Blending reclaimer bucket-wheel current abnormity early warning shutdown protection method

Abstract

The invention relates to the field of bucket-wheel early warning of blending reclaimers. The invention discloses a blending reclaimer bucket-wheel current abnormity early-warning shutdown protection method. A current real-time acquisition module and a current early-warning protection module are built; the current real-time acquisition module is installed in a bucket wheel driving motor power supply loop of the blending reclaimer, and in the working process, the current real-time acquisition module continuously acquires the current of the bucket wheel driving motor power supply loop of a bucket wheel of the blending reclaimer and transmits a current signal acquired in real time to the current early warning protection module; the current early-warning protection module is in electric signal connection with the current real-time acquisition module, a bucket wheel driving motor control switch of the blending reclaimer, the alarm module, the display module, the input module and the storage module, and a plurality of early-warning thresholds are set in the current early-warning protection module according to the type of the blending reclaimer and reclaiming requirements.

Description

Technical Field

[0001] This invention relates to the field of early warning for bucket wheels of mixing and reclaiming machines. Background Technology

[0002] The blending and feeding machine is the main equipment for blending and feeding operations in the ironmaking raw material plant. It is a key piece of equipment for ensuring smooth production and stable quality of blended ore output in ironmaking. Its stable and safe operation is of great significance for smooth raw material logistics, stable raw material quality, and smooth production in all aspects of sintering raw material supply.

[0003] To meet the quality requirements of the sintering raw material (blended ore) output process in the ironmaking plant, the two bucket wheels of the blending and reclaiming machine rotate continuously with the reciprocating motion of the trolley to meet the need for blending and reclaiming material from the end face of the blended ore. During actual production operation, the bucket wheel current exceeded its load capacity, causing abnormal operation of the bucket wheels that was not stopped in time, leading to equipment and production failures. Abnormal operation of the bucket wheels not only interrupts the blending and reclaiming operation, affecting raw material production and quality stability, but also damages surrounding auxiliary facilities, threatening the safety of operators and other personnel on site. Recovery requires crane lifting, working at height, and jacking operations, which are highly dangerous and take more than 10 hours, threatening the supply of sintering raw materials.

[0004] The early warning system for abnormal current in the bucket wheel of the blending and reclaiming machine can detect abnormal operation of the bucket wheel at an early stage, effectively ensuring production safety, reducing unplanned downtime, lowering maintenance costs, extending equipment life, and realizing intelligent operation and maintenance. It also ensures the safety of on-machine personnel and equipment operation, and is of great significance for the smooth and stable continuous output of blended ore in ironmaking, ensuring smooth raw material logistics, stable raw material quality, and the smooth operation of all aspects of raw material supply to sintering blast furnaces. Abnormal operation of the bucket wheel of the blending and reclaiming machine not only interrupts the blending and reclaiming operation, affecting raw material production and quality stability, but also damages surrounding auxiliary facilities, threatening the safety of on-machine operators and other on-site personnel. Summary of the Invention

[0005] The technical problem to be solved by this invention is: how to detect abnormal trends and issue early warning signals in time before the bucket wheel of a mixing and reclaiming machine experiences serious failure or performance degradation, so as to prevent equipment and production failures caused by the bucket wheel's abnormal operation not stopping in time.

[0006] The technical solution adopted in this invention is: a method for abnormal current warning and shutdown protection of a mixing and reclaiming machine bucket wheel, comprising a real-time current acquisition module and a current warning protection module; the real-time current acquisition module is installed in the power supply circuit of the bucket wheel drive motor of the mixing and reclaiming machine. During operation, the real-time current acquisition module continuously acquires the current of the bucket wheel drive motor power supply circuit of the mixing and reclaiming machine bucket wheel and transmits the real-time acquired current signal to the current warning protection module; the current warning protection module is electrically connected to the real-time current acquisition module, the control switch of the bucket wheel drive motor of the mixing and reclaiming machine, an alarm module, a display module, an input module, and a storage module. The current warning protection module is equipped with multiple warning thresholds according to the model of the mixing and reclaiming machine and the material requirements. The current warning protection module extracts the current value and the corresponding time point from the current signal transmitted from the real-time current acquisition module. The current warning protection module compares the current value with each warning threshold and executes warning and shutdown protection actions according to the comparison result and the corresponding duration, and stores the operation process in the storage module; the operator can adjust or set the warning threshold, comparison formula, warning information, shutdown information, and reset the current warning protection module through the input module.

[0007] The real-time current acquisition module is a current sensor. When the current sensor continuously acquires the current of the power supply circuit of the bucket wheel drive motor of the mixing and reclaiming machine, the acquisition frequency is 1 time / second. The current sensor is connected in series or in parallel to the bucket wheel drive motor of the mixing and reclaiming machine.

