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解决方案

综采工作面自动化

塔山综放工作面自动化系统方案要求
Scheme Requirement of the Datong Tashan Caving Roof
Coal Work Surface Automatic System
 
根据塔山全矿井综合自动化2004年12月22日会议纪要和用户要求,为了将塔山放顶煤工作面设备纳入塔山全矿井综合自动化系统,实现塔山矿井的高产高效现代化,Honeywell针对目前综放工作面设备提出如下设计方案与要求:
 
According to the customer’s requirement and  minutes of meeting on Dec.22, 2004 about the Tashan whole mine comprehensive automation, in order to bring the Tashan caving roof coal working surface equipment into the Tashan whole mine comprehensive automatic system to realize the high production, high efficiency and modernization of Tashan mine, Honeywell has proposed the following design scheme and requirements for the current comprehensive caving working face equipments:
 
 
注:塔山全矿井综合自动化系统与综放工作面设备间的信号建议全部采用本质安全型信号。
Note: we suggest that the signal between the Tashan whole mine comprehensive automatic system and the comprehensive caving working face equipments totally adopt the intrinsic safety signal.
 
Honeywell 本质安全型 ExibZM20 PLC介绍。
Introduction to Honeywell I.S ZM20 PLC(Exib)
 
ZM20 PLC 监控单元是一种适用于各种控制任务的通用型、高性能、高可靠性的工业自动化系统,它适用于煤矿井下有甲烷和煤尘爆炸危险的环境中。
ZM20 PLC 监控单元有较强的适用性和可扩展性,可以组成不同的控制规模,小到一条皮带,大到整个工作面几采区的生产过程监测控制。方便灵活,其逻辑控制方式可以通过软件编程来实现,使复杂的控制逻辑变得简单易行。系统中的产品采用简便快捷的直插式插接件相连,使系统在恶劣的环境中也能快速准确的安装和更换。系统中有可靠独立的Profibus(DP and FDL) FSK现场总线和BB22444 TTY(20Ma),确保使系统在可以延伸的地方进行数据通讯。系统中有特定的安全保障回路,与控制回路相连使用,可使系统控制安全可靠。
ZM20 PLC monitoring unit is a general purpose industrial automatic system with high efficiency and high reliability that is applicable to all kinds of control tasks, it is applicable to the environment with risk of explosion because of the methane and coal dust in the mine.
The ZM20 PLC monitoring unit has a strong applicability and expandability.  It can compose different control scale, ranging from a belt to monitoring and control of several mining area of whole working face. It is convenient and flexible, its control logic mode can be realized through software programming, which makes the complex control logic simple and easy. The products in the system adopt the easy and simple plug-in type connector, which makes it possible for the system to be installed and replaced quickly and accurately even in the worst environment. There is reliable independent Profibus(DP and FDL) FSK field bus in the system BB22444 TTY(20Ma), which can ensure the data communication of the system in the place that the system can be extended to. The system has a specified safety guarantee loop connected with the control loop, which can ensure the safety and reliability of the system.
 
ZM20 PLC 监控单元是具有RS485和RS232通讯接口,通过Profibus(DP) FSK现场总线实现与C200区域控制中心链接。ZM20 PLC 监控单元的监测与控制功能由其自身或C200监控站来配置实现,其特点如下:
Ø 本质安全型设备;
Ø Profibus(DP and FDL) FSK本安型现场总线接口,通讯距离不低于5Km;
Ø 具有16个DI,16个DO,12个AI,4个AO;
Ø 具有BB22444 TTY(20Ma)接口;
Ø 体积小,重量轻,接线采用快速插头,安装快速方便,特别适合煤矿的移动性生产,适合矿井的搬家倒面。
Ø Profibus FDL 和BB22444通讯接口,可以与国外众多煤矿制造厂家的设备进行通讯,完全实现综采工作面自动化。如Becker 控制系统、DBT、EICKHOFF支架、BF组合开关、Marco组合开关、安控组合开关、Allenwest负荷中心、SAIT组合开关、DBT三机、EICKHOFF采煤机、EICKHOFF采煤机SL300和SL500、Dodge CST,DBT、DBT LAD、英国FSW和ACE顺槽胶带机, 英国RMIS200/S250泵站,英国BAUSH 1500/2000kVA移动变电站等。
 
