Safety system for hoisting skip car of blast furnace

Abstract

The invention discloses a blast furnace winch skip car safety system which comprises the following steps: supplying power to a device through a UPS (Uninterrupted Power Supply), checking an initial position signal, loading key parameters and checking an equipment state; gradually increasing the frequency of the frequency converter through the master controller, collecting position signals in real time and dynamically adjusting parameters; the master controller monitors a track position and a speed signal in real time and adjusts the output frequency of the frequency converter; when the skip car approaches the target position, the frequency is reduced, the buffer limiting device is verified, and the parking position and the running state are recorded; when the master signal is detected to be abnormal, switching to a standby master, and triggering an alarm to take a shutdown protection measure; and recording a running position signal, a speed curve and fault information, and adjusting running parameters by analyzing data to predict potential faults of the equipment. According to the method, the whole-course dynamic control of the blast furnace winch skip car is realized, the stability, safety and fault prediction capability of operation are improved, and the method is particularly suitable for accurate transportation under high load and multiple working conditions.

Description

Technical Field

[0001] The present invention relates to the technical field of blast furnace safety, and particularly to the safety system of the blast furnace hoist skip. Background Art

[0002] The blast furnace hoist skip is a key equipment for material transportation in the blast furnace smelting process and is widely used in the production links of the metallurgical industry. This equipment transports raw materials from the ground to the top of the blast furnace through a hoist and a track system, providing guarantee for continuous charging in the blast furnace. With the rapid development of the metallurgical industry and the continuous expansion of production scale, higher requirements are put forward for the performance of the skip equipment in terms of the operating efficiency and safety of the blast furnace. Especially under the high-load and high-frequency transportation working conditions, the skip system needs to meet the requirements of precise positioning, stable operation and efficient transportation.

[0003] At present, most of the control systems of the hoist skip on the market adopt a single signal source and limited protection measures. When signal anomalies or equipment failures occur, it is difficult to take effective countermeasures in a timely manner, resulting in operation interruption or even serious accidents. This design is difficult to meet the high safety and reliability requirements of modern blast furnaces for equipment operation.

[0004] In view of the above problems, the present invention provides a safety system for the blast furnace hoist skip, which can effectively improve the safety, stability and intelligent level of the system operation by introducing a multi-signal mechanism, video monitoring assistance and data-driven fault prediction method. Summary of the Invention

[0005] The present invention aims at the above problems and provides a safety system for the blast furnace hoist skip to solve the safety hazards and insufficient control accuracy existing in the prior art during operation.

[0006] To solve the above technical problems, the present invention provides the following technical solutions: The present invention provides a safety system for the blast furnace hoist skip, including the following steps: Step S1, start the UPS power supply to supply power to the master controller, frequency converter and PLC, verify the initial position signal, load key parameters and check the equipment status; Among them, in step S1, the following sub-steps are further included: S1-1, start the uninterruptible power supply (UPS) to supply power to the master controller, frequency converter and PLC. The master controller verifies the current position signal and compares it with the previous operation data to complete the setting of the initial position signal of the system, specifically as shown in formula (1): N Formula (1) Wherein, is the current position signal, is the position recorded at the end of the previous operation, is the encoder resolution, is the current encoder pulse technology; S1-2: Load key control parameters from the PLC, including position signals, speed setpoints, and limit conditions. The frequency converter loads the basic motor parameters and initial settings. The master controller checks the status of the hoist motor and wire rope tension sensor devices to ensure that the encoder signals match the physical parameters of the devices, as shown in Equation (2): Equation (2) where is the coding coefficient, is the diameter of the main hoist, is the encoder resolution; S1-3: The master A and master B synchronously load the initial parameters, including position, speed, and acceleration. By calculating the difference between the two signals, the consistency of the master signals is ensured. This synchronous loading and difference detection is the redundancy mechanism. If a difference is detected, the system automatically triggers the standby master switching mechanism and records the fault log simultaneously; S1-4: Introduce the video monitoring auxiliary function. The video device is installed along the trolley track to capture the device status at the starting position of the operation and transmit the monitoring information to the master control system in real time to provide visual confirmation support for initialization.

