Design And Development Of Monitoring Systems For Mineral Equipments Based On Internet Of Things And Industrial Clouds

Mineral processing industry is a typical one in the process industries,with the characteristics of multi-processes,complex devices and long production lines.The usage process of devices is fixed in the mineral production process.Once a device in the production line has an abnormal shutdown or a serious failure,the following production processes would get severely affected.Hence,the monitoring for devices'whole life-cycles is needed.In order to ensure a safe and stable operation of these devices,reduce their abnormal shutdowns,improve enterprises' production efficiency and reduce the production cost,it is necessary to develop a monitoring system for mineral devices that can fulfill the operating requirements,perfect functions and stable performances in the concentrator.It can conduct on-line monitoring and analysis of mineral processing devices,evaluate their operating status,find fault symptoms and avoid or mitigate serious damages to devise a reasonable maintenance time and plan,realizing real-time monitoring,online diagnosis,fault alarm and planning maintenance for these devices,and achieving the initial intelligent transformation of the mineral processing plant.At present,the existing monitoring systems in concentrators are mostly centralized in the local central monitoring room and lacks the mobile monitoring for devices;No effective inspection measures have been provided to reduce the labor intensity of inspection personnel and improve the inspection efficiency;No maintenance knowledge experience storehouses have been established to provide support for the planned maintenance;Failing to monitor and analyze devices'operational status online leads to the failure of assessing their operational conditions.Therefore,a reasonable maintenance plan cannot be made to reduce their downtime;In addition,the development of equipment monitoring system often requires lots of repetitive code and lacks universal SaaS services to improve its efficiency.This article relies on the project of Jiuquan Iron and Steel Suspension Magnetization roasting beneficiation transformation phase one in Northeastern University State Key Laboratory of Synthetical Automation for Process industry to further study and analyze the existing problems in the current mineral devices monitoring systems.The main research contents are listed as follows.(1)System architecture design based on SaaS services.A system architecture that provides customized Saas services for different concentrators is devised to improve its development efficiency and reduce development costs.(2)Collection,transmission and storage module designs for mineral devices'production data.Data acquisition is made via the use of "wired+wireless" sensors.Data transmission gets done by using distributed messaging middle wares to perfect its efficiency.Data storage uses distributed files and distributed object storage technology to be reliable.(3)Analyzing and servicing the mineral devices' status data.Analyzing their historical operating state data stored in the cloud server and finding out the law of their operating status to provide support for the planned maintenance.Using the fault diagnosis model established on the cloud server to diagnose devices' operation conditions.Servicing their analysis processing via the use of micro-service architecture and SSM framework,so that mobile and remote clients share a set of services,achieving service reusability.(4)Mobile and remote client development.The system development uses front-end and back-end separation,modularization and componentization.Through the combination of module configurations can create different systems for different needs,and hence meet customer's customized requirements.In addition,using front-end and back-end separation and componentizing the similar code to reuse,you can make the entire system development and maintenance more convenient,extensive and reusable.(5)Validating industrially by deploying the system to industrial sites.Setting Jiuquan Iron and Steel Concentrator of Jiayuguan City,Gansu Province as the background,the industrial functional modules are verified.The verification results show that the system has good stability and friendly interface,and can perfectly realize real-time monitoring,fault diagnosis and abnormal alarm of the mineral production process,initially achieving devices' planned maintenance and assisting the staff to analyze their running status so as to improve inspection efficiency.Besides,new beneficiation systems can be quickly built by utilizing SaaS services.This system effectively guarantees the safe and stable operation of devices,greatly reducing labor intensity of the staff and managers in the concentrator and improving development efficiency of the new mineral processing devices' monitoring system.