1 Introduction
Coke coal iron and steel industry chemical treatment process operating point there is more loose distribution of the characteristics of equipment, to meet the technological requirements of the premise, as far as possible to reduce the size of employment and labor intensity, is the subject of automation engineering and technical personnel. As information technology and the rapid development of network communication technology, full use of automation and network technology can be resolved.
2 process described in the Panzhihua Iron and Coal Chemical Plant 1 # coke oven repair ex situ projects, the focus of treatment process can be divided into operation by coke, coke and storage focus screen and put coke, coke dust and other parts handling, transport, the main focus is the completion of the new 1 # coke oven production timely delivery of out of treatment; sieve coke coke is screened mainly divided into less than 5mm, 5mm ~ 10mm, 10 ~ 25mm, 25 ~ 80mm, 80mm and so on more than several different specifications Coke; storage main focus is filtered according to different sizes of coke storage reservoir in different focal positions, the release focus mainly based on the needs of ironworks, the coke from the coke storage warehouse into the delivery conveyor belt to different destinations, or the coke from the coke storage warehouse into the train or automobile transportation to different specifications of coke delivery to the customer. In addition, because the use of coke in the dust during transportation of large belt, in order to protect the environment and health of workers on site, the system designed a dust removal system.
3 system configuration Panzhihua Coal Chemical Process Coke s use of the Schneider Electric Quantum family of control cabinet as a process control system. The control points will be responsible for field data acquisition and control equipment, and staff stop by operating the operation of the equipment on-site real-time surveillance management, the whole system of the device can monitor and centralized control.
3.1 system hardware configuration
PLC hardware configuration shown in Figure 1.
Figure 1 coke processing control system hardware configuration network diagram
(1) PLC control cabinet Schneider Electric Modicon Quantum Series I / O architecture can be used for three main types of architecture to meet the requirements of control systems: local I / O, remote I / O (RIO) and distributed I / O ( DIO), the system uses remote I / O structure. Given the relatively decentralized control devices, distance, In addition, the system also uses fiber-optic repeater RIO point to point communication, this can enhance the anti-clutter the entire network capacity, improve overall stability control system data exchange .
Panzhihua Iron and coal coke chemical plant process control system a total of 5 sets of PLC cabinet, including a # 1 master CPU board installed, the others are I / O cabinet, and 1 #, 2 #, 5 #, 2 points each cabinet station, so the system a total of one master and seven sub-stations.
Master has a CPU board, it can be compatible with the Concept. In order to facilitate communication with other devices, equipped with an Ethernet module is 140 NOE 771 11, it uses Ethernet TCP / IP protocol and operator stations, engineering stations for communication, its transmission rate of 10/100Mbps.
Systems are installed in each sub-station, a MA-0185-100 splitter, and because 4 # 5 # between the station and the distance, in order to ensure smooth communication, we use optical fiber, optical fiber repeater to communicate.
(2) The operator workstation into account site conditions, the system for the real-time monitoring network in the central control room equipped with a single operator station, the specific configuration is as follows:
CPU: pentium 4 processor clocked at 2.4GHz. HDD: 80G, RAM: 512Mb, LAN: 100M, bottom: PBP-13L4 industrial floor PW-300W, Monitor: Samsung 21 "CRT flat screen, 52X CD-ROM, 1.44M floppy drive, with a keyboard and optical mouse.
It and control system, engineers stations Ethernet, through TCP / IP protocol and the INTERNET network interconnection, so that users can at any place, through the INTERNET on the surveillance equipment maintenance.
(3) engineer station engineer station hardware configuration is identical with the operator station. When the operator station fails, the operator can immediately by setting permissions to engineer station converted into the operator workstation.
3.2 system software configuration
(1) PLC control system software, the system uses the Concept V2.6 version of the package, which is based on the Windows 2000 platform, industrial software system with powerful programming configuration function. Concept is very easy to configure, all in I / O modules can be configured through the Concept, the software for each module in the specified I / O addresses, making additions and changes in the configuration of the module is extremely simple, do not change because of the physical location of the application .
With all five kinds of IEC61131-3 programming language, were the order of function charts, function block diagram, ladder diagram, Structured Text, Instruction List. According to technology needs, we are using function block diagram language compiled application.