[0007] Step S2: The PLC issues a start command, and the master controller gradually increases the frequency of the frequency converter, collects the position signal in real time, and dynamically adjusts the parameters; Among them, in step S2, the following sub-steps are also included: S2-1: The PLC issues a start command, and the master controller and the frequency converter work together to make the hoist motor enter the low-speed mode, and the trolley starts smoothly; S2-2: The master controller collects the position signal in real time, transmits the data to the PLC, and gradually increases the motor frequency according to the position signal. The trolley accelerates smoothly and enters the normal operation stage, as shown in Equation (3): Equation (3) where is the motor operating frequency, is the motor speed, is the number of motor pole pairs; S2-3: The master control system combines the buffer limit protection device to pre-check the track position before the trolley starts to ensure that the mechanical limit device works normally. If the status of the track or the limit device is detected to be abnormal, the system prevents the trolley from starting and triggers an alarm; S2-4: During the start-up phase, the master controller gradually increases the output frequency of the frequency converter to make the trolley accelerate smoothly. Combining the position signal and speed feedback collected in real time, the start-up parameters are dynamically adjusted to ensure that the trolley starts smoothly and enters the operation stage.

[0008] Step S3: The master controller monitors the track position and speed signals in real time, adjusts the output frequency of the frequency converter, and sets the acceleration point, high-speed point, and deceleration point in segments. Among them, in step S3, the following sub-steps are also included: S3-1: The master controller continuously detects the track position of the skip. The signal is synchronized with the PLC in real time, and the PLC dynamically adjusts the output frequency of the frequency converter to make the speed of the skip consistent with the target curve. S3-2: Adjust the speed according to the operating state, set the acceleration point, high-speed point, and deceleration point in segments, and dynamically adjust based on the position feedback speed. Specifically, as shown in Equation (4): Equation (4) Where, is the current speed, is the target speed, is the target position, is the current position signal, is the adjustment factor, which determines the smoothness of the speed change; At the acceleration point, the frequency of the frequency converter is increased to make the skip quickly reach the operating speed; at the high-speed point, a stable speed is maintained to optimize the operating efficiency; when approaching the target position at the deceleration point, the frequency is gradually reduced to prepare for stopping. S3-3: Detect the consistency of the wire rope tension, loose rope signal, and master signal. By calculating the wire rope tension and comparing the actual stress with the allowable stress of the material, if abnormalities are found, including loose rope or over-limit, the system immediately stops and triggers an alarm. Specifically, as shown in Equation (5) - Equation (6): Equation (5) Equation (6) Where, is the wire rope tension, is the torque of the drum, is the radius of the wire rope, is the actual stress, is the cross-sectional area, is the maximum allowable stress of the material; S3-4: The master controller dynamically adjusts the speed according to the track position and speed signals collected in real time. Specifically, as shown in Equation (7): Equation (7) Where, is the current speed, is the target speed, is the target position, is the current position signal, is a regulating factor; when the master command A signal is lost or abnormal, the system automatically switches to the master command B to maintain the smooth operation of the skip; S3-5, Real-time docking of video monitoring, combined with the real-time capture of the skip running position by the monitoring system, and optimizing the master command parameters according to the image recognition feedback signal to ensure the matching of the track and speed during the running process.

[0009] Step S4, When the skip approaches the target position, reduce the frequency to decelerate, start the hydraulic braking system, check the buffer limit device and record the parking position and running status; Among them, in step S4, the following sub-steps are also included: S4-1, When the skip approaches the target position, the PLC controls the frequency converter to reduce the frequency, so that the skip decelerates until it stops completely. The master command controller confirms the position accuracy of the parking point and compares it with the target position data. If there is a deviation, adjust it to the accurate position; S4-2, The hydraulic braking system is started to ensure that the skip is firmly parked at the designated position, and the status of the brake is detected in real time, and the parking position and running status are recorded to provide initial parameters for the next operation; S4-3, The master command controller detects the status of the buffer limit device in real time before parking. If it is found that the limit device is not enabled or fails, the system enters the safety mode, and the skip operation is restricted by reducing the speed to ensure the safety during the parking stage; S4-4, After parking, the master command controller compares the actual parking point and the target position data. If there is a deviation, dynamically adjust the limit parameters to complete the position correction and record the parking accuracy.

