Automatic hoisting system for furnace barrel of reduction furnace

Abstract

The utility model provides an automatic hoisting system for a furnace barrel of a reduction furnace, and relates to the field of hoisting equipment. The automatic hoisting system for the furnace barrel of the reduction furnace comprises a bridge crane, a lifting mechanism, a large trolley moving mechanism and a small trolley moving mechanism, the detection equipment is arranged on the bridge crane and is provided with a large and small vehicle positioning device, a lifting positioning device and a monitoring device; the field control equipment is arranged on the bridge crane and is provided with an industrial switch and an airborne antenna; the industrial switch is in wired signal connection with the lifting mechanism, the large and small vehicle moving mechanism, the large and small vehicle positioning device, the lifting positioning device and the monitoring device; the ground control center is provided with a core switch, and a PLC (Programmable Logic Controller), a remote software server and a wireless communication AP (Access Point) box which are connected through optical fibers; wherein the airborne antenna and the wireless communication AP box can carry out wireless signal transmission. Aiming at a complex environment, the hoisting efficiency and the hoisting accuracy are improved.

Description

Technical Field

[0001] The utility model relates to the field of hoisting equipment, in particular to an automatic hoisting system for a reduction furnace drum. Background Art

[0002] In silicon production, the reduction process is a key step in converting silicon oxides (such as silicon dioxide) into pure silicon. When the silicon reduction furnace is in operation, silica and carbonaceous reducing agent are weighed and automatically added to the furnace according to a certain ratio, and then the charge is heated to above 2000 degrees Celsius. Silicon dioxide is reduced by the carbonaceous reducing agent to generate industrial silicon liquid and carbon monoxide gas, which then escapes through the material layer.

[0003] After the reduction operation, the reduction furnace drum usually needs to be hoisted and transported. Due to the complex environment of the silicon reduction work area, the current hoisting and transportation method is a traditional bridge crane operated by remote control, which is convenient for the staff to operate according to the specific situation. However, the manual control method is inefficient, and the accuracy, stability and safety are poor, which cannot meet the growing production capacity demand. Utility Model Content

[0004] In order to solve the problems in the prior art that the manual control method has low efficiency and poor accuracy, stability and safety, the utility model provides a highly automated automatic lifting system for the reduction furnace drum that can adapt to the complex environment of the silicon reduction work area and maintain safety.

[0005] The technical solution adopted by the utility model is:

[0006] An automatic hoisting system for a reduction furnace drum, comprising:

[0007] A bridge crane has at least a lifting mechanism and a trolley moving mechanism, and the lifting mechanism is provided with an intelligent spreader;

[0008] The detection equipment is arranged on the bridge crane and has at least a trolley positioning device, a lifting positioning device and a monitoring device;

[0009] A field control device is arranged on the bridge crane and has at least one industrial switch and an onboard antenna connected to the industrial switch by optical fiber; the industrial switch is connected to the lifting mechanism, the trolley moving mechanism, the trolley positioning device, the lifting positioning device, and the monitoring device by wired signals; and

[0010] The ground control center has at least one core switch, and a PLC controller, a remote software server and a wireless communication AP box connected to the core switch by optical fiber;

[0011] Among them, the airborne antenna and the wireless communication AP box can transmit wireless signals; the remote software server processes the information of the sling position, sling height, on-site images, hoisting object images and storage point images collected by the trolley positioning device, lifting positioning device and monitoring device, and feeds back to the PLC controller for processing and generating work instructions. The ground control center transmits the work instructions back to the on-site control equipment to control the operation of the lifting mechanism and the trolley movement mechanism.

[0012] Furthermore, the remote software server at least has:

[0013] The simulation map module can calculate the simulation map of the entire site through the on-site image information, and display the storage points of the hoisted objects and the locations of obstacles; and

[0014] The material transportation trajectory planning module performs the first path planning from the crane position to the storage point of the hoisting object, the second path planning from the storage point of the hoisting object to the delivery point, and the appropriate transportation height planning.

