Abstract : A fault diagnosis system for mine hoists was developed using 3D force control configuration software. Its human-machine interface (HMI) is separated from process data processing, and it features a built-in independent real-time historical database, powerful distributed alarms, and event handling, improving system development efficiency and enabling more timely and accurate fault detection, thus ensuring the reliable and accurate operation of the mine hoist. Debugging and operational results demonstrate that the system is reliable, has high control precision, and fully meets the requirements of on-site production operation.
Keywords : mine hoist; fault diagnosis; configuration software
1 Introduction
Mine hoists, as typical integrated mechanical and electrical equipment, occupy a crucial position in the entire automated production system and are often referred to as the "throat of the mine." Generally, the main shaft hoist is responsible for hoisting useful minerals mined underground, while the auxiliary shaft hoist is responsible for lowering materials, raising and lowering personnel and equipment. Given the unique working environment of coal mines, a malfunction in a mine hoist can cause incalculable economic losses and personnel casualties. Therefore, this paper, based on the actual needs of coal mines, uses configuration software to establish a mine hoist fault diagnosis system.
Conducting research on hoist fault diagnosis will greatly improve the safety and reliability of equipment operation. The intelligent fault diagnosis and prediction system for hoists obtains real-time data on the current operation of the equipment, accumulates historical trend data, and analyzes and processes the data and signals to identify the types, causes, and severity of equipment faults. It saves fault data and performs accident replay, striving to improve the economic performance of the equipment, avoid sudden accidents, and reduce unnecessary losses, providing strong support for the safe, efficient, and economical operation of coal mine equipment. Therefore, the application of equipment fault diagnosis technology in coal mines is of great significance.
2. Introduction to ForceControl Configuration Software
Beijing Sanweili Control Technology Co., Ltd. is a high-tech enterprise specializing in the research and development and service of monitoring configuration software. Its core software products were first developed in 1992. Driven by independent innovation, the company has gradually established its leading position in the domestic market.
ForceControl configuration software is a specialized software for collecting and controlling on-site production data. Its biggest feature is that it can integrate systems through flexible and diverse "configuration methods" rather than programming methods. It provides a user-friendly development interface and simple engineering implementation methods. By simply "configuring" its various pre-set software modules, the various functions of the monitoring layer can be easily implemented and completed, shortening the system integration time for automation engineers and greatly improving integration efficiency.
3. Diagnostic System Design
The entire diagnostic system is divided into five functional modules: system management, real-time monitoring, print query, alarm, and fault diagnosis, as shown in Figure 1. It primarily monitors the operating conditions of the hoisting system's production process, the safety braking system, and the shaft signaling system. It features event and fault diagnosis alarms, parameter display, and report statistics, guiding operators in operation and maintenance, and helping to diagnose and handle faults. This plays a crucial role in improving system safety, reliability, and hoist operating efficiency.
Figure 1. Monitoring System Structure
When designing the interface, it's essential to consider factors such as visibility, user-friendliness, and the likelihood of accidental operation. The main interface should comprehensively display all system information for easy navigation. This system, integrated with the on-site process flow, primarily features the following interfaces: system startup interface, running interface, manual operation interface, process flow interface, historical curve interface, and report system interface.
4. Generation of trend curves and reports
4.1 Trend Curve
After processing, the data collected by ForceControl on-site is stored, displayed, and analyzed according to real-time and historical data. In the ForceControl toolset, in addition to displaying data in window screens and reports, ForceControl also provides a variety of powerful curve components to analyze and display the data.
These tools allow for the analysis and comparison of current real-time data and stored historical data. They can capture instantaneous process states, zoom in on curves for detailed analysis of process conditions, and compare the functional relationships between two process quantities. ForceControl analysis curves support distributed data logging systems, allowing the analysis and display of various real-time and historical data from other network nodes from any network node. The analysis curves offer rich attribute methods and a user-friendly interface. General users can manipulate the curves using various configuration interfaces, while advanced users can flexibly control the analysis curves using the provided attribute methods for more complex and flexible applications. ForceControl provides two types of trend curves: real-time trend and historical trend. (See Figure 2.)
4.2 Expert Reports
Expert Reports offers spreadsheet-like functionality similar to Excel, enabling more complex report formats. Its purpose is to provide a convenient, flexible, and efficient report design system.
Expert reports are primarily applicable to the field of industrial automation, providing an ideal solution for addressing issues related to chart and report display, input, and printing output during practical development. Using expert reports can significantly reduce report development workload, improve the human-machine interface, and increase configuration efficiency. The operational effect of this system is shown in Figure 3:
5. Conclusion
A mine hoist fault diagnosis system was developed using a real mine hoist experimental setup. The system has been debugged and is operating normally. The temperature and vibration signals of the motor are transmitted to the monitoring interface in real time, meeting the needs of hoist equipment testing. The monitoring interface can also display real-time curves of monitoring signals, event logs, and alarm information, allowing for observation of the hoist's operation and prevention of potential malfunctions, effectively preventing safety accidents caused by hoist failures.
References
[1] Ma Guohua. Monitoring Configuration Software and Its Applications [M]. Beijing: Tsinghua University Press, 2001.
[2] Gong Yunxin, Fang Liyou, eds. Practical Technology of Industrial Configuration Software [M]. Beijing: Tsinghua University Press, 2005.
[3] Xia Zhanguo, Niu Qiang, Zhang Lei, et al. Fault diagnosis system for mine hoists based on FTA [J]. Microcomputer Information, 2008, 24(5-1):160-162.
