基于WinCC的煤矿顶板动态信息监测系统的设计与实现.pdf

万方数据 万方数据 太原理工大学硕士研究生学位论文 I 基于基于 WinCC 的煤矿顶板动态信息监测的煤矿顶板动态信息监测系统的设计系统的设计与实现与实现 摘 要 本文设计的基于WinCC的煤矿顶板动态信息监测系统是应山西煤炭运 销集团科学技术研究有限公司的委托，设计并实现该公司 KJ504 煤矿压力 监测系统的上位机软件。 KJ504 煤矿压力监测系统包括 5 个子系统， 即支架阻力监测系统、 顶板 位移监测系统、锚杆应力监测系统、锚索应力监测系统、煤柱应力监测系 统。本设计主要实现在上位机软件上对各子系统数据进行采集、显示、存 储、分析和报表输出的功能。在对现场进行考察，了解分析现存软件优点 和不足的基础上，提出以 WinCC 组态软件为开发平台，MS SQL2005 为后 台数据库，辅以 VBScript 编程语言对顶板动态信息监测系统进行发开的设 计思路，并提出系统总体设计方案。 在系统开发过程中，重点研究、解决以下关键问题 1 井下数据分站的通讯协议为非标准通讯协议，WinCC 不提供该设备 的驱动，因此设计了 OPC Server 作为通讯接口，WinCC 作为 OPC DA 客户 机，实现分站与上位机的通讯。 2 煤矿开采是一个动态过程，在回采和掘进过程中，巷道长度在变化， 安装在巷道中的传感器数量也在变化，为了在监控界面上及时反映这种动 态过程，同时针对支护监测是以井巷断面组织，而每一个断面布置的传感 器类型基本相同， 为便于现场工程组态，提出了对不同类型传感器进行 “封 装”的思路，在数据组织上对变量实行有序化命名，实现过程变量的统一、 有序化管理。 3 根据液压支架的工作原理和支架工作特性曲线，结合工程师实际工 万方数据 太原理工大学硕士研究生学位论文 II 作经验，采用差分思想，从现场参数中分析、提取出支架初撑力等结构化 参数，进而对工作面推进度及周期来压进行分析。 4 系统使用 WinCC 集成的 SQL2005 数据库实现过程值归档功能，利 用自定义数据库， 对数据分析结果进行标记、 存储， 利用VB脚本实现WinCC 对过程值归档数据库、自定义数据库、Excel 报表模板的直接访问，完成复 杂报表输出功能。 5 利用第三方控件 TeeChart，实现空间趋势图的绘制，进一步完善系 统图形功能。 系统测试工作已在山西煤炭运销集团科学技术研究有限公司完成。经 过测试和完善，系统已用于山西煤炭运销集团阳城四侯煤业有限公司和三 元王庄煤业有限公司生产矿井，系统运行情况良好，为煤矿安全生产提供 了可靠的数据。 关键词巷道，顶板动态，监测系统，WinCC，SQL 数据库 万方数据 太原理工大学硕士研究生学位论文 III The Design and Implementation of Mine Roof Dynamic Ination Monitoring System based on WinCC ABSTRACT The Coal Mine Roof dynamic ination monitoring system based on WinCC, which is entrusted by Shanxi Coal Transportation and Marketing Group Science and Technology Co., Ltd., is designed and implemented as the KJ504 coal mine pressure monitoring system PC sorftware. KJ504 coal mine pressure monitoring system consists of 5 subsystems, namely the roof displacement monitoring system, the anchor stress monitoring system, the cable stress monitoring system, the coal pillar stress monitoring system and the power support resistance monitoring system. The system is designed for the collection, display, storage and report output capabilities to each subsystem data. After analyzing the advantages and disadvantages of the existing software, we put forward the overall design scheme of the roof dynamic ination monitoring system with WinCC configuration software as development plat, MS SQL2005 as the background database, which is supplemented by VBScript programming language. In the process of system development, we focus on the following key issues 1 As the non-standard communication protocol of the tunnel data substation is used and the driver program isn’t provided by WinCC, the OPC Server is designed as communicating interface between data substation and upper monitor, and WinCC served as OPC DA client. 2 Coal mining is a dynamic process. In the process of coal backstoping and driving, the length of the roadway and the numbers of sensors installed in 万方数据 太原理工大学硕士研究生学位论文 IV the roadway are changing. And the Coal Mine roadway is composed of sections. In each section, the types of installed sensors are roughly the same. In order to timely reflect the dynamic process on the monitor screen, and to facilitate the project configuration, the idea of“encapsulating“ different types of sensors is proposed. In the data organization, the variables are named in a certain order, to achieve the unification of process variables, and orderly management. 3 According to the working principle and operating characteristic curve of hydraulic support, and combined with practical experience of engineers, the difference is applied to extracting the structural parameters such as initial support force from actual data. Then the workface advancing and periodic weighting are analyzed. 4 The integrated WinCC SQL2005 database is utilized to archive the process values. And the data analysis results are marked and stored by the custom database. Then the direct accessing to archiving database of process variables, custom database and Excel templates are accomplished by VB scripts to realize the function of complex reports output. 5 The figure of spatial trend is plotted by TeeChart to further improve the system. The work of system test has been completed by Shanxi Coal Transportation and Marketing Group Research Science and Technology Co.,Ltd. Now, the system has been used in Yangcheng Sihou Coal Co. and Sanyuan Wangzhuang Coal Co. mine of Shanxi Coal Transportation and Marketing Group. The system is running well and providing reliable data for coalmine safety production. KEY WORDS Roadway, roof dynamic, monitoring system, WinCC, SQL database 万方数据 太原理工大学硕士研究生学位论文 V 目录 摘 要 ................................................................................................................................. I ABSTRACT ..................................................................................................................... III 目录 ................................................................................................................................... V 图表索引 .......................................................................................................................... IX 第 1 章 绪 论 .................................................................................................................. 