Automated system for monitoring the quality characteristics of coal, transported on the belt-type conveyor, using a non-contact measuring method

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The paper presents a brief description of an automated system, designed to control coal quality in accordance with the specified parameters of the waste rock content owing to obtaining, collecting, processing and storing information from primary instruments, using a radioisotope measuring method.

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Nội dung Text: Automated system for monitoring the quality characteristics of coal, transported on the belt-type conveyor, using a non-contact measuring method

International Journal of Mechanical Engineering and Technology (IJMET) Volume 10, Issue 04, April 2019, pp. 49-53. Article ID: IJMET_10_04_007 Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=10&IType=4 ISSN Print: 0976-6340 and ISSN Online: 0976-6359 © IAEME Publication Scopus Indexed AUTOMATED SYSTEM FOR MONITORING THE QUALITY CHARACTERISTICS OF COAL, TRANSPORTED ON THE BELT-TYPE CONVEYOR, USING A NON-CONTACT MEASURING METHOD Ivan V. Pantyushin Design Center LLC, PhD in Engineering Saint-Petersburg ABSTRACT The paper presents a brief description of an automated system, designed to control coal quality in accordance with the specified parameters of the waste rock content owing to obtaining, collecting, processing and storing information from primary instruments, using a radioisotope measuring method. The system allows the personnel to obtain reliable information on the quality of mined coal in a timely manner. This information is transmitted to the MES at the enterprise to assess the performance and cost of production. Keywords: automated system, database, coal quality, belt-type conveyor, radioisotope measuring method. Cite this Article Ivan V. Pantyushin, Automated System for Monitoring the Quality Characteristics of Coal, Transported on the Belt-Type Conveyor, Using a Non-Contact Measuring Method, International Journal of Mechanical Engineering and Technology, 10(4), 2019, pp. 49-53. http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=10&IType=4 1. INTRODUCTION One of the main ways to increase the economic efficiency of mining enterprises, in combination with cost optimization, is improving the quality of marketable products and reducing its losses [1]. Improving the quality of products and reducing the loss of extracted components is a matter of great importance for enterprises, performing the development of coal deposits, characterized by high scale of gradations in quality characteristics. The initial qualitative non-uniformity of raw minerals at the deposits is associated with increased complexity while solving the following tasks: 1. ensuring some average quality relative to each particular batch of mined raw materials, supplied to the consumer; http://www.iaeme.com/IJMET/index.asp 49 editor@iaeme.com
Automated System for Monitoring the Quality Characteristics of Coal, Transported on the Belt- Type Conveyor, Using a Non-Contact Measuring Method 2. departing from this average quality level should not exceed the permissible values; 3. each batch should be characterized by uniformity of its composition. The assigned tasks are achieved through the creation of an intellectual dynamic product quality control system, integrating the possibility of coal flows simulation [2]. 2. THE SYSTEM STRUCTURE AND FUNCTIONS The automated system is represented by a single hardware-software complex, consisting of measuring systems for monitoring coal quality, weight measuring systems, a server, an automated operator's workplace and remote automated users’ workplaces, combined into a single information network. The flow diagram is presented in Figure 1. The system hierarchy is divided into two levels: 1) the lower level includes a set of devices and sensors designed for obtaining, processing and storing primary information on coal quality characteristics; 2) the upper level consists of a server, automated users’ and operator’s workplaces designed for the deployment of application software, visualization and making the system work properly. Figure.1. The flow diagram of the system for monitoring coal quality characteristics The measuring system for monitoring coal quality characteristics is based on the radioisotope measuring method. The essence of this method resides in the reduction of gamma radiation via coal flow on the belt-type conveyor in motion. The reduction of gamma radiation http://www.iaeme.com/IJMET/index.asp 50 editor@iaeme.com
Ivan V. Pantyushin characterizes volume density of the material, its chemical composition, and presence of various types of medium non-uniformities [3]. The measuring system consists of gamma radiation unit, detector block and unit of registration, storage and transfer of measuring data [4]. Gamma radiation unit it represented as protective collimating device, BGI-45A, via which the given radiation beam angle is formed. Gamma radiation source is IGI-C-3-8 based on radionuclide Сs-137. The detector block consists of a scintillation counter, based on NaJ (Tl) crystal, a microcontroller, a stabilized power source, and a thermostat. The detector block components are mounted on a common chassis, which is fixed in a cylindrical housing (if necessary in an explosion-proof housing). Flux of gamma rays from the source, passed through the controlled medium, is converted in the scintillator into an electrical signal in the form of a flux of square pulses of positive polarity with variable amplitude and duration [5]. The microcontroller includes a clock-pulse generator, a pulse counter based on a counter chip (for direct and scattering channels); RS-485 interface signal shaper with galvanic isolation; external RAM of the controller. The unit of registration, storage and transfer of measuring data includes equipment for monitoring the measuring system operation and power supply, a personal computer of industrial design with visualization feature (Simatic HMI Panel PC). This unit is designed for collecting data from the detector block, preprocessing, storing and transmitting the obtained information to the upper level, monitoring and controlling the measuring system operation, synchronizing with the operation of weight measuring systems. Setting up the detector block is carried out via application