1、3. 控制方式 Automation control description設中控室自動控制，機上自動控制，機上人工控制和機旁現場控制方式，方式選擇開關設在機上控制室內。機上人工控制適用于調試過程中所需要的工況和自動控制出現故障時，要求堆取料機繼續工作，允許按非規定堆料方式堆料和取料工況。機旁現場控制及人工控制適用于檢修、調試和維護工況，此種控制方式下，堆取料機各傳動機構解除互鎖，只能單獨起動和停止。自動控制方式下的堆取料作業由中控室和機上控制室均可實施。There are four control modes for users to select only in the local con

2、trol room: CCR auto control, local panel auto control, local panel manual control and local site control. Local panel manual control mode is only selected for some abnormal situation, like commissioning, or that the machine has to continue working when the CCR control mode cannot work. In this case,

3、 the piles location would not be pre-defined by program.Local panel manual control and local site control are set for local maintenance, commissioning or maintaining the process work in abnormal situations. In such cases, the individual devices would be started or stopped separately, and are not int

4、erlocked by program. CCR auto control & Local panel auto control modes, in these automatic modes, the machine can be controlled automatically from CCR or from local control HMI screen by pre-defined program.3.1堆料自動控制 stacking control description料堆按逆時針方向連續堆成。堆料區域120度。堆料臂從0度逆時針回轉至120度，同時從 +14度變幅至

5、-16度，隨后堆料臂從 120度順時針 回轉至0度，同時從 -16度變幅至 +14度。堆料臂的回轉和變幅運動均為連續運動。Material piling machine piles materials continuously anticlockwise. The piling material area is 120 degrees. The material piling cantilever revolves from 0 degree to 120 degrees anticl

6、ockwise, in the mean time luffings from +14 degrees to -16 degrees. After then, the cantilever revolves back from 120 degrees to 0 degree, and amplitude changes from -16 degrees back to +14 degrees. The movements of swinging and luffing the cantilever are both continuous.當堆料臂回轉往復堆料到料堆高度后，觸動料位計發出信號，將

7、水平回轉移位3度，回轉行程將由120度變為123度，接續的逆時針方式堆料的回轉行程仍為120度。When the machine piles the material to the set height, the level switch would be triggered and the signal would be sent back to PLC. The cantilever will move back horizontally by 3 degrees. The revolving back angle would be changed to 123 degrees from

8、120 degrees. But the continuous revolving angle is still 120 degrees anticlockwise.為減緩堆料臂改變回轉方向時引起的振動，采用變頻調速來控制堆料機的回轉，使之制動前緩減速，起動后緩加速。堆料臂架變幅機構配置變量泵液壓系統。其運動是變速運動并與基本是勻速的回轉運動合成，使堆料臂落料點始終與堆頂保持等距。In order to reduce the vibration when switching the direction of the cantilever, the revolving motor is driv

9、en by frequency converter by decreasing the speed slowly before braking, and increasing the speed slowly for the next start. Hydraulic system would also be used for the luffing mechanism devices. The whole movement is combined with variable motion and constant revolving motion, thus, the distance be

10、tween the pile top level and material discharge position can be maintained.變幅機構起動受回轉機構起動信號控制，停止不受回轉機構停止信號的控制。The starting process of the luffing mechanism would be influenced by the starting of the revolving mechanism. In contrary, the stop process would not be influenced by each.堆料臂架前端底部與堆頂間距保持在0.8

11、1.2米。由設在堆料臂前端的料位探測器引導和控制。The distance between the cantilever material discharge position and pile top position would be kept from 0.8 to 1.2m, and is detected by the level sensor installed in the front of the cantilever堆料機動作聯鎖stacker movement interlock：正常起動：起動指令回轉和變幅起動堆料皮帶機起動來料棧橋皮帶機起動，各環節起動間隔10秒可調。N

12、ormal start: Start command revolving system and luffing system start belt conveyor for stacker start feeding belt conveyor start. The interval time between each step is set as 10 seconds and can be adjusted. 正常停機：是上述順序的逆過程。Normal Stop: feeding belt conveyor stop - belt conveyor for stacker stop - re

13、volving system and luffing system stop - Stop command. The interval time between each step is set as 10 seconds and can be adjusted. 非正常停機：所有傳動同時停機。Abnormal stop: All the drives stop at the same time.堆料機正常停機時，堆料臂停到料堆堆料起始點處。In normal stop situation, the cantilever should go back to the feeding positi

