A mine integrated drive device for continuous mining belt conveyors

Abstract

The present invention discloses a mine integrated drive device for continuous mining belt conveyors, including a tensioning module, a drive module, a main control module, and a tension detection module. The present invention solves the problem of automatic integrated drive of long-distance belt conveyors, and realizes the functions of fully automatic tensioning and driving of the entire belt conveyor only by receiving a start signal, reducing the number of on-site devices. And it detects the tension of the belt conveyor in real time to protect the belt conveyor from over-tension operation.

Description

Technical Field

[0001] The present invention relates to the technical field of motor drive, and particularly relates to a mine integrated drive device for continuous mining belt conveyors. Background Art

[0002] At present, in the coal mining and excavation system, belt conveyors are generally used for coal transportation. Generally, the drive device of the belt conveyor uses an electric motor as the power source, and most of its belt tensioning systems adopt hydraulic tensioning. Along with the development of coal mine informatization and intelligentization, ordinary belt conveyors cannot meet the actual requirements of rapid advancement in mining and excavation. However, with the application and popularization of continuous mining belt conveyors with a length greater than 5000 meters, the hydraulic tensioning system can no longer meet the needs, and its drive system must inevitably change accordingly. The improvement direction is that the tensioning part also uses an electric motor to drive the tensioning winch. Existing frequency conversion drive devices only drive the belt conveyor to operate and cannot complete the control of the electric drive tensioning motor. Generally, 2 - 3 operators are required at the head of the belt conveyor to monitor the operation of various equipment in real time, and the number of equipment to be maintained is large and the complexity is high. This brings problems such as waste of labor and large floor area of the equipment. The current development direction is that there is no longer a driver left at the head of the belt conveyor. The existing equipment has low integration and cannot meet the development requirements of reducing the number of people, high integration, and high informatization. Summary of the Invention

[0003] In view of the above deficiencies in the prior art, the present invention provides a mine integrated drive device for continuous mining belt conveyors.

[0004] In order to achieve the above invention purpose, the technical solution adopted by the present invention is as follows:

[0005] A mine integrated drive device for continuous mining belt conveyors, comprising:

[0006] A tensioning module, configured to start a tensioning motor according to a tensioning start signal sent by a main control module to adjust the tension of the belt conveyor to a pre - tension value, adjust the tension of the belt conveyor within a set tension range according to a tensioning control signal sent by the main control module after the belt conveyor starts up, and in real - time feedback the electric energy generated by releasing the tension to the power grid during the shutdown process of the belt conveyor;

[0007] A drive module, configured to perform frequency modulation and voltage regulation on the input power supply by adopting a dual - path master - slave inverter drive circuit, and adjust the real - time speeds of the main drive motor and the slave drive motor in real time according to a drive control signal sent by the main control module;

[0008] The main control module is used to generate a tensioning start signal according to the host computer start signal and send it to the tensioning module; receive the real-time tension of the belt conveyor collected by the tension detection module, and generate a tension control signal according to the real-time tension of the belt conveyor by using a preset tension control algorithm and send it to the tensioning module; and detect the real-time operating parameters of the drive module, and generate a drive control signal according to the real-time operating parameters of the drive module by using a preset drive control algorithm and send it to the drive module.

[0009] The tension detection module is used to collect the real-time tension of the belt conveyor after the belt conveyor starts up and send it to the main control module.

[0010] Further, the tensioning module specifically includes:

[0011] A first disconnecting switch, a first contactor, an improved LCL unit, a controllable rectifier unit, a first filtering unit, a first inverter unit, and a tensioning motor are connected in sequence to form a tensioning loop; an improved charging unit is connected in parallel at both ends of the first contactor.

[0012] The controllable rectifier unit is used to receive the adjustment signal sent by the main control module, and control the IGBTs in the controllable rectifier unit to conduct and turn off in sequence according to the adjustment signal, so that the grid phase angle is consistent with the output waveform of the controllable rectifier unit through the improved LCL unit.

[0013] The first inverter unit is used to receive the tensioning start signal sent by the main control module, and adjust the conduction and turn-off of each IGBT in the first inverter unit according to the tensioning start signal to control the start of the tensioning motor; and receive the tension control signal sent by the main control module, and adjust the conduction and turn-off sequence of each IGBT in the first inverter unit according to the tension control signal to control the working state of the tensioning motor.

[0014] Further, the improved charging unit specifically includes:

[0015] A first sub-contactor and a second sub-contactor connected in parallel; three contacts of the first sub-contactor are respectively connected to the input three-phase power.

[0016] One of the contacts of the first sub-contactor is connected to the corresponding contact of the second sub-contactor through a rectifier diode; the switch end of the corresponding contact of the second sub-contactor is connected to the switch end of this contact of the first sub-contactor through a second resistor.

[0017] Another one of the contacts of the first sub-contactor is connected to the corresponding contact of the second sub-contactor; the switch end of the corresponding contact of the second sub-contactor is connected to the switch end of this contact of the first sub-contactor through a first resistor.

[0018] Further, the improved LCL unit specifically includes:

[0019] The first inductor unit, the second inductor unit and the first capacitor unit; the first inductor unit is connected to the input three-phase power, and the second inductor unit is connected to the three-phase power output by the first inductor unit; the first capacitor unit is respectively connected to the three-phase power output by the first inductor unit through a third resistor, a fourth resistor and a fifth resistor.

[0020] Further, the drive module specifically includes:

[0021] A first drive loop is formed by sequentially connecting a second disconnect switch, a second contactor, a rectification unit, a filtering unit, a second inverter unit and a first drive motor;

[0022] A second drive loop is formed by sequentially connecting a third disconnect switch, a third contactor, a rectification unit, a filtering unit, a third inverter unit and a second drive motor;

[0023] The second inverter unit and the third inverter unit are used to receive the drive control signals sent by the main control module, and respectively control the IGBTs in the second inverter unit and the third inverter unit to conduct and turn off in sequence according to the drive control signals, output variable AC power supplies, and drive the first drive motor and the second drive motor to start from 0 speed and rise to the rated speed within the acceleration time.