1 1.1 课题背景 ............................................................................................................. 1 1.2 国内外研究现状 ................................................................................................. 1 1.3 课题研究目的和意义 .......................................................................................... 2 1.4 论文研究内容 ...................................................................................................... 2 第 2 章 监测系统设计方案 ............................................................................................ 5 2.1 系统需求分析 ...................................................................................................... 5 2.1.1 井下系统介绍 ........................................................................................... 5 2.1.2 系统功能分析 ........................................................................................... 7 2.1.3 系统性能分析 ........................................................................................... 7 2.2 系统技术方案选择 .............................................................................................. 8 2.2.1 系统技术方案确定 ................................................................................... 8 2.2.2 项目技术路线 ......................................................................................... 10 2.3 系统总体设计 .................................................................................................... 10 2.4 本章小结 ............................................................................................................ 11 第 3 章 支架初撑力提取方法及关键组态技术研究 .................................................. 13 3.1 支架阻力数据处理研究 .................................................................................... 13 3.1.1 支架工作特性 ......................................................................................... 13 3.1.2 基于差分思想的初撑力提取方法 ......................................................... 16 3.1.3 工作面推进度及来压周期分析算法 ..................................................... 22 3.2 监测系统设计中关键组态技术研究 ................................................................ 24 3.2.1 系统变量属性管理 ................................................................................. 24 万方数据 太原理工大学硕士研究生学位论文 VI 3.2.2 界面元件封装设计 ................................................................................. 27 3.2.3 基于 Teechart 控件绘制空间趋势曲线 ................................................. 30 3.2.4 基于 Excel 实现报表输出...................................................................... 32 3.3 本章小结 ............................................................................................................ 34 第 4 章 四侯煤业实际监测系统设计与实现 ............................................................. 37 4.1 四侯煤业项目概况 ............................................................................................ 37 4.2 监控系统设计思路 ............................................................................................ 39 4.3 与数据分站通讯实现 ........................................................................................ 40 4.3.1 OPC 服务器与数据分站通信 ................................................................ 41 4.3.2 WinCC 与 OPC 服务器通讯 .................................................................. 42 4.4 数据库设计 ........................................................................................................ 43 4.4.1 过程值归档数据库设计 ......................................................................... 43 4.4.2 用户归档数据库设计 ............................................................................. 43 4.4.3 自定义数据库设计 ................................................................................. 45 4.4.4 WinCC 直接访问数据库实现 ................................................................ 46 4.5 支架阻力数据处理实现 .................................................................................... 48 4.5.1 初撑力分析 ............................................................................................. 48 4.5.2 推进度分析 ............................................................................................. 51 4.5.3 周期来压分析 ......................................................................................... 52 4.6 菜单结构设计 .................................................................................................... 53 4.7 HMI 设计 ........................................................................................................... 55 4.7.1 元件属性设置界面 ................................................................................. 55 4.7.2 数据实时监测界面 ................................................................................. 55 4.7.3 历史数据查询界面 ................................................................................. 56 4.8 报表设计 ............................................................................................................ 