All-DP communication batching scale data acquisition and control method

Abstract

The invention relates to a full-DP communication batching scale data acquisition and control method, and the method comprises the steps: carrying out the bidirectional data acquisition of the related parameters of a batching scale through a PLC (Programmable Logic Controller) by utilizing a field bus technology, such as the actual flow, given flow, stock bin value, speed, belt load, accumulation, frequency converter control value, operation, alarm, fault reset and other data; the discharging amount of the batching scale is accurately controlled by setting a flow value in a communication mode, the discharging amount of a dragging belt is accurately controlled by setting a stock bin value, the deviation value does not exceed + / -0.2%, and the accuracy state of the batching scale can be pre-judged on line through the load and speed of the belt. According to the DP communication of the method, the functions of the batching scale are realized to the greatest extent, PID parameters are accurately corrected, accurate batching of the batching system is realized, the cable laying amount is greatly reduced, the workload of maintenance personnel is reduced, the labor cost is reduced, the accuracy state of the batching scale is pre-judged on line, and the batching accuracy is improved.

Description

Technical Field

[0001] This patent application belongs to the field of metallurgical equipment technology, and more specifically, it relates to a data collection and control method for a batching scale with full DP communication. Background Art

[0002] Batching is an extremely important link in the sintering production process. It is a process of accurately mixing different iron-containing raw materials, fluxes (quicklime, dolomite, etc.), return ore and fuel according to a preset ratio, and finally transporting them to the sintering machine for high-temperature sintering. After cooling and screening, sintered ore is produced. The mixing process requires a batching scale. The accurate batching of the batching scale is the prerequisite for improving the quality of sintered ore and is of great significance to reducing sintering costs.

[0003] The batching scales currently in use generally use hard wiring to read and control signals. The relevant data of the batching scales that can be read and controlled is relatively small, and the alarm information is not perfect, which cannot effectively improve the accuracy and pre-judgment effect of the batching scales. Combined with current technology, communication is the mainstream direction of the future development of automation instruments, with the characteristics of large data reading, online fault diagnosis, reduced cable laying, and reduced manual maintenance costs.

[0004] Therefore, the batching process needs to use communication methods to read data such as actual flow, given flow, silo value, speed, belt load, cumulative value, inverter control value, as well as operation, alarm, fault reset, etc., so as to achieve large data reading volume, perfect control function, and ensure the accuracy of batching. Summary of the invention

[0005] The technical problem to be solved by the present invention is to provide a data collection and control method for a batching scale with full DP communication. The existing batching scale and hardware equipment are used to redevelop a batching control program. The batching scale data is collected and controlled through DP communication. Data is collected in both directions to maximize the function of the batching scale and achieve accurate batching of the batching system. At the same time, the amount of cable laying is greatly reduced, the workload of maintenance personnel is reduced, and labor costs are reduced. In addition, the accuracy status of the batching scale can be pre-judged online through the belt load and speed.

[0006] In order to solve the above problems, the technical solution adopted by the present invention is: A method for data collection and control of a batching scale with full DP communication, comprising the following steps: S1. System configuration: Parameter configuration and address setting of multiple batching scales are performed through PLC hardware configuration to form PROFIBUS network units; in order to eliminate signal reflection in the communication cable, each PROFIBUS network unit sets the terminal resistance; S2. Data collection and control: The batching system consists of a batching scale, DP cable, gateway module IE-PB-link, PLC (programmable controller), etc. The hardware configuration, networking, and programming of the batching system are carried out, and bidirectional data collection is carried out through the relevant parameters in the GSD file of the batching scale; S3. Online pre-judgment: The batching system pre-judges the accuracy status of the batching scale online through operating parameters, and the operating parameters include but are not limited to one or more of belt load and speed.

[0007] Further, in S1, the PLC hardware configuration refers to: S11. Divide multiple batching scales into N communication units, N ≥ 2, and distribute batching scales of the same batching variety in different PROFIBUS network units. The purpose is: when a communication unit fails, different batching varieties will not be lost, the batching system will not be shut down, and the factors affecting production will be minimized; S12, the address of the PROFIBUS network unit set by the batching scale is 11~33, and the PPO12:0 PKW, 4 Set, 14 PZD type communication message structure is selected; each communication unit is connected to a gateway module IE-PB-link, and the gateway module IE-PB-link is connected to the main switch.

