A tipper control system and method for preventing car bodies from falling off during tipping.

Abstract

This invention provides a control system and method for a tippler to prevent car bodies from falling off during tipping. The control system includes a proximity switch, a proximity switch sensing element, a time relay, a master controller, a hydraulic system, and an electronic control system. The master controller detects the tippler's tilting angle. The time relay sends an electrical signal to the electronic control system when a preset timing duration T is reached. The hydraulic system includes a hydraulic pump, a solenoid valve, a relief valve, and a drive cylinder. During the tippler's return to the zero position, the electronic control system controls the solenoid valve to open based on the electrical signals from the proximity switch and time relay, and controls the hydraulic pump and relief valve to open based on the electrical signal from the master controller when the tippler tilts between 0° and α2, thereby enabling the hydraulic cylinder to drive the tippler's pressure beam to perform the opening action. This invention solves the problem of existing tipplers' pressure beams easily opening accidentally, causing car bodies to fall off.

Description

Technical Field

[0001] This invention relates to the field of tipplers, and more particularly to a tippler control system and method for preventing car bodies from falling off during tipping. Background Technology

[0002] Thermal power plants, steel mills, mines, and docks all use tippers to unload coal from open railway wagons. During the tipping process, there is a safety hazard of the wagons falling out as the pressure beams open. Current tippers rely primarily on position signals from a master controller. This master controller is divided into two parts: a front zone (0-90 degrees) and a rear zone (90-180 degrees). It is connected to the output shaft of the reducer that drives the tipper's tilting mechanism and uses adjustable cams for position (angle) adjustment. The mechanical angle of the tipper during tilting is fed back to the PLC program through the master controller's control points to achieve interlocking. However, the cams in the master controller are made of plastic, and they move as a whole each time a wagon is tilted. With 2-3 trains unloaded daily, this results in approximately 150 movements per day. Over time, this accelerates wear and tear, potentially leading to false signals from the master controller and the risk of wagons falling out. A tippler that relies solely on a master controller to operate automatically may have a risk of the flat beam opening during the tippler's rotation due to a false signal from the master controller, causing the car body to fall off. Summary of the Invention

[0003] In response to the aforementioned technical problem that existing tippler pressure beams are prone to accidentally opening and causing car bodies to fall off, a tippler control system and method are provided to prevent car bodies from falling off during tipping.

[0004] The technical means employed in this invention are as follows:

[0005] A tipper control system for preventing car bodies from falling off during tipping includes a proximity switch, a proximity switch sensing iron, a time relay, a master controller, a hydraulic system, and an electronic control system.

[0006] The proximity switch, the time relay, and the master controller are all electrically connected to the electronic control system.

[0007] The proximity switch is installed on the ground foundation platform at the entrance or exit of the tippler body. The proximity switch sensing element is installed at the entrance or exit of the tippler body. When the tippler body is in the zero position, the proximity switch sensing element corresponds to the position of the proximity switch. The sensing range between the proximity switch and the proximity switch sensing element is between 0° and α1 when the tippler body rotates. α1 represents the preset allowable rotation angle of the tippler body when the pressure beam opens during the process of the electronic control system controlling the tippler body to rotate to the maximum angle and then return to the zero position. The proximity switch is used to send the electrical signal generated by the proximity switch sensing element to the electronic control system.

[0008] The master controller is installed on the tippler body and is used to detect the tippler body's tilting angle and send the corresponding electrical signal to the electronic control system;

[0009] The time relay is used to start timing after the tipper body is flipped to the maximum angle, and to send an electrical signal to the electronic control system when the preset timing duration T is reached, where T represents the time required for the tipper body to return from the maximum angle to α1;

[0010] The hydraulic system includes a hydraulic pump, a solenoid valve, a relief valve, and a drive cylinder for driving the tipper beam; the outlet of the hydraulic pump is connected to the inlet of the drive cylinder via the relief valve, and the solenoid valve is used to control the operation of the drive cylinder.

[0011] The hydraulic pump, the solenoid valve, and the relief valve are electrically connected to the electronic control system. During the process of the tippler body flipping to its maximum angle and returning to the zero position, the electronic control system controls the solenoid valve to open according to the electrical signals sent by the proximity switch and the time relay, and controls the hydraulic pump and the relief valve to open according to the electrical signal sent by the master controller when the tippler body flips to between 0° and α2, so that the hydraulic cylinder can drive the tippler pressing beam to perform the opening action. α2 represents the preset flipping angle of the tippler body when the hydraulic pump starts and the relief valve opens during the process of the electronic control system controlling the tippler body to flip to its maximum angle and return to the zero position, and α2 > α1.

