基于PLC矿井提升绞车设计.doc

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1、1、 课题背景近几年我国煤炭工业蓬勃发展，越来越多的矿山向大型、高效方向发展，井下开采设备和支护设备也向大型化方向发展，需要提高井下提升设备的提升能力。随着老矿山不断向深部煤层开采，深井、超深井不断出现，也要求提高井下提升设备的提升长度和能力。因此，井下提升运输设备能力小，设备落后的矛盾越来越突出；大型设备下井不得不解体，然后在组装条件极差工作面恢复组装，不但效率低下、工人劳动强度大，而且所组装的设备性能难以保证；由于井下提升设备能力的限制，深井、超深井的提升长度不得不加以限制；这些都严重制约着矿山生产的发展。此外，随着国家对于煤矿安全越来越重视及煤矿安全事故的频繁发生，国家安全生产监管部门要

2、求矿井井下采用的提升绞车安全性能要更高。绞车是工业生产过程中一种常见的机械，具有悠久的发展历史和比较成熟的设计制造技术。随着绞车制造技术的不断提高、加工材料的不断改进以及电子控制技术的不断发展，绞车在动力、节能和安全性等方面取得了很大的进步。目前，绞车正被广泛地运用于矿山、港口、工厂、建筑和海洋等诸多领域。在矿山采掘和运输场合，绞车作为重要辅助设备被大量而广泛地运用着，例如矿用提升绞车、调度绞车、耙矿绞车和凿井绞车等。提升绞车可用于矿山竖井或斜井中物品与人员的调度，具有较大的牵引功率和很好的安全性，是矿山生产中不可缺少的设备之一。2、提升绞车发展状况绞车多种多样的用途，决定了绞车的种类和组成形

3、式也是多种多样的。按照绞车卷筒的数量分，绞车可以分为三种:单卷筒绞车、双卷筒绞车和三卷筒绞车。单卷筒绞车是三种类型绞车中最常见的。它只有一个卷筒用来存放缆绳或者铰链，一般用于对卷筒的容绳量要求不高的场合。另外，按照绞车的驱动方式，通常又把绞车分为电动绞车，气动绞车和液压绞车三种。在工程应用中绞车会具有如下一些特点：1）负载时变；2）驱动力矩范围大；3）要求调速方便，高低速运行稳定；4）对安全可靠性要求较高；5）要求具有较好的可操作性。矿井提升绞车包括机械设备及拖动控制系统，是联系地下和地上的重要途径，是矿山生产的咽喉设备，其性能好坏直接关系到矿山的生产效率和安全性及可靠性，它的安全、可靠运行是

4、整个矿井正常生产的必要条件，一旦发生故障，所造成的经济损失是巨大的。“运输是矿井的动脉，提升是咽喉”形象地描述了矿井提升运输系统的工作过程与重要作用。目前，我国矿井提升绞车90%以上是采用单机容量在1000KW以下传统的交流异步电机拖动，采用转子串、切电阻调速，由继电器接触器构成逻辑控制装置；直流电动机拖动的提升绞车不足10%，其中多一半为电动机发电机组供电，采用晶闸管整流传动的只占一少部分。国内外对提升设备经过多年的研究，近几十年来发展的很快，尤其是提升设备的滚筒方式、制动方式和电力拖动、自动化控制等方面有很大的改进，在提升设备的理论和实践方面都取得了丰富的经验。国内外对于提升绞车的优化设计

5、研究属于较冷门的行业，相关的研究成果不太多。 我国的矿用提升绞车其调速原理经历了电阻调速、液压调速、变频调速及行星差动调速等几次大的改进。目前国产提升绞车所采用的调速装置主要有两种类型：一是液压传动调速装置（液压调速），其产品形式即为现有的液压提升绞车；二是电控调速装置（变频调控），其产品形式即为现有的传统JT系列绞车。煤矿提升绞车是煤矿安全生产的重要设备，是安全生产的关键，它能否正常运行，直接关系着煤炭的产量、生产成本及矿井和职工的安全。随着市场经济的发展和矿井标准化建设的需要，提升绞车的运行质量越来越受到各级部门的重视。根据煤矿安全规程规定：投入运行后的提升设备，必须由矿务局机电部门每年进

