Top-loading coke oven vehicle management system

Abstract

The invention provides a top-loading coke oven vehicle management system. According to the method, a ground coordination subsystem, a wireless communication subsystem and an automatic alignment subsystem are included, the ground coordination subsystem comprises a ground coordination controller and a ground coordination upper computer, and the ground coordination subsystem is used for receiving data signals sent by the wireless communication subsystem and processing the data signals; the ground coordination subsystem is used for diagnosing and controlling the production process of the coke oven vehicle; the ground coordination subsystem is used for arranging and issuing a production plan according to production record data and production process requirements, and providing production operation time and planned furnace number information for production vehicles in different furnace areas; the independent modular coke oven vehicle management system researched and developed independently can flexibly adapt to and be compatible with coke oven mechanical equipment of different manufacturers, and a feasible solution can be provided for upgrading old equipment.

Description

Technical Field

[0001] The present invention relates to the technical field of coke oven mechanical equipment, and in particular to a top-loading coke oven vehicle management system. Background Art

[0002] The top-charging coke oven machinery (four major locomotives) primarily consists of four types of vehicles: the coal charging car, the pusher car, the coke interceptor car, and the electric locomotive. The coal charging car operates at the top of the coke oven, primarily receiving coal from the coal tower. It then moves to the target oven, opening and closing the coal loading port cover, aligning the guide sleeve, and controlling the rotation of the coal loading screw to add coal to the carbonization chamber. The coke pushing car operates on the side of the coke oven, primarily opening and closing the oven door and controlling the coke pusher bar to push the mature coke out of the carbonization chamber. It also opens and closes the small oven door and controls the coal leveling bar to level the coal during the loading process. The coke interceptor car operates on the coke oven side, primarily opening and closing the oven door, controlling the advancement, retraction, and locking of the coke guide grid, and directing the mature coke pushed from the pusher car into the coke hopper car. The electric locomotive operates below the coke interceptor car, primarily pulling the coke hopper car to rotate and receive coke. It then travels to the dry quenching tower to receive empty and full hoppers, completing the coke transfer process to the dry quenching tower. The coke oven production site environment is special and operations are frequent. The four locomotive control systems have the characteristics of complex process, decentralized control, multiple parameters, large capacity and high precision requirements.

[0003] Coking enterprises currently face significant environmental pressure, high labor costs, low levels of equipment automation, and challenges such as staff reduction and efficiency improvement, as well as digital upgrades. The coke oven vehicle management system, as the key and core of coke oven machinery and equipment upgrades, directly determines the achievement of these upgrade goals. Currently, similar domestic systems suffer from limited content, single functions, abstract interfaces, and an inability to intuitively represent the entire production process. Furthermore, for international users, these systems suffer from unfriendly human-computer interfaces, lack of multilingual support, and insufficient production visualization. Summary of the Invention

[0004] To address the aforementioned technical issues with existing top-loading coke oven machinery and equipment management systems, which suffer from limited functionality, adaptability, and scalability, a top-loading coke oven vehicle management system is proposed. This independent structure and modular design offer greater flexibility in optimization, reconfiguration, expansion, and upgrade potential to address diverse site conditions and user needs, protecting user investment and adapting to demanding scenarios.

[0005] The technical means adopted in the present invention are as follows: A top-loading coke oven vehicle management system, comprising: A ground coordination subsystem, comprising a ground coordination controller and a ground coordination host computer, is configured to receive and process data signals sent by the wireless communication subsystem; diagnose and control the coke oven vehicle production process; and schedule and publish production plans based on production record data and production process requirements, providing production operation time and planned oven number information for production vehicles in different oven areas. The wireless communication subsystem includes a ground access point and an onboard client. The ground access point is connected to the ground coordination controller and the ground coordination host computer by wires, and the onboard client is connected to the automatic alignment controller, the alignment system, the automatic alignment host computer, and the voice terminal by wires. The wireless communication subsystem connects the four locomotives to the ground coordination network through a wireless medium. The wireless communication subsystem is used for wireless networking and signal coverage, mobile access and data transmission, and network management. The automatic alignment subsystem includes an automatic alignment controller, an alignment system, an automatic alignment host computer and a voice terminal; the automatic alignment subsystem is connected to the top-loading coke oven vehicle by wire; the automatic alignment subsystem is used to perform position detection, oven number identification, locomotive communication, automatic alignment, production interlocking and voice broadcasting of the top-loading coke oven vehicle.

