Control system of gasifier fire grate driving device

Abstract

The utility model discloses a control system of a gasifier fire grate driving device, which comprises a controller, a frequency converter and a switch, the frequency converter comprises a frequency converter control unit, a power supply module and an inversion module, and the frequency converter control unit and the controller are connected with the switch through an industrial Ethernet; the power supply module is electrically connected with the frequency converter control unit and the single-shaft inverter module. The frequency converter control unit is used for controlling the inversion module, the inversion module is electrically connected with the fire grate motor, and the inversion module is used for driving the fire grate motor; according to the utility model, the industrial Ethernet communication module is added on the basis of the existing control, so that the laying of signal cables in a control center can be greatly reduced, and the hardware cost is saved; and meanwhile, a human-computer interaction interface is added, so that the system has perfect functions of running state monitoring, equipment fault diagnosis, operation recording, running recording and the like, and equipment maintenance is more intuitive and convenient.

Description

Technical Field

[0001] This utility model belongs to the field of electrical control technology, and in particular to a control system for a gasifier grate drive device. Background Technology

[0002] A gasifier is a device that converts solid fuels (such as coal and biomass) into syngas. During this process, flammable gases may be generated under high temperature and pressure, which could lead to explosions if leaks or improper operation occur. The grate, a key component of the gasifier, primarily supports the fuel bed and promotes gas flow distribution. The grate motor drive system is the control device that drives the gasifier's ash removal system. It continuously removes residual ash adhering to the gasifier during the gasification process, ensuring the normal operation of the gasifier. During the heating and gasification process, residual coal ash is adsorbed onto the inner side of the gasifier. Excessive ash adsorption severely affects the gasifier's operation. The control system uses frequency conversion technology to drive two grate motors, which in turn drive the gearboxes connected to the grate to rotate. The continuous rotation of the grate removes coal ash and protects the gasifier; therefore, its explosion-proof requirements are crucial.

[0003] Currently, the domestic coal chemical industry widely uses frequency converter technology to drive the grate, achieving the goal of eliminating coal ash by controlling the grate. The control device includes a main control cabinet, a manhole operating column, and an ash lock control panel. It features three-level control: the first level is directly controlled by the cabinet, allowing direct start-up of the grate from the frequency converter operating panel on the cabinet, as well as function control and switching between local and remote control modes; the second level is locally controlled by the ash lock control panel, responsible for starting and stopping the grate and switching between local and external control; the fourth level has a manhole operating column for maintenance operations, during which external control is disabled, but it still allows for starting and stopping the grate and switching between local and external control. The grate drive uses one frequency converter to control two motors. The frequency converter's external control circuit consists of traditional relay circuits, or a programmable logic controller (PLC) can be used to control the equipment's operational logic. Various protection circuits are installed inside the cabinet to ensure the normal operation of the frequency converter and motors. Signal indicator lights are installed on the cabinet door to display the device status. Passive contacts inside the main control cabinet communicate with the remote control center via signal cables.

[0004] However, existing grate control systems have two problems. First, the grate drive motors and manhole operating columns used in the domestic coal chemical industry are all explosion-proof equipment installed at the equipment site. While frequency converters drive the grate motors, the drive control devices are generally installed in safe areas such as the gasification power distribution room or control room. The distance between the frequency converter and the grate motor is quite long, often three or four hundred meters, or even longer. This excessive distance can lead to a series of hazards, such as increased cable resistance causing excessive voltage drop, reduced motor torque, and speed fluctuations; increased cable resistance loss leading to cable heating, accelerated insulation aging, and reduced service life; the frequency converter's output PWM wave, when transmitted through long cables, generates reflected waves due to impedance mismatch, which, when superimposed, create voltage spikes at the motor terminals, causing motor noise and vibration, affecting motor lifespan, and potentially even breaking down the motor winding insulation, causing equipment damage and compromising safety; and increased electromagnetic interference, with EMI radiated from long cables becoming a strong interference source, potentially interfering with the normal operation of surrounding instruments and sensors, leading to equipment malfunctions.

