Bf hoist car safety system

Abstract

The application discloses a blast furnace winding material car safety system, which comprises the following steps: supplying power to the device through a UPS power supply, checking an initial position signal, loading key parameters and checking the equipment state; gradually increasing the frequency of a frequency converter through a main controller, collecting a position signal in real time and dynamically adjusting parameters; the main controller monitors track position and speed signals in real time, and adjusts the output frequency of the frequency converter; when the material car approaches a target position, the frequency is reduced to slow down, a buffer limiting device is checked, and a parking position and running state are recorded; when a main signal anomaly is detected, switching to a backup main signal, triggering an alarm and taking a shutdown protection measure; recording position signals, speed curves and fault information during operation, and adjusting operation parameters by analyzing data to predict potential equipment failures. The application realizes full-process dynamic control of the blast furnace winding material car, improves the stability, safety and fault prediction ability of operation, and is especially suitable for precise transportation under high load and multiple working conditions.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of blast furnace safety, in particular to a blast furnace hoist car safety system. BACKGROUND

[0002] The blast furnace hoist car is a key equipment for material transportation in the blast furnace smelting process, and is widely used in the production link of the metallurgical industry. The equipment transports raw materials from the ground to the top of the blast furnace through a hoist and a rail system, providing protection for continuous feeding in the blast furnace. With the rapid development of the metallurgical industry and the continuous expansion of production scale, the performance of the car equipment is required to be higher in terms of the running efficiency and safety of the blast furnace. Especially under the working conditions of high load and high frequency transportation, the car system needs to meet the requirements of precise positioning, stable operation and efficient transportation.

[0003] At present, the control system of the hoist car on the market mostly uses a single signal source and limited protection measures. When signal anomalies or equipment failures occur, it is difficult to take effective measures in time, resulting in interruption of operation and even serious accidents. Such 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 application provides a blast furnace hoist car safety system, which can effectively improve the safety, stability and intelligent level of system operation by introducing a multi-signal mechanism, video monitoring assistance and data-driven fault prediction method. SUMMARY

[0005] The present application provides a blast furnace hoist car safety system to solve the problems of safety hazards and insufficient control accuracy in the prior art during operation.

[0006] To solve the above technical problems, the present application provides the following technical scheme:

[0007] The present application provides a blast furnace hoist car safety system, comprising the following steps:

[0008] Step S1, start the UPS power supply to supply power to the main order controller, frequency converter and PLC, check the initial position signal, load key parameters and check the equipment state;

[0009] In step S1, the following sub-steps are further included:

[0010] S1-1, start the uninterruptible power supply (UPS) to supply power to the main order controller, frequency converter and PLC, the main order controller checks the current position signal and compares it with the last running data, completes the initial position signal setting of the system, and the specific formula (1) is as follows:

[0011] N formula (1)

[0012] wherein, is the current position signal, is the last running end record position, is the encoder resolution, is the current encoder pulse technology;

[0013] S1-2, load key control parameters from PLC, including position signal, speed set point and limit condition, load motor basic parameters and initial set value from frequency converter, and perform state check on hoist motor and steel wire rope tension sensor device by master controller to ensure that the encoder signal matches the physical parameters of the device, specifically as formula (2):

[0014] Formula (2)

[0015] wherein, is the encoding coefficient, is the main hoist diameter, is the encoder resolution;

[0016] S1-3, synchronously load initial parameters including position, speed and acceleration from master A and master B, and ensure consistency of master signal by calculating the difference value of the two signals; the synchronous loading and difference value detection is a redundancy mechanism, and if the difference value is detected, the system automatically triggers the standby master switching mechanism, and records the fault log at the same time;

[0017] S1-4, introduce video monitoring auxiliary function, install video equipment along the track of the material car, capture the device state 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.