14、on at the first beginning for this pile. 3.2 取料機自動控制 Reclaimer automation control取料機始終按逆時針方向回轉取料。The machine always revolves anticlockwise to reclaim the material. 取料機運行包括端梁行走，刮板鏈運行和料耙驅動三部分。Reclaimer operation includes three parts of end beam travelling, scraper chain motion and material harrow

15、 drive motion.取料機取料能力的調整，采用改變端梁運行速度（變頻調速）來實現。Reclaiming capacity can be adjusted by changing the speed of the end beam travelling through VVVF control.取料機行走驅動裝置2套，同時工作，取料時工作電機采用電機變頻調速，轉向不可逆；行走裝置中還設有調車運行電機，為恒速可逆。There are two sets of travelling drives for reclaimer motion, both working simultaneously

16、. The reclaim working motor is driven by VVVF, and irreversible. The transfer motion motor speed is constant and reversible.取料和調車運行工況對行走驅動裝置的要求如下：The requests for the travelling motion control when reclaiming materials and transferring are as fellow: 取料運行：磁粉離合器結合，調車電機斷電，取料運行電機接通起動。Material reclaimin

17、g operation: electromagnetic clutch engaged, transfer motor power off, reclaim motor power on and started.調車工況：磁粉離合器松開，取料運行電機斷電，調車運行電機接通起動。取料運行電機、離合器和調車電機互鎖。Transferring operation: electromagnetic clutch disengaged, reclaim motor power off and transfer motor power on and started. Reclaim motor and t

18、ransfer motor are mechanical interlocked by electromagnetic clutch.刮板驅動裝置2套，恒速不可逆。Two scraper drives are constant and irreversible.料耙驅動的變頻電機單向不可逆，料耙的雙向運動，由行程兩端接近開關使電磁換向閥換向，實現料耙油缸帶動料耙正反向行程連續運行，電控系統控制變頻電機實現液壓缸的緩慢起動和停止。Material harrow is driven by VVVF and the motor direction is irreversible. The

19、continuous two-way motion of harrow is driven by the hydraulic system. When the proximity switches detect the harrow motion at each set point of the travelling, the electromagnetic directional valve will be energized or deenergized to change the direction. The hydraulic system is controlled by the P

20、LC through VVVF.取料機動作聯鎖：Interlock for Reclaimer Motion:正常起動：起動指令出料皮帶機起動刮板鏈驅動起動料耙驅動起動工作取料運行機構起動，各環節間隔10秒可調。Normal start: Start command material transport belt conveyor start scraper chain drive start material harrow drive start material reclaiming system start. The interval time between each step is

21、set as 10 seconds and can be adjusted. 正常停機：停機指令下達后是上述順序的逆過程。Normal Stop: after stop command, then the reverse sequence of the start procedure as mentioned above.非正常停機：所有傳動同時停機。Abnormal stop: All the drives stop at the same time.4. 監控和保護monitoring and protection4.1堆取料機的堆料臂與橋梁之間相對角度實施監控。堆料機懸臂與取料機橋梁之間

22、設雙道行程限位開關。當相對角度為64度或269度時發出報警，指令由控制系統發布，64和269度報警為預警信號，在機上都有顯示，斷續聲光顯示在機上，61和272度停機，停機信號在中控室顯示。堆料機自動進入正常停機，聲光信號依然存在，報警信號可通過按鈕消除。The angle between the cantilever of the stacker and the bridge would be monitored and recorded, and between which double limit switches would be equipped to ensure the safet

23、y. When the relative angle is 64 degrees or 269 degrees, sound light warning would be triggered and displayed on the HMI, lasted until the alarm release button is pressed. When the relative angle is 61 or 272 degrees, stop command would be triggered and the alarm would be generated and sent to CCR.

24、In this case, the normal stop sequence would be executed then.4.2堆料臂架的變幅角度通過鉸軸處編碼器控制。堆料臂卸料點下方設料位計,通過料位計控制使堆料臂始終與堆頂保持盡可能小的等距落差。The amplitude angle of the stacker cantilever is measured and controlled by the encoder located at the boom pivot. Also the level meter would be installed under the discharge

25、 outlet of the cantilever, through which the min. possible distance between the discharge outlet and pile top would be maintained.4.3堆取料機各驅動機構電機設短路和過載保護并能予以顯示。Short circuit and overload protection should be set and can be displayed for all the drive motors on stacker.4.4堆料機變幅液壓站,取料機料耙液壓站油溫予以監控并能予以顯示

26、。Oil temperature for hydraulic system, including stacker cantilever amplitude control system and reclaimer material harrow control system, should be displayed and monitored.4.5堆料機堆料臂卸料點下方設防撞保護,傳感元件為料位計（CONASEN TC-1）。Level meter would be equipped under the discharge outlet of the stacker cantilever t

