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Yan Xinzhi\Ni Shenggong 2 (1. Shandong Tengzhou Dongda Mining Co., Ltd., Shandong Tengzhou 2775002. Lin Mining Group Yushujing Coal Mine, Erdos 016200, Inner Mongolia). The online automatic monitoring and control is realized, and the air volume of the air compressor is automatically adjusted. It provides a guarantee for the safe production of coal mines.
In coal mining production, the air compressor is mainly responsible for providing power to a large number of pneumatic machinery in the mine. The reliability and safety of its work directly affect the normal production and economic benefits of the mine. At present, most air compressor units have problems of backward control and inconvenient operation. Most of the control loops are relay control. The control mode adopts local decentralized manual operation. The fixed personnel are on duty 24h. The maintenance personnel manually start or stop the air compressor according to the demand of the downhole air volume, and regularly patrol and record the operation status. In addition, the air compressor unit consumes a large amount of electricity, and for a long time it is operated under no-load or light-load conditions, resulting in high energy consumption, serious machine damage, and high operating costs. Therefore, designing a fully automatic centralized monitoring system with convenient operation and perfect functions, monitoring and protecting the air compressor unit, improving the working efficiency of the air compressor unit, reducing energy consumption and prolonging the service life have important practical significance.
1 The composition of the monitoring system The Jinqiu coal mine pressure system consists of a MOGF-9.6/8G air compressor (air-cooled) and three underground SM-5132W air compressors. It is currently the Dongda Mining Co., Ltd. of Tengzhou City, Shandong Province. The deputy mine manager of the responsible company has presided over more than ten projects of mine mechanical and electrical equipment technology upgrading and transformation.
It is composed of Fusheng Electromechanical Co., Ltd. and water-cooled. It is a single-screw mobile air compressor for coal mines. Each air compressor is equipped with a body controller Delcos3100. Through the operation panel of the Delcos3100 controller, the operator can control the start and stop of a single air compressor, see the running status, and set the operating parameters. In addition, the DdcS3100 controller has an RS-485 communication interface that supports the ModbusRTU protocol, which provides conditions for centralized monitoring of air compressor units. The system structure diagram is as shown.
Machine system structure diagram Xin Xin, etc.: Air compressor centralized control and online monitoring and alarm system research and application 1.1 Air compressor centralized control system technical requirements 1) The system uses Siemens PLC to achieve centralized monitoring.
Real-time monitoring of air compressor working conditions, the system can complete the pressure (including air compressor air pressure, lubricant pressure, etc.), temperature (including exhaust temperature, motor temperature, cooling water drainage temperature), air compressor running time And continuous online detection of electrical parameters (including current, voltage, motor power, daily power consumption, etc.).
2) Realize the automatic linkage control of the air compressor and related pneumatic system valves, and start/stop the air compressor operation according to the procedure to improve the accuracy and safety of the operation; and the automatic control of the water cooling circulation system of the air compressor.
3) The control system has three control modes: local manual/in-situ centralized control/remote control. Under the centralized control mode, the operation of the air compressor can be selected in three ways: single-step operation, semi-automatic operation and fully automatic operation.
The single-step operation is mainly used for debugging during maintenance; semi-automatic operation, that is, one-button start-stop; under full-automatic operation, no operator is required to participate, and all air compressors are automatically operated according to certain strategies.
4) The air compressor is fully automatic, and it is required to realize the automatic start and stop of the air compressor as needed. According to the air volume, the number of air compressors can be determined. It is required to realize automatic loading and unloading, and it is required to realize the upper and lower (3+1) air pressure of the well. The machine operates in a balanced manner to achieve uniform wear.
5) Set up a general-purpose centralized control cabinet for mines in the ground air compressor room, equipped with a touch screen man-machine interface, which can display various real-time status of the air compressor; set up explosion-proof explosion for each air compressor in the underground air compressor room There is one sub-station, there is a centralized console for unified management, and the centralized console is also equipped with a touch screen to monitor the data of the air compressor in real time.
6) The system has complete protection and alarm functions, which can realize motor overload shutdown, power supply reverse phase and phase loss protection, exhaust gas temperature and temperature jump, and exceed the maximum working pressure safety valve action (can also be set as air compressor stop) , cooling water failure (water shortage, over temperature) alarm parking, oil pressure loss alarm alarm parking, and so on.