[0018] Step S2, the PLC issues a start instruction, the master controller gradually increases the frequency of the frequency converter, and the position signal is collected in real time and the parameters are dynamically adjusted;

[0019] In step S2, the following sub-steps are further included:

[0020] S2-1, the PLC issues a start instruction, and the master controller and the frequency converter work cooperatively to make the hoist motor enter a low speed mode, and the material car starts to start smoothly;

[0021] S2-2, the master controller collects the position signal in real time, and the data is transmitted to the PLC, and the frequency converter gradually increases the motor frequency according to the position signal, and the material car smoothly accelerates to enter the normal operation stage, specifically as formula (3):

[0022] Formula (3)

[0023] wherein, is the motor operating frequency, is the click rotational speed, is the number of motor pole pairs;

[0024] S2-3, the main order control system combines the buffer limiting protection device, and the track position is pre-checked before the starting of the skip car, so as to ensure that the mechanical limiting device works normally. If it is detected that the track or the limiting device is abnormal, the system prevents the skip car from starting and triggers an alarm;

[0025] S2-4, the main order controller gradually increases the output frequency of the frequency converter, so that the skip car accelerates smoothly. Combined with the real-time collected position signal and speed feedback, the starting parameters are dynamically adjusted to ensure that the skip car starts smoothly and enters the running stage.

[0026] Step S3, the main order controller real-time monitors the track position and speed signal, adjusts the output frequency of the frequency converter, and sets the acceleration point, high-speed point and deceleration point in sections;

[0027] In step S3, the following sub-steps are further included:

[0028] S3-1, the main order controller continuously detects the track position of the skip car, and the signal is synchronized with the PLC in real time. The PLC dynamically adjusts the output frequency of the frequency converter, so that the speed of the skip car is consistent with the target curve;

[0029] S3-2, the speed is adjusted according to the running state, the acceleration point, the high-speed point and the deceleration point are set in sections, and the speed is dynamically adjusted based on the position feedback, specifically as formula (4):

[0030] Formula (4)

[0031] Wherein, 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;

[0032] The acceleration point is achieved by increasing the frequency of the frequency converter, so that the skip car quickly reaches the running speed; the high-speed point keeps the stable speed, and the running efficiency is optimized; when the deceleration point approaches the target position, the frequency is gradually reduced, and the preparation for stopping is made;

[0033] S3-3, the consistency of the steel wire rope tension, the loose rope signal and the main order signal is detected. By comparing the steel wire rope tension and the actual stress with the allowable stress of the material, if the abnormality including the loose rope or the over-limit position is found, the system immediately stops and triggers an alarm, specifically as formula (5)-(6):

[0034] Formula (5)

[0035] Formula (6)

[0036] wherein, is the steel wire rope tension, is the torque of the reel, is the radius of the steel wire rope, is the actual stress, is the cross-sectional area, is the maximum stress allowed by the material;

[0037] S3-4, the master controller dynamically adjusts the speed according to the real-time collected track position and speed signals, specifically as formula (7):

[0038] Formula (7)

[0039] 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 stability of the car running;

[0040] S3-5, real-time video monitoring, combined with the real-time capture of the running position of the car by the monitoring system, the master parameter is optimized according to the image recognition feedback signal to ensure the matching of the track and speed during running.

[0041] Step S4, the car reduces the frequency and slows down when approaching the target position, starts the hydraulic braking system, checks the buffer limiting device and records the parking position and running state;

[0042] wherein in step S4, further comprising the following sub-steps:

[0043] S4-1, when the car approaches the target position, the PLC controls the frequency converter to reduce the frequency, so that the car slows down until it completely stops, and the master controller confirms the parking point position accuracy compared with the target position data, and adjusts to the accurate position if there is deviation;

[0044] S4-2, the hydraulic braking system is started to ensure that the car is stably parked at the specified position, and the state of the brake is detected in real time, the parking position and the running state are recorded, and the initial parameters are provided for the next operation;

[0045] S4-3, the master controller detects the state of the buffer limiting device in real time before parking, if it is found that the limiting device is not enabled or fails, the system enters the safety mode, and the car running is limited by reducing the speed to ensure the safety during the parking stage;

[0046] S4-4, the main order controller compares the actual parking point and the target position data after parking, and if there is a deviation, dynamically adjusts the limiting parameter to complete position correction, and records the parking accuracy.

