Device and method for preventing gate opening signal of hydraulic hoist from jumping

Abstract

A device and method for preventing gate opening signal jump of a hydraulic gate hoist, comprising an absolute encoder arranged on an end cover of a hydraulic oil cylinder, a piston rod of the hydraulic oil cylinder connected to the absolute encoder through a rope, the absolute encoder electrically connected to an opening display controller and a hydraulic gate hoist controller respectively, the Gray code output by the absolute encoder is transmitted to the opening display controller and the hydraulic gate hoist controller in two ways respectively; the opening display controller is used to receive the Gray code and process it into a 4-20mA gate opening current signal to the hydraulic gate hoist controller, the hydraulic gate hoist controller is used to judge the gate opening output by the opening display controller and the gate opening calculated by linear interpolation in real time, and set rules to prevent gate opening signal jump. The gate opening signal anti-jump method and device of the present invention based on the hydraulic oil cylinder stroke and gate opening synergy curve can significantly eliminate the problem of value jumps such as instantaneous mutation and slow attenuation in the opening signal output by the opening display controller.

Description

Technical Field

[0001] The invention belongs to the technical field of anti-jumping of gate opening signals of hydraulic hoists, and in particular relates to an anti-jumping device and method for gate opening signals of hydraulic hoists. Background Art

[0002] Hydraulic gate hoists are widely used in the opening and closing of various types of gates in water conservancy and hydropower projects. The detection, calculation and processing of gate opening signals are the core links of hydraulic gate hoists' opening control. At present, hydraulic gate hoists mostly use absolute encoders and corresponding opening display controllers to realize the monitoring of gate opening signals. The specific method is: the absolute encoder is installed on the end cover of the hydraulic cylinder, and the high-precision rotary encoder is driven to rotate by the wire rope connected to the piston rod, and the Gray code is output to the opening display controller. After data processing, the opening display controller outputs 4-20mA gate opening current signal to the hydraulic gate hoist controller. In the actual long-term operation process, affected by factors such as electromagnetic interference from the on-site environment, aging of the opening display controller, and attenuation of the current signal during transmission, the gate opening signal of the hydraulic gate hoist is prone to instantaneous mutations, slow attenuation and other numerical jump phenomena, which cannot accurately reflect the actual opening of the gate, and has an adverse effect on the control and monitoring of the gate opening and the safe and stable operation of the hydraulic gate hoist. Summary of the invention

[0003] In view of the technical problems existing in the background technology, the hydraulic gate opening signal anti-jump device and method provided by the present invention, the gate opening signal anti-jump method and device based on the hydraulic cylinder stroke and gate opening coordination curve of the present invention, can significantly eliminate the problem of numerical jumps such as instantaneous mutation and slow attenuation in the output opening signal of the opening display and controller.

[0004] In order to solve the above technical problems, the present invention adopts the following technical solutions to achieve:

[0005] A device for preventing gate opening degree signals of a hydraulic hoist from jumping, comprising an absolute encoder arranged on an end cover of a hydraulic oil cylinder, wherein a piston rod of the hydraulic oil cylinder is connected to the absolute encoder through a rope, and characterized in that: the absolute encoder is electrically connected to an opening degree display and control instrument and a hydraulic hoist controller respectively, and the Gray code output by the absolute encoder is transmitted to the opening degree display and control instrument and the hydraulic hoist controller respectively in two ways;

[0006] The opening display and controller is used to receive Gray code and convert it into 4-20mA gate opening current signal to the hydraulic hoist controller.

[0007] The hydraulic hoist controller is used to determine the gate opening output by the opening display and controller and the gate opening calculated by linear interpolation in real time, and set rules to prevent the gate opening signal from jumping.

[0008] Furthermore, the hydraulic hoist controller includes a CPU module, a switch output module, a position decoder module, an analog output module, an analog input module and a back panel;

[0009] The CPU module and the touch screen are connected by communication;

[0010] The switch output module is electrically connected to the relay and is used to output a switch alarm signal of a gate opening failure;

[0011] The position decoder module is electrically connected to the absolute encoder and is used to convert the Gray code into a binary code;

[0012] The analog output module is electrically connected to the monitoring system and is used to output the gate opening analog signal to the monitoring system;

[0013] The analog input module is electrically connected to the opening display and control instrument, and is used to receive the gate opening current signal outputted from the opening display and control instrument;

[0014] The backplane is used to install and fix the CPU module, switch output module, position decoder module, analog output module and analog input module.