The ZM20 PLC monitoring unit has a RS485 and RS232 communication interface; it is linked with the C200 controller station through the Profibus(DP) FSK field bus. The monitoring and control function of the ZM20 PLC monitoring unit is realized through the C200 monitoring station, whose characteristics are as follows.
Ø  Intrinsic safety equipment;
Ø  Profibus (DP and FDL)FSK instrinsic safety field bus interface, the communication distance is no less than 5 KM;
Ø  Having 16 DI, 16 DO, 12AI, 4 AO;
Ø  Having the BB22444 TTY(20Ma) interface;
Ø  Small volume, lightweight, the wiring adopts quick plug, the installation is quick and convenient, which makes it suitable for the mobilizing production of the mine specially and suitable for the moving and conversion of working face of the mine.
Ø  Having the FDL and BB22444 communication interface, which can communicate with the equipments made by many mine equipment manufacturer abroad and realize the automation of the comprehensive mining working face, such as Becker control system, DBT, EICKHOFF supporting frame, BF combined switch, Marco combined switch, safety control combined switch, Allenwest load center, Siter combined switch, DBT three machines, EICKHOFF coal cutter, EICKHOFF coal cutter SL300 and SL500, Dodge CST, DBT, DBT LAD, the FSW and ACE sublevel sealing-tape machine of UK, the RMIS200/S250 pump station of UK, the BAUSH 1500/2000kVA mobile substation of UK, etc.
 
 
 
 
 
1、 DBT的前后刮板运输机、转载机、破碎机等三机。
 
三机系统的参数如下表:
编号
描述
电机电压 KV
电机功率 KW
1
转载机
3.3
450
2
破碎机
3.3
400
3.1
前刮板机机头电机
3.3
750
3.2
前刮板机机尾电机
3.3
750
4.1
后刮板机机头电机
3.3
855
4.2
后刮板机机尾电机
3.3
855
 
全矿井综合自动化系统需要监测三机系统各电机的开停状态和各电机电流。
 
1.        The three machines of conveyor, reversed loader and crusher of the front and back scrapter of DBT
2.         
 
The parameters of the three machines system are shown in the following table:
No.
Description
Motor Voltage  (KV)
Motor power (KW)
1
Reversed loader
3.3
450
2
Crusher
3.3
400
3.1
Front scraper head motor
3.3
750
3.2
Front scraper tail motor
3.3
750
4.1
Back scraper head motor
3.3
855
4.2
Back scraper tail motor
3.3
855
 
The whole mine comprehensive automation system needs to monitor the on-off status and current of the various motors of the three machines system.
 
 
开停状态监测:
现场三机系统的电机开停由Becker Promos控制实现,三机系统负荷中心及组合开关的电机开停的无源返回接点已经返给Promos,因此,全矿井自动化系统监测三机开停可与Promos通讯实现。Promos 提供上述系统电机开停无源返回接点共6个;Promos与矿井自动化系统采用FDL实现通讯,Promos将三机的系统的急停起停信息发送到全矿井自动化系统单元ZM20 PLC中。
 
                                   FDL FSK
Hard Wires
 
                        
             ZM20 PLC                                                                                  Promos
            
Monitoring the on-off status:
The on-off status of motor of the field three machines system is realized by the Promos, the load center of the three machines system and the passive return connection point of the on-off status of the motor of combined switch have been returned to the Promos, for this reason, the start and stop of the three machines system of whole mine automation system can be realized through the communication with the Promos, which will provide 6 passive return connection points for the system motors mentioned above. The communication between the Promos and the mine automation system adopts the FDL, the Promos sends the emergency start and emergency stop information of the three machines system to the system units of ZM20 PLC of the whole mine automation system.
 
