Background brief
Gansu Qilianshan Cement Group Co., Ltd. Gulang Qilianshan Cement Plant has an annual output of 1 million tons of cement. There are 4 stackers and reclaimers in the stacker and the unloader and the long pile plant in the production of the round-dump plant. It is an important task for storing and transporting raw materials. The signal communication between the stacker and the central control room has been transmitted by means of sliding line transmission or wired.
Xi'an Datai Electronics Co., Ltd.
Round pile plant exterior location â–¼
Long pile of factory exteriors â–¼
cause problems
Wired transmission generally uses multi-core communication cables, cable reels or sliding lines. The torque motor used for the cable reel is easy to be damaged; the tensile strength of the communication cable is low and easy to break; the communication of the sliding contact line belongs to the contact communication, and the operation of the stacker and reclaimer causes the unevenness of the track foundation to be uneven, and the track installation is not straight. The slip line is twisted and deformed with the vibration generated by the belt bracket and the installation error of the sliding line; the collector bracket is deformed, and the collector is detached, resulting in poor contact between the carbon brush and the sliding line; Suspension, ground control failure; often the ground conveyor belt and stacker and reclaimer interlock signal is interrupted, only the operator can manually stop, the operation time difference is easy to cause belt pressure, burnt motor and other faults, due to disconnection The fault cannot be timely fed back to the DCS and the interlocked equipment. In severe cases, it causes casualties or major property damage, which seriously affects normal production. According to statistics, the failure rate of the sliding line accounts for 70% of the total failure of the stacker and reclaimer, which has become a bottleneck restricting the normal operation of the pile and the material.
Since the cable needs to be replaced every six months, the high maintenance cost makes the user finally decide to use wireless to complete the communication.
Xi'an Datai Electronics Co., Ltd.
User needs
The main control signals (the stacker, the central control drive and the emergency stop of the stacker, etc.) in the communication between the stacker and the reclaimer in the round-stack plant and the long-stack plant and the central control room DCS system are all from the original Wired control changed to wireless control.
Console of stacker and reclaimer in round stack â–¼
Working state of stacker and reclaimer in long pile â–¼
Wireless communication solution implementation
Xi'an Datai Electronics Co., Ltd.
※ Wireless communication between the round reactor and the central control room
The DCS system in the central control room 200 meters away from the round dump plant needs to control the start and stop of the stacker and reclaimer in the plant, as well as 16 switch signals such as the discharge belt and the start and stop of the feed belt.
Wireless solution and real map with â–¼
※ Wireless communication in long pile plant
The long pile plant is about 300 meters long and has two rows of tracks. The track is filled with high-volume pulverized coal and clay. There are 2 reclaimers on the same side and 1 stacker on the other side. What needs to be done here is the two-way switch signal communication between the three machines and their corresponding control cabinet DCS system. At the same time, the stacker also needs to control the work of two reclaimers to ensure that the material storage and transportation in the long pile can be operated in an orderly manner.
Xi'an Datai Electronics Co., Ltd.
Wireless solution and real map with â–¼
Why use wireless?
Cable solution VS wireless solution
1. Cable wear is serious? Wireless transmission without cable
2. Equipment needs frequent maintenance? No maintenance, lifetime maintenance
3. Is the cost of replacing the cable high? Industrial site has been used for more than eight years without replacement
4. Is the power consumption large? 10w power, energy saving and environmental protection
5. Replace the delay time? Easy to install, no need to change the original program
6. Dust pulverized coal leads to signal instability? 15 years industrial wireless communication terminal
Xi'an Datai Electronics Co., Ltd.
Emergency call
After installing the wireless signal transmission module, the stacker and the reclaimer in the long stack frequently have alarms, so that the stacker and the reclaimer cannot work normally. The PLC wireless communication expert team immediately sent two technicians after receiving the news, and rushed to the user site to provide technical support.
Through on-site field testing and trial and error, it is confirmed that it is caused by equipment system interference. After discovering the problem, the technicians installed our special accessories and the reclaimer was finally working. After another day of observation, it was ensured that all three devices were able to operate normally, and the technicians left the scene with peace of mind.
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