[0006] Furthermore, the specific method of wireless networking and signal coverage is as follows: four types of top-loading coke oven vehicles use four non-overlapping channels respectively, and different types of vehicles with a spatial distance less than a specified value use alternate channels; at least two groups of base stations are set up on the ground access point of the same track equipment according to the signal coverage range, and are networked with three on-board clients respectively; The specific method of mobile access and data transmission is as follows: the ground access point and the vehicle-mounted client use back-to-back MIMO directional antennas, and the antennas of the access point and the client are configured and installed in a manner such that they are equal in height, parallel, less than the specified spacing, perpendicular to the ground, and visible at all travel distances; The network management content includes network structure, working mode, network name, wireless access, multi-channel configuration, roaming switching, modulation coding and authentication encryption.

[0007] Furthermore, the specific method of position detection is as follows: an encoder is installed on the running driven wheel of the top-loading coke oven vehicle, and a high-speed counting module is used to collect the encoder count value to the automatic positioning controller. The automatic positioning controller converts the encoder count value into the stroke value of the current position in combination with the equipment data and control parameters. The automatic positioning controller performs a stroke value synchronization check on the stroke value with the oven number identified by the positioning system to eliminate the cumulative error; in the program oven number position data block of the positioning system, each oven number corresponds to a reference stroke value. During the running process of the equipment, the stroke interval corresponding to the encoder stroke value can be judged as the oven number interval corresponding to the coke oven carbonization chamber, that is, the encoder oven number is judged by the encoder stroke value interval to achieve position detection; The specific method of furnace number identification is as follows: a number recognition device is installed on the top-loading coke oven vehicle, and the number plate at a fixed position on the ground is read during the running process, and is decoded and converted into the corresponding furnace number; during the running process, every time the number recognition device passes by and aligns with a number plate, the decoding device outputs a positioning pulse and the code plate furnace number to the automatic positioning controller to realize furnace number identification.

[0008] Furthermore, the specific method of locomotive communication is as follows: the positioning system is connected to the controller of the top-loading coke oven vehicle through a software and hardware interface to read the locomotive status information, and the locomotive status information includes power closing, operation feedback, mode status, action sequence, limit signal, safety protection, release condition and sensor value. The positioning system generates interlocking and control instructions based on the locomotive status information and sends them to the data block of the top-loading coke oven vehicle to realize data communication with the locomotive.

[0009] Furthermore, the specific method of the automatic alignment includes rough alignment and fine alignment; The coarse alignment method is as follows: the encoder stroke value and the corresponding furnace number are used for coarse alignment. The coarse alignment calculates the distance between the current real-time position and the target furnace number, that is, the difference between the target furnace number stroke value and the current encoder stroke value to control the travel speed, thus achieving travel speed control and coarse alignment. The coarse alignment is used when the distance from the target exceeds one furnace number or is greater than the fine alignment distance. The precise alignment method is as follows: the furnace number detected by the number recognition and decoding device is used for precise alignment. After the coarse alignment speed adjustment, the distance to the target is less than the precise alignment interval, and the equipment runs at the lowest set speed. The travel stop signal is sent at the moment of alignment with the number plate to achieve precise alignment.

[0010] Furthermore, the production interlock includes a main process of pushing coke and a main process of loading coal; The main steps of the coke pushing process are as follows: coke pushing car alignment, coke blocking car alignment, electric locomotive alignment or driving to the target furnace number; The coke pushing car door hook is confirmed, the coke holding car door hook is confirmed, the electric locomotive is aligned, and the voltage regulating system allows the door to be removed; The coke pushing car has removed the door and taken the rear limit, the coke blocking car has removed the door and the coke guide grid is locked, and the electric locomotive is in operation; The coke pushing car is ready to send a request to push coke, the coke blocking car allows coke pushing, and the electric locomotive allows coke pushing; The coke pushing car is activated, the coke blocking car has no emergency stop, and the electric locomotive has no emergency stop; The coke pushing and blocking vehicles have arrived at the door; Waiting for coal to be loaded; The specific steps of the coal loading main process are as follows: The pressure regulating system is waiting for coal loading, the coal loading car is aligned, and the pressure regulating system is allowed to be uncovered; The coal loading car is ready to request coal loading, the pressure regulating system allows coal loading, and the coal loading car is activated; Coke pusher leveling coal alignment, coke pusher preparing to level coal, coal loading car requesting to level coal after loading coal once, coke pusher leveling coal activation; The coal loading car has finished loading, the small furnace door of the coke pushing car has been closed, and the pressure regulating system has started coking timing; The coking timer starts; Among them, allowing the door to be removed includes the following steps: low pressure of ammonia water, closing limit of water seal valve, and opening limit of riser cover; allowing coal loading includes the following steps: opening limit of riser cover, high pressure of ammonia water, and opening limit of water seal valve.

