機(jī)械設(shè)計(jì)外文翻譯-位置指示器用于煉鋼爐液壓泥炮的設(shè)計(jì)【中文2430字】【PDF+中文WORD】,中文2430字,PDF+中文WORD,機(jī)械設(shè)計(jì),外文,翻譯,位置,指示器,用于,煉鋼爐,液壓,設(shè)計(jì),中文,2430,PDF,WORD The Seventh International Conference on Electronic Measurement and Instruments ICEMI2005 2-207Design of Position Indicator Used for Hydraulic Clay Gun in Steel-making Furnace Lin Quanxi1 Dou Manfeng1 Zheng Yayin2 Liu Gequn1（1.Northwestern Polytechnical University，Xian 710072 China）(2.Beijing Jiaotong University,Beijing 100044 China)Abstract:How to indicate the position of hydraulic clay gun accurately is a big problem in iron-smelting blast furnace equipments.In this paper,a position indictor of hydraulic clay gun system based on turbine flow sensors and AT89S52 single processor are presented and an error compensation algorithm which used to improve the measure precision is investigated.A technic of data dump is also described.The whole system can avoid the influence of bad environment while the blast furnace equipment working.Keywords:Hydraulic clay gun;position indictor;turbine flow sensors;89S52;error compensation;data dump.1 Introduction When molten steel is removed from the furnace,a hole is drilled through the refractory liner.A clay gun is used to plug the hole with a refractory clay mix.There are two kinds of clay gun:electric clay gun and hydraulic clay gun in iron-melting blast furnace equipments.Nowadays,the widely used clay gun is the latter for the sake of the influence of the working condition.When iron water is poured down from blast furnace,the temperature of the workshop rises immediately,the air becomes dusty,and the workshop becomes poor visibility.Some mechanical position indictors such as square shaft pointer,heavy hammer pointer and spring pointer are adopted to indicate the position of piston in the cylinder.All these indictors are low life-span;high malfunction ratio and low environment flexibility due to the bad working condition.A noticeable problem is that the data cannot be recorded,so its hard to tell who is to blame once there is an accident.In this paper,a position indictor system which provides a framework for data acquisition,disposal and monitoring has been investigated and applied to the hydraulic clay gun system in steel-making blast furnace.2 Principle,Framework and Problems 2.1 System Principle Considering the bad influence of the working condition,turbine flow sensors are used to obtain the information of the piston indirectly.Turbine flow sensor is used for water inflow or water loss measuring.Turbine rotation frequency(F)is proportional to flow speed(V)i.e.to the quantity(Q)of liquid flow in corresponding part of the cylinder.At every turbine turn the sensor sends through the cable a pulse to the counter.Then the cubage of the cylinder can be gotten from the pulse number.K=F/Q or K=N/V (1)The K-Factor represents the number of output pulses transmitted per gallon of fluid passing through the turbine meter.Each turbine has a unique K-Factor.N represents the total pulse number.Each pulse generated represents a discrete amount of volumetric throughput.2.2 System Framework In this system,two separate set of one-way valves and sensors are equipped in the ductwork to get the information of flowrate.Data sampling,disposal,display and transit are managed in MCU.An upper computer is used for monitoring the current working status and giving the online or offline dada processing.Two kinds of displays are used for the operators.The The Seventh International Conference on Electronic Measurement and Instruments ICEMI2005 2-208main framework of the system is as follows:pumpoilreservoirone way valvesensor1one way valvesensor2hydraulic cylindersamplingMCUdisplayuppercomputer Fig.1 Framework of the position indictor The core system components are detailed in the following descriptions by specialized subsystems to form the full-featured operating environment.2.3 Main Problems Adopting the turbine flow sensors can evade the awful environment,but it also causes some problems.1)How to avoid the rounding error which is due to the programming and make up with the disparity between the back and forth motion of the piston which is due to the difference of the two sensors is the main problem of the system.2)The system should be simple and easily operated without bringing much complexity to the primary system.3)The integrated system should involve data sampling,disposal,display,and