Calcium carbide furnace discharging transportation safety warning control device

Abstract

The invention discloses a calcium carbide furnace discharging transportation safety warning control device. The device is composed of a calcium carbide pot, a steel wire rope, a pot pulling trolley, a guide wheel, a guide rail, a discharge port, an unattended crane, an inner ring winch, an outer ring winch, a tension sensor, an HMI touch screen, a limit hard limit switch, a magnetic induction switch, an infrared induction switch, an AI recognition camera, a field operation box and a PLC smart200 control system. In the discharging process, a winch steel wire rope is controlled to drive a calcium carbide pot to move, a control box can be manually / automatically switched, in the discharging and transporting process of an inner ring winch, a tension sensor is additionally arranged to detect the change of a torque signal borne by the steel wire rope in the moving process in real time, and the purpose of synchronous and coordinated winding and unwinding of the steel wire ropes of the inner ring winch and the outer ring winch is achieved. In a dangerous area, through an AI identification camera, according to a delimited virtual electronic fence, when an abnormal condition occurs, sound and light alarm is performed, and inner and outer ring winches are cut off at the same time, so that personal injury is avoided.

Description

Technical Field

[0001] The present invention belongs to the technical field of electric technologies for calcium carbide production processes, and particularly relates to a method for reforming and applying equipment during the operation of calcium carbide production. Background Art

[0002] Currently, the existing ladle hoist for calcium carbide furnaces is a JM8 slow hoist, which adopts an integrated design of transmission and reducer and a spiral groove drum to avoid the inability to release the rope due to chaotic winding. At the same time, a safety tension sensor is installed on the existing Φ26mm steel wire rope. When the steel wire rope is stressed, it deforms and squeezes the sensor, and the PLC detects the change in the tension of the steel wire rope in real time to avoid operating beyond the load of the steel wire rope. The existing ladle discharging for the 1#, 2#, and 3# furnace eyes of the calcium carbide furnace adopts a common straight track method, which is divided into two discharging methods: the inner circle and the outer circle. Each time when discharging from the inner and outer circles, it is necessary to manually pull and release the steel wire rope one by one, and manually operate to switch the position of the ladle at the furnace eye where discharging occurs, which is time-consuming and laborious, and the labor intensity of workers is high. It is easy to cause safety accidents due to frequent operations. If the phenomenon of calcium carbide flowing off the track occurs during the discharging process of the existing calcium carbide furnace, it will cause the entire track to be unable to pull the ladle out of the track normally, and the 1#, 2#, and 3# calcium carbide furnace eyes restrict and check each other, affecting the normal production of the calcium carbide furnace. It is well known that there are occupational injuries such as high temperature, scalding, mechanical injury, fire, object hitting, electric shock, and secondary injury caused by the fracture of the steel wire rope at the ladle discharging site. Due to the relatively high safety risks at the site, the operation area is managed as a level-four major hazard source. Therefore, it is crucial to have a discharging and transportation system with safe operation, high efficiency, reliable action, and perfect safety interlock. The existing problems are as follows: 1. At the operation site, there is high temperature, and the system constraints only treat the symptoms but not the root causes; 2. During this process, there are many uncertain factors in on-site operation by personnel, and operation errors may also occur; 3. The furnace conditions are unstable, and it is severely affected by high temperature, dust, carbon monoxide, etc. in many aspects, and there are many potential safety hazards. Summary of the Invention

[0003] The purpose of the present invention is to provide a safety warning control device for the discharge and transportation of calcium carbide furnaces. The working process is to control the retraction and extension of the winch in the discharge system to drive the calcium carbide pot to move, complete the transportation of the discharged calcium carbide, and then the unattended crane takes the high-temperature calcium carbide from the pot. The warning control system is provided with an HMI touch screen for displaying the status and parameters, alarm information and settings of the equipment during operation, and an on-site operation box, which is arranged at a convenient location on site according to actual production requirements. Each operation box can manually or automatically operate the discharge and transportation system; the present invention is a safety warning control device for the discharge and transportation of calcium carbide furnaces, which greatly reduces the safety risks at the work site. Multiple protection means are used to protect personnel from the dangerous environment when entering dangerous places, and a series of alarms and actions are used to eliminate safety risks and stop equipment.

