Intelligent feeding control system and method for a roll-over machine

Abstract

The application discloses an intelligent feeding control system and method of a dumper, relates to the technical field of dumper feeding, and comprises a coal type identification module, a material level metering module, a dumper control module, a feeder control module, a belt scale reading module and a PLC controller. The PLC controller is electrically connected with the coal type identification module, the dumper control module, the feeder control module and the belt scale reading module. The feeder control module is connected with a frequency converter for controlling a cam motor and an outlet power component for controlling the discharge port area of an activated feeder. A plurality of different coal feeding operation control models are built in the PLC controller. The intelligent feeding control system and method of the dumper adopt the above structure and steps, select a suitable model according to the coal type to guide the dumper operation, and ensure the stable operation of the belt conveyor.

Description

Technical Field

[0001] This invention relates to the field of tippler feeding technology, and in particular to an intelligent feeding control system and method for tipplers. Background Technology

[0002] Tippers are commonly used machines in ports and industrial sectors such as metallurgy, coal, and thermal power. They are used to unload bulk materials loaded on trains. After coal is transported to the station, the wagons are pushed onto the tipping platform for positioning. Then, the tipper "hugs" the wagons and rotates them 140-170 degrees to begin unloading. During the coal unloading process, the tipper can unload 1-4 wagons at a time. The tipper typically unloads the required material into multiple storage hoppers, and then the material is simultaneously discharged from the multiple storage hoppers onto the conveyor belt below. The conveyor belt then transports the material flowing out of the hoppers.

[0003] Currently, during coal unloading operations, the coal feed rate is controlled based on the remaining amount in the hoppers, thereby adjusting the conveyor belt speed. However, because the amount of material received by the multiple hoppers varies, there is a situation where the hoppers in the middle receive more material than those on the sides. This results in the middle hoppers receiving more material faster and more, while the hoppers on the sides receive less and more material more slowly. Consequently, the material distribution on the conveyor belt is uneven, leading to uneven belt load and increasing the risk of belt tearing, which is detrimental to the long-term stable operation of the conveyor belt. Furthermore, due to the different calorific values ​​and significant differences in composition of different coal types, there are large differences in density between them. These different coal types exhibit different mechanical properties during unloading, posing a challenge to controlling the material flow. Summary of the Invention

[0004] The purpose of this invention is to provide an intelligent feeding control system and method for a tipper, which selects a suitable model based on the type of coal to guide the tipper operation and ensures the smooth operation of the belt conveyor.

[0005] To achieve the above objectives, the present invention provides an intelligent feeding control system for a tipper, including a coal type identification module, a material level metering module, a tipper control module, a feeder control module, a belt scale reading module, and a PLC controller. The PLC controller is electrically connected to the coal type identification module, the tipper control module, the feeder control module, and the belt scale reading module.

[0006] The coal type identification module is installed on the tippler to identify the type of coal and send a type code representing the type of coal to the PLC controller;

[0007] The tippler control module is used to control the start and stop movement of the tippler;

[0008] The material level metering module is connected to the high material level sensor, the low material level sensor and the weighing sensor installed in the hopper and the bottom corner support of the hopper. The hopper metering module receives the measurement data from the high material level sensor, the low material level sensor and the weighing sensor, performs the calculation and sends the material level value to the PLC controller.

[0009] The feeder control module is connected to the frequency converter for controlling the cam motor and the outlet power component for controlling the discharge port area of ​​the activation feeder. The frequency converter changes the feeding amount of the activation feeder by controlling the vibration frequency of the cam motor.

[0010] The belt scale reading module is connected to the belt scale installed on the belt conveyor to read the instantaneous measurement value of the belt scale and generate the real-time measurement curve of the belt scale.

[0011] The PLC controller has several built-in feeding operation control models for different types of coal. The feeding operation control models are numbered according to the type of coal, and there is a correspondence between the type code and the model number. After receiving the type code from the coal type identification module, the PLC controller retrieves the corresponding feeding operation control model and outputs the control mode of the frequency converter. The PLC controller also has a built-in table of coal type and outlet power component adjustment angle. When the PLC controller receives the coal type code, it adjusts the outlet power component to the preset angle through the feeder control module.

[0012] Preferably, the input of the feeding operation control model is the instantaneous value of the belt scale and the real-time measurement curve of the belt scale, the constraint is the stable operating value of the belt scale, and the output is the control mode of the frequency converter, which includes the frequency setpoint and the frequency set time.