[0011] Furthermore, the specific steps of the voice broadcast are as follows: an intelligent voice terminal is installed on the operating console of the driver's cab, the intelligent voice terminal receives the production process instructions of the ground coordination subsystem, and the intelligent voice terminal triggers the corresponding audio signal to realize the intelligent voice broadcast of the production process and safety warning, fault reminder and other information.

[0012] Furthermore, the automatic alignment subsystem includes several automatic alignment controllers, each of which is provided with two groups of PN interfaces and one group of DP interfaces. The automatic alignment controller is connected to the ground coordination subsystem through wireless communication to form a coordination network. The automatic alignment controller is connected to the control system of the top-loading coke oven vehicle through an industrial Ethernet cable to form a locomotive network. The DP interface is used to communicate with partner sites using the Profibus-DP protocol.

[0013] Compared with the prior art, the present invention has the following advantages: The system of the present invention is further optimized, its functions are further improved, and it has unique advantages and scalability for the future; The present invention adopts an independent structure and modular design, and has more flexible optimization reconstruction, expansion and upgrade potential when facing different on-site conditions and different user needs, protecting user investment and adapting to harsh scenarios. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative labor.

[0015] Figure 1 Schematic diagram of the system of the present invention.

[0016] Figure 2 This is a data flow diagram of the present invention. DETAILED DESCRIPTION

[0017] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments of the present invention can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0018] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is in no way intended to limit the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0019] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present invention. As used herein, unless the context clearly indicates otherwise, the singular form is intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0020] Unless otherwise specifically stated, the relative arrangement of the parts and steps, numerical expressions and numerical values ​​described in these embodiments do not limit the scope of the present invention. At the same time, it should be clear that, for ease of description, the sizes of the various parts shown in the drawings are not drawn according to the actual proportional relationship. The techniques, methods and equipment known to ordinary technicians in the relevant fields may not be discussed in detail, but where appropriate, the techniques, methods and equipment should be considered as part of the authorization specification. In all examples shown and discussed here, any specific value should be interpreted as merely exemplary and not as a limitation. Therefore, other examples of the exemplary embodiments may have different values. It should be noted that similar numbers and letters represent similar items in the following figures, so once an item is defined in one figure, it does not need to be further discussed in subsequent figures.

[0021] like Figure 1 and Figure 2 As shown, the present invention provides a top-loading coke oven vehicle management system, including a ground coordination subsystem, a wireless communication subsystem and an automatic alignment subsystem; The ground coordination subsystem is located in the coke oven control room and consists of a controller, a host computer and supporting equipment and facilities. It is the control brain of the coke oven vehicle management system. It is mainly responsible for data collection and processing, interlocking judgment and control, process diagnosis and recording, plan generation and issuance, etc.

[0022] Data collection and processing: Information exchange between various sites is achieved through hardware configuration and network configuration, and computer instruction systems are used for logical operation control and data processing and transmission, so as to realize the circulation of data between different network units and visual presentation on the host computer, such as full equipment overview, equipment visualization, process visualization, and process dynamicization; at the same time, a dynamic programming method is used to establish a big data model of coke oven equipment, and then the various constraints in the production process are delimited through the branch and bound method, and the optimal choice is made according to the optimization measurement of the production process, so as to realize the interlocking and coordinated management of coke oven vehicles and the monitoring of the voltage regulating system corresponding to the current production oven number.

[0023] Process diagnosis and recording: Through the diagnosis and control of the coke oven vehicle production process, combined with the production furnace number information, the latest production data of each production furnace number is recorded, including coke pushing time, maximum coke pushing current, production vehicle number and mode, interlocking status, coke pushing rod furnace wall temperature measurement data, coke guide grid coke cake temperature measurement data, coal loading time, coal loading amount, coking time, etc., to provide a basis for production plan formulation and production operation analysis. At the same time, it can also realize the coking information recording and coking progress display function of all carbonization chambers of the coke oven.

[0024] Plan generation and issuance: Based on production record data and production process requirements, the production plan is arranged and issued by establishing an algorithm model and time synchronization, providing production operation time and planned furnace number information for production vehicles in different furnace areas; at the same time, through the record and planning system, reports can also be generated and printed to provide a strong reference for production analysis; the production plan of this application is divided into 4 independent plans according to the furnace area, combined with the independent interlocking coordination management function of the 4 furnace areas, it can support simultaneous production in multiple furnace areas, providing more possibilities and guarantees for production operations.

[0025] The wireless communication subsystem is mainly composed of ground access points, on-board clients and supporting equipment and facilities. It is the nerve center of the coke oven vehicle management system. It is mainly responsible for coordinating the connection between the four major locomotives of the coke oven and the ground through wireless media to form a network, opening up the upper and lower links to ensure smooth data flow, and realizing wireless networking and signal coverage, mobile access and data transmission, network management and other functions.