[0010] Step S5, When the master command signal is detected to be abnormal, switch to the standby master command, trigger an alarm and take measures for shutdown protection, and at the same time monitor the equipment status and record the fault information; Among them, in step S5, the following sub-steps are also included: S5-1, When the master command signal is detected to be abnormal, that is, the difference between the master command A and master command B signals exceeds the allowable range, trigger the switching mechanism to automatically switch to the standby master command. When switching to the standby master command, the torque will be readjusted, and at the same time an alarm will be triggered and the fault information will be recorded for the operator to troubleshoot, specifically as shown in Equation (8) - Equation (9): Equation (8) Equation (9) Among them, is the difference between the master command signals, are the signals of master command A and B respectively, is the allowable maximum deviation range, is the allowable maximum torque, is the rated torque, is the overload coefficient; S5-2. When an obvious anomaly is detected, immediate shutdown and protection measures need to be taken. For abnormal states of obvious overload or mechanical failure, it is determined whether the maximum capacity is exceeded through calculation of overload protection, and whether the amount of slack rope exceeds the allowable value is calculated through the slack rope detection signal of the wire rope, specifically as shown in Equations (10)-(11): Equation (10) Equation (11) Wherein, is the actual load torque, is the abnormal tension, is the radius of the wire rope drum, is the transmission system efficiency, is the current amount of slack rope, is the length of the wire rope during tension calibration, is the actual length of the wire rope in case of abnormality; S5-3. When the difference between the signals of Master Command A and Master Command B exceeds the threshold, the standby master command takes over the system operation. The specific processing steps include: Suspend the current operation and record the abnormal signal value; automatically load the standby master command parameters; synchronously capture the operating status of the faulty component by video monitoring to provide an auxiliary diagnosis basis for the operator; S5-4. When the speed of the skip exceeds the safety threshold, the system automatically triggers the double brakes and cuts off the power source, and at the same time physically brakes the skip through the buffer limit device to prevent the accident from expanding.

[0011] Step S6. Record the running position signal, speed curve and fault information, adjust the running parameters by analyzing the data, and predict potential equipment faults.

[0012] Among them, in step S6, the following sub-steps are also included: S6-1. Record the position signal, speed curve, fault information and alarm status of each run, and store the data in the PLC or an independent storage module for subsequent analysis, specifically as shown in Equation (12): Equation (12) Wherein, is the displacement, is the initial speed, is the acceleration, is the time; S6-2. Based on the stored running data, evaluate the running efficiency by analyzing the change trends of the speed curve and position signal; adjust the parameters according to the data analysis results; use the data to evaluate the stress and strength of the drum, shaft and connecting components, and predict potential mechanical faults.

[0013] Compared with the prior art, the beneficial effects of the present invention are: By introducing a redundancy mechanism for the master command signal, the present invention automatically switches to the standby master command when the master command A signal is abnormal, and triggers alarm and shutdown protection measures in real time to ensure the safety of system operation. At the same time, combined with the hydraulic braking system and the buffer limit device, the safety during the parking stage is further enhanced, effectively preventing accidents from occurring.

[0014] The present invention adopts the collaborative work of a PLC and a master command controller. By collecting track position and speed signals in real time, dynamically adjusting the output frequency of the frequency converter, and setting acceleration, high-speed, and deceleration points in segments, the smoothness and accuracy of the trolley operation are ensured. This dynamic adjustment mechanism effectively overcomes the instability problem caused by fixed system operation parameters.

[0015] The present invention integrates a video monitoring system and a data analysis function, captures the operation state of the trolley track in real time and records operation data, including speed curves, position signals, and fault information. Through data analysis, not only the operation parameters are optimized, but also potential mechanical faults can be predicted, improving the intelligent management level of the equipment.

[0016] The present invention supports dynamic adjustment under multiple working conditions. Through wire rope tension detection and real-time feedback mechanism, safe operation under high load or complex working conditions is ensured, and significant improvements are achieved in terms of adaptability and reliability, especially suitable for the complex environment of blast furnace metallurgy production. Brief Description of the Drawings

[0017] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention, and therefore should not be regarded as limiting the scope. For those of ordinary skill in the art, without creative efforts, other related drawings can also be obtained based on these drawings.

[0018] Figure 1 It is the method flow chart of the present invention. Detailed Embodiments

[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Apparently, the described embodiments are some, but not all, of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts belong to the scope of protection of the present invention. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the claimed present invention, but is merely for the selected embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts belong to the scope of protection of the present invention.

