Belt conveyor process control method based on programmable controller

Abstract

The invention relates to a belt conveyor process control method based on a programmable controller, equipment involved in the method comprises an industrial controller and a belt conveyor, and the method is a method for assisting an operator to control start and stop of the belt conveyor based on the industrial controller. According to the method, a stockline process is set in an industrial controller, and the functions of linkage starting, linkage stopping, belt conveyor fault interlocking shutdown and the like of the belt conveyor are achieved according to the set stockline process. The starting and stopping time of the belt conveyor is shortened, the labor intensity of workers is reduced, and potential safety hazards are eliminated; and after the middle belt is shut down due to failure, the interlocking shutdown program can prevent materials conveyed by the upstream belt from burying the belt conveyor which is shut down due to failure, so that the time for cleaning the materials is saved, and the production efficiency is greatly improved.

Description

Technical Field

[0001] The invention relates to a belt conveyor process control method based on a programmable controller. Background Art

[0002] In industrial production, belt conveyors are a common material handling equipment, mainly used to transport bulk materials or finished products in various industrial environments. They are widely used. In actual operation, there are some problems. On the one hand, when multiple belt conveyors are started or stopped, manually starting or stopping the belt conveyors one by one will result in a slow start or stop process, high labor intensity for workers, and great safety hazards. On the other hand, when the middle belt stops due to a fault, the materials transported by the upstream belt will bury the faulty belt conveyor, and cleaning the materials is time-consuming and labor-intensive, seriously affecting production efficiency.

[0003] In modern industrial production, belt conveyors are common equipment, and in the era of automation, they are usually remotely controlled through industrial controllers. In today's era, belt conveyors generally only have centralized, running and fault signal collection in the industrial controller system, but there is no control method for linkage start, linkage stop and fault interlock shutdown. Summary of the invention

[0004] In order to solve the above problems, the technical solution adopted by the present invention is: a method for controlling the process flow of a belt conveyor based on a programmable controller, comprising the following steps:

[0005] A method for controlling a belt conveyor process based on a programmable controller comprises the following steps:

[0006] Determine whether n belt conveyors that are operated in sequence and linkage are all in the state of being able to start automatically. When n belt conveyors that are operated in sequence and linkage are all in the state of being able to start automatically, the belt conveyors are controlled in linkage.

[0007] When the belt conveyor starts to transport materials, the belt conveyors are started in reverse order according to the material flow sequence of the n belt conveyors, so as to realize the linkage start of the n belt conveyors;

[0008] When the belt conveyor stops transporting materials, the belt conveyors are controlled to stop in sequence according to the material flow sequence of the n belt conveyors, so as to realize the linkage stop control of the n belt conveyors;

[0009] When any of the n belt conveyors fails during operation, the failed belt conveyor and all belt conveyors in the material flow direction of the failed belt conveyor are controlled to stop in sequence according to the material flow sequence of the belt conveyors, and the fault interlocking shutdown control of the belt conveyors is performed.

[0010] Furthermore, the method also includes obtaining a selection signal sent by a selection switch on the operation box.

[0011] Furthermore, it also includes judging the automatic start-up status of n belt conveyors operating in sequence and linkage by judging whether all the belt conveyors are in a fault-free state, wherein the fault-free state includes no thermal relay fault, no pull rope fault, no deviation fault, no slip fault, and no tearing fault.

[0012] Furthermore, it also includes issuing an early warning warning before each belt conveyor is started.

[0013] Furthermore, when the belt conveyor stops transporting materials, the stopping process of the belt conveyors is controlled in sequence according to the material flow sequence of the n belt conveyors. Each belt conveyor empties the remaining material on the belt and performs a delay, and the delay is calculated based on the belt length.