[0026] Wireless networking and signal coverage: The four types of top-loading coke oven machinery operate on different tracks, at different heights, and in different spatial dimensions (i.e., the coke pusher operates on the ground track near the coke oven, the coal loader operates on the track above the coke oven, the coke interceptor operates on the second-level platform track near the coke oven, and the electric locomotive operates on the ground track near the coke oven). Three devices of the same type share the same track, and in normal operation, two are in use and one is in standby. Therefore, based on the operating characteristics of each type, the four types of equipment use four non-overlapping channels. For example, using a 20MHz bandwidth in the 5GHz band, the coke pusher uses channel 161 (center frequency 5805MHz), the coal loader uses channel 153 (center frequency 5765MHz), the coke interceptor uses channel 165 (center frequency 5825MHz), and the electric locomotive uses channel 149 (center frequency 5745MHz). This allows different types of equipment in close proximity to use alternate channels to avoid adjacent channel interference. Ground access points for equipment on the same track establish at least two base stations based on signal coverage, each networking with three onboard clients to achieve reliable and stable wireless network coverage.

[0027] Mobile access and data transmission: Coke oven machinery and equipment must move along tracks during operation, with a maximum speed of 200m / min. Due to the linear motion of the equipment along the tracks, the wireless design utilizes back-to-back MIMO directional antennas for both access points and clients. These antennas are configured and installed at equal heights, parallel to each other, with a small spacing between them, perpendicular to the ground, and visible throughout the entire travel range. This increases the effective utilization of the transmitting end's radiated power, enhances the receiving end's signal strength, and improves anti-interference capabilities, enabling efficient and reliable mobile access and data transmission.

[0028] Network management: To ensure the quality of wireless communications and network security, it is necessary to manage the network structure, working mode, network name, wireless access, multi-channel configuration, roaming switching, modulation and coding, authentication and encryption, etc.

[0029] The automatic alignment subsystem is distributed in the four major locomotives of the coke oven (i.e., the on-board alignment subsystem, one set for each locomotive). It is mainly composed of a controller, an alignment system, a host computer, an intelligent voice terminal and supporting equipment and facilities. It is the nerve endings of the coke oven vehicle management system; it is mainly responsible for position detection, oven number recognition, locomotive communication, status display, automatic alignment, anti-collision protection, production interlocking, automatic running, one-button operation, voice broadcast, trend curve, alarm record, operation event and other functions of the four major locomotives of the coke oven.

[0030] Position Detection: Using encoders installed on the four main locomotive driven wheels (errors may occur on the driving wheels due to wheel slippage), the encoder count values ​​are collected by the high-speed counting module and transmitted to the controller. This is then converted into the current position stroke value based on the equipment data and control parameters. This stroke value is then synchronized with the furnace number identified by the alignment system to eliminate accumulated errors. In the program's furnace number position data block, each furnace number corresponds to a reference stroke value. During the equipment's travel, the travel interval corresponding to the encoder stroke value can be determined to be the furnace number interval corresponding to the coke oven carbonization chamber. This means that the encoder furnace number is determined based on the encoder stroke value interval, thus achieving position detection.

[0031] Heat number identification: Through the number identification device installed in a specific position on the four major locomotives, the number plate at a fixed position on the ground is read during the running process and converted into the corresponding heat number through decoding. The alignment accuracy can be adjusted on the number identification device according to the operating requirements and actual vehicle conditions of the four major locomotives (generally ±1~±9mm). The higher the accuracy, the stricter the equipment alignment control requirements and the relatively longer the alignment time. Generally, the default benchmark for the four major locomotives is ±5mm, taking into account both alignment accuracy and alignment speed. During the running process, every time the number identification device passes by and aligns with a number plate, the decoding device outputs an alignment pulse and the heat plate heat number to the controller to realize the heat number identification function. During this process, the alignment pulse and the heat plate heat number can be used as the basis for encoder heat number verification and travel value synchronization, improving the stability and reliability of system operation.

[0032] Locomotive communication: The on-board positioning system establishes a communication connection with the locomotive controller through the software and hardware interface, reads the locomotive status information, such as power on, operation feedback, mode status, action sequence, limit signal, safety protection, release conditions, sensor values, etc., and analyzes and processes the data through the positioning system controller, and then writes the interlocking and control instructions into the locomotive data block to realize data communication with the locomotive.