7) With various parameter setting functions, it can set various key parameters in automatic operation, including: air compressor rotation time interval, automatic loading pressure, automatic unloading pressure, automatic starting pressure lower limit, and opening air pressure Machine waiting time interval, adding air compressor stop pressure setting value, and so on. It is also possible to set alarm upper and lower limits for various analog parameters collected in the field.
8) The system requires the access to the mine dispatching room, and the upper computer system is set in the dispatching room. The upper computer system is based on the high-performance industrial control configuration software, which can dynamically display and record all the operating states and fault signals of the air compressor system and generate operation. Reports, reports can be freely queried and printed out. On-line measurement and processing of air compressor operating parameters can be displayed through real-time curve graphs, which is convenient for monitoring the transformation trend of various parameters. It can also be displayed through historical curve graphs and data query at any time. At the same time, air compressor operating parameters Historical data can also be displayed and printed in the form of a report, which is convenient for duty personnel to print duty reports, quantitative research and analysis of relevant personnel, and routine management of pressure safety technology. Through authorization, the operator can issue commands to the air compressor through the host computer system to control the start and stop of the air compressor.
9) The system requires certain fault diagnosis and analysis functions.
It is required to have a fault display function, which can display the system exhaust temperature, exhaust pressure, state unloading, load standby, etc. in real time, realize self-diagnosis shutdown protection for faults, and display the cause of the fault. An audible and visual alarm can be issued when a safety action occurs. Alarm information can be saved to a historical database and can be easily queried. After the fault is removed, the safety reset function can be implemented.
10) This system requires the original Jinqiu coal mine electromechanical automation system as a new subsystem, which requires the system host computer program to be integrated with the original system host computer program.
1.2 Touch screen configuration design system uses Siemens TP270-10 type touch screen as the workshop-level centralized monitoring station. It is a multi-functional human-computer interaction interface based on the standard operating system Microsoft WindowsCE. It has powerful data acquisition and management functions, stable and reliable, friendly interface, convenient display, operation and management. The operator can view the operating status and real-time data of the air compressor through graphs and menus, set the operating parameters such as pressure and time of the air compressor, view the historical data of the system, fault alarm information, and set whether to allow the upper computer. Remote control air compressor. The touch screen visually displays the operating status of the air compressor unit, which is convenient and quick to operate, avoids the cumbersome work of the timing inspection record, and greatly improves the work efficiency and management level.
1.3 PC configuration design system uses PC as the remote monitoring station of the host computer. The network monitors the operation status of the air compressor online, and looks at real-time data such as pressure, temperature, running time, motor voltage, motor current, and output power, records and stores historical data, and provides data query and print functions. When the field device has an action or a fault, it can pop up a prompt message and record it; if the remote control allows, the duty officer can also remotely control the air compressor. Remote monitoring facilitates scheduling and improves the level of management automation, which is the need for the development of coal mine information. Other components include automatic hand switch, emergency stop button, sound and light alarm, etc.
2 Communication system The communication in the system consists of three parts.
2.1 Field Device Communication China's mining control is convenient and the design is simple RS-485 interface standard as the physical communication standard. The RS-485 standard requires a two-wire differential method to transmit and receive data, thus effectively overcoming common mode interference and suppressing line noise. According to the actual situation, the communication protocol adopts the Modbus protocol of single-station multi-slave structure, and adopts Modbus RTU communication mode. The RS-485 standard is the physical layer standard of the bus, which is responsible for level conversion and data transmission and reception. The Modbus protocol constitutes the data link layer protocol of the bus, which specifies the data frame format transmitted on the bus, which is the master station and the slave station. The data is communicated to provide a communication protocol to ensure that valid data is reliably transmitted between the primary station and the secondary station, which together form the RS-485 bus.
2.2 Touch screen communication PLC and touch screen communication are both Siemens products, through the MPI cable to connect the MPI communication port of the PLC and the RS-485 communication port of the touch screen. During configuration, the relevant communication parameters such as the MPI address and slot number of the CPU to be connected are defined. The interface type is MPI, and the baud rate is set to 187.5 kbps for simple configuration operation.
2.3 Host computer communication In the communication between the PLC and the host computer, the PLC connects to the industrial Ethernet through the Ethernet module CP343-1, and the host computer realizes the remote monitoring function through the network. Select the interface type as Industrial Ethernet, the communication rate is 100Mbps, and set the IP address of the PLC and the host computer.
