Mining hoist control system

The Solution of Hoisting System Based on Intelligent Mine

lt is suitable for the demands of upgrading the intelligent control and general management for mine hoist and its related subsystems, providing customized system solutions for high-end customers with intelligent mine operation requirements.

Main characteristics

Based on the high reliability and automatic operation of mine hoist and its related main equipment, taking real-time detection and monitor the key information of main equipment and hoist process, remembering the faults, remotely transmnitting and storing the data and information, intelligently analyzing and specialized processing the invisible fault information. Fully realize the seli-diagnosis of equipment and system, explicit fault alarming, invisible fault warning and so on, supporting the collection of management information and transmission of control instruction related to the equipment, and supporting intelligent remote service, etc.
With the specialized function of “system plug-in", which is convenient to realize the information interaction with other information systems to meet the needs of intelligent mine operation and realization.

“6+1+2"System Scheme

The solution consists of six subsystems, one channel and two platforms, including the control system in the hoist control room, expert intelligence system (equipment level), wlhead control system, shaft and shaft bottom control system, envinonmental monitoring system, intelligent video monitoring system, network commumication and data teleportation channel, dispatch management and monitoring platform, and remote service platform.
 

1)Control system in the hoist control room mainly includes: Power supply system, speed control system, lubrication system, hydraulic system, gate control system, electric control system, as well as the main equipment vibration detection, shaft temperature detection, etc.

2) Expert intelligent system(equipment level)mainly includes: industrial control computer, displayer, collection card, communication networks, and application software packages such as monitoring software and expert think tank. It can monitor real-time information on the working conditions of the main equipments, sensors and actuators of the hoist system as well as external environmental data and information such as temperature and humidity. It manages and analyzes fault and potential fault information of equipment and system, and has advanced intelligent functions such as work condition recurrence, precise maintenance and remote diagnosis. The main software function modules include equipment management module, equipment condition monitoring module, information management module, system condition recurrence module, expert think tank module, system self-diagnosis and remote diagnosis module.

3) The control system at pit head mainly includes: stable rope detection, gate detection, curved rail detection, skip detection, shaft temperature detection, steel rope detection, signal from pit head, operation machine, stable rope adjustment, automatic unloading, etc.

4) The shaft and shaft bottom control system mainly includes: intelligent monitoring of the working condition of equipment such as head frame, cage, tail rope, coal feeder, automatic loading and coalbunker.

5) Environmental monitoring system mainly includes: real-time monitoring of temperature, humidity, vibration, and noise in key places, with early warning and fault alarm functions.

6) Intelligent video surveillance system mainly includes: monitoring key parts and facilities such as pit head, bottom, and hoist control room through visible light and thermal imaging surveillance probes. With the help of machine vision and artificial intelligence AI algorithm, it monitors equipment surface temperature in a non-contact way and determines foreign object area intrusion, etc. It can monitor equipment operating conditions more conveniently, faster, more efficiently and more intelligently.

7) Network communication and data teleportation channel: The system is equipped with rich software and hardware communication interfaces that can interact with system information by dispatching command center and remote service platform through communication network, and can easily realize data teleportation.

8) Scheduling management and monitoring platform: provide software and hardware support to realize data interaction with the mine scheduling management and monitoring platform through communication to meet the user's intelligent mine construction and operation requirements.

9) Remote service platform support system (Locate in Huafei Company, serving national customers): based on reliable network security mechanism support to achieve remote diagnosis of equipment and other intelligent functions through the public network. Remote detection and high-quality service are available for hoist, belt conveyor, main ventilator, and other large mining equipment.