[0008] The current warning protection module is one of a computer, a programmable logic controller, or a PLC controller. The warning thresholds include a first upper current threshold, a second upper current threshold, and a lower current threshold. The comparison formula includes a formula for comparing the current value with each warning threshold. The comparison result is the result of comparing the current value with each warning threshold and the corresponding duration.

[0009] The execution of early warning and shutdown protection actions includes: when the current value is greater than the lower current threshold and less than the first upper current threshold, the bucket wheel drive motor of the mixing and reclaiming machine is in normal working condition, without issuing an early warning or a shutdown signal; when the current value is greater than or equal to the first upper current threshold and less than the second upper current threshold, and the corresponding duration is greater than or equal to 5 seconds, an alarm is triggered through the alarm module to alert personnel and allow for inspection, but no shutdown signal is issued; when the current value is greater than or equal to the second upper current threshold and the corresponding duration is greater than or equal to 180 seconds, an alarm is triggered through the alarm module, and a shutdown signal is also triggered to alert personnel and allow for inspection; when the current value is less than or equal to the lower current threshold and the corresponding duration is greater than or equal to 180 seconds, an alarm is triggered through the alarm module, and a shutdown signal is also triggered to alert personnel and allow for inspection.

[0010] The display module is a monitor with a human-machine interface running on it. When an early warning or shutdown protection action is performed, the information is displayed on the display module.

[0011] The storage module stores the current signal information transmitted from the real-time current acquisition module in real time. The storage module also stores the information generated when executing early warning and shutdown protection actions.

[0012] The beneficial effects of this invention are as follows: In terms of equipment protection, by using graded current monitoring and time-delay protection, serious faults such as motor burnout and mechanical jamming caused by abnormal current are avoided, the service life of core components such as bucket wheel drive motor, bearings, and transmission gears is extended, and equipment maintenance costs are reduced.

[0013] In terms of production assurance: advance warning of abnormal bucket wheel conditions, reducing unplanned downtime (the time of a single unplanned downtime can be shortened from the original 2-4 hours to less than 0.5 hours), ensuring the continuous and stable output of bulk raw materials (blended ore) for ironmaking, avoiding the risk of material shortage in downstream processes, and ensuring smooth production.

[0014] Safety and Operation and Maintenance: Reduce the frequency and safety risks of manual inspections, realize operation and maintenance traceability by automatically recording fault data, promote the transformation of the mixing and reclaiming machine from "passive maintenance" to intelligent operation and maintenance mode of "proactive early warning + predictive maintenance", and at the same time ensure the personal safety of on-machine operators.

[0015] In terms of quality stability: avoid fluctuations in feed volume caused by bucket wheel malfunctions, ensure the uniformity of feed volume of mixed ore, thereby ensuring the stability of raw material quality in subsequent ironmaking processes and reducing product quality problems caused by fluctuations in raw material quality. Detailed Implementation

[0016] A method for early warning and shutdown protection of abnormal current in the bucket wheel of a mixing and reclaiming machine is proposed, which involves building a real-time current acquisition module and a current early warning and protection module.

[0017] The real-time current acquisition module is installed in the power supply circuit of the bucket wheel drive motor of the mixing and reclaiming machine. During operation, the real-time current acquisition module continuously acquires the current of the bucket wheel drive motor power supply circuit of the mixing and reclaiming machine and transmits the real-time acquired current signal to the current early warning and protection module. The real-time current acquisition module is a current sensor. When the current sensor continuously acquires the current of the bucket wheel drive motor power supply circuit of the mixing and reclaiming machine, the acquisition frequency is 1 time / second. The current sensor is connected in series or parallel to the bucket wheel drive motor of the mixing and reclaiming machine. In actual use, the real-time current acquisition module can be a software module that directly acquires the current of the bucket wheel drive motor power supply circuit of the mixing and reclaiming machine through a PLC.

[0018] In one embodiment, a current sensor is connected in series with the bucket wheel drive motor of the mixing and reclaiming machine. When the motor (the bucket wheel drive motor of the mixing and reclaiming machine) is a three-phase AC motor, a current sensor is connected in series with each phase of the AC power supply. Any one current sensor is used as a real-time current acquisition module, and the other two are used as backups.

[0019] In one embodiment, the PLC has data acquisition of the current of the bucket wheel drive motor of the mixing and reclaiming machine. In the process of using this invention, the power supply circuit current of the bucket wheel drive motor of the mixing and reclaiming machine is directly acquired from the PLC through a software module, which is simpler.

