Angle calibration method for stacker-reclaimer in circular coal yard

Abstract

The invention discloses a circular coal yard stacker-reclaimer angle calibration method, and relates to the technical field of coal storage and transportation equipment control, and the method comprises the steps: uniformly arranging a plurality of intelligent memory cards in a rotary track of a circular coal yard stacker-reclaimer along the circumferential direction, and writing angle values of corresponding positions into the intelligent memory cards; an encoder and a microwave reader-writer are installed on a stacking mechanism, a taking mechanism and a swing mechanism of the stacker-reclaimer respectively, the encoder collects real-time angle data of all the mechanisms, and the microwave reader-writer reads the angle value in the intelligent memory card. Multi-point real-time angle calibration is achieved through the microwave recognition technology, the problem that traditional mechanical calibration is prone to being affected by environment interference and gear gaps is solved, the angle detection precision and operation efficiency of the stacker-reclaimer are improved, the equipment maintenance cost is reduced, and intelligent control is achieved.

Description

Technical Field

[0001] The invention relates to the technical field of coal storage and transportation equipment control, and in particular to an angle calibration method for a circular coal yard stacker and reclaimer. Background Art

[0002] With the rapid development of the coal power industry, circular coal yards have been widely used as important coal storage facilities in thermal power plants. The stacker-reclaimer in the circular coal yard is the core equipment of the coal storage and transportation system, and its operating accuracy directly affects the storage efficiency and blending quality of coal. The traditional stacker-reclaimer angle measurement system mainly relies on mechanical encoders and photoelectric encoders for angle detection. These devices are easily affected by the environment and produce cumulative errors during long-term operation. At the same time, due to the prevalence of unfavorable factors such as dust, vibration and temperature changes in the coal yard environment, the measurement accuracy of the encoder gradually decreases, and angle deviations are prone to occur during the start-up and shutdown of the equipment, requiring frequent zero-point calibration, which seriously affects the operating efficiency of the stacker-reclaimer.

[0003] The existing stacker-reclaimer angle calibration technology mainly adopts a fixed reference point calibration method, that is, a limit switch or proximity switch is set at the zero position, and the switch is triggered by a mechanical device to achieve angle calibration. This method has the following technical defects: First, the calibration process requires the equipment to be rotated to the zero position, which reduces the continuous operation capacity of the equipment; second, the mechanical switch is easily affected by coal dust pollution and mechanical wear, resulting in inaccurate triggering; third, a single fixed point calibration cannot effectively solve the angle error caused by gear clearance, especially when the equipment changes the direction of rotation, the clearance of the mechanical transmission system will produce significant angle deviation. In addition, the existing angle calibration technology lacks real-time and intelligent features, and cannot meet the requirements of refined management of modern coal yards.

[0004] In view of the above technical problems, the present invention provides a circular coal yard stacker-reclaimer angle calibration method based on microwave recognition. The invention evenly arranges smart storage cards on the rotary track and uses microwave reading and writing technology to achieve real-time calibration of the angle, belonging to the field of coal storage and transportation equipment control technology. The present invention solves the technical problems of poor real-time performance, low precision, and great environmental influence in the traditional stacker-reclaimer angle calibration, and provides a new technical solution for improving the operation accuracy and work efficiency of the stacker-reclaimer. Summary of the invention

[0005] In view of the above-mentioned problems, the present invention is proposed.

[0006] Therefore, the present invention provides a circular coal yard stacker-reclaimer angle calibration method, which can solve the problems mentioned in the background technology.

[0007] In order to solve the above technical problems, the present invention provides the following technical solutions: A circular coal yard stacker-reclaimer angle calibration method, comprising: S1: a plurality of smart memory cards are evenly arranged along the circumferential direction of the rotary track of the circular coal yard stacker-reclaimer, and the angle values ​​of the corresponding positions are written into the smart memory cards;

[0008] S2: Install encoders and microwave readers on the stacking mechanism, reclaiming mechanism and rotary mechanism of the stacker-reclaimer, respectively. The encoder collects real-time angle data of each mechanism, and the microwave reader reads the angle value in the smart memory card;

[0009] S3: Compare the angle value read by the microwave reader with the real-time angle data collected by the encoder. When there is a deviation between the real-time angle data collected by the encoder and the angle value in the smart memory card, calibrate the encoder according to the angle value in the smart memory card.

[0010] As a preferred solution of the circular coal yard stacker-reclaimer angle calibration method of the present invention, wherein: a plurality of smart memory cards are evenly arranged along the circumferential direction of the rotary track of the circular coal yard stacker-reclaimer, and the angle values ​​of the corresponding positions are written into the smart memory cards, including the following steps:

[0011] Establish an angle positioning coordinate system based on the stacker-reclaimer;

[0012] In the angle positioning coordinate system, the zero position of the stacker-reclaimer is taken as the reference point, and the encoder value of the reference point is set to a preset value;

[0013] Multiple smart memory cards are evenly arranged along the circumferential direction of the stacker-reclaimer rotary track, and an angle value corresponding to its installation position is written into each smart memory card, wherein the angle value includes a clockwise rotation angle value and a counterclockwise rotation angle value.

[0014] As a preferred solution of the circular coal yard stacker-reclaimer angle calibration method of the present invention, wherein: the multiple smart memory cards are evenly arranged along the circumferential direction of the stacker-reclaimer rotary track, and the angle value corresponding to the installation position thereof is written into each smart memory card, wherein the angle value includes a clockwise rotation angle value and a counterclockwise rotation angle value, comprising the following steps:

[0015] Install the first smart memory card at the zero point and set the angle value of the smart memory card to zero degrees;

[0016] Based on the encoder value at the zero point, calculate the encoder value corresponding to each installation point in the clockwise and counterclockwise directions. If the encoder rotates clockwise at 360 degrees, set the encoder value to the value corresponding to zero degrees. If the encoder rotates counterclockwise at 0 degrees, set the encoder value to the value corresponding to 360 degrees.

[0017] The calculated encoder value is written into the smart memory card at the corresponding position, wherein each smart memory card is written with the angle value of the position in both clockwise and counterclockwise rotation. If an angle deviation caused by gear clearance is detected, the clockwise angle value of the corresponding position is increased by a preset compensation amount, and the counterclockwise angle value is decreased by a preset compensation amount.