27、o avoid the collision.4.6刮板輸送鏈尾輪處設斷鏈監測，傳感元件為接近開關。Chain scission monitoring would be equipped at the tail pulley of the scraper chain with the proximity switch.4.7堆料機懸臂變幅行程兩端各設1道極限行程限位開關和工作限位開關。Double limit switches would be equipped at each end of the stacker cantilever luffing range. One for ultima

28、te limit and another for working limit.4.8堆料機上膠帶輸送機上設兩組跑偏保護裝置,膠帶第1級跑偏發出故障報警信號,膠帶第2級跑偏信號發出，堆料機停機。膠帶輸送機正常停機延時5秒制動或斷電，取料刮板機正常停機延時60秒斷電。The belt conveyors on the stacker are equipped with two sets of misalignment switches. One set for the first level belt misalignment will generates the waning. Another

29、one for the second level misalignment will note only generates the alarm, but also stop the system. In normal stop sequence, there should be 5 seconds time interval before the belt conveyor stop or brake, and 60s for the scraper chain.4.9堆料機設有5套干油潤滑泵站，控制系統對各泵站油位監控，泵站油位發訊號動作，控制系統報警。There are totally

30、5 sets of grease oil station for the system. The grease oil level would be monitored. Once the oil is too low, system would generate the alarm.4.10取料機料耙油缸工作行程的兩端設接近開關，控制料耙液壓站系統中電磁換向閥換向，實現料耙油缸正反行程運行。為防止料耙與支撐系統碰撞增設兩個極限行程開關。At two ends of the hydraulic system stroke for the material harrow drive, proxi

31、mity switches would be equipped to control the electromagnetic direction valve, which is set to control the direction of the harrow. In order to protect the harrow from crashing into the supporting system, two ultimate limit switches will be set. 4.11堆料機急停設置如下Emergency stop system for stacker are as

32、 fellow:4.11.1 堆料機上沿堆料臂設置兩套膠帶機驅動急停拉線開關。Two sets of pull cord switches for the belt conveyor on the stacker cantilever.4.11.2 堆料機回轉平臺上設急停開關組，可控制堆料機急停。Emergency stop button is set on the revolving platform of stacker to stop the system immediately.4.11.3堆料機回轉驅動，堆料膠帶機驅動，取料刮板鏈驅動，行走驅動就近設置現場控制開關組，可控制本機構起動

33、、停止、堆料機或取料機急停。For stacker revolving drive, belt conveyors, reclaimer scraper chain drive, travelling drives, local push buttons are set to start, stop or emergency stop the stacker & reclaimer in local control. 4.11.4堆料機變幅液壓站和取料機料耙液壓站控制，參考液壓系統廠家提供的控制原理圖。For the hydraulic system of cantilever amp

34、litude and material harrow control, please refer to the vendors schematic diagrams and specifications.4.12堆料機變幅油缸和取料機料耙油缸設置手動控制行程限位裝置。For the hydraulic system of cantilever amplitude and material harrow control, devices to adjust the stroke limits are equipped.4.13 中心落料斗中設置堵料檢測料位計（CONASEN TC-1），當料位計

35、發出信號時，向DSC發出堵料報警信號，取料機各運行機構按順序停機。Level meter （CONASEN TC-1） is set to detect the material blockage in the falling hopper. When the sensor is triggered, DCS would generate the alarm, and the reclaimer should stop by sequence.5. 潤滑控制Lubrication Control本堆取料機對3個回轉支承（油缸鉸接點和外齒），端梁行走車輪，料耙車輪實施自動定時干油潤滑，共設置5個

36、獨立的干油潤滑泵站。潤滑制度為：上部和中部回轉支承（油缸鉸接點和外齒），堆料機回轉起動即供油，之后供油間隔60分鐘，每次供油時間為10分鐘；下部回轉支承和端梁行走，取料機行走機構起動即供油，之后間隔120分鐘，每次供油時間為15分鐘；料耙系統啟動即供油，之后間隔120分鐘，每次供油時間為15分鐘。上述各潤滑泵供油間隔時間可調。5 independent grease oil stations are set for the stacker & reclaimer system, 3 sets of which are for 3 slewing bearings (cylinder p

37、ivot point and external gear), one for end beam travelling wheel, and the other for the material harrow wheel. The control principle is as follows: for the upper and middle slewing bearings, grease pump starts in accordance with the stacker revolving system, and the pump only continues working for 1