[0033] Status Display: The host computer touch screen displays the entire production process through configuration of screens such as overview, interlocking, travel, vehicle status, alarm messages, operational events, trend curves, and user management. The overview screen primarily presents a bird's-eye view of the coke ovens, displaying key status information for all stations coordinated and managed on the ground level, including all locomotives, the riser pressure regulating system, the dust removal station, the gas header, the coal tower, the carbonization chamber, and the production progress of the furnace group. The interlocking screen, primarily a cross-sectional view of the coke ovens, adaptively displays the coke oven body and carbonization chamber status within the corresponding furnace area, key information and dynamics of the four locomotives, the coke pushing and coal charging process, key information such as the pressure regulating / weighing / dust removal station / gas header / CDQ tower, the last coke pushing / charging furnace number, the semi-automatic sequence for the vehicle, and the control area. The travel screen primarily displays travel interlocking conditions, travel inverter status, furnace number / alignment / speed information, mode selection, operation keys, coordination signals, and operating status. The vehicle status screen primarily displays the operating status of the vehicle's major systems and devices. Screens such as alarm messages, operation events, and trend curves are mainly used as auxiliary references and records of the production process.

[0034] Automatic alignment: The travel value and corresponding furnace number detected by the encoder are primarily used for coarse alignment. This is achieved by calculating the distance between the current real-time position and the target furnace number—that is, the difference between the target furnace number travel value and the current encoder travel value. This is then controlled using a speed control model and speed control algorithm to achieve both travel speed control and coarse alignment. Coarse alignment is generally used when the distance from the target exceeds one furnace number or exceeds the fine alignment distance (the fine alignment distance can be flexibly set between 100 and 300 mm). During this process, the speed varies in real time with distance (full speed is used when the distance exceeds the deceleration distance, a specific speed control curve and algorithm is used within the deceleration distance, and the minimum set speed is used when the distance falls below the fine alignment distance). The furnace number detected by the number recognition and decoding device is primarily used for fine alignment. After coarse alignment speed control, if the distance from the target is less than the fine alignment range and the equipment is operating at the minimum set speed, a travel stop signal is issued at the moment of alignment with the number plate, achieving precise alignment. Coarse positioning and fine alignment complement and verify each other, improving the safety and reliability of automatic alignment. They can also serve as backup for each other, operating in a single-line manner after a device failure, ensuring equipment safety in the fault state and ensuring temporary production support when site conditions are limited. For example, if an encoder failure prevents counting, automatic alignment can still be used. The number recognition and decoding device can be used to synchronize and update the device position in a timely manner. During driving, after reading the number on the code plate before the target furnace number and synchronizing, the machine travels at a speed corresponding to the distance until the target furnace number plate is read. This process may cause inaccurate alignment due to inertia, but fine alignment can be achieved by synchronizing the code plate using the "Slow Speed ​​Sync" button on the screen. If a decoding device failure prevents code plate recognition and synchronization, automatic alignment can still be used, controlling coarse alignment using the encoder stroke value. During this process, the encoder stroke value may cause inaccurate alignment due to accumulated errors, but the "Slow Speed ​​Travel" button on the screen can be used to control travel at the lowest speed and manually observe the alignment to control travel stops.

[0035] Anti-collision protection: The positions of the four major locomotives will change dynamically during production and operation. Corresponding protection measures are required between different equipment to avoid collision accidents caused by vehicle loss of control. The specific implementation principle is to compare the real-time position information of each vehicle received from the ground coordination subsystem with the current travel value of the vehicle, and calculate the relationship between the distance and speed of the two vehicles traveling in opposite directions through the speed control algorithm and the actual deceleration distance of the vehicle. The speed is limited until the speed is lower than the safe distance and parking protection is implemented. The protection only works when traveling in the opposite direction of other vehicles and is not restricted when driving in the opposite direction. Protection is one of the three layers of protection: mechanical, electrical, and program. It is the first layer of protection (program protection) when communication between devices is normal. It can realize real-time speed limit, alarm prompts, parking protection and other functions during driving. If the protection fails, the electrical anti-collision device serves as the second line of defense for protection. If the electrical protection also fails, mechanical stops / buffers and other devices serve as the last line of defense for protection to reduce accident losses.