[0020] Please refer to Figure 1 which is the flowchart of the method for the safety system of the blast furnace hoist skip provided by the embodiment of the present invention, including the following steps: Step S1, start the UPS power supply to supply power to the master controller, frequency converter, and PLC, verify the key parameters of the initial position signal, and check the equipment status; Among them, in step S1, the following sub-steps are further included: S1-1, start the uninterruptible power supply (UPS) to supply power to the master controller, frequency converter, and PLC. The master controller verifies the current position signal and compares it with the previous operation data to complete the setting of the initial position signal of the system, specifically as shown in formula (1): N Formula (1) where is the current position signal, is the position recorded at the end of the previous operation, is the encoder resolution, is the current encoder pulse count; S1-2, load the key control parameters from the PLC, including the position signal, speed setpoint, and limit conditions. The frequency converter loads the basic parameters and initial settings of the motor. The master controller checks the status of the hoist motor and the wire rope tension sensor device to ensure that the encoder signal matches the physical parameters of the device, specifically as shown in formula (2): Formula (2) where is the coding coefficient, is the main hoist diameter, is the encoder resolution; S1-3. The master commands A and B synchronously load initial parameters, including position, speed, and acceleration. By calculating the signal difference between the two, the consistency of the master commands is ensured. This synchronous loading and difference detection is the redundancy mechanism. If a difference is detected, the system automatically triggers the standby master command switching mechanism and records the fault log simultaneously. S1-4. Introduce the video monitoring auxiliary function. The video device is installed along the track of the skip car and is used to capture the device status at the starting position of the operation. The monitoring information is transmitted to the master command control system in real time to provide visual confirmation support for initialization.

[0021] It should be noted that when an abnormality in the signal of master command A (such as signal loss and out-of-tolerance) is detected, the system immediately activates the standby master command (master command B) to take over the operation, ensuring the uninterrupted operation of the device. After the switch, the initial parameters of the standby master command are reloaded to maintain the continuity and consistency of the signal. When the signal abnormality trigger condition is met (such as the signal difference exceeding the threshold or the signal interruption), the switching mechanism is triggered. The switching process includes: pausing the current master command signal → activating the standby master command signal → loading the standby parameters. After the switch, the standby master command will recalibrate the current position signal and speed signal and adjust to the stable operation state.

[0022] Step S2. The PLC issues a start command, and the master command controller gradually increases the frequency of the frequency converter, collects the position signal in real time, and dynamically adjusts the parameters. Among them, in step S2, the following sub-steps are also included: S2-1. The PLC issues a start command, and the master command controller and the frequency converter work together to make the hoist motor enter the low-speed mode, and the skip car starts smoothly. S2-2. The master command controller collects the position signal in real time, and the data is transmitted to the PLC. According to the position signal, the frequency converter gradually increases the motor frequency, and the skip car smoothly accelerates into the normal operation stage. Specifically, as shown in Equation (3): Equation (3) Among them, is the motor operating frequency, is the motor speed, is the number of motor pole pairs; S2-3. The master command control system combines the buffer limit protection device to pre-check the track position before the skip car starts to ensure the normal operation of the mechanical limit device. If an abnormal state of the track or the limit device is detected, the system prevents the skip car from starting and triggers an alarm. S2-4. During the start-up phase, the master command controller gradually increases the output frequency of the frequency converter to make the skip car smoothly accelerate. Combining the position signal collected in real time with the speed feedback, the start-up parameters are dynamically adjusted to ensure that the skip car starts smoothly and enters the operation stage.

[0023] It should be noted that before the skip starts, the system comprehensively checks the track position and the status of the limit device. The track inspection includes track flatness, obstacle detection, and wear condition assessment. The limit device inspection includes the trigger mechanisms of buffer limits and mechanical limiters. The inspection data is collected in real time through sensors and video monitoring and compared with the standard parameters to ensure normal operating conditions. If an abnormality is detected, the system prevents the skip from starting and triggers an alarm. At the same time, the abnormal information is recorded and the safety mode is entered to ensure the safety of the equipment and personnel.

