Unmanned slag salvaging control system for ironmaking plant

Abstract

The invention discloses an unmanned slag salvaging control system for an iron-making plant and belongs to the technical field of slag salvaging control of the iron-making plant. In order to improve the slag salvaging working efficiency of an iron mill, the system comprises a PLC and an upper computer, and the upper computer comprises an unmanned crown block positioning system, an automatic control slag grabbing and unloading system, a transmission system, a safety monitoring system, a slag quantity calculation model system and a video monitoring system; the upper computer is in communication connection with the PLC through an S7. NET Siemens special protocol; the upper computer reads an iniPLCIP address, a CPU type, a rack number, a slot number file, cart and trolley initial position information, cart and trolley in-place information and cart and trolley safety limiting signal information configured by the PLC; the PLC establishes a PLC configuration environment through PN communication and establishes communication connection with two remote IO stations IM155-6 and four frequency converters, and the four frequency converters comprise a cart frequency converter, a trolley frequency converter, a grab bucket lifting frequency converter and a grab bucket opening and closing frequency converter. The working efficiency is improved.

Description

Technical Field

[0001] The invention belongs to the technical field of slag scooping control in an ironmaking plant, and in particular relates to an unmanned slag scooping control system in an ironmaking plant. Background Art

[0002] The water slag flushing process of the blast furnace in an iron and steel plant will produce a large amount of slag. Due to the influence of high temperature during the production process, the water vapor range on the slag pool is relatively large. When the crane is performing the slag grabbing operation, the crane operator is often unable to accurately locate the slag pit in the slag pool with the naked eye. The lifting and opening and closing of the grab bucket can only be done blindly based on memory and habit, which can easily lead to empty grabbing and affect work efficiency. Summary of the invention

[0003] The problem to be solved by the present invention is to improve the slag removal efficiency of an ironmaking plant, and an unmanned slag removal control system for the ironmaking plant is proposed.

[0004] To achieve the above object, the present invention is implemented through the following technical solutions:

[0005] An unmanned slag removal control system for an ironmaking plant, comprising a PLC and a host computer, wherein the PLC is connected to the host computer, and the host computer comprises an unmanned overhead crane positioning system, an automatic control slag removal system, a transmission system, a safety monitoring system, a slag quantity calculation model system, and a video monitoring system;

[0006] The host computer communicates with the PLC through the S7.NET Siemens dedicated protocol; the host computer reads the ini PLC IP address, CPU type, rack number, slot number file, initial position information of the trolley and the trolley, arrival information of the trolley and the trolley, and safety limit signal information of the trolley and the trolley configured by the PLC;

[0007] The PLC establishes a PLC configuration environment through PN communication and establishes communication connections with two remote IO stations IM155-6 and four frequency converters. The four frequency converters include a trolley frequency converter, a small car frequency converter, a grab bucket lifting frequency converter, and a grab bucket opening and closing frequency converter.

[0008] Furthermore, in the unmanned overhead crane positioning system, the X-axis is set to represent the maximum travel distance of the overhead crane trolley, and the Y-axis represents the maximum travel distance of the overhead crane trolley; the slag pool is divided into grids, the grid distance is divided according to the pulse calculation of the absolute encoders of the overhead crane trolley and the overhead crane trolley, and area classification is set in each grid area. The real-time positions of the absolute encoders of the overhead crane trolley and the overhead crane trolley are analyzed by PLC, and the same DB block point information is configured by connecting to the host computer.

[0009] Furthermore, the automatic control slag grabbing and unloading system controls the overhead crane to adjust and move within the X and Y axes, so that the grab bucket can grab the slag within the grid, and configures the slag grabbing area and slag unloading area information according to the slag catching plan, and writes the slag grabbing area and slag unloading area information back to the PLC to control the PLC action, thereby controlling the operation of the overhead crane.