[0018] As a preferred solution of the circular coal yard stacker-reclaimer angle calibration method of the present invention, wherein: an encoder and a microwave reader are respectively installed on the stacking mechanism, the reclaiming mechanism and the rotary mechanism of the stacker-reclaimer, the encoder collects the real-time angle data of each mechanism, and the microwave reader reads the angle value in the smart memory card, comprising the following steps:

[0019] Encoders are respectively arranged on the stacking mechanism, the retrieving mechanism and the rotating mechanism of the stacker-reclaimer, and the encoders rotate with the corresponding mechanisms and count and record the rotation pulses;

[0020] Convert the pulse signal recorded by the encoder into real-time angle data and transmit it to the stacker-reclaimer control PLC;

[0021] A microwave reader is installed on the stacking mechanism, the retrieving mechanism and the rotating mechanism. The microwave reader rotates with the mechanism. When it rotates into the radio frequency signal range of the smart memory card, it reads the angle value stored in the smart memory card and transmits the angle value to the stacker-reclaimer control PLC.

[0022] As a preferred solution of the circular coal yard stacker-reclaimer angle calibration method of the present invention, wherein: a microwave reader is installed on the stacking mechanism, the reclaiming mechanism and the slewing mechanism, and the microwave reader rotates with the mechanism. When the microwave reader rotates to the radio frequency signal range of the smart memory card, the angle value stored in the smart memory card is read and the angle value is transmitted to the stacker-reclaimer control PLC, including the following steps:

[0023] The microwave reader continuously emits microwave signals as the stacker-reclaimer mechanism rotates. When it is detected that the microwave signal interacts with the smart memory card, it is determined that the stacker-reclaimer mechanism has rotated to a preset angle position.

[0024] If signal interaction is detected, the microwave reader reads the angle value stored in the smart memory card and selects the corresponding clockwise angle value or counterclockwise angle value according to the actual rotation direction of the stacking and reclaiming mechanism;

[0025] The read angle value is transmitted together with the rotation direction information of the stacker-reclaimer mechanism to the stacker-reclaimer control PLC. If a data transmission abnormality is detected during the transmission process, the reading operation is re-executed until the data transmission is successful.

[0026] As a preferred solution of the circular coal yard stacker-reclaimer angle calibration method of the present invention, wherein: the angle value read by the microwave reader is compared with the real-time angle data collected by the encoder, and when there is a deviation between the real-time angle data collected by the encoder and the angle value in the smart memory card, the encoder is calibrated according to the angle value in the smart memory card, including the following steps:

[0027] The stacker-reclaimer control PLC receives the real-time angle data transmitted by the encoder and the angle value of the smart memory card read by the microwave reader;

[0028] The data processing unit compares and calculates the real-time angle data of the encoder with the angle value of the smart storage card to obtain the angle deviation value;

[0029] When the angle deviation value is detected, the calibration unit corrects the real-time angle data of the encoder according to the angle value of the smart memory card, and uses the corrected angle data as the actual position angle value of the stacker-reclaimer.

[0030] As a preferred solution of the circular coal yard stacker-reclaimer angle calibration method of the present invention, wherein: when the angle deviation value is detected, the calibration unit corrects the real-time angle data of the encoder according to the angle value of the smart memory card, and uses the corrected angle data as the actual position angle value of the stacker-reclaimer, including the following steps:

[0031] If the angle deviation value is less than the preset threshold, the real-time angle data of the encoder is kept unchanged; if the angle deviation value is greater than or equal to the preset threshold, the calibration operation is triggered;

[0032] When the calibration operation is triggered, the calibration unit writes the angle value of the smart memory card into the counting register of the encoder, and selects the corresponding angle compensation value according to the rotation direction of the stacker-reclaimer, wherein the angle value increases by a first preset compensation amount when rotating clockwise, and decreases by a second preset compensation amount when rotating counterclockwise;

[0033] The calibrated angle value is transmitted to the display unit and used as the reference angle of the stacker-reclaimer at that position, and subsequent angle changes are continuously recorded until the next smart memory card is detected.

[0034] To further solve the above technical problems, the present invention provides the following technical solutions: A circular coal yard stacker-reclaimer angle calibration device based on microwave recognition, comprising: an arrangement module, used to evenly arrange a plurality of smart memory cards along the circumferential direction of the rotary track of the circular coal yard stacker-reclaimer, wherein the angle values ​​of the corresponding positions are written into the smart memory cards;

[0035] A monitoring module is used to install an encoder and a microwave reader on the stacking mechanism, the reclaiming mechanism and the rotary mechanism of the stacker-reclaimer, respectively, wherein the encoder collects the real-time angle data of each mechanism and the microwave reader reads the angle value in the smart memory card;

[0036] The calibration module is used to compare the angle value read by the microwave reader with the real-time angle data collected by the encoder. When there is a deviation between the real-time angle data collected by the encoder and the angle value in the smart memory card, the encoder is calibrated according to the angle value in the smart memory card.

[0037] A computer device comprises a memory and a processor, wherein the memory stores a computer program, and is characterized in that when the processor executes the computer program, the steps of the circular coal yard stacker-reclaimer angle calibration method as described above are implemented.

[0038] A computer-readable storage medium having a computer program stored thereon, characterized in that when the computer program is executed by a processor, the steps of the circular coal yard stacker-reclaimer angle calibration method as described above are implemented.

[0039] The beneficial effects of the present invention are as follows: by evenly arranging multiple smart memory cards on the rotating track, multi-point real-time calibration of the stacker-reclaimer during operation is achieved, without the need to specifically rotate to the zero position for calibration, thereby ensuring the continuous operation efficiency of the equipment. The angle compensation mechanism in both clockwise and counterclockwise directions effectively solves the problem of angle deviation caused by gear clearance and improves the accuracy of angle calibration. The use of microwave recognition technology to replace traditional mechanical or photoelectric angle detection methods avoids the influence of environmental factors such as coal dust and vibration on the detection device, and improves the environmental adaptability and reliability of the system. The smart memory card adopts a non-contact reading method, without mechanical wear, which reduces the maintenance frequency of the equipment and reduces the operation and maintenance costs. The angle calibration process is fully automated, realizing automatic data collection, comparison and calibration, reducing manual intervention and improving the intelligence of the equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative work.