[0014] A belt conveyor process control device based on a programmable controller, comprising:

[0015] Judgment module: judge whether n belt conveyors that are operated in sequence and linkage are all in the state of being able to start automatically. When n belt conveyors that are operated in sequence and linkage are all in the state of being able to start automatically, the belt conveyors are controlled in linkage;

[0017] Control module: When the belt conveyor starts to transport materials, the belt conveyors are started in reverse order according to the material flow sequence of the n belt conveyors, so as to realize the linkage start of the n belt conveyors;

[0018] When the belt conveyor stops transporting materials, the belt conveyors are controlled to stop in sequence according to the material flow sequence of the n belt conveyors, so as to realize the linkage stop control of the n belt conveyors;

[0019] When any of the n belt conveyors fails during operation, the failed belt conveyor and all belt conveyors in the material flow direction of the failed belt conveyor are controlled to stop in sequence according to the material flow sequence of the belt conveyors, and the fault interlocking shutdown control of the belt conveyors is performed.

[0020] A readable storage medium stores a program module, wherein the program module is executed in a processor to implement any of the methods described above.

[0021] The present invention provides a belt conveyor process control method based on a programmable controller, which realizes the single-machine start, linkage start, linkage stop and interlock stop control of the belt conveyor through programmable controller programming, and displays alarm information and sound prompts on the human-machine interface when the machine stops due to a fault.

[0022] The use of belt conveyor process control methods based on programmable controllers can reduce workers' labor intensity, reduce safety hazards, shorten startup time, display alarm information and sound prompts on the human-machine interface when the fault interlocking shutdown occurs, quickly handle faults, and greatly improve production efficiency.

[0023] The method is based on a programmable controller-based belt conveyor process control method arranged in an industrial controller, and the belt conveyor's centralized signal, operating signal, and fault detection signal are collected into the industrial controller.

[0024] The method realizes the single-machine start and single-machine stop control of the belt conveyor in the industrial controller based on the belt conveyor process control method of the programmable controller.

[0025] The method is based on a belt conveyor process control method of a programmable controller and realizes the linkage start and linkage stop of multiple belt conveyors according to on-site process requirements.

[0026] The method is based on a belt conveyor process control method of a programmable controller and realizes the interlocking shutdown of multiple belt conveyors in the fault state according to the on-site process requirements.

[0027] The method of belt conveyor process control based on the programmable controller helps to shorten the start and stop time of the belt conveyor, reduce the labor intensity of workers, and eliminate safety hazards.

[0028] The method of belt conveyor process control based on a programmable controller helps to reduce fault downtime. After the intermediate belt stops due to fault, the interlocking shutdown program will prevent the material transported by the upstream belt from burying the faulty belt conveyor, saving time for cleaning materials and greatly improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0030] Figure 1 This is the flowchart of the method

[0031] Figure 2 The positional relationship and material flow direction of the five conveyor belts are shown;

[0032] Figure 3 The belt conveyor linkage starting process is demonstrated;

[0033] Figure 4 The belt conveyor linkage stopping process is demonstrated;

[0034] Figure 5 The PD5 failure shutdown process is shown;

[0035] Figure 6 The PD4 fault shutdown process is shown;

[0036] Figure 7 The PD3 fault shutdown process is shown;

[0037] Figure 8 The PD2 fault shutdown process is shown;

[0038] Fig. 9 The PD1 fault shutdown process is shown. DETAILED DESCRIPTION

[0039] It should be noted that, in the absence of conflict, the embodiments of the present invention and the features in the embodiments may be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0040] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is by no means intended to limit the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0041] Figure 1 This is the flowchart of the method

[0042] A method for controlling a belt conveyor process based on a programmable controller comprises the following steps:

[0043] S1: Determine whether n belt conveyors that are operated in a sequential linkage mode are all in a state where they can be automatically started. When n belt conveyors that are operated in a sequential linkage mode are all in a state where they can be automatically started, control the belt conveyors in a linkage mode.

[0044] S2: When the belt conveyor starts to transport materials, the belt conveyors are started in reverse order according to the material flow sequence of the n belt conveyors, that is, they are started in the order of the nth belt conveyor, the n-1th belt conveyor, the n-2th belt conveyor... the second belt conveyor, the first belt conveyor; the n belt conveyors are started in linkage;

[0045] When the belt conveyor stops transporting materials, the belt conveyors are controlled to stop in sequence according to the material flow sequence of the n belt conveyors, i.e., the first belt conveyor, the second belt conveyor, ... the n-2nd belt conveyor, the n-1st belt conveyor, and the nth belt conveyor are stopped in sequence; thus realizing the linkage stop control of the n belt conveyors;

[0046] When any of the n belt conveyors fails during operation, the failed belt conveyor and all belt conveyors in the material flow direction of the failed belt conveyor are controlled to stop in sequence according to the material flow sequence of the belt conveyors.