[0024] Further, the main control module specifically includes:

[0025] A main control unit, a first auxiliary control unit, a first optical fiber distribution unit, a second auxiliary control unit, a second optical fiber distribution unit, a third auxiliary control unit, a third optical fiber distribution unit, a fourth auxiliary control unit and a fourth optical fiber distribution unit;

[0026] The main control unit is used to generate a tensioning start signal according to the host computer start signal and send it to the first auxiliary control unit; receive the real-time tension of the belt conveyor collected by the tension detection module, and generate a tension control signal according to the real-time tension of the belt conveyor by using a preset tension control algorithm and send it to the second auxiliary control unit; receive the real-time operation parameters of the second inverter unit and the third inverter unit detected by the third optical fiber distribution unit and the fourth optical fiber distribution unit, and generate a drive control signal according to the real-time operation parameters of the second inverter unit and the third inverter unit by using a preset drive control algorithm and send it to the third auxiliary control unit and the fourth auxiliary control unit;

[0027] The first auxiliary control unit is used to communicate with the first optical fiber distribution unit and send the tensioning start signal to the first optical fiber distribution unit;

[0028] The first optical fiber distribution unit is used to control the conduction and turn-off sequence of the IGBTs in the controllable rectification unit according to the tensioning start signal;

[0029] The second auxiliary control unit is used to communicate with the second optical fiber distribution unit and send the tension control signal to the second optical fiber distribution unit;

[0030] The second optical fiber distribution unit is used to adjust the conduction and turn-off sequence of each IGBT in the first inverter unit according to the tension control signal;

[0031] The third auxiliary control unit and the fourth auxiliary control unit are used to communicate with the third optical fiber distribution unit and the fourth optical fiber distribution unit respectively, send the drive control signals to the third optical fiber distribution unit and the fourth optical fiber distribution unit respectively; receive the real-time operation parameters of the second inverter unit and the third inverter unit sent by the third optical fiber distribution unit and the fourth optical fiber distribution unit and send them to the main control unit;

[0032] The third optical fiber distribution unit and the fourth optical fiber distribution unit are used to control the conduction and turn-off sequence of the IGBTs in the second inverter unit and the third inverter unit respectively according to the drive control signals; and detect the real-time operation parameters of the second inverter unit and the third inverter unit and send them to the third auxiliary control unit and the fourth auxiliary control unit respectively.

[0033] Further, the generating of the tension start signal according to the host computer start signal specifically includes the following steps:

[0034] A1. Generate a tension pre-start signal according to the host computer start signal to control the forward rotation of the tension motor;

[0035] A2. Receive the real-time tension of the belt conveyor collected by the tension detection module, and judge whether the real-time tension reaches the pre-tension value; if so, execute step A3; otherwise, continue to execute step A2;

[0036] A3. Use the main control unit to send a tension health signal to the host computer controller and control the tension loop not to stop.

[0037] Further, the generating of the tension control signal by using a preset tension control algorithm according to the real-time tension of the belt conveyor specifically includes the following steps:

[0038] B1. When the belt conveyor starts, receive the real-time tension of the belt conveyor collected by the tension detection module, and judge whether the real-time tension of the belt conveyor drops; if so, execute step B2; otherwise, continue to execute step B1;

[0039] B2. Use the main control unit to control the forward rotation of the tension motor to slowly raise the tension of the belt conveyor to the rated tension value;

[0040] B3. When the tension of the belt conveyor reaches the rated tension value, use the main control unit to control the output speed of the tension motor to gradually decrease to 0 speed, and after delaying for a set time, use the main control unit to control the tension motor to brake.

[0041] Further, the step of generating a tension control signal by using a preset tension control algorithm according to the real-time tension of the belt conveyor further includes the following steps:

[0042] C1. When the belt conveyor is running, receive the real-time tension of the belt conveyor collected by the tension detection module, and determine whether the real-time tension of the belt conveyor exceeds the tension range; if the real-time tension exceeds the upper limit of the tension range, execute step C2; if the real-time tension exceeds the lower limit of the tension range, execute step C3; otherwise, continue to execute step C1;

[0043] C2. Use the main control unit to control the brake control power supply to release the brake, and control the tension motor to reverse to reduce the tension to the rated tension;

[0044] C3. Use the main control unit to control the brake control power supply to release the brake, and control the tension motor to rotate forward to increase the tension to the rated tension;

[0045] C4. When the tension of the belt conveyor reaches the rated tension value, use the main control unit to control the output speed of the tension motor to gradually decrease to 0 speed, and after a set time delay, use the main control unit to control the tension motor to apply the brake.

[0046] Further, the step of generating a tension control signal by using a preset tension control algorithm according to the real-time tension of the belt conveyor further includes the following steps:

[0047] D1. When the belt conveyor is running, receive the real-time tension of the belt conveyor collected by the tension detection module, and determine whether the change in the real-time tension of the belt conveyor exceeds the set condition; if so, execute step D2; otherwise, continue to execute step D1;

[0048] D2. Use the main control unit to control the tension motor to rotate forward, and at the same time control the brake control power supply to release the brake, so as to reduce the tension to the rated tension;

[0049] D3. When the tension of the belt conveyor reaches the rated tension value, use the main control unit to control the output speed of the tension motor to gradually decrease to 0 speed, and after a set time delay, use the main control unit to control the tension motor to apply the brake.

[0050] The present invention has the following beneficial effects:

[0051] (1) The device of the present invention solves the problem of automatic integrated drive of long-distance belt conveyors, and realizes the functions of fully automatic tensioning and driving of the entire belt conveyor only by receiving a start signal, reducing the number of on-site devices. And it can detect the tension of the belt conveyor in real time to protect the belt conveyor from over-tension operation.

[0052] (2) The present invention solves the problem that resonance is likely to occur between the LCL system of the four-quadrant frequency converter and the power supply system during operation, preventing the overvoltage fault of the frequency converter caused by resonance.