[0004] In order to improve the above reliability, the technical solution adopted by the present invention to solve its technical problems is: multiple detection sensors are applied in the whole system; in addition to the electric stone pot, wire rope, pot pulling trolley, guide wheel, guide rail, on-site operation box, discharge port, and unattended crane, the system highlights the anti-intrusion system composed of the extreme hard limit switch, AI recognition camera, magnetic induction switch, infrared induction switch, and PLC smart200 controller in the warning control system; when the door magnetic induction switch is touched or the electronic fence drawn by the AI ​​recognition camera is broken into, the discharge system controls the winch to retract the wire rope and move, the flash alarm sounds, and the winch stops. Ensure that there is no safety risk for people entering the working area.

[0005] The tension sensor detects the change of the wire rope tension torque signal during operation; multiple measures such as extreme hard limit, tension sensor and travel time soft limit are adopted and installed at the end of the track to block the discharge electric stone pot from being pulled out of the area to increase safety protection, and also to prevent the system from automatically powering off before the winch breaks the rope due to inertia sliding, and stop in time. The mechanical lever has a limited life, so the soft limit, i.e., the program limit, is introduced. The time of the wire rope movement is obtained through experiments, and solidified in the program. The forward and reverse running time of the winch must be within the set time. If it reaches or exceeds the set running time, it will stop automatically, so as to ensure that in the normal working condition, when encountering abnormal conditions, the equipment can be stopped immediately, which plays a role in protecting the safety of personnel and equipment. Principle of program limit: From the known length of the existing wire rope to S1 and S2, V1 and V2 are measured by the inverter setting. According to the formula: T=S / V, the running time setting values ​​of T1 and T2 can be obtained. When it is equal to or greater than the set value, the system stops automatically. Thereby avoiding the occurrence of danger and playing a protective role.

[0006] The AI ​​recognition camera can detect the personnel and production conditions during the normal operation of the discharging system in real time according to the planned monitoring electronic fence, and stop the inner and outer ring winch equipment when an abnormality occurs; when the inner and outer ring winches are in working condition, when a person breaks in, the AI ​​recognition camera will react to the sound and light alarm device according to the planned monitoring electronic fence, and the inner and outer ring winches will stop discharging and transporting at the same time. When a person pushes open the physical door and breaks in, the inner and outer ring winches will also stop discharging and transporting. Unlike the previous single limit door, human factors are reduced, there are no negligence and loopholes, and accidents also decrease. After installing the AI ​​recognition camera, the combination of door opening power off + AI linkage technology is adopted to block the loopholes in reality, improve the safety level of dangerous areas, and further improve the safety management level of enterprises.

[0007] The warning control system is equipped with an HMI touch screen for setting and displaying the status, parameter adjustment and alarm information of the equipment during operation. The inner and outer ring winches are used to remove the high-temperature calcium carbide from the pot through an unattended crane during the operation of the winch. The HMI touch screen is used to display the status and parameters, alarm information and settings of the equipment during operation; and the on-site operation box is used to manually or automatically control the discharge and transportation system according to actual production requirements.

[0008] The on-site operation box allows personnel to independently start and stop the discharge system in the inner and outer ring winches by operating the on-site control box. This avoids single-door failures, delays, and reduced work efficiency. It also takes safety into consideration, allowing operators to operate in a more advantageous position and avoid the possibility of operating in a larger risk zone.

[0009] The warning control system adopts PLC smart200 program to limit the forward and reverse operation of the winch within the set time through the time of the wire retracting and releasing movement in the system, which can play a role in safety protection for the inner and outer ring winch discharge and transportation systems during normal operation.

