Located in Hukou County, Jiujiang city ofJiangxi province, this project is a large-scale sand & aggregates crushingand screening plant for construction use. With design capacity of 2000 t/h, itranks among the top plants in China in aspects of capacity and equipment level.With the help of IoT intelligent system, this project integrates new informationtechnology with traditional crushing equipment and aggregates production. Differentfrom traditional production management mode, it develops in direction of “Intelligent,Transparent, and Energy-efficient”. The application of IoT remote monitoringsystem greatly improved management level for the enterprise and actualproduction efficiency, which promoted the industry progress as well, and set upa new benchmark for the industry. This project is a model for combination of high-techand traditional industry.
Sketch for Production Line
Based on customer’s demand and specific conditionsof this project, we designed nine subsystems for the customer, including IntelligentAutomation Control System for Equipment, Intelligent Crushing System, IntelligentWarehousing System, Intelligent Loading System, Video Surveillance System, “UnitoonJiZhi” Webpage, “Unitoon JiZhi” Television, “Unitoon JiZhi” Smartphone, and IntelligentBig Data Service System. As a result of intelligent information gathering of singleequipment to intelligent control and monitoring of the whole production line, andthe local automatic control to remote real-time monitoring and big dataanalysis, this production line realized its transformation of “IoT +Mining”, andthanks to which the comprehensive income and management level of the productionline was greatly increased.
1. Intelligent Automation Control System for Equipment
The IntelligentAutomation Control System for Equipment perceives information such as dischargeopening size, machine vibration, motor current, liner plate abrasion, bearingtemperature, main shaft rotating speed, output, inventory, etc., by installing manykind of sensor devices like acceleration sensor, abrasion sensor, temperaturesensor etc., on multiple monitoring points of the main and auxiliary equipmenton the production line. Then by adopting PLC and HMI interface as main control unit,it is able to fulfill functions like sequential start, step-down start, linkagecontrol, self-checking, state parameter perception, warnings and alarms, etc.,for crushers, output auto weighing for conveyor equipment, automatic localizationand discharging for the unloading belt conveyor, and automatic loading at thesales stage, etc. So the intelligent transformation of single machine isaccomplished eventually.
2. Intelligent Crushing System
IntelligentCrushing System is one part of the Intelligent Distributed Control System andit is designed based on the Intelligent Automation Control System for SingleEquipment. According to production environment on site, the complete crushingand screening plant can be divided into three sections. Therefore, the distributedautomatic control part of this system is also divided into three parts, too.The front part controls primary crushing, the middle part controls finecrushing, and the rear part controls product screening.
The mainfunctions of this system includes centralized start-stop control for the productionline, automatic coordination for equipment workload, parameter settingfunction, real time monitoring for equipment running status, fault alarm anddiagnosis, query for historical alarm information, etc.
3. Intelligent Warehousing System
The Intelligent Warehousing System controls the automatic loadingfor the unloading conveyor belt. It has functions of automatic loading, as wellas real-time monitoring on input, output, inventory, and stock pile height,etc.
4. Intelligent Loading System
The intelligent Loading System controlsautomatic loading at the sales stage. Ithas functions of auto loading, auto metering, inventory monitoring forwarehouse, arc door status monitoring for stock bin, query for sales records,etc.
5. Video Surveillance System
Full-line Video Surveillance System is designedto achieve visual monitoring of production line. Two cameras monitor thefeeding of two jaw crushers; one camera monitors intermediate hopper; onecamera monitors the discharging of impact crusher; one camera monitors the controlroom; two cameras monitor the finished product bins; eight cameras monitoreight loading systems respectively; In other places cameras are installed every60-80M to achieve a full-line video coverage. Inside the control room, theoperator can monitor the production situations and equipment running status ofoverall production line outside visually through the big led screen.
6. “UnitoonJiZhi” Webpage
The data collected on production site are transmitted in real time to cloud serviceplatform via self-developed remote monitoring device. Data will be edited andcalculated there and then information will be sent to all kinds of terminalscreens. In this project, the customer can realize IoT remote monitoring oftheir production line by three ways, i.e. “Unitoon JiZhi” Webpage, “UnitoonJiZhi” Television, or “Unitoon JiZhi” Smartphone.
“Unitoon JiZhi” Webpage version carries the mostdetailed information about the production line, including line configuration, outputfor each kind of finished products counted by month/day/shift, parameter datafor equipment status, early warnings and alarm information, warehouse storage, truckloading and unloading information, live videos, etc. Meanwhile, the data aredivided into two types, which are the real-time dynamic data and historical statisticdata, so as to provide detailed and diverse data support for the productionmanagers.
7. “Unitoon JiZhi” Television
8. “Unitoon JiZhi” Smartphone
The “UnitoonJiZhi” Smartphone App, has two modules. One is called “Line Status”, whichdisplays the comprehensive information for the complete production line. Theother is called “Equipment Status”, which displays the detailed statusinformation of all main and auxiliary equipment included in production line.Both modules are divided into real-time data interface and historical datainterface: The real-time data interface displays the dynamic data of the day inreal time; and the historical data interface supports historical data statisticsand data analysis by day, week, or month.
By the means of“UnitoonJiZhi” Webpage，“Unitoon JiZhi” Television, or“Unitoon JiZhi” Smartphone mentioned above, the mine owners andproduction managers can monitor their production line anytime and anywhereconveniently, in office, at home or on the trip. No matter where they are.
9. Intelligent Big Data Service System
Massive dynamic and historical data that hasbeen collected previously, can be analyzed by new information systems, tools,and models, to excavate optimized operation mode for single machine, or bestconfiguration scheme for a production line etc., to increase production efficiency,improve production management level, and promote decision-making efficiency.