Multi-element gas uniform mixing system and method for explosion-proof loading and explosion preparation test of coal mine
The PLC-controlled multi-gas mixing system enables rapid and uniform gas mixing in explosion tests of coal mine explosion-proof equipment, solving the problems of long gas mixing cycles and low uniformity in existing technologies. This improves the efficiency and accuracy of the tests and ensures the safety performance evaluation of explosion-proof equipment.
Patent Information
- Application Number
- CN202511419777.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-30
- Publication Date
- 2026-01-02
AI Technical Summary
Existing explosion testing systems for coal mine explosion-proof equipment suffer from long gas mixing cycles, low gas mixing uniformity, and large deviations between the mixed gas composition ratio and expected values during a single test, affecting the accuracy and repeatability of the test.
The multi-element gas mixing system controlled by PLC includes a gas cylinder, an inlet solenoid valve, a gas filtration and drying device, a gas mixing device, a return solenoid valve, a gas analysis module, and an outlet solenoid valve. Through the multi-stage mixing design of the electric mixing module and the funnel structure mixing module, combined with the feedback adjustment of the gas analysis module, the system achieves rapid and uniform mixing of gases.
It improves the gas mixing efficiency and uniformity of multi-gas mixtures, ensures the reliability and accuracy of test data, reduces human intervention, and enhances the reliability and resource utilization of explosion-proof equipment safety performance evaluation.
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Figure CN121244036A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of explosion-proof equipment test, in particular to a coal mine explosion-proof equipment explosion test multi-element gas uniform mixing system and method. BACKGROUND
[0002] Coal mine explosion-proof equipment refers to explosion-proof electromagnetic starter, explosion-proof high-voltage power distribution device, explosion-proof junction box, explosion-proof lighting comprehensive protection device and other equipment used in coal mine underground. It is widely used in flammable and explosive places such as mining, tunneling and transportation. Because of the use environment containing explosive gas such as methane and coal dust, the equipment used in explosive gas environment should be equipped with explosion-proof shell to ensure that the shell inside does not ignite the outside explosive gas when a spark ignites the explosive gas. The design requires that the shell does not damage and deform when subjected to the pressure generated by the internal explosion.
[0003] Explosion test is a necessary inspection item of coal mine explosion-proof equipment type test, and is also a main means to examine its safety performance. In the explosion test of mine products, multi-element mixed gas of methane, hydrogen and air should be used for test, and the concentration ratio of the three gases in mixing is clearly pointed out in the standard. The existing explosion test system has the problems of long gas mixing period, low gas mixing uniformity, difficult to ensure the uniformity of multi-element gas mixing, large deviation between the composition ratio of mixed gas and the expected value, etc. in single test process, which affects the accuracy and repeatability of the test. SUMMARY
[0004] In order to solve the above problems, the purpose of the present application is to provide a coal mine explosion-proof equipment explosion test multi-element gas uniform mixing system and method, which uses PLC to control the explosion test multi-element gas mixing process, realizes the explosion test multi-element gas uniform mixing, and improves the explosion test multi-element gas mixing efficiency.