[0015] Furthermore, the large and small vehicle positioning device is a Gray bus continuous encoding device, and the Gray bus continuous encoding device at least has:

[0016] Cables are laid on the main beam and platform of the bridge crane; and

[0017] The induction box is arranged on the lifting mechanism.

[0018] Furthermore, the lifting mechanism at least has a lifting drum and a lifting motor, and the lifting positioning device includes an absolute encoder, and the absolute encoder is arranged on the output shaft of the lifting drum.

[0019] Furthermore, the lifting and positioning device also includes an incremental encoder, and the incremental encoder is arranged on the lifting motor of the lifting mechanism.

[0020] Furthermore, the monitoring device at least has:

[0021] A ball camera, which is arranged on the end beam of one side of the bridge crane and is provided with a pan / tilt capable of 360-degree rotating monitoring; and

[0022] A gun camera is arranged on the end beam on the other side of the bridge crane and is arranged toward the lifting area of ​​the intelligent lifting device.

[0023] Furthermore, the ground control center also has a network video storage device for storing information collected by the monitoring device.

[0024] Furthermore, the ground control center also has a monitoring station for video playback of the information stored in the network video memory.

[0025] Furthermore, the ground control center is also equipped with a handheld auxiliary device, and the handheld auxiliary device and the airborne antenna can perform wireless signal transmission.

[0026] Furthermore, a rotary encoder is provided on the lifting mechanism; an anti-sway module is provided on the remote software server; and an execution frequency converter is provided on the moving mechanism of the large and small vehicles.

[0027] The beneficial effects of the utility model are:

[0028] 1. The utility model sets a remote software server and a PLC controller in the ground control center, and cooperates with the trolley positioning device, lifting positioning device, monitoring device and other detection equipment set on the bridge crane on site, so as to realize the automated operation of the lifting mechanism, trolley moving mechanism and intelligent lifting device of the bridge crane to adapt to complex environments, and solves the problem that the manual control method in the prior art is low in efficiency and poor in accuracy, stability and safety.

[0029] 2. The utility model also relies on the functions of remote software server to simulate maps and plan paths, and the main control system of the ground control center is far away from the site, thereby realizing the adaptation of the automated lifting system to complex environments. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0031] Figure 1 It is a structural schematic diagram of a lifting system according to an embodiment of the utility model.

[0032] Figure 2 It is a top view of a bridge crane according to an embodiment of the utility model.

[0033] Figure 3 It is a front view of a bridge crane according to an embodiment of the utility model.

[0034] Figure 4 This is a speed curve diagram of the second embodiment of the utility model when the anti-sway function is not activated.

[0035] Figure 5 It is a speed curve diagram of the second embodiment of the utility model when the anti-sway is activated.

[0036] Reference numerals:

[0037] 100-bridge crane, 120-lifting mechanism, 122-lifting drum, 124-lifting motor, 126-intelligent spreader, 140-carriage moving mechanism, 160-main beam, 170-end beam, 180-walking platform;

[0038] 200-detection equipment, 220-lifting and positioning device, 222-absolute encoder, 224-incremental encoder, 240-large and small vehicle positioning device, 244-sensing box, 260-monitoring device, 262-gun camera, 264-ball camera;

[0039] 300-field control equipment, 310-industrial switch, 330-airborne antenna;

[0040] 400- ground control center, 410- core switch, 420- PLC controller, 440- remote software server, 460- wireless communication AP box, 470- monitoring station, 480- network video storage, 490- handheld auxiliary device. DETAILED DESCRIPTION

[0041] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0042] The disclosure below provides many different embodiments or examples to implement different structures of the present invention. In order to simplify the disclosure of the present invention, the components and settings of specific examples are described below. Of course, they are only examples, and the purpose is not to limit the present invention.

[0043] The embodiments of the utility model are described in detail below with reference to the accompanying drawings.

[0044] See also Figure 1-Figure 3 This embodiment provides a reduction furnace drum automatic hoisting system, which is used for the automatic hoisting of the reduction furnace drum in the reduction process working area during the silicon production process. The reduction furnace drum automatic hoisting system mainly includes: a bridge crane 100, a detection device 200, a field control device 300 and a ground control center 400.