[0010] Furthermore, the transmission system performs logical operations according to the distance information and constructs a speed calculation model as follows:

[0011] First, construct the shortest time minJ formula to optimize the shortest time for the overhead crane trolley and the overhead crane trolley to move simultaneously to reach the target. The formula is as follows:

[0012]

[0013] The target time is t f , the initial time is t 0 ;

[0014] Construct the dynamic model of driving, the formula is as follows:

[0015] x 2 (t) = f (x (t) + u (t))

[0016] Where x(t) is the position of the vehicle, u(t) is the control input applied to the vehicle, and f is the function form of the given vehicle position and the control input applied to the vehicle;

[0017] Construct the starting position constraint and the target position constraint conditions, the formula is as follows:

[0018] x(t 0 )=[x 1 (t 0 ),x 2 (t 0 )]

[0019] x(t 1 )=[x 1 (t 1 ),x 2 (t 1 )]

[0020] Among them, x(t 0 ) is the time point t 0 The driving status, where x 1 (t 0 ) and x 2 (t 0 ) are respectively at time point t 0 The position or state value of the vehicle on different coordinate axes; x(t 1 ) is the time point t 1The driving status, where x 1 (t 1 ) and x 2 (t 1 ) are respectively at time point t 1 The position or state value of the vehicle on different coordinate axes;

[0021] Construct the speed constraint condition, the formula is as follows:

[0022] -Vmix≤v(t)≤Vmax

[0023] Among them, Vmix is ​​the lower limit of speed, Vmax is the upper limit of speed, and v(t) is the change of speed over time;

[0024] Construct the traction constraint condition, the formula is as follows:

[0025] -Umix≤u(t)≤Umax

[0026] Among them, Umix is ​​the lower limit of traction force, Umax is the upper limit of traction force, and u(t) is the change of traction force over time;

[0027] Construct the acceleration constraint condition, the formula is as follows:

[0028] -amix≤a(t)≤amax

[0029] Among them, amix is ​​the lower limit of acceleration, amax is the upper limit of acceleration, and a(t) is the change of acceleration over time.

[0030] Furthermore, the safety monitoring system is set up according to the national standard GB28264-2012 "Crane Machinery Safety Monitoring and Management System". The safety monitoring host is connected to the PLC system via Ethernet, reads the data in the PLC, and stores it in the storage unit in the safety monitoring host. The data storage cycle is within 100ms; the safety monitoring system monitors all contactor states, including the current and voltage of the stator and rotor of the main hook motor. The overhead crane's safety monitoring system sets historical curves, real-time curves, real-time status, control flow, and fault statistics functions.

[0031] Furthermore, the slag amount calculation model system collects the flow field and water-slag amount data of the slag pile according to the laser radar, and then processes the slag pile three-dimensional cloud map data, calculates the volume and weight of the slag pile, calculates the volume and weight of the remaining pileable materials in the slag pile, and performs vector modeling of the entire slag pile;

[0032] The collection and processing methods of LiDAR data, including data reading, display, straight line fitting, corner point extraction, arc fitting and pose calculation;

[0033] The laser radar data collection and reading: When the laser radar is working, it emits laser pulses and calculates the distance of the target by measuring the time it takes for the pulses to reflect back; the data reading involves analyzing the received signal, including time, intensity, and angle information, and converting it into point cloud data;

[0034] Data display: Point cloud data is stored in the form of 3D coordinates. Coordinate.cpp is used to process the code for coordinate conversion and display the point cloud data on the screen in real time.

[0035] Linear fitting: In the point cloud data, WeightedFit.cpp is used to perform weighted linear fitting based on the least squares method. By clustering and screening the point cloud data, a point set with a linear trend is found, and then fitting is performed to obtain a linear model;

[0036] Corner point extraction: Harris corner point detection is used to identify key points for object recognition and positioning;

[0037] Arc fitting: Use WeightedFit.h to provide arc fitting algorithm;

[0038] Pose solution: Use Kalman filtering or particle filtering to estimate the motion parameters of the radar by comparing the point cloud differences between consecutive frames to complete the pose solution.