[0012] Furthermore, the tilting angle of the tipper body ranges from 0° to 165°, α1 is 27°, T is 36s, and α2 is 45°.

[0013] Furthermore, the electronic control system controls the time relay to start timing based on the electrical signal sent by the master controller that the tipper body has flipped to the maximum angle.

[0014] Furthermore, the electrical control system includes a PLC controller, and the proximity switch, the time relay, the master controller, the hydraulic oil pump, the solenoid valve, and the relief valve are respectively electrically connected to the PLC controller.

[0015] The present invention also provides a tipper control method for preventing car bodies from falling off during tipping, which employs the aforementioned control system and specifically includes the following steps:

[0016] S1: The electronic control system controls the tipper body to start flipping from the zero position. When the tipper body flips to the maximum angle, the electronic control system controls the tipper body to start returning and simultaneously controls the time relay to start timing.

[0017] S2: When the electronic control system receives an electrical signal from the master controller indicating that the tipper body has flipped to between 0° and α2, it controls the hydraulic oil pump and the overflow valve to open and start supplying hydraulic oil to the hydraulic cylinder.

[0018] S3: When the tipper body flips to between 0° and α1, the proximity switch and the proximity switch sensing iron generate an electrical signal and send it to the electronic control system; when the timing duration of the time relay reaches T, it sends an electrical signal to the electronic control system.

[0019] S4: When the electronic control system receives the electrical signals sent by the proximity switch and the time relay, it controls the solenoid valve to open, so that the hydraulic cylinder starts and uses the hydraulic oil provided by the hydraulic pump to drive the tipper beam to perform the opening action.

[0020] Compared with the prior art, the present invention has the following advantages:

[0021] The tippler control system and method provided by this invention for preventing car bodies from falling off during tippler operation includes three conditions for the electrical control system to open the pressure beam during the tippler's return process: non-contact induction (proximity switch), time control (time relay), and electrical control conditions for the hydraulic system (solenoid valve and relief valve). Compared with the existing tippler control program, this invention further improves the system. The multi-condition control provides better protection and prevents car bodies from falling off during tippler operation due to accidental opening of the pressure beam.

[0022] For the reasons stated above, this invention can be widely applied in the field of tippler machines. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram showing the installation position of the proximity switch and the proximity switch sensing iron according to the present invention.

[0025] In the diagram: 1. The entrance or exit of the tippler body; 2. The proximity switch sensing iron; 3. The proximity switch; 4. The ground foundation platform at the entrance or exit of the tippler body. Detailed Implementation

[0026] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0027] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0029] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0030] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this invention. The directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0031] For ease of description, spatial relative terms such as "above," "over," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation besides the orientation of the device as described in the figures. For example, if the device in the figures is inverted, a device described as "above" or "above" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0032] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0033] Example 1

[0034] This invention provides a tippler control system and method for preventing car bodies from falling off during tippler operation. The system is used to prevent car bodies from falling off due to accidental opening of the pressure beam during the return process after the tippler body has been tipped to its maximum angle. The control system includes a proximity switch, a proximity switch sensing iron, a time relay, a master controller, a hydraulic system, and an electrical control system.

[0035] The proximity switch, the time relay, and the master controller are all electrically connected to the electronic control system.

[0036] like Figure 1 As shown, the proximity switch 3 is installed on the ground foundation platform 4 at the entrance or exit of the tippler body, and the proximity switch sensing iron 2 is installed at the entrance or exit 1 of the tippler body. When the tippler body is in the zero position, the proximity switch sensing iron corresponds to the position of the proximity switch. The sensing range between the proximity switch and the proximity switch sensing iron is between 0° and α1 when the tippler body rotates. α1 represents the preset allowable rotation angle of the tippler body when the pressure beam opens during the process of the electronic control system controlling the tippler body to rotate to the maximum angle and then return to the zero position. The proximity switch is used to send the electrical signal generated by the proximity switch sensing iron to the electronic control system.

[0037] The master controller is installed on the tippler body and is used to detect the tippler body's tilting angle and send the corresponding electrical signal to the electronic control system;

[0038] The time relay is used to start timing after the tipper body is flipped to the maximum angle, and to send an electrical signal to the electronic control system when the preset timing duration T is reached, where T represents the time required for the tipper body to return from the maximum angle to α1;

[0039] The hydraulic system includes a hydraulic pump, a solenoid valve, a relief valve, and a drive cylinder for driving the tipper beam. The outlet of the hydraulic pump is connected to the inlet of the drive cylinder via the relief valve to provide hydraulic power to the hydraulic cylinder. The solenoid valve is used to control the operation of the drive cylinder.