[0010] Furthermore, the AI ​​recognition camera adopts the combination of door opening power off + AI linkage technology. It can not only block the loopholes in reality, but also improve the safety level of dangerous areas and improve the safety factor of personnel in the operating place.

[0011] Compared with the prior art, the beneficial effects of the present invention are as follows: A safety warning control device for the material discharging and transportation of an electric calcium carbide furnace involved in the description of the present invention. During the operation of the hoist, the tension sensors continuously detect the changes in the torque signals in the steel ropes of the inner and outer hoists during operation, which can ensure the synchronous and coordinated winding and unwinding of the steel ropes of the inner and outer hoists. During the calcium carbide production process, it has the function of preventing safety accidents caused by the pulling and breaking of the steel ropes of the inner and outer hoists, and has a reliable protection coefficient; the start and stop of the hoist equipment can adopt local and remote control methods, with a high degree of automation, and can switch between manual and automatic operation modes. There is no need to set up operating personnel for the inner and outer hoists. The system can automatically detect and operate stably for 24 hours through the AI recognition camera according to the established monitoring electronic fence, which not only saves costs for the enterprise and reduces safety accidents caused by human factors, but also adopts multiple detection and protection controls for this set of systems. When encountering emergencies during operation, it can immediately and reliably alarm and stop, preventing the occurrence of safety accidents. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a top view of a safety warning control device for the material discharging and transportation of an electric calcium carbide furnace according to the present invention.

[0013] Figure 2 It is a schematic diagram of the operation steps of the inner hoist of the material discharging and transportation control device of the electric calcium carbide furnace according to the present invention.

[0014] Figure 3 It is a schematic diagram of the operation steps of the outer hoist of the material discharging and transportation control device of the electric calcium carbide furnace according to the present invention.

[0015] Figure 1 In the figure: 11 calcium carbide pot; 15 unmanned overhead crane; 21 HMI touch screen; 22 PLC smart200; 23 overhead crane guide rail; 24 overhead crane gripper; 25 flash alarm.

[0016] Figure 2 In the figure, 1 inner hoist; 2 tension sensor I, 3 tension sensor II, 8 tension sensor III, 9 tension sensor IV; 4 steel rope; 5 ladle trolley; 6 guide wheel; 7 guide rail; 10 inner hoist; 11 calcium carbide pot; 14 discharge port; 16a inner limit hard limit switch; 16b inner infrared induction switch; 17a inner limit hard limit switch; 17b inner infrared induction switch; 18 door magnetic induction switch; 19 AI recognition camera; 20 on-site operation box.

[0017] Figure 3Chinese: 2 Tension Sensor Ⅰ, 3 Tension Sensor Ⅱ, 8 Tension Sensor Ⅲ, 9 Tension Sensor Ⅳ; 4 Steel Wire Rope; 5 Pulling Pot Trolley; 6 Guide Wheel; 7 Guide Rail; 11 Calcium Carbide Pot; 12 Outer Ring Hoist; 13 Outer Ring Hoist; 18 Door Magnet Magnetic Induction Switch; 19 AI Recognition Camera; 20 On-site Operation Box; 26a Outer Ring Extreme Hard Limit Switch; 26b Outer Ring Infrared Induction Switch; 27a Outer Ring Extreme Hard Limit Switch; 27b Outer Ring Infrared Induction Switch. Embodiment

[0018] To describe the present invention in more detail, it is described in conjunction with the accompanying drawings as follows: First, the AI recognition camera 19 shown in Figure 1 in the drawing, according to the designated monitoring electronic fence, when a person breaks in during the working state of the inner and outer rings of the hoist, an audible and visual alarm will be issued in the AI upper system, and at the same time, the hoists running in the inner and outer rings will stop. When a person breaks in by pushing open the physical door manually, the hoist equipment will also stop, so as to protect the personnel from being injured by potential hazard factors during the movement of the equipment on the site.