57 4.9 本章小结 ............................................................................................................ 60 第 5 章 系统测试及应用 ............................................................................................. 61 5.1 系统使用操作步骤 ............................................................................................ 61 万方数据 太原理工大学硕士研究生学位论文 VII 5.2 WinCC 与 OPC 服务器的连接测试 ................................................................. 61 5.3 系统整体功能测试 ............................................................................................ 62 5.4 系统实际运用情况 ............................................................................................ 67 5.5 本章小结 ............................................................................................................ 69 第 6 章 总结与展望 ...................................................................................................... 71 6.1 总结 .................................................................................................................... 71 6.2 展望 .................................................................................................................... 72 参考文献 .......................................................................................................................... 73 致谢 .................................................................................................................................. 77 攻读学位期间发表的学术论文 ...................................................................................... 79 万方数据 太原理工大学硕士研究生学位论文 IX 图表索引 图 1- 1 系统数据组成结构图 ............................................................................................ 3 图 2- 1 采煤工作面示意图 ................................................................................................ 5 图 2- 2 顶板离层仪安装示意图 ........................................................................................ 6 图 2- 3 项目技术路线 ...................................................................................................... 10 图 2- 4 KJ504 煤矿压力监控系统整体结构图 .............................................................. 11 图 3- 1 液压支架结构 ...................................................................................................... 13 图 3- 2 支架的工作特性曲线 .......................................................................................... 15 图 3- 3 支架压力测站布置示意图 .................................................................................. 16 图 3- 4 实测液压支架工作阻力曲线 .............................................................................. 17 图 3- 5 工作面压力与支架工作状态关系分析 .............................................................. 20 图 3- 6 初撑力提取步骤框图 .......................................................................................... 22 图 3- 7 周期来压示意图 ................................................................................................. 23 图 3- 8 系统结构图 .......................................................................................................... 25 图 3- 9 变量命名结构 ...................................................................................................... 26 图 3- 10 批量属性设置界面 ............................................................................................ 27 图 3- 11 传感器封装模型图 ............................................................................................ 28 图 3- 12 运行状态下离层仪封装效果图 ........................................................................ 29 图 3- 13 空间趋势绘制程序流程图 ............................................................................... 31 图 3- 14 空间趋势图 ....................................................................................................... 32 图 3- 15 报表程序流程图 ................................................................................................ 34 图 4- 1 3101、3102 工作面巷道测站布置图 ................................................................. 38 图 4- 2 监控系统与分站通信结构图 .............................................................................. 41 图 4- 3 OPC 与分站通信流程图 ..................................................................................... 42 图 4- 4 离层仪属性表 ...................................................................................................... 45 图 4- 5 原始数据库表 ...................................................................................................... 46 万方数据 太原理工大学硕士研究生学位论文 X 图 4- 6 数据源配置信息 ................................................................................................. 48 图 4- 7 循环末阻力算法流程图 ..................................................................................... 49 图 4- 8 初撑力算法流程图 ............................................................................................. 50 图 4- 9 初撑力提取结果 ................................................................................................. 51 图 4- 10 初撑力频率分布图 ...................................................