Design Of The State Monitoring System For Blast Furnace Gearbox Based On Zigbee And PLC

As we all know the iron and steel industry is the core of China’s heavy industry,development of iron and steel industry is closely related to the rise and fall of a number ofother industries. In the process of improving production efficiency and reducing the accidentrate the ironmaking industry as the main representative do most of its’ work on ensure theequipment performance and the requirements of equipment performance are also gettinghigher and higher. The blast furnace air tight box as the research object, we monitor its’process of production to achieve the production target of high efficiency and energy-saving inthis paper.Blast furnace disperses materials rely on the tilting and rotating devices, the air tight boxis the core of the drive part. Gearbox temperature reflects whether its internal gears are stuck,or other abnormal situations occurred. Compared to conventional gearbox, this airtight boxmainly adopts circulating water assisted with nitrogen to cooling the gearbox, the coolingmethod is very special. Leakage of cooling water, clogged of the water pipe and the openingsize of nitrogen valve are all directly affects the cooling effect, thereby affecting the airtightchamber temperature. So we must monitor its inside temperature, flow rate and pressure ofthe circulatory system inlet and outlet, and adjust the nitrogen valve opening (mainly PIDregulation) to keeping it worked on the best temperature condition. Data acquisition andtransmission mostly using the wired way in production sites, but this wiring collection methodwith a large number of wiring made the complex production more chaos. At the same time,the existing PID adjustment method is regular, its parameters are determined by trial and errormethod and the adjustment effect is not significant.The paper designed an ironmaking gearbox condition monitoring system based onZigBee and PLC technology for meeting above demands and solving the problems. Combinedthe actual production process to collect temperature、flow rate and pressure of the circulatory system inlet and outlet of the airtight box. Then through the ZigBee module realizes the datawireless transmission and fault preliminary judgment. Through VISA in LabVIEW and thedesigned program displays sensor collected data, data storage and data review with TDMStoolkit, briefly describes the production status, and put forward the node active reportingmechanism for timely find fault nodes to improve the existing wireless monitoring systemfrom the Angle of energy consumption.Finally, according to the characteristics of thecontrolled system---pure lag and obtaining difficulty of the mathematical model, the ninepoints controlled theory Smith-the fuzzy PID control scheme is determined, which is forthe regulation of nitrogen valve opening and maintaining the gear box basic a constanttemperature. By experimental verification, this system can complete the target, and run stably.