[0005] In order to achieve the above purpose, the technical scheme adopted by the present application is: a coal mine explosion-proof equipment explosion test multi-element gas uniform mixing system, comprising a plurality of gas cylinders, an inlet electromagnetic valve, a gas filtering and drying device, a gas mixing device, a return electromagnetic valve, a gas analysis module, an outlet electromagnetic valve and a PLC; Different explosion test gases are filled in the plurality of gas cylinders, the gas output ends of the gas cylinders are connected to the inlet ends of the inlet electromagnetic valves through gas pipelines respectively, the outlet end of the inlet electromagnetic valve, the gas filtering and drying device, the gas mixing device and the outlet electromagnetic valve are connected in sequence through gas pipelines; The inlet end and the outlet end of the return electromagnetic valve are connected to the gas pipelines on both sides of the gas mixing device through gas pipelines respectively; The three test ends of the gas analysis module are respectively arranged in the gas pipeline of the gas outlet end of the gas mixing device, the gas inlet end of the return gas electromagnetic valve and the gas inlet end of the outlet gas electromagnetic valve, and are respectively used for testing the gas concentration of the gas outlet end of the gas mixing device, the gas concentration of the gas inlet end of the return gas electromagnetic valve and the gas concentration of the gas inlet end of the outlet gas electromagnetic valve, the test gas concentration of the gas outlet end of the gas mixing device is taken as the first point concentration of the gas pipeline M 1, the test gas concentration of the gas inlet end of the return gas electromagnetic valve is taken as the second point concentration of the gas pipeline M 2, the test gas concentration of the gas inlet end of the outlet gas electromagnetic valve is taken as the third point concentration of the gas pipeline M 3, The inlet control signal, the return gas control signal and the outlet control signal of the PLC are connected with the control ends of the inlet electromagnetic valve, the return gas electromagnetic valve and the outlet electromagnetic valve respectively.
[0006] Further, the number of the gas cylinders is three, and the three gas cylinders are respectively filled with methane, hydrogen and air.
[0007] Further, the communication signal output end of the PLC and the communication signal output end of the gas analysis module are connected with the communication signal input end of the industrial computer, and the control signal input end of the gas mixing device is connected with the control signal output end of the PLC.
[0008] Further, the control signal input end of the PLC is connected with the control signal output end of the touch screen, Further, the display signal output end of the industrial computer is additionally connected with the signal input end of the display.
[0009] Further, the gas mixing device comprises an electric mixing module A, an electric mixing module B, a funnel structure mixing module A and a funnel structure mixing module B, and each explosion test gas is mixed in the electric mixing module A and the electric mixing module B, and then enters the funnel structure mixing module A and the funnel structure mixing module B for mixing.
[0010] The application also provides a mixing method of the above-mentioned coal mine explosion-proof equipment explosion test multi-element gas uniform mixing system, which specifically comprises the following steps: Step 1, the system is powered on, the system test parameters are set through the touch screen, the electric mixing module A, the electric mixing module B of the gas mixing device and the gas cylinder valve are started under the control of the PLC, the rotating speed of the electric mixing module A and the electric mixing module B is controlled according to the gas pressure, the gas mixing device is put into operation, and different explosion test gases are mixed; Step 2, PLC controls the starting of the inlet electromagnetic valve, different explosion test gases in the gas cylinders enter the gas mixing device through the gas pipeline, pass through the gas filtering and drying device, mix after the electric mixing module A and the electric mixing module B, and then enter the funnel structure mixing module A and the funnel structure mixing module B for mixing; Step 3, the three test ends of the gas analysis module test the gas concentration in real time and feed back to the industrial computer, and the industrial computer calculates the average value of the gas concentration at different positions in the gas pipeline space; Step 4, the industrial computer calculates the deviation coefficient and judges the gas concentration compliance by using the deviation coefficient, if it is judged that the gas concentration does not meet the concentration requirement, the outlet electromagnetic valve is closed, the gas return electromagnetic valve is opened, and the speed of the electric mixing module A and the electric mixing module B of the gas mixing device is adjusted, and the gas mixing is re-performed; Step 5, if it is judged that the gas concentration meets the concentration requirement, the gas return electromagnetic valve is closed, the outlet electromagnetic valve is opened, and the multi-element mixed gas is output.