38、0 min. every 60min. For the lower slewing bearing and end beam travelling wheel, the oil pump starts in accordance with the relaimer travelling system. Working for 15 min every 120 min. For material harrow system, pump starts when the harrow drive starts, then working 15 min. every 120 min. The ment

39、ioned interval time can be adjusted.刮板鏈設置稀油潤滑裝置，潤滑制度為刮板起動即供油，之后間隔4小時即供油，每次供油時間為10分鐘。The scraper chain drive is equipped with oil lubrication system, which starts in accordance with the scraper motor, then working for 10 min. every 4 hours.在人工控制和機旁現場控制方式下，上述潤滑方式為手動潤滑。In the mode of local manual auto

40、control or local site control, all the oil lubrication and grease lubrication can only be controlled at site manually, not by program.6. 照明 Illumination要求在堆料機落料區域，取料機取料區域，堆取料機的各轉臺區域、堆取料機的各套驅動裝置就近設置亮度足夠和適宜的照明，滿足巡視和檢修的需要，堆取料機各人行通道，扶梯設置安全照明。Local illumination system should be considered to fulfill the

41、request of on-site inspection and maintenance work for such locations: material discharge area, material reclaiming area, each revolving platform and each drive system. Safety illumination should be considered for the pathway and stairs.7. 機械主機受控元件的電氣技術數據electrical drive technical specifications7.1

42、堆料機堆料膠帶輸送機驅動裝置1套，含下述元件各1臺：Material piling belt conveyor drive system, consist of:電機 EM4400-T 75kw1800 rpm575V60Hz,帶加熱器、測溫元件MotorEM4400-T75kw1800rpm575V60Hz, with heater and temperature measurer.液力偶合器帶溫控開關Liquid coupling, with a temperature switch。制動器：YWZD-315/50，575V,60HZ,0.5KW。Brake: YWZD-315/50，57

43、5V,60HZ,0.5KW.保護裝置含下列控制元件 protect devices include the following control component：DIM1.1 打滑檢測器1個, 24V ,DC（詳見附件樣本）DIM1.1 Belt slip detector, one set, 24V,DC （attached with the specifications）T3Z068雙向拉繩開關2個, 24V ,DC （詳見附件樣本）T3Z068 two-way belt pull cord switch, two sets, 24V ,DC （attached with the spe

44、cifications）ZS73SR跑偏開關4個24V ,DC （詳見附件樣本）ZS73SR Belt misalignment switch, four sets, 24V,DC （attached with the specifications）ZQ900-11防撕裂開關2個，24V ,DC （詳見附件樣本）ZQ900-11 Belt tear detector, two sets, 24V,DC （attached with the specifications）7.2 堆料機回轉驅動裝置1套，含下述元件1臺：Stacker revolving drive system includes

45、:變頻電機（Nema標準） 5.5kw 1800rpm 575V 60Hz變頻調速, 帶加熱器、測溫元件，強冷風扇:575V,60HZ,0.5KWVVVF motor (NEMA standard): 5.5kw, 1800rpm, 575V at 60Hz. With heater, temperature measurement, and cooling air fan: 575V, 60Hz, 0.5kW.制動器，575V,60HZ,0.3KWBrake, 575V, 60Hz, 0.3kW.7.3 堆料機變幅液壓站1套，變幅功率15kw，參考液壓系統廠家提供的電氣原理圖。Hydraul

46、ic system for stacker cantilever amplitude control, 15kw. Specifications refer to the vendors schematic diagram.7.4 取料機刮板鏈驅動裝置2套，每套含下述元件1臺：Two sets of scraper chain drive system for reclaimer, each contains:電機EM445T-4，110kw 1800rpm 575V 60Hz，帶加熱器，測溫元件Motor EM445T-4, 110kw, 1800rpm, 575V, 60Hz, with

47、heater and temperature measurement. 液力偶合器帶溫控開關Liquid coupling, with a temperature switch 7.5 取料機運行驅動裝置2套，每套含下述元件1臺：Two sets of reclaimer drive system, each contains:取料運行電機143T-0.75-4P 0.75kw 1800rpm 575V 60Hz （變頻調速） ，帶加熱器、測溫元件調車運行電機 EM2334T-5，,5.5kw 1200rpm 575V 60Hz，帶加熱器、測溫元件磁粉離合器DLK1-40 24V ,DC,22

