Crown block running state monitoring system based on HMI

Abstract

The invention relates to an HMI-based crown block operation state monitoring system, and belongs to the technical field of metallurgical equipment. According to the technical scheme, key operation state data such as the load weight, the environment temperature and the vibration frequency of the crown block are collected in real time through a strain gauge, a temperature and humidity sensor, a vibration sensor and the like, the data are rapidly processed and analyzed through a data processing module, and the accuracy and the real-time performance of the data are ensured. A speed control cloud 3070 HMI is adopted to display the running state of the crown block through a visual graphical user interface, so that an operator can easily monitor and manage the crown block; meanwhile, an early warning mechanism is introduced, when abnormity is monitored, sound-light alarm is automatically triggered, and the safety of operators is guaranteed. The Siemens S7-300 PLC is used as a core control unit and works cooperatively with the HMI and the serial server, so that stable transmission and accurate control of data are realized. The running state of the crown block is monitored in real time, potential faults are found and processed in time, the fault risk is reduced, and the running performance of the crown block is improved. The system has the characteristics of high integration, easiness in operation, real-time monitoring and the like, innovatively integrates various sensors and communication technologies, and realizes comprehensive monitoring and early warning of the running state of the crown block.

Description

TECHNICAL FIELD

[0001] The present application relates to an HMI-based crown block operation state monitoring system, belonging to the technical field of metallurgical equipment. BACKGROUND

[0002] In the technical field of metallurgical equipment, the crown block, as an important hoisting and transportation device, its running state safety and efficiency are crucial to the production process. However, the traditional crown block operation state monitoring relies on manual inspection and simple sensors, which often have problems such as poor real-time performance, limited monitoring range, insufficient data processing capacity, etc. With the development of industrial automation and intelligent technology, higher requirements are put forward for real-time monitoring and intelligent analysis of the crown block operation state.

[0003] In the prior art, the crown block operation state monitoring system usually includes sensors, data collectors, data processing modules, display interfaces and other components. However, these systems often have the following shortcomings: 1. The types of sensors are single, making it difficult to comprehensively collect the operation state data of the crown block, such as load weight, environmental temperature, vibration frequency and other key parameters; 2. The data processing capacity is limited, which cannot analyze a large amount of data, leading to untimely fault diagnosis and early warning; 3. The display interface is not intuitive enough, making it difficult for operators to quickly understand the running state of the crown block, affecting the monitoring efficiency; 4. Lack of effective early warning mechanism, unable to timely remind the operator when the operation is abnormal, increasing the risk of accidents. SUMMARY

[0004] The purpose of the present application is to provide an HMI-based crown block operation state monitoring system, which can monitor the running state of the crown block in real time, discover and handle potential faults in a timely manner, reduce the risk of failure, and improve the running performance of the crown block. It has the characteristics of high integration, easy operation, real-time monitoring, etc., and innovatively integrates various sensors and communication technologies to realize comprehensive monitoring and early warning of the crown block operation state, solving the above problems in the background technology.

[0005] The technical scheme of the present application is: a kind of HMI-based crown running state monitoring system, containing siemens S7-300 PLC, speed control cloud 3070 HMI, QML1 motor comprehensive protector of gongji, sensor, wireless collector, data processing module and early warning mechanism, the siemens S7-300 PLC is connected with speed control cloud 3070 HMI and zhuolan serial port server by Ethernet communication line;The sensor includes strain gauge, temperature sensor and vibration sensor, is connected to data processing module, and the running state data of crown is collected in real time;The wireless collector is installed on guide rail, is connected to data processing module, receives sensor data and is converted into 485 communication format;The data processing module includes microprocessor and memory, and the received data is quickly processed and analyzed;The HMI interface is designed with touch screen, is integrated with speed control cloud 3070 HMI, and the running state of crown is shown;The early warning mechanism includes audible and visual alarm and emergency stop button, and is connected with data processing module;The QML1 motor comprehensive protector of gongji is installed on the power supply line of crown motor, and is connected with zhuolan serial port server;The zhuolan serial port server is connected with the 485 communication line of QML1 motor comprehensive protector of gongji and wireless collector respectively;The Ethernet communication line is connected with siemens S7-300 PLC, speed control cloud 3070 HMI and zhuolan serial port server respectively, to ensure stable data transmission.