 
                                   FDL FSK
 
                                                               Hard Wires
 
                        
             ZM20 PLC                                                                                  Promos
 
                              
 
电机电流监测:
 
对于破碎机和转载机的电流采取如下方式来实现监测:
 
采用通讯方式实现,全矿井综合自动化系统 监控单元ZM20 PLC与Becker Promos 系统通过Profibus FDL FSK相连,Becker Promos通过BB22444 TTY(20Ma)与DBT PMCV控制器相连,间接地实现对转载机和破碎机电流、开停状态和开关故障信息(过载、漏电、短路等)的监测。
 
Monitoring the motor current:
 
The monitoring of the current of crusher and reversed loader is realized through following method
The method adopts the communication mode, the monitoring units ZM20 PLC connecting with Becker Promos by FDL FSK,then Becker system connecting with DBT PMCV by BB22444 TTY(20Ma),by this way,  the whole mine comprehensive automation system realize the monitoring of the current, on-off status and failure information of the switch (overloading, electrical leakage and short circuit, etc.) of the reversed loader and crusher.
 
对于前后刮板机的电流采用如下方式来实现监测:
采用总线通讯方式实现,DBT 将所有关于前后刮板机需要监测的信息合并到一台PMCV中,全矿井综合自动化系统 监控单元ZM20 PLC与Becker Promos 系统通过Profibus FDL FSK相连,Becker Promos通过BB22444 TTY(20Ma)与DBT PMCV控制器相连,间接地实现对前后刮板机电流、开停状态和开关故障信息(过载、漏电、短路等)的监测,同时可监测CST运行状态(辅助电机、油温、油压、油位等)。
三机系统(破碎机、装载机、前后刮板机)监测信息:
–     机头(尾)错误状态
–     机头(尾)运转状态
–     机头(尾)电机转速
–     机头(尾)减速箱输出转速
–     机头(尾)离合器压力
–     机头(尾)减速箱温度
–     机头(尾)电机电流
–     监测紧链液压缸压力
–     监测紧链液压缸伸缩
–     监测CST系统状态
 
The monitoring of the current of front and back scraper is also realized through the following  method
 
The method adopts the communication mode. The DBT merges the information of the front and back scraper that needs to be monitored into one set of PMCV, the monitoring unit ZM20 PLC connecting with Becker Promos by FDL FSK,then Becker system connecting with DBT PMCV by BB22444 TTY(20Ma),by this way,  the whole mine comprehensive automation system and the PMCD realize the monitoring of the current, on-off status and switch failure information (overloading, electric leakage and short-circuit, etc.) , at the same time, the CST operation status (auxiliary motor, oil temperature, oil pressure, oil level, etc.) can also be monitored.
 
2、 EICKHOFF SL500大采高交流电牵引采煤机
 
SL500电牵引采煤机电压3300V,总装机功率1850KW。
全矿井综合自动化系统系统需要监测采煤机的截割电机、牵引电机、泵电机、破碎电机的开停状态和各电机电流,监测采煤机牵引位置轨迹、牵引速度、牵引方向。全矿井综合自动化系统监控单元ZM20 PLC与EICKHOFF 系统 通过BB22444 TTY(20Ma)实现通讯监测上述工矿信息。另外,Promos采用FDL向全矿井综合自动化系统ZM20 PLC提供采煤机馈电断路器的分合状态和给采煤机总回路电流;或者,Promos采用硬接线方式向全矿井综合自动化系统 ZM20 PLC提供采煤机馈电断路器的分合状态和给采煤机总回路电流,断路器分合状态以无源接点方式提供,采煤机总回路电流采用4-20mA方式提供,4-20mA对应该供电回路的额定电流。
 
 
采煤机监控信息内容
•         保护
–       过载(截隔、牵引、液压泵、破碎电机)
–       过热(截隔电机、牵引电机、泵电机、液压油、牵引变压器)
–       缺水(冷却水)
 
•         监测
–       电流(截隔、牵引、液压泵、破碎电机)
–       温度(截隔、牵引、液压泵、破碎电机、牵引变压器、滚筒高速轴)
–       压力(润滑油、润滑水)
–       运行速度(牵引)
–       运行位置(采煤机)
–       运行方向(采煤机)
–       摇臂高度
 
 
EICKHOFF SL500 Big Mining Height AC Traction Coal Cutter
 
The SL500 electric traction coal cutter adopts a voltage of 3300V, it has a total installed power rating of 1850KW.
The whole mine comprehensive automation system needs to monitor the on-off status of the cutting motor, traction motor, pump motor and crushing motor, as well as the current of various motors, the traction position track, traction speed and traction direction of the coal cutter. The monitoring unit ZM20 PLC and the EICKHOFF system of the whole mine comprehensive automation system realize the communication through BB22444 TTY(20Ma)to monitor the mine information mentioned above. 
 