[0020] The current warning and protection module is electrically connected to the real-time current acquisition module, the bucket wheel drive motor control switch of the mixing and reclaiming machine, the alarm module, the display module, the input module, and the storage module. In one embodiment, the bucket wheel drive motor control switch of the mixing and reclaiming machine is an electromagnetic switch that can be remotely turned off by the current warning and protection module; the alarm module is an existing audible and visual alarm module; the display module is a monitor; the input module is a keyboard; and the storage module is a hard disk.

[0021] The current warning protection module has multiple warning thresholds set according to the model of the mixing and feeding machine and the feeding requirements. The current warning protection module extracts the current value and its corresponding time point from the current signal transmitted from the real-time current acquisition module. The purpose of extracting the time point corresponding to the current value is to obtain the duration for which the current value is less than, greater than, or equal to a certain warning threshold.

[0022] The current warning protection module compares the current value with each warning threshold and executes warning and shutdown protection actions based on the comparison results and corresponding durations, and stores the operation process in the storage module. Operators can adjust or set the warning thresholds, comparison formulas, warning information, shutdown information, and reset the current warning protection module through the input module.

[0023] The current warning protection module is one of a computer, a programmable logic controller, or a PLC controller. The warning thresholds include a first upper current threshold, a second upper current threshold, and a lower current threshold. The comparison formula includes a formula for comparing the current value with each warning threshold. The comparison result is the result of comparing the current value with each warning threshold and the corresponding duration.

[0024] Different models of mixing and feeding machines with different material feeding requirements have different rated power and working power, so a uniform warning threshold (referring to the first current upper limit threshold, the second current upper limit threshold, and the current lower limit threshold) cannot be used. It needs to be set according to the actual situation.

[0025] In one embodiment, the first upper current threshold is 60A, the second upper current threshold is 70A, and the lower current threshold is 50A. Based on continuous detection of the bucket wheel operating current value of the mixing and reclaiming machine, historical fault data, and on-site operating conditions, two levels of current protection logic are preset in the PLC controller, with specific parameters as follows: Level 1 Protection (Early Warning Protection Activated): The first current upper limit threshold is set to 60A with a delay time of 5 seconds. This threshold corresponds to the bucket wheel (mixing and reclaiming machine) operating normally and the equipment reclaiming operation is stable. The protection is activated to prevent accidental shutdown caused by the equipment not reaching the no-load current load value, which would affect the normal operation of production.

[0026] Level 2 protection (blocking state early warning protection): The upper limit threshold of the current is set to 70A and the delay time is 180 seconds. This threshold range covers emergency abnormal scenarios such as bucket wheel blockage, raw material fluctuation, component wear, and motor overload. By using the delay to judge and eliminate instantaneous interference, the system can quickly respond to start the early warning protection shutdown to avoid equipment damage, while avoiding accidental shutdown.

[0027] Level 3 protection (no-load state early warning protection): The current lower limit threshold is set to 50A and the delay time is 180 seconds before triggering an early warning and stopping the machine. This can prevent the failure to detect the bucket wheel no-load or abnormal current output state in time, which may lead to the continuous chain operation of related equipment such as the trolley horizontal pull, resulting in equipment damage and production disruption.

[0028] Write a control program in the PLC controller to realize dynamic monitoring and logical judgment of the collected real-time current signal of the bucket wheel. The specific program logic is as follows: After the program starts, it receives current data transmitted from the current sensor in real time and displays the data synchronously on the human-machine interface (HMI) for operators to view in real time.

[0029] Perform two-level logic judgment on real-time current data: If the real-time current is greater than 60A, when the timing lasts for 5 seconds, the program determines that the conditions for activating the "early warning protection program" are met and triggers the first-level protection start command.

[0030] If the real-time current is less than 50A or greater than 70A, the program will start the second and third level protection timing. When the timing continues for 180 seconds and the current does not recover to the normal range of 50A-70A, the program will determine it as a "continuous abnormal state" and trigger the warning and protection command.

[0031] If the real-time current is within the normal operating range of 50A-60A, the program maintains normal control and does not trigger any protection actions, while continuously monitoring current changes.

[0032] When the PLC controller determines that a first-level or second-level protection logic has been triggered, it immediately executes the following linkage action: Warning Action: A red fault alarm pop-up window appears on the human-machine interface (HMI), displaying information such as "abnormal bucket wheel current (level 1 protection / level 2 protection)". At the same time, the equipment's audible and visual alarm is triggered (sound frequency 1kHz, light flashing red), reminding on-site operators to troubleshoot the fault in a timely manner.

