Wireless control system of stacker-reclaimer
By adopting LoRa wireless communication technology in the stacker control system, the fault problems caused by cable aging and dust environment of existing wired control systems are solved, and the production efficiency and reliability are improved.
Patent Information
- Application Number
- CN202411759035.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-03
- Publication Date
- 2025-04-22
AI Technical Summary
The wired control system of existing stacker is prone to failure due to cable aging and dusty environment, resulting in equipment shutdown, material blockage and equipment damage.
The wireless control system is adopted, including the main control module, the first wireless control module and the second wireless control module, and wireless control module is realized through the LoRa communication connection to realize wireless control of the stacker, avoiding cable failure and reel motor failure.
It improves the efficiency and reliability of the automated production operations of the stacking and extraction yard, reduces equipment failures and production interruptions, and reduces operating costs.
Smart Images
Figure CN119861661A_ABST
Abstract
Description
Technical Field
[0001] The embodiments of the present disclosure belong to the technical field of wireless control of stackers and reclaimers, and particularly relate to a wireless control system for stackers and reclaimers. Background Art
[0002] In large-scale production sites such as cement plants, coal mines, coal washing plants, thermal power plants, steel, metallurgy and ports, stackers are used for automated operations. The control of stackers is currently designed with a series of control points such as central control start / stop, central control emergency stop, operation, start, fault, stacking (retrieving), in pile one, in pile two, stack adjustment, interlocking, etc., and the signal path between the DCS and interlocking equipment. The stacker and reclaimer are transmitted by wire to the DCS or PLC, and the transmission cable usually uses a reel motor to drive the reel to retract and release.
[0003] With the aging of the line and the influence of the on-site dust environment, the cable failure rate is high. The main fault manifestations are as follows:
[0004] (1) Signal transmission cables are bent and aged during long-term use. Cable damage will cause shutdown or disconnection failures that cannot be promptly reported to the DCS and interlocking equipment. The operator can only shut down the system manually. However, manual operation is prone to material blockage and other failures due to time differences in operation, which can cause significant property losses or even casualties.
[0005] (2) The failure rate of the reel motor is high during operation, and reel failure can easily cause downtime. In addition, the reel motor generates a lot of heat during operation, and usually two fans are required to cool it down, which consumes a lot of power;
[0006] (3) The dust density at the production site is high, which can easily lead to unstable control signals, affect production, and even cause equipment short circuits and damage equipment. Summary of the invention
[0007] The embodiment of the present disclosure aims to solve at least one of the technical problems existing in the prior art and provide a wireless control system for a stacker and reclaimer. The system includes a main control module, a first wireless control module and a second wireless control module;
[0008] The main control module is electrically connected to the first wireless control module, and is used to send a control signal to the first wireless control module or receive a feedback signal from the first wireless control module;
[0009] The first wireless control module and the second wireless control module are connected via LoRa communication;
[0010] The second wireless control module is used to be electrically connected to the controlled stacker-reclaimer to send a control signal to the controlled stacker-reclaimer or receive a feedback signal from the controlled stacker-reclaimer.
[0011] Optionally, the main control module is a DCS or a PLC.
[0012] Furthermore, the main control module adopts a 32-bit processor.
[0013] Optionally, the first wireless control module and the second wireless control module implement extended spectrum communication via direct spectrum expansion.
[0014] Furthermore, the spread spectrum communication adopts an automatic optimization algorithm.
[0015] Optionally, the first wireless control module and the second wireless control module communicate with each other using a pseudo-random code.
[0016] Optionally, the communication connection between the first wireless control module and the second wireless control module is divided by channels.
[0017] Optionally, the communication connection between the first wireless control module and the second wireless control module adopts EID identification.
[0018] Furthermore, the first wireless control module and the second wireless control module are both provided with multiple switch inputs and multiple relay outputs;
[0019] Each relay output of the first wireless control module is correspondingly communicated with each switch input of the second wireless control module;
[0020] Each relay output of the second wireless control module is correspondingly communicated with each switch input of the first wireless control module.
[0021] Furthermore, the switch input and the relay output both use 16 channels.
