Ash grabbing control method and system based on bridge type grab crane
By adopting an automated control system in biomass power plants and using sensors and infrared positioning technology, the ash slag of bridge grab cranes is automatically grasped and loaded, and pollution, operational difficulties and efficiency in traditional wet slag removal technology is solved. The problem of low improvements in grasping accuracy and safety and adapts to extreme weather conditions.
Patent Information
- Application Number
- CN202411568992.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-05
- Publication Date
- 2024-12-27
AI Technical Summary
Traditional wet slag removal technology has problems such as environmental pollution, operation difficulties, equipment collision risks and low grab efficiency in biomass power plants. Especially in complex environments and extreme weather conditions, artificially operates bridge grab cranes for ash. When loading slag, it is difficult to achieve efficient and safe grabbing and loading.
Adopt an automated control system based on a bridge grab crane to detect the position and height of ash through sensors, combine infrared shading positioning devices and weighing sensors, draw electronic maps, calculate the grab weight and loading amount in real time, and use DCS automatic control logic to achieve Automatic gripping and loading of ash slag reduces manual operations and improves gripping accuracy and safety.
It realizes precise grabbing and loading of ash, improves operating efficiency, reduces the risk of manual operation, reduces secondary pollution, improves the level of environmental protection, and adapts to stable operation under extreme weather conditions.
Smart Images
Figure CN119191101A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the field of control technology, and in particular to a slag grabbing control method and system based on a bridge grab crane. Background Art
[0002] In biomass power plants, ash treatment is an important link. Traditional wet slag removal technology has many problems in the ash loading process, such as environmental pollution, operational difficulties, equipment collision risks, low grabbing efficiency, etc. These problems not only affect the operating efficiency of the power plant, but also have adverse effects on the environment.
[0003] At present, biomass power plants generally use manually operated bridge grab cranes to load ash and slag. This operation method has the following problems:
[0004] Environmental complexity: The environment in the slag storage room is complex, especially in winter when the moisture is high, which poses a challenge to the stable operation of electronic components.
[0005] The parking position is not fixed: The non-fixed parking position of the vehicle increases the difficulty of automatic detection of slag discharge.
[0006] Wet slag removal problem: The ash contains more water, which increases the difficulty of grabbing and loading.
[0007] Operational safety: Manual operation has problems such as poor visibility and improper operation, which can easily lead to equipment collision and low grasping efficiency.
[0008] Environmental pollution: ash overflow caused by overloading will cause secondary pollution. Summary of the invention
[0009] Based on this, the embodiment of the present application provides a ash grabbing control method and system based on a bridge grab crane, which can realize the digital detection function of the entire device through automatic monitoring means, combined with position detection probes, weighing sensors and occlusion alarms, and realize automatic control of ash grabbing and loading through DCS automatic control logic.
[0010] In a first aspect, a slag grab control method based on a bridge grab crane is provided, the method comprising:
[0011] The position and height of the ash pile to be grabbed are detected by sensors, and an electronic map of the ash pile is drawn based on the data collected by the sensors;
[0012] On the electronic map, the size and position of the vehicle box are confirmed through the infrared blocking positioning device;
[0013] During the grabbing process, it is calculated in real time whether the ash needs to be grabbed and transported back. When transporting the ash, the weighing system of the bridge grab crane is used to calculate the weight of each grab and the amount of ash in the car in real time. Based on the real-time calculation results, it is determined whether the ash grabbing is completed.
[0014] Optionally, the position and height of the ash pile to be grabbed are detected by a sensor, and the method further includes:
[0015] Radar, infrared or ultrasonic sensors are installed on the bridge grab crane to detect the ash stacking position and height in real time. The data collected by the sensors will be transmitted to the central processing system, and the data will be used to draw an electronic map of the ash stacking.