6、行一次检查，每3年进行一次测试，认定合格并签发运行许可证书后方可继续使用每次的测试结果表明大部分的绞车使用良好，但也存在一些带有普遍性的问题，在一定程度上制约了煤炭产量，增加了生产成本，同时也影响了煤矿的安全生产。下面就针对一些主要问题进行归纳:(1)提升设备完好率差，存在重大事故隐患。提升装置必须装设下列保险装置，即防过卷装置、限速装置、深度指示器失效保护装置等，并满足相应的技术要求，但有许多矿用绞车没有设置，违反了相应规定。(2)制动装置可靠性差。制动装置是提升绞车的重要组成部分，根据设计安装要求，制动盘加工表面粗糙度应达到1.6，偏差越小越好，最大不应超过0.5mm但有的矿用绞车安装质量

7、差，滚筒端面凹凸不平，使滚筒在运转时，制动轮间歇摩擦闸瓦，从而造成电机电流波动大，电耗增加，并加速了闸瓦的磨损。还有的绞车松闸不彻底，有时还会因为某些干扰因素引起突然紧闸现象。这种现象会影响机械系统的使用寿命，并有可能造成断绳等事故。(3)绞车实际运行质量较差、效率偏低。在查阅资料中发现大多数绞车均采用手动控制，加速、减速及低速爬行和停车休止时间相对偏长，使绞车提升能力下降，电机电耗增加。近年来，我国各生产厂家对结构、调速装置等进行了许多改进，并推出了许多更新换代的产品。随着计算机技术的飞速发展，计算机和PLC的运算速度加快、存贮能力加大、功能加强、体积减小，使煤矿机械的功能更强、性能更优、效

8、率更高。3、相关解决方案 3.1电控系统改进方案结合矿用提升绞车使用中存在问题及相关资料，本着“安全、可靠、经济运行”的原则对所用的JTK1.2X1.6矿用提升绞车的电控系统进行技术改造。在矿井提升系统中，“可靠性”包含两个含义，一是“安全可靠性”，二是“工作可靠性”。二者密不可分，又各有侧重、相互区别。“安全可靠性”是指当出现故障时，要确保把系统引入安全状态，一般是指安全制动，也就是我们通常所说的“故障安全型”。而“工作可靠性”则要求在一定的时间内，系统尽可能长地保持正常工作状态，这时就要研究如何把系统故障率降到最低。在矿山设备中，如主要通风机、主排水泵等当属此类。对提升系统而言，当然也需要

9、较高的工作可靠性，就是要使提升容器按要求快速、准确地送到规定位置，保证高效长期运行。在确保提升安全、可靠运行的前提下，提高系统运行质量，减少操作难度和维修保养时间，延长系统的有效服务年限，则应是实现系统经济运行的研究课题。在此需着重指出，坚持“安全、可靠、经济运行”的原则不仅仅是设计者的指导思想，也应是用户选型时应坚持的最重要的原则。为了真正实现“安全、可靠、经济运行”的原则，在利用众多新技术、新产品来实现提升系统现代化改造时，必须以“可靠性系统工程”理论为指导。工艺对提升绞车电控系统的要求如下：（1）加（减）速度大小的确定应符合以下条件：应符合国家有关安全生产规程的规定。升降人员时，加速度0

10、.75m/2，升降物料时，加速度1.2/2；应不超过提升绞车的减速器所允许的动力矩。（2）具有良好的调速性能。要求速度平稳，调速方便，调速范围大，能满足各种运行方式及提升阶段（如加速、减速、等速、爬行等）稳定运行的要求；（3）有较好的启动性能。提升绞车不同于其他机械，不可能待系统运转后再装加物料，因此，必须能重载启动，有较高的过负荷能力；（4）特性曲线要硬。要保证负载变化时，提升速度基本上不受影响，防止负载不同时速降过大影响系统正常工作（当然，当负载超过一定的限度时，还要求系统能有效地自我保护，迅速安全制动停车，即所谓要具备挖土机机械特性）；（5）工作方式转换容易。要能够方便地进行自动、半自动

