Views: 0 Author: Site Editor Publish Time: 2026-07-31 Origin: Site
Xuzhou Tian’an Chemical is located in the Longgu Industrial Park, Pei County, Xuzhou, Jiangsu Province. It operates two 65‑chamber stamping‑type coke ovens (models JNDK55‑07 and CS55F‑12) with a combined annual output of 1.8 million tonnes of coke. Production depends on close coordination among five types of mobile machines: the pusher car, coke guide car, quenching car (motorized coke pot car), charging car, and fume extraction car.
Key challenges before the upgrade:
Challenge | Impact |
|---|---|
Oven‑number alignment relied on manual judgement, resulting in insufficient accuracy | Frequent positioning errors |
No interlocking signals between machines | High risk of misoperation |
Lack of systematic scheduling and real‑time coordination | Limited production efficiency |
No proximity protection for machines on the same track | Potential collision hazards |
Forward Technology was engaged to deploy a full interlock system for 5 machines on one 65‑chamber oven, and to restore the interlock systems for another 10 machines across two additional 65‑chamber ovens.
Layer | Components | Functions |
|---|---|---|
Central control room | Industrial PC + 27‑inch display + management software | Schedule planning, animated monitoring, report generation |
Position detection | Gray code bus (409.8 m) + decoders | 2 mm positioning accuracy, automatic oven‑number identification |
On‑board control | PLC + touchscreen + voice module + wireless bridge | Display, control, and voice guidance |
Wireless communication | Multi‑band wireless bridges | Real‑time data exchange between machines and ground station |
1. Automatic Oven‑Number Identification & Positioning
The Gray code bus is laid along the rails. On‑board decoders continuously read position data, which the system converts into corresponding oven numbers and displays on both the cab screens and the central monitor. The system shows the current oven number dynamically whether the machine is moving or stationary, and automatically indicates the correct travel direction and speed based on the planned oven.
2. Interlock Control Logic
Interlock Type | Activation Conditions |
|---|---|
Door‑removal interlock | Door‑extraction device aligns with the target chamber centre (within tolerance) and the current time falls within the allowed push‑time window. |
Level‑1 push permission | Pusher, coke guide, quenching, and fume cars all align with the same chamber + guide chute in position + quenching car door closed or coke pot in place. |
Level‑2 push permission | Level‑1 conditions met + manual push‑permit signals from the three cars + time matches schedule + dust‑removal fan at high speed + coke pot rotating. |
Charging interlock | Charging car aligns with an already pushed‑empty chamber. |
Travel interlock | Charging car can move only after stamping is complete; quenching car can move only after pushing is finished and the coke pot stops rotating; fume car can move only after charging is done and the oven door is closed. |
3. Multi‑Layer Safety Protection
Anti‑collision: When two machines on the same track approach each other, the system automatically reduces speed to the lowest gear, and stops at the preset safe distance. Simultaneous alerts are given via the touchscreen (visual), voice alarm (audible), and control panel buzzer.
Emergency stop: Both the coke guide car and the quenching car are equipped with a red “Push Forbidden” button. In an emergency, the driver can cut power to the pusher ram (in non‑interlock mode, power is cut for 20 seconds, adjustable).
Override / bypass modes: During system faults or maintenance, operators can switch to “unlocked” or “irregular‑order” mode to keep production running.
4. On‑Board Display & Voice Prompts
Machine Type | Display Content |
|---|---|
Pusher / Coke guide / Quenching cars | Pushing process, current curve, door status, chamber number, scheduled times, push‑permit signals, ram stroke |
Charging / Fume cars | Current position, planned oven number, guide sleeve / lid‑opener status, door open/close signals |
Voice system (up to 15 messages) | Readiness alerts, push start/complete, unlocked mode warning, anti‑collision alert, charging complete, etc. |
5. Central Control Production Management
Schedule planning: Manual or automatic sequence‑based planning. Schedules are sent to all machines automatically; modifications can be made either from the central room or from the pusher car in case of unexpected delays.
Data logging: Automatic generation of shift reports (including K1/K2/K3 indices), monthly summaries, and push‑current records – all printable.
Animated monitoring: Real‑time visualisation of chamber conditions, machine movements, pushing/charging/quenching processes on a single screen.
Network connectivity: An Ethernet port is reserved for connection to the plant’s local area network, enabling remote supervision and dispatching.
Parameter | Value |
|---|---|
Positioning accuracy | 2 mm |
Communication rate | 56 MBPS |
Bit error rate | <10⁻⁷ |
Operating temperature (electronics) | -20°C to +60°C |
Operating temperature (Gray code bus) | -60°C to +100°C |
Mean time between failures | >10,000 hours |
Dimension | Results |
|---|---|
Safety | Interlocking, emergency stops, and anti‑collision effectively eliminate misoperation and collision risks. |
Efficiency | Automated alignment and schedule‑driven operation reduce auxiliary time for pushing and charging. |
Management | Production data are automatically recorded and analysed, providing reliable KPI data for K1/K2/K3 assessment. |
Operation | Visual interfaces and voice guidance lower the skill barrier and reduce operator workload. |