[0016] Optionally, the size and position of the vehicle box are confirmed on the electronic map by an infrared blocking positioning device, and further comprising:
[0017] Manual parking is used to confirm the size and position of the vehicle compartment and mark it on the electronic map.
[0018] Optionally, the weight of each grab and the amount of slag in the carriage are calculated in real time, and whether the ash grab is completed is determined according to the real-time calculation results, specifically including:
[0019] Collect the weight data of ash in real time, process the collected weight data, and calculate the weight of ash grabbed each time and the real-time data of the amount of ash loaded in the carriage;
[0020] Based on the real-time calculation results, it is decided whether it is necessary to continue grabbing the ash. If the amount of ash loaded in the car has not reached the preset value, the bridge grab crane will be controlled to continue operating; if it has reached the preset value or exceeded the safety weight limit, the grabbing operation will be stopped; among them, the DCS automatic control logic is adopted to realize the automatic control of the ash grabbing and loading process.
[0021] Optionally, the method further comprises:
[0022] Under extreme weather conditions, the performance of sensors, the ability to draw electronic maps, and the grabbing ability of bridge grab cranes are tested; wherein the extreme weather conditions are low temperatures or high humidity conditions in winter.
[0023] In a second aspect, a slag grab control system based on a bridge grab crane is provided, the system comprising:
[0024] A drawing module is used to detect the position and height of the ash pile to be grabbed through sensors, and draw an electronic map of the ash pile based on the data collected by the sensors;
[0025] A positioning module is used to confirm the size and position of the vehicle box on the electronic map through the infrared blocking positioning device;
[0026] The calculation module is used to calculate in real time whether the ash needs to be grabbed and transported during the grabbing process. When transporting the ash, the weighing system of the bridge grab crane is used to calculate in real time the weight of each grab and the amount of slag in the car, and determine whether the ash grabbing is completed based on the real-time calculation results.
[0027] Optionally, the position and height of the ash pile to be grabbed are detected by a sensor, and the method further includes:
[0028] Radar, infrared or ultrasonic sensors are installed on the bridge grab crane to detect the ash stacking position and height in real time. The data collected by the sensors will be transmitted to the central processing system, and the data will be used to draw an electronic map of the ash stacking.
[0029] Optionally, the size and position of the vehicle box are confirmed on the electronic map by an infrared blocking positioning device, and further comprising:
[0030] Manual parking is used to confirm the size and position of the vehicle compartment and mark it on the electronic map.
[0031] Optionally, the weight of each grab and the amount of slag in the carriage are calculated in real time, and whether the ash grab is completed is determined according to the real-time calculation results, specifically including:
[0032] Collect the weight data of ash in real time, process the collected weight data, and calculate the weight of ash grabbed each time and the real-time data of the amount of ash loaded in the carriage;
[0033] Based on the real-time calculation results, it is decided whether it is necessary to continue grabbing the ash. If the amount of ash loaded in the car has not reached the preset value, the bridge grab crane will be controlled to continue operating; if it has reached the preset value or exceeded the safety weight limit, the grabbing operation will be stopped; among them, the DCS automatic control logic is adopted to realize the automatic control of the ash grabbing and loading process.
[0034] Optionally, the system further comprises:
[0035] Under extreme weather conditions, the performance of sensors, the ability to draw electronic maps, and the grabbing ability of bridge grab cranes are tested; wherein the extreme weather conditions are low temperatures or high humidity conditions in winter.
[0036] The beneficial effects brought by the technical solution provided by the embodiment of the present application include at least:
[0037] (1) The automated control system enables accurate grabbing and loading of ash and slag, significantly improving operating efficiency. The height and position of ash and slag can be monitored in real time, reducing the time and error of manual operation, thereby speeding up the entire grabbing process.
[0038] (2) Reduced reliance on manual operation, reduced workload for operators, and also reduced safety risks caused by human errors. The automation system can operate stably in harsh environments, protecting the safety of operators and avoiding the effects of high temperatures and harmful gases on the human body.