[0011] Further, in the step 3, the calculation formula of the average value of the gas concentration is: ; Wherein, is the average concentration; M 1 is the concentration of the first point of the gas pipeline; M 2 is the concentration of the second point of the gas pipeline; M 3 is the concentration of the third point of the gas pipeline; In the step 4, the calculation process of the deviation coefficient is: Step 401, the industrial computer calculates the difference between the test point concentration and the average concentration, and the calculation formula is: ; Wherein, ΔM is the difference between the test point concentration and the average concentration; Mn is the concentration of different test points of the gas pipeline, taking 1, 2 and 3; Step 402, the industrial computer calculates the deviation coefficient according to the set gas concentration data and the concentration difference, and the calculation formula is as follows: ; Wherein, η is the deviation coefficient; ΔM is the difference between the test point concentration and the average concentration; Ms is the set gas concentration; The judgment standard of the industrial computer for judging the gas concentration compliance by using the deviation coefficient is: η is less than or equal to kMs, which meets the concentration requirement; η is greater than kMs, which does not meet the concentration requirement; k is usually taken as 1.
[0012] Compared with the prior art, the present application has the following beneficial effects: 1. The present application realizes the rapid mixing and circulation of multi-component gas by precisely controlling the cooperative work of the intake solenoid valve, the return solenoid valve and the outlet solenoid valve through PLC, significantly improves the gas distribution efficiency, and greatly improves the test efficiency.
[0013] 2. The present application realizes reliable gas mixing uniformity by multi-stage mixing design of the electric mixing module A, the electric mixing module B, the funnel structure mixing module A and the funnel structure mixing module B, combined with feedback adjustment of the gas analysis module, and the deviation coefficient η is controlled within the range of kMs (k is usually 1).
[0014] 3. The present application realizes closed-loop control by industrial computer based on the average value of the concentration of the first point of the gas pipeline M 1、The concentration of the second point of the gas pipeline M 2 and the concentration of the third point of the gas pipeline M 3, avoids test data fluctuation caused by uneven mixing, and improves the reliability of safety performance evaluation of explosion-proof equipment.
[0015] 4. The multi-component gas uniform mixing system of the present application has high automation, reduces manual intervention through touch screen parameter setting and PLC execution control; the industrial computer and the display real-time display concentration data and deviation coefficient, the operation is simple and convenient, the monitoring is intuitive, and the test risk is reduced.
[0016] 5. The gas filtering and drying device of the present application effectively removes impurities and moisture, ensures the purity of the mixed gas, prolongs the service life of the equipment, and at the same time, the intelligent adjustment function of the return solenoid valve optimizes the gas circulation path, reduces gas waste, and improves resource utilization.
[0017] In summary, the coal mine explosion-proof equipment explosion test multi-component gas uniform mixing system and method of the present application improves the gas mixing efficiency and uniformity of explosion-proof test, solves the technical problems of uneven gas concentration distribution, poor system reliability and other technical problems, and improves the explosion-proof test inspection ability. BRIEF DESCRIPTION OF DRAWINGS
[0018] Figure 1 is the structural block diagram of the coal mine explosion-proof equipment explosion test multi-component gas uniform mixing system of the present application; Figure 2 is a schematic view of the gas mixing device of the present application; Figure 3 is a mixing method flow chart of the coal mine explosion-proof equipment explosion test multi-component gas uniform mixing system of the present application; In the figure, 1, gas cylinder, 2, inlet electromagnetic valve, 3, gas filter and drying device, 4, gas mixing device, 41, electric mixing module A, 42, electric mixing module B, 43, funnel structure mixing module A, 44, funnel structure mixing module B, 5, return gas electromagnetic valve, 6, gas analysis module, 7, outlet electromagnetic valve, 8, PLC, 9, gas pipeline, 10, industrial computer, 11, display, 12, touch screen. DETAILED DESCRIPTION
[0019] The following examples are used to illustrate the present application, but not to limit the scope of the application.
