Control method and control equipment for driving part of direct-drive crusher and direct-drive crusher

Abstract

A control method for a driving part of a direct-driven crusher comprises the following steps: establishing a typical current-load characteristic model; acquiring current data of each phase during operation of the switched reluctance motor in real time, and acquiring continuous current waveform data; comparing the current waveform data with a typical current-load characteristic model, and judging whether the driving part of the crusher is in a high impact load state or not; and dynamically adjusting and switching the working mode of the crusher driving part according to the judgment result. The invention further provides control equipment and the direct-drive crusher. By monitoring the phase current waveform of the switched reluctance motor in real time, extracting the current impact of the switched reluctance motor caused by blocking of large coal and identifying the load state on line, the working mode of the driving part of the crusher is dynamically adjusted and switched, energy consumption and the over-crushing phenomenon are remarkably reduced, the scraper machine is prevented from being blocked by the large coal, and the service life of the crusher is prolonged. And the conveying system is effectively protected.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of coal mine underground crusher, and particularly relates to a direct drive type crusher driving part control method, a control device and a direct drive type crusher. BACKGROUND

[0002] As an important crushing device, the crusher is widely used in the mining, construction, metallurgy and other industries. In the coal mine underground scraper conveyor working face, a special crushing device needs to be configured to process large pieces of coal, and the driving system thereof needs to meet the special requirements of explosion-proof, compactness, high reliability and strong impact load, and the performance thereof directly affects the crushing efficiency and cost.

[0003] At present, the driving system of the crusher mainly includes two forms of traditional indirect driving and direct driving. The traditional driving mode is a typical architecture of "motor + belt / gear reducer", which is widely used, but has a technical bottleneck that cannot be overcome: the belt transmission is prone to low efficiency due to friction loss, and the belt is prone to aging and slipping, and needs to be frequently replaced to maintain tension; the gear reducer can amplify the torque, but the vibration and noise generated by the gear meshing are significant when running at high speed, and the lubricating oil is prone to deterioration due to dust invasion, and the maintenance cycle is short, and the comprehensive maintenance cost is high. The existing direct drive type crusher mainly uses a permanent magnet motor as a driving motor, but the permanent magnet motor can continuously rotate at a constant speed or blindly impact during operation, resulting in high energy consumption and easy over-crushing. SUMMARY

[0004] In order to solve the above technical problems, it is necessary to provide a direct drive type crusher driving part control method.

[0005] A direct drive type crusher driving part control method, comprising the following steps,

[0006] Step S1: establishing a typical current-load characteristic model;

[0007] Step S2: acquiring the phase current data of the switched reluctance motor during operation in real time to obtain continuous current waveform data;

[0008] Step S3: comparing the current waveform data with the typical current-load characteristic model to determine whether the crusher driving part is in a high impact load state;

[0009] Step S4: dynamically adjusting the working mode of the crusher driving part according to the determination result.

[0010] Preferably, in step S3, the impact load state is determined by the following method,

[0011] S31: obtaining an amplitude threshold value and a duration threshold value based on a normal load current setting test;

[0012] S32: Obtain the peak value of the motor phase current and the current integral value in a specific time window in real time to obtain the effective value of the current peak value;

[0013] S33: Determine whether the crusher driving part is in a high-impact load state according to the obtained effective value of the current peak value.

[0014] Preferably, in step S33, the specific judgment criteria are as follows,

[0015] When the effective value of the monitored current peak value continuously exceeds the amplitude threshold value, and its duration reaches or exceeds the duration threshold value, it is determined that the current waveform presents the transient impact characteristics of significantly increased amplitude and increased pulse width, so that it is judged that the crusher is in a high-impact load state.

[0016] Preferably, the working mode of the crusher driving part includes

[0017] High torque impact mode: when it is determined to be a high-impact load state, the driving part switches to this mode, and the driving motor operates in a low-speed range and outputs high instantaneous torque;

[0018] High-efficiency continuous mode: when it is monitored that the current signal is smooth and in a normal load range, the driving part switches to this mode, and the driving motor operates in a predetermined high-efficiency speed-torque range to realize continuous and smooth crushing operation.

[0019] Preferably, the high torque impact mode is realized by cooperatively adjusting the current chopping limit value and the turn-on angle and the turn-off angle.

[0020] Preferably, the specific implementation mode of the high torque impact mode is as follows,

[0021] The current chopping limit value is increased to a preset peak value level to allow a larger current to pass through the motor winding;

[0022] The turn-on angle of each phase winding is advanced to ensure that sufficient current can be established at the early stage of the inductance rising region;

[0023] The turn-off angle is moderately delayed to increase the energy injection of a single conduction period;

[0024] Through the cooperative adjustment of the above parameters, the driving motor operates in a low-speed range and outputs its inherent high instantaneous torque to meet the crushing demand of large hard materials.