[0039] (3) By precisely controlling the capture and loading of ash, secondary pollution caused by ash spillage is avoided. This not only helps protect the environment, but also improves the overall environmental protection level of the biomass power plant, meeting the requirements of sustainable development. BRIEF DESCRIPTION OF THE DRAWINGS
[0040] In order to more clearly illustrate the implementation methods of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for the implementation methods or the description of the prior art. Obviously, the drawings in the following description are only exemplary, and for ordinary technicians in this field, other implementation drawings can be derived from the provided drawings without creative work.
[0041] Figure 1 A slag grab control flow chart based on a bridge grab crane provided in an embodiment of the present application;
[0042] Figure 2 A block diagram of an ash grabbing control system based on a bridge grab crane is provided in an embodiment of the present application. DETAILED DESCRIPTION
[0043] In order to make the purpose, technical solution and advantages of the present application more clearly understood, the present application is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application and are not used to limit the present application.
[0044] In the description of the present invention, the terms "comprises", "has" and any variations thereof are intended to cover non-exclusive inclusions. For example, a process, method, system, product or apparatus comprising a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may also include other steps or units that are not explicitly listed but are inherent to these processes, methods, products or apparatuses, or steps or units added based on further optimization schemes conceived by the present invention.
[0045] In biomass power plants, ash treatment is an important link. Traditional wet slag removal technology has many problems in the ash loading process, such as environmental pollution, operational difficulties, equipment collision risks, low grabbing efficiency, etc. These problems not only affect the operating efficiency of the power plant, but also have adverse effects on the environment.
[0046] At present, biomass power plants generally use manually operated bridge grab cranes to load ash and slag. This operation method has the following problems:
[0047] Environmental complexity: The environment in the slag storage room is complex, especially in winter when the moisture is high, which poses a challenge to the stable operation of electronic components.
[0048] The parking position is not fixed: The non-fixed parking position of the vehicle increases the difficulty of automatic detection of slag discharge.
[0049] Wet slag removal problem: The ash contains more water, which increases the difficulty of grabbing and loading.
[0050] Operational safety: Manual operation has problems such as poor visibility and improper operation, which can easily lead to equipment collision and low grasping efficiency.
[0051] Environmental pollution: ash overflow caused by overloading will cause secondary pollution.
[0052] Please refer to Figure 1 , which shows a flow chart of a slag grabbing control method based on a bridge grab crane provided in an embodiment of the present application. The method may include the following steps:
[0053] S1, detects the position and height of the ash pile to be grabbed through sensors, and draws an electronic map of the ash pile based on the data collected by the sensors.
[0054] In this step, radar, infrared or ultrasonic sensors need to be installed on the bridge grab crane first. These sensors will be responsible for detecting the location and height of the ash pile in real time. The data collected by the sensors will be transmitted to the central processing system, which will use the data to draw an electronic map of the ash pile. This map not only needs to reflect the three-dimensional spatial distribution of the ash, but also should be able to be updated in real time to adapt to changes in the ash pile situation. In order to improve the accuracy of the system, it may be necessary to calibrate the sensors regularly and ensure that they can work stably under various environmental conditions (such as high temperature, high humidity, dust, etc.).
[0055] S2, confirm the size and position of the vehicle box on the electronic map through the infrared blocking positioning device.
[0056] On the electronic map, an infrared occlusion positioning device is used to confirm the size and position of the carriage. This device can emit infrared signals, which are reflected back when encountering obstacles, thereby determining the boundaries of the carriage. In this way, the system can accurately identify the location of the carriage and mark it on the electronic map. The key step is to ensure the accuracy and reliability of the infrared positioning device and its seamless integration with the electronic map system. In addition, it is necessary to consider the possible movement of the carriage to ensure that the system can update the location information of the carriage in real time.
