Coal blockage detection system and method for coal feeder
Through the combination of ultrasonic sensor and DCS control unit, the contactless measurement of the coal flow distance of the coal feeder is achieved, and the false alarm problem caused by the malfunction of the contact coal pile sensor is solved, ensuring the safe and stable operation of the powdering system.
Patent Information
- Application Number
- CN202411637885.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-15
- Publication Date
- 2025-01-07
AI Technical Summary
The existing contact coal pile sensors are prone to mismoval or refusal due to the jam shaft of the baffle, which leads to unreliable coal blocking switches and false alarms, causing the powder making system to be shut down and affecting the safe and stable operation of the unit.
The ultrasonic sensor is used to combine it with the DCS control unit to measure the coal flow distance of the coal feeder through non-contact type, determine whether the coal is blocked, generate an alarm signal, avoid malfunction of the switch, and ensure stable operation of the system.
By measuring the coal flow distance by contactlessly measuring the coal flow distance, we can accurately determine whether the coal feeder is blocked, avoid false alarms, ensure the safe and stable operation of the powder making system, and reduce the risk of equipment shutdown and personnel injury.
Smart Images
Figure CN119262730A_ABST
Abstract
Description
Technical Field
[0001] The present disclosure relates to the technical field of pulverizing systems for coal-fired power plants, and in particular to a coal feeder blockage detection system and method. Background Art
[0002] At present, in the field of pulverizing technology, the baffle contact type mechanical switch is mainly used for the detection of coal blockage signal of the coal feeder of the pulverizing system. Its main working principle is that when the coal level reaches a certain height, the baffle is caused to rotate, and the coaxial cam inside it triggers the internal micro switch to activate the normally open contact to close and send out a coal blockage signal; that is, the normally open contact of the travel switch in the housing of the coal blockage sensor based on the travel switch is closed, and this contact is respectively connected to the coal blockage end of the main machine, the contact is closed to alarm, and then the signal is transmitted to the control system host to output the corresponding signal through the control relay to stop the operation of the coal feeder.
[0003] In the related technology, the existing contact-type coal pile sensor is prone to malfunction or refusal to operate due to the jamming of the baffle shaft, which causes the coal blocking switch to be unreliable and false alarms to occur, causing the pulverizing system to shut down and affecting the safe and stable operation of the unit. Summary of the invention
[0004] The purpose of the present disclosure is to provide a coal feeder blockage detection system and method to solve the problems in the related art.
[0005] In order to achieve the above-mentioned object, in a first aspect, the present disclosure provides a coal feeder blockage detection system, comprising a power supply unit, an ultrasonic sensor and a DCS control unit; The ultrasonic sensor is connected to the power supply unit and the DCS control unit respectively, and is used to measure the coal flow distance of the coal feeder, and transmit the measured coal flow distance to the DCS control unit in the form of an analog signal; The power supply unit is connected to the ultrasonic sensor and is used to supply power to the ultrasonic sensor; The DCS control unit is connected to the ultrasonic sensor and is used to receive the analog signal sent by the ultrasonic sensor and perform control processing.
[0006] Optionally, the DCS control unit includes a logic control module for determining whether the coal feeder is in a coal-blocked state or a coal-out state according to the analog signal, and generating a corresponding alarm signal according to the determination result.
[0007] Optionally, the DCS control unit includes an alarm module connected to the logic control module, configured to receive an alarm signal sent by the logic control unit and trigger an audible and visual alarm.
[0008] Optionally, the DCS control unit also includes a display module for displaying alarm information.
[0009] Optionally, the ultrasonic sensor is used to be installed at a preset position on the front end surface of the coal drop port of the coal feeder.
[0010] In a second aspect, the present disclosure further provides a method for detecting coal blockage in a coal feeder, which is applied to the coal blockage detection system in the first aspect, and the method comprises: Obtain the coal flow distance of the coal feeder through ultrasonic sensors; determining whether the coal feeder is in a coal blocking state according to the coal flow distance of the coal feeder; When the coal feeder is in a coal-blocked state, an alarm is issued.
[0011] Optionally, the ultrasonic sensor includes a first ultrasonic sensor and a second ultrasonic sensor, and obtaining the coal flow distance of the coal feeder by using the ultrasonic sensor includes: The first coal flow distance is acquired through the first ultrasonic sensor, and the second coal flow distance is acquired through the second ultrasonic sensor.
[0012] Optionally, the method comprises: When the difference between the first coal flow distance and the second coal flow distance is less than a first preset threshold, determining one of the first coal flow distance and the second coal flow distance as a target coal flow distance; The step of determining whether the coal feeder is in a coal blocking state according to the coal flow distance of the coal feeder includes: When the target coal flow distance is less than or equal to the second preset threshold, it is determined that the coal feeder is in a coal blocking state.