[0047] The method also includes obtaining a selection signal sent by a selection switch on the operation box. The gear position of the selection switch includes selection in the middle and selection beside the machine. When the selection is in the middle, the programmable controller can control the start and stop of the belt conveyor. When the selection is beside the machine, only the machine beside the machine box can start and stop the belt conveyor, and the programmable controller cannot control the belt conveyor.

[0048] It also includes judging the automatic start-up status of n belt conveyors operating in sequence and linkage by judging whether all the belt conveyors are in a fault-free state, wherein the fault-free state includes no thermal relay fault, no pull rope fault, no deviation fault, no slip fault, and no tearing fault.

[0049] When the n belt conveyors are all in a fault-free state, the n belt conveyors are operated to load materials; when any of the n belt conveyors is in a faulty state, no loading or other operations are performed;

[0050] The method further includes providing an early warning before each belt conveyor starts to transport materials; the early warning may be a bell or a warning light;

[0051] When the belt conveyor stops transporting materials, the stopping process of the belt conveyors is controlled in sequence according to the material flow sequence of the n belt conveyors, so as to realize the fault interlocking shutdown control of the belt conveyors;

[0052] Each belt conveyor is delayed to empty the excess material on the belt, and the delay is calculated based on the length of the belt.

[0053] This function is realized by using a programmable controller, which includes but is not limited to PLC, DCS, etc., and also includes other devices that can realize this function according to this patent. The programmable controller collects the concentration, operation, fault and other signals of the belt conveyor, processes the collected signals and realizes single-action control of the belt conveyor;

[0054] Process the collected signals and realize the linkage start and linkage stop control of the belt conveyor;

[0055] The collected signals are processed and fault interlock shutdown control of the belt conveyor is realized.

[0056] A belt conveyor process control device based on a programmable controller, comprising:

[0057] Acquisition module: used to obtain the operation signals of n belt conveyors that operate in sequence;

[0058] Judgment module: when the belt conveyor starts to transport materials, it controls the start of the belt conveyors in reverse order according to the material flow sequence of the n belt conveyors, so as to realize the linkage start of the n belt conveyors;

[0059] When the belt conveyor stops transporting materials, the belt conveyors are controlled to stop in sequence according to the material flow sequence of the n belt conveyors, so as to realize the linkage stop control of the n belt conveyors;

[0060] When any of the n belt conveyors fails during operation, the failed belt conveyor and all belt conveyors in the material flow direction of the failed belt conveyor are controlled to stop in sequence according to the material flow sequence of the belt conveyors, and the fault interlocking shutdown control of the belt conveyors is performed.

[0061] A readable storage medium stores a program module, wherein the program module is executed in a processor to implement any of the methods described above.

[0062] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0063] Example 1: Take the control of 5 belt conveyors (PD1-PD5) as an example:

[0064] Figure 2 Displays the positional relationship and material flow direction of the 5 conveyor belts

[0065] Linkage start sequence: PD1 (1st belt conveyor) → PD2 (2nd belt conveyor) → PD3 (3rd belt conveyor) → PD4 (4th belt conveyor) → PD5 (5th belt conveyor);

[0066] Linkage stop sequence: PD5→PD4→PD3→PD2→PD1;

[0067] Material flow direction: PD5→PD4→PD3→PD2→PD1;

[0068] Figure 3 The belt conveyor linkage starting process is demonstrated;

[0069] Step 201, determine whether PD1 meets the starting conditions. If PD1 meets the starting conditions, execute step 202. If PD1 does not meet the starting conditions, end the process. The starting condition refers to the belt conveyor being in a fault-free state;

[0070] Step 202, PD1 linkage starts.