[0057] S3, during the grabbing process, calculate in real time whether it is necessary to grab and transport the ash, and when transporting the ash, use the weighing system of the bridge grab crane to calculate in real time the weight of each grab and the amount of slag in the car, and determine whether the ash grabbing is completed based on the real-time calculation results.
[0058] During the grabbing process, the system will calculate in real time whether it is necessary to grab and transport the ash. This involves estimating the volume and weight of the ash, as well as calculating the capacity of the car box. Using the weighing system on the bridge grab crane, the system can calculate in real time the weight of each grab and the total amount of ash loaded in the car box. Based on these real-time calculation results, the system will decide whether it is necessary to continue grabbing the ash or whether the capacity limit of the car box has been reached.
[0059] In the embodiment of the present application, in the implementation of the slag grab control method based on the bridge grab crane, real-time calculation and slag grab control is a key step. The following is a detailed description of this step:
[0060] Real-time data collection and processing: During the grabbing process, the weight data of the ash and slag must be collected in real time. This is usually achieved by installing a weighing sensor on the bridge grab crane, which can monitor the weight of the ash and slag grabbed each time in real time. At the same time, the total amount of ash and slag loaded in the carriage needs to be measured, which can be achieved by installing a weighing module at the bottom of the carriage. The weighing module can collect the weight of the material tank, and then transmit the data of multiple weighing modules to the display instrument through the junction box, and the instrument can display the weight information in real time.
[0061] Data processing and calculation: The collected weight data needs to be processed by the background server. The server will calculate the real-time data of the weight of ash and slag grabbed each time and the amount of slag loaded in the carriage based on the weighing system data of the bridge grab crane. This step involves real-time data processing and calculation, and it is necessary to ensure the accuracy and efficiency of the data processing algorithm.
[0062] Decision-making and control: Based on the real-time calculation results, the system will decide whether to continue grabbing ash and slag. If the amount of slag in the carriage does not reach the preset value, the system will control the bridge grab crane to continue operating; if it has reached the preset value or exceeded the safety weight limit, the system will stop the grabbing operation. This step requires the implementation of automated control logic to ensure the safety and efficiency of the entire grabbing process. For example, the DCS automatic control logic can be used to realize the automated control of the ash and slag grabbing and loading process.
[0063] Optimization and adjustment: In actual operation, various unexpected situations may occur, such as changes in the fluidity of ash and slag, fluctuations in the accuracy of bridge grab cranes, etc. Therefore, the system needs to have certain optimization and adjustment capabilities, and adjust the grab strategy according to real-time data to ensure the stability and accuracy of the grab process. This may involve fine-tuning the bridge grab crane, optimizing the carriage loading strategy, etc.
[0064] Safety monitoring and alarm: During the grabbing process, the system also needs to monitor the safety of the operation in real time, such as monitoring the distance between the bridge grab crane and the carriage to prevent collisions. Once a potential safety risk is detected, the system will trigger an alarm mechanism to promptly remind the operator to take measures to ensure the safety of the entire grabbing process.
[0065] In an optional embodiment of the present application, a field test of the slag grabbing control method is conducted under severe winter conditions to ensure the stability and reliability of the system under extreme conditions. The following are the details of implementing this test:
[0066] Sensor performance testing: In winter conditions of low temperatures and high humidity, the performance of radar, infrared or ultrasonic sensors must first be tested. This includes testing the response time and accuracy of the sensors in low temperature environments, and whether they can work properly in high humidity conditions. It is necessary to ensure that the sensors will not be damaged by low temperatures or misread by water vapor. During the test, the sensors may need to be preheated or other protective measures may be taken to ensure their normal operation in winter conditions.
[0067] Electronic map drawing and updating: In severe weather conditions, the ash deposits may become difficult to identify due to snow and ice cover. Therefore, the electronic map drawing and updating capabilities need to be tested to ensure that the system can accurately reflect the actual ash deposits. This may involve adjusting the electronic map software to adapt to the visual effects and data collection requirements in winter conditions. The test needs to verify whether the electronic map can be updated in a timely manner and whether the location and height of the ash can be accurately displayed under snow or ice cover.