[0015] Preferably, the anti-jumping method of the hydraulic hoist gate opening signal anti-jumping device comprises the following steps:

[0016] Step 1: Initialize the anti-jump device of the gate opening signal of the hydraulic hoist, read the cylinder stroke and gate opening association curve data table obtained by segmented measurement in the electromechanical installation or system joint debugging on the touch screen, and read the cylinder stroke coefficient K, cylinder stroke offset P, cylinder stroke zero code value M0, cylinder stroke code value lower limit M 低 And the cylinder stroke code value upper limit M 高 ;

[0017] Step 2: Check whether the Gray code conversion value M of the absolute encoder in the hydraulic gate hoist controller is normal. The judgment condition is: Check and judge whether M 低 <M<M 高 ;

[0018] If yes, go to step 3;

[0019] If not, the output cylinder encoder is faulty, go to step 8;

[0020] Step 3: Record the current Gray code conversion value M and the opening Y of the opening display and control instrument;

[0021] Step 4: According to the current Gray code conversion value M and the cylinder stroke and gate opening association curve data table, the cylinder stroke S and the gate linear difference opening Y are calculated by linear difference calculation. 表 ;

[0022] Step 5: Calculate the opening Y of the opening display and controller and the linear difference opening Y of the gate 表 The absolute value of the difference △Y, △Y=|YY 表 |;

[0023] Step 6: If the opening jump fault or △Y>Y 限 , hold for 2 seconds, output gate linear interpolation opening Y 表 , go to step 7; otherwise, output the opening Y of the opening display and controller, and return to step 2; where Y limit represents the opening jump alarm limit,

[0024] Step 7: Output opening jump fault;

[0025] Step 8: Check whether there is a manual fault reset signal. If so, return to step 2; otherwise, continue to perform the detection operation of this step.

[0026] Furthermore, the cylinder stroke S and the gate linear difference opening Y in step 4 表 The calculation method is as follows:

[0027] Step 4.1: Since the cylinder stroke S is linearly related to the encoder Gray code conversion value M, the relationship expression is: S = (M-M0)K+P;

[0028] In the formula, the cylinder stroke coefficient K is calculated by the actual action distance L of one rotation of the absolute encoder and the single-turn accuracy N. The calculation formula is: K = L / 2 N ;

[0029] The cylinder stroke zero code value M0 is calculated from the Gray code conversion value M when the gate is fully closed, and the calculation formula is: M0 = M-(SP) / K;

[0030] Step 4.2: Calculate the gate linear difference opening Y corresponding to the current cylinder stroke S 表 ;

[0031] Y 表 =Y i-1 +(SS i-1 )(Y i -Y i-1 ) / (Si-S i-1 );

[0032] In the above formula, i and n are both positive integers, and 1 <i≤n,Y i S is the cylinder stroke i Corresponding gate opening; Y i and S i The value is obtained through the cylinder stroke and gate opening correlation curve data table.

[0033] This patent can achieve the following beneficial effects:

[0034] 1. The present invention is a gate opening signal anti-jump method and device based on the hydraulic cylinder stroke and gate opening synergy curve, which can significantly eliminate the problem of instantaneous mutation, slow attenuation and other numerical jumps in the output opening signal of the opening display and control instrument.

[0035] 2. Absolute encoder fault judgment, opening jump fault judgment and cylinder stroke calculation have been added to facilitate operators to view the cause of the fault and cylinder stroke changes on the touch screen.

[0036] 3. When the gate opening jumps or the opening deviation exceeds the limit, the output hydraulic cylinder stroke and gate opening association curve uses the opening value calculated by linear difference, otherwise the output opening value of the opening display controller is used to ensure that the gate opening signal is stable, reliable and accurate.

[0037] 4. The structure and principle are simple, the method is easy to understand and has strong feasibility. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] The present invention will be further described below in conjunction with the accompanying drawings and embodiments:

[0039] Figure 1 It is a system structure diagram of the present invention;

[0040] Figure 2 It is a flow chart of the present invention.

