Automatic material distribution device and material distribution method of rail-mounted discharging car

Abstract

The invention belongs to the technical field of ferrous metallurgy material distribution, and particularly relates to an automatic material distribution device and a material distribution method of a rail-mounted discharging car, a real-time stock bin material level detection system, a real-time discharging car position detection system, a discharging car electrical control system and a power supply system are all connected with a PLC (programmable logic controller), the PLC is connected with an upper computer, industrial Ethernet communication is adopted, and the PLC is connected with the upper computer. And the high-definition digital video monitoring system transmits the data back to a central control room. The method comprises the following specific steps that S1, stock bin material level information, unloading vehicle position information and unloading vehicle power system information are transmitted to a PLC; s2, analyzing the data after PLC data processing, and uploading an analysis result to an upper computer; and S3, the upper computer provides a user operation interface and displays feedback data, an operation instruction is sent to the PLC, and the PLC controls the electrical control system, the power supply system, the stock bin and the unloading vehicle according to the instruction. According to the device and the method, the labor intensity is reduced, and unmanned and automatic cloth production of the rail type discharging car is realized.

Description

Technical Field

[0001] The invention belongs to the technical field of steel metallurgy material distribution, and in particular relates to an automatic material distribution device and a material distribution method for a track-type unloading vehicle. Background Art

[0002] In the iron and steel metallurgical industry, rail-mounted unloading vehicles are widely used for the distribution of raw ore bins, sintered finished product bins, ironmaking troughs, and steelmaking solvent bins due to their simple structure and high reliability. The distribution of traditional rail-mounted unloading vehicles is manually operated. It is manually driven to the designated bin on site according to the instructions. The materials on the belt conveyor are lifted and unloaded into the corresponding bin through the unloading funnels at both ends of the unloading vehicle. Due to the lack of corresponding data support, all operations rely on the experience and level of the on-site operators, and the main defects are as follows: (1) On-site operators fail to grasp the material level in the silo in a timely manner, and the real-time performance of moving vehicles and emptying silos is poor, which easily leads to major production accidents such as material overflowing from the silo, damaging the unloading vehicle, and breaking the feeding belt, causing huge economic losses to the company; (2) Most of the transported materials are in block or powder form. During the high-drop unloading process when the materials fall into the silo through the unloading funnel, the dust is dispersed in the working environment, causing dust to spread throughout the working environment, increasing the risk of silicosis among on-site operators. (3) For material distribution occasions with large material flow and small silo volume, the silo is filled in a short time, manual silo emptying operations are frequent, labor intensity is high, and it causes harm to the physical and mental health of on-site operators; (4) When the operator manually moves the warehouse, the power cable of the towed rail-mounted unloading vehicle carries strong electricity, posing a safety risk of electric shock. Summary of the invention

[0003] The object of the present invention is to provide an automatic material distributing device and a material distributing method for a track-type unloading vehicle, so as to solve the problems raised in the above-mentioned background technology.

[0004] In order to achieve the above object, the present invention adopts the following technical scheme: An automatic material distribution device for a rail-type unloading vehicle comprises a real-time detection system for a silo material level, a real-time detection system for a unloading vehicle position, an electrical control system for the unloading vehicle, a PLC, a host computer, a high-definition digital video monitoring system and a power supply system. The real-time detection system for the silo material level, the real-time detection system for the unloading vehicle position, the electrical control system for the unloading vehicle and the power supply system are all connected to the PLC, and the PLC is connected to the host computer and adopts industrial Ethernet communication; the high-definition digital video monitoring system is transmitted back to a control room via optical fiber.

[0005] The silo material level real-time detection system adopts a high-frequency radar level meter. The silo material level signal is introduced into the PLC for program control, and the PLC transmits it to the host computer for display, and establishes the material level historical data trend for easy query and analysis.

[0006] The real-time position detection system for the unloading truck adopts a scale system, which uses Gray code encoding to detect the position with a resolution of millimeters. The scale system can accurately detect the specific position of the unloading truck in real time. The scale signal transmits the position signal to the PLC via DP communication for program control, and the PLC transmits it to the host computer for display, and establishes the historical data trend of the parking space for easy query and analysis.

[0007] The power supply system includes a sliding line and an automatic air switch. The automatic air switch is connected to a PLC. The PLC controls the automatic air switch in two ways, one manual and one automatic. The unloading vehicle automatically drives the sliding line to slide for power supply.