[0024] Step S3: The master controller continuously monitors the track position and speed signals, adjusts the output frequency of the frequency converter, and sets the acceleration points, high-speed points, and deceleration points in segments. In step S3, the following sub-steps are further included: S3-1: The master controller continuously detects the skip track position, and the signal is synchronized with the PLC in real time. The PLC dynamically adjusts the output frequency of the frequency converter to keep the skip speed consistent with the target curve. S3-2: The speed is adjusted according to the operating state, and the acceleration points, high-speed points, and deceleration points are set in segments. The speed is dynamically adjusted based on the position feedback, as shown in Equation (4): Equation (4) Where, is the current speed, is the target speed, is the target position, is the current position signal, is the adjustment factor, which determines the smoothness of the speed change; At the acceleration point, the frequency of the frequency converter is increased to make the skip quickly reach the operating speed. At the high-speed point, a stable speed is maintained to optimize the operating efficiency. When approaching the target position at the deceleration point, the frequency is gradually reduced to prepare for parking. S3-3: Detect the consistency of the wire rope tension, loose rope signal, and master signal. By calculating the wire rope tension and comparing the actual stress with the allowable stress of the material, if abnormalities are found, including loose rope or over-limit, the system immediately stops and triggers an alarm, as shown in Equation (5) - Equation (6): Equation (5) Equation (6) Where, is the wire rope tension, is the torque of the drum, is the radius of the wire rope, is the actual stress, is the cross-sectional area, is the maximum allowable stress of the material; S3-4. The master controller dynamically adjusts the speed according to the real-time collected track position and speed signals, specifically as shown in Equation (7): Equation (7) Wherein, is the current speed, is the target speed, is the target position, is the current position signal, is the adjustment factor; when the master A signal is lost or abnormal, the system automatically switches to master B to maintain the smooth running of the skip. S3-5. Real-time docking of video monitoring, combined with the real-time capture of the skip running position by the monitoring system, optimizes the master parameters according to the image recognition feedback signal to ensure the matching of the track and speed during the running process.

[0025] It should be noted that the speed adjustment function of S3-2 is applicable to the dynamic adjustment of the entire track section during the running process of the skip, specifically including the acceleration section, the high-speed section and the deceleration section. This function adjusts the current speed according to the running requirements of different stages by real-time monitoring the distance between the current position and the target position of the skip, so that the skip runs smoothly.

[0026] The speed adjustment function of S3-4 focuses on the parking stage and is activated when the skip approaches the target position (such as within 5 meters from the target point). The core purpose of this function is to ensure that the skip can stop safely and accurately at the target position by gradually reducing the speed.

[0027] Step S4. When the skip approaches the target position, reduce the frequency to decelerate, start the hydraulic braking system, check the buffer limit device and record the parking position and running status; Among them, in step S4, the following sub-steps are also included: S4-1. When the skip approaches the target position, the PLC controls the frequency converter to reduce the frequency, so that the skip decelerates until it stops completely. The master controller confirms the position accuracy of the parking point and compares it with the target position data. If there is a deviation, adjust it to the accurate position; S4-2. The hydraulic braking system is started to ensure that the skip is firmly parked at the designated position, and the status of the brake is detected in real time, and the parking position and running status are recorded to provide initial parameters for the next run; S4-3. The master controller detects the status of the buffer limit device in real time before parking. If it is found that the limit device is not enabled or fails, the system enters the safety mode and restricts the skip running by reducing the speed to ensure the safety during the parking stage; S4-4. After parking, the master controller compares the actual parking point and the target position data. If there is a deviation, dynamically adjust the limit parameters to complete the position correction and record the parking accuracy.

[0028] It should be noted that during the deceleration stage of the master controller, the position accuracy of the parking point is monitored in real time to ensure that the skip can accurately dock at the target position. The master controller compares the real-time collected track position signals with the target position data. If a deviation is detected between the skip parking point and the target position, the system will immediately adjust the parking parameters to ensure accurate docking of the skip.

[0029] During the parking stage, the master controller comprehensively checks the parking state, including the states of the braking system and the buffer limit device. After the hydraulic braking system is started, the master controller confirms whether the brake is fully effective to ensure the stable docking of the skip, checks the operating state of the buffer limit device, and verifies whether its operation during the parking stage is normal. If an abnormality in the braking system or the limit device is detected, the system will record the fault information and prompt the operator to handle it through an alarm.