[0013] The constraint objective is to calculate the output amount that should be allocated to each activated feeder to ensure that the belt running state meets the stable operating value under the current instantaneous value of the belt scale, based on the instantaneous value, real-time measurement curve, and stable operating value of the belt scale. Based on the output amount of the activated feeder, the frequency setting value and frequency setting time of each frequency converter are calculated to ensure that the instantaneous value of the belt scale is stable near the stable operating value.

[0014] Preferably, the weighing sensor senses the weight of the coal in the hopper and calculates the coal level based on the shape of the hopper; the high level sensor is used to sense the highest value of the hopper level, and when the amount of coal in the hopper triggers the highest value, the tipper control module controls the tipper to stop tipping; the low level sensor is used to sense the lowest value of the hopper level.

[0015] A smart feeding control method for a tipper, comprising the following steps:

[0016] S1. After the coal train enters the tippler, the coal type identification module identifies the type of coal and sends a type code representing the type of coal to the PLC controller.

[0017] S2, the PLC controller receives the type code, retrieves the corresponding number of the feeding operation control model for calculation, outputs the control mode of the frequency converter under different coal types, and outputs the preset angle of the outlet power component according to the comparison table of coal type and outlet power component adjustment angle.

[0018] S3, the PLC controller sends execution commands to the frequency converter and outlet power component of the activated feeder through the feeder control module, so that the frequency converter operates according to the control mode and the outlet power component is adjusted to the appropriate angle;

[0019] S4. The PLC controller controls the tipper to start tipping operations through the tipper control module. During the operation, the material level metering module and the belt scale reading module feed back material level data and belt scale weight data to the PLC controller in real time, and compare them with the preset curve of the feeding operation control model to calculate the error between the real-time feedback data and the preset curve data. When the error is within the allowable fluctuation range, the equipment continues to run; when the error exceeds the allowable fluctuation range, the PLC controller alarms.

[0020] Therefore, the present invention provides an intelligent feeding system and method for a tipper using the above-described structure and steps. The PLC control system retrieves the corresponding numbered feeding operation control model based on the type of coal, outputs the control mode of the frequency converter and the adjustment angle of the outlet power component, enabling the frequency converter to operate at a set frequency and time. This adjusts the vibration speed of the cam motor and activates the feeder's discharge area, thereby controlling the material quantity. This ensures that the instantaneous value of the belt scale remains stable near the normal operating value during normal belt operation, avoiding uneven belt load, reducing the risk of belt tearing, and maintaining safe equipment operation.

[0021] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the structure of an embodiment of the intelligent feeding control system for a tipper according to the present invention;

[0023] Figure 2 This is a flowchart illustrating an embodiment of an intelligent feeding control method for a tipper according to the present invention.

[0024] Figure 3 This is a structural diagram showing the interface positions of the hopper and the activation feeder in an embodiment of the present invention.

[0025] Figure Labels

[0026] 1. Hopper; 2. Activation feeder; 3. Cam motor; 4. Frequency converter; 5. Activation block; 6. Outlet power component. Detailed Implementation

[0027] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0028] Example

[0029] like Figure 1 As shown, an intelligent feeding control system for a tipper includes a coal type identification module, a material level metering module, a tipper control module, a feeder control module, a belt scale reading module, and a PLC controller. The PLC controller is electrically connected to the coal type identification module, the tipper control module, the feeder control module, and the belt scale reading module.

[0030] A coal type identification module is installed on the tipper to identify the type of coal and send a type code representing the coal type to the PLC controller. The reason why coal type makes tipping operation difficult is that different types of coal have different densities and particle shapes, and therefore produce different vibration curves when they fall due to the vibration of the activated feeder 2.

[0031] The tippler control module is used to control the start and stop of the tippler.

