Background description
Gansu Qilianshan Cement Group Co., Ltd. Gulang Qilianshan Cement Plant has an annual output of 1 million tons of cement. There are a total of 4 stackers and reclaimers in the stackers and blankers in the roundhouse plant and in the long stack. It is an important task to store and transport raw materials. The signal communication between the stacker-reclaimer and the central control room has previously been carried out using trolley wire transmission, ie, wired transmission.
Xi'an Da Tai Electronics Co., Ltd.
Roundhouse Factory Exterior â–¼
Long stack factory location â–¼
cause problems
Wired transmission generally uses multi-core communication cables, cable reels, or trolley wires. The torque motor equipped with cable reel is easy to damage; the communication cable has low tensile strength and is easy to pull off; the contact of the trolley line belongs to contact communication, and the year-round operation of the stacker-reclaimer causes uneven subsidence of the track foundation, and the track installation is not straight. Sliding line with the belt machine frame vibration, as well as slip line installation error and other reasons, making the trolley line twisted and deformed; collector bracket deformation, the collector off, resulting in carbon brush and slippery contact often bad; automatic linkage signal In the off-hours, the ground control is out of order; often the ground belt and the stacker-reclaimer interlock signal is interrupted, and only the operator can manually stop the machine. If the operation time is too short, it may cause problems such as belt pressing and burning of the motor. The fault cannot be fed back to the DCS and the interlocked equipment in a timely manner. When it is serious, it causes casualties or major property damage, which seriously affects normal production. According to statistics, the failure rate of the trolley line accounts for 70% of the total failure of the stacker-reclaimer, which has become a bottleneck restricting the normal operation of the stacker and reclaimer.
Since the cable needs to be replaced every six months, the high maintenance cost allows users to finally decide to use wireless to complete the communication.
Xi'an Da Tai Electronics Co., Ltd.
User needs
The main control signals in the communication between the stacker and reclaimer and the central control room DCS system in the production of round stack plants and long stack plants (the central control of the stacker, reclaimer, and emergency stop, etc.) are all from the original Wired control changed to wireless control.
Round Stacker Reclaimer Console â–¼
Working status of stacker and reclaimer in long stack â–¼
Wireless communication scheme implementation
Xi'an Da Tai Electronics Co., Ltd.
※ Wireless communication between round stack plant and central control room
The DCS system in the central control room 200 meters away from the round stack plant needs to control the starting and stopping of the stacker-reclaimer in the factory, and the 16-way switch signals such as the start and stop of the discharging belt and the feeding belt.
Wireless Solution and Reality Maps â–¼
※ Wireless communication in long stack building
The length of the long stack building is about 300 meters long and there are two tracks. Between the rails there are high accumulations of coal powder and clay. There are 2 reclaimers on the same side and 1 stacker on the other. What needs to be completed here is that the three machines and their corresponding control cabinet DCS system perform two-way switching signal communication. At the same time, the stacker also needs to control the operation of the two reclaimers to ensure that the materials in the long stack can be stored and transported in an orderly manner.
Xi'an Da Tai Electronics Co., Ltd.
Wireless Solution and Reality Maps â–¼
Why use wireless?
Wired Solutions VS Wireless Solutions
1. Serious cable wear? Wireless transmission without cable
2. Does the device need frequent maintenance? No maintenance, lifetime maintenance
3. The cost of replacing cables is high? Industrial site used more than eight years without replacement
4. What is the power consumption? 10W power, energy saving and environmental protection
5. Replacement delay time? Easy to install, no need to change the original program
6. Dust dust causes unstable signal? 15 years of industrial wireless communication terminal
Xi'an Da Tai Electronics Co., Ltd.
Emergency call
After the wireless signal transmission module is installed, frequent alarms occur in the working status of the stacker and the reclaimer in the long stack, so that the stacker and the reclaimer cannot work normally. After receiving the news, the PLC wireless communication expert team dispatched two technicians, who rushed to the site to give technical support.
Through on-site inspections and repeated tests, it was confirmed that the equipment system caused interference. After the problem was discovered, the technician added our special accessories and the reclaimer finally worked properly. After one more day of observation, it was ensured that all three equipments were operating normally and the technicians left the site with peace of mind.
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