(2) The operator station software, the system uses the learned Astra s 1500tag server version control software (with Schneider Quantum IOServer) production operator control screen. It is based on the Windows 2000 platform, industrial software, directly from the PLC program-level input tag definition, can effectivelyShorten the development time for quick, convenient and accurate aim, it can automatically update the tags, to ensure synchronization with the control system, and protect data integrity, and support all network communication protocols, making the process stops smooth exchange of data.
4 system function
4.1 control of the system by the transport belt conveyor, vibrating screen, shutter and other basic equipment, which uses the control equipment, communications modules, control stations and other devices to achieve the belt conveyor, vibrating screen, flap centralized control and monitoring purposes. Concrete realization of the functions are as follows:
(1) diversity controlled automatic control mode, set control manually, place three ways to switch. Normal production, the use of centralized control automated equipment according to process requirements and process the order automatically start and stop by the operator station; centralized control manual, the operator can operate the station equipment, an interlock and linkage relations; in maintenance equipment used in situ methods, are next to each device with local operator control box, a work-place from the switch and stop button easy operation in the field;
(2) device before the start made by the central control station early warning signals, warning, after 30s, if the site were automatically activated to meet the conditions of centralized control, equipment, automatic start sequence. On-site parking available button to stop the boot process; equipment before the start of an early warning signal, suggesting that the officer should immediately away from the equipment;
(3) according to process requirements, the entire focus process control system 22 expected lines, the operator can select different conditions of incoming material lines, the flap automatically switch place, convenient and quick.
(4) the installation of belt conveyor pull the cord, deviation protection, low-speed protection, these signals are set access control system, to participate in the emergency stop and interlock equipment parking; to ensure that equipment and personal safety;
(5) of the equipment failure and abnormal parameters of real-time alarm, and make sound and light tips. General fault alarm only, on-site parking or serious non-normal fault, faulty equipment and downstream equipment, emergency stop, delay coal flow along the upstream equipment Interlock.
(6) in accordance with the nature of the fault belt conveyor systems, emergency stop, stop, or the order of sound and light alarm signals;
4.2 monitoring to ensure that personnel and equipment safety, the operator can be in the control room operator station on the Central Monitoring the coke handling of the production process, complete production and related sectors, "telemetry, remote and remote control" to achieve transport Coke deal with comprehensive automation of production. Concrete realization of the functions are as follows:
(1) to provide an interactive Chinese interface of the operating platform, real-time display of each line for equipment running status;
(2) The relations between process and chain of each line for automatic / manual control;
(3) real-time monitoring of all electrical current, temperature and other parameters. Allows maintenance personnel to detect the potential failure of some mechanical equipment hazards;
(4) in the operator station in accordance with the fault time sequence that showed the state of all control equipment failure, fault type, fault location, and other information, easy to find fault maintenance personnel, timely fast fault;
(5) To ensure personal safety, information security alarm on the failure to confirm that only confirmed after the failure to restart the device.
5 control system features a Schneider PLC of the series launched a comprehensive automation platform, with modular, scalable architecture, and all of the modules can be hot plug, no slot restrictions on any module, it is particularly suitable industrial and real-time control of the production process. Specific features are as follows:
(1) use the controller more advanced, real-time systems, reliability, data processing speed;
(2) program based on coaxial cable remote I / O architecture, the system has high security. Easy system expansion, which can increase the node;
(3) Quantum Series control cabinet communication network speed, transfer rate of 1544Mbps, high reliability;
(4) The operator station intuitive and friendly interface, easy operation, complete functions;
(5) reduce wiring costs, due to the use of remote communication network, so that wiring is more convenient, and greatly reduce the amount of cable;
(6) multi-mode of operation. Control methods are: focus on interaction, focus manually, place manually, the system is flexible and reliable. In centralized mode, all the equipment the Central Control Room operator to operate through the operator station;
(7) a variety of process options. In the interaction mode, the transport process in accordance with process selection, belts start by counter-current direction and speed under the belt, driving the length of delay, in order to avoid the phenomenon of accumulation of coke;
(8) with real-time alarm monitoring, security, recognition mechanisms, and data logging capabilities. The quality of the operators without special requirements, training simple.
6 Conclusion In summary, the treatment process control system in the practical application of focus, the performance is stable and reliable network technology is relatively mature and can meet the production needs. Put into operation in August this year since the system is stable and reliable anti-interference ability, easy to maintain, as the normal production of coke oven to provide a reliable guarantee.