[0041] Figure 1 The overall flow chart of the present invention;

[0042] Figure 2 The rotation and pitch recording diagram of the stacker-reclaimer proposed by the present invention;

[0043] Figure 3 A network topology diagram for positioning and calibration of the stacker-reclaimer proposed in the present invention;

[0044] Figure 4 The operation step diagram proposed by the present invention;

[0045] Figure 5 A diagram of a computer device proposed for the present invention. DETAILED DESCRIPTION

[0046] In order to make the above-mentioned purposes, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the drawings of the specification. Obviously, the described embodiments are part of the embodiments of the present invention, but not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary persons in the art without creative work should fall within the scope of protection of the present invention.

[0047] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0048] Example 1, reference Figure 1 , is an embodiment of the present invention, and provides a circular coal yard stacker-reclaimer angle calibration method, comprising:

[0049] S1: A smart memory card is installed every 60 degrees on the rotary track of the circular coal yard stacker and reclaimer, and the angle value of the corresponding position is written into the smart memory card;

[0050] S11: Establishing an angle positioning coordinate system based on the stacker-reclaimer;

[0051] It should be noted that in traditional technology, stackers usually rely on zero limit switches as angle references. This single reference point measurement method causes angle errors to accumulate as the equipment rotates. At the same time, due to the lack of a complete angle coordinate system, there is a lack of unified standards for angle compensation when the equipment moves in different directions. Especially in the presence of gear clearance, the angle measurement accuracy is difficult to guarantee. First, the coordinate system provides a clear position reference for the subsequent arrangement of smart storage cards, so that the angle values ​​of each measuring point have a unified benchmark, ensuring the consistency of the measurement standard; secondly, because the coordinate system takes into account the angle difference of the stacker at different steering directions, it provides a theoretical basis for angle compensation in the clockwise and counterclockwise directions, and solves the measurement error caused by gear clearance; thirdly, the coordinate system achieves full-cycle angle coverage, avoiding the problem of frequent zero calibration in traditional technology, and improving the continuous operation capacity of the equipment. These improvements are achieved on the basis of fully considering the actual operating characteristics of the stacker, mainly reflected in the improvement of the systematicness and practicality of the measurement benchmark, laying the foundation for achieving high-precision angle calibration.

[0052] S12: In the angle positioning coordinate system, the zero position of the stacker-reclaimer is used as a reference point, and the encoder value of the reference point is set to a preset value;

[0053] It should be noted that by installing smart memory cards at preset angle intervals on the stacker-reclaimer rotary track, a plurality of angle calibration measuring points distributed in a ring are constructed, which effectively solves the key problems in the traditional stacker-reclaimer angle calibration system. In the prior art, angle calibration usually relies on a single point or a small number of fixed points. This method leads to insufficient coverage of calibration points and too large intervals. When the stacker-reclaimer runs a long distance between two calibration points, factors such as mechanical wear and environmental interference will cause the angle measurement error to gradually accumulate, seriously affecting the positioning accuracy of the equipment. To address this problem, this step adopts a uniformly distributed multi-point calibration scheme, which effectively reduces the error accumulation effect by shortening the angle interval between adjacent calibration points, ensuring that the stacker-reclaimer can obtain timely calibration data at any position. At the same time, the use of smart memory cards with non-contact microwave recognition technology to replace traditional mechanical or photoelectric calibration devices not only overcomes the effects of coal dust pollution and mechanical wear, but also significantly improves the environmental adaptability and service life of the calibration system. This ring-distributed measuring point network provides reliable data support for achieving all-round angle calibration by storing standard angle values ​​at each measuring point. Although these improvements are optimizations based on existing angle measurement technology, they have significant advantages in the rationality of calibration point distribution and the reliability of measurement methods, effectively improving the accuracy and stability of the entire system and providing a strong guarantee for the precise positioning control of the stacker-reclaimer.

[0054] S13: evenly arranging multiple smart memory cards along the circumferential direction of the stacker-reclaimer rotary track, and writing an angle value corresponding to its installation position into each smart memory card, wherein the angle value includes a clockwise rotation angle value and a counterclockwise rotation angle value.

[0055] S131: Install the first smart memory card at the zero point, and set the angle value of the smart memory card to zero degrees;

[0056] S132: Based on the encoder value at the zero point position, the encoder values ​​corresponding to each installation point in the clockwise direction and the counterclockwise direction are calculated respectively. If the encoder value is rotated clockwise at the 360-degree position, the encoder value is set to the value corresponding to zero degrees. If the encoder value is rotated counterclockwise at the 0-degree position, the encoder value is set to the value corresponding to 360 degrees.

[0057] S133: Write the calculated encoder value into the smart memory card at the corresponding position, wherein each smart memory card writes the angle value of the position in both clockwise and counterclockwise rotation. If an angle deviation caused by gear clearance is detected, the clockwise angle value of the corresponding position increases by a preset compensation amount, and the counterclockwise angle value decreases by a preset compensation amount.

[0058] It should be noted that by installing a microwave reader on the stacker and reclaimer and connecting the angle encoder with the calibration unit, a complete angle detection and calibration system is formed, which effectively solves the key technical problems faced by the traditional stacker and reclaimer angle measurement system in practical applications. In the prior art, the angle measurement device often operates independently and lacks an effective calibration mechanism, which makes it difficult to correct the accumulated errors in the long-term operation process in a timely manner. At the same time, traditional contact or photoelectric sensors are easily interfered in harsh coal yard environments, affecting the reliability of the measurement. This step establishes a closed-loop angle detection and calibration mechanism by combining microwave reading and writing technology with angle encoder measurement. The microwave reader can accurately identify the standard angle value stored in the smart memory card in a non-contact state. This non-contact data acquisition method not only avoids mechanical wear, but also has strong anti-interference ability, and can maintain stable operation even in dusty and vibrating environments. When the microwave reader detects the smart memory card, the calibration unit will immediately compare the standard angle value in the memory card with the real-time angle of the encoder, and perform real-time calibration when necessary. This timely response calibration mechanism effectively prevents the accumulation of angle errors. Especially when considering the influence of gear clearance, the system can automatically select the corresponding compensation strategy according to the movement direction of the stacker and reclaimer to ensure the accuracy of angle measurement. This integrated design not only improves the reliability and accuracy of the system, but also simplifies maintenance work, providing a solid technical foundation for the precise control of the stacker and reclaimer. Although these improvements are based on existing technologies, their advantages in system integration and practical application provide a practical and effective solution to the problem of angle measurement of stackers and reclaimers.

