Double-master mutual inspection control system for blast furnace charging skip and working method of double-master mutual inspection control system

Abstract

The invention discloses a blast furnace charging skip double-master mutual inspection control system and a working method thereof, the system comprises two digital master controllers, PLCs in the digital master controllers have Ethernet communication capability and are used for receiving and processing position and state information from the two master controllers, and data transmission is carried out between the PLCs and an upper computer; according to the invention, mutual monitoring between the two master controllers is realized through the dual-digital master mutual inspection control system. When one master command has a fault, the other master command can timely perceive the fault, so that the out-of-control system caused by the fault of a single master command is effectively avoided, the reliability of the blast furnace charging skip control system is remarkably improved, and the system can send alarm information to an upper computer in an extremely short time once an abnormality is found, so that the system is convenient to use. And an operator can quickly respond and take measures in time, so that further expansion of an accident is avoided, and the loss is reduced to the greatest extent.

Description

Technical Field

[0001] The invention belongs to the technical field of industrial automation control, and particularly relates to a double master command mutual inspection control system for a blast furnace skip car and its working method. Background Technique

[0002] In the control system of a blast furnace skip car, the master command controller is a crucial component. It undertakes the task of sending precise control instructions to ensure that the skip car can run accurately according to the predetermined trajectory and speed. However, the traditional master command control system has obvious defects, and the most prominent one is the lack of an effective detection mechanism. During the actual operation, once a master command fails, due to the inability to detect and handle it in a timely manner, it is very likely to cause the entire system to get out of control. This will not only seriously interfere with the continuity of blast furnace production, lead to production interruption, increase production costs, but also pose a great threat to production safety and may trigger serious safety accidents. Therefore, how to significantly improve the reliability of the master command control of the blast furnace skip car operation has become a technical problem that urgently needs to be solved in the current field of industrial automation control. Summary of the Invention

[0003] The purpose of the invention is to provide a double master command mutual inspection control system for a blast furnace skip car and its working method to solve the problems raised in the above background technique.

[0004] To achieve the above purpose, the invention provides the following technical solution: A double master command mutual inspection control system for a blast furnace skip car, including two digital master command controllers. The PLC in the digital master command controller has the ability of Ethernet communication, which is used to receive and process the position and status information from the two master commands, and to enable data transmission between the PLC and the upper computer.

[0005] The two digital master command controllers are mutually controlled and connected for monitoring, and the upper computer is connected to the two digital master command controllers through Ethernet to monitor and transmit the working data of the blast furnace skip car.

[0006] Preferably, it also includes a PLC program for mutually collecting the position and status information of the two master command controllers and a mutual inspection program for judging the working status of the other master command by using the collected information, making up for the deficiencies of the traditional system, effectively improving the system detection ability, making faults nowhere to hide, greatly improving the comprehensiveness and accuracy of the system's monitoring of the master command working status, and further improving the reliability of the blast furnace skip car control system.

[0007] Preferably, when the mutual inspection program detects an abnormality, the abnormality information is transmitted to the upper computer in real time through Ethernet for alarm. Through real-time alarm via Ethernet, the operator can know the master command abnormality situation in the first time, take measures quickly, avoid production interruption caused by the failure not being processed in time, reduce the risk of safety accidents, and effectively ensure the continuity and safety of blast furnace production.

[0008] Preferably, it also includes a program that transmits abnormal information to the host computer in real time via Ethernet for alarm when an abnormality is found. Even if an instruction failure occurs suddenly, an alarm can be issued in time, so that the operator can respond quickly, prevent the fault from expanding, reduce the adverse impact on blast furnace production, improve the timeliness and effectiveness of the system's response to faults, and ensure smooth production operation.