[0047] Step S5, when detecting abnormality of the main order signal, switch to the standby main order, trigger alarm and take shutdown protection measures, monitor equipment state and record fault information at the same time;

[0048] In step S5, the following sub-steps are further included:

[0049] S5-1, when detecting abnormality of the main order signal, i.e. the difference between the main order A and B signals exceeds the allowed range, trigger the switching mechanism to automatically switch to the standby main order, and when switching to the standby main order, re-adjust the torque, trigger alarm and record fault information for the operator to troubleshoot, as shown in formula (8) - formula (9):

[0050] Formula (8)

[0051] Formula (9)

[0052] Wherein, is the difference between the main order signals, are the signals of main order A and B respectively, is the allowed maximum deviation range, is the allowed maximum torque, is the rated torque, is the overload coefficient;

[0053] S5-2, when detecting obvious abnormality, shutdown and protection measures need to be taken immediately, for obvious overload or mechanical failure abnormal state, whether the maximum capacity is exceeded is judged by calculating overload protection, whether the slack rope exceeds the allowed value is calculated by the steel wire rope slack detection signal, as shown in formula (10) - formula (11):

[0054] Formula (10)

[0055] Formula (11)

[0056] Wherein, is the actual load torque, is the abnormal tension, is the radius of the steel wire rope drum, is the transmission system efficiency, is the current slack rope amount, is the length of the steel wire rope at the time of tension calibration, is the actual length of the steel wire rope under abnormal conditions;

[0057] S5-3, when the master order A and the master order B signal difference value exceeds the threshold value, the standby master order takes over the system operation, and the specific processing steps include:

[0058] Suspend the current operation and record the abnormal signal value; automatically load the standby master order parameters; video monitoring synchronously captures the running state of the fault component to provide auxiliary diagnostic basis for the operator;

[0059] S5-4, when the speed of the skip car exceeds the safety threshold, the system automatically triggers the double brake and cuts off the power source, and at the same time, the skip car is physically braked through the buffer limiting device to prevent the expansion of the accident.

[0060] Step S6, record the position signal, speed curve and fault information of the running, adjust the running parameters through analyzing the data, and predict the potential failure of the equipment.

[0061] In step S6, the following sub-steps are further included:

[0062] S6-1, record the position signal, speed curve, fault information and alarm state of each running, and store the data in PLC or independent storage module for subsequent analysis, specifically as formula (12):

[0063] Formula (12)

[0064] Wherein, is the displacement, is the initial speed, is the acceleration, is the time;

[0065] S6-2, based on the stored running data, the running efficiency is evaluated by analyzing the change trend of the speed curve and the position signal; the parameters are adjusted according to the data analysis result; the stress and strength of the reel, shaft and connecting components are evaluated by using the data to predict potential mechanical failure.

[0066] Compared with the prior art, the beneficial effects of the present application are:

[0067] The present application introduces the redundancy mechanism of the master order signal, automatically switches to the standby master order when the master order A signal is abnormal, and triggers the alarm and shutdown protection measures in real time, ensures the safety of the system operation, and further enhances the safety of the parking stage by combining the hydraulic brake system and the buffer limiting device, effectively prevents accidents.

[0068] The present application adopts the cooperative work of PLC and master order controller, collects the track position and speed signal in real time, dynamically adjusts the output frequency of the frequency converter, sets the acceleration, high speed and deceleration points in sections, ensures the stability and accuracy of the skip car running, and this kind of dynamic adjustment mechanism effectively overcomes the instability problem caused by the fixed system running parameters.

[0069] The application integrates a video monitoring system and data analysis function, captures the track running state of the material car in real time and records the running data, including the speed curve, position signal and fault information, optimizes the running parameters through data analysis, can predict potential mechanical faults and improves the intelligent management level of the equipment.

[0070] The application supports dynamic adjustment under multiple working conditions, ensures safe operation under high load or complex working conditions through steel wire rope tension detection and real-time feedback mechanism, has significant improvement in adaptability and reliability and is particularly suitable for the complex environment of blast furnace metallurgical production. BRIEF DESCRIPTION OF DRAWINGS

[0071] In order to more clearly illustrate the technical solutions of the embodiments of the application, the following will briefly introduce the drawings needed to be used in the embodiments, and understand that the following drawings only show some embodiments of the application, and should not be regarded as limiting the scope, and for those skilled in the art, other related drawings can also be obtained without creative labor.