[0071] Step 203, determine whether PD2 meets the start-up conditions. If PD2 meets the start-up conditions, execute step 204. If PD2 does not meet the start-up conditions, end the process.

[0072] Step 204, PD2 linkage starts.

[0073] Step 205, determine whether PD3 meets the start-up conditions. If PD3 meets the start-up conditions, execute step 206. If PD3 does not meet the start-up conditions, end the process.

[0074] Step 206, PD3 linkage starts.

[0075] Step 207, determine whether PD4 meets the start-up conditions. If PD4 meets the start-up conditions, execute step 208. If PD4 does not meet the start-up conditions, end the process.

[0076] Step 208, PD4 linkage starts.

[0077] Step 209, determine whether PD5 meets the start-up conditions. If PD5 meets the start-up conditions, execute step 210. If PD5 does not meet the start-up conditions, end the process.

[0078] Step 210, PD5 is started in linkage, and the linkage start process ends.

[0079] Figure 4 The belt conveyor linkage stopping process is demonstrated;

[0080] Step 301, the belt linkage stop process is started, and the PD5 linkage stop instruction is issued.

[0081] Step 302, delaying the belt to empty the remaining material, the delay time is calculated based on the belt length. The delay time is equal to the belt length divided by the belt conveyor running speed;

[0082] Step 303, determine whether PD5 stops, if PD5 stops, execute step 304, if PD5 does not stop, alarm and end the linkage stop process.

[0083] Step 304, PD4 linkage stop instruction is issued.

[0084] Step 305, delaying the belt to empty the remaining material, the delay time is calculated based on the belt length.

[0085] Step 306, determine whether PD4 stops. If PD5 stops, execute step 307. If PD4 does not stop, alarm and end the linkage stop process.

[0086] Step 307: PD3 linkage stop instruction is issued.

[0087] Step 308 is a delay to empty the remaining material on the belt, and the delay time is calculated based on the length of the belt.

[0088] Step 309, determine whether PD3 stops, if PD3 stops, execute step 310, if PD3 does not stop, alarm and end the linkage stop process.

[0089] Step 310: PD2 linkage stop instruction is issued.

[0090] Step 311 is to delay the emptying of the remaining material on the belt, and the delay time is calculated based on the length of the belt.

[0091] Step 312, determine whether PD2 stops. If PD2 stops, execute step 313. If PD2 does not stop, alarm and end the linkage stop process.

[0092] Step 313, PD1 linkage stop instruction is issued.

[0093] Step 314 is a delay for emptying the remaining material on the belt, and the delay time is calculated based on the length of the belt.

[0094] Step 315, determine whether PD1 stops, if PD1 stops, the linkage stop process ends.

[0095] Figure 5 The PD5 failure shutdown process is shown;

[0096] Step 401, PD5 fault signal arrives.

[0097] Step 402, determine whether PD5 is shut down. If PD5 is shut down, the PD5 fault shutdown process ends, and the running status of other belts remains unchanged.

[0098] Figure 6 The PD4 fault shutdown process is shown;

[0099] Step 501, PD4 fault signal arrives.

[0100] Step 502, determine whether PD4 is shut down, if PD4 is shut down, execute step 503.

[0101] Step 503, PD5 interlock shutdown command is issued. If PD5 stops, the PD4 fault shutdown process ends, and the running status of other belts remains unchanged.

[0102] Figure 7 The PD3 fault shutdown process is shown;

[0103] Step 601, PD3 fault signal arrives.

[0104] Step 602, determine whether PD3 is shut down, if PD3 is shut down, execute step 603.

[0105] Step 603: PD4 interlock shutdown command is issued. If PD4 stops, step 604 is executed.

[0106] Step 604, PD5 interlock shutdown command is issued. If PD5 stops, the PD3 fault shutdown process ends, and the running status of other belts remains unchanged.

[0107] Figure 8 The PD2 fault shutdown process is shown;

[0108] Step 701, PD2 fault signal arrives.

[0109] Step 702, determine whether PD2 is shut down, if PD2 is shut down, execute step 703.