[0008] Furthermore, the data collection and control in S2 refers to reading and collecting the hexadecimal ID codes of the batching scale's actual flow, given flow, silo value, speed, belt load, accumulation, inverter control value, and operation, alarm, fault reset and other data (as shown in Table 1), and accurately controlling the discharge amount of the batching scale through the quantitative value, and accurately controlling the discharge amount of the traction belt conveyor through the silo value. The traction belt conveyor is used in conjunction with the batching scale.

[0009] Furthermore, in the “precise control of the material discharge amount of the batching scale through the quantitative value, and the precise control of the material discharge amount of the dragging belt through the silo value”, the deviation value does not exceed ±0.2%.

[0010] Furthermore, in S3, the trend changes of belt load (kg / m) and speed (m / s), according to the reasonable range of upper and lower limit fluctuations (±5kg / m range, 0.008m / s range), and the historical data trend chart are used to comprehensively judge the operating status of the accuracy of the batching scale and detect abnormal situations in time.

[0011] Through the trend change of belt load (kg / m), according to the reasonable range of upper and lower limit fluctuations (within ±5kg / m), it is found through the historical data trend chart that the belt load (kg / m) trend chart moves forward in a rectangular shape, indicating that the load of the batching scale is in a stable state. If there are upward or downward diamond shapes in the trend chart, it indicates that the zero point of the batching scale is drifting, and it is necessary to check for mechanical jamming, belt deviation, or instrument maintenance personnel to calibrate the zero point. When the proportion does not change, the belt speed (m / s) is within the reasonable range of 0.008m / s, and observing the trend chart is equivalent to the belt load (kg / m).

[0012] Furthermore, an alarm value is provided, and a function reminder is provided through the alarm value.

[0013] Due to the adoption of the above technical solution, the beneficial effects achieved by the present invention are: The present invention utilizes existing batching scales and hardware equipment to develop a batching control program, and adopts PROFIBUS-DP communication mode to collect and control batching scale data. This mode has the advantages of high speed and low cost, and is used for communication between equipment and control system and distributed I / O, so that the function of the batching scale can be maximized.

[0014] The method of the present invention can read data such as actual flow, given flow, silo value, speed, belt load, cumulative value, inverter control value, and operation, alarm, fault reset, etc., and can realize large-scale data reading. At the same time, the control function is perfect, and PID parameters can be accurately corrected to achieve accurate batching of the batching system, greatly reduce the amount of cable laying, reduce the workload of maintenance personnel, reduce labor costs, and pre-judge the accuracy status of the batching scale online, so as to effectively improve the batching accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 is a hardware configuration diagram of the present invention; Figure 2 It is the material control diagram of the present invention; Figure 3 is the silo control diagram of the present invention; Figure 4 It is a load trend diagram of the batching scale belt of the present invention; Figure 5 It is a trend diagram of the belt speed of the batching scale of the present invention. DETAILED DESCRIPTION

[0016] The present invention is further described in detail below with reference to the embodiments.

[0017] A method for data acquisition and control of batching scales with full DP communication, which uses PLC to use PROFIBUS fieldbus technology to perform bidirectional data acquisition on GSD (electronic database file) related parameters in the batching scale, such as actual flow, given flow, silo value, speed, belt load, accumulation, inverter control value, and operation, alarm, fault reset and other data, to achieve precise control of the discharge amount of the batching scale through quantitative values, and precise control of the discharge amount of the dragging belt by the silo value, with the control deviation value not exceeding ±0.2%.

[0018] The batching scale system consists of a quantitative feeder control system and a traction belt conveyor control system. The quantitative feeder control system consists of a belt conveyor, a batching scale, a motor, a frequency converter, a DP cable, a gateway module IE-PB-link, a PLC (programmable controller), etc. The batching scale consists of a batching meter, a speed measuring device, and a weighing sensor. Its working method is that the host computer sends a set flow and an intermediate bin set value to the batching meter. The batching scale is adjusted by its own PID, and the PID parameters are finely set to control the output to the feeder frequency converter and the traction belt conveyor frequency converter respectively, and control the speed of the on-site motor to achieve precise control.

[0019] The technical solution of the present invention comprises the following steps: S1. System configuration: Parameter configuration and address setting of multiple batching scales are performed through PLC hardware configuration to form PROFIBUS network units; in order to eliminate signal reflection in the communication cable, each PROFIBUS network unit sets the terminal resistance.

[0020] The PLC hardware configuration is: divide multiple batching scales into N communication units, N ≥ 2, and the batching scales of the same batching variety are distributed in different PROFIBUS network units. Now take the actual sintering plant batching scale configuration as an example, there are a total of 23 batching scales, which are divided into 5 communication units.

