大齿轮喷油润滑装置的监控
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摘要
煤磨机、球磨机广泛应用于水泥厂、电厂、矿山、冶金行业,其大型开式齿轮工作环境恶劣,为了减少齿轮运转时的噪音,延长齿轮的使用寿命,减少润滑剂的消耗量,国内外对改进矿用球磨机润滑装置作了很多的研究,以实现润滑的均匀性与对控制回路的保护。随着信息技术与工业自动化控制技术的飞速发展,PLC(可编程序控制器)、触摸屏、远程监控技术的应用日趋成熟与广泛,从控制方式的发展趋势上看,实现球磨机润滑的自动控制与远程监控已是必然,鉴于此,我们提出了本课题的研究方向。
通过阅读大量文献资料,对球磨机润滑装置的控制系统在国内外的发展状况以及PLC与触摸屏、远程监控的应用进行了综述。通过分析球磨机喷油润滑装置的工作原理及各部分构成的作用,设计了控制系统的电气控制方案,决定开发一种基于PLC、触摸屏和远程监控技术的球磨机润滑装置的控制系统。以实现该喷油润滑装置均匀润滑、定时、定量并能对温度监控的要求。
为了完成相应的控制功能,本课题进行了控制系统硬件与软件的设计,所做的工作主要可分为以下四部分：
1.电气控制系统主电路与控制电路的设计。画出了控制系统的主电路与控制电路的电气原理图,并选择了电气元件,进行安装调试。
2.PLC硬件系统与程序的设计。根据控制要求以及输入输出点数,对比性能,选择SIMATIC S7-200 PLC系列CPU226作为主控模块,温度信号采用EM231热电阻模块输入。进行了I/O地址分配,编制了PLC应用程序,在现场控制柜面板上满足自动控制与手动控制方式的转换,实现报警信号显示。在实际生产中,只需编制不同的PLC程序,就能满足不同的控制要求。
3.触摸屏硬件与软件的设计。现场控制柜面板上安装Eview MT4300C触摸屏进行监控调节,制作了触摸屏画面,设置了变量。在工作现场通过触摸屏修改PLC的一些工艺参数,就可调整与控制润滑与间歇时间、油温上下限数值。
4.远程组态控制系统的设计。在监控室配置计算机与组态王软件,组态王计算机与现场的PLC之间通过通讯电缆线相连,对润滑装置的工作状况与有关参数进行远程实时监控与调整。
本控制系统设计完成后,进行了现场调试,设备运行稳定,使球磨机的齿轮润滑状况得到了明显改善,解决了实际生产中容易出现的问题,达到了预期目标,增强了系统判断和处理故障的能力,提高了作业效率。
Coal mill and ball mill are used in cement plants, power plants, mining, metallurgical and other industries, the large-scale opens the type gears of Coal mill and ball mil working conditions are bad. In order to reduce gear noise when running, extend the life of gear and reduce lubricant consumption, many research have been done to the mineral product ball mill lubricating arrangement's lubrication's uniformity and in control loop's protection at home and abroad. As information technology、industrial automation、control technology development rapidly, and PLC (programmable logic controller), touch screen, remote monitoring technology have matured and used widely,trends from the Control point of view, to achieve ball control and remote monitoring lubrication is necessary. In view of this, we propose research directions in this topic.
By reading a lot of literature, the ball mill lubrication device control system development at home and abroad as well as PLC and touch screen, remote monitoring of the applications were reviewed. By analyzing the work of Ball spray lubricating device schematic and the parts, we designed the control system of electric control program,and we decided to develop the control system of the mill lubrication device,which based on PLC, touch screen and remote monitoring. The system can spray lubrication Lubrication uniform, regular, quantitative, and can meet the requirements of temperature monitoring.
In order to complete the corresponding control functions, the subject of the control system hardware and software design, the work can be divided into four parts:
1.Electrical control system main circuit and control circuit design.We draw the main electrical circuit and control circuit diagram,select the electrical components and installed wiring.
2.The designs of PLC hardware system and procedures. According to the control requirements, and input and output points, compared to performance, select the SIMATIC S7-200 PLC series CPU226 as the main control module, and the EM231 RTD temperature is signal input module. We had I/O address assignment, the preparation of the PLC application. Counter at the scene control panel and manual control methods to meet the automatic conversion, an alarm signal display. Thus, in actual production, just different kinds of PLC process control can be achieved in different ways.
3.The designs of touching-screen hardware system and procedures. We installed the Eview MT4300C touch screen on the control cabinet, produced touch-screen pictures,and set the variables. By using the touch screen modify PLC some parameters, you can adjust and control the time and intermittent lubrication, oil temperature on the lower limit value.
