Hoisting Type Vibroflot Hoisting Control System and Control Method

Abstract

The present invention relates to the technical field of foundation construction, specifically to a winch control system and control method for a vibratory compactor of a crane. The system includes a winch control system, a real-time detection device, and a winch brake safety control system. The winch control system can remotely control the working state of the winch. The real-time detection device analyzes and judges whether the winch is in a normal working state according to the collected data information, and feeds it back to the main controller and the winch brake safety control system in real time. The independent winch brake safety control system can stop the winch in time according to the abnormal signal. The purpose is to collect the pulling force, speed, and acceleration values of the vibratory compactor through sensors, remotely control the ascending, descending, or changing of the movement speed of the vibrator; and comprehensively judge and analyze the working state of the vibrator according to the information of the sensors. Combining with the independent winch brake safety control system, it can prevent safety accidents caused by the failure of the winch.

Description

Technical Field

[0001] The present invention belongs to the technical field of foundation construction, and particularly relates to a winch control system and control method for a crane-mounted vibroflot. Background Art

[0002] A vibroflot is a commonly used device in vibroflotation construction. After vibroflotation construction on the foundation, it can improve the bearing capacity of the foundation, reduce the settlement amount, increase the foundation stability, and enhance the anti-seismic liquefaction ability. During vibroflotation construction, in addition to the vibroflot, a walking hoisting device, a pumping water supply system, a control console, etc. are also required.

[0003] Currently, most of the vibroflotation construction relies on a winch controller of a crane to control the direction, position, and speed of the vibroflot. In the existing construction operations, only the winch can be used for simple start, stop, and forward and reverse speed control, and the operation of the winch needs to be manually completed by the operator. The entire operation process is complex and requires continuous monitoring of the motion parameters of the vibroflot, and it is not very suitable for the existing construction environment.

[0004] Moreover, the existing crane-mounted vibroflot does not have a safety protection system design, and does not consider how to prevent safety accidents in the case where the vibroflot rises too fast and causes the steel wire rope to break when a sudden situation occurs, or the lifting rope moves freely due to a winch failure. Summary of the Invention

[0005] In order to solve the problems that the automation degree of the winch of the existing crane-mounted vibroflot is not high and there is no effective safety control system, the present invention provides a winch control system and control method for a crane-mounted vibroflot. The control system can collect the tension, speed, and acceleration values of the vibroflot through sensors, and can remotely control the rise, fall, or change of the speed of the vibrator; and the present invention can comprehensively judge and analyze the working state of the vibrator, and combine with an independent winch brake safety control system to prevent safety accidents from occurring when the winch fails.

[0006] The technical solution adopted by the present invention is as follows:

[0007] A winch control method for a crane-mounted vibroflot includes the following steps:

[0008] 1) The main controller sends an instruction to the winch control system to operate the winch to control the rise, fall, or speed change of the vibroflot;

[0009] 2) The real-time detection device collects the data of the tension sensor, speed sensor, and acceleration sensor in real time, and after analyzing the motion state by the microcontroller in the real-time detection device, sends the data to the main controller and the winch brake safety control system;

[0010] 3) The winch brake safety control system determines whether it is in a safe state based on the data sent by the real-time detection device. If not, it cuts off the power supply of the winch or activates the safety device inside the winch to make it stop.

[0011] Preferably, the winch control system adopts a PID control algorithm to make the moving speed of the vibroflot in a smoothly changing state.

[0012] Preferably, the data signal sent by the microcontroller in step 2) is transmitted to the main controller after being optically isolated, and then transmitted by the main controller to the frequency converter in the winch control system, and the winch is controlled to rise, fall or change speed by the frequency converter.

[0013] Preferably, the tension sensor is arranged at the connection of the steel rope and the vibroflot, the speed sensor is arranged at the winch, and the acceleration sensor is arranged on the vibroflot.

[0014] Preferably, the speed sensor is an encoder, and the output signal of the encoder is transmitted to the microcontroller after being optically isolated.

[0015] Preferably, the main controller is an in-vehicle tablet, which is arranged on the vibroflot crane, and the in-vehicle tablet is wirelessly communicatively connected with the winch control system and the real-time detection device.

[0016] The winch-type vibroflot winch control system includes a winch control system, a real-time detection device and a winch brake safety control system;

[0017] The winch control system is wirelessly communicatively connected with the main controller. The winch control system includes a frequency converter, and the frequency converter is connected with the winch motor to control the winch motor through the frequency converter;

[0018] The real-time detection device includes a tension sensor, a speed sensor and an acceleration sensor, and the real-time detection device is wirelessly communicatively connected with the main controller and the winch brake safety control system;

[0019] The winch brake safety control system includes a safety control device inside the winch, and the winch is controlled to stop working through the safety control device.

[0020] Preferably, a microcontroller is arranged in the real-time detection device. The microcontroller is connected with the tension sensor, the speed sensor and the acceleration sensor, and transmits the analyzed data of the tension sensor, the speed sensor and the acceleration sensor to the main controller.