11、、手动、验绳、调绳等工作方式的转换，操作方便，控制灵活，不至于因工作方式的转换影响正常生产；（6）尽量采用新技术和节能设备，易于实现自动化控制和提高整个系统的工作效率；（7）要求具备各种必要的连锁和安全保护环节，确保系统安全运行；（8）要尽量节约投资和降低运转费用。3.2 PLC介绍PLC英文全称Programmable Logic Controller ,中文全称为可编程逻辑控制器。可编程控制器是一种数字运算操作的电子系统，专为工业环境下应用而设计的，它采用一类可编程的存储器，用于其内部存储程序、执行逻辑运算、顺序控制、定时和计数，算术操作等面向用户的指令，并通过数字式或者模拟式输入输出控制

12、各种类型的机械或生产过程。可编程控制器及其外部有关设备都按易于与工业控制系统连成一个整体，易于扩充其功能原则设计的。可编程控制器的性能指标是有使用者先提出的，它具有以下特点：1）可靠性高；2）编程方便，易于使用；3）对环境要求低；4）与其他装置配置联结方便。PLC是采用微机技术的通用工业自动化装置，是一种数字运算操作的电子系统，该电子系统采用一类可编程的存储器用其内部存储的控制程序、执行逻辑运算、顺序控制、定时和计数、算术运算等操作，并通过数字式或模拟式、输入输出来控制被控对象。可编程控制器及其外围扩展模块都可以方便的与工业控制系统连成一个整体、能方便的扩充其功能，PLC正改变工厂自动控制的面

13、貌，对传统产业技术的改造，发展新型控制系统有重大的现在实用意义！PLC是以微处理器为核心，综合了计算机技术、自动控制技术和通信技术而发展起来的一种新型、通用的自动控制装置，具有结构简单、性能优越、可靠性高、灵活通用、易于编程、使用方便等优点，近年来在工业自动控制、机电一体化、改造传统产业等方面得到了广泛应用。目前，PLC在国内外已广泛应用于钢铁、石油、化工、电力、建材、机械制造、汽车、轻纺、交通运输、环保及文化娱乐等各个行业。4、参考文献1王朝晖.矿井提升绞车系统新技术及装备M.煤炭工业出版社.1999.2夏荣海.郝玉琛.矿井提升绞车机械设备M.中国矿业学院出版社.1995.3卢燕.矿井提升绞

14、车电力拖动与控制M.冶金工业出版社.2001.4杨兴瑶.电动机调速的原理及系统M.水利电力出版社.2004.5蒋宏民.PLC技术在我国矿井交流提升系统中的应用研究J.冶金矿山设计与建设.1998.30(4):18-296叶予光.梁南丁.基于PLC技术的矿井提升绞车电控系统J.机电一体化.2004(6):69-707矿井提升绞车故障处理和技术改造A.见编委会编著.矿井提升绞车故障处理和技术改造C.机械工业出版社,2005.283332.8黄仰金.矿山副井提升绞车计算机控制系统的设计及应用D.中南大学硕士学位论文.20049乔磊明.矿用交流提升绞车电控系统研究D.辽宁工程技术大学硕士论文.2007

15、10徐爱民.交流提升绞车变频运行电控系统J.煤炭工程.2006(3)：727311胡省三等.应用高新技术改造传统煤炭工业J.中国煤炭.2002(3)12彭虎锋.新一代国产矿井提升绞车电控系统研究D.湖南大学硕士学位论文.200413Zhiyong Zuo,Yiqing Zhan etalResearch on full digital electric control system of heavy boring machineJIntelligent Control and Automation,2000(5)：3697-3700英文文献1 Issue backgroundIn recent