software implementing the primary converter verification and calibration methods [6, 7]. Weight measuring systems are designed to determine the rate of loading and accounting of the material carried out, using cargo weighing at the specified site of conveyor. Weight measuring systems comprise conveyor-type scales, having a strain measuring bridge, installed on prisms of metering skid (Milltronics MSI), a conveyor belt speed sensor (RBSS) and a secondary transducer for processing, storing and transmitting the obtained information to the upper level (BW500 integrator). The upper level of the system, consisting of a server and automated users’ and operator’s workplaces, is designed to implement the following functions of the system: technical condition monitoring; obtaining information from the lower level of the system; entering external additional information; input data processing and output data release; automated input data errors processing; event logging; data filing; reporting documents generation; access rights differentiation and information protection. 3. DESCRIPTION OF THE SOFTWARE AND THE SYSTEM OPERATION The software of the unit of registration, storage and transfer of measuring data includes the following: Microsoft Windows 7; Microsoft Net Framework v4.7; PostgreSQL v9.5; application software for the system setting up and operation. The server provides for installation of the following software: Microsoft Windows Server 2012; Microsoft SQL Server 2012; Wonderware System Platform 2014R2 (Historian Server, Information Server), KEPServerEX. The automated system operator’s workplace is provided with the following software: Microsoft Windows 7; InTouch for System Platform 2014R2 with Historian Client; application software for the system operation. http://www.iaeme.com/IJMET/index.asp 51 editor@iaeme.com
Automated System for Monitoring the Quality Characteristics of Coal, Transported on the Belt- Type Conveyor, Using a Non-Contact Measuring Method Microsoft Net Framework v4.7 is designed for the deployment of application software to perform coal quality measuring system setting up and operation. The data obtained from the detector block is stored in tables of the PostgreSQL v9.5 database. Data obtaining from coal quality measuring systems is performed via connecting Microsoft SQL Server 2012 to PostgreSQL v9.5 via LinkedServer. To do this, on the server, where Microsoft SQL Server 2012 is installed, the data source for PostgreSQL v9.5 is configured and the PostgreSQL ODBC driver is installed. Data obtaining from the weight measuring systems is performed via the Kepware OPC server (Modbus RTU protocol) for transmission to the Historian Server upon the SuiteLink protocol. First of all, the data, obtained from quality control measuring systems and weight terminals, enter the tables with so-called “raw” data, and then, by virtue of data processing requests, is recorded into the tables with “pure” data. The transfer is carried out via a software procedure in Transact-SQL language (procedural extension of SQL language), performing data processing with exception of errors and the system malfunctions [8]. For the correctness of the obtained “pure” data, the system time synchronization of all system components is provided. The application software of the automated system operator’s workplace, developed on the basis of InTouch for System Platform 2014R2, implements the analysis, visualization and generation of reporting documents with respect to technological parameters. The development of a visualization system for the system users is implemented according to a WEB-technology using one of programming languages of the server applications. The existing system uses “php” Hypertext Preprocessor, a general-purpose scripting language. The shell that runs the server application is the Wonderware Information Server. In connection therewith, any WEB-browser can be the client on the user's computer. Based on the Wonderware System Platform software package, the transfer of information on the performance and coal quality characteristics to the MES at the enterprise is implemented to assess the economic efficiency of separate production areas and the enterprise as a whole. 4. CONCLUSION The automated system for monitoring coal quality characteristics ensures the transfer of up-to- date information on the quantity and quality of mined coal to the following structural subdivisions of the mining enterprise: 1. mining and geological services to control the mining process; 2. engineering-technological services, responsible for the preparation of technological enrichment processes; 3. Managing bodies of the enterprise to assess the performance and cost of production. REFERENCES [1] O.I. Orlov, A.G. Dudarev (Gornyi Zhurnal, 2012). (1S) The technology of averaging the quality ores by JSC «Karelian pellet». [2] V.A. Makarov, E.G. Malinovsky, I.I. Kazer, G.S. Kurchin, A.V. (J. Sib. Fed. Univ. Eng. technol., 2016) 126-132. (9(1)) Efimov Dynamic quality management system mineral. [3] N.D. Betenekov, E.I. Denisov, V.D. Puzakov, (2004). Elements of radiometry and spectrometry of ionizing radiation. [4] I.N.Voytyuk, A.V. Kopteva, Continuous noncontact method of measuring the amount of mined rock and its ash content at a belt conveyor, Proceedings of 2015 International Conference on Mechanical Engineering, Automation and Control Systems, MEACS 2015, 2016. http://www.iaeme.com/IJMET/index.asp 52 editor@iaeme.com
Ivan V. Pantyushin [5] I.N. Voytyuk , O.M. Bolshunova, Ensuring energy efficiency of the belt-type conveyor electric motor drive operation due to noncontact control of mass discharge of cargo during its transport in mining condition, Proceedings of the 2019 IEEE Conference of Russian Young Researchers in Electrical and Electronic Engineering, ElConRus 2019, 2019, 736- 739. [6] A.V. Kopteva, I.N. Voytyuk, The algorithm of measuring parameters of separate oil streams components, IOP Conference Series: Materials Science and Engineering, 177(1), 2017. [7] I.N. Voytyuk, A.V. Kopteva, Testing the system detection unit for measuring solid minerals bulk density, IOP Conference Series: Earth and Environmental Science, 87(3), 2017. [8] R.M. Snyder, Using transact-SQL and simulation techniques to create virtual M&M'S, Journal of Computing Sciences in Colleges archive, 18 (2), 2002, 153-164. http://www.iaeme.com/IJMET/index.asp 53 editor@iaeme.com