[0008] The high-definition digital video monitoring system includes a high-definition digital camera, a gigabit switch, a network hard disk recorder and a monitor. The high-definition digital camera is connected to the gigabit switch, the gigabit switch is connected to the network hard disk recorder, and the network hard disk recorder is connected to the monitor. The high-definition digital camera is arranged on site in the high-level silo, focusing on all-round monitoring of the unloading vehicle body, the unloading vehicle material port, the unloading vehicle travel position, the sliding line contact part, etc., so as to facilitate the centralized control worker to conduct real-time video monitoring of the status of the high-level silo; the high-definition digital camera on site is transmitted to the control room through Category 6 network cables and collected through the gigabit switch; the high-definition digital camera on the unloading vehicle is projected to the fixed bridge installed on site through the wireless bridge installed on the unloading vehicle, and then transmitted to the gigabit switch in the control room, and transmitted to the monitor in the control room through optical fiber for real-time monitoring.

[0009] An automatic material distribution method for a rail-type unloading vehicle based on the above detection device has the following specific steps: S1: Real-time detection of the silo material level is carried out through the high-frequency radar level meter, the position of the unloading vehicle is detected in real time through the scale system, the power system of the unloading vehicle is controlled through the unloading vehicle electrical control system, and the high-level silo is monitored in real time through the high-definition digital video monitoring system. The silo material level information, unloading vehicle position information, and unloading vehicle power system information are transmitted to the PLC, and the high-level silo video information without blind spots is transmitted back to the control room; S2: After receiving the silo material level information, the unloading vehicle position information and the unloading vehicle power system information data, the PLC analyzes the data and uploads the analysis results to the host computer; S3: The host computer provides a user operation interface and displays feedback data, and sends operation instructions to the PLC. The PLC controls the electrical control system, power supply system, silo and unloading vehicle according to the instructions. Combined with the actual production and the safe operation requirements of the unloading vehicle, multiple modes of operation and safety measures are set: (1) Remote manual material distribution: In the specified operation mode, when controlling the material distribution, the central control worker needs to remotely and manually operate the unloading vehicle. The central control worker uses the mouse to operate the button of the silo to be distributed on the human-machine interface. The host computer issues an operation instruction, and the PLC controls the unloading vehicle to immediately move from the current position to the silo specified by the central control worker and stop unloading. When the silo material level exceeds the set material level value, the host computer operation interface alarms to remind the central control worker to perform the silo unloading operation; (2) Automatic material distribution: In normal operation mode, the unloading vehicle automatically distributes materials according to the program settings. The centralized control operator operates the "automatic material distribution" button on the human-machine interface with the mouse, and the host computer issues an operation instruction. The PLC controls the unloading vehicle to automatically distribute materials from the low-number silo to the high-number silo starting from the current position; (3) Priority material distribution: When priority material distribution is required for certain silos according to production needs, the central control worker selects the silo to be prioritized by mouse operation on the upper computer human-machine interface. The upper computer issues an operation instruction, and the PLC controls the unloading vehicle to automatically distribute material to the selected silo in priority. (4) Refilling: When the material level of all silos reaches the upper limit setting value of the silo material level, it is necessary to control the high-level material distribution of the silo. The centralized control worker uses the mouse to operate the "refilling setting" button on the human-machine interface, and the refilling setting pops up to set the refilling of the silo. When the refilling material level reaches the set value, the upper computer issues an operation instruction, and the PLC controls the unloading vehicle to refill the next silo in sequence; (5) Forbidden material distribution: When material distribution operations are not allowed for certain bins, the centralized control operator uses the mouse to operate the "Forbidden material distribution" button for a certain bin on the upper computer human-machine interface. The upper computer issues an operation instruction, and the PLC controls the unloading vehicle not to distribute material to the bin. (6) Emergency stop: To prevent the main contactor of the unloading vehicle from sticking and causing the unloading vehicle to lose control and cause a major equipment accident, the main power switch of the unloading vehicle is replaced with an automatic air switch that can be disconnected remotely. There are two modes of action: 1. When the main contactor sticks and the unloading vehicle does not stop at the designated position or the unloading vehicle continues to run outward when it reaches the terminal silo, the program automatically triggers a signal to force the main power air switch to disconnect; 2. The centralized control worker uses the mouse to operate the "circuit breaker opening" button on the screen to force the circuit breaker to open, the upper computer issues an operation instruction, and the PLC controls the main power air switch to be forced to disconnect; (7) Historical data query: The upper computer human-machine interface is designed with silo material level indication alarm button, parking space indication alarm button, material level historical trend curve query diagram and parking space historical trend curve query diagram to facilitate analysis and judgment of system control.