[0013] Optionally, the method further comprises: When the difference between the first coal flow distance and the second coal flow distance is greater than or equal to the first preset threshold, an alarm prompt indicating measurement abnormality is output.
[0014] Optionally, the method further comprises: When the target coal flow distance is greater than a third preset threshold, an alarm indicating that a coal shortage has occurred is output.
[0015] Through the above technical solution, the ultrasonic sensor is connected to the power supply unit and the DCS control unit respectively, and is used to measure the coal flow distance of the coal feeder, and transmit the measured coal flow distance to the DCS control unit in the form of an analog signal; the power supply unit is connected to the ultrasonic sensor, and is used to supply power to the ultrasonic sensor; the DCS control unit is connected to the ultrasonic sensor, and is used to receive the analog signal sent by the ultrasonic sensor and perform control processing. In this way, it is possible to determine whether there is coal blockage by non-contact measurement of the coal flow distance, avoid the pulverizing system shutdown caused by malfunction of the switch, and ensure the safe and stable operation of the unit.
[0016] Other features and advantages of the present disclosure will be described in detail in the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The accompanying drawings are used to provide a further understanding of the present disclosure and constitute a part of the specification. Together with the following specific embodiments, they are used to explain the present disclosure but do not constitute a limitation of the present disclosure. In the accompanying drawings: Figure 1 It is a block diagram of a coal feeder blockage detection system according to an exemplary embodiment of the present disclosure.
[0018] Figure 2 It is a schematic diagram showing a method of measuring coal flow distance according to an exemplary embodiment of the present disclosure.
[0019] Figure 3 The figure is a schematic diagram of ultrasonic sensor measurement wiring according to an exemplary embodiment of the present disclosure.
[0020] Figure 4 It is a flow chart of a method for detecting coal blockage in a coal feeder according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION
[0021] The specific implementation of the present disclosure is described in detail below in conjunction with the accompanying drawings. It should be understood that the specific implementation described herein is only used to illustrate and explain the present disclosure, and is not used to limit the present disclosure.
[0022] As mentioned in the background technology, in the related technology, the existing contact type coal pile sensor is prone to malfunction or refusal to operate due to the jamming of the baffle shaft, resulting in unreliable coal blockage switch and false alarm, causing the pulverizing system to shut down and affecting the safe and stable operation of the unit.
[0023] In view of this, the embodiments of the present disclosure provide a coal feeder blockage detection system and method, which can avoid the pulverizing system from shutting down due to malfunction of the switch, and ensure the safe and stable operation of the unit.
[0024] Figure 1 A coal feeder blockage detection system is shown according to an exemplary embodiment of the present disclosure, referring to Figure 1 , the coal feeder coal blocking detection system may include a power supply unit 101, an ultrasonic sensor 102 and a DCS control unit 103; The ultrasonic sensor 102 is connected to the power supply unit 101 and the DCS control unit 103 respectively, and is used to measure the coal flow distance of the coal feeder, and transmit the measured coal flow distance to the DCS control unit 103 in the form of an analog signal.
[0025] It should be understood that a non-contact analog distance measurement method can be used to measure the distance between the falling coal flow of the coal feeder belt and the front end face of the coal feeder through an ultrasonic sensor to determine whether there is coal blockage and the coal flow conditions. The coal flow distance during normal operation of the coal feeder can usually be between 180mm and 280mm.
[0026] For example, the specific parameters of the ultrasonic sensor used for analog distance measurement can be as follows: the measurement range is 50mm-500mm, the protection level is IP67, which can be waterproof and oil-proof, the response time is 32ms, the accuracy error is ±1%, and the resolution is 0.17mm.
[0027] For example, the DCS channel configuration of the analog measurement point may be performed according to actual conditions, and the embodiments of the present disclosure are not limited to this.
[0028] The power supply unit 101 is connected to the ultrasonic sensor 102 and is used to supply power to the ultrasonic sensor 102 .
[0029] The DCS control unit 103 is connected to the ultrasonic sensor 102 and is used to receive the analog signal sent by the ultrasonic sensor 102 and perform control processing.
[0030] It should be understood that a DCS (Distributed Control System) is a system that can centrally control and monitor multiple devices or processes. When the measured values of the ultrasonic sensor are transmitted to the DCS control unit in the form of an analog signal, the analog signal can be monitored and linked. The monitoring operation can include real-time display of sensor measurements, setting alarm thresholds, or recording and storing relevant data for subsequent fault diagnosis. The linkage operation can trigger actions of other devices or systems based on the sensor measurement values, such as stopping the operation of the coal feeder, adjusting equipment parameters or sounding an alarm, and starting the coal cleaning equipment to eliminate blockages, thereby avoiding further deterioration of coal blockages, improving safety and reliability, and reducing the risk of equipment damage or personal injury.
