Automatic Control of Supplying the Uninterrupted Action Loading Machine at Casual Outside Influence Academic research paper on "Economics and business"

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Engineering

Procedía Engineering 129 (2015) 274 - 279

www.elsevier.com/locate/procedia

International Conference on Industrial Engineering

Automatic control of supplying the uninterrupted action loading machine at casual outside influence

Khazanovich G.S.a, Otrokov A. V.a,*> Breusov A.N.a

a Shakhty institute (branch) of Platov South-Russian state polytechnic university (NPI), 1, Lenin Square, Shakhty, Rostov region, Russia Abstract

The condition of the loading process research, working out the principles and installations of automatic control of supplying the loading machines with grabbing claws is considered. The experience of application of discrete control system with regulated upper and lower levels of turning in the adjusters of loading the grabbing part engines is based. The task of automatic control providing, with the consideration of occasional character of forming the load with the grabbing claws, the achievement of maximum productivity at keeping power and energy limits, is formulated. The necessary mathematical models and control algorithms, the peculiarity of which is preliminary modeling of the process, putting the results into the system of microprocessing control and consideration of deviations from the standard variant, are worked out. Using the offered system provides with the productivity increase up to 15 %, increasing the reliability and reducing labour capacity in the machine control.

© 2015 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.Org/licenses/by-nc-nd/4.0/).

Peer-review under responsibility of the organizing committee of the International Conference on Industrial Engineering (ICIE-2015)

Keywords: loading machine of uninterrupted action; productivity of the machine; automatic supply to the pile; mechatronic system of control; occasional character of loading to the drive; maximum frequency of the drive switching on; sensors of the main parameters; defence from overloading; turning in the adjuster of current level; control algorithm.

1. Introduction

Loading machine with grabbing claws was patented for the first time by Joseph Joy in 1916. The unique trajectory of the claws movement became the standard in the branch and is used at underground loading macines, and cutting combines all over the world. The machines of 2PNB-2 type produced in Russia are the greatest part of the loading machines parks at the Eastern Donetsk Basin mines. They are equipped with twin grabbing claws and, in

* Corresponding author. Tel.: +7-918-509-03-07; fax: +7-8636-22-30-88.

E-mail address: oav711@gmail.com

1877-7058 © 2015 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

Peer-review under responsibility of the organizing committee of the International Conference on Industrial Engineering (ICIE-2015) doi: 10.1016/j .proeng.2015. 12.048

spite of their having been industrially produced, are hand-operated. Casual character of forming loads to the drive of grabbing claws mechanism owing to non-homogeneous characteristics of the pile material and changing conditions of forming the volumes of grabbing the material with the claws makes impossible to use the machine resources completely even at the considerable experiences of the operator. In consequence of it the problem of creating an automatic equipment which would give the possibility to increase the reliability and efficiency of the machine in the whole and decrease the labour capacity of the loading process for the operator is quite actual.

2. Short history of working out the system of controlling supply

The collective bodies of scientists of the Novocherkassk polytechnical institute (now Platov South-Russian state polytechnic university (NPI)) [ 1, 2], the Communarsk mining metallurgical institute (the town of Altchevsk, Ukrainian SSR) [3], the institute of geotechnical mechanics of the Academy of Science of the Ukrainian SSR (the city of Dnepropetrovsk) [4], as well as the Copeisk and Yasnogorsk plants producing the machines of this type had been going in for working out the systems of the automatic control of the loading machines of the PNB type during the last 50 years.

The main problem is the principle of the supply control which is determined with physics of the process of interaction of grabbing claws with the pile. The two conceptions are based: 1) the velocity of automatic supply should change smoothly into the functions of loading in the drive of the grabbing part [1]; 2) interrupted supply of the machine the beginning and ending of the cycle of which depend on the level of load in the drive [2]. Among the realized in the experimental and tested models there were machines with a regulated drive of direct current [3], double-differential hydrodrive [1], asynchronous drive with relay-controlled and impulsive regulators [2, 5]. Produced by the Copeisk machine building plant the machine 1PNB-2D with relay-controlled regulator of supplying passed industrial test successfully [2, 5], other models were tested in stand conditions.

3. Peculiarities of the loading machine interaction with the mining mass pile

Working out the system of automatic control of supplying the loading machine should be based on the results of the analysis of interactions in the system of "the pile - loading organ - travelling part - drive - control system".

