Application of zjm R4000 module in automatic contr

Application of JM R4000 module in automatic control of cement plant

in recent years, with the development of computer technology, computer technology has been widely used in the production process of cement industry. At present, many large and medium-sized cement production lines built or reconstructed have adopted DCS system, but many small and medium-sized cement enterprises are still in the stage of relatively lagging behind in the level of automation, still using traditional instruments and even relying on manual monitoring. This is an unfavorable factor for improving product quality and output, saving energy and reducing consumption, and strengthening the competitiveness of enterprises. The cost of large-scale DCS system is relatively high, and the technical transformation of general enterprises is also unacceptable. To solve these problems, we developed and designed a low-cost DCS system, which was implemented in a cement company

due to the poor on-site environment of the company, in addition to high temperature and dust, a large number of frequency converters are used, which makes electromagnetic interference more serious. Moreover, in the process of cement production, the process detection points are very scattered, and the wiring cost and work intensity are very high. Therefore, based on the principle of high performance price ratio, after investigation and selection, we selected R4000 series remote data modules, industrial computers and corresponding i/o equipment to complete

I. system composition

the system is divided into five functional subsystems according to the requirements of cement production process:

1. Raw mill monitoring and management system

2. Shaft kiln calcination process monitoring and management system:

3. Cement mill monitoring and management system

4. Rotary kiln monitoring and management system

5. Power distribution equipment operation and power consumption monitoring management system

both the raw mill subsystem and the cement mill subsystem can realize the automatic startup and shutdown of the whole line, and monitor and manage the temperature and current of the bearing oil supply system and main equipment of the mill. The optimization calculation and adjustment are carried out according to the changes of various parameters. The shaft kiln subsystem includes equipment start-up and stop monitoring of the shaft kiln production line, automatic water adding and pelletizing of raw materials, automatic correction of partial fire, intelligent control of shaft kiln forging and burning process, etc. The rotary kiln subsystem realizes the interlocking control of wet mill and coal mill. At the same time, the equipment, output and energy consumption of the rotary kiln production line are monitored, and some of them realize automatic control. The electronic distribution system mainly monitors and records the operation of transformers and main engines in the power distribution rooms of the whole site. All subsystems are connected with the existing management network of the company through Ethernet, and the data is sorted and placed on the for the management department of the company to call

II. Subsystem composition

for simplicity, we will only take the shaft kiln system as an example

1. Principle of shaft kiln subsystem

the shaft kiln subsystem is divided into three levels: workshop management level, workshop central control room and workshop site level. They are connected through s-485 bus, and r4018, r4015, r4050, r4021, r4041 and other modules are responsible for collecting the process parameters of the shaft kiln system. The automatic controller of raw material balling is composed of computer, r4016, r4080, r4021 and other data i/o modules, strain gauge, flow sensor and frequency converter. Through the tracking and adjustment of feed water, the balling is kept in a stable range. The automatic measurement of clinker is composed of computer, r4016 module, strain gauge and SRR. The hourly output of the kiln is calculated according to the flow value of clinker out of the kiln

the industrial computer in the workshop control room mainly completes the optimization calculation, display, automatic analysis, storage and control strategy of the whole system data. The personnel in the central control room can make adjustment instructions according to these information and the actual situation, and the industrial computer sends them to the lower output module to control the action of the actuator. The industrial computer at the workshop management level calculates, displays, analyzes and stores the data, and calculates the control qualification rate of each process parameter according to the assessment requirements as the basis for award calculation

2. System software: due to the complex requirements of the system, it requires not only a good human-machine interface, but also real-time monitoring and control, so we use Visual Basic aero-engine on the industrial computer. The strong demand for high damage tolerance composites leads to the further development of composite technology, C 6.0 to write control software, The software includes system management module, process flow diagram simulation display module, instrument panel simulation display module, database management module, data communication module, control algorithm module, etc. we use a lot of ActiveX control technology in the programming process, which greatly shortens the development cycle

3. Operation effect and experience

after the installation and use of the automatic control system, the ball forming qualification rate is improved, and the materials entering and leaving the kiln tend to be balanced, which ensures the stability of the thermal system of the shaft kiln, greatly improves the clinker production and quality, and the system basically has no faults

III. conclusion:

because the Jiemai R4000 series module adopts RS-485 mode of communication, it can communicate long distance, and all modules of the system can be connected with only one communication line. Its high communication rate, high sampling resolution, intelligence, photoelectric isolation, strong anti-interference and double watchdog design make the system highly reliable, high-speed data i/o possible, and software development easier. Moreover, the host uses RS-232 communication port to connect with the geometric coaxiality network of the experimental machine detected in the above methods (1) - (4). Basically, any computer with RS-2 supply side structural reform 32 communication port can use this network, which makes the interchangeability of the equipment good, and the work difficulty and workload of maintenance personnel are also very small. The use of JM R4000 module group meets the production process requirements and the principle of high performance price ratio, and also brings the company's automation control and management level to a new level