Intelligent automatic control system for ore crushing and conveying

Abstract

The application provides a kind of intelligent automation control system of ore crushing and conveying, the system includes ore crushing and conveying module, control module and monitoring module, the control module includes master station controller and substation controller, the master station controller is used for with substation controller data communication and logic protection function setting, the substation controller is used for signal acquisition and control of ore crushing and conveying module, the monitoring module includes video monitoring server and several cameras, the camera is used for recording the video signal of ore crushing and conveying module area, the video monitoring server is used for receiving the control data of master station controller and the video data of camera and carrying out display, the ore crushing and conveying module is electrically connected with substation controller, the substation controller is electrically connected with master station controller;The application can realize the automatic control and interlock protection function of ore crushing and conveying equipment by collecting the sensor signal of ore crushing and conveying equipment.

Description

Technical Field

[0001] This invention relates to the field of ore crushing and conveying systems, and more particularly to an intelligent automated control system for ore crushing and conveying. Background Technology

[0002] In modern mining production, crushing and conveying are crucial links, and their efficiency and reliability directly affect the overall profitability and safety of mining operations. Traditional crushing and conveying systems rely primarily on manual operation and monitoring, which has many drawbacks, such as: lack of protection during equipment operation, posing safety hazards; and low production efficiency due to manual operation. On the other hand, the monitoring of the conveying system's operational status is also relatively lagging. Belt conveyors are commonly used conveying equipment in mines, and their long-distance, multi-transfer point layout makes manual inspection difficult, resulting in delayed fault detection. Once problems such as belt misalignment, slippage, blockage, or motor overload occur, not only will the equipment be damaged, but it may also lead to safety accidents, causing huge economic losses and personal injury risks. Summary of the Invention

[0003] Therefore, the purpose of this invention is to provide an intelligent automated control system for ore crushing and conveying, so as to at least solve the above problems.

[0004] The technical solution adopted in this invention is as follows: An intelligent automated control system for ore crushing and conveying includes a ore crushing and conveying module, a control module, and a monitoring module. The control module includes a master station controller and substation controllers. The master station controller is used for data communication and logic protection function settings with the substation controllers. The substation controllers are used for signal acquisition and control of the ore crushing and conveying module. The monitoring module includes a video monitoring server and several cameras. The cameras are used to record video signals of the ore crushing and conveying module area. The video monitoring server is used to receive and display control data from the master station controller and video data from the cameras. The ore crushing and conveying module is electrically connected to the substation controllers, the substation controllers are electrically connected to the master station controller, and the master station controller and cameras are electrically connected to the video monitoring server.

[0005] Furthermore, the ore crushing and conveying module includes an iron plate feeder, a gyratory crusher, a belt conveyor, an oil pump, and a water pump. The substation controller includes an iron plate layer controller, a gyratory layer controller, a belt layer controller, a drive layer controller, an oil pump layer controller, and a water pump layer controller. The iron plate layer controller is electrically connected to the iron plate feeder, the gyratory layer controller is electrically connected to the gyratory crusher, the belt layer controller and the drive layer controller are both electrically connected to the belt conveyor, the oil pump layer controller is electrically connected to the oil pump, and the water pump layer controller is electrically connected to the water pump.

[0006] Furthermore, the iron plate layer controller is used for signal acquisition and control of vibration, temperature, operating status, and start / stop of the iron plate feeder; the gyratory layer controller is used for signal acquisition and control of vibration and temperature of the gyratory crusher, operating status, and start / stop of the gyratory high-voltage frequency converter; the belt layer controller is used for signal acquisition and control of belt-side protection switch sensors, electric whistles, drum temperature, and vibration of the belt conveyor; the drive layer controller is used for signal acquisition and control of vibration and temperature of the belt drive motor of the belt conveyor, and start / stop and operating status of the motor frequency converter; the oil pump layer controller is used for signal acquisition and control of oil temperature, oil pressure, liquid level, start / stop, and operating status of the oil pump; and the water pump layer controller is used for signal acquisition and control of start / stop and operating status of the water pump, and liquid level and pressure of the water tank.

[0007] Furthermore, the crushing and conveying module also includes a high-voltage switchgear, a low-voltage switchgear, and a dust removal device. The main station controller collects and controls the start-up, shutdown, and operating status signals of the high-voltage switchgear, the low-voltage switchgear, and the dust removal device. The high-voltage switchgear, the low-voltage switchgear, and the dust removal device are all electrically connected to the main station controller.

[0008] Furthermore, the system also includes a mobile monitoring module, which is communicatively connected to the video monitoring server and used to remotely monitor the control data of the main station controller and the video data of the cameras.

[0009] Furthermore, the master station controller and the substation controllers communicate using the industrial Ethernet protocol and establish a ring network connection through single-mode optical fiber.

[0010] Furthermore, the main station control cabinet is equipped with lighting and heat dissipation devices, and the substation control cabinet is a rainproof stainless steel wall-mounted cabinet.