[0045] like Figure 1-Figure 3As shown in , the bridge crane 100 is arranged in the reduction process working area, and has a common bridge structure, as well as a lifting mechanism 120 and a large and small vehicle moving mechanism 140. Among them, the bridge structure mainly includes a main beam 160, an end beam 170 connected at both ends of the main beam 160, and a walkway 180 installed on the outside of the main beam 160. The lifting mechanism 120 is provided with an intelligent sling 126, and the intelligent sling 126 can be automatically grasped and released by remote control or control of the lifting mechanism 120. In addition, the lifting mechanism 120 and the large and small vehicle moving mechanism 140 are connected to the field control device 300 through wires, can receive signals transmitted by the field control device 300, and work under the control of the ground control center 400.

[0046] like Figure 1-Figure 3 As shown in the figure, the detection device 200 is arranged on the bridge crane 100, and is used to collect the on-site information required for the modeling and path planning of the ground control center 400. The information detection device 200 has a large and small car positioning device 240, a lifting positioning device 220, and a monitoring device 260. Among them, the large and small car positioning device 240 is used to detect the horizontal position information of the intelligent spreader 126 of the bridge crane 100; the lifting positioning device 220 is used to detect the height information of the intelligent spreader 126 in the vertical direction; the monitoring device 260 collects the information of the on-site image, the image of the hoisting object, and the image of the storage point through multi-directional monitoring of the site.

[0047] like Figure 1-Figure 3 As shown in , the field control device 300 is arranged on the bridge crane 100, and is used to integrate the working information of the bridge crane 100 and the collected information of the detection device 200, and transmit them to the ground control center 400 in a centralized manner, and receive the feedback signal of the ground control center 400 to control the working of the bridge crane 100. The field control device 300 has an industrial switch 310, and an airborne antenna 330 connected to the industrial switch 310 by optical fiber. The industrial switch 310 is connected to the lifting mechanism 120, the large and small vehicle moving mechanism 140, the large and small vehicle positioning device 240, the lifting and positioning device 220, and the monitoring device 260 by wired signals. Among them, the industrial switch 310 is connected to the lifting mechanism 120, the large and small vehicle moving mechanism 140, the large and small vehicle positioning device 240, and the lifting and positioning device 220 through wires to transmit signals; the industrial switch 310 is connected to the monitoring device 260 by optical fiber to transmit signals. In addition, the airborne antenna 330 transmits signals to the ground control center 400 through wireless signal transmission.

[0048] like Figure 1As shown in , the ground control center 400 is set outside the reduction process work area. Due to the centralized processing of the information collected by the detection equipment 200, on-site analysis and route planning are performed, and work instructions are issued to the bridge crane 100. The ground control center 400 has a core switch 410, a PLC controller 420, a remote software server 440 and a wireless communication AP box 460 connected to the core switch 410 by optical fiber. Among them, the airborne antenna 330 and the wireless communication AP box 460 can transmit wireless signals; the remote software server 440 processes the information of the sling position, sling height, on-site image, hoisting object image and storage point image collected by the large and small vehicle positioning device 240, the lifting positioning device 220 and the monitoring device 260, and feeds back to the PLC controller 420 to generate work instructions, and then transmits the work instructions back to the on-site control device 300 through the ground control center 400 to control the lifting mechanism 120 and the large and small vehicle moving mechanism 140 to work. In this embodiment, the remote software server 440 performs on-site analysis and route planning through the simulation map module and the material transportation trajectory planning module. In addition, in the wireless communication AP box 460, the optical transmission signal is converted into a wireless signal and radiated to the warehouse area through the fan antenna. The airborne antenna 330 on the crane can receive the wireless signal and form a reliable wireless signal transmission with the ground control center 400.