[0033] Shutdown protection action: The PLC controller sends a power-off command to the contactor of the bucket wheel drive motor, controlling the bucket wheel drive motor to stop running immediately; to avoid the accumulation or interruption of raw materials in subsequent processes due to the bucket wheel stopping; the system automatically records the fault occurrence time, current value, fault type and other data, and stores them in the historical database for later fault analysis and maintenance traceability.

[0034] After the on-site operators have troubleshooted and resolved the fault (such as clearing blocked raw materials, replacing worn parts, and restoring the raw material supply), they can send a reset command to the PLC controller through the "Fault Reset" button on the human-machine interface. After receiving the reset command, the controller will clear the alarm record, release the shutdown protection state, and after the operators confirm that the equipment is in normal condition, they can start the bucket wheel drive motor to resume the normal material handling operation of the mixing and feeding machine.

[0035] This invention can be implemented using existing PLC control programs. The real-time current acquisition module and the current early warning protection module can both be software control modules in the PLC. The control switch of the bucket wheel drive motor of the mixing and feeding machine can also be a software module. The alarm module, display module, input module, and storage module can be directly implemented using the same functional modules of the existing PLC.

Claims

1. A method for early warning and shutdown protection of abnormal current in the bucket wheel of a mixing and reclaiming machine, characterized in that: Build a real-time current acquisition module and a current early warning and protection module; The real-time current acquisition module is installed in the power supply circuit of the bucket wheel drive motor of the mixing and reclaiming machine. During operation, the real-time current acquisition module continuously acquires the current of the power supply circuit of the bucket wheel drive motor of the mixing and reclaiming machine and transmits the real-time acquired current signal to the current early warning protection module. The current warning and protection module is electrically connected to the real-time current acquisition module, the bucket wheel drive motor control switch of the mixing and feeding machine, the alarm module, the display module, the input module, and the storage module. The current warning and protection module has multiple warning thresholds set according to the model of the mixing and feeding machine and the material feeding requirements. It extracts the current value and its corresponding time point from the current signal transmitted from the real-time current acquisition module. The current warning and protection module compares the current value with each warning threshold and executes warning and shutdown protection actions based on the comparison result and the corresponding duration, storing the operation process in the storage module. Operators can adjust or set warning thresholds, comparison formulas, warning information, shutdown information, and reset the current warning and protection module through the input module.

2. The method for abnormal current warning and shutdown protection of a mixing and reclaiming machine bucket wheel according to claim 1, characterized in that: The real-time current acquisition module is a current sensor. When the current sensor continuously acquires the current of the power supply circuit of the bucket wheel drive motor of the mixing and reclaiming machine, the acquisition frequency is 1 time / second. The current sensor is connected in series or in parallel to the bucket wheel drive motor of the mixing and reclaiming machine.

3. The method for abnormal current warning and shutdown protection of a mixing and reclaiming machine bucket wheel according to claim 1, characterized in that: The current warning protection module is one of a computer, a programmable logic controller, or a PLC controller. The warning thresholds include a first upper current threshold, a second upper current threshold, and a lower current threshold. The comparison formula includes a formula for comparing the current value with each warning threshold. The comparison result is the result of comparing the current value with each warning threshold and the corresponding duration.

4. The method for abnormal current warning and shutdown protection of a mixing and reclaiming machine bucket wheel according to claim 3, characterized in that: The execution of early warning and shutdown protection actions includes: when the current value is greater than the lower current threshold and less than the first upper current threshold, the bucket wheel drive motor of the mixing and reclaiming machine is in normal working condition, without issuing an early warning or a shutdown signal; when the current value is greater than or equal to the first upper current threshold and less than the second upper current threshold, and the corresponding duration is greater than or equal to 5 seconds, an alarm is triggered through the alarm module to alert personnel and allow for inspection, but no shutdown signal is issued; when the current value is greater than or equal to the second upper current threshold and the corresponding duration is greater than or equal to 180 seconds, an alarm is triggered through the alarm module, and a shutdown signal is also triggered to alert personnel and allow for inspection; when the current value is less than or equal to the lower current threshold and the corresponding duration is greater than or equal to 180 seconds, an alarm is triggered through the alarm module, and a shutdown signal is also triggered to alert personnel and allow for inspection.

5. The method for abnormal current warning and shutdown protection of a mixing and reclaiming machine bucket wheel according to claim 1, characterized in that: The display module is a monitor with a human-machine interface running on it. When an early warning or shutdown protection action is performed, the information is displayed on the display module.

6. The method for abnormal current warning and shutdown protection of a mixing and reclaiming machine bucket wheel according to claim 1, characterized in that: The storage module stores the current signal information transmitted from the real-time current acquisition module in real time. The storage module also stores the information generated when executing early warning and shutdown protection actions.