Additionally, the Promos adopts the FDL to provide the whole mine comprehensive automation system ZM20 PLC with the on-off status of power feed breaker of the coal cutter and provide the general loop of the coal cutter with current; or, the Promos adopts the hard wiring mode to provide the whole mine comprehensive automation system ZM20 PLC with on-off status of the power feed breaker and provide the coal cutter with general loop current. The on-off status of the breaker is provided in the passive mode, while the coal cutter general loop current adopts the 4-20mA mode, which is corresponding to the rated current of the loop.
 
3、  乳化液泵站和喷雾泵站
Hauhinco乳化液泵和喷雾泵参数如下:
编号
描述
电机电压 KV
电机功率 KW
1
乳化液泵
3.3
4*200
2
喷雾泵
3.3
2*132
 
Emulsion pump station and atomizing pump station
 
The parameters of Hauhinco emulsion pump and atomizing pump are as following:
No.
Description
Motor Voltage  KV
Motor Power  KW
1
Emulsion pump
3.3
4*200
2
Atomizing pump
3.3
2*132
 
乳化液泵站
全矿井综合自动化系统需要监测乳化液泵站各主电机的开停状态和各机电流,监测乳化液箱的液位(高液位、低夜位、干液位等),监测注水阀的开关状态,监测乳化液管路出口压力、流量,监测乳化液温度,监测4台卸载阀的开关状态。全矿井综合自动化 监控单元ZM20 PLC与Hauhinco乳化液泵站系统 通过BB22444 TTY(20Ma)实现通讯监测上述工矿信息。
 
Emulsion pump station
The whole mine comprehensive automation system needs to monitor the on-off status of the various main motors of the emulsion pump station and the current of the motors, to monitor the liquid level of the emulsion tank (high liquid level, low liquid level, empty liquid level, etc.), monitor the on-off status of the priming valve, to monitor the discharge pressure and flow of the emulsion  pipelines, t o monitor the temperature of emulsion,  and to monitor the on-off status of the 4 unloader valve. The monitoring unit ZM20 PLC of the whole mine comprehensive automation system and the Hauhinco emulsion pump station system realize the communication through the BB22444 TTY(20Ma) to monitor the mine information mentioned above.
 
喷雾泵站
全矿井综合自动化系统需要监测喷雾泵站各主电机的开停状态和各机电流,监测喷雾泵水箱的液位(高液位、低夜位、干液位等),监测喷雾泵管路出口压力、流量,监测水温等。全矿井综合自动化监控单元ZM20 PLC与Hauhinco泵站 PM32系统 通过BB22444 TTY(20Ma)实现通讯监测上述工矿信息。
 
Atomizing pump station
The whole mine comprehensive automation system needs to needs to monitor the on-off status of the various main motors of the atomizing pump station and the current of the motors, to monitor the liquid level of the water tank of the atomizing pump system (high liquid level, low liquid level, empty liquid level, etc.), to monitor the discharge pressure and flow of the atomizing pipelines, monitor the water temperature, etc. The monitoring unit ZM20 PLC of the whole mine comprehensive automation system and the Hauhinco pump station PM32 system realize the communication through the BB22444 TTY(20Ma) to monitor the mine information mentioned above.
 
 
4、 Allen Wester SAIT 负荷中心
全矿井综合自动化系统需要将综放工作面2台Allen Wester 和2台SAIT负荷中心的如下信息监测到系统中:
•         Allen Wester 10KV/3300V移动负荷中心系统监测
–     前刮板:(通过开关采集,包括电缆)
•         模拟量(2个):工作总电流、工作电压
•         数字量(7个):过载、短路、绝缘故障、相不平衡、先导故障以及开停状态。
–       后刮板:(通过开关采集,包括电缆)
•         模拟量(2个):工作总电流、工作电压
•         数字量(7个):过载、短路、绝缘故障、相不平衡、先导故障以及开停状态
 