[0021] The PROFIBUS address set for the batching scale is 11-33, and the PPO12:0 PKW, 4 Set, 14 PZD communication message structure is selected. Each communication unit is connected to a gateway module IE-PB-link, which is a DP to network port communication device. The gateway module IE-PB-link communicates with the main switch and uses the TCP / IP protocol to communicate with the S7-400H to exchange data. When a communication unit fails, different batching varieties will not be lost, and the batching system will not shut down, which will minimize the factors affecting production.

[0022] like Figure 1The hardware configuration diagram shown has five gateway modules, namely (124)IE, (125)IE, (123)IE, (121)IE, and (122)IE. The five gateway modules are respectively connected to PROFIBUS (3):DP master system (2981), PROFIBUS (4):DP master system (2980), PROFIBUS (3):DP master system (2982), PROFIBUS (3):DP master system (2984), and PROFIBUS (3):DP master system (2983).

[0023] S2. Data collection and control are as follows: Since the batching system is composed of a batching scale, DP cable, gateway module IE-PB-link, PLC (programmable controller), etc., the batching system is hardware configured, networked, and programmed, and bidirectional data collection is performed through the relevant parameters in the GSD file of the batching scale.

[0024] In actual operation, the hexadecimal ID code (HEX) of the batching scale actual flow, given flow, silo value, speed, belt load, accumulation, inverter control value, and operation, alarm, fault reset and other data are read and collected, as shown in the communication address table in Table 1, and the program is developed in the PLC software for programming and control. The traction belt conveyor is used in conjunction with the batching scale to ultimately achieve the following goals: the unloading amount of the batching scale is accurately controlled by the quantitative value, and the unloading amount of the traction belt conveyor is accurately controlled by the silo value, and the deviation value does not exceed ±0.2%.

[0025]

[0026] Table 1 Figure 2 This is a fixed material control chart. The feeding equipment are 1#, 2#, 3#, 4#, 5#, 6#, 7_1#, 7_2#. The first six are mixed materials, and the last two are quicklime. The ratios are set to 10.00, 15.40, 17.00, 15.00, 17.00, 10.00, 1.2, and 2.4. The set outputs are 64.1 / 98.8 / 109.0 / 96.2 / 109.0 / 64.1 / 7.7 / 15.4, and the actual flow rates are +64.1, +98.9, +108.9, +96.4, +110.1, +63.9, +7.7, and +15.4, respectively. The accumulated flow rates are: 11246 / 7928 / 13322 / 12336 / 13267 / 6106 / 935 / 1696. The total amount of the first six feeding devices is 64205, and the total amount of the last two feeding devices is 2632.

[0027] Figure 3This is the silo control diagram. The feeding equipment are 1#, 2#, 3#, 4#, 5#, 6#, 7_1#, and 7_2#. The first six are mixed materials, and the last two are quicklime. The set silo values ​​are 3.00, 3.00, 3.00, 3.00, 3.00, 3.00, 1.00, and 1.00 (light font under the trapezoid). The actual silo values ​​displayed are 3.00 / 3.00 / 3.00 / 3.00 / 3.00 / 3.00 / 1.00 / 1.01 (font inside the trapezoid). By comparing the two, it can be seen that the error is very small and the control accuracy is high.

[0028] S3. Online pre-judgment: The batching system pre-judges the accuracy of the batching scale online through operating parameters, including but not limited to one or more of belt load and speed. Through the trend changes of belt load (kg / m) and speed (m / s), according to the reasonable range of upper and lower limit fluctuations (with a range of ±5kg / m and 0.008m / s), and through the historical data trend chart, the accuracy of the batching scale is comprehensively judged and abnormal conditions are discovered in time.

[0029] Figure 4 This is the load trend diagram of the batching scale belt. The project is subdivided into feeding equipment (1#~17#), ore trough selection (mixed material, quicklime, dolomite, dust removal ash, fuel, high return, burnt return), belt speed (0.06791 / 0.08163 / 0.02357 / 0.01428 / 0.028340.10919, etc.), belt load (0.36189 / 0.29191 / 0.08489 / 0.05446 / 0.07365 / 0.10965 / 0.09435 / 0.30978, etc.), set output (88.4 / 80.7 / 12.7 / 45.9 / 15.3 / 114.8, etc.), actual flow (+88.5, +79.0, +12.7, +45.8, +15.1, +114.6, etc.), and the trend chart is in the middle. Through the trend change of belt load (kg / m), according to the reasonable range of upper and lower limits (with a range of ±5kg / m), it is found through the historical data trend chart that the belt load (kg / m) trend chart moves forward in a rectangular shape, indicating that the load of the batching scale is in a stable state. If there is an upward or downward diamond shape in the trend chart, it indicates that the zero point of the batching scale is drifting, and it is necessary to check the mechanical jamming, belt deviation or instrument maintenance personnel to check the zero point.