3 The control requirements of the software design system are as follows: the manual automatic transfer switch is a manual air compressor, which is only controlled by its DeICS3100 controller to facilitate machine maintenance and maintenance. At this time, the PLC can only collect data from the Delcs3100 controller. The air compressor cannot be controlled; the air compressor with automatic manual switch and automatic remote control will be centrally supervised by the PLC. The PLC will determine the number of air compressors to be operated according to the change of wind pressure, and the wind pressure can be satisfied. The need for wind in the underground, and according to the length of the air compressor running time, they rotate work; when the remote control setting on the touch screen is invalid, the upper computer can only monitor the operating status of the air compressor without control authority, when remote control When the automatic and manual automatic transfer switch is in the automatic state, the air compressor will be remotely controlled only by the upper computer.
Package, it uses structured programming, program readability, debugging and maintenance is convenient. The main program flow chart of a single air compressor is as shown.
1) System structure. The intelligent sensor distributed in each measuring point is connected to a public transmission line (4-core communication cable) to communicate with the intelligent terminal, which is extremely convenient for installation and maintenance. When adding measuring points, it is only necessary to connect the smart sensors to the common transmission line through the three-way (or two-way) junction box, and the number of used cables is small, and each intelligent terminal has more measuring points, up to 100. While each sensor of a general safety monitoring system requires a separate cable to communicate with the monitoring terminal, a large number of cables are required. In addition, each monitoring terminal can only connect up to 16 sensors.
2) System reliability issues. The scheme establishes two systems (ie, automatic monitoring control system and manual monitoring control system), then the two systems can be operated separately without affecting each other. One system has problems, and the other system will not be affected, and the security is improved. If only one system is used, once the system fails, all the measurement contents cannot be reflected to the monitoring center in time, which affects the safe and stable production of the enterprise.
3) Communication content issues. The smart sensors distributed at each measuring point can directly measure the measured size and send it to the microcomputer of the intelligent terminal and the monitoring center. The sensor enables on-site display, alarm and control.
4) The failure of the local sensor and its connection will not affect the system Xinxin, etc.: The research and application of the centralized control of the air compressor and the online monitoring and alarm system work normally, thus ensuring the reliability, technological advancement and structural rationality of the whole system. Operational reliability, fault dispersion and easy maintenance.
The operating system, the human-machine interface is friendly, and the functions are more perfect. All function operations have mouse tracking prompts and system help functions, which greatly facilitates the use and operation of non-professionals.
6) The system application software uses high-level language programming and database to store data. The software has strong functions and adopts modular structure to ensure redundant error correction, real-time and reliability.
7) The monitoring computer is equipped with lightning protection equipment, which improves the anti-jamming and lightning-proof capability of the system and is safer and more reliable. The cable joints are connected by a connection box or a cable connector, which is convenient to install, disassemble and move.
8) The monitoring computer centralizes all functions of the entire system.
Configuring a long-delay UPS power supply ensures that the power system provides power during a power outage to ensure normal and reliable operation of the monitoring system.
9) The system increases or decreases the intelligent terminal, which is defined by the monitoring computer. The type and address of the smart terminal matching sensor are automatically scanned and generated by the intelligent terminal, which makes the user configuration work easier and more convenient.
10) The intelligent terminal adopts the performance CPU to realize intelligence, miniaturization and low power consumption, and can be used in various occasions alone.
11) The smart sensor section has a liquid crystal display that displays the measured value. For ease of use, the system defines a variety of smart sensors, each with a fixed function.
12) Whether the sensor alarm function is enabled, the alarm upper and lower limits, etc. can be set and modified by the monitoring software.
13) The intelligent terminal supplies power to each smart sensor through two power buses. If the bus line is too long, an optocoupler type repeater can be used to extend the communication distance.
5 Conclusion PLC has a relatively high cost performance, and can be compatible with the communication protocol supported by the field device. The system adopts CP341 module as the Modbus master station scheme has certain practical significance. On-site commissioning and operation show that the system is stable, safe and reliable, improves the operating efficiency of the air compressor unit, and realizes the automation of monitoring and management. The system can be applied not only to the monitoring of air compressors in coal mines, but also to other occasions.
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