[0009] The present invention also provides a working method of a blast furnace charge car dual-master mutual inspection control system, which specifically includes the following steps:

[0010] S1. Start the system, and the two master controllers send position and status information to their corresponding PLCs respectively;

[0011] S2. After receiving the information, the PLC determines the working status of the other party's master command through the mutual inspection program;

[0012] S3. If an abnormality is detected, the alarm mechanism is immediately triggered and the abnormality information is sent to the host computer via the network;

[0013] S4. After receiving the alarm information, the host computer performs corresponding processing.

[0014] Preferably, the corresponding processing includes issuing an audible and visual alarm and recording a fault log. In complex industrial environments, abnormal conditions can be quickly notified to relevant personnel, allowing them to quickly locate the problem. Recording a fault log provides detailed information for subsequent fault analysis, helping technicians to gain a deeper understanding of the cause and process of the fault.

[0015] Preferably, during the operation of the system, the system is regularly subjected to maintenance operations such as hardware equipment inspection and software program backup and update. Regular hardware inspection can timely discover potential equipment problems and repair and replace them. Software backup can prevent data loss. Software update can fix vulnerabilities and improve performance, thereby comprehensively improving the stability and reliability of the system, extending the service life of the system, and reducing the possibility of failures caused by equipment and software problems.

[0016] Preferably, when the system encounters a sudden failure, the problem can be quickly located and repaired based on the alarm information and fault log provided by the system. The technicians can quickly lock the fault point, shorten the troubleshooting time, perform repairs in time, reduce the downtime of the blast furnace charge car control system, ensure efficient production operation, and reduce economic losses caused by failures.

[0017] Compared with the prior art, the technical effects and advantages of the present invention are as follows: the blast furnace charge car dual master mutual inspection control system and its working method,

[0018] Through the dual digital master mutual inspection control system, the present invention realizes the mutual monitoring between two master controllers. When one master controller fails, the other master controller can detect it in time, thus effectively avoiding the system out of control caused by the failure of a single master controller and significantly improving the reliability of the blast furnace skip control system.

[0019] Once the present invention detects an abnormality, the system can send alarm information to the upper computer within an extremely short time, enabling the operator to make a quick response, take timely measures, avoid the further expansion of the accident, and minimize the losses to the greatest extent.

[0020] The structure design of this system is simple and clear, and the functions of each component are clear, facilitating daily maintenance and fault troubleshooting. Whether it is the inspection and replacement of hardware devices or the debugging and optimization of software programs, they can all be carried out efficiently, reducing the maintenance cost and improving the production efficiency. Brief Description of the Drawings

[0021] Figure 1 It is a block diagram of the dual master mutual inspection control system for the blast furnace skip of the present invention. Detailed Embodiment

[0022] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0023] Please refer to Figure 1 , the present invention provides a technical solution: a dual master mutual inspection control system for a blast furnace skip, including two digital master controllers. The PLC in the digital master controller has the ability of Ethernet communication, which is used to receive and process the position and status information from the two masters, and enable data transmission between the PLC and the upper computer;

[0024] When building the control system architecture of the blast furnace skip, according to the layout of the blast furnace production process and the running track of the skip, accurately select the installation positions of the two digital master controllers. It is necessary to ensure that the sensing components of the master controller are closely related to the key moving parts of the skip, such as connecting through mechanical linkages or high-precision encoders, so as to accurately and real-time sense the position and status information of the skip. During the installation process, use tools such as a spirit level to ensure that the levelness and perpendicularity errors of the installation plane of the master controller are controlled within a very small range, avoiding position detection deviation caused by installation tilt.

[0025] For the Ethernet, high-quality network cables compliant with the industrial Ethernet standard are selected to connect the PLCs in the two digital master controllers to the host computer. During the wiring process, the principle of separating strong and weak electricity is followed to prevent electromagnetic interference from affecting the stability of data transmission. Each section of the network cable is clearly marked with the start and end device port information. After the connection is completed, a professional network testing tool, such as a network cable tester, is used to comprehensively detect the network connectivity to ensure that there are no problems such as open circuits or short circuits in the network link. At the same time, in the network settings interface of the PLC and the host computer, parameters such as the IP address, subnet mask, and gateway are correctly configured to ensure that the data transmission path is unobstructed.