[0068] Stability and reliability test of bridge grab crane: In winter conditions, the mechanical parts of the bridge grab crane may become fragile due to low temperature, and the lubricating oil may become more viscous, affecting the normal operation of the equipment. Therefore, it is necessary to conduct comprehensive stability and reliability tests on the bridge grab crane, including operation tests under low temperature conditions and grab tests on ice and snow covered ash. The test needs to check whether the various parts of the bridge grab crane can work properly and whether special maintenance or adjustments are required under winter conditions.
[0069] Adaptability test of automatic control system: The automatic control system needs to be tested for adaptability under harsh winter conditions to ensure that it can operate stably under low temperature and high humidity conditions. This includes testing the computing power of the backend server and verifying the response speed and accuracy of the DCS automatic control logic. The test needs to ensure that the system can make decisions quickly and accurately under winter conditions and can adjust the grasping strategy in time to adapt to environmental changes.
[0070] Testing of security monitoring and alarm systems: Security monitoring and alarm systems are even more important in winter conditions. The system needs to be tested to ensure that it can still detect potential safety risks in a timely manner and issue an alarm in a timely manner when covered with ice and snow or visibility is low. The test needs to verify the response time and accuracy of the alarm system, as well as whether additional safety measures are required in severe weather conditions.
[0071] like Figure 2 The embodiment of the present application also provides a slag grab control system based on a bridge grab crane. The system includes:
[0072] A drawing module is used to detect the position and height of the ash pile to be grabbed through sensors, and draw an electronic map of the ash pile based on the data collected by the sensors;
[0073] A positioning module is used to confirm the size and position of the vehicle box on the electronic map through the infrared blocking positioning device;
[0074] The calculation module is used to calculate in real time whether the ash needs to be grabbed and transported during the grabbing process. When transporting the ash, the weighing system of the bridge grab crane is used to calculate in real time the weight of each grab and the amount of slag in the car, and determine whether the ash grabbing is completed based on the real-time calculation results.
[0075] The ash grabbing control system based on a bridge grab crane provided in the embodiment of the present application is used to implement the above-mentioned ash grabbing control method based on a bridge grab crane. For the specific definition of the ash grabbing control system based on a bridge grab crane, please refer to the definition of the ash grabbing control method based on a bridge grab crane in the above text, which will not be repeated here. Each part of the above-mentioned ash grabbing control system based on a bridge grab crane can be fully or partially implemented by software, hardware and a combination thereof. The above-mentioned modules can be embedded in or independent of the processor in the device in the form of hardware, or can be stored in the memory in the device in the form of software, so that the processor can call and execute the operations corresponding to the above-mentioned modules.
[0076] The technical features of the above-described embodiments may be arbitrarily combined. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.
[0077] The above-described embodiments only express several implementation methods of the present application, and the descriptions thereof are relatively specific and detailed, but they cannot be construed as limiting the scope of the patent application. It should be pointed out that, for a person of ordinary skill in the art, several variations and improvements can be made without departing from the concept of the present application, and these all belong to the protection scope of the present application. Therefore, the protection scope of the patent application shall be subject to the attached claims.
Claims
1. A slag grab control method based on a bridge grab crane, characterized in that: The method comprises: The position and height of the ash pile to be grabbed are detected by sensors, and an electronic map of the ash pile is drawn based on the data collected by the sensors; On the electronic map, the size and position of the vehicle box are confirmed through the infrared blocking positioning device; During the grabbing process, it is calculated in real time whether the ash needs to be grabbed and transported back. When transporting the ash, the weighing system of the bridge grab crane is used to calculate the weight of each grab and the amount of ash in the car in real time. Based on the real-time calculation results, it is determined whether the ash grabbing is completed.