[0110] Step 703: PD3 interlock shutdown command is issued. If PD3 stops, step 704 is executed.

[0111] Step 704: PD4 interlock shutdown command is issued. If PD4 stops, then step 705 is executed.

[0112] Step 705, PD5 interlock shutdown command is issued. If PD5 stops, the PD2 fault shutdown process ends, and the running status of other belts remains unchanged.

[0113] Fig. 9 The PD1 fault shutdown process is shown;

[0114] Step 801, PD1 fault signal arrives.

[0115] Step 802, determine whether PD1 is shut down, if PD1 is shut down, execute step 803.

[0116] Step 803: PD2 interlock shutdown command is issued. If PD2 stops, step 804 is executed.

[0117] Step 804: PD3 interlock shutdown command is issued. If PD3 stops, then step 805 is executed.

[0118] Step 805: PD4 interlock shutdown command is issued. If PD4 stops, step 806 is executed.

[0119] Step 806: PD5 interlock shutdown command is issued. If PD5 stops, the PD1 fault shutdown process ends, and the running status of other belts remains unchanged.

[0120] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for controlling a belt conveyor process based on a programmable controller, characterized in that: The following steps are involved: Determine whether n belt conveyors that are operated in sequence and linkage are all in the state of being able to start automatically. When n belt conveyors that are operated in sequence and linkage are all in the state of being able to start automatically, the belt conveyors are controlled in linkage. When the belt conveyor starts to transport materials, the belt conveyors are started in reverse order according to the material flow sequence of the n belt conveyors, so as to realize the linkage start of the n belt conveyors; When the belt conveyor stops transporting materials, the belt conveyors are controlled to stop in sequence according to the material flow sequence of the n belt conveyors, so as to realize the linkage stop control of the n belt conveyors; When any of the n belt conveyors fails during operation, the failed belt conveyor and all belt conveyors in the material flow direction of the failed belt conveyor are controlled to stop in sequence according to the material flow sequence of the belt conveyors, and the fault interlocking shutdown control of the belt conveyors is performed.

2. A method for controlling a belt conveyor process based on a programmable controller according to claim 1, characterized in that: It also includes obtaining the selection signal sent by the selection switch on the operation box.

3. The method for controlling a belt conveyor process based on a programmable controller according to claim 1, characterized in that: It also includes judging the automatic start-up status of n belt conveyors operating in sequence and linkage by judging whether all the belt conveyors are in a fault-free state, wherein the fault-free state includes no thermal relay fault, no pull rope fault, no deviation fault, no slip fault, and no tearing fault.

4. The method for controlling a belt conveyor process based on a programmable controller according to claim 1, characterized in that: It also includes an early warning alert before each conveyor belt is started.

5. The method for controlling a belt conveyor process based on a programmable controller according to claim 3, characterized in that: When the belt conveyor stops transporting materials, the belt conveyor stops in sequence according to the material flow sequence of the n belt conveyors. Each belt conveyor is delayed to empty the excess material on the belt, and the delay is calculated based on the length of the belt.

6. A belt conveyor process control device based on a programmable controller, characterized in that: include Judgment module: judge whether n belt conveyors that are operated in sequence and linkage are all in the state of being able to start automatically. When n belt conveyors that are operated in sequence and linkage are all in the state of being able to start automatically, the belt conveyors are controlled in linkage; Control module: When the belt conveyor starts to transport materials, the belt conveyors are started in reverse order according to the material flow sequence of the n belt conveyors, so as to realize the linkage start of the n belt conveyors; When the belt conveyor stops transporting materials, the belt conveyors are controlled to stop in sequence according to the material flow sequence of the n belt conveyors, so as to realize the linkage stop control of the n belt conveyors; When any of the n belt conveyors fails during operation, the failed belt conveyor and all belt conveyors in the material flow direction of the failed belt conveyor are controlled to stop in sequence according to the material flow sequence of the belt conveyors, and the fault interlocking shutdown control of the belt conveyors is performed.

7. A readable storage medium storing a program module, characterized in that: The program module is executed in a processor to implement the method according to any one of claims 1 to 6.

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