[0041] In the figure: hydraulic cylinder 1, absolute encoder 2, opening display and control instrument 3, hydraulic gate hoist controller 4, CPU module 41, switch output module 42, position decoder module 43, analog output module 44, analog input module 45, back panel 46. DETAILED DESCRIPTION

[0042] The preferred solution is Figure 1 to Figure 2 As shown, a hydraulic hoist gate opening signal anti-jump device includes an absolute encoder 2 arranged on the end cover of a hydraulic oil cylinder 1, the piston rod of the hydraulic oil cylinder 1 is connected to the absolute encoder 2 through a rope, the absolute encoder 2 is electrically connected to an opening display controller 3 and a hydraulic hoist controller 4 respectively, and the Gray code output by the absolute encoder 2 is transmitted to the opening display controller 3 and the hydraulic hoist controller 4 in two ways respectively;

[0043] The opening display controller 3 is used to receive the Gray code and convert it into a 4-20mA gate opening current signal to the hydraulic hoist controller 4.

[0044] The hydraulic gate hoist controller 4 is used to determine the gate opening output by the opening display and control instrument 3 and the gate opening calculated by linear interpolation in real time, and set rules to prevent the gate opening signal from jumping.

[0045] The absolute encoder 2 in the present invention outputs a Gray code to the opening display and control instrument and the hydraulic gate opening machine controller respectively. The controller uses a linear interpolation calculation method based on the hydraulic cylinder stroke and gate opening co-connection curve to perform real-time jump fault judgment on the gate opening signal. In this embodiment, the selection of various components is as follows:

[0046] The absolute encoder 2 can adopt the YQX-II type built-in gate opening sensor device. By referring to the technical data, the actual action distance L and single-turn accuracy N of the absolute encoder can be known after one rotation.

[0047] The opening display controller 3 can adopt SMJ-Ⅱ absolute universal displacement controller, which directly receives the signal from the encoder, and outputs 4-20mA current signal after processing and completing various operations (including arc nonlinear conversion).

[0048] The hydraulic gate hoist controller 4 can adopt Siemens S7-300 series PLC, in which the model of CPU module 41 is 6ES7314-1AG14-0AB0, the model of switch output module 42 is 6ES7322-1BL00-0AB0, the model of position decoder module 43 is 6ES7338-4BC01-0AB0, the model of analog output module 44 is 6ES7332-5HD01-0AB0, the model of analog input module 45 is 6ES7331-7PF01-0AB0, and the model of backplane 46 is 6ES7390-1AF30-0AA0.

[0049] The touch screen 5 may be a Siemens touch screen of model 6AV2124-0GC01-0AX0.

[0050] Furthermore, the hydraulic gate hoist controller 4 includes a CPU module 41, a switch output module 42, a position decoder module 43, an analog output module 44, an analog input module 45 and a backplane 46; the CPU module 41, the switch output module 42, the position decoder module 43, the analog output module 44, and the analog input module 45 communicate through the backplane bus.

[0051] The CPU module 41 and the touch screen 5 are connected by communication;

[0052] The switch output module 42 is electrically connected to the relay and is used to output a switch alarm signal of a gate opening failure;

[0053] The position decoder module 43 is electrically connected to the absolute encoder 2 and is used to convert Gray code into binary code. The function of the position decoder module is similar to that of the analog module, and is used to parse the Gray code signal of the absolute encoder and convert it into binary code that can be recognized by the controller.

[0054] The analog output module 44 is electrically connected to the monitoring system and is used to output the gate opening analog signal to the monitoring system;

[0055] The analog input module 45 is electrically connected to the opening display and control instrument 3, and is used to receive the gate opening current signal outputted from the opening display and control instrument 3;

[0056] The backplane 46 is used to install and fix the CPU module 41 , the switch output module 42 , the position decoder module 43 , the analog output module 44 and the analog input module 45 .

