Intelligent control system design for water treatment device in coal mine
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摘要: 煤矿综采工作面乳化液配制用水水处理装置多采用手动或液控方式进行制水与滤芯清洗，无法实时监测产水数据和装置工作状态，自动化程度低，操作复杂，维护工作量大。通过分析煤矿井下水处理装置智能控制需求，设计了双控制器热冗余方案，即采用2台控制器分别实现水处理装置制水和自动清洗功能。基于该方案设计了煤矿井下水处理装置智能控制系统：以KXH12B型矿用本安型控制器为核心控制单元，采集水箱液位传感器、压力传感器、流量传感器、电导率仪等监测的数据，实时监测水处理装置运行状态；2台控制器以主从模式分工协作，主从控制器分别实现自动制水、自动清洗等控制功能，且在主控制器发生故障时，其制水功能可自动切换至从控制器，保障了煤矿井下乳化液配制用水不受影响。搭建测试平台进行系统测试，结果表明该系统实现了自动制水、自动清洗、数据监测等控制功能及主从控制器热切换功能。该系统已应用于煤矿现场水处理装置，运行稳定可靠，实现了煤矿井下制水设备无人值守。Abstract: The water treatment device for emulsion preparation in fully mechanized mining face mostly adopts manual or hydraulic control mode for water preparation and filter element cleaning. It is unable to monitor water production data and device working status in real-time. It has low degree of automation, complex operation and heavy maintenance workload. By analyzing intelligent control requirements of the water treatment device in underground coal mine, a thermal redundancy scheme of double controllers is designed. The scheme has two controllers that are used to realize the water preparation and automatic cleaning functions of the water treatment device respectively. Based on the scheme, an intelligent control system for water treatment device in underground coal mine is designed. The KXH12B mine-used intrinsically safe controller is used as the core control unit to collect the data of water tank level sensor, pressure sensor, flow sensor and conductivity meter. The water treatment device operation status is monitored in real-time. The two controllers work in a master-slave mode. The master-slave controllers realize control functions of automatic water preparation and automatic cleaning respectively. When the main controller fails, its water preparation function can be automatically switched to the slave controller. This ensures that the water for emulsion preparation in coal mine is not affected. The test platform is built to test the system, and the results show that the system realizes control functions of automatic water preparation, automatic cleaning and data monitoring. The system also realizes the hot-switching function of master and slave controllers. The system has been applied to the water treatment device in a coal mine. It runs stably and reliably, and realizes unattended operation of the water treatment device in coal mine.
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图 2 水处理装置智能控制系统功能需求架构
Figure 2. Structure of intelligent control system function requirement for water treatment device
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图 3 水处理装置智能控制系统总体方案
Figure 3. The total scheme of intelligent control system of water treatment device
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图 6 水处理装置智能控制系统硬件结构
Figure 6. Hardware structure of intelligent control system of water treatment device
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图 7 水处理装置智能控制系统软件设计方案
Figure 7. Software design scheme of intelligent control system of water treatment device
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图 10 主从控制器热切换程序流程
Figure 10. Hot-switching flow between main controller and the slave one
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图 12 主从控制器热切换测试
Figure 12. Hot-switching test between main controller and the slave one
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