[0072] Figure 1 is a method flowchart of the application. DETAILED DESCRIPTION

[0073] In order to make the purpose, technical solutions and advantages of the embodiments of the application more clear, the following will combine the drawings in the embodiments of the application to clearly and completely describe the technical solutions in the embodiments of the application. Obviously, the described embodiments are part of the embodiments of the application, rather than all the embodiments. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative labor belong to the scope protected by the application. Therefore, the following detailed description of the embodiments of the application provided in the drawings is not intended to limit the scope of the claimed application, but only for selected embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative labor belong to the scope protected by the application.

[0074] Please refer to Figure 1 is a method flowchart of the blast furnace hoist material car safety system provided by the embodiment of the application, including the following steps:

[0075] Step S1, start the UPS power supply to supply power to the main order controller, frequency converter and PLC, check the initial position signal, load key parameters and check the equipment state;

[0076] In step S1, the following substeps are also included:

[0077] S1-1, start the uninterruptible power supply (UPS) to supply power to the main controller, frequency converter and PLC, the main controller checks the current position signal and compares it with the last running data, completes the initial position signal setting of the system, specifically as formula (1):

[0078] N Formula (1)

[0079] Wherein, is the current position signal, is the last running position recorded, is the encoder resolution, is the current encoder pulse technology;

[0080] S1-2, load key control parameters from PLC, including position signal, speed set point and limit condition, frequency converter loads basic parameters and initial set value of motor, main controller checks the state of hoist motor and steel wire rope tension sensor device, ensures that the encoder signal matches the physical parameters of the device, specifically as formula (2):

[0081] Formula (2)

[0082] Wherein, is the encoding coefficient, is the main hoist diameter, is the encoder resolution;

[0083] S1-3, main order A and main order B synchronously load initial parameters, including position, speed and acceleration, by calculating the difference value of the two signals, ensure the consistency of the main signal; this synchronous loading and difference detection is a redundant mechanism, if the difference is detected, the system automatically triggers the standby main order switching mechanism, and records the fault log at the same time;

[0084] S1-4, introduce video monitoring auxiliary function, video equipment is installed along the track of the car, used to capture the running starting position of the device state, real-time transmission of monitoring information to the main control system, provides visual confirmation support for initialization.

[0085] It should be noted that when the main order A signal is abnormal (such as signal loss and over difference), the system immediately starts the standby main order (main order B) to take over the operation, ensures that the device runs without interruption, reloads the initial parameters of the standby main order after switching, to maintain the continuity and consistency of the signal; when the signal abnormal trigger condition is met (such as signal difference exceeds threshold or signal interruption), trigger the switching mechanism, the switching process includes: pause the current main order signal → activate the standby main order signal → load standby parameters; after switching, the standby main order will recalibrate the current position signal and speed signal, adjust to stable running state.

[0086] Step S2, the PLC issues a start command, and the main controller gradually increases the frequency of the frequency converter, and real-time acquisition of the position signal and dynamic adjustment of the parameters are performed.

[0087] In step S2, the following sub-steps are further included:

[0088] S2-1, the PLC issues a start command, and the main controller and the frequency converter work together to make the hoist motor enter a low-speed mode, and the car starts to start smoothly;

[0089] S2-2, the main controller real-time acquisition of the position signal, data transmission to PLC, according to the position signal frequency converter gradually increase the motor frequency, car smooth acceleration into the normal operation stage, as formula (3):

[0090] Formula (3)

[0091] Wherein, is the motor operating frequency, is the click speed, is the number of motor pole pairs;

[0092] S2-3, the main control system combines the buffer limiting protection device, and pre-checks the track position before the car starts, to ensure that the mechanical limiting device works normally, and if the track or limiting device state is detected to be abnormal, the system prevents the car from starting and triggers an alarm;

[0093] S2-4, the main controller gradually increases the frequency converter output frequency during the start-up stage, so that the car accelerates smoothly, and combines the real-time acquisition of the position signal and the speed feedback to dynamically adjust the start-up parameters, so that the car starts smoothly and enters the running stage.

[0094] It should be noted that before the car starts, the system conducts a comprehensive inspection of the track position and the state of the limiting device, the track inspection includes track flatness, obstacle detection and wear condition evaluation, and the limiting device inspection includes the triggering mechanism of the buffer limiting and the mechanical limiter; The inspection data is collected in real time by sensors and video monitoring, and compared with the standard parameters to ensure that the operating conditions are normal; If an abnormality is detected, the system prevents the car from starting and triggers an alarm, and records the abnormal information, and enters a safety mode to protect the equipment and personnel safety.