[0011] Compared with the prior art, the beneficial effects of the present invention are: This invention provides an intelligent automated control system for ore crushing and conveying. By collecting sensor signals from ore crushing and conveying equipment, it realizes automated control and interlocking protection functions for the equipment, enabling automated production and management in mining sites. This improves the safety of crushing and belt conveying, enhances the working environment for operators, addresses the severe shortage of operators, increases production efficiency, and achieves both quality and efficiency improvements. Attached Figure Description

[0012] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only preferred embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0013] Figure 1 This is a schematic diagram of the system flow structure provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the control module structure provided in an embodiment of the present invention. Detailed Implementation

[0014] The principles and features of the present invention are described below with reference to the accompanying drawings. The listed embodiments are only used to explain the present invention and are not intended to limit the scope of the present invention.

[0015] Reference Figure 1 This invention provides an intelligent automated control system for ore crushing and conveying. The system includes a ore crushing and conveying module, a control module, and a monitoring module. The control module includes a master station controller and substation controllers. The master station controller is used for data communication and logic protection function settings with the substation controllers. The substation controllers are used for signal acquisition and control of the ore crushing and conveying module. The monitoring module includes a video monitoring server and several cameras. The cameras are used to record video signals of the ore crushing and conveying module area. The video monitoring server is used to receive and display the control data from the master station controller and the video data from the cameras. The ore crushing and conveying module is electrically connected to the substation controllers, the substation controllers are electrically connected to the master station controller, and the master station controller and the cameras are electrically connected to the video monitoring server.

[0016] For example, both the main station controller and the substation controller are PCL control cabinets, both using Rittal standard control cabinets, configured as follows: separate cabinets for incoming power supply and UPS power supply; UPS power supply: capacity 6kVA, AC220 5% / AC220V 5%, with a delay of no less than 1 hour; regulated power supply: capacity of 7.5kVA, input power range of AC180V-AC260V, power supply and load voltage regulation rate of no more than 1%; industrial-grade AC / DC power module: input AC220V, output DC24V, 20A, with redundant modules. The system is operated and controlled via a host computer, which issues system operation commands through the keyboard and mouse. The host computer has functions including real-time online monitoring of equipment operation, generation of fault reports, historical record querying, generation of shift, daily, weekly, and monthly production reports, historical record querying, and printing. When the crushing and conveying module starts working, the substation controller will perform a self-check on the crushing and conveying module. If a problem is found, the crushing and conveying module will be stopped and an alarm will be triggered. When a piece of equipment in the crushing and conveying module fails and stops automatically, the equipment in the material receiving direction will stop at the same time as the failed equipment and enter the fault alarm handling program. The host computer will display the cause of the failed equipment, make historical records and generate a record report.

[0017] Cameras and the main station controller transmit on-site video data and equipment operation and control data to the video monitoring server via a ring network fiber optic cable. The video monitoring server's display screen shows the content in the form of graphics, tables, curves, and videos, displaying information such as safety monitoring, production scheduling, and production operation monitoring during the crushing and transportation process, providing comprehensive feedback on the operational status of crushing and transportation. The video monitoring server also has a video playback function, enabling the playback of historical video data.

[0018] The ore crushing and conveying module includes an iron plate feeder, a gyratory crusher, a belt conveyor, an oil pump, and a water pump. The substation controller includes an iron plate layer controller, a gyratory layer controller, a belt layer controller, a drive layer controller, an oil pump layer controller, and a water pump layer controller. The iron plate layer controller is electrically connected to the iron plate feeder, the gyratory layer controller is electrically connected to the gyratory crusher, the belt layer controller and the drive layer controller are both electrically connected to the belt conveyor, the oil pump layer controller is electrically connected to the oil pump, and the water pump layer controller is electrically connected to the water pump.

[0019] The iron plate layer controller is used for the acquisition and control of signals related to vibration, temperature, operating status, and start / stop of the iron plate feeder. The gyratory layer controller is used for the acquisition and control of signals related to vibration and temperature of the gyratory crusher, operating status, and start / stop of the gyratory high-voltage frequency converter. The belt layer controller is used for the acquisition and control of signals related to the belt protection switch sensor, electric horn, and drum temperature and vibration of the belt conveyor. The drive layer controller is used for the acquisition and control of signals related to vibration and temperature of the belt drive motor of the belt conveyor, and start / stop and operating status of the motor frequency converter. The oil pump layer controller is used for the acquisition and control of signals related to oil temperature, oil pressure, level, start / stop, and operating status of the oil pump. The water pump layer controller is used for the acquisition and control of signals related to start / stop and operating status of the water pump, and level and pressure of the water tank.

