Stacker, Shiploader, Hopper, Bucket Wheel Reclaimer Manufacturer
Pubdate：11-11-2024 Views：3377
Bulk materials ship loader plays a crucial role in port loading operations. These machines are typically subject to complex working conditions, involve multiple drive systems, and have large installed power capacities. Their key characteristics include complicated operational conditions, multiple drive devices, and high power requirements. The efficient operation of ship loading machines depends on advanced electronic control systems, which function as the "brain" of the machine, accurately controlling the movements of various components to ensure smooth loading operations.
The control system of a ship loading machine consists of hard-wired circuits, a PLC (Programmable Logic Controller), and communication lines. The hard-wired circuits, including relays and contactors, provide basic electrical control for the machine. The PLC serves as the core of the overall logical control, linking the machine's various components through remote stations and multiple devices, enabling precise control of all machine functions. Communication lines ensure seamless information transfer between different parts. The drive system includes protection and measurement units, AC variable frequency motors, and inverters. The protection and measurement units safeguard the machine's safe operation, while the motors and inverters supply power to the various drive mechanisms.
The ship loader has several key functions, such as the telescoping boom feature, which allows the machine to adapt to different loading distances. The pitching boom and hoist control functions adjust the loading height and angle, improving efficiency and precision. The traveling function enables the machine to move flexibly within the port, meeting different loading demands. These collaborative functions allow the shiploader to efficiently complete port loading operations. For example, ship loader machines can reach production rates of up to 6000 t/h, with some advanced machines, such as Brazil's LLX12000, achieving rated capacities of 12,000 t/h and peak production rates of 15,000 t/h, setting world records.
The shiploading machine's electronic control system employs automatic loading control technology, which automatically detects the hold position and the material distance. Advanced sensors precisely detect the location of the hold and the distance between the material and the loading machine. Based on the boom conveyor flow, the system optimizes the loading path. This control ensures even material distribution, significantly improving loading efficiency and quality while reducing the operator's workload. For instance, after adopting this automatic control technology, some large ports have seen loading efficiency increase by approximately 30%, while operators' labor intensity decreased by around 40%.
The control of boom pitching and hoist mechanisms is a key technology of the ship loader's electronic control system. The torque validation feature ensures smooth speed adjustments and stable braking of the system. This guarantees that the boom pitching, rotation, hoisting, and swinging reach precise positions. For example, the pitching angle of the boom can be controlled with an accuracy of ±0.5°, and the hoist swing position can be accurate to ±1 cm, ensuring efficient and precise loading operations.
Accurate measurement of material flow is critical to loading operations. An electronic belt scale mounted on the boom conveyor measures and records the tonnage of the material being loaded. These electronic scales are highly accurate and stable, with measurement precision up to ±0.5%. This provides reliable data for logistics management and cost accounting in ports.
The standardized software framework and modular programming in the electronic control system play a vital role. These include fault protection and shutdown programs, operational programs, speed control programs, and acceleration/deceleration control programs, all of which work together to optimize the loading process. The standardized design of these modules enhances system stability and reliability while facilitating maintenance and upgrades. For example, if a fault occurs, the fault protection program can respond quickly and stop the loading machine's operation to prevent further damage or accidents.
Comprehensive safety features are essential in the electronic control system. These include collision prevention for the boom and hoist, protection against over-tight or slack cables, limit switch protection, belt slippage and tear detection, motor overcurrent, overload, over-speed, stall protection, and oil pressure regulation. These safety measures ensure the machine operates safely, protecting both the equipment and the operators. For instance, if the belt slips, the system can detect it and take corrective action, preventing further damage and potential safety risks.
The shiploader's user-friendly HMI features an intuitive interface and intelligent fault handling and maintenance functions. It displays operational speeds, bearing temperatures, motor current/voltage, position data, and operational statistics, reducing the operator's workload and facilitating management. For example, operators can monitor the machine's status through the HMI interface, allowing them to quickly detect and address any issues, improving efficiency and safety.
The overall logical control of the ship loading machine is carried out by a PLC system. This system's efficiency is crucial for real-world operations. The PLC connection system links remote stations and several devices, employing DHRIO communication for key components such as hoists, boom pitching, boom telescoping, and traveling mechanisms, ensuring real-time data transmission to the PLC. For example, when wind speeds change, the wind speed sensor sends a signal to the PLC, which adjusts the machine's settings accordingly, ensuring safe operation under different wind conditions.
The ship loading machine communicates with the central control system through various methods, including hard-wired and fiber optic connections. This ensures the reliable transmission of interlock signals and equipment status updates, and it also allows the machine to receive instructions from the central system. The central control system assigns IP addresses, and the ship loading machine is equipped with an Ethernet switch to connect to the central PLC. This communication setup ensures stable and reliable data exchange, enabling real-time monitoring and efficient troubleshooting.
The ship loading machine uses an AC-DC-AC variable frequency power supply system for its drive system. This system is chosen due to the high power and number of electric drives in the machine. Power is centrally supplied from the electrical room to various drive systems, ensuring stable operation under different conditions and improving energy efficiency.
The drive system includes electric motors, brakes, and reducers, with the main electric motors driving the walking, hoisting, and telescoping mechanisms. Special devices, such as track clamps and anchor systems, ensure that the machine does not slide under strong winds. The walking distance is measured by a walking encoder and transmitted to the PLC.
Early ship loading machine electronic control systems used traditional relay and contactor logic circuits. While these systems met basic operational needs, they had many limitations, such as low precision and poor reliability. Over time, PLC technology was incorporated, improving control precision and system stability. Communication technologies have also advanced from wired methods to fiber optics and wireless AP, ensuring faster and more reliable information transfer.
The use of 5G technology has marked a significant breakthrough, with the National Energy Group's Huanghua Port using 5G for remote control of loading operations. Additionally, the introduction of automated monitoring and maintenance systems has further enhanced the flexibility and efficiency of ship loading operations.
With the rapid development of artificial intelligence, electronic control systems are becoming increasingly intelligent. AI algorithms can analyze operational data, predict potential faults, and adjust system parameters for optimized loading. This intelligence can enhance efficiency by 20% and reduce maintenance costs by 30%.
To meet the varied needs of different types of ships, electronic control systems will become more diversified. Different ship types, such as large ocean-going vessels or small river vessels, require specialized systems to achieve optimal performance.
With increasing demands for fuel efficiency and emission control, electronic control systems are evolving to improve performance. Advanced sensors and control algorithms will optimize fuel usage and reduce emissions, potentially increasing fuel efficiency by 15% and reducing emissions by 20%.