[0053] (3) It solves the problem of slow charging speed in the charging circuit, resulting in the charging failure fault caused by the frequency converter failing to complete charging within a certain period of time.

[0054] (4) The present invention reduces the number of positions for the head driver of the belt conveyor. In the past, 2 - 3 drivers needed to be configured. Now, with the automatic operation and remote control of the equipment, the driver position is cancelled, saving production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Figure 1 It is a schematic structural diagram of a mine-used combined mine-used integrated drive device in an embodiment of the present invention;

[0056] Figure 2 It is a schematic structural diagram of an improved charging unit and an improved LCL unit in an embodiment of the present invention;

[0057] Figure 3 It is a schematic structural diagram of a tension detection module in an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0058] The following describes the specific embodiments of the present invention to facilitate those skilled in the art of the present technology to understand the present invention. However, it should be clear that the present invention is not limited to the scope of the specific embodiments. For those of ordinary skill in the art of the present technology, as long as various changes are within the spirit and scope of the present invention defined and determined by the appended claims, these changes are obvious, and all inventions and creations using the concept of the present invention are within the scope of protection.

[0059] The embodiment of the present invention provides a mine-used combined mine-used integrated drive device for the integrated drive of a continuous mining belt conveyor in a coal mine roadway heading face. The present invention can solve the following existing problems: 1. There are various types of equipment at the head part of the continuous mining belt conveyor, and the maintenance is complex. The belt conveyor driver needs to have various capabilities, and the requirements for the driver are high; 2. On the basis of reducing the capabilities of the belt conveyor driver, cancel the permanent staff positions at the head; 3. The speed regulating device needs to have the function of automatically and intelligently adjusting the speed of the belt conveyor. According to the above requirements, an integrated drive device is invented to achieve the effect of reducing the number of people automatically. Secondly, this device should have the functions of automatically tensioning the belt and automatically driving the belt conveyor to operate and have intelligent speed regulation. The power supply voltage of a general mine-used explosion-proof and intrinsically safe mine-used integrated drive device is 1140V.

[0060] As Figures 1 to 3 shown, the embodiment of the present invention provides a mine-used integrated drive device for a continuous mining belt conveyor, including:

[0061] The tensioning module is used to start the tensioning motor according to the tensioning start signal sent by the main control module to adjust the tension of the belt conveyor to the pre-tension value, adjust the tension of the belt conveyor within the set tension range according to the tensioning control signal sent by the main control module after the belt conveyor starts up, and in real time feed back the electric energy generated by releasing the tension to the power grid during the shutdown process of the belt conveyor;

[0062] The driving module is used to perform frequency modulation and voltage regulation on the input power supply by using a dual-channel master-slave inverter drive circuit, and adjust the real-time speeds of the main driving motor and the slave driving motor in real time according to the driving control signal sent by the main control module;

[0063] The main control module is used to generate a tensioning start signal according to the upper computer start signal and send it to the tensioning module; receive the real-time tension of the belt conveyor collected by the tension detection module, generate a tensioning control signal according to the real-time tension of the belt conveyor by using a preset tensioning control algorithm and send it to the tensioning module; and detect the real-time operation parameters of the driving module, generate a driving control signal according to the real-time operation parameters of the driving module by using a preset driving control algorithm and send it to the driving module;

[0064] The tension detection module is used to collect the real-time tension of the belt conveyor after the belt conveyor starts up and send it to the main control module.

[0065] In an alternative embodiment of the present invention, after receiving the start signal, the tensioning module of this embodiment must monitor the magnitude of the tension value in real time to ensure that the tension is within a suitable range before the start-up stage of the belt conveyor, the main driving roller does not slip when the main driving motor starts, ensure the pre-tension of the belt conveyor, and maintain the dynamic stability of the belt tension in real time. When the belt conveyor reaches the rated operating speed after starting up, it monitors the tension in real time, and when the tension value deviates from the reference value by a certain amount, it adjusts the speed of the motor to change the tension magnitude to ensure that it is within a reasonable tension range. During the shutdown process of the belt conveyor, the tension is quickly released to protect the stable structure of the head of the belt conveyor. When the tensioning system works, the process of releasing the tension is the braking process of the motor, and power generation will occur during this stage. This device needs to feed back the energy to the power grid in real time.

[0066] The tensioning module of this embodiment specifically includes:

[0067] A tensioning circuit is formed by sequentially connecting a first disconnector, a first contactor, an improved LCL unit, a controlled rectifier unit, a first filter unit, a first inverter unit and a tensioning motor; an improved charging unit is connected in parallel at both ends of the first contactor;

[0068] The controlled rectifier unit is used to receive the adjustment signal sent by the main control module, and control the IGBTs in the controlled rectifier unit to conduct and turn off in sequence according to the adjustment signal, so that the phase angle of the power grid is consistent with the output waveform of the controlled rectifier unit through the improved LCL unit;

[0069] The first inverter unit is used to receive the tension start signal sent by the main control module, adjust the conduction and cutoff of each IGBT in the first inverter unit according to the tension start signal to control the start of the tension motor; and receive the tension control signal sent by the main control module, and adjust the conduction and cutoff sequence of each IGBT in the first inverter unit according to the tension control signal to control the working state of the tension motor.

[0070] In this embodiment, the main control unit sends commands to the first auxiliary control module through CANOPEN. The first auxiliary control module communicates with the first optical fiber distribution unit through an optical fiber. The first optical fiber distribution unit controls the IGBTs in the controllable rectifier unit to conduct and cutoff in sequence, so that the grid phase angle is consistent with the output waveform of the controllable rectifier unit through the LCL, which can illustrate that the controllable rectifier unit and the grid are in the same system. At this time, the DC voltage in the filtering unit of the tension circuit cooperates with the grid, and the power generated during the braking process of the tension motor is connected to the grid through the filtering unit. The main control unit sends commands to the second auxiliary control module to control the first inverter unit to adjust the conduction and cutoff of each IGBT to drive the tension motor to work, where the load tension motor is a high-speed permanent magnet motor. Both the first inverter unit and the controllable rectifier unit include 3 independently controllable double IGBTs with a withstand voltage of 3300V.

