全自动装车系统的研究应用

Research and application of fully automated loading system

神东煤炭集团洗选中心现有10座选煤厂采用快速装车系统,年装车量约2亿t。快速装车系统装车效率高,但自动化程度相对较低,工作量大,主观因素造成的煤炭浪费现象严重,影响装车速度和精度。针对以上问题,笔者通过可编程控制技术原理与传感器的应用,对原有快速装车系统进行升级改造,自行研发了一套新型全自动装车系统。具体措施为在装车站一定位置增设雷达测速传感器和光电传感器,分别检测火车的实时装车速度和火车车厢运行位置,利用可编程控制技术自动调节装车系统定量仓液压闸板放煤的开启时间点,进而实现全自动装车。通过以上技术措施,装车系统的装车精度已提升到99%以上,适应了不同车型的全自动装车。全自动装车系统的应用释放了装车员80%的劳动力,降低了选煤厂装车成本,可节约因装车溜槽与车辆碰撞产生的维修费、劳务用工费用、劳务装车质量差、超偏载等问题造成的经济损失共计约1500万元/a。提高了装车量控制精度,杜绝了不规范操作造成的装车质量差,超、偏载等问题,保证了系统的稳定性和安全性。

Allthe 11 coal preparation plants of Shendong Coal Group Washing Center adopt the fast loading system with the annual loading capacity about 200 million tons.The rapid loading system has high loading efficiency,but the degree of automation is relatively low,the workload is large,and the waste of coal caused by subjective factors is serious,which affects the speed and accuracy of loading.In view of the above problems,the original rapid loading system was upgraded through the principle of programmable control technology and the application of sensors,and a new automatic loading system was developed.The specific measures were to add radar speed sensor and photoelectric sensor at a certain position of the loading station,the real-time loading speed of the train and the running position of the train were detected,respectively,and the programmable control technology was used to automatically adjust the opening time of the coal loading system point,so as to achieve fully automatic loading.Through the above technical measures,the loading accuracy of the loading system has been increased to over 99%,which is adapted to the automatic loading of different models.80%of the labor of the loader is released by application of the fully automatic loading system,which reduces the loading cost of the coal preparation plant and saves about 15 million yuan/a of the economic losses caused by the problems such as maintenance costs,labor costs,overload and unbalanced load and labor loading quality caused by the collision between the loading chute and the vehicle.The accuracy of loading quantity control is improved,and the problem of poor loading quality,super and partial load caused by irregular operation is eliminated,and the stability and safety of the system are ensured.