[0039] Furthermore, the video surveillance system adopts a full network digital video surveillance architecture: the front end uses a high-definition network camera for video acquisition, which is directly connected to the video transmission network of the warehouse area through the network port of the camera, and transmitted to the back end for centralized storage and management. The transmission backbone network adopts a gigabit optical fiber network, and the back end completes the centralized preview, control, management, storage and video distribution functions of the entire video surveillance system through a centralized management platform, realizing centralized management of the warehouse area high-definition digital video surveillance system.

[0040] Beneficial effects of the present invention:

[0041] The unmanned slag dredging control system of an ironmaking plant described in the present invention realizes unmanned intelligent operation of a slag dredging bridge grab crane through an unmanned overhead crane positioning system, an automatic control slag grabbing and unloading system, a transmission system, a safety monitoring system, a slag quantity calculation model system, and a video monitoring system in combination with a position detection sensor, adopts an absolute value encoder for height detection, adopts an absolute value encoder for grab bucket opening and closing degree detection, and adopts microwave radar detection for unloading area detection, thereby improving work efficiency and reducing safety accidents during the work process. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 This is a schematic structural diagram of an unmanned slag removal control system for an ironmaking plant according to the present invention;

[0043] Figure 2 This is a photo of a control panel of an unmanned slag removal control system for an ironmaking plant described in the present invention. DETAILED DESCRIPTION

[0044] In order to make the purpose, technical solution and advantages of the present invention more clear, the present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention, that is, the specific embodiments described are only part of the embodiments of the present invention, rather than all of the specific embodiments. The components of the specific embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations, and the present invention can also have other embodiments.

[0045] Therefore, the following detailed description of the specific embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents the selected specific embodiments of the present invention. Based on the specific embodiments of the present invention, all other specific embodiments obtained by those skilled in the art without making creative work are within the scope of protection of the present invention.

[0046] In order to further understand the content, features and effects of the present invention, the following specific implementation methods are given as examples, and the attached Figure 1 -Attached Figure 2 The detailed instructions are as follows:

[0047] Embodiment 1:

[0048] An unmanned slag removal control system for an ironmaking plant, comprising a PLC and a host computer, wherein the PLC is connected to the host computer, and the host computer comprises an unmanned overhead crane positioning system, an automatic control slag removal system, a transmission system, a safety monitoring system, a slag quantity calculation model system, and a video monitoring system;

[0049] The host computer communicates with the PLC through the S7.NET Siemens dedicated protocol; the host computer reads the ini PLC IP address, CPU type, rack number, slot number file, initial position information of the trolley and the trolley, arrival information of the trolley and the trolley, and safety limit signal information of the trolley and the trolley configured by the PLC;

[0050] The PLC establishes a PLC configuration environment through PN communication and establishes communication connections with two remote IO stations IM155-6 and four frequency converters. The four frequency converters include a trolley frequency converter, a small car frequency converter, a grab bucket lifting frequency converter, and a grab bucket opening and closing frequency converter.

[0051] Furthermore, in the unmanned overhead crane positioning system, the X-axis is set to represent the maximum travel distance of the overhead crane trolley, and the Y-axis represents the maximum travel distance of the overhead crane trolley; the slag pool is divided into grids, the grid distance is divided according to the pulse calculation of the absolute encoders of the overhead crane trolley and the overhead crane trolley, and area classification is set in each grid area. The real-time positions of the absolute encoders of the overhead crane trolley and the overhead crane trolley are analyzed by PLC, and the same DB block point information is configured by connecting to the host computer.

[0052] Furthermore, the automatic control slag grabbing and unloading system controls the overhead crane to adjust and move within the X and Y axes, so that the grab bucket can grab the slag within the grid, and configures the slag grabbing area and slag unloading area information according to the slag catching plan, and writes the slag grabbing area and slag unloading area information back to the PLC to control the PLC action, thereby controlling the operation of the overhead crane.