[0030] Step S5: When an abnormal master command signal is detected, switch to the standby master command, trigger an alarm and take shutdown protection measures, while monitoring the equipment status and recording the fault information; Among them, in step S5, the following sub-steps are also included: S5-1: When an abnormal master command signal is detected, that is, the difference between the master command A and master command B signals exceeds the allowable range, trigger the switching mechanism to automatically switch to the standby master command. When switching to the standby master command, the torque will be readjusted, and at the same time, an alarm will be triggered and the fault information will be recorded for the operator to troubleshoot, specifically as shown in equations (8)-(9): Equation (8) Equation (9) Among them, is the difference between the master command signals, are the signals of master command A and B respectively, is the allowable maximum deviation range, is the allowable maximum torque, is the rated torque, is the overload coefficient; S5-2: When an obvious abnormality is detected, immediate shutdown and protection measures need to be taken. For abnormal states such as obvious overload or mechanical failure, it is judged whether it exceeds the maximum capacity through calculating the overload protection, and the amount of slack of the wire rope is calculated through the wire rope slack detection signal to check whether it exceeds the allowable value, specifically as shown in equations (10)-(11): Equation (10) Equation (11) Among them, is the actual load torque, is the abnormal tension, is the radius of the wire rope drum, is the transmission system efficiency, is the current amount of slack rope, is the length of the wire rope during tension calibration, is the actual length of the wire rope in case of abnormality; S5-3. When the signal difference between master command A and master command B exceeds the threshold, the standby master command takes over the system operation. The specific processing steps include: Pause the current operation and record the abnormal signal value; automatically load the standby master command parameters; the video monitoring synchronously captures the operation status of the faulty component to provide an auxiliary diagnosis basis for the operator; S5-4. When the skip speed exceeds the safety threshold, the system automatically triggers the double brakes and cuts off the power source. At the same time, the skip is physically braked through the buffer limit device to prevent the accident from expanding.

[0031] It should be noted that the triggering conditions of the standby master command are as follows: when the master command A signal is abnormal, such as signal loss, exceeding the allowable deviation range or signal interference; the signal difference between master command A and master command B exceeds the set threshold; the master command controller will continuously monitor the signal consistency of master command A and master command B. When an abnormality is detected, the system will immediately trigger the standby master command switching mechanism.

[0032] The system detects the abnormality of the master command A signal (such as signal interruption, deviation exceeding the limit) through the signal monitoring algorithm. The system suspends the control signal of master command A and enables the standby master command (master command B) to take over the operation, and loads the initial parameters of the standby master command, including position, speed and acceleration; the standby master command recalibrates the current state according to the real-time collected operation data to ensure the system smoothly transitions to the standby operation mode.

[0033] Step S6. Record the running position signal, speed curve and fault information, and adjust the operation parameters by analyzing the data to predict potential equipment faults.

[0034] Among them, in step S6, the following sub-steps are also included: S6-1. Record the position signal, speed curve, fault information and alarm status of each operation. The data is stored in the PLC or an independent storage module for subsequent analysis. Specifically, as shown in Equation (12): Equation (12) Wherein, is the displacement, is the initial speed, is the acceleration, is the time; S6-2. Based on the stored operation data, evaluate the operation efficiency by analyzing the change trends of the speed curve and position signal; adjust the parameters according to the data analysis results; use the data to evaluate the stress and strength of the drum, shaft and connecting components to predict potential mechanical faults.

[0035] It should be noted that for trend analysis, the changing trends of the speed curve and position signal are analyzed to determine whether the operating state conforms to the target curve, such as whether the speed is stable and whether the stopping point is accurate. By comparing the operation data of multiple runs, the changing trend of the operation efficiency is found.

[0036] For anomaly analysis, the fault information and alarm records are checked, the specific reasons for the anomaly triggering are analyzed, the normal operation parameters are compared with the abnormal operation parameters, the key influencing factors are found, and potential equipment problems (such as wire rope slack, track anomaly) are identified.

[0037] For predictive analysis, based on historical data and combined with the stress, tension and speed characteristics of the equipment operation, possible mechanical failures are predicted. For example, by analyzing the tension change of the wire rope, the risk of its wear or breakage is predicted; the response time and braking force change trend of the hydraulic braking system are evaluated to predict its performance degradation.