Introduction to Main Function Modules of Expert lntelligent Software System

Module 1 "Equipment Conditions Monitoring Module"

To detect at real-time, record and monitor the working condition of the system equipment in the field through safe and reliable technical means, and the state information of the equipment is displayed in a dynamic and intuitive way.
1) Medium and low voltage power supply equipment: Voltage, Current, Power, Power Factor, fault information.
2) Motor drive equipment (VFD and speed regulation device): Voltage, Current, Power, Power factor, fault information, etc.
3) The three-dimensional mechanical vibration, noise, bearing temperature of motor, gearbox, drum and other main mechanical and electrical equipment, wire rope operating conditions;
4) Lubrication station, hydraulic station and brake control: brake oil pressure, pressure difference, oil temperature, oil quality, lubricating oil temperature, brake clearance, brake fatigue and brake swing, etc.
5) Information monitoring related to hoisting process : container position，running speed, speed diagram, torque diagram, signal status, running direction, forward and reverse to correct place, acceleration and deceleration information.

Module 2 "System Condition Recurrence Module"

This module is the front module of the system expert think tank. According to the need of problem analysis, the user can select operation condition recurrence of a single or Multi- equipment at the corresponding fault time. This function greatly facilitates the analysis of the cause of equipment failure, helps to find the reason, and eliminate the deep causes in the equipment and management.

Module 3 "Fault Management Module"

This module mainly focuses on statistics, classification, summarization and in-depth analysis of fault and potential fault information existing in equipment operation, and comprehensive analysis and judgment with the help of expert experience or previous problem handling experience. It provides support to realize the intelligent operation, fault diagnosis, and troubleshooting of the upgrading system. The system assists maintenance personnel in locking out fault phenomena, analyzing fault causes, and guiding troubleshooting.

Module 4"Precision Maintenance Module”

To ensure the safety performance of the hoist system, the user should conduct relevant protection tests and equipment maintenance inspections on a daily basis according to the regulations. The system can quantify and monitor the hidden dangers of the main equipment according to the actual operating condition of the equipment each shift, and warn the equipment amount parts with excessive indicators for daily maintenance, key maintenance and enhanced maintenance distribution. Automatically remind the maintenance personnel to check and deal with in time, and the system automatically records the results of problem ranking.

"Module 5 Self-diagnosis Module"

Expert think tank has a three-level self-diagnosis function of sensor self-diagnosis, major equipment self-diagnosis and hoisting system self-diagnosis set up according to different configurations of on-site equipment. Improved system reliability and potential fault prediction capability.

Module 6"Equipment Management Module "

Establish equipment files, overhaul and daily maintenance information, and provide accurate maintenance guidance throughout the entire life cycle of the equipment.
 

Main features of expert intelligence software system

1、The system is based on the full coverage of sensor sensing of hoisting equipment, which can realize a series of inteligent functions such as unmanned operation and control of hoist, inteligent video monitoring elevator cagefeeling, accurate maintenance, remote technical support, and automation of monitoring and management, greatly improving the safety and reliability of the system.
2、Besed on a reliable and flexible network communication framework, the system can realize sel-diagnostic functions at the sensing layer, control layer and execution layer of key equipment. Support advanced operation recquirements such as mine hoist unattended, remote control, remote monitoring, remote technical support and emergency drive.
3、The system is equipped with intelligent visible light and thermal imaging video monitoring software and hardware faclities which can monitor the surface temperature of the equipment in a non-contact manner and detect any foreign objects into the area, etc.
4、It has the ability to conduct in-depth comprehensive analysis and specialized processing of equipment working condition data, which can accurately judge the operation condition of system equipment and predict the potential failure of major equipment. Can provide comprehensive equipment maintenance warning information, improve equipment maintenance targeting and significantly reduce equipment faiure downtime.
5、With sensor self-diagnosis, equipment self-diagnosis, and system self-diagnosis functions, remote technical support and troubleshooting are available.
6、The cell phone APP can be used to get to know the operation status of the equipment, which is convenient for the operators and managers to know the operation status of the equipment in time; equipped with Ethemet, RBS485, CAN, MODUBUS and other rich communication interfaces, making it easy to transmit data remotely.