[0053] Furthermore, the transmission system performs logical operations according to the distance information and constructs a speed calculation model as follows:

[0054] First, construct the shortest time minJ formula to optimize the shortest time for the overhead crane trolley and the overhead crane trolley to move simultaneously to reach the target. The formula is as follows:

[0055]

[0056] The target time is t f , the initial time is t 0 ;

[0057] Construct the dynamic model of driving, the formula is as follows:

[0058] x 2 (t) = f (x (t) + u (t))

[0059] Where x(t) is the position of the vehicle, u(t) is the control input applied to the vehicle, and f is the function form of the given vehicle position and the control input applied to the vehicle;

[0060] Construct the starting position constraint and the target position constraint conditions, the formula is as follows:

[0061] x(t 0 )=[x 1 (t 0 ),x 2 (t 0 )]

[0062] x(t 1 )=[x 1 (t 1 ),x 2 (t 1 )]

[0063] Among them, x(t0 ) is the time point t 0 The driving status, where x 1 (t 0 ) and x 2 (t 0 ) are respectively at time point t 0 The position or state value of the vehicle on different coordinate axes; x(t 1 ) is the time point t 1 The driving status, where x 1 (t 1 ) and x 2 (t 1 ) are respectively at time point t 1 The position or state value of the vehicle on different coordinate axes;

[0064] Construct the speed constraint condition, the formula is as follows:

[0065] -Vmix≤v(t)≤Vmax

[0066] Among them, Vmix is ​​the lower limit of speed, Vmax is the upper limit of speed, and v(t) is the change of speed over time;

[0067] Construct the traction constraint condition, the formula is as follows:

[0068] -Umix≤u(t)≤Umax

[0069] Among them, Umix is ​​the lower limit of traction force, Umax is the upper limit of traction force, and u(t) is the change of traction force over time;

[0070] Construct the acceleration constraint condition, the formula is as follows:

[0071] -amix≤a(t)≤amax

[0072] Among them, amix is ​​the lower limit of acceleration, amax is the upper limit of acceleration, and a(t) is the change of acceleration over time.

[0073] Furthermore, the safety monitoring system is set up according to the national standard GB28264-2012 "Crane Machinery Safety Monitoring and Management System". The safety monitoring host is connected to the PLC system via Ethernet, reads the data in the PLC, and stores it in the storage unit in the safety monitoring host. The data storage cycle is within 100ms; the safety monitoring system monitors all contactor states, including the current and voltage of the stator and rotor of the main hook motor. The overhead crane's safety monitoring system sets historical curves, real-time curves, real-time status, control flow, and fault statistics functions.

[0074] Furthermore, the slag amount calculation model system collects the flow field and water-slag amount data of the slag pile according to the laser radar, and then processes the slag pile three-dimensional cloud map data, calculates the volume and weight of the slag pile, calculates the volume and weight of the remaining pileable materials in the slag pile, and performs vector modeling of the entire slag pile;

[0075] The collection and processing methods of LiDAR data, including data reading, display, straight line fitting, corner point extraction, arc fitting and pose calculation;

[0076] The laser radar data collection and reading: When the laser radar is working, it emits laser pulses and calculates the distance of the target by measuring the time it takes for the pulses to reflect back; the data reading involves analyzing the received signal, including time, intensity, and angle information, and converting it into point cloud data;

[0077] Data display: Point cloud data is stored in the form of 3D coordinates. Coordinate.cpp is used to process the code for coordinate conversion and display the point cloud data on the screen in real time.

[0078] Linear fitting: In the point cloud data, WeightedFit.cpp is used to perform weighted linear fitting based on the least squares method. By clustering and screening the point cloud data, a point set with a linear trend is found, and then fitting is performed to obtain a linear model;

[0079] Corner point extraction: Harris corner point detection is used to identify key points for object recognition and positioning;

[0080] Arc fitting: Use WeightedFit.h to provide arc fitting algorithm;

[0081] Pose solution: Use Kalman filtering or particle filtering to estimate the motion parameters of the radar by comparing the point cloud differences between consecutive frames to complete the pose solution.