[0022] A wireless control system for a stacker and reclaimer in an embodiment of the present disclosure provides wireless control modules for use in pairs and adopts LoRa wireless transmission technology to synchronize the input and output states of both ends, thereby performing wireless link transformation on the DCS / PLC control cable of the stacker and reclaimer in the material yard, thereby avoiding the influence of cable damage, reel motor failure or on-site dust on the production process of the stacker and reclaimer, improving the efficiency and reliability of the automated production operation of the stacker and reclaimer, and benefiting the enterprise and social and economic benefits. BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Figure 1 The present invention is a schematic structural diagram of a wireless control system for a stacker-reclaimer according to an embodiment of the present invention. DETAILED DESCRIPTION
[0024] The following will be combined with the drawings in the embodiments of the present disclosure to clearly and completely describe the technical solutions in the embodiments of the present disclosure. Obviously, the described embodiments are only part of the embodiments of the present disclosure, not all of the embodiments. Based on the embodiments in the present disclosure, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present disclosure.
[0025] In addition, the described features, structures or characteristics may be combined in one or more embodiments in any suitable manner. In the following description, many specific details are provided to provide a full understanding of the embodiments of the present disclosure. However, those skilled in the art will appreciate that the technical solutions of the present disclosure may be practiced without one or more of the specific details, or other methods, components, devices, steps, etc. may be adopted. In other cases, known methods, devices, implementations or operations are not shown or described in detail to avoid blurring the various aspects of the present disclosure.
[0026] The flowcharts shown in the accompanying drawings are only exemplary and do not necessarily include all the contents and operations / steps, nor must they be executed in the order described. For example, some operations / steps can be decomposed, and some operations / steps can be combined or partially combined, so the actual execution order may change according to actual conditions.
[0027] It should be understood that although the terms first, second, third, etc. may be used in this disclosure to describe various components, these components should not be limited by these terms. These terms are used to distinguish one component from another component. Therefore, the first component discussed below can be referred to as the second component without departing from the teachings of the concepts of the present disclosure. As used in this disclosure, the term "and / or" includes any one of the associated listed items and all combinations of one or more.
[0028] Those skilled in the art will appreciate that the drawings are merely schematic diagrams of example embodiments, and the modules or processes in the drawings are not necessarily necessary for implementing the present disclosure, and therefore cannot be used to limit the protection scope of the present disclosure.
[0029] like Figure 1As shown, an embodiment of the present disclosure provides a wireless control system for a stacker and reclaimer, the system comprising a main control module 100, a first wireless control module 200 and a second wireless control module 300. The main control module 100 is electrically connected to the first wireless control module 200, and is used to send a control signal to the first wireless control module 200 or receive a feedback signal from the first wireless control module 200. The first wireless control module 200 and the second wireless control module 300 are connected via LoRa communication. The second wireless control module 300 is used to be electrically connected to a controlled stacker and reclaimer 400, so as to send a control signal to the controlled stacker and reclaimer 400 or receive a feedback signal from the controlled stacker and reclaimer 400.
[0030] Specifically, the two wireless control modules of the stacker-reclaimer wireless control system are two wireless controllers, which are used in pairs. The two synchronize input and output states through wireless transmission technology. When the main control module 100 sends a control signal to the first wireless control module 200, the second wireless control module 300 synchronously sends the same control signal to the controlled stacker-reclaimer 400; when the second wireless control module 300 receives the feedback signal from the controlled stacker-reclaimer 400, the first wireless control module 200 synchronously sends the same feedback signal to the main control module 100. The wireless transmission technology between the first wireless control module 200 and the second wireless control module 300 adopts LoRa (Long Range Radio) technology, which is a long-distance low-power radio technology. In this way, the user can remotely control the controlled stacker-reclaimer 400 through the main control module 100 without on-site wiring.
[0031] In the working scenario of the stacker-reclaimer in the material yard, the electromagnetic environment is complex. The start, stop and operation of various motors will cause electromagnetic interference. Various metal towers and equipment will also cause wireless multipath propagation interference and other effects. Therefore, high requirements are placed on the response time of the main control module, the reliability of wireless equipment and wireless links.
[0032] Exemplarily, the main control module may be a DCS (Distributed Control System) or a PLC (Programmable Logic Controller). Real-time monitoring of the wireless link can improve the reliability of wireless link transmission.
[0033] Exemplarily, the main control chip of the main control module adopts a 32-bit high-performance processor, so as to realize short-delay transmission of its DI signal, wireless link and DO signal, and the end-to-end response time of the wireless control channel is no more than 200ms.
[0034] Exemplarily, the first wireless control module and the second wireless control module implement extended spectrum communication by using direct spectrum expansion, which directly filters out strong wireless electromagnetic interference.