[0010] Compared with the prior art, the present invention has the following beneficial effects: (1) The real-time detection system for the silo material level, the real-time detection system for the position of the unloading vehicle, the electrical control system of the unloading vehicle and the high-definition digital video monitoring system can be used to detect and monitor the material level of the silo and the unloading vehicle, the position of the unloading vehicle and the on-site video from various angles in real time. Combined with the PLC, the data can be analyzed in time and the upper computer can display the feedback information in real time. Operation instructions can be issued according to the analysis results to replace manual unloading, reduce labor intensity, reduce the risk of occupational diseases, and avoid major production accidents caused by manual untimely grasp of the silo material level and poor real-time performance of moving the vehicle and unloading the silo. The rail-type unloading vehicle material distribution production can be unmanned and automated, with good real-time performance, high reliability, stable production process, energy saving and consumption reduction, and cost reduction. (2) The power supply system of the unloading truck adopts a sliding line method to avoid the risk of electric shock when the operator drags the power cable of the rail-type unloading truck, reducing safety hazards while providing more stable power supply. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 It is a schematic diagram of the structure of the present invention. DETAILED DESCRIPTION

[0012] The technical solution of the present invention is clearly and completely described below in conjunction with the accompanying drawings and embodiments.

[0013] The material distribution site has 20 silos and 1 unloading truck.

[0014] like Figure 1 As shown, an automatic material distribution device for a rail-type unloading car includes 20 high-frequency radar level meters, 1 scale system, an electrical control system for the unloading car, a high-definition digital video monitoring system, a PLC, a host computer and a 140-meter sliding line. The 20 high-frequency radar level meters, 1 scale system, the electrical control system for the unloading car and the automatic air switch of the 140-meter sliding line are all connected to the PLC, and the PLC is connected to the host computer, using industrial Ethernet communication. The high-definition digital video monitoring system is transmitted back to the control room through optical fiber. The on-site unloading car has a travel distance of 128 meters. Therefore, a highly reliable, wear-resistant, downward-opening C-type sliding line is used to power the car, so as to achieve stable and reliable operation of the power supply mode.

[0015] Each high-frequency radar level meter on site detects the material level of a silo, and the scale system detects the position of the unloading vehicle. The high-definition digital video monitoring system includes high-definition digital cameras, switches, network hard disk recorders and monitors. The high-definition digital cameras are connected to the gigabit switch, the gigabit switch is connected to the network hard disk recorder, the network hard disk recorder is connected to the monitor, the gigabit switch is placed in the control room, and the network hard disk recorder and monitor are placed in the centralized control room. High-definition digital cameras are arranged on site at the high-level silo, focusing on all-round monitoring of the unloading vehicle body, the unloading vehicle material port, the unloading vehicle travel position, the sliding line contact position, etc., so as to facilitate the centralized control worker to conduct real-time video monitoring of the status of the high-level silo; the high-definition digital cameras on site are transmitted to the on-site control room through Category 6 network cables and collected through the gigabit switch; the high-definition digital camera on the unloading vehicle is projected to the fixed bridge installed on site through the wireless bridge installed on the unloading vehicle, and then transmitted to the gigabit switch in the on-site control room, and transmitted to the monitor in the centralized control room through optical fiber for real-time monitoring, and at the same time, the PLC transmits it to the host computer for display.