[0059] S2: Encoders and microwave readers are installed on the stacking mechanism, reclaiming mechanism and rotary mechanism of the stacker-reclaimer respectively. The encoder collects the real-time angle data of each mechanism, and the microwave reader reads the angle value in the smart memory card;

[0060] S21: Encoders are respectively arranged on the stacking mechanism, the reclaiming mechanism and the rotary mechanism of the stacker-reclaimer, and the encoders rotate along with the corresponding mechanisms and count and record the rotation pulses;

[0061] It should be noted that by collecting the angle deviation data of the stacker and reclaimer in both clockwise and counterclockwise directions, the problem of inaccurate angle measurement caused by gear clearance in the mechanical transmission system of the stacker and reclaimer is solved. In traditional measurement methods, the differential influence of gear clearance on angle measurement in different movement directions is often ignored, which leads to angle positioning errors when the equipment is reversing. Especially after the stacker and reclaimer has been running for a long time, gear wear will aggravate this error, and the traditional single angle compensation method is difficult to adapt to the characteristics of this dynamic change. This step innovatively proposes a two-way angle deviation acquisition scheme, by allowing the stacker and reclaimer to pass each measuring point in clockwise and counterclockwise directions respectively, and recording the deviation between the actual angle value and the standard angle value in the two directions. This data acquisition method fully considers the mechanical transmission characteristics and can accurately reflect the degree of influence of gear clearance in different movement directions. By comparing and analyzing these deviation data, the system establishes an angle compensation model related to the movement direction, providing a reliable data basis for subsequent precise calibration. This compensation mechanism based on actual operation data not only improves the accuracy of angle measurement, but also adapts to the operation requirements of the equipment under different working conditions, and effectively solves the problem of insufficient angle measurement accuracy in traditional technology. It is worth noting that although this improvement is an optimization of the existing technology, it has demonstrated its pertinence and effectiveness in solving actual engineering problems, providing a practical technical solution for improving the positioning accuracy of stacker-reclaimers.

[0062] S22: convert the pulse signal recorded by the encoder into real-time angle data and transmit it to the stacker-reclaimer control PLC;

[0063] It should be noted that by establishing a bidirectional angle compensation model, the angle deviation data of the stacker and reclaimer during clockwise and counterclockwise movement is systematically processed, which solves the technical problem that the traditional angle compensation method is difficult to cope with complex motion states. In the prior art, angle compensation usually adopts a single correction value, which cannot effectively handle the dynamic characteristics of the equipment in different motion directions, resulting in unsatisfactory angle calibration effect. Based on the measured angle deviation data, this step establishes independent compensation models for clockwise and counterclockwise directions, and converts discrete measurement data into continuous compensation curves through mathematical modeling methods. This bidirectional compensation mechanism fully considers the nonlinear characteristics of the mechanical transmission system and can provide corresponding compensation values ​​for specific situations of different positions and motion directions. In practical applications, the system automatically selects the corresponding compensation model according to the current motion direction of the stacker and reclaimer to realize intelligent adjustment of angle calibration. This adaptive compensation method based on direction recognition not only improves the accuracy of angle calibration, but also enhances the system's adaptability to changes in the dynamic characteristics of the equipment. Especially when considering long-term use factors such as gear wear and clearance changes, the bidirectional compensation model shows good adaptability and can continuously maintain a high calibration accuracy. Although this improvement is developed based on the existing angle compensation technology, it shows obvious technical advantages and practical value when dealing with angle calibration problems under complex motion states, and provides reliable technical support for improving the positioning accuracy of stacker reclaimers.

[0064] S23: Install microwave readers on the stacking mechanism, the retrieving mechanism and the rotating mechanism. The microwave readers rotate with the mechanisms. When they rotate to the radio frequency signal range of the smart memory card, they read the angle value stored in the smart memory card and transmit the angle value to the stacker-reclaimer control PLC.

[0065] S231: the microwave reader / writer continuously emits microwave signals as the stacker / reclaimer mechanism rotates, and when it is detected that the microwave signals interact with the smart memory card, it is determined that the stacker / reclaimer mechanism has rotated to a preset angle position;

[0066] S232: If signal interaction is detected, the microwave reader reads the angle value stored in the smart memory card, and selects a corresponding clockwise angle value or counterclockwise angle value according to the actual rotation direction of the stacking and reclaiming mechanism;

[0067] S233: The read angle value is transmitted together with the rotation direction information of the stacker-reclaimer mechanism to the stacker-reclaimer control PLC. If a data transmission abnormality is detected during the transmission process, the reading operation is re-executed until the data transmission is successful.

[0068] It should be noted that by establishing an angle compensation database, the system stores and manages compensation data under different operating conditions, which solves the problem of the lack of data support and historical analysis capabilities of the traditional angle calibration system. In the prior art, angle compensation data is often recorded or stored in a simple manner, which makes it difficult to accumulate and analyze trends over a long period of time, which limits the system's ability to adapt to changes in equipment status. This step innovatively constructs a special angle compensation database to systematically manage key data such as measurement point position, movement direction, standard angle value, measured angle value, and compensation value. This structured data storage method not only facilitates the rapid call of compensation data, but also provides a data basis for the evaluation of equipment operating status. By recording the historical change trend of the compensation value, the database can reflect the wear state and performance changes of the mechanical transmission system, providing a basis for predictive maintenance. At the same time, the system can dynamically optimize the compensation strategy based on the historical data in the database, so that the angle calibration effect is more in line with the actual operating characteristics of the equipment. Especially in the long-term operation of the equipment, this intelligent compensation mechanism based on data accumulation shows good adaptive ability and can respond to dynamic changes in equipment performance in a timely manner. Although this improvement is an optimization of the existing data management method, it has obvious advantages in improving the system's intelligence level and maintenance efficiency, and provides strong support for the precise control and condition monitoring of the stacker-reclaimer.