[0095] Step S3, the main controller real-time monitors the track position and speed signal, adjusts the frequency converter output frequency, and sets the acceleration point, high-speed point and deceleration point in sections;

[0096] In step S3, the following sub-steps are further included:

[0097] S3-1, the main controller continuously detects the position of the track, 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 track consistent with the target curve;

[0098] S3-2, speed adjustment according to the running state, segmented setting of acceleration point, high speed point and deceleration point, dynamic adjustment of speed based on position feedback, specifically as formula (4):

[0099] Formula (4)

[0100] Wherein, 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 speed change;

[0101] The acceleration point is achieved by increasing the frequency of the frequency converter, so that the track quickly reaches the running speed; the high speed point keeps the stable speed, and optimizes the running efficiency; the deceleration point gradually reduces the frequency when approaching the target position, and prepares for parking;

[0102] S3-3, detect the consistency of steel wire rope tension, loose rope signal and main signal, through the calculation of steel wire rope tension and actual stress and material allowable stress comparison, if found abnormal including loose rope or over limit, the system immediately stop and trigger alarm, specifically as formula (5) - formula (6):

[0103] Formula (5)

[0104] Formula (6)

[0105] Wherein, is the tension of the steel wire rope, is the torque of the drum, is the radius of the steel wire rope, is the actual stress, is the cross-sectional area, is the maximum stress allowed by the material;

[0106] S3-4, the main controller dynamically adjusts the speed according to the real-time collected track position and speed signal, specifically as formula (7):

[0107] Formula (7)

[0108] Wherein, is the current speed, is the target speed, is the target position, is the current position signal, Adjusting factor; when the command A signal is lost or abnormal, the system automatically switches to command B to maintain the smoothness of the car operation;

[0109] S3-5, real-time video monitoring interface, combined with the real-time capture of the car running position by the monitoring system, the master command parameters are optimized according to the image recognition feedback signal to ensure the matching of the track and speed during operation.

[0110] 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 operation of the car, 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 car, so that the car runs smoothly.

[0111] The speed adjustment function of S3-4 focuses on the parking stage and starts when the car approaches the target position (such as within 5 meters of the target point). The core purpose of this function is to ensure that the car can safely and accurately park at the target position by gradually reducing the speed.

[0112] Step S4, reduce the frequency and decelerate when the car approaches the target position, start the hydraulic braking system, check the buffer limiting device and record the parking position and running state;

[0113] In step S4, the following sub-steps are also included:

[0114] S4-1, when the car approaches the target position, the PLC controls the frequency converter to reduce the frequency, so that the car decelerates until it completely stops, and the master command controller confirms the parking point position accuracy compared with the target position data, and adjusts to the accurate position if there is deviation;

[0115] S4-2, the hydraulic braking system is started to ensure that the car is stably parked at the specified position, and the brake state is detected in real time to record the parking position and running state, providing initial parameters for the next operation;

[0116] S4-3, the master command controller detects the state of the buffer limiting device in real time before parking, and if it finds that the limiting device is not enabled or fails, the system enters the safety mode to limit the car operation by reducing the speed to ensure the safety of the parking stage;

[0117] S4-4, after parking, the master command controller compares the actual parking point and the target position data, and if there is deviation, dynamically adjusts the limiting parameters to complete the position correction, and records the parking accuracy.

[0118] It should be noted that the main controller will monitor the position accuracy of the stopping point in the deceleration stage of the skip car, to ensure that the skip car can be accurately parked at the target position. The main controller compares the real-time collected track position signal with the target position data. If it is detected that the stopping point of the skip car deviates from the target position, the system will immediately adjust the stopping parameters to ensure accurate parking of the skip car.

[0119] The main controller will comprehensively check the stopping state during the stopping stage, including the state of the braking system and the buffer limiting device. After the hydraulic braking system is started, the main controller confirms whether the brake is fully effective to ensure that the skip car is parked stably. The running state of the buffer limiting device is checked to verify whether it is working normally during the stopping stage. If it is detected that the braking system or the limiting device is abnormal, the system will record the fault information and prompt the operator to handle it through alarm.