[0038] The above are only the preferred embodiments of the present invention and are not used to limit the present invention. For those skilled in the art, various changes and modifications can be made to the present invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. Blast furnace hoisting car safety system, characterized by: The following steps are involved: Step S1, start the UPS power supply to supply power to the main controller, inverter and PLC, verify the initial position signal, load key parameters and check the equipment status; Step S2, the PLC issues a start command, the main controller gradually increases the frequency of the inverter, collects position signals in real time and dynamically adjusts parameters; Step S3, the master controller monitors the track position and speed signal in real time, adjusts the inverter output frequency, and sets the acceleration point, high speed point and deceleration point in sections; Step S4, when the material vehicle approaches the target position, the frequency is reduced and the speed is slowed down, the hydraulic brake system is started, the buffer limit device is checked, and the parking position and operating status are recorded; Step S5, when the main command signal is detected to be abnormal, the system switches to the backup main command, triggers an alarm, takes shutdown protection measures, and monitors the equipment status and records fault information; Step S6, recording the running position signal, speed curve and fault information, adjusting the running parameters by analyzing the data, and predicting potential equipment failures.

2. The blast furnace hoisting car safety system according to claim 1 is characterized in that: Wherein step S1 also includes the following sub-steps: S1-1, start the uninterruptible power supply (UPS) to supply power to the master controller, inverter and PLC. The master controller verifies the current position signal and compares it with the last operation data to complete the initial position signal setting of the system, as shown in formula (1): N-type (1) in, is the current position signal, The location where the last run ended. is the encoder resolution, For current encoder pulse technology; S1-2, load key control parameters from PLC, including position signal, speed set point and limit condition, the inverter loads basic motor parameters and initial setting value, and the master controller performs status check on the winch motor and wire rope tension sensor equipment to ensure that the encoder signal matches the physical parameters of the equipment, as shown in formula (2): Formula (2) in, is the coding coefficient, Main winch diameter, is the encoder resolution; S1-3, master command A and master command B synchronously load initial parameters, including position, speed and acceleration, and ensure the consistency of master command signals by calculating the difference between the two signals; this synchronous loading and difference detection is a redundancy mechanism. If a difference is detected, the system automatically triggers the backup master command switching mechanism and records the fault log at the same time; S1-4, introduces video monitoring auxiliary function. Video equipment is installed along the material car track to capture the equipment status at the starting position of operation, and transmits the monitoring information to the main control system in real time to provide visual confirmation support for initialization.

3. The blast furnace hoisting car safety system according to claim 1 is characterized in that: Wherein step S2 also includes the following sub-steps: S2-1, PLC issues a start command, the main controller and the frequency converter work together to make the hoist motor enter the low-speed mode, and the material car starts to start smoothly; S2-2, the main controller collects the position signal in real time, and the data is transmitted to the PLC. According to the position signal, the inverter gradually increases the motor frequency, and the material car accelerates smoothly and enters the normal operation stage, as shown in formula (3): Formula (3) in, is the motor operating frequency, is the click speed, is the number of motor pole pairs; S2-3, the main control system combines with the buffer limit protection device to pre-check the track position before the material car starts to ensure the normal operation of the mechanical limit device. If an abnormal state of the track or limit device is detected, the system prevents the material car from starting and triggers an alarm; S2-4, during the startup phase, the main controller gradually increases the inverter output frequency to accelerate the material cart smoothly. Combined with the real-time collected position signal and speed feedback, the startup parameters are dynamically adjusted to ensure that the material cart starts smoothly and enters the operation phase.