[0082] Furthermore, the video surveillance system adopts a full network digital video surveillance architecture: the front end uses a high-definition network camera for video acquisition, which is directly connected to the video transmission network of the warehouse area through the network port of the camera, and transmitted to the back end for centralized storage and management. The transmission backbone network adopts a gigabit optical fiber network, and the back end completes the centralized preview, control, management, storage and video distribution functions of the entire video surveillance system through a centralized management platform, realizing centralized management of the warehouse area high-definition digital video surveillance system.

[0083] Furthermore, the working method of the unmanned slag removal control system of the ironmaking plant comprises the following steps:

[0084] The crane starts to power on and starts at the initial position → accepts the operation command from the host computer → checks whether the crane is in normal state;

[0085] If the crane is in normal condition → check whether the crane is in automatic state → accurately locate the current position of vehicles → find the target area → move vehicles → accelerate and decelerate in advance → reach the target position for grabbing slag → the grab bucket descends → the grab bucket descends into place → the grab bucket opens → the grab bucket closes → the grab bucket rises → rises into place → find the position of the slag unloading area → vehicles move → reach the target area → unload the slag → end.

[0086] Furthermore, the present embodiment is applied to the No. 1 blast furnace water slag flushing in the ironmaking plant, and a manual 5t grab bucket crane is overall transformed to realize the unmanned intelligent operation of the slag bridge grab bucket crane as follows:

[0087] The system architecture of the unmanned overhead crane for slag in the ironmaking plant consists of the overhead crane electronic control, transmission system, position detection sensor (the large / small trolley adopts an absolute encoder positioner), height detection (using an absolute encoder), grab opening and closing detection (using an absolute encoder), unloading area (using microwave radar detection), video monitoring system, etc. Among them: the overhead crane electronic control PLC, transmission system, and sensor realize the manual and automatic control of the overhead crane. The overhead crane electronic control PLC collects the position information of the large and small trolleys of the overhead crane and the height, receives the lifting instructions from the ground information management system, and automatically controls the overhead crane; the entire overhead crane is controlled by PLC. The lifting and opening and closing of the large and small trolleys and grab buckets are all controlled by closed-loop variable frequency vector speed regulation. The absolute value encoder of the large and small trolleys: detects the real-time position of the large and small trolleys of the overhead crane; the Z-axis (height) encoder: measures the lifting height of the grab bucket; the opening and closing encoder: measures the value of the grab bucket opening and closing; the status display screen: is used to display the status information of the overhead crane such as automatic, manual, and maintenance; the unmanned fully automatic overhead crane has two operating modes: automatic control and manual control, and the operating mode is switched on the cockpit linkage console. The large / small car is positioned by an absolute encoder; the main / secondary rope of the grab bucket uses an absolute encoder to establish a two-dimensional spatial coordinate system, with the starting position as the origin, to locate the position of the crane and the hoist in real time, to track the starting and target positions of each hoisting, and to analyze the position of the slag each time it is hoisted. According to the on-site inspection, the span of the 1# blast furnace crane is 19.5 meters and the length is 60 meters. Based on the maximum opening size of the grab bucket of 2.5 meters, a grid rectangular coordinate system is established, with the X axis representing the maximum travel distance of the crane trolley and the Y axis representing the maximum travel distance of the crane trolley; the slag pool is divided into grids, and the grid distance is divided according to the pulse calculation of the absolute encoder of the large and small cars, and each grid area is classified. The crane can be adjusted and moved within the X and Y axes, and the grab bucket can grab the slag within the grid.