[0057] Preferably, the anti-jumping method of the hydraulic hoist gate opening signal anti-jumping device comprises the following steps:

[0058] Step 1: Initialize the anti-jump device of the gate opening signal of the hydraulic hoist, read the cylinder stroke and gate opening association curve data table obtained by segmented measurement in the electromechanical installation or system joint debugging on the touch screen, and read the cylinder stroke coefficient K, cylinder stroke offset P, cylinder stroke zero code value M0, cylinder stroke code value lower limit M 低 And the cylinder stroke code value upper limit M 高 ;

[0059] Step 2: Check whether the Gray code conversion value M of the absolute encoder 2 in the hydraulic gate hoist controller is normal. The judgment condition is: Check and judge whether M 低 <M<M 高 ;

[0060] If yes, go to step 3;

[0061] If not, the output cylinder encoder is faulty, go to step 8;

[0062] Step 3: Record the current Gray code conversion value M and the opening Y of the opening display and control instrument;

[0063] Step 4: According to the current Gray code conversion value M and the cylinder stroke and gate opening association curve data table, the cylinder stroke S and the gate linear difference opening Y are calculated by linear difference calculation. 表 ;

[0064] Step 5: Calculate the opening Y of the opening display and controller and the linear difference opening Y of the gate 表 The absolute value of the difference △Y, △Y=|YY 表 |;

[0065] Cylinder stroke S and gate linear difference opening Y 表 The calculation method is as follows:

[0066] Step 4.1: Since the cylinder stroke S is linearly related to the encoder Gray code conversion value M, the relationship expression is: S = (M-M0)K+P;

[0067] In the formula, the cylinder stroke coefficient K is calculated by the actual action distance L of one rotation of the absolute encoder and the single-turn accuracy N. The calculation formula is: K = L / 2 N ;

[0068] The cylinder stroke zero code value M0 is calculated from the Gray code conversion value M when the gate is fully closed, and the calculation formula is: M0 = M-(SP) / K;

[0069] Step 4.2: Calculate the gate linear difference opening Y corresponding to the current cylinder stroke S 表 ;

[0070] Y 表 =Y i-1 +(SS i-1 )(Y i -Y i-1 ) / (Si-S i-1 );

[0071] In the above formula, i and n are both positive integers, and 1 <i≤n,Y i S is the cylinder stroke i Corresponding gate opening; Y i and S i The value is obtained through the cylinder stroke and gate opening correlation curve data table.

[0072] The cylinder stroke and gate opening degree association curve data table is as follows:

[0073] <![CDATA[S1]]> <![CDATA[S2]]> <![CDATA[S3]]> … <![CDATA[S i-1 ]]> <![CDATA[S i ]]> … <![CDATA[S n-1 ]]> <![CDATA[S n ]]> <![CDATA[Y1]]> <![CDATA[Y2]]> <![CDATA[Y3]]> … <![CDATA[Y i-1 ]]> <![CDATA[Y i ]]> … <![CDATA[Y n-1 ]]> <![CDATA[Y n ]]>

[0074] Step 6: If the opening jump fault or △Y>Y 限 , hold for 2 seconds, output gate linear interpolation opening Y 表 , go to step 7; otherwise, output the opening Y of the opening display and controller, and return to step 2; where Y limit represents the opening jump alarm limit,

[0075] Step 7: Output opening jump fault;

[0076] Step 8: Check whether there is a manual fault reset signal. If so, return to step 2; otherwise, continue to perform the detection operation of this step.

[0077] In the above process, the absolute encoder outputs a Gray code to the opening display and controller and the hydraulic hoist controller respectively. The controller uses a linear interpolation calculation method based on the hydraulic cylinder stroke and gate opening co-connection curve to perform real-time jump fault judgment on the gate opening signal to ensure that the gate opening signal is true, accurate and reliable. The present invention is applicable to a hydraulic hoist that uses a hydraulic cylinder absolute encoder and an opening display and controller to realize gate opening signal monitoring, and solves the problem that the gate opening signal is prone to instantaneous mutation, slow attenuation and other numerical jump phenomena during the long-term operation of the hydraulic hoist.

[0078] The above embodiments are only preferred technical solutions of the present invention and should not be regarded as limiting the present invention. The protection scope of the present invention shall be the technical solutions recorded in the claims, including equivalent replacement solutions of the technical features in the technical solutions recorded in the claims. That is, equivalent replacement improvements within this scope are also within the protection scope of the present invention.