[0071] Among them, the improved charging unit specifically includes:

[0072] A first sub-contactor and a second sub-contactor connected in parallel; three contacts of the first sub-contactor are respectively connected to the input three-phase power.

[0073] One of the contacts of the first sub-contactor is connected to the corresponding contact of the second sub-contactor through a rectifier diode; the switch terminal of the corresponding contact of the second sub-contactor is connected to the switch terminal of this contact of the first sub-contactor through a second resistor.

[0074] Another one of the contacts of the first sub-contactor is connected to the corresponding contact of the second sub-contactor; the switch terminal of the corresponding contact of the second sub-contactor is connected to the switch terminal of this contact of the first sub-contactor through a first resistor.

[0075] The improved charging unit and the improved LCL unit are located Figure 1 between the disconnecting switch of the shown tension circuit and the controllable rectifier unit. Because there is an LCL circuit at the rear stage of the charging circuit and there are three-phase AC capacitors in the LCL, after the second sub-contactor KM2 charging contactor is closed, the energy will be absorbed by the capacitor, which is equivalent to applying 1140V alternating current between the charging resistor and the capacitor, and the filtering unit cannot be charged. As Figure 2As shown in the figure, a V1 rectifying diode is added to one of the phase charging circuits of the improved charging circuit. By utilizing the unidirectional conductivity of the rectifying diode, it is ensured that energy only flows from the power supply direction to the rectifying direction. Additionally, R1 / R2 charging resistors are configured to limit the magnitude of the charging current and prevent excessive current from damaging the first sub-contactor KM2. When the bus voltage reaches 1200V, the second sub-contactor KM2 is disconnected, and the first sub-contactor KM1 is engaged to complete the charging logic.

[0076] The improved charging unit in this embodiment enables the bus voltage to rise rapidly during the charging of the tensioning frequency conversion circuit. When there is a capacitor in the subsequent stage, the energy is absorbed by the capacitor, resulting in a very slow rise in the bus voltage and causing charging failure.

[0077] Among them, the improved LCL unit specifically includes:

[0078] A first inductor sub-unit, a second inductor sub-unit, and a first capacitor sub-unit; the first inductor sub-unit is connected to the input three-phase power, and the second inductor sub-unit is connected to the three-phase power output by the first inductor sub-unit; the first capacitor sub-unit is respectively connected to the three-phase power output by the first inductor sub-unit through a third resistor, a fourth resistor, and a fifth resistor.

[0079] On the basis of the original L1, L2, and C1 existing in the improved LCL unit, three absorption resistors R3, R4, and R5 are added. Their resistance values should be as small as possible and the power should be sufficient because the current during the operation of the LCL is generally proportional to the motor power. When the normal tensioning circuit is in the standby state, the first sub-contactor KM1 is in the closed state, and the controllable rectifying circuit is in the stopped state. At this time, there may be an oscillation circuit composed of a power transformer, a power supply line, a contactor, and an LCL circuit, resulting in resonance of the power supply voltage and causing the bus voltage in the filtering unit to rise until the frequency conversion circuit reports an overvoltage fault. The presence of the three resistors R3, R4, and R5 destroys the conditions for generating resonance, that is, it improves the circuit so that it does not enter the resonance state.

[0080] The improved LCL unit in this embodiment can prevent the situation where the bus voltage rises due to resonance caused by the power supply side in the tensioning system. As Figure 2 shown, resistors R1, R2, and R3 are connected in series with the capacitor C of the feedback device to destroy the conditions for generating resonance, suppress current mutation, and reduce interference to the power supply voltage.

[0081] In an alternative embodiment of the present invention, when the host computer startup signal is given to the mine integrated drive device, the tensioning system works first. When the tension value allows the main drive motor to start, the drive module of this embodiment automatically starts. The load of the main drive system is two low-speed direct drive motors. The main drive frequency conversion part of the present invention is a two-way inverter drive system, operating in a master-slave mode. The main controller issues a startup command, and its third auxiliary control unit and fourth auxiliary control unit receive the command, control the optical fiber distribution module to drive each drive unit through optical fibers, control the IGBT to complete the SPWM modulation, and complete the process of frequency modulation and voltage regulation. The optical fiber distribution module monitors the current and voltage in real time and uploads them to the third auxiliary control unit and the fourth auxiliary control unit. During this process, the main controller needs to detect the real-time speed, torque, and current of the two inverter units in real time. According to the torque difference between the master machine and the slave machine, the following speed of the slave machine is adjusted to ensure that the torque difference between the master and slave machines < 5%. As shown in the figure, the main drive circuit of the present invention shares a rectification unit and a filtering unit to ensure that when the main and slave powers of the drive circuit are unbalanced, the energy generated by the reverse-dragging power generation is absorbed and the bus voltage rise is suppressed.

[0082] The drive module of this embodiment specifically includes:

[0083] A first drive circuit is formed by sequentially connecting a second disconnector, a second contactor, a rectification unit, a filtering unit, a second inverter unit, and a first drive motor;

[0084] A second drive circuit is formed by sequentially connecting a third disconnector, a third contactor, a rectification unit, a filtering unit, a third inverter unit, and a second drive motor;

[0085] The second inverter unit and the third inverter unit are used to receive the drive control signals sent by the main control module, and respectively control the IGBTs in the second inverter unit and the third inverter unit to conduct and turn off in sequence according to the drive control signals, output a variable AC power supply, and drive the first drive motor and the second drive motor to start from 0 speed and rise to the rated speed within the acceleration time.