[0021] Preferably, the tension sensor is arranged at the connection of the steel rope and the vibroflot, the speed sensor is arranged at the winch, and the acceleration sensor is arranged on the vibroflot.

[0022] Preferably, the master controller is an in-vehicle tablet, which is arranged on the vibroflot crane. The in-vehicle tablet is wirelessly communicatively connected to the hoist control system and the real-time detection device.

[0023] The beneficial effects of the present invention are as follows:

[0024] 1) Through the hoist control system of the present invention, the start, stop, forward and reverse speeds of the hoist can be controlled remotely through the in-vehicle tablet, and the speed of the hoist can also be smoothly changed through the PID algorithm, thereby preventing excessive pulling force caused by sudden speed changes, resulting in steel wire breakage and the vibroflot falling off.

[0025] 2) Through the real-time detection device of the present invention, the data of the tension sensor, speed sensor and acceleration sensor can be collected in real time, and after the collected data is integrated and analyzed by the microcontroller, the analysis status is sent to the master controller and the hoist brake safety control system, thereby ensuring that the hoist is in a safe working environment. If an abnormality occurs, it can be controlled through the hoist brake safety control system to make the hoist stop.

[0026] 3) In the present invention, the hoist control system and the hoist brake safety control system are two independently operating systems that do not interfere with each other or control each other; when the steel wire breaks due to the too-fast rise of the vibroflot, or the vibroflot free-falls due to a failure of the hoist control system, the hoist brake safety control system is activated to cut off the power supply of the hoist emergently, or control the safety control device inside the hoist to lock the steel wire of the hoist, avoiding safety failures. Description of the Drawings

[0027] Figure 1 is the control system structure diagram of the present invention;

[0028] Figure 2 is the working flow chart of the hoist safety monitoring system in the present invention;

[0029] Figure 3 is the structural schematic diagram of the hoist control device;

[0030] Figure 4 is the structural schematic diagram of the real-time detection device. Detailed Embodiments

[0031] In order to make the purpose, technical solutions and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0032] The present invention is applicable to the vibroflotation method construction in foundation work.

[0033] Hoisting type vibroflot winch control method, comprising the following steps:

[0034] 1) The master controller sends instructions to the winch control system to operate the winch to control the vibroflot to rise, fall or change speed; the winch control system adopts a PID control algorithm to make the movement speed of the vibroflot in a smoothly changing state. The master controller is an in-vehicle tablet, which is arranged on the vibroflot crane, and the in-vehicle tablet is wirelessly communicatively connected to the winch control system and the real-time detection device, whereby remote control of the winch can be realized.

[0035] 2) As Figure 2 shown, it is the working flow chart of the winch safety monitoring system. The real-time detection device collects the data of the tension sensor, speed sensor and acceleration sensor in real time, and after analyzing the motion state of the data by the microcontroller in the real-time detection device, it sends the data to the master controller and the winch brake safety control system; the real-time detection device continuously collects the AD values of the tension, speed and acceleration, converts the AD values into real-time data through calculation by the microcontroller, and analyzes the motion state of the vibroflot by the microcontroller. The speed sensor is an encoder, and the output signal of the encoder is transmitted to the microcontroller after being optically isolated.

[0036] The data signal sent by the microcontroller is also transmitted to the master controller after being optically isolated, and then transmitted by the master controller to the frequency converter in the winch control system, and the frequency converter controls the rise, fall or speed change of the winch. Optical isolation can make the transmitted signal more stable and accurate.

[0037] 3) The winch brake safety control system judges whether it is in a safe state according to the data sent by the real-time detection device. If not, it cuts off the power supply of the winch or starts the safety device inside the winch to make it stop. When the vibroflot is in an abnormal working state, the safety control device in the winch brake safety control system is started, and the safety control device can cut off the power supply of the winch and stop the steel wire rope.

[0038] As Figure 1 shown, it is the structure diagram of the hoisting type vibroflot winch control system, including a winch control system, a real-time detection device and a winch brake safety control system; among them, the winch control system and the winch brake safety control system are two independent systems. The winch brake safety control system works independently in this system, is not controlled by the master controller and the winch control system, only receives the sensor data returned by the real-time device, makes its own judgment, and controls the safety control device by itself once an abnormality occurs.

[0039] The winch control system is wirelessly communicatively connected to the master controller. In this embodiment, the master controller is a vehicle-mounted tablet which is disposed on the vibroflot crane. The winch control system includes a frequency converter which is connected to the winch motor, and the winch motor is controlled by the frequency converter. The control instruction issued by the master controller controls the frequency converter in the winch control system, and then controls the winch motor through the frequency converter, so as to realize the control of the vibroflot. As Figure 3 shown, it is a schematic structural diagram of the winch control system. By detecting the signal fed back by the microcontroller in real time and sending it to the frequency converter, finally the frequency converter completes the setting of the start, stop and speed of the winch. The frequency converter can also feed back its status to the microcontroller.

