磨矿过程计算机控制系统软件的设计与开发
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摘要
磨矿过程是选矿厂生产过程的最重要环节之一,其主要任务是将矿石经过物理的研磨和分级,使有用矿物与脉石单体解离,为后续的选别作业创造条件。本文以中钢集团山东矿业有限公司苍山选矿厂磨矿生产过程自动化工程项目为背景,依托国家863计划“大型磨机智能控制系统”,开展工程的实际应用及科学研究,研究了磨矿过程的控制方法,包括控制策略和控制算法,进行了磨矿生产过程计算机控制系统软件的设计与开发,包括生产过程控制系统的设计与开发以及过程监控系统的设计与开发。此外,本文还对基于最优评价指标的控制器参数整定方法进行了研究。本文的主要工作内容如下：
(1)结合苍山选矿厂磨矿生产过程的特点以及过程自动化控制的要求,提出了磨矿过程的控制方法,包括过程回路控制方法和逻辑联锁控制方法。针对过程回路控制方法,通过采集现场数据,建立被控对象模型。控制器参数应用基于最优评价指标的参数整定方法进行整定,整定得出的控制器参数具有适应被控对象的特性,对现场控制器参数的调试有很好的指导意义。针对磨矿生产过程设备采用三种逻辑联锁控制控制方式：设备单机联锁控制,主用与备用设备之间切换联锁控制,设备顺序联锁控制。
(2)结合磨矿过程的特点和控制要求,进行了磨矿过程计算机控制系统软件的设计工作,包括过程控制系统软件的结构和功能设计以及过程监控系统软件的结构和功能设计两部分；同时提出了具有过程控制和过程监控两层结构的过程自动化系统,该系统具体物理实现框架由工业以太网、控制网和设备网三层网络结构组成,进而实现控制系统的信息集成和功能集成。
(3)在上述工作基础上,进行了磨矿过程计算机控制系统软件的开发工作,包括过程控制系统软件的开发、过程监控系统软件的开发以及上下位机通讯软件的开发。过程控制系统软件的开发具体完成过程控制回路程序和设备逻辑联锁控制程序的编写工作；过程监控系统软件的开发具体完成运行管理监控和系统管理监控的人机界面开发工作；上下位机通讯软件的开发具体完成上位机和下位机之间的网络通讯实现工作。
(4)本文设计与开发的计算机控制系统已经成功应用于苍山选矿厂磨矿过程的实际生产过程中。工程应用中,过程监控系统软件功能得到了充分的验证,过程控制系统软件功能取得了良好的工程实施效果,同时基于最优评价指标整定控制器参数的方法也为现场控制器参数的调试工作提供了有益的指导。从实际的运行效果来看,系统稳定可靠、控制灵活、操作方便,降低了生产成本,减轻了操作人员的劳动强度,达到了现场的预期要求。
Grinding process is one of the most important procedures in the mineral processing plant. Its main task is to separate the valuable minerals from the discardable gangue after physical grinding and classification, and avail to the subsequent sorting process. On the background of the project of Cangshan concentrator grinding process automation project, which is built in China Steel Group Shandong Mining Co., Ltd., and "intelligent control system for large-scale mill" of national 863 program, the practical application of engineering and scientific is researched, and the grinding process control methods are studied, including control strategy and control algorithm. And the computer control system software design and development of the grinding process is developed, including the production process control system design and development, as well as process monitoring system design and development. In addition, the methods of PID controller parameters based on the optimal evaluation is aslo studied. The main work of this article reads as follows:
(1) Combining the grinding process characteristics of Cangshan concentrator, as well as the requirements of process automation control, the grinding process control methods, including process control method and logic interlocking control method is proposed. As for the process loop control method, gather field data and establish charged object model. Controller parameters is based on the method of optimal tuning PID evaluation application. The obtained PID controller parameters are provided with the characteristics of adapting the controlled object. It is a very good guide for the controller parameters on-site testing. The production process of grinding equipment is provided with three interlocking control logic control:the single interlocking control of equipment, the main and back-up switch interlocking control of equipment; the order interlocking control of equipment.
(2) Combining the characteristics of grinding process and control requirements, the computer control system software of grinding process is designed, including two parts, the structure and function design of process control system software, as well as the structure and function design of process monitoring system software; at the same time, the two-layer structure of process automation systems is designed, including the process control system and the process monitoring system. The system framework of the specific physical realization is composed of three layers network, including the industrial Ethernet network, control network and equipment network. And then information integration and function integration of computer control system are achieved.
(3) Based on the above mentioned strategy, the computer control system software of grinding process is developed, including process control system software development, process monitoring system software development, as well as upper and lower communication software development. Process control system software development is specifically completed programs of process control loop and logic interlocking control program of equipment; process monitoring system software is specifically completed the development of the human-machine interface, including the development of operation management monitoring and the development of system management monitoring; upper and lower communication is specifically completed the achievement of nerwork communication of upper and lower computer.
(4) The computer controll system of designed and developed in this paper has been successfully applied to the actual production process of grinding process in Cangshan concentrator. In the engineering applications, the function of process monitoring system software has been fully verified, and a good results of process control system software fuction has been achieved. At the same time, evaluation based on the optimal controller parameter tuning method has provided a useful guide for on-site controller parameters tuning. From the practical operating effects, the system is stable and reliable, flexible to control, easy to operate, lower production costs, reduced operator labor intensity and reached the expectations of the scene.