[0069] S3: Compare the angle value read by the microwave reader with the real-time angle data collected by the encoder. When there is a deviation between the real-time angle data collected by the encoder and the angle value in the smart memory card, calibrate the encoder according to the angle value in the smart memory card.

[0070] S31: The stacker-reclaimer control PLC receives the real-time angle data transmitted by the encoder and the angle value of the smart memory card read by the microwave reader;

[0071] It should be noted that by real-time detection of the motion state and position information of the stacker and reclaimer, a dynamic angle calibration mechanism is established to solve the technical problems of lag response and poor real-time performance of the traditional calibration system. In the prior art, angle calibration is often carried out in a fixed time interval or a specific position triggering method. This passive calibration strategy is difficult to meet the real-time requirements for angle accuracy when the equipment is running continuously. This step innovatively combines motion state monitoring with angle calibration. The system collects parameters such as the rotation speed, acceleration, and motion direction of the stacker and reclaimer in real time, and determines whether it is close to the calibration point according to the current position of the equipment. This active state monitoring mechanism can predict the calibration requirements in advance and reserve sufficient response time for the system to call the corresponding compensation strategy. Especially under the working conditions of high-speed operation or frequent changes of direction of the equipment, the system can intelligently adjust the calibration strategy according to the motion characteristics to ensure the accuracy of angle measurement. At the same time, the real-time monitoring mechanism also establishes continuous tracking of the equipment operation status. By analyzing the changing trend of motion parameters, abnormal conditions that may affect the angle measurement accuracy can be discovered in time. This method of closely combining state monitoring with calibration control not only improves the response speed and calibration effect of the system, but also enhances the reliability and stability of equipment operation. Although this improvement is an optimization based on the existing monitoring technology, its advantages in achieving rapid response and intelligent control provide an effective technical solution for improving the operating efficiency and control accuracy of the stacker-reclaimer.

[0072] S32: The data processing unit compares and calculates the real-time angle data of the encoder with the angle value of the smart storage card to obtain an angle deviation value;

[0073] It should be noted that by real-time identification of the direction of motion of the stacker and reclaimer when it passes through the angle calibration measuring point, the intelligent switching of the compensation strategy is realized, and the technical problem of inaccurate compensation of the traditional angle calibration system during the equipment reversing process is solved. In the prior art, angle compensation often adopts a unified compensation value, and fails to fully consider the influence of the change in motion direction on the compensation effect, resulting in angle positioning deviation when the equipment is reversing. This step analyzes the motion state of the stacker and reclaimer in real time, accurately determines its actual motion direction when it passes through the measuring point, and thus calls a compensation model that matches the current motion characteristics. This dynamic compensation mechanism based on direction recognition can accurately deal with the differential effects of gear clearance under different motion directions. The system will automatically select the corresponding compensation parameters from the database according to the identified motion direction to achieve seamless switching of compensation strategies. Especially under the working conditions of frequent reversing of the equipment, this intelligent compensation method shows significant advantages and can ensure the continuity and accuracy of angle measurement. At the same time, the system also establishes a monitoring mechanism for changes in motion direction, and continuously optimizes the compensation strategy by recording and analyzing the angle deviation characteristics during the reversing process, thereby improving the system's adaptability to complex working conditions. This solution, which combines direction recognition with compensation control, not only improves the accuracy of angle calibration, but also enhances the intelligence level of the system. Although this improvement is a deepening application of the existing compensation technology, it shows unique technical advantages and practical value when dealing with angle calibration problems under dynamic operation conditions, providing a reliable guarantee for improving the positioning control level of the stacker-reclaimer.

[0074] S33: When the angle deviation value is detected, the calibration unit corrects the real-time angle data of the encoder according to the angle value of the smart memory card, and uses the corrected angle data as the actual position angle value of the stacker-reclaimer.

[0075] S331: If the angle deviation value is less than the preset threshold, the real-time angle data of the encoder is kept unchanged; if the angle deviation value is greater than or equal to the preset threshold, a calibration operation is triggered;

[0076] S332: When the calibration operation is triggered, the calibration unit writes the angle value of the smart memory card into the counting register of the encoder, and selects a corresponding angle compensation value according to the rotation direction of the stacker-reclaimer, wherein the angle value increases by a first preset compensation amount when the stacker-reclaimer rotates clockwise, and decreases by a second preset compensation amount when the stacker-reclaimer rotates counterclockwise;

[0077] S333: The calibrated angle value is transmitted to the display unit, and the angle value is used as the reference angle of the stacker-reclaimer at the position, and subsequent angle changes are continuously recorded until the next smart memory card is detected.

[0078] It should be noted that by calculating the deviation value between the current angle and the standard angle in real time, and calling the corresponding compensation model for dynamic correction according to the movement direction of the equipment, the problems of insufficient compensation accuracy and poor real-time performance of the traditional angle calibration system are solved. In the prior art, angle calibration usually adopts a simple linear compensation method, which cannot accurately reflect the actual angle deviation characteristics of the equipment under different operating conditions, resulting in unsatisfactory calibration effect. This step innovatively establishes a set of real-time angle calculation and compensation mechanisms. When the stacker and reclaimer passes the calibration measuring point, the system immediately compares the difference between the measured angle and the standard angle value, and extracts the most suitable compensation parameters from the database in combination with the current movement direction. This dynamic calculation and real-time compensation method can effectively eliminate the nonlinear error and gear clearance in the mechanical transmission system. Especially when the operating state of the equipment changes frequently, the system can quickly adjust the compensation strategy according to the real-time calculation results to ensure the accuracy of the angle measurement. At the same time, the system also establishes a real-time evaluation mechanism for the compensation effect. By analyzing the changes in the angle deviation before and after compensation, the compensation parameters are continuously optimized to improve the adaptive ability of the system. This scheme that combines real-time calculation, dynamic compensation and effect evaluation not only improves the accuracy and real-time performance of angle calibration, but also enhances the reliability of the system. Although this improvement is an optimization based on the existing compensation technology, it shows significant advantages in achieving precise angle calibration and intelligent compensation, providing effective technical support for improving the positioning accuracy and control performance of the stacker and reclaimer.