[0088] System architecture: The crane control system consists of crane electric control, transmission system, position detection sensor (the crane / trolley adopts wireless microwave radar locator), height detection (using absolute value encoder), grab opening and closing degree detection (using absolute value encoder), wireless communication system, etc. Among them: the crane electric control PLC, transmission system, and sensor realize the manual and automatic control of the crane. The crane electric control PLC collects the crane, trolley, and height position information, receives the lifting instructions from the ground information management system, and automatically controls the crane; the crane is controlled by PLC. The lifting and opening and closing of the trolley and grab bucket adopt closed-loop variable frequency vector speed regulation. Wireless microwave radar: detects the real-time position of the crane / trolley; Z-axis (height) encoder: measures the lifting height of the grab bucket; opening and closing degree encoder: measures the value of the grab bucket opening and closing degree; status display screen: used to display the crane status information such as automatic, manual, and maintenance; the unmanned fully automatic crane has two operating modes: automatic control and manual control. The operating mode is switched on the cockpit linkage console. Automatic mode: normal operation mode. The unmanned fully automatic overhead crane operates automatically according to the operating instructions generated by the information management system without the need for human intervention.

[0089] Automatic control system:

[0090] According to the slag removal mode selected by the user, first, a two-dimensional spatial coordinate system is established, with the starting position as the origin, the position of the overhead crane and the hoisting device is located in real time, the starting and target positions of each lifting are tracked, the position area of ​​the slag of each lifting is analyzed for positioning, and the grab automatically grabs and unloads the slag.

[0091] Overhead crane electronic control system:

[0092] Specially designed for grab crane, it has high safety and reliability. The whole vehicle hoisting mechanism adopts digital voltage and speed controller drive solution; the running mechanism adopts variable frequency drive solution.

[0093] Power supply and power supply mode:

[0094] The power supply mode of the overhead crane adopts three-phase three-wire power supply, with a voltage level of AC380V, 50Hz; the power supply is introduced into the transformer on the overhead crane through the busbar and then enters the main power circuit breaker. The power supply for power, lighting, control, etc. is led out from the circuit breaker.

[0095] The overhead crane is equipped with a separate lighting transformer, and the primary and secondary ends of the transformer are both equipped with circuit breaker protection, providing AC220V power for lighting, maintenance sockets and auxiliary circuits. A separate control transformer is equipped with circuit breaker protection for the primary and secondary ends of the transformer, providing AC220V control power for the control circuit. The trolley power feeding device adopts cable pulley and drag flat cable power supply type.

[0096] Each organization drives the solution system:

[0097] The lifting mechanism and grab opening and closing mechanism adopt metallurgical special YZP variable frequency motor, driven by variable frequency speed regulating device. The frequency converter adopts Siemens S120 series.

[0098] The translation mechanism (large and small car) adopts metallurgical special YZP variable frequency motor, driven by variable frequency speed regulating device. The frequency converter adopts Siemens S120 series.

[0099] PLC control system:

[0100] The vehicle control system adopts Siemens S7-1500F safety series PLC centralized control. The CPU module is equipped with a memory card. The I / O receives the given signals of each mechanism and outputs the fault status signal and the control signal of each mechanism. The CPU on the PLC host performs logical operations for control protection and interlocking. 20% spare input / output points are reserved, and the spare input / output points are wired to the terminal block. The PLC system should be equipped with UPS power supply. The PLC should work for at least 2 hours after power failure. The communication protocol between the PLC and the inverter and remote station adopts Profinet.

[0101] Security monitoring system:

[0102] The safety monitoring system should fully meet the requirements of the national standard GB28264-2012 "Crane Machinery Safety Monitoring and Management System".

[0103] The crane is equipped with a safety monitoring system to display the main operating status of the crane. The safety monitoring host is connected to the PLC system via Ethernet, reads the data in the PLC system, and stores it in the storage unit in the monitoring host, which can ensure that the data storage cycle is within 100ms. Safety monitoring needs to monitor all contactor states, the current and voltage of the stator and rotor of the main hook motor. The safety monitoring system of the crane needs to add historical curves, real-time curves, real-time status, control flow, and fault statistics functions.

[0104] Safety protection device:

[0105] Parking options:

[0106] A. Normal parking: When the mechanism stops normally, it is first braked electrically, and when the running speed drops to the set speed, the brake closes.

[0107] B. Fault stop: The main power of the vehicle is cut off and the brake is closed immediately.