[0049] A specific implementation of this embodiment is:

[0050] First, after the bridge crane 100 is turned on, the monitoring device 260 is started synchronously, and begins to collect on-site image information and transmit it to the ground control center 400. The simulation map module of the remote software server 440 calculates a simulation map of the entire site based on the on-site image information, including displaying the storage point of the hoisted object and the location of obstacles; then, the position of the hoist in the simulation map is calculated in combination with the hoisting equipment position information to form a relatively complete on-site map.

[0051] Next, the system enters the normal process control mode and waits for the operator to arrange the work plan, including selecting the storage point for the hoisting object and determining the location of the delivery point; after the operator sets the work plan, the material transportation trajectory planning module of the remote software server 440 performs effective optimal path planning based on the simulated complete site map, including the first path planning from the crane position to the storage point for the hoisting object, the second path planning from the storage point for the hoisting object to the delivery point, and the appropriate transportation height planning. The above path planning all belong to linear optimal planning problems with constraints. During the calculation process, various constraints are classified and the corresponding model equations are given. Then, the Lagrange multiplier method is used to solve them, and finally the optimal path is obtained. This optimization problem belongs to an optimization problem with fixed starting and terminal ends, and the computer solution process is relatively fast; then, an instruction is issued through the PLC controller 420, and the trolley moving mechanism 140 drives the bridge crane 100 to automatically move to the storage point for the hoisting object according to the first path planning.

[0052] After arriving at the storage point, the monitoring device 260 collects the image of the hoisting object and transmits it to the remote software server 440, and then issues a command through the PLC controller 420, the lifting mechanism 120 drives the intelligent hoist 126 to automatically descend to the position of the hoisting object, and the intelligent hoist 126 automatically grabs it; after grabbing the hoisting object, the lifting mechanism 120 drives the intelligent hoist 126 to rise to a suitable transportation height, and the large and small vehicle moving mechanism 140 drives the bridge crane 100 to automatically move to the storage point of the hoisting object according to the second path planning; at the storage point, the monitoring device 260 collects the image of the storage point, transmits it to the remote software server 440, and then issues a command through the PLC controller 420, the lifting mechanism 120 drives the intelligent hoist 126 to automatically descend to the storage point, and the intelligent hoist 126 is automatically released.

[0053] The reduction furnace drum automatic hoisting system of the present embodiment performs the above process automatically, quickly and efficiently, and can be repeated continuously for multiple times, thereby improving the efficiency and accuracy of the reduction furnace drum hoisting process.

[0054] In this embodiment, the reduction furnace drum automatic lifting system realizes the automatic operation of the lifting mechanism 120, the trolley moving mechanism 140 and the intelligent lifting device 126 of the bridge crane 100 to adapt to complex environments by setting a remote software server 440 and a PLC controller 420 in the ground control center 400, and cooperating with the detection equipment 200 such as the trolley positioning device 240, the lifting positioning device 220 and the monitoring device 260 set on the on-site bridge crane 100, thereby solving the problem that the manual control method in the prior art is low in efficiency and has poor accuracy, stability and safety.

[0055] At the same time, in this embodiment, the remote software server 440 is also relied on to simulate the map and plan the path function, and the main control system of the ground control center 400 is far away from the site, so that the automated lifting system can adapt to complex environments.

[0056] Preferably, in one or more embodiments, the large and small car positioning device 240 adopts a Gray bus continuous encoding device, which mainly includes a cable and an induction box 244. The cable is laid on the main beam 160 and the platform 180; the induction box 244 is arranged on the lifting mechanism 120, and components such as an induction loop, a scale analyzer, a scale generator, a vernier pointer, a protocol conversion module, and installation accessories are arranged inside. The Gray bus continuous encoding device uses the induction principle of a single-turn coil to transmit the horizontal position information of the intelligent sling 126 to the induction loop through electromagnetic coupling.