[0036] Production interlocking: The four major locomotives perform their respective duties and are interlocked and restricted with each other during the production process, which is divided into two main processes: coke pushing and coal loading. The main process of coke pushing: the planned time has arrived (coke pushing car is in position, coke blocking car is in position, electric locomotive is in position or is heading towards the target furnace number) → door removal preparation (coke pushing car door hook confirmation, coke blocking car door hook confirmation, electric locomotive alignment is OK, voltage regulating system allows door removal) → coke pushing preparation (coke pushing car has removed the door and the door removal rear limit, coke blocking car has removed the door and the coke guide grid is locked, electric locomotive tank rotation operation) → coke pushing confirmation (coke pushing car is ready and sends a request to push coke, coke blocking car allows pushing coke, electric locomotive allows pushing coke) → coke pushing starts (coke pushing car coke pushing is activated, coke blocking car has no emergency stop, electric locomotive has no emergency stop) → coke pushing ends (coke pushing car has arrived at the door, coke blocking car has arrived at the door) → waiting for coal loading. The main coal loading process: Coal loading preparation (pressure regulating system waits for coal loading, coal-charging car is aligned, and pressure regulating system allows cover opening) → Coal loading (coal-charging car is ready for loading, pressure regulating system allows loading, and coal-charging car activates coal loading) → Coal leveling (coal-charging car is aligned, coke-charging car prepares for leveling, coal-charging car completes loading and requests leveling, and coke-charging car activates coal leveling) → Coal loading completion (coal-charging car completes loading, coke-charging car small furnace door is closed, and pressure regulating system begins coking timer) → Coking timer begins. The pressure regulating system has two key interlocks: allowing door opening: ammonia low pressure → water seal valve closing limit → riser cover opening limit; allowing coal loading: riser cover opening limit → ammonia high pressure → water seal valve opening limit. These interlocks refer to interlocks between individual cars and the pressure regulating system. The interlocking of this car primarily focuses on the car itself and will not be elaborated here.

[0037] Automatic Travel: In manual mode, you need to manually enter the target furnace number and click the "Start Driving to Target Furnace Number" button to control travel and precise positioning. In automatic mode, there is no need to enter a target furnace number. The target furnace number is automatically generated based on the planned furnace number and time sent by the ground coordination subsystem. Clicking the "Automatically Go to Next Furnace Number" button enables one-click travel and positioning. In one-button cycle operation mode, there is no need to enter a target furnace number or click the start button. As long as the equipment is operating normally, travel control and precise positioning are automatically completed according to the planned furnace number and time.

[0038] One-touch operation: By clicking the "One-touch Start" button on the interlocking screen of the four locomotives, the four locomotives can execute each step according to the process flow. Depending on production needs, these functions are divided into single-furnace, cycle, and remote control modes. Single-furnace one-touch operation means that in automatic mode, simply clicking "One-touch Start" automatically controls the gantry's semi-automatic sequence (after activation, a single button switches the gantry's subsystems to automatic mode, and the corresponding semi-automatic sequence is executed based on gantry status feedback). The gantry stops after completing all actions for the current heat. Then, clicking "Automatically move to next heat" on the travel screen enables one-touch travel alignment. Cycle mode means that in automatic mode, after selecting "Cycle Heat," clicking the "One-touch Start" button enables fully automated, cycled production for multiple heats according to the production plan. Remote control mode allows operation to be delegated to a remote control room once the gantry is stable and fully automated, enabling unmanned, fully automated, one-touch cycle operation.

[0039] Voice broadcast: Through the intelligent voice terminal installed on the operating console of the driver's cab, the on-board positioning system controller receives the production process instructions of the ground coordination subsystem, controls the voice terminal to trigger the corresponding audio signal, and realizes intelligent voice broadcast of information such as production process, safety warning, and fault reminder.

[0040] Trend curve / alarm record / operation event: Through the trend, alarm, event and other controls of the host computer operation system, key process variables are archived and recorded, and displayed in real time on the corresponding screen.

[0041] The automatic alignment subsystem utilizes a standalone controller design, with each controller having two PN interfaces and one DP interface. The controller can connect to the ground coordination subsystem via wireless communication to form a coordination network, and to the locomotive control system via an industrial Ethernet cable to form a locomotive network. The DP interface is primarily used for communication with partner sites using the Profibus-DP protocol, while also allowing for interfacing with legacy systems (which can be used for both upgrading and retrofitting legacy equipment and as temporary production support during the transition phase of retrofits). The vehicle's alignment system and trolley control system achieve real-time data exchange and flexible interface definition through standardized network interfaces. In actual operation, this standalone controller and open interface design easily address issues such as large customization limitations, inconsistent interfaces, system incompatibilities, and expansion difficulties, thereby improving the system's adaptability and compatibility with equipment from different manufacturers.