[0005] Secondly, existing technologies using a single frequency converter to drive two grate motors can only operate in V / F mode, resulting in low control precision, insufficient output torque at low speeds, and poor dynamic response. When the grate jams, manual operation of the equipment in high torque mode is required to force the frequency converter to increase torque by a certain percentage. This is cumbersome and makes it difficult to guarantee the safety of equipment operation. If two frequency converters are used, controlling the synchronization of the two grate motors becomes difficult.

[0006] To monitor the load of each motor, Hall effect current transformers are installed in each motor circuit to measure the motor current, but the monitoring information is not comprehensive enough. The lack of a touchscreen means that the indicator lights on the control cabinet panel are used to simply determine whether the equipment is running or malfunctioning, without providing detailed monitoring of equipment operation and fault information. Some factories do not have gray lock controls, which necessitates changing the control circuit wiring or modifying the PLC program for proper operation. Utility Model Content

[0007] The purpose of this invention is to provide a control system for a gasifier grate drive device to solve the problems mentioned in the background art.

[0008] To achieve the above objectives, this utility model provides the following technical solution: a control system for a gasifier grate drive device, comprising a controller, a frequency converter, and a switch. The frequency converter includes a frequency converter control unit, a power supply module, and an inverter module. Both the frequency converter control unit and the controller are connected to the switch via an industrial Ethernet network. The power supply module is electrically connected to both the frequency converter control unit and the inverter module. The power supply module is used to supply power to the frequency converter control unit and the inverter module.

[0009] The frequency converter control unit controls the inverter module, which is electrically connected to the grate motor and drives it. The switch is used for signal forwarding.

[0010] As a preferred embodiment, the inverter module consists of two single-axis inverter modules or one dual-axis inverter module, with each inverter module's inverter shaft driving a grate motor independently.

[0011] As a preferred embodiment, there are two grate motors.

[0012] As a preferred embodiment, a touchscreen is also included, which is connected to the switch via an industrial Ethernet network.

[0013] As a preferred implementation scheme, the controller, frequency converter, switch, and touch screen are all located inside the control cabinet, which is installed in the power distribution room in the safe zone. This scheme solves the problems of low control accuracy of grate drive, insufficient output torque at low speed, and poor dynamic response performance in the existing technology.

[0014] In another preferred embodiment, the controller, switch, and touchscreen are all located within a control cabinet. The frequency converter control unit, power module, and inverter module are located within an explosion-proof distribution cabinet. A power control switch is installed within the control cabinet and is electrically connected to the power module. The power control switch controls whether the power module is energized. The explosion-proof distribution cabinet is located within the grate drive area, and the frequency converter employs a multi-vector drive method to ensure torque output during low-speed operation of the grate motor.

[0015] As a preferred embodiment, the present invention also includes a manhole operating column, a gray lock control panel, and a remote control center; the manhole operating column, the gray lock control panel, and the remote control center are all electrically connected to the controller; the switch is connected to the remote control center via an industrial Ethernet; the controller receives operating signals from the manhole operating column, the gray lock control panel, and the remote control center.

[0016] As a preferred implementation, the manhole operating column is installed at the grate drive site and near the equipment maintenance hole, and uses explosion-proof devices. The signal of the manhole operating column is connected to the control cabinet through the control cable. The manhole operating column is used during equipment debugging or maintenance and has the highest operating authority.

[0017] As a preferred embodiment, the ash lock control panel is located around the ash lock, and the signal from the ash lock control panel is connected to the control cabinet via a control cable; the remote control center can remotely send signals to the controller, thereby realizing remote control of the grate drive device.

[0018] As a preferred embodiment, the controller uses a Siemens S7-1200 series PLC to handle signal acquisition and control logic processing; the electrical connection is achieved using a signal cable.

[0019] As a preferred implementation, in addition to the regular operation and fault indicator lights, the control cabinet panel is equipped with a touch screen as a human-machine interface. The touch screen can monitor the operating status of the equipment in real time and complete all related control operations. The screen has historical data information related to maintenance and diagnosis, such as operation records, running records, and alarm records. It can intuitively display equipment control permissions, interlock information, fault codes and corresponding fault information descriptions.