[0032] The material level metering module is connected to the high-level sensor, low-level sensor, and weighing sensor installed inside hopper 1, and the weighing sensor installed on the bottom corner support of hopper 1. The hopper 1 metering module receives the measurement data from the high-level sensor, low-level sensor, and weighing sensor, performs calculations, and sends the material level value to the PLC controller. The weighing sensor senses the weight of the coal in hopper 1 and calculates the coal level based on the shape of hopper 1. The high-level sensor is used to sense the highest material level in hopper 1. When the amount of coal in hopper 1 triggers the highest material level, the tipper control module controls the tipper to stop tipping. The low-level sensor is used to sense the lowest material level in hopper 1. Both excessively high and low material levels in hopper 1 will affect the feeding operation. A low material level can easily cause an excessive instantaneous feeding volume, stopping the conveyor belt and causing regional coal jamming. To avoid this situation, during the first cycle of the tipper's operation, ensure that hopper 1 contains at least 30% coal before starting the activation feeder 2 to reduce the possibility of a sudden large flow of material.

[0033] like Figure 3 As shown, the feeder control module is connected to the frequency converter 4 for controlling the cam motor 3 and the outlet power unit 6 for controlling the discharge port area of ​​the activation feeder 2. The frequency converter 4 changes the feeding amount of the activation feeder 2 by controlling the vibration frequency of the cam motor 3. The activation block 5 is located in the center of the activation feeder 2, and disperses the coal from the hopper 1 through vibration. The outlet power unit 6 is located at the outlet edge and can take various forms, including but not limited to hydraulic cylinders, hydraulic brakes, motors, etc., to change the shape of the discharge port to adapt to different types of coal.

[0034] The belt scale reading module is connected to the belt scale installed on the belt conveyor. It is used to read the instantaneous measurement value of the belt scale and generate the real-time measurement curve of the belt scale.

[0035] The PLC controller has several built-in feeding operation control models for different types of coal. The feeding operation control models are numbered according to the type of coal, and there is a correspondence between the type code and the model number. After receiving the type code from the coal type identification module, the PLC controller retrieves the corresponding feeding operation control model and outputs the control mode of the frequency converter 4. The PLC controller also has a built-in table of the coal type and the adjustment angle of the outlet power component 6. When the PLC controller receives the coal type code, it adjusts the outlet power component 6 to the preset angle through the feeder control module.

[0036] The inputs to the feeding operation control model are the instantaneous values ​​and real-time measurement curves of the belt scale. The constraints are the stable operating values ​​of the belt scale. The output is the control mode of inverter 4, which includes the frequency setpoint and the frequency set time. The feeding operation control model is established based on historical experience. Its model framework is limited by the rated parameters of the equipment, the type of train, the belt load-bearing capacity, and climatic conditions. The establishment method refers to existing technologies.

[0037] The constraint objective is to calculate the output amount that should be allocated to each activated feeder 2 under the current instantaneous value of the belt scale to ensure that the belt running state meets the stable operating value, based on the instantaneous value, real-time measurement curve, and stable operating value of the belt scale. Based on the output amount of the activated feeder 2, the frequency setting value and frequency setting time of each frequency converter 4 are calculated to ensure that the instantaneous value of the belt scale is stable near the stable operating value.

[0038] A smart feeding control method for a tipper, comprising the following steps:

[0039] S1. After the coal train enters the tippler, the coal type identification module identifies the type of coal and sends a type code representing the type of coal to the PLC controller.

[0040] S2, the PLC controller receives the type code, retrieves the corresponding number of the feeding operation control model for calculation, outputs the control mode of the frequency converter 4 under different coal types, and outputs the preset angle of the outlet power component 6 according to the comparison table of coal type and outlet power component 6 adjustment angle.

[0041] S3, the PLC controller sends execution commands to the frequency converter 4 and the outlet power component 6 of the activated feeder 2 through the feeder control module, so that the frequency converter 4 operates according to the control mode and the outlet power component 6 is adjusted to a suitable angle.

[0042] S4. The PLC controller controls the tipper to start tipping operations through the tipper control module. During the operation, the material level metering module and the belt scale reading module feed back material level data and belt scale weight data to the PLC controller in real time, and compare them with the preset curve of the feeding operation control model to calculate the error between the real-time feedback data and the preset curve data. When the error is within the allowable fluctuation range, the equipment continues to run; when the error exceeds the allowable fluctuation range, the PLC controller alarms.

[0043] Therefore, the present invention provides an intelligent feeding system and method for a tipper using the above-described structure and steps. The PLC control system retrieves the corresponding numbered feeding operation control model according to the type of coal, outputs the control mode of the frequency converter 4 and the adjustment angle of the outlet power component 6, so that the frequency converter 4 runs according to the set frequency and set time, adjusts the vibration speed of the cam motor 3 and activates the discharge area of ​​the feeder 2, thereby controlling the amount of material, ensuring that the instantaneous value of the belt scale remains stable near the stable operating value during normal belt operation, avoiding uneven belt load, reducing the risk of belt tearing, and maintaining the safe operation of the equipment.