[0025] Preferably, the specific implementation mode of the high-efficiency continuous mode is as follows,

[0026] Single-pulse voltage PWM control or reduced current chopping limit value is adopted to reduce switching loss and copper loss;

[0027] The turn-on angle is appropriately delayed to avoid invalid power-on in the inductance gentle region.

[0028] The switch-off angle is appropriately advanced to avoid the rotor entering the negative torque area caused by the inductance drop;

[0029] Through the synergistic optimization of the above parameters, the motor is forced to operate in a predetermined high-efficiency speed-torque range, realizing continuous, smooth and high-energy-efficiency crushing operation, aiming to maximize the processing capacity and system energy efficiency.

[0030] Preferably, in step S1, a typical current-load characteristic model is established by the following method,

[0031] By performing crushing tests on the test platform using materials of known specifications, corresponding motor current data is collected, and after statistical analysis, a corresponding relationship database of load characteristics and current waveform characteristics is established, thereby forming a characteristic model.

[0032] It is also necessary to provide a control device.

[0033] A control device, comprising a processor and a memory storing program instructions, the processor invoking the executable program code stored in the memory to execute the direct drive crusher drive part control method described above.

[0034] It is also necessary to provide a direct drive crusher.

[0035] A direct drive crusher, comprising a crusher body and a control device used in conjunction with the crusher body.

[0036] Compared with the prior art, the direct drive crusher drive part control method provided by the present application extracts current surges caused by large coal block jamming by real-time monitoring of the phase current waveform of the switched reluctance motor, and identifies the load state online. Based on this, the system can automatically switch between "high torque impact mode" and "high-efficiency continuous mode", realizing the conversion from uniform speed operation to intelligent response to locked rotor, and ensuring the continuous and efficient operation of the scraper conveyor. By intelligently sensing the current and automatically switching the crushing mode, the system can adaptively crush large coal blocks, rather than continuously uniform idling or blind impact. This not only significantly reduces energy consumption and over-crushing phenomenon, but also effectively protects the conveying system by preventing large coal blocks from jamming the scraper conveyor, reduces the risk of full-line shutdown, and improves the overall efficiency of the entire mining and conveying system. DETAILED DESCRIPTION

[0037] The technical solutions in the embodiments of the present application will be described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present application, not all. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0038] In one embodiment, the application provides a direct drive crusher drive control method, comprising the following steps,

[0039] Step S1: Establish a typical current-load characteristic model;

[0040] Step S2: Real-time acquisition of each phase current data of the switched reluctance motor during operation, obtaining continuous current waveform data; wherein the current data can be obtained by real-time sampling and monitoring of the current sensor;

[0041] Step S3: Compare the current waveform data with the typical current-load characteristic model to determine whether the crusher drive is in a high impact load state;

[0042] Step S4: According to the judgment result, dynamically adjust the control signal parameters output to the switched reluctance motor, and realize dynamic adjustment of the working mode of the crusher drive.

[0043] Specifically, in step S3, the impact load state is determined by the following method,

[0044] S31: Obtain the amplitude threshold value and the duration threshold value based on the normal load current setting test;

[0045] S32: Real-time acquisition of the peak value of the motor phase current and the current integral value within a certain time window, to obtain the effective value of the current peak value;

[0046] S33: Determine whether the crusher drive is in a high impact load state according to the obtained current peak effective value.

[0047] Specifically, in step S33, the specific judgment criteria are as follows,

[0048] When the effective value of the monitored current peak value continuously exceeds the amplitude threshold value, and its duration reaches or exceeds the duration threshold value, it is determined that the current waveform presents the transient impact characteristics of significantly increased amplitude and increased pulse width, thereby determining that the crusher is in a high impact load state.

[0049] Specifically, the working mode of the crusher drive includes,

[0050] High torque impact mode: when it is determined that the high impact load state, the drive is switched to this mode, the drive motor runs in the low speed area, and outputs high instantaneous torque;

[0051] High efficiency continuous mode: when the current signal is monitored to be smooth and in the normal load range, the drive is switched to this mode, the drive motor runs in the predetermined high efficiency speed-torque interval, and realizes continuous and smooth crushing operation.

[0052] Specifically, the high torque impact mode is realized by adjusting the current chopping limit and the turn-on angle and the turn-off angle.

[0053] In detail, the high torque impact mode is realized in the following way,

[0054] The current chopping limit is increased to a preset peak level to allow a larger current to pass through the motor winding;

[0055] The turn-on angle of each phase winding is advanced to ensure that sufficient current is established at the beginning of the inductance rising region;

[0056] The turn-off angle is appropriately delayed to increase the energy injection of a single conduction period;

[0057] Through the coordinated adjustment of the above parameters, the drive motor operates in the low speed region and outputs its inherent high instantaneous torque to meet the crushing demand of large hard materials.