[0019] Secondly, during the movement of the hoist, risks and personal accidents such as the steel wire rope being pulled and broken and the calcium carbide pot derailing and toppling may occur. In this invention patent, triple protection of tension sensors, limit mechanical switches, photoelectric switch limits, and operation time limits is adopted to ensure accurate positioning and safe control of the calcium carbide pot. When the tension sensors detect unbalanced pulling and releasing, they will alarm and the inner and outer ring hoists will stop working. When the limit mechanical magnetic induction switch detects an object trigger or the limit hard limit switch triggers a signal, the inner and outer ring hoists will stop working.

[0020] As Figure 1 The part shown is the control part of a safety warning control device for the calcium carbide furnace discharging and transporting. The calcium carbide furnace discharging and transporting control device flows the molten calcium carbide into the 11 calcium carbide pots through the inner and outer ring hoists → 15 unmanned overhead crane control → 23 overhead crane guide rails and 24 overhead crane grippers to complete the discharging and transporting process. It is displayed on the human-machine HMI touch screen 21 after analog-to-digital conversion in the PLCsmart200 controller 22 of the safety warning control device. The 25 flash alarm is an essential part of the control in the dangerous area during the entire discharging and transporting process.

[0021] As Figure 2The operating steps of the inner-ring hoist of a calcium carbide furnace discharging and transporting control device are as follows: Place the on-site operation box 20 in the inner-ring and automatic working positions. The inner-ring hoist 1 rotates forward, and the inner-ring hoist 10 rotates in reverse → The tension sensors I (2), II (3), III (8), and IV (9) simultaneously receive force and feedback signals to the PLCsmart200 controller 22 in the safety warning control device. After analog-to-digital conversion, the signals are displayed on the human-machine HMI touch screen 21, showing the operator the lateral and longitudinal force data clearly → Keep the steel wire rope 4 running forward → The ladle trolley 5 moves along the guide rail 7 → Turns through the guide wheel 6 and moves in an arc → Stops at the discharging port 14 → After the molten calcium carbide flows into the calcium carbide ladle 11 → The steel wire rope 4 continues to run forward to the unloading area and waits. Figure 1 The shown 15 unattended overhead crane control → The overhead crane guide rail 23 and the overhead crane gripper 24 complete the discharging and transporting work process → When the calcium carbide ladle 11 is within 1 meter of the limit of the 16a inner-ring hard limit switch, the 16b inner-ring infrared induction switch signal will be triggered and sent to the PLC controller smart200 to execute the program logic and output to cut off the action of the hoist drive controller → If the calcium carbide ladle 11 continues to move forward due to inertia and touches the limit mechanical magnetic induction switch 18 and detects an object, triggering the 17a inner-ring hard limit switch trigger signal, the 17b inner-ring infrared induction switch signal will act and the discharging system will stop working.

[0022] As Figure 3 The operating steps of the outer-ring hoist of a calcium carbide furnace discharging and transporting control device are as follows: Place the on-site operation box 20 in the outer-ring and automatic working positions. The outer-ring hoist 12 rotates forward, and the outer-ring hoist 13 rotates in reverse → The tension sensors I (2), II (3), III (8), and IV (9) simultaneously receive force and feedback signals to the PLCsmart200 controller 22 in the safety warning control device. After analog-to-digital conversion, the signals are displayed on the human-machine HMI touch screen 21, showing the operator the lateral and longitudinal force data clearly → Keep the steel wire rope 4 running forward → The ladle trolley 5 moves along the guide rail 7 → Turns through the guide wheel 6 and moves in an arc → Stops at the discharging port 14 → After the molten calcium carbide flows into the calcium carbide ladle 11 → The steel wire rope 4 continues to run forward to the unloading area and waits. Figure 1 The shown 15 unattended overhead crane control → The overhead crane guide rail 23 and the overhead crane gripper 24 complete the discharging and transporting work process → When the calcium carbide ladle 11 is within 1 meter of the limit of the 26a outer-ring hard limit switch, the 26b outer-ring infrared induction switch signal will be triggered and sent to the PLC controller smart200 to execute the program logic and output to cut off the action of the hoist drive controller → If the calcium carbide ladle 11 continues to move forward due to inertia and touches the limit mechanical magnetic induction switch 18 and detects an object, triggering the 27a outer-ring hard limit switch trigger signal, the 27b outer-ring infrared induction switch signal will act and the discharging system will stop working.