[0086] The load of the main drive system of this embodiment is two low-speed direct drive motors. The main drive frequency conversion part of the present invention is a two-way frequency conversion drive system, operating in a master-slave mode. As Figure 1As shown: The main controller issues a start command, and its third and fourth auxiliary control units receive the command to control the fiber optic distribution module to drive each drive unit through the optical fiber, control the IGBT to conduct and turn off in sequence, output a variable AC power supply, drive the motor to start from 0 speed, and rise to the rated speed within the acceleration time. The fiber optic distribution module monitors the current and voltage in real time and uploads them to the third and fourth auxiliary control units. During this process, the main controller needs to detect the real-time speed, torque, and current of the two inverter units in real time. According to the torque difference between the master and slave machines, the following speed of the slave machine is adjusted to ensure that the torque difference between the master and slave machines < 5%. The collected speed and current are used to monitor the real-time data. As shown in the figure, the main drive circuit of the present invention shares a rectification unit and a filtering unit to ensure that when the main and slave powers of the drive circuit are unbalanced, the energy generated by the counter-dragging power generation is absorbed and the bus voltage rise is suppressed. The power supply voltage of the variable frequency drive circuit is 1140V.

[0087] In an alternative embodiment of the present invention, the main control module of this embodiment specifically includes:

[0088] The main control unit, the first auxiliary control unit, the first fiber optic distribution unit, the second auxiliary control unit, the second fiber optic distribution unit, the third auxiliary control unit, the third fiber optic distribution unit, the fourth auxiliary control unit, and the fourth fiber optic distribution unit;

[0089] The main control unit is used to generate a tension start signal according to the start signal from the upper computer and send it to the first auxiliary control unit; receive the real-time tension of the belt conveyor collected by the tension detection module, and generate a tension control signal according to the real-time tension of the belt conveyor using a preset tension control algorithm and send it to the second auxiliary control unit; receive the real-time operation parameters of the second and third inverter units detected by the third and fourth fiber optic distribution units, and generate a drive control signal according to the real-time operation parameters of the second and third inverter units using a preset drive control algorithm and send it to the third and fourth auxiliary control units;

[0090] The first auxiliary control unit is used to communicate with the first fiber optic distribution unit and send the tension start signal to the first fiber optic distribution unit;

[0091] The first fiber optic distribution unit is used to control the conduction and turn-off sequence of the IGBT in the controllable rectifier unit according to the tension start signal;

[0092] The second auxiliary control unit is used to communicate with the second fiber optic distribution unit and send the tension control signal to the second fiber optic distribution unit;

[0093] The second fiber optic distribution unit is used to adjust the conduction and turn-off sequence of each IGBT in the first inverter unit according to the tension control signal;

[0094] The third auxiliary control unit and the fourth auxiliary control unit are used to communicate with the third optical fiber distribution unit and the fourth optical fiber distribution unit respectively, send drive control signals to the third optical fiber distribution unit and the fourth optical fiber distribution unit respectively, receive the real-time operation parameters of the second inverter unit and the third inverter unit sent by the third optical fiber distribution unit and the fourth optical fiber distribution unit, and send them to the main control unit.

[0095] The third optical fiber distribution unit and the fourth optical fiber distribution unit are used to control the IGBT conduction and cutoff sequence in the second inverter unit and the third inverter unit respectively according to the drive control signal, and detect the real-time operation parameters of the second inverter unit and the third inverter unit and send them to the third auxiliary control unit and the fourth auxiliary control unit respectively.

[0096] Generating a tension start signal according to the host computer start signal in this embodiment specifically includes the following steps:

[0097] A1. Generate a tension pre-start signal according to the host computer start signal to control the forward rotation of the tension motor.

[0098] A2. Receive the real-time tension of the belt conveyor collected by the tension detection module, and judge whether the real-time tension reaches the pre-tension value. If so, execute step A3; otherwise, continue to execute step A2.

[0099] A3. Use the main control unit to send a tension health signal to the host computer controller and control the tension loop not to stop.

[0100] Generating a tension control signal according to the real-time tension of the belt conveyor by using a preset tension control algorithm in this embodiment specifically includes the following steps:

[0101] B1. When the belt conveyor starts, receive the real-time tension of the belt conveyor collected by the tension detection module, and judge whether the real-time tension of the belt conveyor drops. If so, execute step B2; otherwise, continue to execute step B1.

[0102] B2. Use the main control unit to control the forward rotation of the tension motor to slowly raise the tension of the belt conveyor to the rated tension value.

[0103] B3. When the tension of the belt conveyor reaches the rated tension value, use the main control unit to control the output speed of the tension motor to gradually decrease to 0 speed, and after a set time delay, use the main control unit to control the tension motor to brake.

[0104] Generating a tension control signal according to the real-time tension of the belt conveyor by using a preset tension control algorithm in this embodiment further includes the following steps:

[0105] C1. When the belt conveyor is running, receive the real-time tension of the belt conveyor collected by the tension detection module, and determine whether the real-time tension of the belt conveyor exceeds the tension range; if the real-time tension exceeds the upper limit of the tension range, execute step C2; if the real-time tension exceeds the lower limit of the tension range, execute step C3; otherwise, continue to execute step C1;

[0106] C2. Use the main control unit to control the brake control power supply to release the brake, and control the tensioning motor to reverse to reduce the tension to the rated tension;

[0107] C3. Use the main control unit to control the brake control power supply to release the brake, and control the tensioning motor to rotate forward to increase the tension to the rated tension;

[0108] C4. When the tension of the belt conveyor reaches the rated tension value, use the main control unit to control the output speed of the tensioning motor to gradually decrease to 0 speed, and after a set delay time, use the main control unit to control the tensioning motor to apply the brake.

[0109] This embodiment also includes the following steps for generating a tension control signal by using a preset tension control algorithm according to the real-time tension of the belt conveyor:

[0110] D1. When the belt conveyor is running, receive the real-time tension of the belt conveyor collected by the tension detection module, and determine whether the change in the real-time tension of the belt conveyor exceeds the set condition; if so, execute step D2; otherwise, continue to execute step D1;

[0111] D2. Use the main control unit to control the tensioning motor to rotate forward, and at the same time control the brake control power supply to release the brake so that the tension is reduced to the rated tension;

[0112] D3. When the tension of the belt conveyor reaches the rated tension value, use the main control unit to control the output speed of the tensioning motor to gradually decrease to 0 speed, and after a set delay time, use the main control unit to control the tensioning motor to apply the brake.