[0044] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the technical solutions of the present invention, and these modifications or equivalent substitutions cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

Claims

1. An intelligent feed control system for a roll-over machine, characterized by: It includes a coal type identification module, a material level metering module, a tipper control module, a feeder control module, a belt scale reading module, and a PLC controller. The PLC controller is electrically connected to the coal type identification module, the tipper control module, the feeder control module, and the belt scale reading module. The coal type identification module is installed on the tipper to identify the type of coal and send a type code representing the type of coal to the PLC controller; The tippler control module is used to control the start and stop movement of the tippler; The material level metering module is connected to the high material level sensor, the low material level sensor and the weighing sensor installed in the hopper and the bottom corner support of the hopper. The hopper metering module receives the measurement data from the high material level sensor, the low material level sensor and the weighing sensor, performs the calculation and sends the material level value to the PLC controller. The feeder control module is connected to the frequency converter for controlling the cam motor and the outlet power component for controlling the discharge port area of ​​the activation feeder. The frequency converter changes the feeding amount of the activation feeder by controlling the vibration frequency of the cam motor. The belt scale reading module is connected to the belt scale installed on the belt conveyor to read the instantaneous measurement value of the belt scale and generate the real-time measurement curve of the belt scale. The PLC controller has several built-in feeding operation control models for different types of coal. The feeding operation control models are numbered according to the type of coal, and there is a correspondence between the type code and the model number. After receiving the type code from the coal type identification module, the PLC controller retrieves the corresponding feeding operation control model and outputs the control mode of the frequency converter. The PLC controller also has a built-in table of coal type and outlet power component adjustment angle. When the PLC controller receives the coal type code, it adjusts the outlet power component to the preset angle through the feeder control module.

2. The intelligent feed control system for a roll-over machine according to claim 1, wherein: The inputs to the feeding operation control model are the instantaneous value of the belt scale and the real-time measurement curve of the belt scale. The constraints are the stable operating value of the belt scale. The output is the control mode of the frequency converter. The control mode includes the frequency setpoint and the frequency set time. The constraint objective is to calculate the output amount that should be allocated to each activated feeder to ensure that the belt running state meets the stable operating value under the current instantaneous value of the belt scale, based on the instantaneous value, real-time measurement curve, and stable operating value of the belt scale. Based on the output amount of the activated feeder, the frequency setting value and frequency setting time of each frequency converter are calculated to ensure that the instantaneous value of the belt scale is stable near the stable operating value.

3. The intelligent feed control system for a roll-over machine of claim 1, wherein: The weighing sensor senses the weight of the coal in the hopper and calculates the coal level based on the shape of the hopper; the high level sensor senses the highest level in the hopper, and when the amount of coal in the hopper triggers the highest level, the tipper control module controls the tipper to stop tipping; the low level sensor senses the lowest level in the hopper.

4. A method for intelligent feeding control of a dumper, using a system for intelligent feeding control of a dumper according to any one of claims 1 to 3, characterized in that The steps are as follows: S1. After the coal train enters the tippler, the coal type identification module identifies the type of coal and sends a type code representing the type of coal to the PLC controller. S2, the PLC controller receives the type code, retrieves the corresponding number of the feeding operation control model for calculation, outputs the control mode of the frequency converter under different coal types, and outputs the preset angle of the outlet power component according to the comparison table of coal type and outlet power component adjustment angle. S3, the PLC controller sends execution commands to the frequency converter and outlet power component of the activated feeder through the feeder control module, so that the frequency converter operates according to the control mode and the outlet power component is adjusted to the appropriate angle; S4. The PLC controller controls the tipper to start tipping operations through the tipper control module. During the operation, the material level metering module and the belt scale reading module feed back material level data and belt scale weight data to the PLC controller in real time, and compare them with the preset curve of the feeding operation control model to calculate the error between the real-time feedback data and the preset curve data. When the error is within the allowable fluctuation range, the equipment continues to run; when the error exceeds the allowable fluctuation range, the PLC controller alarms.

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