[0079] In summary, the present invention realizes multi-point real-time calibration of the stacker and reclaimer during operation by evenly arranging multiple smart memory cards on the rotating track, without the need to rotate to the zero position for calibration, thereby ensuring the continuous operation efficiency of the equipment. The angle compensation mechanism in both clockwise and counterclockwise directions effectively solves the problem of angle deviation caused by gear clearance and improves the accuracy of angle calibration. The use of microwave recognition technology to replace traditional mechanical or photoelectric angle detection methods avoids the influence of environmental factors such as coal dust and vibration on the detection device, and improves the environmental adaptability and reliability of the system. The smart memory card adopts a non-contact reading method, without mechanical wear, which reduces the maintenance frequency of the equipment and reduces the operation and maintenance costs. The angle calibration process is fully automated to realize automatic data collection, comparison and calibration, reduce manual intervention, and improve the intelligence of the equipment.

[0080] Embodiment 2 is an embodiment of the present invention, which provides a circular coal yard stacker-reclaimer angle calibration device based on microwave recognition, comprising: an arrangement module, used to evenly arrange a plurality of smart memory cards along the circumferential direction of the rotary track of the circular coal yard stacker-reclaimer, and write the angle value of the corresponding position into the smart memory card;

[0081] The monitoring module is used to install encoders and microwave readers on the stacking mechanism, reclaiming mechanism and rotary mechanism of the stacker-reclaimer, respectively. The encoder collects the real-time angle data of each mechanism, and the microwave reader reads the angle value in the smart memory card;

[0082] The calibration module is used to compare the angle value read by the microwave reader with the real-time angle data collected by the encoder. When there is a deviation between the real-time angle data collected by the encoder and the angle value in the smart memory card, the encoder is calibrated according to the angle value in the smart memory card.

[0083] Example 3, reference Figure 5 , is an embodiment of the present invention, which is different from the previous embodiment in that: if the function is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, or the part that contributes to the prior art or the part of the technical solution, can be embodied in the form of a software product. The computer software product is stored in a storage medium, including several instructions for a computer device (which can be a personal computer, a server, or a network device, etc.) to perform all or part of the steps of the methods of each embodiment of the present invention. The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), disk or optical disk, etc. Various media that can store program codes.

[0084] The logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as an ordered list of executable instructions for implementing logical functions, and can be embodied in any computer-readable medium for use by an instruction execution system, device or apparatus (such as a computer-based system, a system including a processor, or other system that can fetch instructions from an instruction execution system, device or apparatus and execute instructions), or in conjunction with such instruction execution systems, devices or apparatuses. For the purposes of this specification, "computer-readable medium" can be any device that can contain, store, communicate, propagate or transmit a program for use by an instruction execution system, device or apparatus, or in conjunction with such instruction execution systems, devices or apparatuses.

[0085] More specific examples of computer-readable media (a non-exhaustive list) include the following: an electrical connection with one or more wires (electronic device), a portable computer disk case (magnetic device), a random access memory (RAM), a read-only memory (ROM), an erasable and programmable read-only memory (EPROM or flash memory), an optical fiber device, and a portable compact disk read-only memory (CDROM). In addition, the computer-readable medium may even be a paper or other suitable medium on which the program is printed, since the program may be obtained electronically, for example, by optically scanning the paper or other medium, followed by editing, deciphering, or processing in another suitable manner as necessary, and then stored in a computer memory.

[0086] It should be understood that the various parts of the present invention can be implemented by hardware, software, firmware or a combination thereof. In the above-mentioned embodiments, a plurality of steps or methods can be implemented by software or firmware stored in a memory and executed by a suitable instruction execution system. For example, if implemented by hardware, as in another embodiment, it can be implemented by any one of the following technologies known in the art or their combination: a discrete logic circuit having a logic gate circuit for implementing a logic function for a data signal, a dedicated integrated circuit having a suitable combination of logic gate circuits, a programmable gate array (PGA), a field programmable gate array (FPGA), etc.

[0087] Example 4, reference Figure 2 to Figure 4 , is an embodiment of the present invention, and provides another implementation of a circular coal yard stacker-reclaimer angle calibration method. This embodiment mainly relates to a circular coal yard stacker-reclaimer angle calibration device based on microwave recognition.

[0088] like Figure 3 The figure shows the topological structure of the stacker-reclaimer positioning calibration network. The equipment is mainly composed of a stacker-reclaimer control PLC, an encoder, a microwave reader, an intelligent memory card (each card has a fixed angle value), a data processing unit and a display unit.

[0089] Stacker-reclaimer control PLC: used for whole machine data collection and execution of stacker-reclaimer control instructions. In this invention patent, it is used to collect real-time angle information measured by encoders of stacking, reclaiming and rotary mechanisms.

[0090] Encoder: Track the rotation angle of the stacking, retrieving and rotating mechanisms, collect angle information in real time, and upload it to the PLC system.

[0091] Microwave reader: used to read data. It rotates with the stacking and retrieving rotary mechanism. After reaching a fixed position, it reads the value in the smart memory card and transmits it to the PLC control system to calibrate the error value of the rotary mechanism encoder.

[0092] Smart memory card: (Each card has a fixed angle value written on it, arranged along the circumference, one card is arranged every 60 degrees).

[0093] Data processing unit: processes the received electrical signals and reads the angle of the stacker-reclaimer.

[0094] Calibration unit: compares and calibrates the read angle value with the encoder calculated value.

[0095] The main principles and steps of the technical solution of this embodiment are:

[0096] Working principle of microwave identification and calibration system: The stacking and reclaiming rotary and pitching mechanisms of the stacker and reclaimer are equipped with encoders, which rotate with the above mechanisms and are used to detect the angles of the above mechanisms. Microwave reader: rotates with the stacking and reclaiming rotary mechanisms, and is used to read the values ​​in the smart memory card after reaching a fixed position, and transmit them to the control system to calibrate the error value of the rotary mechanism encoder, which can be used in conjunction with the continuous measurement encoder to calibrate the angle of the stacker and reclaimer.