16、 years, vigorous development of Chinas coal industry, a growing number of mines go to large-scale, efficient development of underground mining equipment and support equipment to the direction of large-scale development,so they need to improve the underground to enhance the ability to upgrade equipme

17、nt. As the old deep mines continue to coal mining, deep well, ultra-deep emerging, also called for lifting equipment to raise mine the length and the ability to upgrade. Therefore, the underground transport equipment to enhance the capacity of small, outdated facilities will be more striking; had to

18、 go down the disintegration of large-scale equipment, and then face conditions in the assembly to restore the assembly, not only inefficient, labor-intensive workers,The assembly and it is difficult to guarantee the performance of the equipment; as a result of mines ability to upgrade equipment, dee

19、p well, ultra-deep the length of the upgrade had to be limited; these are seriously restricting the development of mining production. In addition, as more and more countries attach importance to coal mine safety and coal mine safety accidents occur frequently, the state regulatory requirements for p

20、roduction safety underground mine hoist used in higher security performance.Winch is the industrial production process of a common machinery, has a long history of development and the design and manufacture of more mature technology. With the winch the continuous improvement of manufacturing technol

21、ogy, processing of the continuous improvement of materials and electronic control technology continues to develop, winch power, energy and security has made great progress.At present, the winch is being widely used in mining, ports, factories, construction and marine fields. Mining and transport in

22、mining occasion, as an important auxiliary winch equipment and extensive use of a large number of, for example, mine hoist, winch scheduling, rake mine, such as winch and hoist shaft sinking. Hoist can be used in the mine shaft or inclined shaft of goods and personnel scheduling, with more power and

23、 good traction safety, mine production is not one of lack of equipment2 The development of hoist Winch a wide range of uses, determines the type and composition of winch is also a wide variety of forms. Winch drum in accordance with the number of points, winch can be divided into three types: single

24、-drum winch, double drum winch and three drum winch. Three single-drum winch is the most common type of winch. It is only one cable reel is used to store or hinge is generally used for the volume of drum rope capacity less demanding occasions. In addition, the driving method in accordance with the w

25、inch, usually turned into electric winch winch, pneumatic winch and hydraulic winch three.Winch in the engineering applications will have the following features: 1) time-varying load; 2) driving torque range; 3) requirements to facilitate speed, high-speed running stability; 4) require a higher secu

26、rity and reliability; 5) requires better maneuverability.Mine hoist winch including mechanical equipment and drag the control system, contact the ground and the ground is an important way is to set up the throat of mine productionPrepared, and its performance is directly related to the quality of mi

27、ne productivity and safety and reliability, it is safe, reliable operation of the mine isOften a necessary condition for production, in the event of failure, the economic loss is enormous. Transport is the arteries of mine to enhance the pharyngealThroat image to describe the mine hoist transport sy

28、stem with an important role in the process.At present, mine hoist winch is more than 90% of stand-alone capacity of 1000KW following the traditional drag induction motor using rotor string, cut resistance governor, by the relay - contactor logic control device constituted; DC Motor Drive hoist of le

29、ss than 10%, of which more than half of the motor - generator set power supply, the use of thyristor rectifier drive only a small part. Upgrade the equipment at home and abroad after many years of research, to develop rapidly in recent decades, especially the way drum lifting equipment, means and po

30、wer brake drag, automation control, a significant improvement,Upgrade the equipment in the theory and practice has made a wealth of experience. Hoist at home and abroad for the optimization design study of the industry are less popular, relevant research results are not too many.Chinas mining hoist

31、the principle of its speed governor resistor experienced, hydraulic speed control, frequency conversion governor and planets, such as differential drive of several majorImprovement. At present, China-made hoist speed control device used in the main there are two types: first, hydraulic speed control