[0016] An automatic material distribution method for a rail-type unloading vehicle based on the above detection device has the following specific steps: S1: Real-time detection of the silo material level is carried out through the high-frequency radar level meter, the position of the unloading vehicle is detected in real time through the scale system, the power system of the unloading vehicle is controlled through the unloading vehicle electrical control system, and the high-level silo is monitored in real time through the high-definition digital video monitoring system. The silo material level information, unloading vehicle position information, and unloading vehicle power system information are transmitted to the PLC, and the high-level silo video information without blind spots is transmitted back to the control room; S2: After receiving the silo material level information, the unloading vehicle position information and the unloading vehicle power system information data, the PLC analyzes the data and uploads the analysis results to the host computer; S3: The host computer provides a user operation interface and displays feedback data, sends operation instructions to the PLC, and the PLC controls the electrical control system, power supply system, silo and unloading vehicle according to the instructions; combined with the actual production and the safe operation requirements of the unloading vehicle, set up multiple modes of operation and safety measures: (1) Remote manual material distribution: In the specified operation mode, when controlling the material distribution, the central control worker needs to remotely and manually operate the unloading vehicle. The central control worker uses the mouse to operate the button of the silo to be distributed on the human-machine interface. The unloading vehicle immediately moves from the current position to the silo specified by the central control worker and stops unloading. When the silo material level exceeds the set material level value, the upper computer operation interface alarms to remind the central control worker to perform the silo unloading operation; (2) Automatic material distribution: In normal operation mode, the unloading car automatically distributes materials according to the program settings. The centralized control operator operates the "automatic material distribution" button on the human-machine interface with a mouse, and the unloading car will automatically distribute materials from the low-numbered silo to the high-numbered silo starting from the current position. For example, if the car is now in silo No. 3, when the material distribution in silo No. 3 reaches the set value, it will automatically move to silo No. 4, which can reduce the wear of the sliding line caused by the frequent movement of the unloading car; (3) Priority material distribution: When priority material distribution is required for certain silos according to production needs, the centralized control worker selects the silo to be loaded with materials by mouse operation on the upper computer human-machine interface, and the program will automatically control the unloading vehicle to automatically distribute materials to the selected silo; (4) Refilling: When the material level of all silos reaches the upper limit setting value of the silo material level, it is necessary to control the high-level material distribution of the silo. The centralized control worker uses the mouse to operate the "refilling setting" button on the human-machine interface, and the refilling setting pops up to set the refilling of the silo. When the refilling level reaches the set value, the unloading vehicle automatically goes to the next silo to refill in sequence; (5) Forbidden to place materials: When placing materials in certain bins is not allowed, the centralized control operator can use the mouse to operate the "Forbidden to place materials" button on a certain bin on the upper computer human-machine interface, and the unloading vehicle will not place materials in that bin; (6) Emergency shutdown: The centralized control operator uses the mouse to operate the "circuit breaker opening" button on the screen to force the circuit breaker to open, so that the main power switch is disconnected; (7) Historical data query: The upper computer human-machine interface is designed with material level indication alarm button, parking space indication alarm button, material level historical trend curve query diagram and parking space historical trend curve query diagram to facilitate analysis and judgment of system control.

[0017] After using this device and method, the operating efficiency is increased by 25% compared with manual operation, and the equipment wear cost is reduced by 15%.

Claims

1. An automatic material distribution device for a rail-type unloading vehicle, characterized in that: It includes a silo material level real-time detection system, a discharge vehicle position real-time detection system, a discharge vehicle electrical control system, a PLC, a host computer, a high-definition digital video monitoring system and a power supply system. The silo material level real-time detection system, the discharge vehicle position real-time detection system, the discharge vehicle electrical control system and the power supply system are all connected to the PLC, and the PLC is connected to the host computer and adopts industrial Ethernet communication; the high-definition digital video monitoring system is transmitted back to the control room.

2. The automatic material distribution device of a rail-type unloading vehicle according to claim 1, characterized in that: The silo material level real-time detection system adopts a high-frequency radar level meter.

3. The automatic material distribution device of a rail-type unloading vehicle according to claim 2, characterized in that: The real-time position detection system for the unloading truck adopts a scale system, which uses Gray code encoding to detect the position with a resolution of millimeters. The scale system can accurately detect the specific position of the unloading truck in real time. The scale signal transmits the position signal to the PLC via DP communication for program control, and the PLC transmits it to the host computer for display, and establishes the historical data trend of the parking space for easy query and analysis.

4. The automatic material distribution device of a rail-type unloading vehicle according to claim 3, characterized in that: The power supply system includes a sliding line and an automatic air switch. The automatic air switch is connected to a PLC. The PLC controls the automatic air switch in two ways, one manual and one automatic. The unloading vehicle automatically drives the sliding line to slide for power supply.