[0097] 1. Establish a positioning coordinate system: The stacker-reclaimer is a key device for stacking and retrieving coal in a circular coal yard. The role of its positioning system is to ensure that the stacker-reclaimer can operate accurately in the designated area of ​​the coal yard. Based on this, a coordinate system based on angle detection is established for the stacker-reclaimer. Independent encoders are configured for the stacking rotation, retrieving rotation, and retrieving pitch mechanisms, and the encoders record the angle position of each mechanism in real time based on the counting pulses.

[0098] 2. Design an automatic calibration device: The positioning and measuring encoders of the various mechanisms of the stacker and reclaimer will produce cumulative deviations due to factors such as mechanical wear. Therefore, microwave (RFID) recognition technology is used to calibrate and identify the position of the encoder. The device includes an RFID reader and multiple RFID tags (smart memory cards). The RFID tags are installed every 60° along the stacking and reclaiming rotary tracks.

[0099] 3. Automatic calibration: After the RFID tag enters the RF signal range of the reader, the position information stored in the chip is scanned and read by the reader. After the reader reads and decodes this information, it sends it to the stacker control PLC to compare the accuracy with the position information measured by the encoder. If there is a deviation, calibration is performed. This layout can achieve automatic calibration of the stacker position once during normal stacking and reclaiming operations as long as the RFID carrier set at a fixed angle passes through.

[0100] 4. Rotation record

[0101] The actual site of the stacker-reclaimer is circular. In order to facilitate understanding and description, it is described in a hexagonal shape.

[0102] like Figure 4 As shown, the operation steps are:

[0103] (1) Set the encoder value of point G to 2000000;

[0104] (2) As point G rotates counterclockwise, during the FZ process, the RFID reader at FA detects the serial number (1-6) and writes the encoder value at that time to the corresponding PLC address;

[0105] (3) When reaching Z, it is necessary to align with the actual zero point (visually align the No. 0 sign) and record the encoder value at this time;

[0106] (4) As the rotation returns to point H, the current encoder value is recorded;

[0107] (5) Subtract the encoder value at point H from the encoder value at point G to get the number of encoder revolutions.

[0108] (6) The encoder value of AF corresponds to the encoder value of point Z, which is the relative position of AF relative to the zero point (if it is a negative value, add the encoder value corresponding to one circle);

[0109] (7) Add 500,000 (reference point) to the values ​​of the six relative positions;

[0110] (8) Determine left turn and right turn at 360 degrees and 0 degrees (a left turn of 0 degrees is assigned the encoder value corresponding to 360 degrees, and a right turn of 360 degrees is assigned the encoder value corresponding to 0 degrees, i.e., the reference point (500000));

[0111] (9) Same as above, except that the data is recorded clockwise from 500000 (reference point) to observe whether the encoder value difference after one revolution is consistent with the reverse rotation.

[0112] 5. Pitch record

[0113] (1) Change the encoder value at point A to 500000 and record the current actual angle;

[0114] (2) Change the angle to point B, then the angle difference between AB corresponds to the difference in encoder values;

[0115] (3) The method is repeated to obtain the encoder value difference corresponding to the angle difference at different positions;

[0116] (4) Finally, the ratio of the corresponding angle to the encoder difference is obtained.

[0117] like Figure 2 The figure shows the rotation and pitch record of the stacker-reclaimer.

[0118] Preferably, this embodiment has the following advantages: 1. By adding a microwave calibration device to the fixed angle of the above-mentioned mechanism of the stacker-reclaimer, it is possible to achieve real-time calibration of the angle collected by the encoder regularly after stacking, retrieving, and pitching to a certain angle. In the microwave identification card, the corresponding angle can be different according to the different rotation directions. For example, in a microwave identification card that rotates 60 degrees, the left turn calibration angle is 59.9 degrees, and the right turn calibration angle is 60.1 degrees, which effectively overcomes the angle difference caused by gear clearance.

[0119] 2. Avoid the original encoder angle measurement, which has a large cumulative error and requires regular manual rotation of the mechanism to the zero calibration position for calibration. In the original calibration mode, the cumulative time required to calibrate the above three mechanisms is about 1 hour, which affects the stacking efficiency. It saves the power consumption of the structure rotation.

[0120] 3. This patented invention can achieve angle calibration in the normal working range. Angle calibration can protect the angle between mechanisms. The accuracy of the pitch angle ensures the uniformity of material collection without overloading, thus protecting the scraper equipment.

[0121] Compared with the circular coal yard, the accurate stockpile rotation angle avoids the mixing of different types of coal, ensures the accuracy of the blending of economical coal, and avoids the boiler combustion risk and environmental protection over-emission risk caused by different coal qualities at the junction.

[0122] 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 preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A circular coal yard stacker-reclaimer angle calibration method, characterized in that: include: A plurality of smart memory cards are evenly arranged along the circumferential direction of the rotary track of the circular coal yard stacker and reclaimer, and the angle values ​​of the corresponding positions are written into the smart memory cards; Encoders and microwave readers are installed on the stacking mechanism, reclaiming mechanism and rotary mechanism of the stacker-reclaimer, respectively. The encoder collects real-time angle data of each mechanism, and the microwave reader reads the angle value in the smart memory card. The angle value read by the microwave reader is compared with the real-time angle data collected by the encoder. When there is a deviation between the real-time angle data collected by the encoder and the angle value in the smart memory card, the encoder is calibrated according to the angle value in the smart memory card.

2. The circular coal yard stacker-reclaimer angle calibration method according to claim 1, characterized in that: The method of evenly arranging a plurality of smart memory cards along the circumferential direction of the rotary track of the circular coal yard stacker and reclaimer, and writing the angle values ​​of corresponding positions into the smart memory cards, comprises the following steps: Establish an angle positioning coordinate system based on the stacker-reclaimer; In the angle positioning coordinate system, the zero position of the stacker-reclaimer is taken as the reference point, and the encoder value of the reference point is set to a preset value; Multiple smart memory cards are evenly arranged along the circumferential direction of the stacker-reclaimer rotary track, and an angle value corresponding to its installation position is written into each smart memory card, wherein the angle value includes a clockwise rotation angle value and a counterclockwise rotation angle value.