32、 device (hydraulic governor), the form of its products is available hydraulic hoist; Second Speed Electronically Controlled devices (frequency control), and its products is available in the traditional form of JT series winch. Coal mine safety hoist is an important equipment manufacturing is the key

33、 to safe production, it can operate normally with a direct bearing on the output of coal, production cost and the safety of the mine and the workers. With the development of the market economy and the need for standardization of mine,The quality of the operation of hoist is receiving increasing atte

34、ntion at all levels.According to Coal Mine Safety Regulations provides that: After put into operation to upgrade the equipment, by the Mining Electrical and Mechanical Services Department must carry out a check every year, every 3 years to conduct a test and found to be eligible to run for issuing p

35、ermits in order to continue to use after. Every time the test results show that the use of most of the winch good, but there are some issues with the universal, to some extent, restricted the production of coal, an increase of production costs, but also the impact of the coal mine production safety.

36、 Heres some of the key issues for induction:(1) to enhance the rate of poor equipment in good condition, there is risk of major accidents.Enhance the device must be installed in the following device, namely, anti-roll-off device, device speed, depth indicator, such as fail-safe device, and to meet t

37、he technical requirements, but there are many mines have not been provided with the winch, in violation of corresponding provisions.(2) poor reliability of the braking device.Hoist brake is an important component of the design and installation in accordance with the requirements of brake disc surfac

38、e roughness should reach 1.6, the better the smaller the deviation, the greatest should not exceed 0.5mm. However, some mining winch installation of poor quality, end cylinder surfaces, so that when the drum in the running, brake wheel intermittent brake shoe friction, resulting in fluctuations in m

39、otor current, and power consumption increased, and accelerated wear of the brake shoe. Song of the winch brake was also not complete, and sometimes because some factors interfere with the phenomenon of sudden tight gates. This phenomenon will affect the service life of mechanical systems and may cau

40、se accidents such as broken chairs.(3) poor quality winch operation, efficiency is low.Found in the majority of data access using manual winch control, acceleration, deceleration and low-speed crawling and side parking relatively long rest, so that the capability to drop winch, mechanical and electr

41、ical power consumption to increase. In recent years, manufacturers of the various structures, such as speed control devices for a number of improvements and the introduction of a number of replacement products. With the rapid development of computer technology, computer and PLC to speed up the compu

42、tation speed, storage capacity increased to enhance the roles of size decreases, so that the function of coal mining machinery stronger, better performance and efficient.3 The relevant solutions3.1 Electronic control system to improve the programCombined with the use of mining hoist the problems and

43、 related information, the spirit of safe, reliable and economic operation principle JTK1.2X1.6 used for mine hoist the electronic control system for technological transformation.In the mine hoist system, the reliability contains two meanings, one security and reliability, the second is reliability.

44、The two are inseparable, and have different emphases, and the difference between each other.Security and reliability refers to when there is failure to ensure that the introduction of the system security status, generally refers to the safety brake, which is what we usually call fail-safe type. And

45、reliability requires a certain amount of time, the system as long as possible to maintain a normal working state, then we must look at ways to minimize the system failure rate. In mining equipment, such as the main fan, such as the main course of such drainage pump. To enhance the system and, of cou

46、rse, work requiring a higher level of reliability, is to upgrade the container in accordance with the requirements quickly and accurately to the provisions of the location to ensure efficient long-term operation.To ensure that the upgrade in a safe, reliable operation under the premise of the system

47、 to improve quality and reduce the difficulty of the operation and maintenance time, extend the effective length of service system should be to achieve economic operation system research.In this need to stress that adherence to the safe, reliable and economic operation principle guiding ideology is

48、not just designers, we should also insist on the user selection to be the most important principle. In order to truly safe, reliable and economic operation principle, in the use of many new technologies and new products to enhance the system to achieve modernization, it is important to the reliabili

49、ty engineering theory as a guide.Hoist technology for electronic control system requirements are as follows:(1) increase (decrease) the size should be determined by the speed with the following conditions: should be consistent with national security-related provisions of the production order. Staff move