[0120] Step S5, switch to the standby master when detecting abnormal master signal, trigger alarm and take shutdown protection measures, monitor equipment state and record fault information at the same time;

[0121] In step S5, the following sub-steps are further included:

[0122] S5-1, when the main signal is detected to be abnormal, i.e. the difference between the main A and B signals exceeds the allowed range, the switching mechanism is triggered to automatically switch to the standby master. When switching to the standby master, the torque will be adjusted again, and the alarm will be triggered and the fault information will be recorded for the operator to troubleshoot. Specifically, as shown in formula (8) and formula (9):

[0123] Formula (8)

[0124] Formula (9)

[0125] Wherein, is the difference between the main signals, are the signals of main A and B respectively, is the allowed maximum deviation range, is the allowed maximum torque, is the rated torque, is the overload coefficient;

[0126] S5-2, when obvious abnormality is detected, shutdown and protection measures need to be taken immediately. For obvious overload or mechanical failure, whether the maximum capacity is exceeded is judged by calculating the overload protection. Whether the slack rope exceeds the allowed value is calculated by the steel wire rope slack detection signal. Specifically, as shown in formula (10) and formula (11):

[0127] Formula (10)

[0128] Formula (11)

[0129] wherein, is the actual load torque, is the abnormal tension, is the steel wire rope drum radius, is the transmission system efficiency, is the current slack rope amount, is the steel wire rope length at the time of tension calibration, is the actual length of the steel wire rope under abnormal conditions;

[0130] S5-3, when the master A and master B signal difference exceeds the threshold value, the standby master takes over the system operation, and the specific processing steps include:

[0131] suspend the current operation and record the abnormal signal value; automatically load the standby master parameters; video monitoring synchronously captures the running state of the fault component to provide auxiliary diagnostic basis for the operator;

[0132] S5-4, when the car speed exceeds the safety threshold, the system automatically triggers the double brake and cuts off the power source, and at the same time, through the buffer limiting device, the physical brake of the car is carried out to prevent the expansion of the accident.

[0133] It should be noted that the triggering condition of the standby master is that the master A signal is abnormal, for example, signal loss, exceeding the allowed deviation range or signal interference; the master A and master B signal difference exceeds the set threshold value; the master controller will monitor the signal consistency of master A and master B in real time, and when the abnormality is detected, the system will immediately trigger the standby master switching mechanism.

[0134] The system detects the master A signal abnormality (such as signal interruption, deviation overrun) through the signal monitoring algorithm, suspends the control signal of master A, enables the standby master (master B) to take over the operation, loads the initial parameters of the standby master, including position, speed and acceleration; the standby master recalibrates the current state according to the real-time collected operation data to ensure smooth transition of the system to standby operation mode.

[0135] Step S6, record the position signal, speed curve and fault information of the running, adjust the running parameters through data analysis, and predict the potential failure of the equipment.

[0136] In step S6, the following sub-steps are further included:

[0137] S6-1, record the position signal, speed curve, fault information and alarm state of each operation, and store the data in PLC or independent storage module for subsequent analysis, specifically as formula (12):

[0138] Formula (12)

[0139] wherein, is displacement, is initial velocity, is acceleration, is time;

[0140] S6-2, based on the stored operation data, evaluates the operation efficiency by analyzing the change trend of the speed curve and the position signal; adjusts the parameters according to the data analysis result; and predicts potential mechanical failures by using the data to evaluate the stress and strength of the reel, shaft and connecting components.

[0141] It should be noted that the trend analysis analyzes the change trend of the speed curve and the position signal to determine whether the operation state conforms to the target curve, such as whether the speed is smooth and whether the parking point is accurate. By comparing multiple operation data, the change trend of the operation efficiency is found.

[0142] Abnormal analysis checks fault information and alarm records, analyzes the specific reasons for abnormal triggering, compares normal operation parameters with abnormal operation parameters, finds out the key influencing factors, and identifies potential equipment problems (such as slack steel wire rope and abnormal track).