[0031] Figure 2 is a schematic diagram showing a method of measuring coal flow distance according to an exemplary embodiment of the present disclosure, referring to Figure 2 The belt 1 drives multiple coal blocks to move to form a coal flow. When the coal reaches the coal dropping position and falls, the distance between the falling coal flow and the front end face 2 of the coal feeder is the coal flow distance, which can be measured by an ultrasonic sensor installed at the front end face of the coal feeder.
[0032] Through the above system, the ultrasonic sensor is connected to the power supply unit and the DCS control unit respectively, and is used to measure the coal flow distance of the coal feeder, and transmit the measured coal flow distance to the DCS control unit in the form of an analog signal; the power supply unit is connected to the ultrasonic sensor to supply power to the ultrasonic sensor; the DCS control unit is connected to the ultrasonic sensor to receive the analog signal sent by the ultrasonic sensor and perform control processing. In this way, it is possible to determine whether there is coal blockage by non-contact measurement of the coal flow distance, avoid the pulverizing system shutdown caused by malfunction of the switch, and ensure the safe and stable operation of the unit.
[0033] Figure 3 is a schematic diagram of an ultrasonic sensor measurement wiring diagram according to an exemplary embodiment of the present disclosure, referring to Figure 3 The ultrasonic sensor 102 can be connected to the power supply unit 101 and the DCS control unit 103 through corresponding lines, wherein the power supply unit 101 can be configured with a power switch and a 24V DC power board, and the ultrasonic sensor 102 can include a BN brown wire, a WH white wire, a BK black wire, a BU blue wire and a GY gray wire, and the corresponding line connection is performed in combination with the setting of the sensor, and the 4-20mA analog output wiring method can be used to connect to the DCS control unit 103.
[0034] Optionally, the DCS control unit 103 may include a logic control module for determining whether the coal feeder is in a coal-blocked state or a coal-out state according to the analog signal, and generating a corresponding alarm signal according to the determination result.
[0035] Optionally, the DCS control unit 103 may include an alarm module connected to the logic control module, configured to receive an alarm signal sent by the logic control unit and trigger an audible and visual alarm.
[0036] For example, the alarm module can send out an alarm through sound, light, etc. to notify relevant staff to prompt the occurrence of corresponding situations such as coal blockage.
[0037] Optionally, the DCS control unit 103 may further include a display module for displaying alarm information.
[0038] For example, the display module can be in the form of an LED display screen to display relevant alarm information to achieve a more intuitive prompt effect.
[0039] Optionally, the ultrasonic sensor 102 is used to be installed at a preset position on the front end surface of the coal drop port of the coal feeder.
[0040] It should be understood that the ultrasonic sensor can be installed by tapping M18*1.0 metric fine thread at the preset position on the front end face of the coal drop port of the coal feeder, and there is no need to open the coal feeder end cover to enter the narrow space inside the coal feeder when inspecting or dealing with defects, which can facilitate maintenance and optimize the safety of the pulverizing system.
[0041] The present disclosure also provides a method for detecting coal blockage in a coal feeder, which is applied to the above-mentioned coal feeder blockage detection system. Figure 4 The method for detecting coal feeder blockage may include the following steps: Step S201, obtaining the coal flow distance of the coal feeder through an ultrasonic sensor; Step S202, determining whether the coal feeder is in a coal blocking state according to the coal flow distance of the coal feeder; Step S203: When the coal feeder is in a coal-blocked state, an alarm is issued.
[0042] Through the above method, it is possible to determine whether there is coal blockage by measuring the coal flow distance in a non-contact manner, thereby avoiding the pulverizing system shutdown caused by malfunction of the switch, and ensuring the safe and stable operation of the unit.
[0043] Optionally, the ultrasonic sensor may include a first ultrasonic sensor and a second ultrasonic sensor, and step S201 may include: The first coal flow distance is acquired through the first ultrasonic sensor, and the second coal flow distance is acquired through the second ultrasonic sensor.
[0044] Optionally, the method may include: When the difference between the first coal flow distance and the second coal flow distance is less than a first preset threshold, one of the first coal flow distance and the second coal flow distance is determined as the target coal flow distance.
[0045] It should be understood that using two ultrasonic sensors to measure the distance of two coal flows can improve the reliability of the detection results. Specifically, the difference between the coal flow distances measured by the two ultrasonic sensors is compared. If the difference is less than the preset threshold, it means that the measurement is normal, and one of the coal flow distances can be selected as the target coal flow distance.
[0046] For example, the first preset threshold may be set to 150 mm, that is, when the difference between the first coal flow distance and the second coal flow distance is less than 150 mm, one of the first coal flow distance and the second coal flow distance may be determined as the target coal flow distance.