[0020] As a preferred implementation, the touch screen, controller, and control unit are connected to the switch via industrial Ethernet and signal cables. The controller controls the frequency converter through network communication and reads the frequency converter's operating status data and fault information.

[0021] Compared with the prior art, the technical effects and advantages of this utility model are as follows:

[0022] The control system for the gasifier grate drive unit adopts a multi-drive control scheme, equipped with one power supply module and two single-axis inverter modules or one dual-axis inverter module. This enables precise synchronous control of the grate motors and accurate monitoring of the load status of each motor, such as motor current, voltage, output torque, and output active power. It eliminates the need for Hall effect current sensors to detect the current of individual motors, reducing potential points of failure. Furthermore, because each inverter shaft controls only one motor, the motor control mode can be set to vector control mode, ensuring torque output at low speeds. The motor can output full-load torque even at zero speed, eliminating the need for a separate high-torque mode, ensuring safe grate operation and simplifying manual operation.

[0023] When this invention adopts a distributed design, the frequency converter is installed at the equipment site via an explosion-proof control box, near the grate motor, while the controller is placed within the original safe area. The main control cabinet provides power to the frequency converter via a power cable, transmitting sinusoidal AC power. Harmonics and electromagnetic interference are significantly improved. The frequency converter is very close to the grate motor, eliminating the need for output reactors or sinusoidal filters. The power cable also does not need to be deliberately lengthened, greatly reducing hardware costs. The motor operates smoothly and reliably, effectively extending the service life of the motor and cables.

[0024] The gasifier grate drive control system uses a programmable logic controller (PLC) as its core, responsible for signal acquisition and control logic processing. The touchscreen, controller, and frequency converter control unit are connected via an industrial Ethernet network. The frequency converter is controlled via network communication, and its operating status data and fault information are read. Conventional hard-wired signal interfaces are retained, allowing data exchange with the remote control center via traditional hard-wired methods through signal cables, or via industrial Ethernet. This reduces the amount of control cabling required and lowers hardware costs.

[0025] The gasifier grate drive control system requires manual cleaning and maintenance of the furnace during system maintenance. The gasifier maintenance platform is equipped with a maintenance manhole and manhole operating column. The manhole allows observation of the furnace interior and entry for cleaning and maintenance. The manhole operating column features control mode selection and start / stop buttons, allowing local operation of the grate motor. When ash is released from the furnace, the grate can be operated independently from the ash lock position. An ash lock control panel with start / stop buttons and control mode switching is located at the ash lock. If ash lock operation is not required, the ash lock control function can be directly disabled through the human interface without changing the control circuit or modifying the program. Control of multiple operations is handled by the programmable controller and displayed on the touchscreen. The control priority is: manhole operating column > main control cabinet > ash lock control panel > remote control center. Attached Figure Description

[0026] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0027] Figure 1 This is a schematic diagram of the structure of this utility model;

[0028] Figure 2 This is another structural schematic diagram of the present invention;

[0029] Explanation of reference numerals in the attached figures:

[0030] In the picture:

[0031] 1. Control cabinet; 2. Manhole operating column; 3. Ash lock control panel; 4. Remote control center; 5. Explosion-proof power distribution cabinet; 6. Equipment maintenance hole; 7. Grate motor; 8. Ash lock; 10. Power control switch; 11. Frequency converter control unit; 12. Power module; 13. Inverter module; 21. Switch; 31. Touch screen; 32. Controller; 101. Industrial Ethernet; 102. Signal cable. Detailed Implementation

[0032] In the following description, numerous specific details are set forth in order to provide a more thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention can be practiced without one or more of these details. In other instances, certain technical features well-known in the art have not been described in order to avoid confusion with the present invention.

[0033] Unless otherwise defined, the directions mentioned herein, such as up, down, left, right, front, back, inside, and outside, are based on the directions shown in the figures of this utility model, and are explained here together.