[0042] This system takes the current problems faced by coke oven machinery and equipment in digital upgrades, such as system adaptation difficulties, poor overall system compatibility, wide-ranging involvement and complex structure, the need to consider production operations during the upgrade process, and insufficient future scalability as its starting point. The system adopts a modular and scalable structural design for the main functions, HMI screens, program structures, and data blocks in the system. Taking the program structure as an example, it is divided into basic, coordination, communication and other groups. Taking coordination as an example, it is further divided into several units such as general data, status data, furnace group data, records and plans. Taking the data of furnace group A as an example, it mainly completes the processing and forwarding of the production status of the locomotive working in furnace area A, the judgment and control of the production steps, the production records and the generation of plans. The corresponding status data are stored in the corresponding data blocks; each modular structure performs its own duties at the same level, and is closely connected with standardized interfaces at different levels. The entire control system adopts a tree topology to implement different functions, and the screen structure also adopts a modular design. The ground coordination subsystem screen in the central control room integrates coordination, planning, overview, interlocking, alarm messages, operation events, trend curves, user management and other screens; the on-board screen integrates overview, interlocking, running, vehicle status, and alarm / operation / trend / management screens according to different vehicle models and working furnace areas; the modular design can be flexibly configured as needed in actual operation, providing hardware and software support for subsequent expansion.

[0043] Visualization and dynamics: The HMI screen is the user-facing visualization of the system and the most intuitive form of expression of the production process. It adopts a new design concept, giving dynamic display to key information, and more comprehensively displays the status information of the four major locomotives, partner sites, and production processes. All status signals are green for availability, gray for missing, pink for operation, and yellow for warnings. All carbonization chambers use different colors to display the coking progress based on the coal loading record and coking time. The communication status with all sites is displayed using a heartbeat pulse flashing display, allowing for timely detection of network connection problems. All four networked locomotives dynamically display their position, furnace number, working / standby, stroke value, travel status, and other information in the furnace area, allowing intuitive judgment of the current travel and alignment status. The visual and dynamic display of status information of the four major locomotives, voltage regulating system, furnace body, dust removal station, coal tower / CDQ tower, and the use of a process-based approach to express production processes and interlocking signals greatly enhances visualization.

[0044] This invention was implemented in a new coking project at the MMK Steel Plant in Russia. MMK, once the world's largest steel complex, is a symbol of heavy industrialization. This invention has been applied to key projects in overseas markets and has high economic and practical value.

[0045] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A top-loading coke oven vehicle management system, characterized in that: include: A ground coordination subsystem, comprising a ground coordination controller and a ground coordination host computer, is configured to receive and process data signals sent by the wireless communication subsystem; diagnose and control the coke oven vehicle production process; and schedule and publish production plans based on production record data and production process requirements, providing production operation time and planned oven number information for production vehicles in different oven areas. The wireless communication subsystem includes a ground access point and an onboard client. The ground access point is connected to the ground coordination controller and the ground coordination host computer by wires, and the onboard client is connected to the automatic alignment controller, the alignment system, the automatic alignment host computer, and the voice terminal by wires. The wireless communication subsystem connects the four locomotives to the ground coordination network through a wireless medium. The wireless communication subsystem is used for wireless networking and signal coverage, mobile access and data transmission, and network management. The automatic alignment subsystem includes an automatic alignment controller, an alignment system, an automatic alignment host computer and a voice terminal; the automatic alignment subsystem is connected to the top-loading coke oven vehicle by wire; the automatic alignment subsystem is used to perform position detection, oven number identification, locomotive communication, automatic alignment, production interlocking and voice broadcasting of the top-loading coke oven vehicle.

2. The top-loading coke oven vehicle management system according to claim 1, characterized in that: The specific method of wireless networking and signal coverage is as follows: four types of top-loading coke oven vehicles use four non-overlapping channels respectively, and different types of vehicles with a spatial distance less than a specified value use alternate channels; at least two groups of base stations are set up on the ground access point of the same track equipment according to the signal coverage range, and are networked with three vehicle-mounted clients respectively; The specific method of mobile access and data transmission is as follows: the ground access point and the vehicle-mounted client use back-to-back MIMO directional antennas, and the antennas of the access point and the client are configured and installed in a manner such that they are equal in height, parallel, less than the specified spacing, perpendicular to the ground, and visible at all travel distances; The network management content includes network structure, working mode, network name, wireless access, multi-channel configuration, roaming switching, modulation coding and authentication encryption.