[0143] Prediction analysis predicts possible mechanical failures according to historical data, combined with the stress, tension and speed characteristics of the equipment operation, such as predicting the wear or fracture risk of the steel wire rope by analyzing the tension change of the steel wire rope; and evaluating the response time and braking force change trend of the hydraulic braking system to predict its performance degradation.

[0144] The above only describes the preferred embodiments of the present application and is not used to limit the present application. For those skilled in the art, the present application has various modifications and changes. Any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A blast furnace hoist car safety system, characterized by, Its operation includes the following steps: Step S1, start the UPS power supply for the main order controller, frequency converter and PLC, check the initial position signal load key parameters and check the equipment state; Step S2, the PLC issues a start command, the main order controller gradually increases the frequency of the frequency converter, collects the position signal in real time and dynamically adjusts the parameters; Step S3, the main order controller monitors the track position and speed signal in real time, adjusts the output frequency of the frequency converter, and sets the acceleration point, high speed point and deceleration point in sections; Step S4, when the car approaches the target position, the frequency is reduced and the hydraulic brake system is started, the buffer limiting device is checked and the parking position and running state are recorded; Step S5, when the main order signal is detected, switch to the standby main order, trigger the alarm and take the shutdown protection measures, at the same time monitor the equipment state and record the fault information; In step S5, further comprising the following sub steps: S5-1, when the main order signal is detected, that is, the difference between main order A or main order B signal exceeds the allowed range, trigger the switching mechanism to automatically switch to the standby main order, when switching to the standby main order, re-adjust the torque, at the same time trigger the alarm and record the fault information for the operator to check, as formula (8) - formula (9): Equation (8) Equation (9) wherein, is a master signal difference, are master A and B signals, respectively, is a maximum allowable deviation range, is a maximum allowable torque, is a rated torque, is an overload factor; S5-2, when obvious abnormality is detected, shutdown and protection measures need to be taken immediately, for obvious overload or mechanical failure, whether the maximum capacity is exceeded is judged by calculating the overload protection, whether the slack rope exceeds the allowed value is calculated by the steel wire rope slack detection signal, as formula (10) - formula (11): Equation (10) Equation (11) wherein, is the actual load torque, is the abnormal tension, is the steel rope drum radius, is the transmission system efficiency, is the current slack rope amount, is the steel rope length at the time of tension calibration, is the actual steel rope length in the abnormal situation; S5-3, when the difference between main order A and main order B signal exceeds the threshold value, the standby main order takes over the system operation, the specific processing steps include: Pause the current operation and record the abnormal signal value; automatically load the standby main order parameters; video monitoring synchronously captures the running state of the fault component, providing auxiliary diagnosis basis for the operator; S5-4, when the car speed exceeds the safety threshold, the system automatically triggers the double brake and cuts off the power source, at the same time, the buffer limiting device is used to physically brake the car to prevent the accident from expanding; Step S6, record the running position signal, speed curve and fault information, adjust the running parameters by analyzing the data, and predict the potential failure of the equipment.

2. The safety system of the blast furnace winding car according to claim 1, wherein in step S1, further comprising the following sub steps: S1-1, start the uninterruptible power supply (UPS) to supply power for the main order controller, frequency converter and PLC, the main order controller checks the current position signal and compares it with the last running data to complete the initial position signal setting of the system, as formula (1): S1-2, load key control parameters from PLC, including position signal, speed set point and limiting condition, frequency converter loads basic parameters and initial setting value of motor, main order controller checks the state of winding motor and steel wire rope tension sensor equipment to ensure that the encoder signal matches the physical parameters of the equipment, as formula (2): N Formula (1) wherein, is a current position signal, is a last run end recorded position, is an encoder resolution, is a current encoder pulse technique; ​ Equation (2) wherein, is the encoder resolution, is the main hoist diameter, is the encoder resolution; S1-3, the master A and the master B synchronously load the initial parameters including position, speed and acceleration, and ensure the consistency of the master signals by calculating the difference value of the two signals; the synchronous loading and difference value detection are the redundancy mechanism, and if the difference value is detected, the system automatically triggers the standby master switching mechanism, and records the fault log at the same time; S1-4, the video monitoring auxiliary function is introduced, the video equipment is installed along the track of the charging car, which is used to capture the equipment state of the starting position, and the monitoring information is transmitted to the master control system in real time to provide visual confirmation support for initialization.

