Emergency operation device and method for direct-current electric control hoist

Abstract

The invention discloses a direct-current electric control hoist emergency operation device and an operation method. The emergency operation device for the direct-current electric control hoist comprises a clutch, a speed reducer, a direct-current motor and a direct-current driving system, a working shaft of a direct-current motor controlled by a direct-current driving system is connected with an input shaft of a speed reducer, and an output shaft of the speed reducer is in transmission connection with a clutch installed at the power input shaft end of the hoist. A hydraulic control emergency operation device is changed into the direct-current electric control emergency operation device, the direct-current motor is high in efficiency and large in output torque, the efficiency can reach 90% at the rated rotating speed, the efficiency is reduced when the rotating speed is larger than or smaller than the rated rotating speed, and the requirements that the higher the lifting efficiency is, the better the descending efficiency is and the better the descending efficiency is during emergency operation of the hoist are met; and the size and the weight of the hoist emergency operation device are greatly reduced. Meanwhile, the emergency operation method is simple in step, convenient and fast, the gate can be closed in time within the set time, and fault expansion is avoided.

Description

Technical Field

[0001] The invention relates to a gate hoist for water conservancy projects, hydropower projects or pumped storage power stations, and in particular to an emergency operating device for a direct current electric controlled gate hoist. The invention also relates to an emergency operating method for a direct current electric controlled gate hoist. Background Art

[0002] The gate hoist, which plays an important role in water conservancy projects, hydropower projects, and pumped storage power stations (such as flood discharge working gate gate hoist, emergency gate gate hoist, etc.), usually has a working motor and one or two power supplies. The motor is equipped with a set of inverter control. When the power supply of the winch gate hoist fails, or the motor of the gate hoist fails, or the inverter fails, the gate hoist will not work properly. At present, the response to power supply failure is generally to configure a diesel generator, but the power of the diesel generator cannot be less than the power of the gate hoist motor, so the space occupied is large, and a special diesel generator room (car) and corresponding control system are required, which has high investment costs and poor economic efficiency.

[0003] In response to the technical problem of how to open the gate in an emergency state when the motor of the winch hoist fails, resulting in the gate not being able to close within the specified time, or the power supply or motor failure cannot be repaired in time, the Chinese invention patent (patent number 201110091274.2, invention name "Emergency operating device of winch hoist and gate system") discloses a technical solution using a hydraulic emergency operating device in conjunction with a portable fuel hydraulic pump station, that is, the speed of the hydraulic pump hydraulic motor is controlled by a speed regulating valve to achieve the dual purpose of controlling the gate to completely close the gate at a specified speed; at the same time, the portable fuel hydraulic pump station generates pressure oil to drive the hydraulic pump hydraulic motor to rotate, thereby driving the gate to open. However, due to the high cost of the hydraulic emergency operating device and the portable fuel hydraulic pump station, the price of each set is usually around RMB 150,000-500,000. For hydraulic hoists, which are usually small in tonnage, the cost of an emergency operating device is basically equivalent to the cost of a hoist, and the technical and economic efficiency is low and difficult to implement. Therefore, small and medium-sized hoists are still mainly equipped with manual hoists. The deadweight of the gate lifted by the super-large gate hoist is usually much smaller than the rated opening and closing load. Taking the 3200kN gate hoist of the inlet and outlet accident gate of Hunan Pingjiang Pumped Storage Power Station as an example, the gate itself weighs only 62 tons. When the hydraulic emergency operating device controls the hydraulic motor through the speed regulating valve and relies on the gate's own gravity to descend, the gate is at risk of getting stuck and unable to fall due to its own insufficient weight. Therefore, the super-large gate hoist also needs to be driven by a portable fuel hydraulic pump station when the gate descends. Summary of the invention

[0004] The purpose of the present invention is to provide a low-cost, safe, reliable, environmentally friendly and labor-saving DC electric control gate hoist emergency operation device, which can safely close or open the gate at a faster speed when the gate hoist power supply or the motor or frequency converter fails, providing a new idea for the emergency operation of the gate hoist.

[0005] To achieve the above purpose, the present invention can adopt the following technical solutions: The DC electric-controlled hoist emergency operation device of the present invention comprises: clutch, reducer, DC motor, DC drive system; The working shaft of the DC motor controlled by the DC drive system is connected to the input shaft of the reducer, and the output shaft of the reducer is transmission-connected to the clutch installed at the end of the power input shaft of the gate hoist.