KTDK-ZN-ZKT-V Intelligent Mine Hoisting Electrical Control System

lntroduction

KTDK-ZN-ZKT-V intelligent mine hoisting electrical control system, is a new generation of hoisting electrical control system specially designed for the future intelligent mine construction. It is suitable for intelligent upgrade requirements of different types of mine hoisting systems drived by AC/DC motors such as vertical shaft, inclined shaft,single rope, multi-rope, etc. Especially in complex hoisting places such as multi-level and multi-machine drive, the advantages are more pronounced.
"The system adheres to the high-reliability design principle of safer, more inteligent and better, and meets all the requirements of process control, safety protection and intelligent control of mine hoist. The hardware and software of the product are modular design,with compact structure, beautiful and elegant,safe and reliable, etc.It is a tailor-made system solution for future high-end customers to realize intelligent and highly reliable operation of hoist system, and is the first choice for large mine users to realize intelligent upgrade of hoist system.

Main Characteristics

1、Based on a reliable and flexible network communication framework, the system can realize sel-diagnostic functions at the sensing layer,control layer and execution layer of key equipment.Support advanced operation requirements such as mine hoist unattended,remote control,remote monitoring,remote technical support and emergency drive.
2、It has the ability of in-depth comprehensive analysis and specialized processing of equipment working condition data, accurately assessing system equipments operation condition and predicting the potential failure of major equipment. Through the cell phone APP,it is convenient for the operators and managers to stay informed about the equipment's operation condition on time.
3、The system is equipped with intelligent visible light and thermal imaging video monitoring software and hardware facilities, which can monitor the surface temperature of the equipment in a non-contact manner and detect any foneign objects into the area, etc.
4、With a professional 'system plug-in" function, it is convenient to interact with multiple systems and achieve intelligent mine realization and operation.Configured with Ethernet,RS485,CAN, MODUBUS and other rich communication interfaces, data remote transmission can be easily achieved.
5、The system has sensor self-diagnosis function and embedded expert think tank to support equipment remote diagnosis and service.It can provide accurate maintenance guide to reduce equipment maintenance workload,reduce equipment failure rate and improve equipment trouble-free operation time.

6+1+2 Introduction of intelligent solutions

The solution consists of six subsystems, one channel and two platforms, including the control system in the hoist control room, expert intelligence system (equipment level), pit head control system, shaft and shaft bottom control system, environmental monitoring system, intelligent video monitoring system, network communication and data teleportation channel, dispatch management and monitoring platform, and remote service platform.

1)Control system in the hoist control room mainly includes: Power supply system,speed control system,lubrication system, hydraulic system, gate control system, electric control system, as well as the main equipment vibration detection, shaft temperature detection, etc.
2) Expert intelligent system(equipment level)mainly includes: industrial control computer, displayer, collection card, communication networks,and application software packages such as monitoring software and expert think tank. It can monitor real-time information on the working conditions of the main equipments,sensors and actuators of the hoist system as well as external environmental data and information such as temperature and humidity. It manages and analyzes fault and potential fault information of equipment and system, and has advanced intelligent functions such as work condition recurrence, precise maintenance and remote diagnosis. The main software function modules include equipment management module,equipment condition monitoring module, information management module, system condition recurrence module,expert think tank module,system self-diagnosis and remote diagnosis module.