Claims

1. A device for preventing gate opening degree signals from jumping when using a hydraulic hoist, comprising an absolute encoder (2) arranged on an end cover of a hydraulic cylinder (1), wherein a piston rod of the hydraulic cylinder (1) is connected to the absolute encoder (2) via a rope, and characterized in that: The absolute encoder (2) is electrically connected to the opening display and control instrument (3) and the hydraulic gate hoist controller (4) respectively, and the Gray code output by the absolute encoder (2) is transmitted to the opening display and control instrument (3) and the hydraulic gate hoist controller (4) in two paths respectively; The opening display and control instrument (3) is used to receive the Gray code and process it to convert it into a 4-20mA gate opening current signal to the hydraulic gate hoist controller (4); The hydraulic gate hoist controller (4) is used to determine in real time the gate opening output by the opening display and control instrument (3) and the gate opening calculated by linear interpolation, and to set rules to prevent the gate opening signal from jumping; The hydraulic gate hoist controller (4) comprises a CPU module (41), a switch output module (42), a position decoder module (43), an analog output module (44), an analog input module (45) and a back panel (46); The CPU module (41) and the touch screen (5) are connected by communication; The switch output module (42) is electrically connected to the relay and is used to output a switch alarm signal of a gate opening failure; The position decoder module (43) is electrically connected to the absolute encoder (2) and is used to convert Gray code into binary code; The analog output module (44) is electrically connected to the monitoring system and is used to output a gate opening analog signal to the monitoring system; The analog input module (45) is electrically connected to the opening display and control instrument (3) and is used to receive the gate opening current signal outputted from the opening display and control instrument (3); The anti-jumping method of the hydraulic hoist gate opening signal anti-jumping device comprises the following steps: Step 1: Initialize the anti-jump device of the gate opening signal of the hydraulic hoist, read the cylinder stroke and gate opening association curve data table obtained by segmented measurement in the electromechanical installation or system joint debugging on the touch screen, and read the cylinder stroke coefficient K, cylinder stroke offset P, cylinder stroke zero code value M0, cylinder stroke code value lower limit M 低 And the cylinder stroke code value upper limit M 高 ; Step 2: Check whether the Gray code conversion value M of the absolute encoder (2) in the hydraulic gate hoist controller is normal. The judgment condition is: Check and judge whether M 低 <M<M 高 ; If yes, go to step 3; If not, the output cylinder encoder is faulty, go to step 8; Step 3: Record the current Gray code conversion value M and the opening Y of the opening display and control instrument; Step 4: According to the current Gray code conversion value M and the cylinder stroke and gate opening association curve data table, the cylinder stroke S and the gate linear difference opening Y are calculated by linear difference calculation. 表 ; Step 5: Calculate the opening Y of the opening display and controller and the linear difference opening Y of the gate 表 The absolute value of the difference △Y, △Y=|YY 表 |; Step 6: If the opening jump fault or △Y>Y 限 , hold for 2 seconds, output gate linear interpolation opening Y 表 , go to step 7; otherwise, output the opening Y of the opening display and controller, and return to step 2; where Y limit represents the opening jump alarm limit, Step 7: Output opening jump fault; Step 8: Check whether there is a manual fault reset signal. If so, return to step 2; otherwise, continue to perform the detection operation of this step; The cylinder stroke S and gate linear difference opening Y in step 4 表 The calculation method is as follows: Step 4.1: Since the cylinder stroke S is linearly related to the encoder Gray code conversion value M, the relationship expression is: S=(M-M0)K+P; In the formula, the cylinder stroke coefficient K is calculated by the actual action distance L of one rotation of the absolute encoder and the single-turn accuracy N. The calculation formula is: K=L / 2 N ; The cylinder stroke zero code value M0 is calculated from the Gray code conversion value M when the gate is fully closed. The calculation formula is: M0=M-(SP) / K; Step 4.2: Calculate the gate linear difference opening Y corresponding to the current cylinder stroke S 表 ; AND 表 =And i-1 +(SS i-1 )(AND i -AND i-1 ) / (If-If i-1 ); In the above formula, i and n are both positive integers, and 1 <i≤n,Y i S is the cylinder stroke i Corresponding gate opening; Y i and S i The value is obtained through the cylinder stroke and gate opening correlation curve data table.

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