[0006] The present invention changes the hydraulically controlled emergency operating device into a DC electrically controlled emergency operating device. The DC motor has high efficiency and large output torque. The efficiency can reach 90% at the rated speed. When the speed is greater than or less than the rated speed, the efficiency decreases, which meets the requirements of the hoist having the higher the lifting efficiency, the better, and the lower the lowering efficiency, the better, and greatly reduces the size and weight of the hoist emergency operating device.

[0007] The reducer adopted in the present invention has a modular structure and a transmission ratio of 10~25. The output end speed is greater than 0.1 times the speed of the gate hoist motor, the output end rated torque is greater than the rated torque of the gate hoist motor, and the input power is greater than 0.1 times the input power of the gate hoist motor.

[0008] The DC motor used in the present invention is an excitation DC motor with a braking mechanism, and its power is ≥ 0.1 times the power of the hoist motor.

[0009] The DC drive system used in the present invention includes a DC drive power supply (battery pack), a microprocessor controller, a power drive circuit and a control operation panel; The DC drive power supply provides DC power to the power drive circuit, and provides working power to the microprocessor controller after voltage conversion through the power module; the power circuit can be shut off by the electric lock switch and the emergency stop button, and the battery pack power can be displayed through the power meter for safe operation.

[0010] By controlling the buttons on the operation panel to drive the DC motor to run up, down or stop, and by controlling the knob on the operation panel to adjust the running speed of the DC motor, the emergency opening and closing operation function without electricity can be realized.

[0011] The microprocessor controller is the core of the entire DC drive system. It receives input instructions from the control panel, outputs DC drive signals after calculation and processing, and controls the power drive circuit. At the same time, the microprocessor controller can also detect the current, voltage, speed and component failures of the drive circuit to ensure the normal operation of the motor.

[0012] During operation, the microprocessor controller receives the unpowered descent command on the control operation panel, controls the current to pass through the resistor box of the gate opening and closing machine electronic control system, and controls the gate to descend unpowered through energy-consuming braking, thereby realizing the unpowered emergency door closing operation function.

[0013] The power drive circuit of the present invention is composed of a power drive chip, a high-power transistor and a freewheeling diode, and is used for controlling the operation and speed regulation of a DC motor.

[0014] The DC electric-controlled hoist emergency operation method of the present invention adopts the DC electric-controlled hoist emergency operation device specially designed in the present application, and the specific steps are as follows: When the hoist power supply, motor or frequency converter fails, the DC electric hoist emergency operation device of the present invention is operated to connect the output shaft of the reducer with the hoist power input shaft through the clutch; Manually release the working brake and safety brake of the gate hoist; Start the DC motor to control the hoist to rise or fall.

[0015] The advantages of the present invention are compact structure and low cost. The total cost of an emergency operation device can be reduced to 50,000-150,000, which is only one-third of the hydraulic emergency operation device. In addition, the present invention is safer, more reliable and more environmentally friendly than the hydraulic emergency operation device. The DC electric emergency operation device has its own power battery and control system, which can start quickly, and the gate has no risk of getting stuck. It is highly efficient and pollution-free. Compared with the manual opening and closing device, it is not only labor-saving, but also has a fast opening and closing speed. At the same time, the emergency operation method of the present invention has simple steps, is convenient and fast, and can close the gate in time within the specified time, avoiding the expansion of the fault. At the same time, if the device is simply modified (the reducer type can be changed according to the layout type of the hoist, so that the overall structure is beautiful and compact: for example, planetary gears, bevel gears or helical gear reducers are used; the connection with the DC motor can be vertical, horizontal, etc.), it can also be used on screw hoists, mobile hoists and hydraulic hoists, which improves the adaptability of the emergency device. When a fault occurs in the power supply, motor or frequency converter of the gate hoist, the emergency operation method of the present invention has simple steps, is convenient and quick, and can close the gate in time within a specified time, thus avoiding the expansion of the fault. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a structural schematic diagram of the present invention.

[0017] Figure 2 It is a control system diagram of the DC motor of the present invention.

[0018] Figure 3 It is a schematic diagram of the power drive circuit adopted by the present invention. DETAILED DESCRIPTION

[0019] The present invention is described in more detail below with reference to the accompanying drawings to facilitate understanding by those skilled in the art.