[0026] PLC program writing: Professional programming software suitable for the PLC hardware is selected, such as Siemens Step7, Mitsubishi GXWorks, etc. During the program writing process, the functions of collecting the position and status information of the master controllers are encapsulated into independent function blocks. By defining a data structure, the storage format of the collected data is precisely planned to ensure data type matching and efficient storage. According to the communication protocol characteristics of different brands of PLCs, corresponding communication driver programs are written to achieve stable and high-speed data interaction between the two master controllers. At the same time, a data verification mechanism, such as CRC verification, is set in the program to verify the integrity of the collected data and prevent errors in the data during transmission. The two digital master controllers are connected to each other for control and monitoring, and the host computer monitors and transmits the working data of the blast furnace skip through the Ethernet connection to the two digital master controllers.

[0027] It also includes a PLC program for mutually collecting the position and status information of the two master controllers and a mutual inspection program for judging the working status of the other master based on the collected information. The mutual inspection program makes logical judgments based on the collected position and status information of the master. Using the state machine algorithm, according to different stages of the skip operation, such as rising, falling, stopping, etc., the normal threshold range of the master working status is set. For example, during the rising stage of the skip, if the position change rate feedback by the master exceeds the preset range, or the status signal has an abnormal jump, it is determined that the master is working abnormally. By establishing a fault knowledge base, different types of abnormal situations are associated with corresponding fault causes and treatment suggestions to provide strong support for subsequent fault diagnosis. After the program writing is completed, strict code review is carried out to ensure that the program logic is rigorous and there are no loopholes.

[0028] When an abnormality is detected during the mutual inspection process, the abnormal information is transmitted in real time to the host computer via Ethernet for alarm; it also includes a program for transmitting the abnormal information in real time to the host computer via Ethernet when an abnormality is detected, parameter setting and debugging: In the PLC, set the data acquisition period. According to the running speed and control accuracy requirements of the blast furnace skip, generally set the period between 10 - 100 ms to ensure that the command information can be obtained in a timely manner. At the same time, finely adjust the threshold parameters in the mutual inspection program. Through multiple simulations of the actual operating conditions of the skip and combining with the on-site test results, determine the optimal parameter values. In the host computer, configure the alarm information display interface, set the alarm priorities and display colors for different types of abnormalities to facilitate the operators to quickly identify important faults. After completing the parameter setting, conduct system joint debugging, simulate various normal and abnormal operating conditions, comprehensively test the operation effect of the program, and promptly discover and solve problems such as parameter mismatch and unstable program operation.

[0029] The present invention also provides a working method for the dual command mutual inspection control system of the blast furnace skip, which specifically includes the following steps:

[0030] S1. Start the system, and the two command controllers respectively send the position and status information to their corresponding PLCs.

[0031] S2. After the PLC receives the information, judge the working status of the other command through the mutual inspection program.

[0032] S3. If an abnormality is found, immediately trigger the alarm mechanism and send the abnormal information to the host computer via the network.

[0033] S4. After the host computer receives the alarm information, perform corresponding processing.

[0034] The corresponding processing includes emitting audible and visual alarms and recording fault logs.

[0035] During the operation of the system, regularly conduct maintenance operations such as checking the hardware devices of the system and backing up and updating the software programs.

[0036] When the system encounters a sudden failure, based on the alarm information and fault logs provided by the system, quickly locate the problem and perform repair processing.

[0037] After the system is started and put into operation, set up a special operation status monitoring area on the host computer monitoring interface to display in real time key indicators such as the information transmission rate and packet loss rate between the two command controllers and the PLC. By drawing a data trend graph, visually display the changes in the command position and status information over time to facilitate the operators to promptly discover abnormal fluctuations in the data. At the same time, set up a system heartbeat detection mechanism to send heartbeat packets to the host computer regularly. If the host computer does not receive a heartbeat packet within the specified time, it is determined that the system communication is abnormal and an alarm is immediately issued.