48、50W,0.9A(詳見樣本)7.6 取料機料耙液壓站1套，功率75kw，參考液壓系統廠家提供的電氣原理圖。Hydraulic system for reclaimer material harrow control, 75kw. Specifications refer to the vendors schematic diagram.7.7 干油潤滑泵站5套，每套含1臺：Five sets of grease oil system, each contains:電機0.25kw, 1800rpm, 575V, 60Hz，帶油位發訊器, DC24VMotor 0.25kw, 1800rpm,

49、575V, 60Hz, with oil level meter, DC24V.7.8 刮板鏈潤滑1套，參考液壓系統廠家提供的電氣原理圖。Oil lubrication system for scraper chain drive, specifications please refer to vendors schematic diagram.8. 電機電壓575V 60Hzmotor voltage 575V 60Hz.9. 控制主機、變頻控制器控制臺置于機上控制室內，控制室內設空調。Plc panel and VVVF converter are located in the contr

50、ol room on the machine, with air conditioning.10. 堆取料機所需低壓元件及變頻器采用施耐德或AB產品（有UL或者CSA認證），主機設計考慮安裝。The brand of Schneider or AB would be considered for the LV components and VVVF drive (with UL or CSA certificate).11. 回轉碥碼器選用徑向接線方式。Radial lead-out connection is used for the rotation encoder.12. 電控系統應控制

51、堆取料機實現下述功能：The control principles of the PLC system are described as:12.1堆料機在正常堆料作業時，電控系統應控制堆料臂如3.1條所述的動作要求進行堆料作業。For material piling work, the stacker should follow the control instructions as item described in item 3.1.12.2初始料堆。料場沒有料的情況下，要能夠先堆出滿足正常堆料要求的初始料堆。建立初始料堆的原則是：Initial material piling is ta

52、ken place when there are no material piles at the first begging. Then the first qualified material pile should be acquired. The principles are as follows: (1) 盡可能保證物料得到均化；Ensure the materials are homogenized.(2) 在120°扇形區域內建立初始料堆；The initial material pile should be formed in the 120 degrees sect

53、or range. (3) 建立完成的初始料堆的堆頂要120°范圍內順時針由標準堆高降到0，并保證在正常堆料時堆料臂卸料點軌跡與堆頂為等落差。堆料臂前端距堆頂高度保持在0.81.2米。The top level of the formed initial material pile is requested to decrease from the standard level to 0 (bottom) in the 120 degrees sector range clockwise. The parallel distance between the track of the

54、cantilever discharge outlet and pile top level should be constant and maintained between 0.8 to 1.2m.12.3殘余料堆恢復。當來料系統出現故障時，控制取料機在取到料堆高度只有標準堆高的1/2時取料機停止作業。來料系統故障排除，堆料機再次起動進行堆料時，控制系統要控制堆料機將料堆恢復至正常作業時的形狀，即堆頂滿足正常堆料作業的要求，然后堆料機轉入正常堆料作業。Material piling recoveryOnce the material feeding belt conveyor fails,

55、 the reclaimer should stop running if the material piles drops to half level of the set value. After the feeding belt is recovered, the stacker can start, and only when the material piles level can fulfill the request for normal operation, the reclaimer can be put into operation again.12.4錯位堆料。當取料機運

56、行至靠近堆料區域出現碰撞危險時，即取料機與堆料臂逆時針行程起點的夾角為64度時控制系統應控制堆料臂自動逆時針位移55度，此時堆料機要在按層堆料的形狀下將料堆恢復至正常堆料作業時的形狀即堆頂滿足正常堆料作業的要求，然后堆料機轉入正常堆料作業。Anti-collision operationTo avoid the collision, when the reclaimer runs near the stacker piling region, the stacking cantilever should revolve by 55 degrees anticlockwise if the an

57、gel between the reclaimer and the stacking cantilever in anticlockwise direction reaches 64 degrees. In this case, the stacker should work to recover the material piles to fulfill the normal operation request, and then the stacker would switch to normal operation mode.12.5緊急堆料。當取料機停止工作，而此時堆料還在運行，堆料臂

58、逆時針運行的終點與取料機的夾角為269度時，控制系統應控制堆料機不再前行。此時如來料系統已沒有物料，應控制堆料機停機，如還在繼續給料，要發出信號給中控室的同時，控制堆料機分層將物料堆在沒有達到標準堆高的料堆區域在。當堆料區堆尾達到自然安息角37°時應控制堆料機及整個來料系統停機。Emergency material pilingWhen the stacker is running while the reclaimer system shuts down, if the angle between the reclaimer and the end position of the stacking cantilever in the anticlockwise direction reaches 269 degrees, the stacker should not keep revolving. After then, if the material is not feeding from the belt, the stacker should stop immediately, but if the material is still feeding, the information should be s