monitoring.3 Lower Computer 3.1 Working Mode of the System The system can be operated in three different modes according to the different working period for the hydraulic clay gun.a)Calibration Mode.This makes the system universal.The total pulse number of the cylinder is obtained in this mode.b)Tamping Mode.In this mode,workers stuff the cylinder with clay in a tight way.The information of the piston can be seen by the loaders,operators and monitors.C)Extrusion Mode.In this mode,workers extrude the clay to jam the taphole.The main and important data is sampled during this mode and also be displayed.3.2 Controller Block-Diagram The core processing unit is based on the AT89S52.The AT89S52 is a low-power,high performance CMOS 8-bit microcontroller with 8Kb bytes of in-system programmable flash memory.The AT89S52 also provides the following features:8K bytes of flash,256 bytes of RAM,32 I/O lines,watchdog timer,two data pointers,three 16-bit timer/counters,a six-vector two-level interrupt architecture,a full duplex serial port,on-chip oscillator,and clock circuitry.The controller block-diagram of the system is as follows:AT89S52T0(P3.4)T1(P3.5)P0.0P0.1 P0.6P0.7RXD(P3.0)TXD(P3.1)RESETXTAL1XTAL2sensor1sensor2Opto-couple circuitOpto-couple circuit8155PAPBLED1LED2RS232 andRS485PCP1.2P1.3P1.4satus displayINT0INT1TampingExtrusionAD0AD1.AD7CalibrationP1.0P1.5P1.6P1.7 Fig.2 Controller block-diagram The whole control block-diagram consists of the following elements:-Sensors are used to get the information of the quantity of liquid and send pulses.-AT89S52 is used to control the data flow of tamping,extrusion and calibration,and to give the proper information of displaying,alerting and communicating with the upper computer.-Both RS232 and RS485 communication protocols are used for data transmitting.-Two kinds of LED are used in this system,one is for the inside,and the other is for the outside.3.3 Transmitting Data to Upper Computer To make the system more universal,both RS232 and RS485 communication protocols are adopted.RS232 provides single-ended data communications between a transmitter and a receiver at relatively slow The Seventh International Conference on Electronic Measurement and Instruments ICEMI2005 2-209data rates(115k bits/second)and short distances(up to 50 ft at the maximum data rate).RS485 links provide more communication reliability over a long distance at a high speed for industrial plants.Adopted RS485 communication protocol needs to install an RS485 interface in an expansion slot of the computer or to convert the RS232 level signal coming out the computer serial port to an RS485 signal.A RS232/RS485 converter is introduced in this system.3.4 Implementation For Software The software part can be included several parts:calculation,counting,communication and monitoring.3.4.1 Calibration The total pulse numbers are different with different cylinders.The calibration process is to get the total pulse number of one-way moving of the piston.An average calculation is used to improve the precision of the system.If total step number is arranged,the step length number which used for the initial count number of the counter and residual number will be obtained.There are probably two different initial count numbers for the separate counters used for the forth or back moving because of the separate turbine sensors.The program flow chart for one way is as follows:calibrationaveragesingle counting sumstep lengthnumberresidualnumberstep numberinitial countingnumber for timer Fig.3 Calibration flow chart 3.4.2 Counting For the forward course,one counter(T0)increases with the piston moves to the mouth of the hydraulic clay gun,while for the backward,the other counter(T1)increases with the piston retreats and the counter(T0)keeps the same.The program for the counter(T0)is as follows:T0INT:INC 5BH INC 31H;current step register,low bit INC 6AH;temp step register MOV A,31H CJNE A,#00H,DDD0 INC 30H;current step register,high bit 3.4.3 Error compensation integral part(I)average(eg:100 share)residual part(R)sumtemporary stepnumber(T)average(eg:100 share)(A)clear temporary stepregister(T=0)subtract 1 from currentstep register(C)return0YesNoR*T-I*A Fig.4 Forward compensation The following error compensation is used to make up the influence of residual number while calculating.If the step number is assigned 100,it is sure that the pulse number of every step is not always