4.Remote Control System Configuration. We have computers and the ZU TAI WANG software in the control room.Computer is connected with PLC by communication cable. By chosing a free serial communication port, We know the lubricating device working.
After this control system design completes, we installed the wiring and debugged the equipment. The large ball mill gear lubrication situation has significantly improved. The control scheme is easy to solve the practical problems of production to achieve the desired goals, and enhance the system's ability to judge and deal with failure, improve operational efficiency.
通过阅读大量文献资料,对球磨机润滑装置的控制系统在国内外的发展状况以及PLC与触摸屏、远程监控的应用进行了综述。通过分析球磨机喷油润滑装置的工作原理及各部分构成的作用,设计了控制系统的电气控制方案,决定开发一种基于PLC、触摸屏和远程监控技术的球磨机润滑装置的控制系统。以实现该喷油润滑装置均匀润滑、定时、定量并能对温度监控的要求。
为了完成相应的控制功能,本课题进行了控制系统硬件与软件的设计,所做的工作主要可分为以下四部分：
1.电气控制系统主电路与控制电路的设计。画出了控制系统的主电路与控制电路的电气原理图,并选择了电气元件,进行安装调试。
2.PLC硬件系统与程序的设计。根据控制要求以及输入输出点数,对比性能,选择SIMATIC S7-200 PLC系列CPU226作为主控模块,温度信号采用EM231热电阻模块输入。进行了I/O地址分配,编制了PLC应用程序,在现场控制柜面板上满足自动控制与手动控制方式的转换,实现报警信号显示。在实际生产中,只需编制不同的PLC程序,就能满足不同的控制要求。
3.触摸屏硬件与软件的设计。现场控制柜面板上安装Eview MT4300C触摸屏进行监控调节,制作了触摸屏画面,设置了变量。在工作现场通过触摸屏修改PLC的一些工艺参数,就可调整与控制润滑与间歇时间、油温上下限数值。
4.远程组态控制系统的设计。在监控室配置计算机与组态王软件,组态王计算机与现场的PLC之间通过通讯电缆线相连,对润滑装置的工作状况与有关参数进行远程实时监控与调整。
本控制系统设计完成后,进行了现场调试,设备运行稳定,使球磨机的齿轮润滑状况得到了明显改善,解决了实际生产中容易出现的问题,达到了预期目标,增强了系统判断和处理故障的能力,提高了作业效率。
Coal mill and ball mill are used in cement plants, power plants, mining, metallurgical and other industries, the large-scale opens the type gears of Coal mill and ball mil working conditions are bad. In order to reduce gear noise when running, extend the life of gear and reduce lubricant consumption, many research have been done to the mineral product ball mill lubricating arrangement's lubrication's uniformity and in control loop's protection at home and abroad. As information technology、industrial automation、control technology development rapidly, and PLC (programmable logic controller), touch screen, remote monitoring technology have matured and used widely,trends from the Control point of view, to achieve ball control and remote monitoring lubrication is necessary. In view of this, we propose research directions in this topic.
By reading a lot of literature, the ball mill lubrication device control system development at home and abroad as well as PLC and touch screen, remote monitoring of the applications were reviewed. By analyzing the work of Ball spray lubricating device schematic and the parts, we designed the control system of electric control program,and we decided to develop the control system of the mill lubrication device,which based on PLC, touch screen and remote monitoring. The system can spray lubrication Lubrication uniform, regular, quantitative, and can meet the requirements of temperature monitoring.
In order to complete the corresponding control functions, the subject of the control system hardware and software design, the work can be divided into four parts:
1.Electrical control system main circuit and control circuit design.We draw the main electrical circuit and control circuit diagram,select the electrical components and installed wiring.
2.The designs of PLC hardware system and procedures. According to the control requirements, and input and output points, compared to performance, select the SIMATIC S7-200 PLC series CPU226 as the main control module, and the EM231 RTD temperature is signal input module. We had I/O address assignment, the preparation of the PLC application. Counter at the scene control panel and manual control methods to meet the automatic conversion, an alarm signal display. Thus, in actual production, just different kinds of PLC process control can be achieved in different ways.
3.The designs of touching-screen hardware system and procedures. We installed the Eview MT4300C touch screen on the control cabinet, produced touch-screen pictures,and set the variables. By using the touch screen modify PLC some parameters, you can adjust and control the time and intermittent lubrication, oil temperature on the lower limit value.
4.Remote Control System Configuration. We have computers and the ZU TAI WANG software in the control room.Computer is connected with PLC by communication cable. By chosing a free serial communication port, We know the lubricating device working.
After this control system design completes, we installed the wiring and debugged the equipment. The large ball mill gear lubrication situation has significantly improved. The control scheme is easy to solve the practical problems of production to achieve the desired goals, and enhance the system's ability to judge and deal with failure, improve operational efficiency.