[0020] like Figure 1 As shown, the DC electric-controlled gate hoist emergency operating device of the present invention includes a clutch 1, a reducer 2, and a DC motor 3. The working shaft of the DC motor 3 controlled by the DC drive system is connected to the input shaft of the reducer 2, and the output shaft of the reducer 2 is transmission-connected to the clutch 1 installed at the power input shaft end of the gate hoist motor 4.

[0021] The reducer 2 used in the present invention has a modular structure and a transmission ratio of 10~25. Its output end speed is greater than 0.1 times the speed of the hoist motor, the output end rated torque is greater than the rated torque of the hoist motor, and its input power is greater than 0.1 times the input power of the hoist motor.

[0022] The DC motor 3 used in the present invention is an excitation DC motor with a braking mechanism, and its power is 0.1 times the power of the hoist motor.

[0023] The DC drive system used in the present invention is as follows Figure 2 As shown, it includes a battery pack PS, a microprocessor controller TMS320X240, a power drive circuit and a control operation panel; The battery pack PS provides DC power to the power drive circuit, and provides working power to the microprocessor controller and other components after voltage transformation by the power module AH8690; the power circuit can be shut off by the electric lock switch SA1 and the emergency stop button SA2, and the power meter PW displays the power of the battery pack PS for safe operation.

[0024] The buttons (up, down, stop) on the control panel are used to drive the DC motor to run up, down or stop, and the knob on the control panel is used to adjust the running speed of the DC motor.

[0025] The microprocessor controller TMS320X240 is the core of the entire DC drive system. It receives input instructions from the control operation panel, and outputs PWM DC drive signals PWM1 and PWM2 after calculation and processing to control the power drive circuit. At the same time, the microprocessor controller can also detect the current, voltage, speed and component failure of the drive circuit to ensure the normal operation of the motor.

[0026] During normal operation, the microprocessor controller receives the unpowered descent command on the control operation panel, controls the current to pass through the resistor box Rf of the gate opening and closing machine electronic control system, and controls the gate to descend unpowered through energy-consuming braking.

[0027] The power drive circuit of the present invention is composed of a power drive chip IR2110S, high-power IGBT transistors VT1-VT4 and freewheeling diodes VD1-VD4, and is used to control the operation and speed regulation of a DC motor. Figure 3 As shown: The power drive circuit receives the PWM control signals PWM1 and PWM2 output by the microprocessor. After the IR2110S power amplification, it controls the two sets of transistors VT1 and VT4, VT2 and VT3 to be turned on and off respectively, and can drive the DC motor to rotate forward and reverse: VT1 and VT4 are turned on, VT2 and VT3 are turned off, and the DC motor rotates forward; VT1 and VT4 are turned off, VT2 and VT3 are turned on, and the DC motor reverses. By changing the high and low level time (i.e., duty cycle) of the PWM1 and PWM2 signals by the speed knob, the running speed of the motor can be changed.

[0028] The control system uses a powerful intelligent microprocessor, which can obtain more accurate modulation signals to ensure smooth starting and braking of the motor; obtain larger starting current and faster starting speed; at the same time, the control system is equipped with battery protection, overcurrent protection, overvoltage and undervoltage protection functions, which is convenient for detection and maintenance. Of course, the DC drive system of the present invention may also adopt other control methods as long as the same effect can be achieved.

[0029] For example, the DC electric-controlled gate hoist emergency operating device of the present invention is matched to a 3200kN fixed winch gate hoist, and its hoisting motor is selected according to the static function, using a three-phase AC asynchronous variable frequency motor specially used for cranes, model QABP355M8B 160kW 740r / min.

[0030] Calculate the rated speed of the output end of reducer 2 of the emergency operation device, which should be no less than 0.1 times the rated speed of motor 4. The speed of motor 4 is 740r / min, and the output speed of reducer 2 is greater than 74r / min; Calculate the rated torque of the output end of reducer 2 of the emergency operation device, which should not be less than the rated torque of motor 4. The torque of motor 4 is 2065Nm, and the input torque of reducer 2 is greater than 2065Nm; Calculate the input power of reducer 2 of the emergency operation device, which should be no less than 0.1 times the input power of motor 4. The power of motor 4 is 160kN, and the input power of reducer 2 is 18.5kw. According to the above parameters, the corresponding three-in-one reducer is selected, and the service coefficient is not less than 1.4. The reducer 2 of this application uses Guomao K series three-in-one reducer K97, whose parameters are: input power 18.5kw, input torque 2290, input speed 77r / min, service coefficient 1.9, which meets the use requirements.