[0023] In the start-up process steps and stop process steps, the safety detection device is not triggered, and the entire start-up process runs smoothly. When personnel open the door and trigger the magnetic switch, the discharging process will immediately stop and an alarm will be issued. At the same time, when personnel cross the steel wire rope during the normal operation of the discharging system, the AI recognition camera in the safety warning control device will generate an alarm and cut off all power according to the defined monitoring electronic fence.

[0024] In the description of the present invention, it should be noted that unless otherwise clearly specified and defined, the terms "set", "safe", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection, a direct connection, or an indirect connection through an intermediate medium. It can be the communication inside two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0025] The above is only the preferred embodiment of the present invention and is not used to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions recorded in the foregoing embodiments or perform equivalent replacements for some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A safety warning control device for the discharge and transportation of an electric calcium carbide furnace, characterized in that: It includes a discharging system and a warning control system; the discharging system includes a calcium carbide pot, steel wire ropes, a pot-pulling trolley, guide wheels, guide rails, a on-site operation box, a discharging port, and an unattended overhead crane; the warning control system includes limit hard limit switches, AI recognition cameras, magnetic induction switches, infrared induction switches, HMI touch screens, and PLC smart200; the winches include an inner winch and an outer winch; the discharging system controls the inner winch and the outer winch to wind and unwind the steel wire ropes to drive the calcium carbide pot to move; the on-site operation box can manually and automatically control the operation of the inner and outer discharging and transportation systems.

2. The safety warning control device for the material discharging and transportation of an electric calcium carbide furnace according to claim 1, wherein: During operation, the tension sensor detects changes in the wire rope tension torque signals of the inner winch and the outer winch.

3. The safety warning control device for the material discharging and transportation of an electric calcium carbide furnace according to claim 1, characterized in that: The AI recognition camera can, according to the formulated monitoring electronic fence, detect the personnel situation and production situation during the normal operation of the discharging system in real time, and stop the inner and outer winches when abnormalities occur; when the inner and outer winches are in the working state, when a person breaks in, it will be reflected in the sound and light alarm device according to the formulated monitoring electronic fence by the AI recognition camera, and at the same time, the discharging and transportation of the inner and outer winches will stop working. When a person manually pushes open the physical door and breaks in, the discharging and transportation systems of the inner and outer winches will also stop working.

4. The safety warning control device for the material discharging and transportation of an electric calcium carbide furnace according to claim 1, wherein: The warning control system is provided with an HMI touch screen for setting and displaying the status and parameter adjustment and alarm information during the operation of the equipment.

5. The safety warning control device for the material discharging and transportation of an electric calcium carbide furnace according to claim 1, wherein: For the on-site operation box, personnel can independently complete the start and stop operations of the discharging system in the inner and outer winch discharging and transportation systems by operating the on-site control box.

6. The safety warning control device for the material discharging and transportation of an electric calcium carbide furnace according to claim 1, wherein: The warning control system uses the PLC smart200 program to limit the forward and reverse operation of the winches within the set time in the system by the time of winding and unwinding the steel wire.

7. The safety warning control device for the material discharging and transportation of an electric calcium carbide furnace according to claim 1, characterized in that: The AI recognition camera adopts the combination of door-opening power-off + AI linkage technology.

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