[0057] Preferably, in one or more embodiments, the lifting and positioning device 220 includes an absolute encoder 222. The absolute encoder 222 is arranged on the output shaft of the lifting drum 122 of the lifting mechanism 120. By detecting the number of rotations and angles of the lifting drum 122, the height information of the intelligent sling 126 in the vertical direction is obtained. The height information can be fed back in real time during the rising and falling process of the intelligent sling 126, and the ground control center 400 is assisted to obtain real-time height information during the lifting process, provide correction instructions, and improve the accuracy of the lifting operation. Further, the lifting and positioning device 220 also includes an incremental encoder 224, which is arranged on the lifting motor 124 of the lifting mechanism 120, and records the number of rotations and angles by recording rotation pulses. When the incremental encoder 224 and the control system are powered off, the currently recorded position will be lost, so the incremental encoder 224 is suitable for use in conjunction with the absolute encoder 222 on the lifting drum 122 as a calibration.

[0058] Preferably, in one or more embodiments, the monitoring device 260 has a ball camera 264 and a gun camera 262. The ball camera 264 is arranged on the end beam 170 on one side of the bridge crane 100, and is provided with a pan / tilt that can rotate 360 ​​degrees for monitoring, for collecting on-site image information of the entire reduction process working area. The gun camera 262 is arranged on the end beam 170 on the other side of the bridge crane 100, and is arranged toward the lifting area of ​​the intelligent sling 126, for collecting information on the image of the lifting object and the image of the storage point when the intelligent sling 126 reaches the corresponding position. In addition, the ball camera 264 and the gun camera 262 are automatically turned off and stop working when the bridge crane 100 stops running; when the bridge crane 100 starts to start running, the monitoring function is automatically turned on.

[0059] Preferably, in one or more embodiments, the ground control center 400 also has a network video storage 480 in the control room, and all the information collected by the monitoring device 260 is transmitted back to the network video storage 480 for storage. The network video storage 480 uses a hard disk capacity of 2T, which can meet the video storage requirements and can forward video signals. Further, the ground control center 400 also has a monitoring station 470, which is equipped with two 24-inch monitors and a video decoder for video playback of the information stored in the network video storage 480. The core device of the video decoder is a computer, and the video decoding server has an independent graphics card. The performance of the independent graphics card meets the requirements of displaying more than 8 channels of video at the same time.

[0060] Preferably, in one or more embodiments, the ground control center 400 is equipped with a handheld auxiliary device 490 for manual operation in certain situations. The handheld auxiliary device 490 and the airborne antenna 330 can transmit wireless signals to control the lifting mechanism 120 and the trolley moving mechanism 140 on the bridge crane 100 by bypassing the remote software server 440 and the PLC controller 420 when the system fails.

[0061] However, in the above embodiment, the intelligent hoist 126 has obvious swing in the direction of the trolley and the direction of the truck during operation, which seriously affects the operating efficiency of the lifting system and also causes safety hazards. In order to further solve these problems on the basis of the above embodiment, a second embodiment is provided below.

[0062] See also Figure 4-Figure 5 In the second embodiment, anti-swaying improvements are mainly made to the lifting mechanism 120, the PLC controller 420 and the large and small car moving mechanism 140.

[0063] The lifting mechanism 120 is provided with a rotary encoder as a rope length detection device to collect rope length information of the lifting mechanism 120, and cooperate with other information collected by the monitoring equipment as the basis for simulation calculation. The remote software server 440 is provided with an anti-sway module to calculate and modulate the speed setting value of the large and small vehicle moving mechanism 140 according to the rope length information, and generate a speed adjustment curve, such as Figure 5 The PLC controller 420 then issues commands in real time. The large and small car moving mechanism 140 is provided with an execution inverter, which can adjust the acceleration and deceleration according to the command of the PLC controller 420, adjust the operation of the large and small car moving mechanism 140, and finally realize the anti-sway function.

[0064] The above shows and describes the basic principle, main features and advantages of the utility model. Those skilled in the art should understand that the utility model is not limited by the above embodiments. The above embodiments and descriptions are only preferred examples of the utility model and are not used to limit the utility model. Without departing from the spirit and scope of the utility model, the utility model may have various changes and improvements, which fall within the scope of the utility model to be protected. The scope of protection claimed by the utility model is defined by the attached claims and their equivalents.