•            SAIT 10KV/3300V移动负荷中心:
–     采煤机:(通过开关采集,包括电缆)
•         模拟量(2个):工作总电流、工作电压
•         数字量(7个):过载、短路、绝缘故障、相不平衡、先导故障以及开停状态。
–     破碎机:(通过开关采集,包括电缆)
•         模拟量(2个):工作总电流、工作电压
•         数字量(7个):过载、短路、绝缘故障、相不平衡、先导故障以及开停状态。
–     转载机:(通过开关采集,包括电缆)
•         模拟量(2个):工作总电流、工作电压
•         数字量(7个):过载、短路、绝缘故障、相不平衡、先导故障以及开停状态。
–     泵站:(通过开关采集,包括电缆)
•          模拟量(2个):工作总电流、工作电压
•         数字量(7个):过载、短路、绝缘故障、相不平衡、先导故障以及开停状态
 
•         全矿井综合自动化监控单元ZM20 PLC分别与2台Allen Wester 通过BB22444 TTY(20Ma)实现通讯监测上述工矿信息;与2台SAIT的通讯,由Becker Promos 完成,在由Promos 通过FDL 传给ZM20 PLC。
•         The method adopts the communication 2 modes,for Allen Wester the ZM20 PLC connecting with them by BB22444 TTY(20Ma) directly;for SAIT,the monitoring unit ZM20 PLC connecting with Becker Promos by FDL FSK,then Becker system connecting with SAIT by their internal bus,by this way,  the whole mine comprehensive automation system  can also be monitored.
 
5、 Becker集中控制系统提供的信息:
工作面沿线急停信号(数字量25个)、DBT(PMCV)传输的信号(包括CST的信号)、冷却水流量故障(数字量6个)。电磁阀开停状态(数字量6个)。
•         The Becker system will supply signal from DBT,SAIT and itself.
 
6、 液压支架(暂缓执行)
 
全矿井综合自动化系统监测支架立柱的当前压力、初撑力、压力趋向和油缸位置(即支架立柱伸缩量),监测支架顶梁倾斜度,监测支架的位移,在地面操作站显示支架(工作面状态和操作状态,模拟压力和油缸位置)信息,实时和历史显示查询支架工作状态信息与移架轨迹。
全矿井综合自动化系统监控单元ZM20 PLC与支架 电液控制系统中的主控制单元或计算机 通过BB22444实现通讯监测上述工矿信息。
 
如果支架监测系统单独自成一体,即支架系统单独将信息采集到地面中控室计算机进行处理,则全矿井综合自动化服务器与支架计算机在地面中控室通过TCP/IP OPC或者ODBC 实现数据连接共享,将支架系统的信息集成到全矿井自动化系统中。
 
Hydraulic supportDelayed
 
The whole mine comprehensive automation system monitor the current pressure, setting load, pressure trend and oil tank position (viz. the stretching of the support column)of the support column, monitor the gradient of the top beam of the support, monitor the displacement of the support, display the support information (working face status, operation status, simulated pressure and oil tank position) on the ground operation station, locate and display the  working status information and support motion track in real-time mode and history mode.
The monitoring unit ZM20 PLC of the whole mine comprehensive automation system and the main control unit or computer of the support electro-hydraulic control system realize communication through BB22444 to monitor the mine information mentioned above, the main control units Modbus Node of the electro-hydraulic control system of the support acts as Slave.
 
If the support monitoring system forms a unique system independently, which means that the support system collects the information to the central control room on the ground for processing independently, the whole mine comprehensive automation server and the support computer realize data linkage sharing through TCP/IP OPC or Modbus in the central control room on the ground, and integrates the information of the support into the whole mine automation system.
 
建议:
为了很好而彻底地实现综放工作面自动化,塔山有必要协调工作面各个设备厂家举行一个设计方案联络会,确定工作面自动化的通讯联络接口实施。
Suggestion:
In order to realize the automation of the comprehensive caving working face totally and soundly, Tashan has the need to coordinate the equipment manufacturers of working face to hold a design scheme meeting for the implementation of the communication contact interface of working face.
 
需联络厂家:
Honeywell,
Becker,
DBT,
EICKHOFF,
AllenWester,
CCRI 天地开采所,
Hauhinco,
支架电液系统厂家
 
Manufacturers to contact:
Honeywell,
Becker,
DBT,
EICKHOFF,
AllenWester,
CCRI  Tiandi  Mining  Post,
Hauhinco,
Manufacturer of electro-hydraulic system of the support
 
 

 
 
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