[0058] Specifically, the high efficiency continuous mode is realized in the following way,

[0059] Single pulse voltage PWM control or reduced current chopping limit is adopted to reduce switching loss and copper loss;

[0060] The turn-on angle is appropriately delayed to avoid invalid energization in the inductance gentle region;

[0061] The turn-off angle is appropriately advanced to avoid negative torque generated by the rotor entering the inductance descending region;

[0062] Through the coordinated optimization of the above parameters, the motor is forced to operate in a predetermined high efficiency speed-torque region, realizing continuous, smooth and high energy efficient crushing operation, aiming to maximize the processing capacity and system energy efficiency.

[0063] Specifically, in step S1, a typical current-load characteristic model is established in the following way,

[0064] Through crushing tests on the test platform using materials of known specifications, corresponding motor current data is collected, and after statistical analysis, a corresponding relationship database of load characteristics and current waveform characteristics is established, thereby forming a characteristic model.

[0065] In one embodiment, the present application provides a control device comprising a processor and a memory storing program instructions, the processor invoking the executable program code stored in the memory to execute the direct drive crusher drive part control method.

[0066] In one embodiment, the present application provides a direct drive crusher comprising a crusher body and a control device used in conjunction with the crusher body.

[0067] The above-disclosed embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of the invention. Those skilled in the art will understand that implementing all or part of the above-described embodiments and making equivalent changes in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A direct drive crusher drive section control method, characterized by: The method comprises the following steps, Step S1: establishing a typical current-load characteristic model; Step S2: obtaining continuous current waveform data by acquiring real-time phase current data of the switched reluctance motor during operation; Step S3: comparing the current waveform data with the typical current-load characteristic model to determine whether the crusher driving part is in a high impact load state; Step S4: dynamically adjusting the working mode of the crusher driving part according to the determination result.

2. The direct drive crusher drive section control method of claim 1, characterized in that: In step S3, the impact load state is determined by the following method, S31: obtaining an amplitude threshold value and a duration threshold value based on a normal load current setting test; S32: obtaining the peak value of the motor phase current and the current integral value in a specific time window to obtain the effective value of the current peak value; S33: determining whether the crusher driving part is in a high impact load state according to the obtained current peak effective value.

3. The direct drive crusher drive section control method of claim 2, characterized in that: In step S33, the specific determination standard is as follows, When the effective value of the monitored current peak value continuously exceeds the amplitude threshold value, and its duration reaches or exceeds the duration threshold value, it is determined that the current waveform presents a transient impact characteristic of significantly increased amplitude and increased pulse width, thereby determining that the crusher is in a high impact load state.

4. The direct drive crusher drive portion control method of claim 3, characterized by: The working mode of the crusher driving part includes High torque impact mode: when it is determined that the high impact load state, the driving part switches to this mode, and the driving motor operates in the low speed area to output high instantaneous torque; High efficiency continuous mode: when the current signal is monitored to be smooth and in the normal load range, the driving part switches to this mode, and the driving motor operates in the predetermined high efficiency speed-torque interval to realize continuous and smooth crushing operation.

5. The direct drive crusher drive portion control method of claim 4, characterized by: The high torque impact mode is realized by cooperatively adjusting the current chopping limit value and the opening angle and the closing angle.

6. The direct drive crusher drive portion control method of claim 5, characterized by: The specific implementation method of the high torque impact mode is as follows, The current chopping limit value is increased to a preset peak value to allow a larger current to pass through the motor winding; The opening angle of each phase winding is advanced to ensure that sufficient current can be established in the early stage of the inductance rising area; The closing angle is appropriately delayed to increase the energy injection of a single conduction period; Through the cooperative adjustment of the above parameters, the driving motor operates in the low speed area and outputs its inherent high instantaneous torque to meet the crushing demand of large hard materials.

7. The direct drive crusher drive portion control method of claim 6, characterized by: The specific implementation method of the high efficiency continuous mode is as follows, Single pulse voltage PWM control or reducing the current chopping limit value is adopted to reduce the switching loss and copper loss; The opening angle is appropriately delayed to avoid invalid power-on in the inductance gentle area; The closing angle is appropriately advanced to avoid negative torque generated by the rotor entering the inductance descending area; Through the cooperative optimization of the above parameters, the motor is forced to operate in the predetermined high efficiency speed-torque interval to realize continuous, smooth and high energy efficiency crushing operation, aiming to maximize the processing capacity and system energy efficiency.

8. The direct drive crusher drive section control method of claim 1, characterized by: In step S1, the typical current-load characteristic model is established by the following method, By using known specifications of materials for crushing test on the test platform, the corresponding motor current data is collected, and the corresponding relationship database of load characteristics and current waveform characteristics is established after statistical analysis, thereby forming the characteristic model.

9. A control device characterized by comprising: The application relates to a direct drive crusher drive part control method, and a direct drive crusher drive part control device.

10. A direct drive crusher characterized by: The application relates to a direct drive crusher drive part control method, and a direct drive crusher drive part control device.