引文
[1]缪克军.DTM筒式球磨机润滑改良方案.《中国设备管理》2001年第4期P46
[2]张永康,黄建平.大型球磨机开式传动齿轮润滑系统改造《中国设备工程》2007年第12期P46-48
[3]李国厚；杨青杰；余泽通.球磨机润滑站控制系统的设计.《金属矿山》2005年第9期P74-75
[4]张长胜,万舟,王成 基于PLC网络的球磨机润滑监控系统的应用.昆明理工大学学报2002年P65-67
[5]Blanke, H.-J.A. Systems approach to lubrication of large industrial open gears. Source: Proc 1989 Int Power Transm Gearing Conf:New Technol Power Transm 90's,1989, P347-354
[6]Gesdorf, Edward J. OPEN GEAR SPRAY SYSTEMS-RECENT DEVELOPMENTS.Source:NLGI Spokesman, Volume 52, Apr 1988, P17-28
[7]蒋冬青.PLC在球磨机润滑系统上的应用.《陕西建材》1998年第4期P22
[8]赵文涛,王建军.球磨机润滑系统改造.《水泥》1999年第12期P41-42
[9]唐全盛.PLC在大型磨机稀油站控制系统中的应用《水泥》2003年03期P45-47
[10]谭志中.湿式球磨机润滑系统的改进.《有色设备》2003年02期P36-37
[11]李霄燕等基于模糊自整定PID的矿热炉电极控制系统设计《铁合金》2009年第40卷第5期P32-34
[12]冯清秀等.基于PLC的开式齿轮润滑控制系统.《机电一体化》2004年01期P57-59
[13]李华.新型油流量传感器在球磨机润滑系统的应用《水泥工程》2002年第3期P37-38
[14]邓汝橼 球磨机润滑系统改造.《水泥》2003年第3期P54-55
[15]段世方.DTM2900/500型球磨机润滑改进《华东电力》2002年第8期P73-74
[16]宁保健.球磨机润滑系统的改进《有色设备》2003年第2期P37-38
[17]李国厚.PLC在球磨机润滑控制中的应用《工矿自动化》2006年第1期P71-73
[18]袁林.利用PLC改造球磨机喷雾润滑系统方案《电工技术》2004年第04期P27-28
[19]Funke, Paul; Piorko, Ingo; Wittek, Reinhard. Comparison of the Lubricating Effectiveness in Cold Rolling of Artificially Aged Rolling Oil Emulsions with the Parameters Determined by the Four-Ball Wear Tester. Source:Archiv fuer das Eisenhuettenwesen, Sep 1974, P591-596
[20]李正根等.自动喷雾润滑装置在球磨机上的应用《矿业快报》2001年第22期P25-26
[21]孔连凯等.球磨机润滑油站电气控制回路的改进《东北电力技术》2004年第25卷第7期P44-45
[22]Pugh, James R. (Lubriquip, Inc). Incorporating predictive monitoring functions in automatic lubrication systems. Source:SME Technical Paper (Series) MS,1989, p712
[23]Moate, Peter (Interlube Systems Ltd). DESIGNING FOR AUTOMATIC LUBRICATION. Source:Engineering Materials and Design, May,1987, p 33-34
[24]Brown, Joseph (Power Transmission Design, Cleveland, OH, USA). WHAT'S NEW IN CENTRAL LUBRICATION. Source:Power Transmission Design, v 30, n 10, Oct,1988, p 41-44
[25]王永华.现代电气控制及PLC应用技术.北京航空航天大学出版社,2008.2.P1-290
[26]李方园.触摸屏工程应用.电子工业出版社,2008.4.P1-239
[27]陈世利等.触摸屏的工作原理及典型应用. 《单片机与嵌入式系统应用》2002年第2期P11-14
[28]Arora, N. (University of Michigan); Gala, S.; Lee, B.; Luntz, J.; Moyne, J.; Tilbury, D. A 'controls workflow management'HMI to configure and maintain an event based control system.. Source:Proceedings-Eighth International Workshop on Discrete Event Systems, WODES 2006, Proceedings-Eighth International Workshop on Discrete Event Systems, WODES 2006,2006, p 463-464
[29]黄坤荣等.pLC和触摸屏控制系统在灭菌器上的应用《国内外机电一体化技术》2005年第1期P56-57
[30]谢子洪等.PLC和触摸屏技术在矿热炉中的应用《铁合金》2007年第2期P41-45
[31]廖常初.西门子人机界面(触摸屏)组态与应用技术.机械工业出版社,2009.1.P1-273
[32]Albert, E.; Alpuente, M.; Falaschi, M.; Julian, P.; Vidal, G. Improving control in functional logic program specialization. Source:Lecture Notes in Computer Science, v 1503,1998, p 262