integer and the residual number may be ignored.Thats to say,the The Seventh International Conference on Electronic Measurement and Instruments ICEMI2005 2-210total counting step is less than the actual total steps.Once the piston moves again and again,a great error will occur.An error compensation algorithm is introduced for the forward and backward motion.A temporary step register which used for the compensation counts every pulse during the piston moving.Once one compensation step is considered,clear the temporary step registers,restart counting and prepare for the next compensation.Forward and backward compensation flow charts are as follows:integral part(I)average(eg:100 share)residual part(R)sumtemporary stepnumber(T)average(eg:100 share)(A)clear temporary stepregister(T=0)pluse 1 from currentstep register(C)return0YesNoR*T-I*A Fig.5 Backward compensation 3.4.4 Monitoring A remote monitor system is used to take good advantage of historical and current data and give instructions to operation and management.Auto-analysis of historical data will provide the optimum amount of stuffing and extrusion.The optimization process can also be done artificially.4 Data Analysis In the system,two kinds of data processing are presented to make it more universal.One is for the spot-workers,which makes them operate the joy stick correctly.The other is for the manager worker for a further analysis to get an optimum amount for tamping and extrusion.4.1 On-line Data Processing The software system provides for real-time conversion of measured pulses to displacement,by applying calibrations and performing calculations.4.2 Off-line Data Analysis Archived data can be interactively analyzed and visualized with the help of a universal data analysis program.This program can be used for plotting waveforms of individual data channels as well as for performing simple mathematical operations on single or combined waveforms.The user can extend the processing capabilities by adding any custom algorithms.5 Conclusions The error compensation algorithm makes the system reliable.The system has been already successfully applied to monitor the working status of hydraulic clay gun.The experience based on the workers confirms that the system is veracious,flexible,reconfigurable,extendible,and scalable.Reference 1Fuehan,R.J.,etc.The Future Steelmaking Industry and Its Technologies,INEL-95/0046,Idaho National Engineering Laboratory,Idaho Falls,Idaho,December 1994 2Quan linyue,The application of Turbine Flow in Flow Measurement in Waterworks,Process Automation Instrumentation,Vol.23,No.12,2002 3SPONSLER CO.,INC,Turbine flowmeters for liquid measurement,2002 4ATMEL Corporation,89S52,2005 5S.Sharonov,J.M.Nogiec,An Embedded Power Supply Controller,Pac97,Vancouver,1997 6J.M.Nogiec,E.Desavouret,etc.A Distributed Monitoring and Control System,IEEE,1998,37133715 7Tang hui,A Flow Rate Monitoring Meter Based-on 8098 The Seventh International Conference on Electronic Measurement and Instruments ICEMI2005 2-211Single Chip Computer,Instrument technology and Sensors,Vol.3,1996 Author Biographies Lin Quan-xi(1979),male,received the electromechanical B.S.degree in ShenYang Institute of Aeronautical Engineering,ShenYang,China,in 2002.Currently he is a master candidate in the department of electric machine&electric engineering of Northwestern Polytechnology University,Shannxi,China,mostly pursues the research of rare earth motor design and motion control.Dou Man-feng(1967),male,received the B.S.,M.E.and Ph.D degrees in Electronic Engineering from Northwestern Polytechnology University,Shannxi,China.He is currently a professor.His research interests are power electronics,motor design,motor drives,electrical machine and motion control system.Zheng Ya-yin(1978),male,received the electromechanical degree B.S.degree in ShenYang Institute of Aeronautical Engineering,ShenYang,China,in 2002.Currently he is a master candidate in the department of Electronic Engineering of Beijing Jiaotong University,Beijing China,mostly pursues the research of detecting and measuring.Liu Ge-qun,male,received the M.Eng.degrees in Control Theory and Engineering from Northwestern Polytechnical University,Xian,China,in 2003.He is currently a doctor candidate in the Automation College,Northwestern Polytechnical University,Xian,China.His research interests include Modern Control Theory,Intelligent Control,and Flight Control Systems.