[0113] Specifically, this embodiment automatically realizes tension logic control, including loosening the belt and tightening the belt, with the set tension reference value as the tension target; among them, the forward rotation of the tensioning motor is to tighten the steel wire rope, making the belt tension increase, and the reverse rotation of the tensioning motor is to loosen the steel wire rope, making the belt tension decrease. The mine integrated drive device will repeat and cycle among the following four states: a, b, c, d.

[0114] a. Tension startup stage: First, when the mine integrated drive device receives an external startup signal (the signal is a digital input signal from the upper computer), it enters the pre-tension startup state. The main control unit controls the output frequency of the second auxiliary control unit in the tension circuit, causing the tension motor to rotate forward and increasing the tension to reach the pre-tension state (generally, the pre-tension force is greater than the rated tension force). At this time, the main control unit senses the tension magnitude through the tension detection system. When the tension reaches the pre-tension value, it sends a tension health signal (the tension health signal is a digital signal) to the upper computer controller, and the main control unit controls the tension circuit to keep running. The purpose of pre-tensioning is to ensure that the tension is within an appropriate range before the startup stage of the belt conveyor, so that the tension is sufficient when the main drive motor starts, and the friction between the main drive roller and the belt is sufficient to prevent slipping.

[0115] b. Drive circuit startup stage: After the main control unit controls the tension motor to tighten the tension to the pre-tension force, the main control unit controls the third and fourth auxiliary control units, causing the main drive circuits corresponding to the third and fourth auxiliary control units to control the drive motor to rotate. After the main drive roller rotates, the tension will rapidly decrease. The main control unit controls the tension circuit to immediately enter the belt-tightening mode, that is, the tension circuit controls the tension motor to rotate forward, rapidly increasing the tension of the belt conveyor, and constantly monitoring the tension magnitude (the tension is detected in real time through the tension detection system), so that the tension slowly rises to the rated tension value. As the belt conveyor reaches the rated belt speed, the tension circuit dynamically adjusts the tension to the rated range. At this time, when the tension is closer to the rated tension value, the output speed of the tension motor gradually decreases to 0 speed. Then, after a certain delay, the output of the tension circuit is cut off, and the main control unit controls the brake to brake the output shaft of the tension motor. In this way, after the tension circuit stops running, the brake is used to ensure that the tension motor is not reversed by the tension of the belt.

[0116] c. Operation stage:

[0117] During the normal operation stage of the belt conveyor, the tension of the entire belt conveyor is usually in a slow change due to the amount of coal fed onto the belt conveyor, elastic changes, and the position change of the continuous miner at the head. It may exceed the upper limit of the tension range or be lower than the lower limit of the tension range. At this time, it is necessary to adjust the tension to the rated tension to ensure the stability of the belt conveyor tension. Generally, for example: if the tension is set to 50 KN, the upper limit of the tension range is set to 55 KN, and the lower limit of the tension range is set to 45 KN.

[0118] 1) During the operation of the main drive circuit (i.e., when the tensioning circuit is in the standby state), when the main control unit monitors through the tension detection system that the tension slowly drops to the lower limit of the rated range, the main control unit controls the brake control power supply to release the brake, and controls the tensioning motor to rotate forward. The forward rotation process is the belt-tightening process, and the belt is tightened to the rated tension. At this time, the tensioning motor is stopped, and the brake is engaged. After that, the tensioning circuit enters the standby state. During this process, the main drive circuit operates normally.

[0119] 2) During the operation of the main drive circuit (i.e., when the tensioning circuit is in the standby state), when the main control unit monitors through the tension detection system that the tension slowly rises to the upper limit of the rated range, the main control unit controls the brake control power supply to release the brake, and controls the tensioning motor to rotate in reverse. The reverse rotation process is the belt-loosening process, and the belt is loosened to the rated tension. At this time, the tensioning motor is stopped, and the brake is engaged. After that, the tensioning circuit enters the standby state. During this process, the main drive circuit operates normally.

[0120] d. Emergency shutdown stage of the belt conveyor: During the normal operation of the drive circuit, when the main control unit of the mine integrated drive device detects through the tension detection system that the tension rises rapidly (for example: within 3S, the tension rises rapidly by more than 1.5 times the rated tension), the main control unit controls the second auxiliary control unit to drive the tensioning motor to rotate in reverse, and at the same time controls the brake control power supply to release the brake, entering the fast belt-loosening mode (fast belt-loosening means that the tensioning motor rotates at the maximum reverse speed). After a certain delay, it is judged whether the tension has entered the rated range. If the tension slowly drops to the rated tension, and at this time the output speed of the tensioning motor is 0 speed, the main control unit controls the brake to engage through the brake power supply. After the brake is engaged, the tensioning circuit stops, and the integrated drive device enters the standby state.

[0121] In an alternative embodiment of the present invention, such as Figure 3As shown in the figure, the tension detection module of this embodiment uses a complete set of devices such as an A3 tension sensor, an A2 signal conversion device (converting 0 - 25 mV to 4 - 20 mA), an A4 local operation box, and the main control unit of the mine integrated drive device to monitor the tension value in real time, so as to feedback to the frequency conversion drive device and dynamically adjust the motor output speed to ensure that the tension value is within an appropriate range. The range of the A3 tension sensor is 200 KN, and the signal is 0 - 25 mV. The A2 signal conversion device converts the 0 - 25 mV signal into a 4 - 20 mA signal and transmits it to the local operation box, and the local operation box needs to provide a 12V power supply signal to the signal conversion device. The signal conversion device supplies power to the tension sensor. In addition, the local operation box has a local / automatic control state switch. When the local / automatic knob of the local operation box is turned to the local state, the local tight belt and loose belt operations are effective. When the local / automatic knob of the local operation box is turned to the automatic state, the control rights of the tight belt and loose belt are transferred to the main control unit of the frequency conversion drive device. All signals communicate with the main controller of the mine integrated drive device.