Claims

1. An automatic hoisting system for a reduction furnace drum, characterized in that: Include: A bridge crane (100) comprises at least a lifting mechanism (120) and a carriage moving mechanism (140), wherein the lifting mechanism (120) is provided with an intelligent lifting device (126); A detection device (200) is arranged on the bridge crane (100) and comprises at least a trolley positioning device (240), a lifting positioning device (220) and a monitoring device (260); The field control device (300) is arranged on the bridge crane (100) and has at least one industrial switch (310) and an onboard antenna (330) connected to the industrial switch (310) by optical fiber; the industrial switch (310) is connected to the lifting mechanism (120), the carriage moving mechanism (140), the carriage positioning device (240), the lifting positioning device (220), and the monitoring device (260) by wired signals; and A ground control center (400) has at least one core switch (410), and a PLC controller (420), a remote software server (440), and a wireless communication AP box (460) connected to the core switch (410) via optical fibers; The airborne antenna (330) and the wireless communication AP box (460) can perform wireless signal transmission; the remote software server (440) processes the information of the sling position, sling height, on-site image, hoisting object image and storage point image collected by the trolley positioning device (240), the lifting positioning device (220) and the monitoring device (260), and feeds it back to the PLC controller (420) for processing and generating work instructions, and the ground control center (400) transmits the work instructions back to the on-site control device (300) to control the operation of the lifting mechanism (120) and the trolley moving mechanism (140).

2. The reduction furnace drum automatic hoisting system according to claim 1, characterized in that: The remote software server (440) has at least: The simulation map module can calculate the simulation map of the entire site through the on-site image information, and display the storage points of the hoisted objects and the locations of obstacles; and The material transportation trajectory planning module performs the first path planning from the crane position to the storage point of the hoisted object, the second path planning from the storage point of the hoisted object to the delivery point, and the appropriate transportation height planning.

3. The automatic hoisting system for the reduction furnace drum according to claim 1, characterized in that: The carriage positioning device (240) is a Gray busbar continuous encoding device, and the Gray busbar continuous encoding device at least has: Cables are laid on the main beam (160) and the platform (180) of the bridge crane (100); and The induction box (244) is arranged on the lifting mechanism (120).

4. The automatic hoisting system for the reduction furnace drum according to claim 1, characterized in that: The lifting mechanism (120) comprises at least a lifting drum (122) and a lifting motor (124); the lifting positioning device (220) comprises an absolute value encoder (222); and the absolute value encoder (222) is arranged on an output shaft of the lifting drum (122).

5. The automatic hoisting system for the reduction furnace drum according to claim 4, characterized in that: The lifting and positioning device (220) further comprises an incremental encoder (224), wherein the incremental encoder (224) is arranged on the lifting motor (124) of the lifting mechanism (120).

6. The automatic hoisting system for the reduction furnace drum according to claim 1, characterized in that: The monitoring device (260) at least comprises: a dome camera (264), arranged on an end beam (170) on one side of the bridge crane (100), and provided with a pan / tilt head capable of 360-degree rotation for monitoring; and A gun camera (262) is arranged on the end beam (170) on the other side of the bridge crane (100) and is arranged toward the lifting area of ​​the intelligent lifting device (126).

7. The automatic hoisting system for the reduction furnace drum according to claim 1, characterized in that: The ground control center (400) also has a network video storage (480) for storing information collected by the monitoring device (260).

8. The automatic hoisting system for the reduction furnace drum according to claim 7, characterized in that: The ground control center (400) also has a monitoring station (470) for video playback of information stored in the network video storage (480).

9. The automatic hoisting system for a reduction furnace drum according to claim 1, characterized in that: The ground control center (400) is also equipped with a handheld auxiliary device (490), and the handheld auxiliary device (490) and the airborne antenna (330) can perform wireless signal transmission.

10. The automatic hoisting system for a reduction furnace drum according to any one of claims 1 to 9, characterized in that: The lifting mechanism (120) is provided with a rotary encoder; the remote software server (440) is provided with an anti-sway module; and the large and small vehicle moving mechanism (140) is provided with an execution frequency converter.

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