[0006] The siemens S7-300 PLC has an Ethernet communication module, and interacts with speed control cloud 3070 HMI and zhuolan serial port server.

[0007] The sensor has a waterproof shell for wireless transmission of temperature data, and has battery power supply and antenna;The sensor includes temperature sensor and vibration sensor;The temperature sensor includes temperature sensor one installed on the motor of crown and temperature sensor two installed on the bearing of crown wheel, respectively collects the temperature signal of motor and wheel, and sends signal by wireless frequency of 433MHz;The vibration sensor includes vibration sensor one installed on the motor of crown and vibration sensor two installed on the bearing of crown wheel, respectively collects the vibration signal of motor and wheel, and sends signal by wireless frequency of 433MHz.

[0008] The data processing module uses high-speed microprocessor and high-efficiency memory to quickly process and analyze the crown running state data.

[0009] The HMI interface has a high-resolution display screen and an intuitive graphical user interface, supports multiple data display formats and interactive operations.

[0010] The early warning mechanism automatically triggers audible and visual alarm when detecting abnormal crown operation, and immediately stops the crown operation through the emergency stop button.

[0011] The long-term QML1 motor comprehensive protection device has overload, underload and open-phase protection functions, and converts abnormal state signals into 485 signal outputs.

[0012] The Zhuolan serial port server converts 485 signals into Ethernet signals, realizes conversion between different communication protocols, and guarantees the compatibility and stability of data transmission.

[0013] The application integrates Siemens S7-300 PLC, speed control cloud 3070 HMI, long-term QML1 motor comprehensive protection device, various sensors, wireless collector, data processing module, early warning mechanism and other core components. The system collects key operation state data such as load weight, environmental temperature and vibration frequency of the crown block in real time through strain gauges, temperature and humidity sensors, vibration sensors and the like, and quickly processes and analyzes these data by using the data processing module, so as to ensure the accuracy and real-time performance of the data. The speed control cloud 3070 HMI displays the operation state of the crown block through an intuitive graphical user interface, so that the operator can easily monitor and manage; at the same time, the early warning mechanism is introduced, and when an abnormality is monitored, an audible and visual alarm is automatically triggered, so as to ensure the safety of the operator. The Siemens S7-300 PLC as the core control unit cooperates with the HMI and the serial port server to realize stable data transmission and accurate control.

[0014] The application has the advantages that the operation state of the crown block is monitored in real time, potential faults are found and handled in time, the fault risk is reduced, and the operation performance of the crown block is improved; the application has the characteristics of high integration, easy operation and real-time monitoring, and innovatively integrates various sensors and communication technologies to realize comprehensive monitoring and early warning of the operation state of the crown block. BRIEF DESCRIPTION OF DRAWINGS

[0015] Figure 1 is a whole structure schematic diagram of the embodiment of the application In the figure: 1, data server. 2, speed control cloud 3070 HMI. 3, ground remote control PLC. 4, wireless collector. 5, wireless network bridge. 6, wireless receiver. 7, Siemens S7-300 PLC. 8, long-term QML1 motor comprehensive protection device. 9, large car frequency converter. 10, small car frequency converter. 11, main hook frequency converter. 12, main hook encoder. 13, small car PLC. 14, wire winder. 15, driver's room PLC. 16, LED information display screen. 17, protocol converter. 18, large car decoder. 19, small car decoder. 20, weighing system. 21, sling system. 22, gantry hook. 23, safety warning light. 24, driving console. 25, video tracking monitoring.