[0030] Figure 5This is the trend chart of the batching scale belt speed. The project is subdivided into feeding equipment (1#~17#), ore tank selection (mixed material, quicklime, dolomite, dust removal ash, fuel, high return, burn return), belt speed (0.06827 / 0.02356 / 0.01435 / 0.04132, etc.), belt load (0.36048 / 0.29129 / 0.08584 / 0.07555 / 0.03515 / 009450 / 0.29454, etc.), set output (88.4 / 80.7 / 12.7 / 45.9 / 15.3 / 114.8, etc.), actual flow (+88.6, +81.5, +12.6, +46.0, +15.5, +114.4, etc.), etc., and the trend chart is in the middle. Through the trend change of belt speed (m / s), according to the reasonable range of upper and lower limit fluctuations (with a range of ±0.008m / s), it is found through the historical data trend chart that when the ratio does not change, the belt speed (m / s) trend chart moves in a rectangular shape within the reasonable range of 0.008m / s, indicating that the speed of the batching scale is controlled in a stable state. If there are upward or downward diamond shapes in the trend chart, it indicates that the zero point of the batching scale is drifting or there is a lack of material or overflow. Please ask the instrument maintenance personnel to check the zero point or the post personnel to check the process conditions, etc.

[0031] The batching scale belt load trend chart and the batching scale belt speed trend chart are both equipped with alarm values. Function reminders are provided through alarm values, which are more intuitive and eye-catching, and facilitate the collection and control of batching scale data.

Claims

1. A method for data collection and control of batching scales with full DP communication, characterized in that The following steps are involved: S1. System configuration: Parameter configuration and address setting of multiple batching scales are performed through PLC hardware configuration to form PROFIBUS network units; in order to eliminate signal reflection in the communication cable, each PROFIBUS network unit sets the terminal resistance; S2, Data collection and control: Hardware configuration, networking, programming of the batching system, and bidirectional data collection through the relevant parameters in the GSD file of the batching scale; S3. Online pre-judgment: The batching system pre-judges the accuracy status of the batching scale online through operating parameters, and the operating parameters include but are not limited to one or more of belt load and speed.

2. According to claim 1, a method for data collection and control of batching scales with full DP communication, characterized in that: In S1, PLC hardware configuration refers to: S11, dividing multiple batching scales into N communication units, N ≥ 2, and batching scales belonging to the same batching variety are distributed in different PROFIBUS network units; S12, the address of the PROFIBUS network unit set by the batching scale is 11-33, and the communication message structure of PPO12:0 PKW, 4 Set, 14PZD is selected; Each communication unit is connected to a gateway module IE-PB-link, and the gateway module IE-PB-link is connected to the main switch.

3. The method for data collection and control of a batching scale with full DP communication according to claim 2 is characterized in that: The data collection and control in S2 refers to reading and collecting the hexadecimal ID codes of the batching scale's actual flow, given flow, silo value, speed, belt load, accumulation, inverter control value, and operation, alarm, fault reset and other data, and accurately controlling the batching scale's discharge amount through the quantitative value, and accurately controlling the silo value's discharge amount of the dragging belt conveyor. The dragging belt conveyor is used in conjunction with the batching scale.

4. The method for data collection and control of a batching scale with full DP communication according to claim 3 is characterized in that: In "accurately control the discharge amount of the batching scale through the quantitative value, and accurately control the discharge amount of the dragging belt through the silo value", the deviation value does not exceed ±0.2%.

5. The method for data collection and control of a batching scale with full DP communication according to claim 1 is characterized in that: In S3, the accuracy status of the batching scale is comprehensively judged through the trend changes of belt load and speed, according to the reasonable range of upper and lower limit fluctuations, and through the historical data trend chart, and abnormal situations are discovered in time.

6. The method for data collection and control of a batching scale with full DP communication according to claim 5 is characterized in that: An alarm value is also provided, through which function reminders are given.

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