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[43]Nakamatsu, Kazumi; Akama, Seiki; Abe, Jair M. Real-time intelligent process order control based on a paraconsistent annotated logic program EVALPSN. Source:2008 5th International Multi-Conference on Systems, Signals and Devices, SSD'08,2008 5th International Multi-Conference on Systems, Signals and Devices, SSD'08,2008, p 463
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[2]张永康,黄建平.大型球磨机开式传动齿轮润滑系统改造《中国设备工程》2007年第12期P46-48
[3]李国厚；杨青杰；余泽通.球磨机润滑站控制系统的设计.《金属矿山》2005年第9期P74-75
[4]张长胜,万舟,王成 基于PLC网络的球磨机润滑监控系统的应用.昆明理工大学学报2002年P65-67
[5]Blanke, H.-J.A. Systems approach to lubrication of large industrial open gears. Source: Proc 1989 Int Power Transm Gearing Conf:New Technol Power Transm 90's,1989, P347-354
[6]Gesdorf, Edward J. OPEN GEAR SPRAY SYSTEMS-RECENT DEVELOPMENTS.Source:NLGI Spokesman, Volume 52, Apr 1988, P17-28
[7]蒋冬青.PLC在球磨机润滑系统上的应用.《陕西建材》1998年第4期P22
[8]赵文涛,王建军.球磨机润滑系统改造.《水泥》1999年第12期P41-42
[9]唐全盛.PLC在大型磨机稀油站控制系统中的应用《水泥》2003年03期P45-47
[10]谭志中.湿式球磨机润滑系统的改进.《有色设备》2003年02期P36-37
[11]李霄燕等基于模糊自整定PID的矿热炉电极控制系统设计《铁合金》2009年第40卷第5期P32-34
[12]冯清秀等.基于PLC的开式齿轮润滑控制系统.《机电一体化》2004年01期P57-59
[13]李华.新型油流量传感器在球磨机润滑系统的应用《水泥工程》2002年第3期P37-38
[14]邓汝橼 球磨机润滑系统改造.《水泥》2003年第3期P54-55
[15]段世方.DTM2900/500型球磨机润滑改进《华东电力》2002年第8期P73-74
[16]宁保健.球磨机润滑系统的改进《有色设备》2003年第2期P37-38
[17]李国厚.PLC在球磨机润滑控制中的应用《工矿自动化》2006年第1期P71-73
[18]袁林.利用PLC改造球磨机喷雾润滑系统方案《电工技术》2004年第04期P27-28
[19]Funke, Paul; Piorko, Ingo; Wittek, Reinhard. Comparison of the Lubricating Effectiveness in Cold Rolling of Artificially Aged Rolling Oil Emulsions with the Parameters Determined by the Four-Ball Wear Tester. Source:Archiv fuer das Eisenhuettenwesen, Sep 1974, P591-596
[20]李正根等.自动喷雾润滑装置在球磨机上的应用《矿业快报》2001年第22期P25-26
[21]孔连凯等.球磨机润滑油站电气控制回路的改进《东北电力技术》2004年第25卷第7期P44-45
[22]Pugh, James R. (Lubriquip, Inc). Incorporating predictive monitoring functions in automatic lubrication systems. Source:SME Technical Paper (Series) MS,1989, p712
[23]Moate, Peter (Interlube Systems Ltd). DESIGNING FOR AUTOMATIC LUBRICATION. Source:Engineering Materials and Design, May,1987, p 33-34
[24]Brown, Joseph (Power Transmission Design, Cleveland, OH, USA). WHAT'S NEW IN CENTRAL LUBRICATION. Source:Power Transmission Design, v 30, n 10, Oct,1988, p 41-44
[25]王永华.现代电气控制及PLC应用技术.北京航空航天大学出版社,2008.2.P1-290
[26]李方园.触摸屏工程应用.电子工业出版社,2008.4.P1-239
[27]陈世利等.触摸屏的工作原理及典型应用. 《单片机与嵌入式系统应用》2002年第2期P11-14
[28]Arora, N. (University of Michigan); Gala, S.; Lee, B.; Luntz, J.; Moyne, J.; Tilbury, D. A 'controls workflow management'HMI to configure and maintain an event based control system.. Source:Proceedings-Eighth International Workshop on Discrete Event Systems, WODES 2006, Proceedings-Eighth International Workshop on Discrete Event Systems, WODES 2006,2006, p 463-464
[29]黄坤荣等.pLC和触摸屏控制系统在灭菌器上的应用《国内外机电一体化技术》2005年第1期P56-57
[30]谢子洪等.PLC和触摸屏技术在矿热炉中的应用《铁合金》2007年第2期P41-45
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