[0035] Exemplarily, the spread spectrum communication uses an automatic optimization algorithm to optimize the spectrum within the communication channel, thereby transforming the radio multipath effect into high diffraction efficiency, greatly improving the signal propagation distance of wireless transmission.
[0036] Exemplarily, the communication between the first wireless control module and the second wireless control module may adopt multiple technologies such as pseudo-random code, channel division, and identification of device EID to achieve optimal anti-interference capability.
[0037] For example, Figure 1 As shown, the first wireless control module 200 and the second wireless control module 300 are both provided with 16 switch inputs DI1 to DI16 and 16 relay outputs DO1 to DO16. Each relay output of the first wireless control module 200 is correspondingly connected to each switch input of the second wireless control module 300; each relay output of the second wireless control module 300 is correspondingly connected to each switch input of the first wireless control module 200. For example, when the DI2 port of the first wireless control module 200 receives a switch input control signal sent from the main control module 100, the signal is transmitted to the second wireless control module 300 via the wireless communication link, and the DO2 port in the second wireless control module 300 sends a relay output control signal to the controlled stacker-reclaimer 400 accordingly; similarly, when the DI2 port of the second wireless control module 300 receives a switch input feedback signal sent from the controlled stacker-reclaimer 400, the signal is transmitted to the first wireless control module 200 via the wireless communication link, and the DO2 port in the first wireless control module 200 sends a relay input feedback signal to the main control module 100 accordingly.
[0038] The first wireless control module and the second wireless control module uniformly use a ZR-WIRELESS-COM-16 controller, and the parameters and specifications thereof are shown in Table 1 below:
[0039] Table 1
[0040]
[0041] A wireless control system for a stacker and reclaimer in an embodiment of the present disclosure provides wireless control modules for use in pairs and adopts LoRa wireless transmission technology to synchronize the input and output states of both ends, thereby performing wireless link transformation on the DCS / PLC control cable of the stacker and reclaimer in the material yard, thereby avoiding the influence of cable damage, reel motor failure or on-site dust on the production process of the stacker and reclaimer, improving the efficiency and reliability of the automated production operation of the stacker and reclaimer, and benefiting the enterprise and social and economic benefits.
[0042] It is to be understood that the above embodiments are merely exemplary embodiments used to illustrate the principles of the present disclosure, but the present disclosure is not limited thereto. For those of ordinary skill in the art, various modifications and improvements can be made without departing from the spirit and substance of the present disclosure, and these modifications and improvements are also considered to be within the scope of protection of the present disclosure.
Claims
1. A wireless control system for a stacker and reclaimer, characterized in that: The system includes a main control module, a first wireless control module and a second wireless control module; The main control module is electrically connected to the first wireless control module, and is used to send a control signal to the first wireless control module or receive a feedback signal from the first wireless control module; The first wireless control module and the second wireless control module are connected via LoRa communication; The second wireless control module is used to be electrically connected to the controlled stacker-reclaimer to send a control signal to the controlled stacker-reclaimer or receive a feedback signal from the controlled stacker-reclaimer.
2. The wireless control system for stacker and reclaimer according to claim 1, characterized in that: The main control module is a DCS or a PLC.
3. The wireless control system for stacker and reclaimer according to claim 2, characterized in that: The main control module adopts a 32-bit processor.
4. The wireless control system for stacker and reclaimer according to claim 1, characterized in that: The first wireless control module and the second wireless control module implement spread spectrum communication through direct spectrum expansion.
5. The wireless control system for stacker and reclaimer according to claim 4, characterized in that: The spread spectrum communication uses an automatic optimization algorithm.
6. The wireless control system for stacker and reclaimer according to claim 1, characterized in that: The first wireless control module and the second wireless control module are connected to each other by using a pseudo-random code.
7. The wireless control system for stacker and reclaimer according to claim 1, characterized in that: The communication connection between the first wireless control module and the second wireless control module is divided by channels.
8. The wireless control system for stacker and reclaimer according to claim 1, characterized in that: The communication connection between the first wireless control module and the second wireless control module is identified by EID.
9. The wireless control system for a stacker and reclaimer according to any one of claims 1 to 8, characterized in that: The first wireless control module and the second wireless control module are both provided with multiple switch inputs and multiple relay outputs; Each relay output of the first wireless control module is correspondingly communicated with each switch input of the second wireless control module; Each relay output of the second wireless control module is correspondingly communicated with each switch input of the first wireless control module.
10. The wireless control system for stacker and reclaimer according to claim 9, characterized in that: The switch input and the relay output both use 16 channels.