[0016] Figure 2It is the schematic diagram of the installation position of the sensor of the application on the motor of the crown block; In the figure: 10-1 temperature sensor one; 11-1 vibration sensor one; 13-1 motor body; 13-2 motor junction box; 13-3 motor cooling fan; Figure 3 It is the schematic diagram of the installation position of the sensor of the application on the bearing of the crown block; In the figure: 10-2 temperature sensor two; 11-2 vibration sensor two; 14-1 wheel body; 14-2 bearing seat body; 14-3 bearing seat transparent cover; 14-4 bearing seat cover; 14-5 shaft end cover; 14-6 bearing; 14-7 sealing ring. DETAILED DESCRIPTION

[0017] In order to make the purpose, technical scheme and advantages of the embodiment of the application clearer, the technical scheme of the embodiment of the application will be clearly and completely described below in combination with the drawings in the embodiment. Obviously, the described embodiment is a part of the embodiments of the application, not all the embodiments of the application. All other embodiments obtained by those skilled in the art without creative labor on the basis of the embodiments in the application belong to the protection scope of the application.

[0018] A crown block running state monitoring system based on HMI, comprising a Siemens S7-300 PLC 7, a speed control cloud 3070 HMI 2, a Gaoke QML1 motor comprehensive protector 8, a sensor 10, a wireless collector 4, a data processing module 5 and an early warning mechanism 6, the Siemens S7-300 PLC 7 is connected with the speed control cloud 3070 HMI 2 and the Zhuo Lan serial port server 11 through an Ethernet communication line 12; the sensor 10 comprises a strain gauge, a temperature sensor and a vibration sensor, is connected to the data processing module 5, and collects the running state data of the crown block in real time; the wireless collector 4 is installed on the guide rail, is connected to the data processing module 5, receives the sensor data and converts it into 485 communication format; the data processing module 5 comprises a microprocessor and a memory, and quickly processes and analyzes the received data; the HMI interface 2 is designed with a touch screen, is integrated with the speed control cloud 3070 HMI, and displays the running state of the crown block; the early warning mechanism 6 comprises an audible and visual alarm and an emergency stop button, and is connected with the data processing module 5; the Gaoke QML1 motor comprehensive protector 8 is installed on the power supply line of the crown block motor, and is connected with the Zhuo Lan serial port server 11; the Zhuo Lan serial port server 11 is connected with the 485 communication line of the Gaoke QML1 motor comprehensive protector 8 and the wireless collector 4 respectively; the Ethernet communication line 12 is connected with the Siemens S7-300 PLC 7, the speed control cloud 3070 HMI 2 and the Zhuo Lan serial port server 11 respectively, and ensures stable data transmission.

[0019] The Siemens S7-300 PLC 7 is provided with an Ethernet communication module, and interacts with the speed control cloud 3070 HMI 2 and the Qianlan serial port server 11.

[0020] The sensor 10 has a waterproof shell and transmits temperature data wirelessly, and has battery power supply and an antenna; the sensor includes a temperature sensor and a vibration sensor; the temperature sensor includes a temperature sensor one 10-1 installed on a motor of the crown block and a temperature sensor two 10-2 installed on a bearing of a wheel of the crown block, respectively collects temperature signals of the motor and the wheel, and transmits signals through a wireless frequency of 433 MHz; the vibration sensor includes a vibration sensor one 11-1 installed on the motor of the crown block and a vibration sensor two 11-2 installed on the bearing of the wheel of the crown block, respectively collects vibration signals of the motor and the wheel, and transmits signals through a wireless frequency of 433 MHz.

[0021] The data processing module 5 adopts a high-speed microprocessor and a high-efficiency memory to quickly process and analyze the running state data of the crown block.

[0022] The HMI interface 2 has a high-resolution display screen and an intuitive graphical user interface, supports multiple data display formats and interactive operations.

[0023] The early warning mechanism 6 automatically triggers an audible and visual alarm when detecting an abnormal running of the crown block, and immediately stops the running of the crown block through an emergency stop button.

[0024] The Qianji QML1 motor comprehensive protector 8 has overload, underload and open-phase protection functions, and converts abnormal state signals into 485 signal outputs.

[0025] The Qianlan serial port server 11 converts 485 signals into Ethernet signals, realizes conversion between different communication protocols, and guarantees compatibility and stability of data transmission.