[0040] The real-time detection device includes a tension sensor, a speed sensor and an acceleration sensor. The real-time detection device is wirelessly communicatively connected to the master controller and the winch brake safety control system. The real-time detection device integrates the data collected by the tension sensor, the speed sensor and the acceleration sensor, and judges whether the vibroflot is in a normal working state, and sends this state to the master controller and the winch brake safety control system in real time. If it is in a normal working state, the winch brake safety control system does not work. If it is in an abnormal state, the winch brake safety control system works to make the winch stop. The master controller receives the sensor data returned by the real-time detection device and calculates through the PID algorithm, and sends a control instruction to the winch control system to realize the control of the start, stop and forward and reverse rotation of the winch. The PID algorithm can ensure that the winch runs at a smooth speed.

[0041] The winch brake safety control system includes a safety control device inside the winch, and the winch is controlled to stop working through the safety control device. The winch brake safety control system calculates and judges the sensor data collected by the real-time detection device. When a fault occurs, it directly controls the safety control device inside the winch to stop the winch from working, avoiding the occurrence of safety accidents.

[0042] As Figure 4As shown in the figure, it is a schematic structural diagram of a real-time detection device. A real-time detection microcontroller is provided inside the real-time detection device. The real-time detection microcontroller is connected to a tensile force sensor, a speed sensor, and an acceleration sensor, and transmits the analyzed data of the tensile force sensor, the speed sensor, and the acceleration sensor to the master controller. The tensile force sensor is arranged at the connection between the steel wire rope and the vibroflot, so that the tensile force on the steel wire rope can be accurately measured; the speed sensor is arranged at the winch, and the speed sensor is realized through an encoder arranged at the winch; the acceleration sensor is arranged on the vibroflot, and is mainly used to measure the acceleration of the vibroflot, that is, the acceleration on the steel wire rope. The real-time detection microcontroller can analyze and judge whether the vibroflot is currently in a normal working state based on the three sensors, and when an abnormality occurs, it can timely send a control instruction to control the safety control device inside the winch to lock the steel wire rope to avoid safety accidents.

[0043] The above embodiments are preferred embodiments. It should be noted that the above preferred embodiments should not be regarded as a limitation of the invention. The protection scope of the invention should be subject to the scope defined by the claims. For those of ordinary skill in the art in this technical field, without departing from the spirit and scope of the invention, several improvements and refinements can also be made, and these improvements and refinements should also be regarded as the protection scope of the invention.

Claims

1. Hoisting type vibroflot winch control method, characterized in that, it is applied to the hoisting type vibroflot winch control system. The hoisting type vibroflot winch control system includes a winch control system, a real-time detection device and a winch brake safety control system; the winch control system is wirelessly communicatively connected to the master controller. The winch control system includes an inverter, and the inverter is connected to the winch motor to control the winch motor through the inverter; the real-time detection device includes a tension sensor, a speed sensor and an acceleration sensor. The real-time detection device is wirelessly communicatively connected to the master controller and the winch brake safety control system; the winch brake safety control system includes a safety control device inside the winch to control the winch to stop working through the safety control device; a microcontroller is arranged in the real-time detection device, and the microcontroller is connected to the tension sensor, the speed sensor and the acceleration sensor, and after analyzing the data of the tension sensor, the speed sensor and the acceleration sensor, it transmits the data to the master controller; the tension sensor is arranged at the connection of the steel rope and the vibroflot, the speed sensor is arranged at the winch, and the acceleration sensor is arranged on the vibroflot; the master controller is an in-vehicle tablet, and the in-vehicle tablet is arranged on the vibroflot crane. The in-vehicle tablet is wirelessly communicatively connected to the winch control system and the real-time detection device. The hoisting type vibroflot winch control method includes the following steps: 1) The master controller sends an instruction to the winch control system to operate the winch to control the vibroflot to rise, fall or change speed; the winch control system adopts a PID control algorithm to make the movement speed of the vibroflot in a smoothly changing state; 2) The real-time detection device collects the data of the tension sensor, the speed sensor and the acceleration sensor in real time, and after analyzing the motion state of the data by the microcontroller in the real-time detection device, it sends the data to the master controller and the winch brake safety control system; the data signal sent by the microcontroller is transmitted to the master controller after being optically isolated, and then transmitted by the master controller to the inverter in the winch control system, and the inverter controls the winch to rise, fall or change speed; 3) The winch brake safety control system judges whether it is in a safe state according to the data sent by the real-time detection device. If not, it cuts off the power supply of the winch or starts the safety device inside the winch to make it stop.

2. The hoisting type vibroflot winch control method according to claim 1, characterized in that: the speed sensor is an encoder, and the output signal of the encoder is transmitted to the microcontroller after being optically isolated.

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