[0020] Example 1
[0021] As shown in the figure, the coal mine explosion-proof equipment explosion test multi-gas uniform mixing system comprises a plurality of gas cylinders 1, an inlet electromagnetic valve 2, a gas filter and drying device 3, a gas mixing device 4, a return gas electromagnetic valve 5, a gas analysis module 6, an outlet electromagnetic valve 7 and a PLC 8. Figure 1 The plurality of gas cylinders 1 contain different explosion test gases, and the gas output ends of each gas cylinder 1 are connected to the gas inlet end of the inlet electromagnetic valve 2 through the gas pipeline 9. The gas outlet end of the inlet electromagnetic valve 2, the gas filter and drying device 3, the gas mixing device 4 and the outlet electromagnetic valve 7 are connected in sequence through the gas pipeline 9. The gas inlet end and the gas outlet end of the return gas electromagnetic valve 5 are connected to the gas pipelines 9 on both sides of the gas mixing device 4 through the gas pipelines 9. The three test ends of the gas analysis module 6 are respectively placed in the gas pipelines 9 of the gas outlet end of the gas mixing device 4, the gas inlet end of the return gas electromagnetic valve 5 and the gas inlet end of the outlet electromagnetic valve 7, and are respectively used to test the gas concentration of the gas outlet end of the gas mixing device 4, the gas concentration of the gas inlet end of the return gas electromagnetic valve 5 and the gas concentration of the gas inlet end of the outlet electromagnetic valve 7. M The test gas concentration of the gas outlet end of the gas mixing device 4 is taken as the first point concentration of the gas pipeline 9. M The test gas concentration of the gas inlet end of the return gas electromagnetic valve 5 is taken as the second point concentration of the gas pipeline 9. M The test gas concentration of the gas inlet end of the outlet electromagnetic valve 7 is taken as the third point concentration of the gas pipeline 9. The number of the gas cylinders 1 is three, which contain methane, hydrogen and air respectively.
[0022] The gas inlet control signal, the return gas control signal and the outlet control signal input ends of the PLC 8 are connected to the control ends of the inlet electromagnetic valve 2, the return gas electromagnetic valve 5 and the outlet electromagnetic valve 7 respectively.
[0023] The communication signal output end of the PLC 8 and the communication signal output end of the gas analysis module 6 are connected with the communication signal input end of the industrial computer 10, and the control signal input end of the gas mixing device 4 is connected with the control signal output end of the PLC 8.
[0024] The control signal input end of the PLC 8 is connected with the control signal output end of the touch screen 12, The display signal output end of the industrial computer 10 is additionally connected with the signal input end of the display 11.
[0025] Referring to Figure 2 , the gas mixing device 4 includes an electric mixing module A41, an electric mixing module B42, a funnel structure mixing module A43 and a funnel structure mixing module B44, and each explosion test gas is mixed by the electric mixing module A41 and the electric mixing module B42 after entering the funnel structure mixing module A43 and the funnel structure mixing module B44 for mixing.
[0026] Example Two
[0027] As Figure 3 shown, the mixing method of the coal mine explosion-proof equipment explosion test multi-element gas uniform mixing system is realized by using the coal mine explosion-proof equipment explosion test multi-element gas uniform mixing system described in Example One, and specifically includes the following steps: Step 1, the system is powered on, the system test parameters are set through the touch screen 12, the PLC 8 controls the electric mixing module A41, the electric mixing module B42 and the gas cylinder 1 valve of the gas mixing device 4 to start, and the rotation speed of the electric mixing module A41 and the electric mixing module B42 is controlled according to the gas pressure, the gas mixing device 4 is put into operation, and different explosion test gases are mixed; Step 2, the PLC 8 controls the gas inlet electromagnetic valve 2 to start, and different explosion test gases in each gas cylinder 1 enter the gas mixing device 4 through the gas pipeline 9, the gas filtering and drying device 3, the electric mixing module A41 and the electric mixing module B42, and then enter the funnel structure mixing module A43 and the funnel structure mixing module B44 for mixing; Step 3, the three test ends of the gas analysis module 6 test the gas concentration in real time and feed back to the industrial computer 10, and the industrial computer 10 calculates the average value of the gas concentration at different positions of the gas pipeline 9; In the step 3, the calculation formula of the average value of the gas concentration calculated by the industrial computer 10 is: ; Among them, is the average concentration, M1 is the concentration at the first point of the gas pipeline 9, M2 is the concentration at the second point of the gas pipeline 9, and M3 is the concentration at the third point of the gas pipeline 9. Step 4, the industrial computer 10 calculates the deviation coefficient and judges the gas concentration compliance by using the deviation coefficient, if the gas concentration is judged not to meet the concentration requirement, the gas outlet solenoid valve 7 is closed, the gas return solenoid valve 5 is opened, and the speed of the electric mixing module A41 and the electric mixing module B42 of the gas mixing device 4 is adjusted, and the gas mixing is re-performed; Step 5, if the gas concentration is judged to meet the concentration requirement, the gas return solenoid valve 5 is closed, the gas outlet solenoid valve 7 is opened, and the multi-element mixed gas is output.