3. The blast furnace winding car safety system according to claim 1, wherein in step S2, further comprising the following sub-steps: S2-1, the PLC issues a start instruction, and the master controller and the frequency converter work cooperatively to make the winding machine motor enter a low-speed mode, and the charging car starts to start smoothly; S2-2, the master controller collects the position signal in real time, and the data is transmitted to the PLC, and the frequency converter gradually increases the motor frequency according to the position signal, and the charging car smoothly accelerates to enter the normal running stage, and the specific formula is as follows: S2-3, the master control system combines the buffer limiting protection device to pre-check the track position before the charging car starts, and ensures that the mechanical limiting device works normally, and if it is detected that the track or the limiting device is abnormal, the system prevents the charging car from starting and triggers an alarm; Equation (3) wherein, is the motor operating frequency, is the click rotational speed, is the motor pole pair number; S2-4, the master controller gradually increases the output frequency of the frequency converter during the starting stage to make the charging car accelerate smoothly, and dynamically adjusts the starting parameters combined with the real-time collected position signal and speed feedback to ensure that the charging car starts smoothly and enters the running stage.

4. The blast furnace winding car safety system according to claim 1, wherein in step S3, further comprising the following sub-steps: S3-1, the master controller continuously detects the track position of the charging car, and 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 charging car consistent with the target curve; S3-2, the speed is adjusted according to the running state, and the acceleration point, the high-speed point and the deceleration point are set segmentally, and the speed is dynamically adjusted based on the position feedback, and the specific formula is as follows: The acceleration point makes the charging car quickly reach the running speed by increasing the frequency of the frequency converter; the high-speed point keeps the stable speed to optimize the running efficiency; and the deceleration point gradually reduces the frequency when approaching the target position to prepare for parking; S3-3, the consistency of the steel wire rope tension, the loose rope signal and the master signal is detected, and if the abnormality including the loose rope or the over-limit is found by comparing the steel wire rope tension and the actual stress with the allowable stress of the material, the system immediately stops and triggers an alarm, and the specific formulas are as follows: Equation (4) wherein, is the current speed, is the target speed, is the target position, is the current position signal, is a regulation factor determining the degree of smoothing of the speed change; S3-4, the master controller dynamically adjusts the speed according to the real-time collected track position and speed signal, and the specific formula is as follows: S3-5, the video monitoring is connected in real time, and the running position of the charging car is captured in real time combined with the monitoring system, and the master parameters are optimized according to the image recognition feedback signal to ensure the matching of the track and the speed in the running process. Equation (5) Equation (6) wherein, is the steel cable tension, is the torque of the drum, is the radius of the steel cable, is the actual stress, is the cross-sectional area, is the maximum stress allowed by the material; 5. The blast furnace winding car safety system according to claim 1, wherein in step S4, further comprising the following sub-steps: 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, keeping the smoothness of the car running; ​ ​ ​ S4-1, when the skip approaches the target position, the PLC controls the frequency converter to reduce the frequency, so that the skip slows down until it completely stops, and the main controller confirms the position accuracy of the stopping point compared with the target position data, and adjusts to the accurate position if there is deviation; S4-2, the hydraulic brake system is started to ensure that the skip is stably parked at the specified position, and the state of the brake is detected in real time, the parking position and the running state are recorded, and the initial parameters are provided for the next operation; S4-3, the main controller detects the state of the buffer limiting device in real time before parking, if it is found that the limiting device is not enabled or fails, the system enters the safety mode, and the speed is limited 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, and dynamically adjusts the limiting parameters to complete the position correction if there is deviation, and records the parking accuracy.

6. The safety system of the blast furnace winding skip according to claim 1, wherein in step S6, the following sub-steps are further included: S6-1, record the position signal, speed curve, fault information and alarm state of each operation, and store the data in the PLC or an independent storage module for subsequent analysis, specifically as formula (12): S6-2, based on the stored operation data, the running efficiency is evaluated by analyzing the change trend of the speed curve and the position signal, the parameters are adjusted according to the data analysis results, and the potential mechanical failure is predicted by using the data to evaluate the stress and strength of the winding drum, shaft and connecting parts. Equation (12) wherein, is the displacement, is the initial velocity, is the acceleration, is the time; ​

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