[0034] The connection method can adopt existing methods such as bonding, welding, and bolting, depending on the actual needs. Techniques, methods and equipment known to those skilled in the art may not be discussed in detail. However, where appropriate, the techniques, methods and equipment should be regarded as part of the specification. The proportions of the components in the drawings are for reference only and can be adjusted to a certain extent according to the actual use.

[0035] In the following embodiments, the electrical connection is made using signal cable 102.

[0036] Please see Figure 1 As shown, a control system for a gasifier grate drive device is provided in this embodiment. This system includes a controller 32, a frequency converter, and a switch 21. The frequency converter includes a frequency converter control unit 11, a power supply module 12, and an inverter module 13. Both the frequency converter control unit 11 and the controller 32 are connected to the switch 21 via an industrial Ethernet network. The power supply module 12 is electrically connected to both the frequency converter control unit 11 and the inverter module 13, and supplies power to both.

[0037] The inverter control unit 11 is used to control the inverter module 13, which is electrically connected to the grate motor 7 and is used to drive the grate motor 7.

[0038] As a preferred embodiment, there are two grate motors 7 and two single-axis inverter modules 13, with each inverter module 13's inverter shaft driving one grate motor 7 independently.

[0039] As a preferred embodiment, a touch screen 31 is also included, which is connected to the switch 21 via an industrial Ethernet 101.

[0040] As a preferred implementation, the controller 32, switch 21, frequency converter, and touch screen 31 are all located inside the control cabinet 1, which is installed in the power distribution room of the safe zone. The frequency converter adopts a multi-vector drive mode to ensure torque output when the grate motor 7 is running at low speed.

[0041] As a preferred embodiment, the present invention also includes a manhole operating column 2, a gray lock control panel 3, and a remote control center 4; the manhole operating column 2, the gray lock control panel 3, and the remote control center 4 are all electrically connected to the controller 32; the switch 21 is connected to the remote control center 4 via an industrial Ethernet 101; the controller 32 receives operating signals from the manhole operating column 2, the gray lock control panel 3, and the remote control center 4.

[0042] As a preferred embodiment, the manhole operating column 2 is installed at the grate drive site, near the equipment inspection hole 6, and is equipped with explosion-proof devices. The manhole operating column 2 is used during equipment commissioning or maintenance and has the highest operating authority.

[0043] As a preferred implementation, the ash lock control panel 3 is positioned around the ash lock 8. When the operating authority is switched to ash lock control, the grate motor can be controlled via the ash lock control panel 3. If the user equipment does not have ash lock control, the ash lock control function can be directly disabled via the touch screen 31 without changing the control circuit or modifying the program.

[0044] As a preferred implementation, the controller 32 adopts a Siemens S7-1200 series PLC to control the frequency converter through network communication and read the frequency converter's operating status data and fault information.

[0045] As a preferred implementation, in addition to the regular operation and fault indicator lights on the control cabinet panel 1, a touch screen 31 is configured as a human-machine interface. The screen can monitor the operating status of the equipment in real time and complete all related control operations. The screen has historical data information related to maintenance and diagnosis, such as operation records, operation records, and alarm records. It can intuitively display the equipment control authority, interlock information, fault codes and corresponding fault information descriptions.

[0046] like Figure 2The diagram shows another configuration of this utility model. The other components are positioned in the same location, but the controller 32, switch 21, and touchscreen 31 are all located inside the control cabinet. The frequency converter control unit 11, power module 12, and inverter module 13 are located inside the explosion-proof distribution cabinet 5. A power control switch 10 is installed inside the control cabinet 1, and the power control switch 10 is connected to the power module 12 via a wire. The power control switch 10 is used to control whether the power module 12 is energized.

[0047] The explosion-proof distribution cabinet 5 is located near the grate motor 7 and within the grate drive area; the control cabinet 1 is installed in the power distribution room in the safe zone. This distributed layout greatly shortens the cable length. The control cabinet provides power to the frequency converter through the power cable, transmitting sinusoidal AC power. Harmonics and electromagnetic interference are significantly improved. The frequency converter and the grate motor are very close, eliminating the need for output reactors or sinusoidal filters. The power cable does not need to be deliberately enlarged, greatly reducing hardware costs. The motor runs smoothly and reliably, effectively extending the service life of the motor and cables.