[0028] In the step 4, the calculation process of the deviation coefficient is as follows: Step 401, the industrial computer 10 calculates the difference between the test point concentration and the average concentration, and the calculation formula is: ; Wherein, ΔM is the difference between the test point concentration and the average concentration; Mn is the concentration of different test points of the gas pipeline, taking 1, 2, 3; Step 402, the industrial computer 10 calculates the deviation coefficient according to the set gas concentration data and the concentration difference, and the calculation formula is as follows: ; Wherein, η is the deviation coefficient; ΔM is the difference between the test point concentration and the average concentration; Ms is the set gas concentration; The judgment standard of the industrial computer 10 for judging the gas concentration compliance by using the deviation coefficient is: η is less than or equal to kMs, which meets the concentration requirement; η is greater than kMs, which does not meet the concentration requirement; k is usually taken as 1.
[0029] It can be understood that although the embodiments of the present application have been shown and described, it can be understood by those skilled in the art that various changes, modifications, replacements and variations can be made to these embodiments without departing from the principles and spirits of the present application, and the scope of the present application is defined by the appended claims and their equivalents.
Claims
1. A multi-element gas homogeneous mixing system for explosion testing of explosion-proof equipment in coal mines, characterized in that, It includes multiple gas cylinders, an inlet solenoid valve, a gas filtration and drying device, a gas mixing device, a return solenoid valve, a gas analysis module, an outlet solenoid valve, and a PLC; The multiple gas cylinders contain different explosion test gases. The gas output end of each gas cylinder is connected to the inlet end of the inlet solenoid valve through a gas pipeline. The outlet end of the inlet solenoid valve, the gas filter and dryer, the gas mixing device, and the outlet solenoid valve are connected in sequence through gas pipelines. The inlet and outlet of the return solenoid valve are respectively connected to the gas pipelines on both sides of the gas mixing device through gas pipelines. The three test terminals of the gas analysis module are respectively placed in the gas pipelines at the outlet of the gas mixing device, the inlet of the return solenoid valve, and the inlet of the outlet solenoid valve. These terminals are used to test the gas concentration at the outlet of the gas mixing device, the inlet of the return solenoid valve, and the inlet of the outlet solenoid valve, respectively. The test gas concentration at the outlet of the gas mixing device is used as the first point concentration in the gas pipeline. M 1. The test gas concentration at the inlet of the return gas solenoid valve is used as the concentration at point 2 of the gas pipeline. M 2; The test gas concentration at the inlet end of the outlet solenoid valve is used as the concentration at point 3 in the gas pipeline. M 3; The input terminals of the PLC for the air intake control signal, air return control signal, and air outlet control signal are respectively connected to the control terminals of the air intake solenoid valve, air return solenoid valve, and air outlet solenoid valve.
2. The multi-element gas uniform mixing system for explosion testing of explosion-proof equipment in coal mines as described in claim 1, characterized in that, The number of gas cylinders is three, each containing methane, hydrogen, and air respectively.