[0026] In the embodiment, the system of the application comprises a Siemens S7-300 PLC 7, a speed control cloud 3070 HMI 2, a Qianji QML1 motor comprehensive protector 8, a sensor 10, a wireless collector 4, a data processing module 5, an HMI interface 2, an early warning mechanism 6, a Qianlan serial port server 11 and an Ethernet communication line 12.

[0027] The sensor 10 includes a strain gauge (an attribute internally provided by the sensor), a temperature sensor, a vibration sensor and the like, and is used to collect key parameters such as a load weight, an environmental temperature and a vibration frequency of the crown block in real time. These sensors can comprehensively monitor the running state of the crown block, and ensure accuracy and real-time performance of data.

[0028] The data processing module 5: contains a microprocessor and a memory, responsible for rapid processing and analysis of received data. This module ensures the accuracy and real-time of the headstock running data, providing effective data support for the operator.

[0029] The HMI interface 2: adopts a touch screen design, which displays the running state of the headstock to the operator in the form of charts or animations through an intuitive graphical user interface. This design facilitates real-time monitoring and management of the headstock running state by the operator.

[0030] The early warning mechanism 6: includes an audible and visual alarm and an emergency stop button. When the system detects abnormal operation of the headstock, it will automatically trigger an alarm to remind the operator to take appropriate measures. The emergency stop button can immediately stop the headstock from running, preventing accidents.

[0031] The Siemens S7-300 PLC: as the core control unit, it has rich input and output interfaces, can accurately collect various signals in the running process of the headstock, and stably output control instructions to drive the operation mechanism of the headstock. The PLC is also equipped with an Ethernet communication module for data interaction with other devices.

[0032] The speed control cloud 3070 HMI2: connected with the Siemens S7-300 PLC and the Zhaolan serial port server through Ethernet communication lines, used to receive input and output state data sent by the PLC, as well as data from the QML1 motor comprehensive protector and wireless collector converted by the Zhaolan serial port server. The HMI has a high-resolution display screen that can intuitively display relevant running data of the headstock.

[0033] The QML1 motor comprehensive protector 8: installed on the power supply line of the headstock motor, it can real-time collect current signals of the motor, and has multiple protection functions such as overload, underload, open phase, and leakage. It converts the collected current signals and its own detected abnormal state signals into 485 signal output.

[0034] The temperature sensor: including temperature sensor one 10-1 installed on the headstock motor and temperature sensor two 10-2 installed on the headstock wheel bearing, respectively collecting temperature signals of the motor and the wheel, and sending signals through wireless frequency of 433MHz.

[0035] The vibration sensor: including vibration sensor one 11-1 installed on the headstock motor and vibration sensor two 11-2 installed on the headstock wheel bearing, respectively collecting vibration signals of the motor and the wheel, and sending signals through wireless frequency of 433MHz.

[0036] The wireless collector 4 is installed in a guide rail mode, has a wireless frequency of 433MHz, is used for receiving temperature and sensor working voltage data uploaded by a wireless temperature sensor, and has a function of converting the received data into a 485 communication format.

[0037] The Zolan serial port server 11 is connected with the 485 communication lines of the common QML1 motor comprehensive protector and the wireless collector respectively, converts the 485 signals output by them into Ethernet signals, and transmits data with the speed control cloud 3070 HMI through an Ethernet communication line.

[0038] The Ethernet communication line 12 adopts a network cable and other lines meeting the Ethernet standard, and is connected with the Siemens S7-300 PLC, the speed control cloud 3070 HMI and the Zolan serial port server, so as to ensure that data can be stably and quickly transmitted in the system.

[0039] The present application realizes comprehensive monitoring and intelligent analysis of the running state of the crown block, improves the safety and efficiency of the crown block operation, and has the following advantages compared with the prior art: (1) Comprehensive monitoring: through the integration of multiple sensors, comprehensive monitoring of the running state of the crown block is realized.

[0040] (2) Intelligent analysis: the data processing module can quickly process and analyze a large amount of data, and provide effective fault diagnosis and early warning.

[0041] (3) Intuitive display: the HMI interface displays the running state of the crown block in the form of charts or animations, which is convenient for operators to monitor and manage.