[0122] In this embodiment, a complete set of devices including a tension sensor, a signal conversion device (converting to 4 - 20 mA), a local operation box, and the main controller of the mine integrated drive device are used to monitor the tension value in real time, so as to feedback to the main control unit of the mine integrated drive device and dynamically adjust the motor output speed to ensure that the tension value is within an appropriate range.

[0123] In an alternative embodiment of the present invention, this embodiment is also configured with multiple auxiliary industrial frequency output circuits (1140V) to supply power to the corresponding cooling fans and cooling systems. In addition, the mine integrated drive device supports the MODBUS / TCP and modbus RTU protocols, can communicate with the upper computer, complete the speed regulation of the drive system, fault reset, and realize remote automatic operation.

[0124] The present invention is described with reference to the flowcharts and / or block diagrams of methods, devices (systems), and computer program products according to embodiments of the present invention. It should be understood that each process and / or block in the flowchart and / or block diagram, as well as the combination of processes and / or blocks in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to the processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing devices to generate a machine, so that the instructions executed by the processor of the computer or other programmable data processing devices generate a device for realizing the functions specified in Figure 1 one process or multiple processes and / or blocks Figure 1 one block or multiple blocks.

[0125] These computer program instructions can also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to operate in a particular manner, such that the instructions stored in the computer-readable memory produce a manufacture including an instruction means that implements the functions specified in one or more of the processes Figure 1 or blocks Figure 1 specified in one or more of the processes and / or blocks.

[0126] These computer program instructions can also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process, whereby the instructions executed on the computer or other programmable apparatus provide steps for implementing the functions specified in one or more of the processes Figure 1 or blocks Figure 1 specified in one or more of the blocks.

[0127] Specific embodiments are used in the present invention to elaborate the principles and implementation manners of the present invention. The description of the above embodiments is only for helping to understand the method of the present invention and its core idea; at the same time, for those of ordinary skill in the art, according to the idea of the present invention, there will be changes in the specific implementation manners and application scopes. In summary, the content of this specification should not be construed as a limitation to the present invention.

[0128] Those of ordinary skill in the art will realize that the embodiments described herein are for helping the reader understand the principles of the present invention and should be understood that the protection scope of the present invention is not limited to such specific statements and embodiments. Those of ordinary skill in the art can make various other specific deformations and combinations that do not depart from the essence of the present invention based on the technical revelations disclosed in the present invention, and these deformations and combinations are still within the protection scope of the present invention.

Claims

1. A mine integrated drive device for continuous mining belt conveyors, characterized in that, Including: A tensioning module, which is used to start the tensioning motor according to the tensioning start signal sent by the main control module to adjust the tension of the belt conveyor to the pre-tension value, adjust the tension of the belt conveyor within the set tension range according to the tensioning control signal sent by the main control module after the belt conveyor starts up, and in real time feed back the electric energy generated by releasing the tension into the power grid during the shutdown process of the belt conveyor; The tensioning module specifically includes: A first disconnect switch, a first contactor, an improved LCL unit, a controlled rectifier unit, a first filter unit, a first inverter unit and a tensioning motor are connected in sequence to form a tensioning circuit; An improved charging unit is connected in parallel at both ends of the first contactor; The controlled rectifier unit is used to receive the adjustment signal sent by the main control module, and control the IGBTs in the controlled rectifier unit to conduct and turn off in sequence according to the adjustment signal, so that the phase angle of the power grid is consistent with the output waveform of the controlled rectifier unit through the improved LCL unit; The first inverter unit is used to receive the tensioning start signal sent by the main control module, adjust the conduction and turn-off of each IGBT in the first inverter unit according to the tensioning start signal to control the start of the tensioning motor; And receive the tensioning control signal sent by the main control module, and adjust the conduction and turn-off sequence of each IGBT in the first inverter unit according to the tensioning control signal to control the working state of the tensioning motor; A drive module, which is used to perform frequency modulation and voltage regulation on the input power supply by using a dual-channel master-slave inverter drive circuit, and adjust the real-time speeds of the main drive motor and the slave drive motor in real time according to the drive control signal sent by the main control module; A main control module, which is used to generate a tensioning start signal according to the start signal of the upper computer and send it to the tensioning module; Receive the real-time tension of the belt conveyor collected by the tension detection module, generate a tensioning control signal according to the real-time tension of the belt conveyor by using a preset tensioning control algorithm and send it to the tensioning module; And detect the real-time operation parameters of the drive module, generate a drive control signal according to the real-time operation parameters of the drive module by using a preset drive control algorithm and send it to the drive module; A tension detection module, which is used to collect the real-time tension of the belt conveyor after the belt conveyor starts up and send it to the main control module.

2. The integrated mining drive device for continuous mining belt conveyors according to claim 1, characterized in that, The improved charging unit specifically includes: A first sub-contactor and a second sub-contactor connected in parallel; Three contacts of the first sub-contactor are respectively connected to the input three-phase power; One of the contacts of the first sub-contactor is connected to the corresponding contact of the second sub-contactor through a rectifier diode; The switch end of the corresponding contact of the second sub-contactor is connected to the switch end of this contact of the first sub-contactor through a second resistor; Another one of the contacts of the first sub-contactor is connected to the corresponding contact of the second sub-contactor; The switch end of the corresponding contact of the second sub-contactor is connected to the switch end of this contact of the first sub-contactor through a first resistor.

3. The integrated mining drive device for continuous mining belt conveyors according to claim 2, characterized in that, The improved LCL unit specifically includes: A first inductor sub-unit, a second inductor sub-unit and a first capacitor sub-unit; The first inductor sub-unit is connected to the input three-phase power, and the second inductor sub-unit is connected to the three-phase power output by the first inductor sub-unit; The first capacitor sub-unit is respectively connected to the three-phase power output by the first inductor sub-unit through a third resistor, a fourth resistor and a fifth resistor.