3. The multi-element gas uniform mixing system for explosion testing of explosion-proof equipment in coal mines as described in claim 1, characterized in that, The communication signal output terminals of the PLC and the gas analysis module are both connected to the communication signal input terminal of the industrial computer, and the control signal input terminal of the gas mixing device is connected to the control signal output terminal of the PLC.
4. The multi-element gas uniform mixing system for explosion testing of explosion-proof equipment in coal mines as described in claim 1, characterized in that, The control signal input terminal of the PLC is connected to the control signal output terminal of the touch screen.
5. The multi-element gas uniform mixing system for explosion testing of explosion-proof equipment in coal mines as described in claim 3, characterized in that, The display signal output terminal of the industrial computer is also connected to the signal input terminal of the monitor.
6. The multi-element gas uniform mixing system for explosion testing of explosion-proof equipment in coal mines as described in claim 1, characterized in that, The gas mixing device includes an electric mixing module A, an electric mixing module B, a funnel-structure mixing module A, and a funnel-structure mixing module B. Each explosion test gas is mixed in the gas mixing device through the electric mixing module A and the electric mixing module B, and then enters the funnel-structure mixing module A and the funnel-structure mixing module B for further mixing.
7. A mixing method for a multi-element gas homogeneous mixing system for explosion testing of explosion-proof equipment in coal mines, wherein the multi-element gas homogeneous mixing system for explosion testing of explosion-proof equipment in coal mines as described in any one of claims 1-6 is characterized in that, Specifically, the following steps are included: Step 1: Power on the system, set the system test parameters via the touch screen, and the PLC controls the start of the electric mixing module A, electric mixing module B and gas cylinder valve of the gas mixing device. The PLC also controls the rotation speed of electric mixing module A and electric mixing module B according to the gas pressure. The gas mixing device is put into operation and waits for different explosion test gases to be mixed. Step 2: The PLC controls the start of the air intake solenoid valve. Different explosion test gases in each gas cylinder enter the gas mixing device through the gas pipeline and the gas filtration and drying device. After being mixed by electric mixing module A and electric mixing module B, they enter the funnel structure mixing module A and funnel structure mixing module B for further mixing. Step 3: The three test terminals of the gas analysis module test the gas concentration in real time and feed it back to the industrial computer. The industrial computer calculates the average gas concentration at different locations in the gas pipeline space. Step 4: The industrial computer calculates the deviation coefficient and uses the deviation coefficient to judge the gas concentration compliance. If the gas concentration does not meet the concentration requirements, the outlet solenoid valve is closed, the return solenoid valve is opened, and the speeds of the electric mixing module A and electric mixing module B of the gas mixing device are adjusted to redistribute the gas. Step 5: If the gas concentration meets the requirements, close the return gas solenoid valve and open the output gas solenoid valve to output the multi-component mixed gas.
8. The mixing method of the multi-element gas homogeneous mixing system for explosion testing of explosion-proof equipment in coal mines as described in claim 7, characterized in that, In step 3, the formula for calculating the average gas concentration using an industrial computer is as follows: ； in, Average concentration; M 1 represents the concentration at point 1 in the gas pipeline; M 2 represents the concentration at point 2 in the gas pipeline; M 3 represents the concentration at the third point in the gas pipeline; In step 4, the calculation process for the deviation coefficient is as follows: Step 401: The industrial computer calculates the difference between the concentration at the test point and the average concentration. The calculation formula is as follows: ； Where, Δ M This represents the difference between the concentration at the test point and the average concentration. M n For the concentration at different test points in the gas pipeline, take values 1, 2, and 3; Step 402: The industrial computer calculates the deviation coefficient based on the set gas concentration data and concentration difference. The calculation formula is as follows: ； in, η Δ is the deviation coefficient. M This represents the difference between the concentration at the test point and the average concentration. M s The set gas concentration; The criteria for industrial computers to judge the compliance of gas concentration using deviation coefficients are as follows: η Less than or equal to k M s It meets the concentration requirements; η Greater than k M s This does not meet the concentration requirements; k is usually taken as 1.