[0042] (4) Safety warning: the early warning mechanism can alarm in time in abnormal conditions to prevent accidents.

[0043] The present application has a wide application prospect in the field of metallurgical equipment technology, and can effectively improve the safety and efficiency of the crown block operation, and meet the high standard requirements of modern industrial production. Example 1

[0044] The core components of the overhead crane operation state monitoring system device include a Siemens S7-300 PLC 7, a speed control cloud 3070 HMI 2, a Gaoji QML1 motor comprehensive protector 8, sensors 10, a wireless collector 4, a data processing module 5, an HMI interface 2, a warning mechanism 6, a Zhuo Lan serial server 11, and an Ethernet communication line 12. The sensors include strain gauges, temperature and humidity sensors, vibration sensors, and are installed at key positions of the overhead crane to collect key parameters such as load weight, environmental temperature, and vibration frequency in real time. The strain gauges are used to monitor the load weight, the temperature and humidity sensors are used to monitor the environmental temperature and humidity, and the vibration sensors are used to monitor the vibration of the overhead crane. The data processing module receives the data collected by the sensors and processes and analyzes it quickly to ensure the accuracy and real-time nature of the data.

[0045] The HMI interface 15 displays the operation state of the overhead crane to the operator in the form of charts or animations through a touch screen design. The operator can monitor the operation state of the overhead crane in real time through the HMI interface 15 and perform fault diagnosis and system debugging. The warning mechanism 6 includes an audible and visual alarm and an emergency stop button. When the system detects an abnormal operation of the overhead crane, it will automatically trigger an alarm to remind the operator to take appropriate measures. The emergency stop button can immediately stop the operation of the overhead crane to prevent accidents. The connection mode of the system device is as follows: The Siemens S7-300 PLC 7 is connected to the speed control cloud 3070 HMI 15 and the Zhuo Lan serial server 11 through the Ethernet communication line 16. The data collected by the sensors is transmitted to the data processing module 5 through the wireless collector 4. The HMI interface 15 is connected to the speed control cloud 3070 HMI for displaying the operation state of the overhead crane. The warning mechanism 6 is connected to the data processing module 5 for receiving abnormal state signals and triggering alarms. Example 2

[0046] In this example, we will apply the HMI-based overhead crane operation state monitoring system device to the overhead crane operation monitoring in a metallurgical plant. The following are the specific operation steps and effects of the system device in actual application: Operation steps: Device installation: First, install strain gauges, temperature sensors, vibration sensors, and other sensors at key positions of the overhead crane. The strain gauges are used to monitor the load weight, the temperature sensors are used to monitor the environmental temperature and humidity, and the vibration sensors are used to monitor the vibration of the overhead crane. The Gaoji QML1 motor comprehensive protector is installed on the power supply line of the motor to collect the current signal of the motor in real time.

[0047] Data collection and transmission: The data collected by the sensors is collected by the wireless collector and converted to 485 communication format. The wireless collector transmits the data to the data processing module through the 485 communication line.

[0048] Data processing: The data processing module quickly processes and analyzes the received data, ensuring the accuracy and real-time nature of the headstock operation data.

[0049] Data display: The speed control cloud 3070 HMI receives the input / output state data sent by the PLC through the Ethernet communication line, as well as the data of the common QML1 motor comprehensive protector and wireless collector converted by the Zhuo Lan serial port server. The HMI interface uses a touch screen design, displaying the running state of the headstock to the operator in the form of charts or animations.

[0050] Early warning and control: The early warning mechanism includes an audible and visual alarm and an emergency stop button. When the system detects abnormal operation of the headstock, it will automatically trigger an alarm to remind the operator to take appropriate measures. The emergency stop button can immediately stop the operation of the headstock, preventing accidents. Implementation effect

[0051] 1. Real-time monitoring: The operator can monitor the running state of the headstock in real time through the HMI interface, including key data such as motor current, temperature, and wheel temperature.

[0052] 2. Fault diagnosis: The HMI interface supports multiple data display formats and interactive operations, allowing the operator to easily view the on-off status of each input / output point, quickly diagnose faults, and debug the system.