The conclusions about the interaction of the pile and the loading organ of the machine with grabbing claws are based both on the materials of the preceding research [6-8] including the loading organs with grabbing spiders having the similar regularities [9, 10], and on the results of computer and physical modeling conducted in the mechatronic system of automatic control [1-4, 11, 12]. The interaction of the control system and the loading machines is reflected in the works [13-15], the influence of casual processes at loading large lumps material is reflected in the works [16, 17].

As the preceding investigations showed, at loading the pile of large lumps rock of more than 0.5 m high, discrete supplying control (i.e. the cycle of supplying should include 2-4 scooping) is the most effective. However, unlike the previously created relay regulator [3], for the concrete conditions automatic choice of regulating parameters should be realized, i.e. the upper Ju and lower Ji levels of turning in the adjusters of loading in dependence on the current load to the drive of the aggregate of limitations. When the loading reaches the meaning Ju, the supplying stops, when the loading reaches the meaning Jl, the supplying renews. Besides, on the previous investigations casual character of forming loads is not considered, but it is especially essential at loading large lump material.

Load M to the claws, and therefore the current of engines of the grabbing part in the period of every disc rotation is the separate realization of the casual function M from corner of turning the driving crank p. Moreover, the considered casual functionM= f(p) has a number of peculiarities:

• mathematical expectation and correlative function at changing the corner of turning 0 < p < 2n do not stay

constant but consist conditionally of four parts - inculcation of the claw into the pile, scooping the portion of the

material, pushing the portion of the material into the conveyer and idle running;

• in the process of loading the machine and the loading organ installed on it are in two conditions:

• immovable - with working some quantity of scooping;

• supplying - moving the machine to the pile. In each of these conditions some conditional depth of inculcation and the volume of the material in the active zone is realized, that is why the characteristics of the

casual function will also be changed not only because of angle of turning the driving crank, but also because of the place of the loading organ concerning the pile; • distribution of the mining mass lump in the zone of grabbing claws plays an important role at forming every realization of the casual function M = f(^). This function is also unstable and is dependent on the pile loading out the machine approaching to the face, large size of the lumps is increased.

The enumerated factors and peculiarities of forming casual load at the entrance to the system of dripping of the loading organ should be taken into consideration at working out the principles of creating automatic control of moving the machine to the pile.

4. The control object construction and structure

The loading machine consists of a loading organ, receiving-transmitting conveyor, moving part, electro- and hydroequipment. The loading organ situated on the front part of the machine is rigidly connected with the receiving part of the conveyor. In modern machines of PNB type drives of the main parts are fulfilled according to the individual scheme. Grabbing claws are moved from two electrical engines via the mechanical reducing gears connected with synchronizing shaft or a gear. The grabbing claws movement trajectory is provided by crank-level or crank-link mechanisms the leading parts of with qre driving discs with eccentrically situated fingers. The scraper receiving-transmitting conveyor has an immovable and manipulation parts. The last serves for loading the following transport means. The running part is usually of a caterpillar type and consists of two bogies with group drive. Every caterpillar bogie has independent turning on and turning off via a multidisc clutch controlled from the valuable hydrodrive with the help of electrohydrovalve. The grabbing claws move uninterruptedly, and the operator's task is to form the maximum volume of the material moving the machint to the pile. The peculiarities of the process of controlling the loading machine are (Fig. 1):

• the machine is given only forward to the pile;

• making the decision on turning on the supply is realized after finishing the next in turn cycle of scooping the materials with the claws;

• the end of giving the machine is realized according to the condition of forming on the feeder the most permissible volume of the material for the load on the drive of the grabbing claws, it results in the maximum productivity of loading.

Control panel

Operator T Automatic control system

Information about the state of loader and pile of rot k

r: o o

=|> Data ~ ■ Interaction of the components of the system Control signals System components

Fig. 1. Structural-functional scheme of the loading machine 2PNB-2.

5. The main task of controlling

The purpose of creating mechatronic system of automatic control of supply is reaching the maximum possible value of average productivity of the loading machine at loading out the volume of a pile between two next in turn cycles of maneuverings considering the maximum power, energy possibilities of the machine, fulfilling the demands of reliability and safety, considering the following limitation:

• equivalent power of drives of grabbing and running parts should not exceed the permissible meaning;

• frequency of turning on the supplying mechanism should not exceed the maximum permissible meaning;

• pressure effort of the running part should be in permissible limits with consideration of the factors of adhesion of caterpillar with the ground and the power of running drive.