[0108] Limit device:

[0109] Lifting limit: set three levels of rising and two levels of falling protection, equipped with rotation limit and heavy hammer limit. The rotation limit completes the first and second level protection functions. First level: deceleration level (deceleration to 1st gear speed); second level: (when the limit limit is activated, the mechanism stops according to parking mode A) cut off the rising or falling power circuit of the mechanism, allowing descent or rise; third level: there is a heavy hammer limit to cut off the total power supply of the crane. Translation limit: the trolley and the small car are equipped with end stop limit.

[0110] Other devices:

[0111] Emergency protection: An emergency stop button is installed on the linkage platform, and the operator can quickly cut off the power of the mechanism and the control power supply in an emergency. At the same time, an emergency stop switch is also installed in the electrical room of the overhead crane, so that maintenance personnel can stop the operation of the overhead crane at the above position.

[0112] Overload limiter: The main hoisting mechanism is equipped with an overload limiter, which is equipped with one (4~20mA) output signal. The load limiting function of the main hoisting is realized by the overload limiter.

[0113] Overspeed protection: The lifting mechanism is equipped with an overspeed protection switch. When the overspeed switch is activated, the mechanism stops according to parking method B.

[0114] It should be noted that relational terms such as "first" and "second" are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.

[0115] Although the present application has been described above with reference to specific embodiments, various modifications may be made thereto and parts thereof may be replaced with equivalents without departing from the scope of the present application. In particular, as long as there is no structural conflict, the various features in the specific embodiments disclosed in the present application may be used in combination with each other in any manner, and the fact that these combinations are not exhaustively described in this specification is only for the sake of omitting space and saving resources. Therefore, the present application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. An unmanned slag removal control system for an ironmaking plant, characterized in that: It includes a PLC and a host computer, wherein the PLC is connected to the host computer, and the host computer includes an unmanned overhead crane positioning system, an automatic control slag grabbing and unloading system, a transmission system, a safety monitoring system, a slag volume calculation model system, and a video monitoring system; The host computer communicates with the PLC through the S7.NET Siemens dedicated protocol; the host computer reads the ini PLC IP address, CPU type, rack number, slot number file, initial position information of the trolley and the trolley, arrival information of the trolley and the trolley, and safety limit signal information of the trolley and the trolley configured by the PLC; The PLC establishes a PLC configuration environment through PN communication and establishes communication connections with two remote IO stations IM155-6 and four frequency converters. The four frequency converters include a trolley frequency converter, a small car frequency converter, a grab bucket lifting frequency converter, and a grab bucket opening and closing frequency converter.

2. The unmanned slag removal control system for an ironmaking plant according to claim 2 is characterized in that: In the unmanned overhead crane positioning system, the X-axis is set to represent the maximum travel distance of the overhead crane trolley, and the Y-axis represents the maximum travel distance of the overhead crane trolley; the slag pool is divided into grids, the grid distance is divided according to the pulse calculation of the absolute encoders of the overhead crane trolley and the overhead crane trolley, and area classification is set in each grid area. The real-time positions of the absolute encoders of the overhead crane trolley and the overhead crane trolley are analyzed by PLC, and the same DB block point information is configured by connecting to the host computer.

3. The unmanned slag removal control system for an ironmaking plant according to claim 2 is characterized in that: The automatic control slag grabbing and unloading system controls the overhead crane to adjust and move within the X and Y axes, so that the grab bucket can grab the slag within the grid, and configures the slag grabbing area and slag unloading area information according to the slag catching plan, and writes the slag grabbing area and slag unloading area information back to the PLC to control the PLC action, thereby controlling the operation of the overhead crane.