3) The control system at pit head mainly includes: stable rope detection,gate detection, curved rail detection, skip detection, shaft temperature detection, steel rope detection, signal from pit head, operation machine,stable rope adjustment, automatic unloading, etc.
4) The shaft and shaft bottom control system mainly includes:intelligent monitoring of the working condition of equipment such as head frame, cage, tail rope, coal feeder,automatic loading and coal bunker.
5) Environmental monitoring system mainly includes: real-time monitoring of temperature, humidity, vibration, and noise in key places,with early warning and fault alarm functions.
6) Intelligent video surveillance system mainly includes: monitoring key parts and facilities such as pit head, bottom, and hoist control room through visible light and thermal imaging surveillance probes. With the help of machine vision and artificial intelligence AI algorithm, it monitors equipment surface temperature in a non-contact way and determines foreign object area intrusion, etc. It can monitor equipment operating conditions more conveniently, faster,more efficiently and more intelligently.
7) Network communication and data teleportation channel: The system is equipped with rich software and hardware communication interfaces that can interact with system information by dispatching command center and remote service platform through communication network,and can easily realize data teleportation.
8) Scheduling management and monitoring platform: provide software and hardware support to realize data interaction with the mine scheduling management and monitoring platform through communication to meet the users intelligent mine construction and operation requirements.
9) Remote service platform support system(Locate in Huafei Company,serving national customers): based on reliable network security mechanism support to achieve remote diagnosis of equipment and other intelligent functions through the public network. Remote detection and high-quality service are available for hoist, belt conveyor,main ventilator, and other large mining equipment.

ZTDK-DC Hoist Electrical Control Device

Usage : Applicable to coal mines, metallurgy, non-ferrous metal mines and other vertical shafts, inclined shafts or other hoisting occasions requiring high power and high performance speed control, as electrical control equipment for various types of hoists driven by DC motors.
Configuration:

ZTDK-ZN-ZKT intelligent DC main console 

Performance: ZTDK-ZN-ZKT intelligent DC main console is the control core of DC hoist electric control device,which adopts Siemens S7 series (S7-200;S7-300) programmable controllers with advanced technology and reliable performance, with full digital SIMOREG DC MASTER 6RA70 produced by Siemens or DCS800 DC speed regulating device from ABB to form DC speed regulating cabinet, with constant magnetic field and the way of armature commutation, to complete the motor drive,lifting conditions control and the necessary electrical protection functions, but also the use of a number of patented technologies developed by our company,forming a special controller for the hoist. It has six features: process control is fully digital,safety circuit is double-wire system, control circuit is modular, color screen shows parameters at any time, alarm content is linguistic, control process is programmed,etc.

Technical Characteristics :
logic control mode: PLC programmings
Available hoisting speed: ≤20m/s;
Distance measuring accuracy:≤1.5mm.
 

ZTDK-TS DC speed regulating cabinet

Usage: ZTDK-TS DC speed regulating cabinet is the key equipment in the electric control device of ZTDK DC hoist,which adopts the equipment with the same performance as 6RA and DCS made by Huafei , and is used for speed regulation and control of DC motor in the way of constant magnetic field and armature commutation.
Characteristics: All digital logic non-loop thyristor rectifier equipment is used to form the main circuit power supply, all control functions are completed by parameter setting; the speed regulator and current regulator parameters can be automatically optimized by the system; the current speed is double closed-loop,four-quadrant operation can be achieved to meet various control requirements. Magnetic field current closed-loop regulation, weak magnetic speed control can be achieved. After the additional option, the speed regulating cabinet can complete the tension control system communication,speed interlock, and other process or technical function requirements. The main circuit has 6 pulses, a series of 12 pulses, and a parallel of 12 pulses and other configurations, and has armature overvoltage absorption protection function.

ZTDK-LC DC excitation cabinet

Usage: ZTDK-LC DC excitation cabinet is supporting equipment for the ZTDK DC hoist electric control device, mainly to provide excitation power for DC motors and has the function of double excitation switching and excitation overvoltage protection.

KXT160 Mining Hoist Signal Device

KXTA60 Mining Hoist Signal Device is a multi-level mining hoist signal device that designed according to the coal industry standard, which consists of signal box, pit head signal station, underground signal station, sound and light alarm, auxiliary signal device and other equipment. This device adopts programmable controller as the control core to complete data acquisition, logic operation processing and output control: CAN field bus technology is used to complete data interactive acquisition; audio bus technology is used to realize the duplex amplified telephone communication function between devices. This device can be applied to a maximum of 16 levels, the system wiring is convenient, safe,and reliable.