4. The blast furnace hoisting car safety system according to claim 1 is characterized in that: Wherein step S3 also includes the following sub-steps: S3-1, the master controller continuously detects the position of the material car track, the signal is synchronized with the PLC in real time, and the PLC dynamically adjusts the inverter output frequency to keep the material car speed consistent with the target curve; S3-2, adjust the speed according to the running status, set the acceleration point, high speed point and deceleration point in sections, and dynamically adjust the speed based on position feedback, as shown in formula (4): Formula (4) in, is the current speed, is the target speed, is the target location, is the current position signal, is the adjustment factor, which determines the smoothness of speed change; The acceleration point increases the frequency of the inverter to enable the material car to quickly reach the operating speed; the high-speed point maintains a stable speed to optimize the operating efficiency; when the deceleration point approaches the target position, the frequency is gradually reduced to prepare for parking; S3-3, detect the consistency of wire rope tension, loose rope signal and master command signal, calculate the wire rope tension and compare the actual stress with the allowable stress of the material. If an abnormality is found, including loose rope or over-limit, the system will stop immediately and trigger an alarm, as shown in formula (5)-formula (6): Formula (5) Formula (6) in, is the wire rope tension, is the torque of the drum, is the radius of the wire rope, is the actual stress, is the cross-sectional area, is the maximum stress allowed by the material; S3-4, the master controller dynamically adjusts the speed according to the real-time acquired track position and speed signals, as shown in formula (7): Formula (7) in, is the current speed, is the target speed, is the target location, is the current position signal, is the adjustment factor; when the master command A signal is lost or abnormal, the system automatically switches to the master command B to maintain the stability of the material car operation; S3-5, real-time docking of video surveillance, combined with the real-time capture of the running position of the material car by the monitoring system, optimizes the main command parameters according to the image recognition feedback signal to ensure the track and speed match during operation.

5. The blast furnace hoisting car safety system according to claim 1 is characterized in that: Wherein step S4 also includes the following sub-steps: S4-1, when the material vehicle approaches the target position, the PLC controls the inverter to reduce the frequency, so that the material vehicle slows down until it stops completely. The main controller confirms the position accuracy of the parking point and compares it with the target position data. If there is a deviation, it is adjusted to the accurate position; S4-2, the hydraulic brake system is started to ensure that the material car is parked firmly at the designated position, and the brake status is detected in real time, the parking position and operating status are recorded, and the initial parameters are provided for the next operation; S4-3, the master controller detects the status of the buffer limit device in real time before parking. If it is found that the limit device is not enabled or fails, the system enters the safety mode and limits the operation of the material vehicle by reducing the speed to ensure the safety of the parking stage; S4-4, after parking, the main controller compares the actual parking point and the target position data. If there is a deviation, the limit parameters are dynamically adjusted to complete the position correction and the parking accuracy is recorded.

6. The blast furnace hoisting car safety system according to claim 1 is characterized in that: Wherein, in step S5, the following sub-steps are also included: S5-1, when an abnormality of the main command signal is detected, that is, the difference between the main command A and the main command B signal exceeds the allowable range, the switching mechanism is triggered to automatically switch to the backup main command. When switching to the backup main command, the torque will be readjusted, and an alarm will be triggered and the fault information will be recorded for the operator to check, as shown in formula (8)-formula (9): Formula (8) Formula (9) in, is the difference of the main command signal, They are the signals of the master command A and B respectively. is the maximum allowable deviation range, To allow the maximum torque, is the rated torque, is the overload factor; S5-2: When an obvious abnormality is detected, shutdown and protection measures need to be taken immediately. For an abnormal state of obvious overload or mechanical failure, the overload protection is calculated to determine whether it exceeds the maximum capacity. The wire rope slack detection signal is used to calculate whether the slack rope amount exceeds the allowable value. The specific details are as follows: Formula (10) Formula (11) in, is the actual load torque, Abnormal tension, is the wire rope drum radius, is the transmission system efficiency, is the current slack rope amount, is the length of the wire rope during tension calibration, It is the actual length of the wire rope under abnormal conditions; S5-3, when the difference between the master command A and the master command B exceeds the threshold, the backup master command takes over the system operation. The specific processing steps include: Pause the current operation and record the abnormal signal value; automatically load the backup master command parameters; video monitoring synchronously captures the operating status of the faulty components to provide the operator with auxiliary diagnosis basis; S5-4, when the speed of the material truck exceeds the safety threshold, the system automatically triggers the double brakes and cuts off the power source, and at the same time physically brakes the material truck through the buffer limit device to prevent the accident from escalating.

7. The blast furnace hoisting car safety system according to claim 1 is characterized in that: Wherein, in step S6, the following sub-steps are also included: S6-1, record the position signal, speed curve, fault information and alarm status of each operation, and store the data in PLC or independent storage module for subsequent analysis, as shown in formula (12): Formula (12) in, is the displacement, is the initial velocity, is the acceleration, For time; S6-2, based on the stored operating data, evaluates the operating efficiency by analyzing the changing trends of the speed curve and position signal; adjusts parameters according to the data analysis results; uses the data to evaluate the stress and strength of the reel, shaft and connecting parts to predict potential mechanical failures.

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