4. The unmanned slag removal control system for an ironmaking plant according to claim 3 is characterized in that: The transmission system performs logical operations based on the distance information and constructs a speed calculation model as follows: First, construct the shortest time minJ formula to optimize the shortest time for the overhead crane trolley and the overhead crane trolley to move simultaneously to reach the target. The formula is as follows: The target time is t f , the initial time is t0; Construct the dynamic model of driving, the formula is as follows: x 2 (t)=f(x(t)+u(t)) Where x(t) is the position of the vehicle, u(t) is the control input applied to the vehicle, and f is the function form of the given vehicle position and the control input applied to the vehicle; Construct the starting position constraint and the target position constraint conditions, the formula is as follows: x(t0)=[x1(t0),x2(t0)] x(t1)=[x1(t1),x2(t1)] Among them, x(t0) is the state of the vehicle at time point t0, and x1(t0) and x2(t0) are the positions or state values ​​of the vehicle on different coordinate axes at time point t0; x(t1) is the state of the vehicle at time point t1, and x1(t1) and x2(t1) are the positions or state values ​​of the vehicle on different coordinate axes at time point t1; Construct the speed constraint condition, the formula is as follows: -Vmix≤v(t)≤Vmax Among them, Vmix is ​​the lower limit of speed, Vmax is the upper limit of speed, and v(t) is the change of speed over time; Construct the traction constraint condition, the formula is as follows: -Umix≤u(t)≤Umax Among them, Umix is ​​the lower limit of traction force, Umax is the upper limit of traction force, and u(t) is the change of traction force over time; Construct the acceleration constraint condition, the formula is as follows: -amix≤a(t)≤amax Among them, amix is ​​the lower limit of acceleration, amax is the upper limit of acceleration, and a(t) is the change of acceleration over time.

5. The unmanned slag removal control system for an ironmaking plant according to claim 4, characterized in that: The safety monitoring system is set up according to the national standard GB28264-2012 "Crane Machinery Safety Monitoring and Management System". The safety monitoring host is connected to the PLC system via Ethernet, reads the data in the PLC, and stores it in the storage unit in the safety monitoring host. The data storage cycle is within 100ms; The safety monitoring system monitors the status of all contactors, including the current and voltage of the stator and rotor of the main hook motor. The overhead crane's safety monitoring system is equipped with historical curves, real-time curves, real-time status, control flow, and fault statistics functions.

6. The unmanned slag removal control system for an ironmaking plant according to claim 5, characterized in that: The slag amount calculation model system collects the flow field and water-slag amount data of the slag pile according to the laser radar, and then processes the 3D cloud map data of the slag pile, calculates the volume and weight of the slag pile, calculates the volume and weight of the remaining pileable materials in the slag pile, and performs vector modeling of the entire slag pile; The collection and processing methods of LiDAR data, including data reading, display, straight line fitting, corner point extraction, arc fitting and pose calculation; The laser radar data collection and reading: When the laser radar is working, it emits laser pulses and calculates the distance of the target by measuring the time it takes for the pulses to reflect back; the data reading involves analyzing the received signal, including time, intensity, and angle information, and converting it into point cloud data; Data display: Point cloud data is stored in the form of 3D coordinates. Coordinate.cpp is used to process the code for coordinate conversion and display the point cloud data on the screen in real time. Linear fitting: In the point cloud data, WeightedFit.cpp is used to perform weighted linear fitting based on the least squares method. By clustering and screening the point cloud data, a point set with a linear trend is found, and then fitting is performed to obtain a linear model; Corner point extraction: Harris corner point detection is used to identify key points for object recognition and positioning; Arc fitting: Use WeightedFit.h to provide arc fitting algorithm; Pose solution: Use Kalman filtering or particle filtering to estimate the motion parameters of the radar by comparing the point cloud differences between consecutive frames to complete the pose solution.

7. The unmanned slag removal control system for an ironmaking plant according to claim 6, characterized in that: The video surveillance system adopts a full network digital video surveillance architecture: the front end uses a high-definition network camera for video acquisition, which is directly connected to the video transmission network of the warehouse area through the network port of the camera, and transmitted to the back end for centralized storage and management. The transmission backbone network adopts a gigabit optical fiber network, and the back end completes the centralized preview, control, management, storage and video distribution of the entire video surveillance system through a centralized management platform, realizing centralized management of the warehouse area high-definition digital video surveillance system.

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