2. The ash grabbing control method according to claim 1, characterized in that: The position and height of the ash pile to be grabbed are detected by sensors, and also include: Radar, infrared or ultrasonic sensors are installed on the bridge grab crane to detect the ash stacking position and height in real time. The data collected by the sensors will be transmitted to the central processing system, and the data will be used to draw an electronic map of the ash stacking.
3. The ash grabbing control method according to claim 1, characterized in that: On the electronic map, the size and position of the vehicle box are confirmed by the infrared blocking positioning device, which also includes: Manual parking is used to confirm the size and position of the vehicle compartment and mark it on the electronic map.
4. The ash grabbing control method according to claim 1, characterized in that: Calculate the weight of each grab and the amount of slag in the carriage in real time, and determine whether the ash grab is completed based on the real-time calculation results, including: Collect the weight data of ash in real time, process the collected weight data, and calculate the weight of ash grabbed each time and the real-time data of the amount of ash loaded in the carriage; Based on the real-time calculation results, it is decided whether it is necessary to continue grabbing the ash. If the amount of ash loaded in the car has not reached the preset value, the bridge grab crane will be controlled to continue operating; if it has reached the preset value or exceeded the safety weight limit, the grabbing operation will be stopped; among them, the DCS automatic control logic is adopted to realize the automatic control of the ash grabbing and loading process.
5. The ash grabbing control method according to claim 1, characterized in that: The method further comprises: Under extreme weather conditions, the performance of sensors, the ability to draw electronic maps, and the grabbing ability of bridge grab cranes are tested; wherein the extreme weather conditions are low temperatures or high humidity conditions in winter.
6. A slag grabbing control system based on a bridge grab crane, characterized in that: The system comprises: A drawing module is used to detect the position and height of the ash pile to be grabbed through sensors, and draw an electronic map of the ash pile based on the data collected by the sensors; A positioning module is used to confirm the size and position of the vehicle box on the electronic map through the infrared blocking positioning device; The calculation module is used to calculate in real time whether the ash needs to be grabbed and transported during the grabbing process. When transporting the ash, the weighing system of the bridge grab crane is used to calculate in real time the weight of each grab and the amount of slag in the car, and determine whether the ash grabbing is completed based on the real-time calculation results.
7. The ash grabbing control system according to claim 6, characterized in that: The position and height of the ash pile to be grabbed are detected by sensors, and also include: Radar, infrared or ultrasonic sensors are installed on the bridge grab crane to detect the ash stacking position and height in real time. The data collected by the sensors will be transmitted to the central processing system, and the data will be used to draw an electronic map of the ash stacking.
8. The ash grabbing control system according to claim 6, characterized in that: On the electronic map, the size and position of the vehicle box are confirmed by the infrared blocking positioning device, which also includes: Manual parking is used to confirm the size and position of the vehicle compartment and mark it on the electronic map.
9. The ash grabbing control system according to claim 6, characterized in that: Calculate the weight of each grab and the amount of slag in the carriage in real time, and determine whether the ash grab is completed based on the real-time calculation results, including: Collect the weight data of ash in real time, process the collected weight data, and calculate the weight of ash grabbed each time and the real-time data of the amount of ash loaded in the carriage; Based on the real-time calculation results, it is decided whether it is necessary to continue grabbing the ash. If the amount of ash loaded in the car has not reached the preset value, the bridge grab crane will be controlled to continue operating; if it has reached the preset value or exceeded the safety weight limit, the grabbing operation will be stopped; among them, the DCS automatic control logic is adopted to realize the automatic control of the ash grabbing and loading process.
10. The ash grabbing control system according to claim 6, characterized in that: The system further comprises: Under extreme weather conditions, the performance of sensors, the ability to draw electronic maps, and the grabbing ability of bridge grab cranes are tested; wherein the extreme weather conditions are low temperatures or high humidity conditions in winter.