System Overview
The main mine fan is an extra-large key device in the entire mine production. Its normal operation is the fundamental guarantee for the continuous and safe production of the mine. The main fan online system consists of a Programmable Logic Controller (PLC), an industrial computer monitoring station, and sensors such as pressure, temperature, and vibration. Using mature PLCs and configuration monitoring software, the system can monitor the operating status of two fans simultaneously, performing real-time online monitoring of ventilation performance parameters such as air pressure, wind speed, fan operating status, motor vibration, temperature, and bearing temperature. A remote monitoring system is established using the C/S architecture to effectively improve system safety.
The main fan online monitoring system mainly has the following advantages
01
Monitoring the real-time operating status of the fan: By monitoring the fan parameters, it accurately understands the operating status and surge volume of the fan, as well as the electricity usage, bearing temperature, and vibration of the fan;
02
Intelligent and reliable alarm function: It allows specific setting of parameter thresholds, limits monitoring of parameters such as bearing temperature and fan vibration, and provides timely audio and visual alarm signals when limits are exceeded, facilitating timely handling;
03
Improving equipment management level: The system timely understands the operation of the fan, providing reliable technical support to effectively prevent equipment failures and offering reliable information for managers to formulate equipment maintenance plans.
System Composition
The main fan online monitoring system primarily consists of sensors, electrical parameter collection modules, PLC, upper computer, and video surveillance. The PLC hardware mainly includes a power module, CPU, digital input/output module, analog input/output module, and communication module.
Industrial computer and upper computer software: Remote control, remote data display, remote operating status monitoring, and video surveillance, supporting web browsing, and capable of interfacing with the mine automation system platform;
Digital signal control: Mainly used to collect the status of switches, motor contactors, and thermal relays, the operation and fault status of frequency converters, the status of air door contactors and the air door's fully open or closed position, control of low-voltage cabinet switchgear operations, motor forward/reverse and variable frequency/constant frequency startup, as well as the opening and closing of air doors;
Analog signal collection: Mainly involves collecting signals from the fan's negative pressure and flow, pressure, temperature, air volume, motor temperature and vibration, frequency converter parameters, and the electrical parameters of low-voltage cabinets;
Communication method: The system uses standard 485 communication to handle communication with the electrical parameter collection modules inside various low-voltage cabinets and communicates with the upper computer via Ethernet;
Video surveillance system: Real-time monitoring of the operating status of the main fan on site.
System Functions
The mine main fan online monitoring system utilizes a configuration software platform, equipped with an Ethernet interface and supports the TCP/IP protocol. It transmits data information via the mine's optical fiber ring network, enabling remote monitoring, control, and data sharing of fan equipment. The monitoring system's functions include:
- Primarily monitors the operating status of the main fan and motor (operation, standby, maintenance, fault), monitors motor bearing vibration, temperature, and motor stator temperature. It also monitors the static pressure, total pressure, air volume, wind speed, and temperature of the airflow in the ducts. Additionally, it monitors motor voltage, current, frequency, active power, reactive power, power factor, active energy, and reactive energy;
- Provides historical information querying and printing for parameters such as front and rear bearing temperatures of the motor, motor stator temperature, vibration, motor voltage, current, static and total pressure in the duct, and methane concentration in the air flow. It issues real-time alarms when critical parameters exceed limits, which can be set by the user;
- Records real-time data of fan switches and sensor statuses, the specific moments of starting and stopping each main motor, equipment operating time, etc. It can generate reports and trend graphs upon request, and supports printing and exporting functions;
- Monitoring data can be searched under different conditions and easily printed. Authorized network terminal users can remotely view monitoring data;
- Provides program and data security management functions; different users can have different access rights, preventing unauthorized users from modifying monitoring system parameters;
- The fan online monitoring subsystem connects locally to a ring network switch, quickly accessing the mine's comprehensive automation platform via industrial Ethernet. It provides an OPC interface for seamless integration with the automation platform, enabling monitoring and data sharing of the fan;
- Enables remote control of the fan's automatic start/stop, automatic switching, and reverse operation. It supports various control modes: local manual, local automatic, remote manual, and remote automatic.
System Communication Interface
The PLC system is equipped with an RS485 communication module and a standard TCP/IP protocol Ethernet interface, facilitating connections with smart power supply equipment or other intelligent devices on-site to achieve data read/write functionality. Communication between the PLC system and the surface-level upper computer is accomplished through fiber optic transmission. The entire network adopts open Ethernet standard technology used in the field of industrial automation. Devices can be connected from the field level up to the management level. This setup supports communication across the system and supports engineering and configuration throughout the mine, extending down to the field level, all while adhering to IT standards. This enhances the usability of the product and the maintainability of the system. Real-time Ethernet communication is used, with channel data response times less than 150 milliseconds.
Video Surveillance System
The video surveillance system collects live image information through video cameras using fiber optic communication media to transmit to the monitoring center. This allows for remote and convenient monitoring of on-site conditions, thereby enhancing the system's reliability and safety.
Main Functions
(1) Information Collection: The image signals captured by the cameras are transmitted in real-time to display screens.
(2) Video Sub-control Management: Enables simultaneous monitoring of multiple different video signals and supports remote monitoring, remote access, and alarm linkage.
(3) Monitoring Function: Any video signal can be monitored through the display screens.
(4) Playback Function: Allows real-time querying and playback of images saved on the hard disk recorder.
(5) Recording Function: The hard disk recorder provides real-time and scheduled recording storage.
(6) Switching Function: Automatically cycles through pre-set images at set time intervals.
(7) Preview Function: Users can directly access IP cameras or video servers through the Internet Explorer browser.
(8) Video File Query Function: Video files from all cameras can be searched by time, alarm records, and other criteria.