As the disorderly mining, environmental destruction,vicious competition and other problems caused by small mining enterprisesbecome more and more serious, it is imperative for the sand & gravelindustry to adjust its structure by building more large-scale green mines, andthis project was rightly born at this time. Located in a city of Henanprovince, this project integrated more than ten small mining enterprises,brought in IoT intelligent technology for production and management, and hasbeen built as an intelligent sand and aggregates production line with theleading technology and scale in China. The design capacity reaches 5000 t/h. IoTintelligent designing covers the full process of crushing, screening, andconveying process, which enhances the intelligent control level of equipmentand production line, greatly reduces production cost, and obviously increasesthe economic returns. It meets the requirement of industry upgrading policy forthe local government.
Taking the features and customer demandsinto consideration, we designed six subsystems for this customer including IntelligentAutomation Control System for Equipment, Intelligent Crushing System,Intelligent Warehousing and Loading System, Video Surveillance System, “UnitoonJiZhi” Webpage, and “Unitoon JiZhi” Smartphone. Green production and industrialized managementfor sand and stone industry is realized successfully.
The IntelligentAutomation Control System for Equipment perceives information such as dischargeopening size, travel of spindle, hydraulic pressure, machine vibration, motorcurrent, bearing temperature, main shaft rotating speed, output, inventory,etc., by installing many kind of sensor devices like acceleration sensor,abrasion sensor, temperature sensor, radar etc., on multiple monitoring pointsof the main and auxiliary equipment on the production line. Then by adoptingPLC and HMI interface as main control unit, it is able to fulfill functionslike sequential start, step-down start, linkage control, self-checking, stateparameter perception, warnings and alarms, etc., for crushers, output autoweighing for conveyor equipment, automatic localization and discharging for theunloading belt conveyor, and automatic loading at the sales stage, etc. So theintelligent transformation of single machine is accomplished eventually.
IntelligentCrushing System is designed based on the intelligent automation control systemfor single machine, to realize centralized automatic control of all machinesfor primary crushing, secondary crushing and screening, as well as thereal-time monitoring on equipment running status. The main functions of thissystem includes centralized start-stop control for the production line,automatic coordination for equipment workload, parameter setting function, realtime monitoring for equipment running status, fault alarm and diagnosis, queryfor historical alarm information, etc.
The Intelligent Warehousing System controlsthe automatic loading for the unloading conveyor belt. It has functions ofautomatic loading, as well as real-time monitoring on input, output, inventory,and stock pile height, etc.
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.
This projectcovers large area and space, and the centralized control room is set up insidethe office building, therefore it is inconvenient for the operators to visuallyhave a look at the equipment outside; The workers’ uncivilized behavior andunprofessional operation is great potential safety hazard which may affectproduction operation; Meanwhile, lack of reference for production staffassessment and high management cost brought damages to the enterprisemanagement efficiency; Equipment and production line faults can’t be easilylocalized, and there is no means for accident liability investigation. To solvethese problems mentioned above, high-definition infrared cameras have beeninstalled to realize a 24-hour full-line video monitoring from crushing and screeningto the storing and truck loading area, so that the operators can monitor theproduction site visually through large screen in the control room, tofacilitate production scheduling for them, and eventually to enhance productionand management efficiency.
Customer can realize remote monitoring on productionstatus by at least two ways, i.e. “Unitoon JiZhi” Webpage version or “UnitoonJiZhi” Smartphone version.
“Unitoon JiZhi” Smartphonehas two modules. One is called “Line Status”, which displays the comprehensivestatus information for the production line. The other one is called “Equipment Status”,which displays detailed parameter data for the equipment.