3. The top-loading coke oven vehicle management system according to claim 1, characterized in that: The specific method of position detection is as follows: an encoder is installed on the running driven wheel of the top-loading coke oven vehicle, and a high-speed counting module is used to collect the encoder count value to the automatic positioning controller. The automatic positioning controller converts the encoder count value into the stroke value of the current position in combination with the equipment data and control parameters. The automatic positioning controller performs a stroke value synchronization check on the stroke value and the oven number identified by the positioning system to eliminate the cumulative error; in the program oven number position data block of the positioning system, each oven number corresponds to a reference stroke value. During the running process of the equipment, the stroke interval corresponding to the encoder stroke value can be judged as the oven number interval corresponding to the coke oven carbonization chamber, that is, the encoder oven number is judged by the encoder stroke value interval to achieve position detection; The specific method of furnace number identification is as follows: a number recognition device is installed on the top-loading coke oven vehicle, and the number plate at a fixed position on the ground is read during the running process, and is decoded and converted into the corresponding furnace number; during the running process, every time the number recognition device passes by and aligns with a number plate, the decoding device outputs a positioning pulse and the code plate furnace number to the automatic positioning controller to realize furnace number identification.

4. The top-loading coke oven vehicle management system according to claim 1, characterized in that: The specific method of locomotive communication is as follows: the positioning system is connected to the controller of the top-loading coke oven vehicle through a software and hardware interface to read the locomotive status information, and the locomotive status information includes power closing, operation feedback, mode status, action sequence, limit signal, safety protection, release condition and sensor value. The positioning system generates interlocking and control instructions based on the locomotive status information and sends them to the data block of the top-loading coke oven vehicle to realize data communication with the locomotive.

5. The top-loading coke oven vehicle management system according to claim 3, characterized in that: The specific method of automatic alignment includes rough alignment and fine alignment; The coarse alignment method is as follows: the encoder stroke value and the corresponding furnace number are used for coarse alignment. The coarse alignment calculates the distance between the current real-time position and the target furnace number, that is, the difference between the target furnace number stroke value and the current encoder stroke value to control the travel speed, thus achieving travel speed control and coarse alignment. The coarse alignment is used when the distance from the target exceeds one furnace number or is greater than the fine alignment distance. The precise alignment method is as follows: the furnace number detected by the number recognition and decoding device is used for precise alignment. After the coarse alignment speed adjustment, the distance to the target is less than the precise alignment interval, and the equipment runs at the lowest set speed. The travel stop signal is sent at the moment of alignment with the number plate to achieve precise alignment.

6. The top-loading coke oven vehicle management system according to claim 1, characterized in that: The production interlock includes the main process of pushing coke and the main process of loading coal; The main steps of the coke pushing process are as follows: coke pushing car alignment, coke blocking car alignment, electric locomotive alignment or driving to the target furnace number; The coke pushing car door hook is confirmed, the coke holding car door hook is confirmed, the electric locomotive is aligned, and the voltage regulating system allows the door to be removed; The coke pushing car has removed the door and taken the rear limit, the coke blocking car has removed the door and the coke guide grid is locked, and the electric locomotive is in operation; The coke pushing car is ready to send a request to push coke, the coke blocking car allows coke pushing, and the electric locomotive allows coke pushing; The coke pushing car is activated, the coke blocking car has no emergency stop, and the electric locomotive has no emergency stop; The coke pushing and blocking vehicles have arrived at the door; Waiting for coal to be loaded; The specific steps of the coal loading main process are as follows: The pressure regulating system is waiting for coal loading, the coal loading car is aligned, and the pressure regulating system is allowed to be uncovered; The coal loading car is ready to request coal loading, the pressure regulating system allows coal loading, and the coal loading car is activated; Coke pusher leveling coal alignment, coke pusher preparing to level coal, coal loading car requesting to level coal after loading coal once, coke pusher leveling coal activation; The coal loading car has finished loading, the small furnace door of the coke pushing car has been closed, and the pressure regulating system has started coking timing; The coking timer starts; Among them, allowing the door to be removed includes the following steps: low pressure of ammonia water, closing limit of water seal valve, and opening limit of riser cover; allowing coal loading includes the following steps: opening limit of riser cover, high pressure of ammonia water, and opening limit of water seal valve.

7. The top-loading coke oven vehicle management system according to claim 1, characterized in that: The specific steps of the voice broadcast are as follows: an intelligent voice terminal is installed on the operating console of the driver's cab, the intelligent voice terminal receives the production process instructions of the ground coordination subsystem, and the intelligent voice terminal triggers the corresponding audio signal to realize the intelligent voice broadcast of the production process and safety warning, fault reminder and other information.

8. The top-loading coke oven vehicle management system according to claim 1, characterized in that: The automatic alignment subsystem includes several automatic alignment controllers, each of which is equipped with two sets of PN interfaces and one set of DP interfaces. The automatic alignment controller is connected to the ground coordination subsystem through wireless communication to form a coordination network. The automatic alignment controller is connected to the control system of the top-loading coke oven vehicle through an industrial Ethernet cable to form a locomotive network. The DP interface is used to communicate with partner sites using the Profibus-DP protocol.

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