(1)结合苍山选矿厂磨矿生产过程的特点以及过程自动化控制的要求,提出了磨矿过程的控制方法,包括过程回路控制方法和逻辑联锁控制方法。针对过程回路控制方法,通过采集现场数据,建立被控对象模型。控制器参数应用基于最优评价指标的参数整定方法进行整定,整定得出的控制器参数具有适应被控对象的特性,对现场控制器参数的调试有很好的指导意义。针对磨矿生产过程设备采用三种逻辑联锁控制控制方式：设备单机联锁控制,主用与备用设备之间切换联锁控制,设备顺序联锁控制。
(2)结合磨矿过程的特点和控制要求,进行了磨矿过程计算机控制系统软件的设计工作,包括过程控制系统软件的结构和功能设计以及过程监控系统软件的结构和功能设计两部分；同时提出了具有过程控制和过程监控两层结构的过程自动化系统,该系统具体物理实现框架由工业以太网、控制网和设备网三层网络结构组成,进而实现控制系统的信息集成和功能集成。
(3)在上述工作基础上,进行了磨矿过程计算机控制系统软件的开发工作,包括过程控制系统软件的开发、过程监控系统软件的开发以及上下位机通讯软件的开发。过程控制系统软件的开发具体完成过程控制回路程序和设备逻辑联锁控制程序的编写工作；过程监控系统软件的开发具体完成运行管理监控和系统管理监控的人机界面开发工作；上下位机通讯软件的开发具体完成上位机和下位机之间的网络通讯实现工作。
(4)本文设计与开发的计算机控制系统已经成功应用于苍山选矿厂磨矿过程的实际生产过程中。工程应用中,过程监控系统软件功能得到了充分的验证,过程控制系统软件功能取得了良好的工程实施效果,同时基于最优评价指标整定控制器参数的方法也为现场控制器参数的调试工作提供了有益的指导。从实际的运行效果来看,系统稳定可靠、控制灵活、操作方便,降低了生产成本,减轻了操作人员的劳动强度,达到了现场的预期要求。
Grinding process is one of the most important procedures in the mineral processing plant. Its main task is to separate the valuable minerals from the discardable gangue after physical grinding and classification, and avail to the subsequent sorting process. On the background of the project of Cangshan concentrator grinding process automation project, which is built in China Steel Group Shandong Mining Co., Ltd., and "intelligent control system for large-scale mill" of national 863 program, the practical application of engineering and scientific is researched, and the grinding process control methods are studied, including control strategy and control algorithm. And the computer control system software design and development of the grinding process is developed, including the production process control system design and development, as well as process monitoring system design and development. In addition, the methods of PID controller parameters based on the optimal evaluation is aslo studied. The main work of this article reads as follows:
(1) Combining the grinding process characteristics of Cangshan concentrator, as well as the requirements of process automation control, the grinding process control methods, including process control method and logic interlocking control method is proposed. As for the process loop control method, gather field data and establish charged object model. Controller parameters is based on the method of optimal tuning PID evaluation application. The obtained PID controller parameters are provided with the characteristics of adapting the controlled object. It is a very good guide for the controller parameters on-site testing. The production process of grinding equipment is provided with three interlocking control logic control:the single interlocking control of equipment, the main and back-up switch interlocking control of equipment; the order interlocking control of equipment.
(2) Combining the characteristics of grinding process and control requirements, the computer control system software of grinding process is designed, including two parts, the structure and function design of process control system software, as well as the structure and function design of process monitoring system software; at the same time, the two-layer structure of process automation systems is designed, including the process control system and the process monitoring system. The system framework of the specific physical realization is composed of three layers network, including the industrial Ethernet network, control network and equipment network. And then information integration and function integration of computer control system are achieved.
(3) Based on the above mentioned strategy, the computer control system software of grinding process is developed, including process control system software development, process monitoring system software development, as well as upper and lower communication software development. Process control system software development is specifically completed programs of process control loop and logic interlocking control program of equipment; process monitoring system software is specifically completed the development of the human-machine interface, including the development of operation management monitoring and the development of system management monitoring; upper and lower communication is specifically completed the achievement of nerwork communication of upper and lower computer.
(4) The computer controll system of designed and developed in this paper has been successfully applied to the actual production process of grinding process in Cangshan concentrator. In the engineering applications, the function of process monitoring system software has been fully verified, and a good results of process control system software fuction has been achieved. At the same time, evaluation based on the optimal controller parameter tuning method has provided a useful guide for on-site controller parameters tuning. From the practical operating effects, the system is stable and reliable, flexible to control, easy to operate, lower production costs, reduced operator labor intensity and reached the expectations of the scene.
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2.余永富.从炼铁工业发展现状讨论我国铁矿石选矿值得注意的若干问题[J],国外金属矿山,2001,5：40-44
3.余永富.从炼铁工业发展讨论我国铁矿选矿发展方向[J],金属矿山,2002,8：5-9
4.余永富.我国铁矿资源有效利用及选矿发展的方向[J],金属矿山,2001,2：9-11
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