5. The automatic material distribution device of a rail-type unloading vehicle according to claim 4, characterized in that: The high-definition digital video monitoring system includes a high-definition digital camera, a switch, a hard disk recorder and a monitor. The high-definition digital camera is connected to a gigabit switch, the gigabit switch is connected to a network hard disk recorder, and the network hard disk recorder is connected to a monitor. A high-definition digital camera is arranged on site in the high-level silo, focusing on all-round monitoring of the unloading vehicle body, the unloading vehicle material port, the unloading vehicle travel position, the sliding line contact part, etc., so as to facilitate the centralized control worker to conduct real-time video monitoring of the status of the high-level silo; the high-definition digital camera on site is transmitted to the control room through a Category 6 network cable and collected through a gigabit switch; the high-definition digital camera on the unloading vehicle is projected to the fixed bridge installed on site through a wireless bridge installed on the unloading vehicle, and then transmitted to the gigabit switch in the control room, and transmitted to the monitor in the centralized control room through optical fiber for real-time monitoring.

6. An automatic material distribution method for a rail-type unloading vehicle based on the detection device of claim 5, characterized in that: The specific steps are as follows: S1: Real-time detection of the silo material level is carried out through the high-frequency radar level meter, the position of the unloading vehicle is detected in real time through the scale system, the power system of the unloading vehicle is controlled through the unloading vehicle electrical control system, and the silo and high-level silo are monitored in real time through the high-definition digital video monitoring system. The silo material level information, unloading vehicle position information, and unloading vehicle power system information are transmitted to the PLC; S2: After receiving the silo material level information, the unloading vehicle position information and the unloading vehicle power system information data, the PLC analyzes the data and uploads the analysis results to the host computer; S3: The host computer provides a user operation interface and displays feedback data, and sends operation instructions to the PLC. The PLC controls the electrical control system, power supply system, silo and unloading vehicle according to the instructions. Combined with the actual production and the safe operation requirements of the unloading vehicle, multiple modes of operation and safety measures are set: (1) Remote manual material distribution: In the specified operation mode, when controlling the material distribution, the central control worker needs to remotely and manually operate the unloading vehicle. The central control worker uses the mouse to operate the button of the silo to be distributed on the human-machine interface. The host computer issues an operation instruction, and the PLC controls the unloading vehicle to immediately move from the current position to the silo specified by the central control worker and stop unloading. When the silo material level exceeds the set material level value, the host computer operation interface alarms to remind the central control worker to perform the silo unloading operation; (2) Automatic material distribution: In normal operation mode, the unloading vehicle automatically distributes materials according to the program settings. The centralized control operator operates the "automatic material distribution" button on the human-machine interface with the mouse, and the host computer issues an operation instruction. The PLC controls the unloading vehicle to automatically distribute materials from the low-number silo to the high-number silo starting from the current position; (3) Priority material distribution: When certain silos are given priority material distribution according to production needs, the centralized control worker selects the silo to be given priority material distribution by mouse operation on the upper computer human-machine interface. The upper computer issues an operation instruction, and the PLC controls the unloading vehicle to automatically distribute material to the selected silo in priority. (4) Refilling: When the material level of all silos reaches the upper limit setting value of the silo material level, it is necessary to control the high-level material distribution of the silo. The centralized control worker uses the mouse to operate the "refilling setting" button on the human-machine interface, and the refilling setting pops up to set the refilling of the silo. When the refilling material level reaches the set value, the upper computer issues an operation instruction, and the PLC controls the unloading vehicle to refill the next silo in sequence; (5) Forbidden to place materials: When placing materials in certain bins is not allowed, the central control operator uses the mouse to operate the "Forbidden to place materials" button on a certain bin on the upper computer human-machine interface. The upper computer issues an operation instruction, and the PLC controls the unloading vehicle not to place materials in the bin. (6) Emergency shutdown: To prevent the main contactor of the unloading vehicle from sticking and causing the unloading vehicle to lose control and cause a major equipment accident, there are two ways to replace the main power switch of the unloading vehicle with an automatic air switch that can be disconnected remotely:

1. When the main contactor sticks and causes the unloading vehicle to fail to stop at the designated location or the unloading vehicle continues to run outward when it reaches the terminal silo, the program automatically triggers a signal to force the main power air switch to disconnect; 2. The centralized control worker uses the mouse to operate the "circuit breaker opening" button on the screen to force the circuit breaker to open, the upper computer issues an operation instruction, and the PLC controls the main power air switch to be forced to disconnect; (7) Historical data query: The upper computer human-machine interface is designed with silo material level indication alarm button, parking space indication alarm button, material level historical trend curve query diagram and parking space historical trend curve query diagram to facilitate analysis and judgment of system control.

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