[0047] Step S202 may include: When the target coal flow distance is less than or equal to the second preset threshold, it is determined that the coal feeder is in a coal blocking state.
[0048] For example, the second preset threshold value may be set to 80 mm according to actual test conditions. That is, when the target coal flow distance is less than or equal to 80 mm, it can be determined that the coal feeder is in a coal blocking state.
[0049] Optionally, the method further comprises: When the difference between the first coal flow distance and the second coal flow distance is greater than or equal to the first preset threshold, an alarm prompt indicating measurement abnormality is output.
[0050] It should be understood that the difference between the coal flow distances measured by the two ultrasonic sensors can be compared. If the difference exceeds a preset threshold, it indicates that the measurement is abnormal and the sensor needs to be checked, thereby improving the reliability of the measurement results.
[0051] Optionally, the method further comprises: When the target coal flow distance is greater than the third preset threshold, an alarm indicating that a coal shortage has occurred is output.
[0052] It should be understood that coal flow distance measurement can effectively and timely respond to coal flow conditions. When the raw coal bin is out of coal, no coal falls at the belt coal drop port. At this time, it is detected that the coal flow distance is greater than the preset threshold, and an alarm prompt indicating the coal outage is output, so that corresponding treatment measures can be taken.
[0053] For example, the third preset threshold value may be set to 400 mm according to actual test conditions. That is, when the target coal flow distance is greater than 400 mm, a coal shortage occurs, and an alarm indicating that a coal shortage occurs may be output.
[0054] The preferred embodiments of the present disclosure are described in detail above in conjunction with the accompanying drawings; however, the present disclosure is not limited to the specific details in the above embodiments. Within the technical concept of the present disclosure, a variety of simple modifications can be made to the technical solution of the present disclosure, and these simple modifications all fall within the protection scope of the present disclosure.
[0055] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the present disclosure will not further describe various possible combinations.
[0056] In addition, various embodiments of the present disclosure may be arbitrarily combined, and as long as they do not violate the concept of the present disclosure, they should also be regarded as the contents disclosed by the present disclosure.
Claims
1. A coal feeder blockage detection system, characterized in that: Includes power supply unit, ultrasonic sensor and DCS control unit; The ultrasonic sensor is connected to the power supply unit and the DCS control unit respectively, and is used to measure the coal flow distance of the coal feeder, and transmit the measured coal flow distance to the DCS control unit in the form of an analog signal; The power supply unit is connected to the ultrasonic sensor and is used to supply power to the ultrasonic sensor; The DCS control unit is connected to the ultrasonic sensor and is used to receive the analog signal sent by the ultrasonic sensor and perform control processing.
2. The system according to claim 1, characterized in that The DCS control unit includes a logic control module, which is used to determine whether the coal feeder is in a coal blocking state or a coal shortage state according to the analog signal, and generate a corresponding alarm signal according to the determination result.
3. The system according to claim 2, characterized in that The DCS control unit includes an alarm module connected to the logic control module, and is used to receive an alarm signal sent by the logic control unit and trigger an audible and visual alarm.
4. The system according to claim 3, characterized in that The DCS control unit also includes a display module for displaying alarm information.
5. The system according to claim 1, characterized in that The ultrasonic sensor is used to be installed at a preset position on the front end surface of the coal drop port of the coal feeder.
6. A method for detecting coal feeder blockage, characterized in that: Applied to the coal feeder blockage detection system according to any one of claims 1 to 5, the method comprising: Obtain the coal flow distance of the coal feeder through ultrasonic sensors; determining whether the coal feeder is in a coal blocking state according to the coal flow distance of the coal feeder; When the coal feeder is in a coal-blocked state, an alarm is issued.
7. The method according to claim 6, characterized in that The ultrasonic sensor includes a first ultrasonic sensor and a second ultrasonic sensor, and obtaining the coal flow distance of the coal feeder by using the ultrasonic sensor includes: The first coal flow distance is acquired through the first ultrasonic sensor, and the second coal flow distance is acquired through the second ultrasonic sensor.
8. The method according to claim 7, characterized in that The method comprises: When the difference between the first coal flow distance and the second coal flow distance is less than a first preset threshold, determining one of the first coal flow distance and the second coal flow distance as a target coal flow distance; The step of determining whether the coal feeder is in a coal blocking state according to the coal flow distance of the coal feeder includes: When the target coal flow distance is less than or equal to the second preset threshold, it is determined that the coal feeder is in a coal blocking state.
9. The method according to claim 8, characterized in that The method further comprises: When the difference between the first coal flow distance and the second coal flow distance is greater than or equal to the first preset threshold, an alarm prompt indicating measurement abnormality is output.
10. The method according to claim 8, characterized in that The method further comprises: When the target coal flow distance is greater than a third preset threshold, an alarm indicating that a coal shortage has occurred is output.