These limitations should be kept in the concrete conditions of work of the loading machine: the angle of inclination of the underground working, hardness, coarseness and humidity of the mining mass being loaded, the pile high.

An addition the demands of adaptivity are made to the system of automatic control, i.e. self-turning for the optimal meaning of lower and upper levels of turning in the adjusters of loading in the adjusters of loading in dependence on the conditions of work of the loading machine.

6. Mathematical model and algorithm

Mathematical model of control is the combination of mathematical correlations and algorithm of microcontroller actions with the help of which, after finishing every complete revolving of the leading disks, the forming of controlling signal of "turning on / turning off electrohydrovalve of the running mechanism" with the purpose of reaching the maximum meaning of the average productivity of the loading organ takes place.

Analytical function for the purpose can be written as [16]:

-q--j^ %dt ^ max (1)

T1 + T2

where q0 - normative productivity;

Tj - time of giving the machine to the mining mass pile;

T2 - time of loading of the rock mass during stationary feeder;

X - coefficient of productivity (% = qmin / qmax).

With the consideration of the peculiarities of physical phenomena of mining mass loading by twins grabbing claws it is established that the automatic system of controlling the supply of the loading machine of uninterrupted action is mainly reduced to discrete acts of comparison and correcting the meanings of the levels of turning in the adjusters of upper Ju and lower Ji after each next in turn scooping. Comparison is fulfilled by confronting "standard" and actual processes pf forming the loading organ productivity and loading the engines of grabbing part with the consideration of fulfilling the combination of limitations.

For modeling on a computer the standard coming of the working process of loading mathematical models received as a result of complex experimental investigations on physical models and natural samples are used:

• of a grab volume in a single scooping;

• the volume of the material on the active zone;

• calculated depth of penetrating after finishing next in turn scooping;

• maximum depth pf penetration of the nose of the plate restricted by the pressure effort on linking the caterpillar with the ground;

• resistance to penetration of the inclined plate into the pile;

• mathematical expectations of a casual function of the moment on the shaft of the leading disk (on phases of the claw movement, from the depth pf penetration and other factors);

• forming the frequency-response component of casual function of the moment on the shaft of the leading disk — spectrum density;

• electromechanical characteristic of the grabbing part drive;

• mathematical models of limitation:

• on power of drive of the loading process and breaking for the maneuvering;

• on maximum loading with consideration of casual character of the process and the velocity of increasing the signal;

• on the frequency of turning on the frictional clutch and electrohydrovalve with the considerable of heating the construction.

Using the results of preliminary modeling gives the possibility to prognose with the necessary the character of changing the load, its value for scooping. The analysis of changing the main coefficients — productivity, the level and character of loading the drive of the grabbing part (according to the value of mathematical expectation, spectral density of the load, availability of throwing out behind the upper level of forming in the adjuster), active volume of the pile and others — give the possibility to choose optimal algorithm of control, i.e. to turn in the adjusters of upper and lower levels and to choose the algorithm of their changing in such a way to provide the maximum meaning of the function in purpose with keeping all the restrictions.

The system offered for correcting and turning in the adjusters of loading levels is used the measurement of deviation of the four main indexes: productivity, the engine temperature, the engine current frequency of turning on the mechanism of supplying. As for every measured index there are two possible variants of correlations demanded and real indexes: productivity, the engine temperature, the engine current, frequency of turning on the mechanism of supplying. As for the every measured index there are two possible variants of correlations demanded and real indexes: the first one - derivation is in the normal limits, the second one - the derivation increases the adopted value, we receive 16 possible variants of the system state, the program action of microprocessor controlling system on changing the level of turning in the adjusters in the next in turn cycle of scooping corresponds to each of them.

7. Short conclusions

• The task of automatic controlling the process of loading by the machine with grabbing claws is formulated.

• Mathematical models and algorithms of searching maximum productivity of the loading machine with consideration of casual character of the process of loading.

• Computer modeling has demonstrated the possibility of automatic controlling the process of loading and shown the possibility of increasing the productivity for 5 - 15 %, the reserve on the frequency of supplying being 5 - 10 %, in heating the engines of the grabbing part being 10 - 20 % in comparison with manual control of loading.

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