[0038] Conduct a comprehensive inspection of the hardware devices once a week, including cleaning the shell of the master controller to prevent dust accumulation from affecting heat dissipation and sensing accuracy; checking the network cable connection ports to ensure firm connection without signs of looseness; detecting the temperature of the PLC module. If the temperature is too high, clean the dust accumulated on the cooling fan in time or check the cooling system. Back up the software program once a month, store the backup files in a dedicated external storage device, and adopt encryption measures to prevent data leakage. Update the software program once a quarter. According to the problems accumulated during the system operation and the optimization requirements, repair program vulnerabilities, upgrade algorithms, and improve system performance;

[0039] When the system encounters a sudden failure, the operator can quickly locate the problem according to the alarm information of the upper computer and the fault log. For example, if the alarm information indicates that the position data of a certain master is abnormal, first check whether the communication line between the master controller and the PLC is loose. If the line is normal, further check whether the master sensor is damaged. During the fault repair process, use professional fault diagnosis tools, such as using an oscilloscope to detect the output signal of the sensor and using a programming cable to connect to the PLC for online diagnosis. After the repair is completed, conduct a comprehensive test on the system to ensure that the fault has been completely eliminated and the system resumes normal operation. At the same time, record the fault cause and the processing process in detail to provide a reference basis for subsequent system maintenance and optimization

[0040] Finally, it should be noted that the above are only the preferred embodiments of the present invention and are 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 on some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A double master order mutual inspection control system for a blast furnace skip, characterized in that, It includes two digital master controllers. The PLCs inside the digital master controllers have the ability of Ethernet communication, which are used to receive and process the position and status information from the two masters, and to enable data transmission between the PLCs and the upper computer. The two digital master controllers are mutually controlled, connected and monitored, and the upper computer monitors and transmits the working data of the blast furnace skip through Ethernet connection to the two digital master controllers.

2. The double master order mutual inspection control system for a blast furnace skip according to claim 1, wherein: It also includes a PLC program for mutually collecting the position and status information of the two master controllers and a mutual inspection program for judging the working status of the other master by using the collected information.

3. The double master command mutual inspection control system for a blast furnace skip according to claim 2, characterized in that: When the mutual inspection program detects an abnormality, the abnormality information is transmitted to the upper computer in real time through Ethernet for alarming.

4. A double master order mutual inspection control system for a blast furnace skip, characterized in that: It also includes a program for transmitting the abnormality information to the upper computer in real time through Ethernet for alarming when an abnormality is detected.

5. A working method of the double master order mutual inspection control system for a blast furnace skip according to any one of claims 1-4, characterized in that: Specifically, it includes the following steps: S1. Start the system, and the two master controllers respectively send the position and status information to their corresponding PLCs. S2. After receiving the information, the PLC judges the working status of the other master through the mutual inspection program. S3. If an abnormality is detected, the alarm mechanism is immediately triggered, and the abnormality information is sent to the upper computer through the network. S4. After receiving the alarm information, the upper computer performs corresponding processing.

6. The working method of a double master order mutual inspection control system for a blast furnace skip according to claim 5, characterized in that: The corresponding processing includes giving out audible and visual alarms and recording fault logs.

7. The working method of a double master order mutual inspection control system for a blast furnace skip according to claim 5, characterized in that: During the operation of the system, maintenance operations such as regularly checking the hardware devices of the system and backing up and updating the software programs are carried out.

8. The working method of a double master order mutual inspection control system for a blast furnace skip according to claim 5, characterized in that: When the system encounters an unexpected fault, based on the alarm information and fault logs provided by the system, the problem is quickly located and repaired.

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