3. The circular coal yard stacker-reclaimer angle calibration method according to claim 2, characterized in that: The method of evenly arranging a plurality of smart memory cards along the circumferential direction of the stacker-reclaimer rotary track and writing an angle value corresponding to the installation position thereof into each smart memory card, wherein the angle value includes a clockwise rotation angle value and a counterclockwise rotation angle value, comprises the following steps: Install the first smart memory card at the zero point and set the angle value of the smart memory card to zero degrees; Based on the encoder value at the zero point, calculate the encoder value corresponding to each installation point in the clockwise and counterclockwise directions. If the encoder rotates clockwise at 360 degrees, set the encoder value to the value corresponding to zero degrees. If the encoder rotates counterclockwise at 0 degrees, set the encoder value to the value corresponding to 360 degrees. The calculated encoder value is written into the smart memory card at the corresponding position, wherein each smart memory card is written with the angle value of the position in both clockwise and counterclockwise rotation. If an angle deviation caused by gear clearance is detected, the clockwise angle value of the corresponding position is increased by a preset compensation amount, and the counterclockwise angle value is decreased by a preset compensation amount.

4. The circular coal yard stacker-reclaimer angle calibration method according to claim 3, characterized in that: The method comprises the following steps: installing an encoder and a microwave reader / writer on the stacking mechanism, the retrieving mechanism and the rotating mechanism of the stacker / reclaimer respectively, wherein the encoder collects the real-time angle data of each mechanism and the microwave reader / writer reads the angle value in the smart memory card: Encoders are respectively arranged on the stacking mechanism, the retrieving mechanism and the rotating mechanism of the stacker-reclaimer, and the encoders rotate with the corresponding mechanisms and count and record the rotation pulses; Convert the pulse signal recorded by the encoder into real-time angle data and transmit it to the stacker-reclaimer control PLC; A microwave reader is installed on the stacking mechanism, the retrieving mechanism and the rotating mechanism. The microwave reader rotates with the mechanism. When it rotates into the radio frequency signal range of the smart memory card, it reads the angle value stored in the smart memory card and transmits the angle value to the stacker-reclaimer control PLC.

5. The circular coal yard stacker-reclaimer angle calibration method according to claim 4, characterized in that: The microwave reader is installed on the stacking mechanism, the retrieving mechanism and the rotating mechanism. The microwave reader rotates with the mechanism. When the microwave reader rotates to the radio frequency signal range of the smart memory card, the angle value stored in the smart memory card is read and the angle value is transmitted to the stacker-reclaimer control PLC, including the following steps: The microwave reader continuously emits microwave signals as the stacker-reclaimer mechanism rotates. When it is detected that the microwave signal interacts with the smart memory card, it is determined that the stacker-reclaimer mechanism has rotated to a preset angle position. If signal interaction is detected, the microwave reader reads the angle value stored in the smart memory card and selects the corresponding clockwise angle value or counterclockwise angle value according to the actual rotation direction of the stacking and reclaiming mechanism; The read angle value is transmitted together with the rotation direction information of the stacker-reclaimer mechanism to the stacker-reclaimer control PLC. If a data transmission abnormality is detected during the transmission process, the reading operation is re-executed until the data transmission is successful.

6. The circular coal yard stacker-reclaimer angle calibration method according to claim 5, characterized in that: The angle value read by the microwave reader is compared with the real-time angle data collected by the encoder. When there is a deviation between the real-time angle data collected by the encoder and the angle value in the smart memory card, the encoder is calibrated according to the angle value in the smart memory card, including the following steps: The stacker-reclaimer control PLC receives the real-time angle data transmitted by the encoder and the angle value of the smart memory card read by the microwave reader; The data processing unit compares and calculates the real-time angle data of the encoder with the angle value of the smart storage card to obtain the angle deviation value; When the angle deviation value is detected, the calibration unit corrects the real-time angle data of the encoder according to the angle value of the smart memory card, and uses the corrected angle data as the actual position angle value of the stacker-reclaimer.

7. The circular coal yard stacker-reclaimer angle calibration method according to claim 6, characterized in that: When the angle deviation value is detected, the calibration unit corrects the real-time angle data of the encoder according to the angle value of the smart memory card, and uses the corrected angle data as the actual position angle value of the stacker-reclaimer, including the following steps: If the angle deviation value is less than the preset threshold, the real-time angle data of the encoder is kept unchanged; If the angle deviation value is greater than or equal to the preset threshold, a calibration operation is triggered; When the calibration operation is triggered, the calibration unit writes the angle value of the smart memory card into the counting register of the encoder, and selects the corresponding angle compensation value according to the rotation direction of the stacker-reclaimer, wherein the angle value increases by a first preset compensation amount when rotating clockwise, and decreases by a second preset compensation amount when rotating counterclockwise; The calibrated angle value is transmitted to the display unit and used as the reference angle of the stacker-reclaimer at that position, and subsequent angle changes are continuously recorded until the next smart memory card is detected.

8. A device using the circular coal yard stacker-reclaimer angle calibration method as claimed in any one of claims 1 to 7, characterized in that: include: An arrangement module is used to evenly arrange a plurality of smart memory cards along the circumferential direction on the rotary track of the circular coal yard stacker and reclaimer, and the angle values ​​of corresponding positions are written into the smart memory cards; A monitoring module is used to install an encoder and a microwave reader on the stacking mechanism, the reclaiming mechanism and the rotary mechanism of the stacker-reclaimer, respectively, wherein the encoder collects the real-time angle data of each mechanism and the microwave reader reads the angle value in the smart memory card; The calibration module is used to compare the angle value read by the microwave reader with the real-time angle data collected by the encoder. When there is a deviation between the real-time angle data collected by the encoder and the angle value in the smart memory card, the encoder is calibrated according to the angle value in the smart memory card.

9. A computer device comprising a memory and a processor, wherein the memory stores a computer program, wherein: When the processor executes the computer program, the steps of the circular coal yard stacker-reclaimer angle calibration method described in any one of claims 1 to 7 are implemented.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the steps of the circular coal yard stacker-reclaimer angle calibration method according to any one of claims 1 to 7 are implemented.

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