Swirl Well Fully Automatic Slag Removal Unmanned Crane Control System

Based on the PLC as the control core, the unmanned driving system realizes automatic control through 3D laser sensors, frequency converters, and various detection components, realizes monitoring and operation through upper computer management software, and realizes communication with driving vehicles through wireless communication equipment. The fully automatic control of the slag-grabbing crane is realized, and the slag-grabbing of the whole pool is completed independently by the crane without personnel participation. When there are many vehicles and many slag pools, remote centralized and unified control can be realized.

Application scenarios such as unmanned driving in ironmaking slag pools, unmanned driving in power plant sewage slag pools, and unmanned driving in swirl well slag pools.

 

Unmanned Crane

 

Industry Background

Hydrocyclone is a vortex-type sedimentation tank widely used in the metallurgical industry to recover the iron oxide scale and recycle water. Cleaning iron oxide scale in hydrocyclones has always been a bottleneck that restricts production. Typically, the iron oxide scale that accumulates at the bottom of the hydrocyclone is grabbed out by a slag grabber after a certain period and returned to the steelmaking process for recycling. To ensure the hydrocyclone operates normally, regular slag-grabbing operations are necessary. These operations usually involve manually operating single-girder bridge cranes and grabs, leading to simple repetitive tasks and low labour efficiency. To improve labour efficiency and meet the requirements of intelligent manufacturing in the steel industry, automating these repetitive tasks is essential.

The fully automatic slag-grabbing unmanned crane system for hydrocyclones achieves automatic alignment of vehicle operations, detection of position drop offsets, interlocking of lifting actions, computer management of production processes, and ultimately unmanned driving. This automation is crucial for the safety production in steel plants, enhancing production management, improving product quality, and increasing economic benefits.

 

System Function Introduction

1. Retrofit Existing Crane:

Based on the existing crane, the retrofit enables the unmanned crane system to automatically complete tasks from grabbing slag from the slag pool to the slag heap yard or from the slag heap yard to the slag transport vehicle.

2. Real-Time 3D Hook Position Detection:

The system detects the three-dimensional position of the crane hook in real-time and monitors the operational status of the crane. It features anti-sway functionality, with an overall solution that effectively eliminates 90% of swings, ensuring that the four ropes remain evenly stressed when the grab closes.

3. Visual Online Hook Tracking:

The system tracks the hook status visually and determines the hook drop position in real-time, allowing the system to traverse the entire hydrocyclone, enabling the crane to grab materials along the edges while protecting the grab and the walls.

4. Display and Monitor Work Instructions:

Work instructions are displayed on the crane, and their execution is monitored.

5. Restricted Area Avoidance:

Based on the target position of the work instructions, the current crane location, and the slag level data of the storage yard, the system automatically calculates the optimal path for the crane to avoid restricted areas.

6. Dual-Signal Dual-Detection Dual-Correction Design:

The unmanned crane is designed with a “dual-signal, dual-detection, dual-correction” principle for safety, featuring automatic cruising, centralized vehicle control, remote monitoring, video linkage, automatic deviation correction, and safe path functionalities. It aims to achieve “unmanned operation with supervised monitoring.” In the event of a communication fault between the onboard PLC and the management station, the equipment automatically stops at its current position to ensure safety.

7. Continuous Slag Handling:

During continuous slag handling, the system can transfer slag, stack slag, and automatically load vehicles. It automatically recognizes the vehicle size and calculates the loading amount.

 

 

System Characteristics

1)Advanced Maturity:

The selected equipment and technologies represent the world’s advanced and mainstream products and technologies, widely used in multiple fields.

2)Real-Time Capability:

Data transmission between the vehicle and ground equipment is facilitated through a wireless local area network (LAN), compliant with IEEE 802.11b/g standards, achieving a maximum transmission rate of 54Mbps. Additionally, the equipment’s excellent wireless coverage and reception performance ensure real-time and rapid data transmission.

3)Accurate Position Detection:

Utilizing base station positioning technology, the system provides absolute and reliable address information without error codes or accumulated errors, with a positioning accuracy of 10cm.

4)High Reliability:

The selected equipment is specifically designed for industrial site environments, featuring high resistance to electromagnetic interference, seismic activity, temperature variations, dust, and water. Capable of continuous operation 24/7, it meets the demands of use in steel and other industries.

5)Enhanced Security:

The selected equipment incorporates various security technologies to effectively prevent unauthorized access. With wide voltage input ranges, the equipment remains unaffected by voltage fluctuations and possesses filtering capabilities for voltage spikes. All devices are low-power, generating minimal heat and posing no impact on the power grid or electromagnetic interference on other electronic devices.

Metallurgical Intelligence
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Металлургический интеллект
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