[0020] For example, the substation controller collects protection signals from the crushing and conveying module (such as rope pulling signals, belt slippage signals, belt misalignment signals, belt longitudinal tear signals, interface signals and emergency stop signals of the permanent magnet motor frequency conversion control system, etc.), motor overload, short circuit, undervoltage, and phase loss signals, high-voltage motor temperature rise and load current signals, bus voltage signals, power factor, power management, and centralized, operation, and fault signals and start and stop command signals of various process equipment. The substation controller executes relevant control and protection functions based on the collected signals.

[0021] The crushing and conveying module also includes a high-voltage switchgear, a low-voltage switchgear, and a dust removal device. The main station controller collects and controls the start-up, shutdown, and operating status signals of the high-voltage switchgear, the low-voltage switchgear, and the dust removal device. The high-voltage switchgear, the low-voltage switchgear, and the dust removal device are all electrically connected to the main station controller.

[0022] The system also includes a mobile monitoring module, which is communicatively connected to a video monitoring server and used to remotely monitor the control data of the main station controller and the video data of the cameras.

[0023] The master station controller and the substation controllers communicate using the industrial Ethernet protocol and establish a ring network connection through single-mode optical fiber.

[0024] For example, the substation controller synchronously transmits interlocking signals and commands to the iron plate feeder, gyratory crusher, belt conveyor, oil pump and water pump through both communication bus and control cable; the main station controller and the integrated protection device of the high voltage switchgear use ModBus communication; the control cable uses ZR-KVVRP-450 / 750 shielded control cable.

[0025] The main station control cabinet is equipped with lighting and heat dissipation devices, while the substation control cabinet is a rainproof stainless steel wall-mounted cabinet.

[0026] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An intelligent automated control system for ore crushing and conveying, characterized in that, The system includes a ore crushing and conveying module, a control module, and a monitoring module. The control module includes a master station controller and substation controllers. The master station controller is used for data communication and logic protection function settings with the substation controllers. The substation controllers are used for signal acquisition and control of the ore crushing and conveying module. The monitoring module includes a video monitoring server and several cameras. The cameras are used to record video signals of the ore crushing and conveying module area. The video monitoring server is used to receive control data from the master station controller and video data from the cameras and display them. The ore crushing and conveying module is electrically connected to the substation controllers, the substation controllers are electrically connected to the master station controller, and the master station controller and cameras are electrically connected to the video monitoring server.

2. The intelligent automated control system for ore crushing and conveying according to claim 1, characterized in that, The ore crushing and conveying module includes an iron plate feeder, a gyratory crusher, a belt conveyor, an oil pump, and a water pump. The substation controller includes an iron plate layer controller, a gyratory layer controller, a belt layer controller, a drive layer controller, an oil pump layer controller, and a water pump layer controller. The iron plate layer controller is electrically connected to the iron plate feeder, the gyratory layer controller is electrically connected to the gyratory crusher, the belt layer controller and the drive layer controller are both electrically connected to the belt conveyor, the oil pump layer controller is electrically connected to the oil pump, and the water pump layer controller is electrically connected to the water pump.

3. The intelligent automated control system for ore crushing and conveying according to claim 2, characterized in that, The iron plate layer controller is used for the acquisition and control of signals related to vibration, temperature, operating status, and start / stop of the iron plate feeder. The gyratory layer controller is used for the acquisition and control of signals related to vibration and temperature of the gyratory crusher, operating status, and start / stop of the gyratory high-voltage frequency converter. The belt layer controller is used for the acquisition and control of signals related to the belt protection switch sensor, electric horn, and drum temperature and vibration of the belt conveyor. The drive layer controller is used for the acquisition and control of signals related to vibration and temperature of the belt drive motor of the belt conveyor, and start / stop and operating status of the motor frequency converter. The oil pump layer controller is used for the acquisition and control of signals related to oil temperature, oil pressure, level, start / stop, and operating status of the oil pump. The water pump layer controller is used for the acquisition and control of signals related to start / stop and operating status of the water pump, and level and pressure of the water tank.

4. The intelligent automated control system for ore crushing and conveying according to claim 1, characterized in that, The crushing and conveying module also includes a high-voltage switchgear, a low-voltage switchgear, and a dust removal device. The main station controller collects and controls the start-up, shutdown, and operating status signals of the high-voltage switchgear, the low-voltage switchgear, and the dust removal device. The high-voltage switchgear, the low-voltage switchgear, and the dust removal device are all electrically connected to the main station controller.

5. The intelligent automated control system for ore crushing and conveying according to claim 1, characterized in that, The system also includes a mobile monitoring module, which is communicatively connected to a video monitoring server and used to remotely monitor the control data of the main station controller and the video data of the cameras.

6. The intelligent automated control system for ore crushing and conveying according to claim 1, characterized in that, The master station controller and the substation controllers communicate using the industrial Ethernet protocol and establish a ring network connection through single-mode optical fiber.

7. The intelligent automated control system for ore crushing and conveying according to claim 1, characterized in that, The main station control cabinet is equipped with lighting and heat dissipation devices, while the substation control cabinet is a rainproof stainless steel wall-mounted cabinet.

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