[0031] According to the reducer input shaft φ75 of the winch and the input shaft φ75 of the selected three-in-one reducer, clutch 1 uses a manual spline clutch.

[0032] The DC motor 3 of the present application uses a Z4 series excitation DC motor, with a speed regulator output voltage of 160V~400V, a power of 18.5KW, a torque of 125Nm, a speed range of 750-3000r / min, a rated speed of 1500 r / min, and a weak magnetic speed of 3600r / min.

[0033] The gate hoist is a special opening and closing equipment for the gate. Its opening and closing load is considered according to the limit load. The gate itself is relatively light. The gate weight corresponding to the 3200kN gate hoist is only 62 tons. When the emergency operating device operates the gate to descend, the torque required by the motor is only 0.2 times the rated torque. Therefore, the descent speed can be close to the weak magnetic speed of the motor, and the maximum descent speed can reach 0.4 times the rated descent speed of the gate hoist.

[0034] The selection of battery pack PS is calculated based on the working condition of lifting 10 meters with a rated load of 3200kN. The energy required is 32000000 joules, which is about 8.9kwh. Considering the power consumption loss, the battery capacity should not be less than 2 times of the required energy, so a 24kwh automotive ternary lithium battery is selected.

[0035] After selecting the above parts, press Figure 1 To assemble: The working shaft of the DC motor 3 is connected to the input shaft of the reducer 2, and the output shaft of the reducer 2 is transmission-connected to the motor 4 of the gate hoist through a manual spline clutch 1.

[0036] The control system of the DC motor 3 is as follows Figure 2 Well connected; for easy operation, it can be controlled by panel or remote control.

[0037] When the power supply, motor or frequency converter of the gate hoist fails, the manual spline clutch 1 is activated to connect the output shaft of the reducer 2 with the input shaft of the gate hoist motor 4; Manually release the working brake and safety brake of the gate hoist; Start the DC motor 3 and use the DC motor 3 to control the hoist to rise or fall.

Claims

1. A DC electric hoist emergency operation device, characterized in that: include: clutch, reducer, DC motor, DC drive system; The working shaft of the DC motor controlled by the DC drive system is connected to the input shaft of the reducer, and the output shaft of the reducer is transmission-connected to the clutch installed at the end of the power input shaft of the gate hoist.

2. The DC electric controlled hoist emergency operation device according to claim 1 is characterized in that: The reducer has a modular structure and a transmission ratio of 10 to 25. The output speed is greater than 0.1 times the speed of the gate hoist motor, the rated torque of the output is greater than the rated torque of the gate hoist motor, and the input power is greater than 0.1 times the input power of the gate hoist motor.

3. The DC electric controlled hoist emergency operation device according to claim 1 is characterized in that: The DC motor is an excitation DC motor with a braking mechanism, and its power is ≥ 0.1 times the power of the gate hoist motor.

4. The DC electric controlled hoist emergency operation device according to claim 1 is characterized in that: The DC drive system includes a DC drive power supply, a microprocessor controller, a power drive circuit and a control operation panel; The DC driving power supply provides DC power to the power driving circuit, and provides working power to the microprocessor controller after voltage conversion through the power supply module; The buttons on the operation panel are used to drive the DC motor to run up, down or stop, and the knobs on the operation panel are used to adjust the running speed of the DC motor; The microprocessor controller receives the input command from the control operation panel and outputs a DC drive signal after calculation and processing.

5. The DC electric controlled hoist emergency operation device according to claim 4 is characterized in that: The power drive circuit is composed of a power drive chip, a high-power transistor and a freewheeling diode, and is used to control the operation and speed regulation of the DC motor.

6. A DC electric controlled hoist emergency operation method, characterized in that: Using any one of the operating devices in claims 1-5, the specific steps are: When the hoist power supply, motor or frequency converter fails, the DC electric hoist emergency operation device of the present invention is operated to connect the output shaft of the reducer with the hoist power input shaft through the clutch; Manually release the working brake and safety brake of the gate hoist; Start the DC motor to control the hoist to rise or fall.

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