[0053] 3. Safety warning: The early warning mechanism can timely alarm in abnormal conditions, reminding the operator to take appropriate measures, and at the same time, the emergency stop button can immediately stop the operation of the headstock, effectively preventing accidents.

Claims

1. A crane operation status monitoring system based on HMI, characterized in that: The system includes a Siemens S7-300 PLC (7), a Speed ​​Control Cloud 3070 HMI (2), a Gongjiu QML1 motor integrated protector (8), a sensor (10), a wireless data acquisition device (4), a data processing module (5), and an early warning mechanism (6). The Siemens S7-300 PLC (7) is connected to the Speed ​​Control Cloud 3070 HMI (2) and the Zhuolan serial server (11) via an Ethernet communication line (12). The sensor (10) includes strain gauges, temperature sensors, and vibration sensors, and is connected to the data processing module (5) to collect the crane's operating status data in real time. The wireless data acquisition device (4) is installed on the guide rail and connected to the data processing module (5) to receive sensor data and convert it into 485 communication format. The data processing module (5) includes a microprocessor and a memory to quickly process and analyze the received data. The HMI interface (2) adopts a touch screen design and is connected to the Speed ​​Control Cloud 3070 HMI (2). The HMI is integrated to display the operating status of the crane; the early warning mechanism (6) includes an audible and visual alarm and an emergency stop button, which are connected to the data processing module (5); the Gongjiu QML1 motor integrated protector (8) is installed on the power supply line of the crane motor and is connected to the Zhuolan serial port server (11); the Zhuolan serial port server (11) is connected to the 485 communication lines of the Gongjiu QML1 motor integrated protector (8) and the wireless acquisition device (4) respectively; the Ethernet communication line (12) is connected to the Siemens S7-300 PLC (7), the Speed ​​Control Cloud 3070 HMI (2) and the Zhuolan serial port server (11) respectively to ensure stable data transmission.

2. The overhead crane operation status monitoring system based on HMI according to claim 1, characterized in that: The Siemens S7-300 PLC (7) is equipped with an Ethernet communication module, which interacts with the Speed ​​Control Cloud 3070 HMI (2) and the Zhuolan serial port server (11) for data exchange.

3. The overhead crane operation status monitoring system based on HMI according to claim 1, characterized in that: The sensor (10) has a waterproof housing for wirelessly transmitting temperature data and is battery powered and has an antenna; the sensor includes a temperature sensor and a vibration sensor; the temperature sensor includes a temperature sensor one (10-1) installed on the crane motor and a temperature sensor two (10-2) installed on the crane wheel bearing, which respectively collect the temperature signals of the motor and the wheel and transmit them through a wireless signal with a frequency of 433MHz; the vibration sensor includes a vibration sensor one (11-1) installed on the crane motor and a vibration sensor two (11-2) installed on the crane wheel bearing, which respectively collect the vibration signals of the motor and the wheel and transmit them through a wireless signal with a frequency of 433MHz.

4. The overhead crane operation status monitoring system based on HMI according to claim 1, characterized in that: The data processing module (5) uses a high-speed microprocessor and a high-efficiency memory to quickly process and analyze the crane's operating status data.

5. The overhead crane operation status monitoring system based on HMI according to claim 1, characterized in that: The HMI interface (2) has a high-resolution display screen and an intuitive graphical user interface, supporting multiple data display formats and interactive operations.

6. The overhead crane operation status monitoring system based on HMI according to claim 1, characterized in that: The warning mechanism (6) automatically triggers an audible and visual alarm when it detects an abnormal operation of the overhead crane, and immediately stops the operation of the overhead crane by pressing the emergency stop button.

7. The overhead crane operation status monitoring system based on HMI according to claim 1, characterized in that: The Gongjiu QML1 motor integrated protector (8) has overload, underload and phase loss protection functions, and converts abnormal status signals into 485 signal output.

8. The overhead crane operation status monitoring system based on HMI according to claim 1, characterized in that: The Zhuolan serial port server (11) converts the 485 signal into an Ethernet signal, realizing the conversion between different communication protocols and ensuring the compatibility and stability of data transmission.

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