[0048] The method of using this utility model is as follows: when using... Figure 1 When the central control system is operating, the signals received by the controller 32 are sent to the remote control center 4 through the switch 21. The remote control center 4 analyzes the signals and sends them back to the controller 32. The controller 32 then sends instructions to the frequency converter control unit 11. The frequency converter control unit 11 sends signals to the inverter module 13. The inverter module 13 controls the grate motor 7, thereby realizing the rotation of the grate. At the same time, the controller 32 can also send the collected data to the touch screen 31 and the remote control center 4 through the switch 21 to realize the control of the gasifier grate drive device.

[0049] When using Figure 2 When operating the control system, the operation steps are the same, and the controller 32 controls the power control switch 10 to open.

[0050] During system maintenance, manual cleaning and maintenance of the furnace are required. The gasifier maintenance platform is equipped with a maintenance manhole and manhole operating column 2. The furnace condition can be observed through the maintenance manhole, and personnel can enter the furnace to perform cleaning and maintenance work. The manhole operating column 2 is equipped with control mode selection and start / stop buttons, allowing local operation of the grate motor. When ash is released from the furnace, the grate can be operated independently at the ash lock 8 position. An ash lock control panel 3 is located at ash lock 8, with start / stop buttons and control mode switching. If ash lock 8 operation is not required, the ash lock control function can be directly disabled via the touch screen 31 without changing the control circuit or modifying the program. The control of multiple operations is handled by the programmable controller and displayed on the touch screen 31.

[0051] It should be noted that, in this document, relational terms such as "one" and "two" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, the phrase "comprising an element defined as..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0052] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A gasifier grate drive control system comprising a controller (32), characterized by, Still include frequency converter, switch (21), the frequency converter includes frequency converter control unit (11), power module (12), inverter module (13), the frequency converter control unit (11), controller (32) are connected with switch (21) through industrial ethernet;The power module (12) is electrically connected with frequency converter control unit (11) and inverter module (13) respectively; The frequency converter control unit (11) is used to control inverter module (13), inverter module (13) is electrically connected with grate motor (7), and inverter module (13) is used to drive grate motor (7).

2. A control system for a grate drive of a gasifier according to claim 1, characterized in that The inverter module (13) is two single-shaft inverter modules or one double-shaft inverter module, and each inverter module (13) drives one grate motor (7) independently.

3. A control system for a grate drive of a gasifier according to claim 2, characterized in that The grate motor (7) is two.

4. The control system for a grate drive of a gasifier according to claim 1, wherein Still include touch screen (31), and the touch screen (31) is connected with switch (21) through industrial ethernet.

5. A control system for a grate drive of a gasifier according to claim 4, characterized in that The controller (32), switch (21), touch screen (31), frequency converter are located in control cabinet cabinet body (1), and the control cabinet cabinet body (1) is installed in the power distribution room in the safety area.

6. A control system for a grate drive of a gasifier according to claim 4, characterized in that The controller (32), switch (21), touch screen (31) are located in control cabinet cabinet body (1), and the frequency converter control unit (11), power module (12), inverter module (13) are located in the explosion-proof power distribution cabinet (5), and the control cabinet cabinet body (1) is provided with power control switch (10), and the power control switch is electrically connected with power module (12).

7. A grate drive control system for a gasifier according to claim 5 or 6, characterized in that Still include manhole operating column (2), ash lock control panel (3), remote control center (4);The manhole operating column (2), ash lock control panel (3), remote control center (4) are electrically connected with controller (32);The switch (21) is connected with remote control center (4) through industrial ethernet;The controller (32) receives the operation signal of manhole operating column, ash lock control panel (3), remote control center.

8. A gasifier grate drive control system according to claim 7, wherein, The manhole operating column (2) is used when grate driving device is debugged or maintained, and has the highest operation authority.

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