amount runs to the belt line head unloading port when the belt line continues to run the determined distance.

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