4. The integrated mining drive device for continuous mining belt conveyor according to claim 3, characterized in that, The drive module specifically includes: A first drive loop is formed by sequentially connecting a second disconnector, a second contactor, a rectification unit, a filtering unit, a second inverter unit, and a first drive motor; A second drive loop is formed by sequentially connecting a third disconnector, a third contactor, a rectification unit, a filtering unit, a third inverter unit, and a second drive motor; The second inverter unit and the third inverter unit are used to receive drive control signals sent by the main control module, and respectively control the IGBTs in the second inverter unit and the third inverter unit to conduct and turn off in sequence according to the drive control signals, output variable AC power supplies, and drive the first drive motor and the second drive motor to start from 0 speed and rise to the rated speed within the acceleration time.

5. The integrated mining drive device for continuous mining belt conveyor according to claim 4, characterized in that, The main control module specifically includes: A main control unit, a first auxiliary control unit, a first optical fiber distribution unit, a second auxiliary control unit, a second optical fiber distribution unit, a third auxiliary control unit, a third optical fiber distribution unit, a fourth auxiliary control unit, and a fourth optical fiber distribution unit; The main control unit is used to generate a tensioning start signal according to the host computer start signal and send it to the first auxiliary control unit; receive the real-time tension of the belt conveyor collected by the tension detection module, and generate a tension control signal according to the real-time tension of the belt conveyor by using a preset tension control algorithm and send it to the second auxiliary control unit; receive the real-time operation parameters of the second inverter unit and the third inverter unit detected by the third optical fiber distribution unit and the fourth optical fiber distribution unit, and generate a drive control signal according to the real-time operation parameters of the second inverter unit and the third inverter unit by using a preset drive control algorithm and send it to the third auxiliary control unit and the fourth auxiliary control unit; The first auxiliary control unit is used to communicate with the first optical fiber distribution unit and send the tensioning start signal to the first optical fiber distribution unit; The first optical fiber distribution unit is used to control the conduction and turn-off sequence of the IGBTs in the controllable rectification unit according to the tensioning start signal; The second auxiliary control unit is used to communicate with the second optical fiber distribution unit and send the tension control signal to the second optical fiber distribution unit; The second optical fiber distribution unit is used to adjust the conduction and turn-off sequence of each IGBT in the first inverter unit according to the tension control signal; The third auxiliary control unit and the fourth auxiliary control unit are used to communicate with the third optical fiber distribution unit and the fourth optical fiber distribution unit respectively, and send the drive control signals to the third optical fiber distribution unit and the fourth optical fiber distribution unit respectively; receive the real-time operation parameters of the second inverter unit and the third inverter unit sent by the third optical fiber distribution unit and the fourth optical fiber distribution unit and send them to the main control unit; The third optical fiber distribution unit and the fourth optical fiber distribution unit are used to control the conduction and turn-off sequence of the IGBTs in the second inverter unit and the third inverter unit respectively according to the drive control signals; and detect the real-time operation parameters of the second inverter unit and the third inverter unit and send them to the third auxiliary control unit and the fourth auxiliary control unit respectively.

6. The integrated mining drive device for continuous mining belt conveyor according to claim 5, characterized in that, The generation of the tensioning start signal according to the host computer start signal specifically includes the following steps: A1. Generate a tensioning pre-start signal according to the host computer start signal to control the forward rotation of the tensioning motor; A2. Receive the real-time tension of the belt conveyor collected by the tension detection module, and determine whether the real-time tension reaches the pre-tension value. If so, execute step A3; otherwise, continue to execute step A2. A3. Use the main control unit to send a tension health signal to the host controller and control the tension loop without stopping the machine.

7. The integrated mining drive device for continuous mining belt conveyors according to claim 6, wherein, The generation of the tension control signal by using the preset tension control algorithm according to the real-time tension of the belt conveyor specifically includes the following steps: B1. When the belt conveyor starts, receive the real-time tension of the belt conveyor collected by the tension detection module, and determine whether the real-time tension of the belt conveyor decreases. If so, execute step B2; otherwise, continue to execute step B1. B2. Use the main control unit to control the tension motor to rotate forward, so that the tension of the belt conveyor slowly rises to the rated tension value. B3. When the tension of the belt conveyor reaches the rated tension value, use the main control unit to control the output speed of the tension motor to gradually decrease to 0 speed, and after delaying the set time, use the main control unit to control the tension motor to brake.

8. A mining integrated drive device for continuous mining belt conveyors according to claim 7, characterized in that The generation of the tension control signal by using the preset tension control algorithm according to the real-time tension of the belt conveyor further includes the following steps: C1. When the belt conveyor is running, receive the real-time tension of the belt conveyor collected by the tension detection module, and determine whether the real-time tension of the belt conveyor exceeds the tension range. If the real-time tension exceeds the upper limit of the tension range, execute step C2; if the real-time tension exceeds the lower limit of the tension range, execute step C3; otherwise, continue to execute step C1. C2. Use the main control unit to control the brake control power supply to release the brake, and control the tension motor to rotate in reverse to reduce the tension to the rated tension. C3. Use the main control unit to control the brake control power supply to release the brake, and control the tension motor to rotate forward to increase the tension to the rated tension. C4. When the tension of the belt conveyor reaches the rated tension value, use the main control unit to control the output speed of the tension motor to gradually decrease to 0 speed, and after delaying the set time, use the main control unit to control the tension motor to brake.

9. The integrated mining drive device for continuous mining belt conveyors according to claim 8, wherein, The generation of the tension control signal by using the preset tension control algorithm according to the real-time tension of the belt conveyor further includes the following steps: D1. When the belt conveyor is running, receive the real-time tension of the belt conveyor collected by the tension detection module, and determine whether the change in the real-time tension of the belt conveyor exceeds the set condition. If so, execute step D2; otherwise, continue to execute step D1. D2. Use the main control unit to control the tension motor to rotate forward and at the same time control the brake control power supply to release the brake, so that the tension is reduced to the rated tension. D3. When the tension of the belt conveyor reaches the rated tension value, use the main control unit to control the output speed of the tension motor to gradually decrease to 0 speed, and after delaying the set time, use the main control unit to control the tension motor to brake.

Images