[0040] The hydraulic pump, the solenoid valve, and the relief valve are electrically connected to the electronic control system. During the process of the tippler body flipping to its maximum angle and returning to the zero position, the electronic control system controls the solenoid valve to open based on the electrical signals sent by the proximity switch and the time relay, providing power to the hydraulic cylinder. Based on the electrical signal sent by the master controller when the tippler body flips to between 0° and α2, the electronic control system controls the hydraulic pump and the relief valve to open, enabling the hydraulic pump to provide hydraulic power to the hydraulic cylinder, thereby driving the tippler's pressure beam to perform the opening action. α2 represents the preset flipping angle of the tippler body corresponding to the allowed start of the hydraulic pump and opening of the relief valve during the process of the electronic control system controlling the tippler body to flip to its maximum angle and return to the zero position, and α2 > α1.

[0041] In existing technologies, controlling the action of the tippler beam via a hydraulic system using a single condition is often incomplete. To improve the reliability of the hydraulic cylinder's operational control, the control system provided by this invention requires two conditions to control the tippler beam to perform the opening action. One condition is that the solenoid valve needs to open to provide power to the hydraulic cylinder, which is achieved by the electronic control system receiving electrical signals from the proximity switch and the time relay. The other condition is that the hydraulic pump needs to start and the relief valve needs to open to provide hydraulic power to the hydraulic cylinder to achieve cylinder extension and retraction, which is achieved by the electronic control system receiving electrical signals from the master controller when the tippler body rotates to between 0° and α2. This further ensures the safety and reliability of the tippler beam during the return process from the perspective of hydraulic system control.

[0042] Furthermore, the electronic control system controls the operation of the drive cylinder by controlling the operation of the hydraulic oil pump, the overflow valve and the solenoid valve, thereby controlling the operation of the tippler's pressing beam;

[0043] During the process of the tippler body being rotated to its maximum angle and then returning to α2, the electronic control system controls the hydraulic oil pump and the overflow valve to close, so that the hydraulic cylinder is in a pressure-holding state and cannot move. At the same time, before the tippler body is rotated to α1, the electronic control system controls the solenoid valve to remain closed, and the hydraulic cylinder cannot move when the solenoid valve is closed, thereby ensuring that the tippler pressing beam will not be accidentally opened and cause the car body to fall off during the return of the tippler body.

[0044] Furthermore, the electronic control system can control the tipper body to flip within a certain angle range; in this embodiment, the flipping angle range of the tipper body is 0° to 165°, and the tipper body being in the zero position refers to the state when the flipping angle of the tipper body is 0°; the flipping degree range of the tipper body is 0° to 165°, α1 is 27°, T is 36s, and α2 is 45°.

[0045] Furthermore, the electronic control system controls the time relay to start timing based on the electrical signal sent by the master controller that the tipper body has flipped to the maximum angle.

[0046] Furthermore, the electrical control system includes a PLC controller, and the proximity switch, the time relay, the master controller, the hydraulic oil pump, the solenoid valve, and the relief valve are respectively electrically connected to the PLC controller.

[0047] The tipper control method for preventing car bodies from falling off during tipping provided by this invention employs the aforementioned control system and specifically includes the following steps:

[0048] S1: The electronic control system controls the tipper body to start flipping from the zero position. When the tipper body flips to the maximum angle, the electronic control system controls the tipper body to start returning and simultaneously controls the time relay to start timing.

[0049] S2: When the electronic control system receives an electrical signal from the master controller indicating that the tipper body has flipped to between 0° and α2, it controls the hydraulic oil pump and the overflow valve to open and start supplying hydraulic oil to the hydraulic cylinder.

[0050] S3: When the tipper body flips to between 0° and α1, the proximity switch and the proximity switch sensing iron generate an electrical signal and send it to the electronic control system; when the timing duration of the time relay reaches T, it sends an electrical signal to the electronic control system.

[0051] S4: When the electronic control system receives the electrical signals sent by the proximity switch and the time relay, it controls the solenoid valve to open, so that the hydraulic cylinder starts and uses the hydraulic oil provided by the hydraulic pump to drive the tipper beam to perform the opening action.

[0052] In existing tippers, the opening condition of the pressure beam during the return process is usually achieved solely by a signal provided by the master controller. However, the hardware is prone to wear and fatigue, and if a signal is mistakenly sent to the electronic control system, the pressure beam may open erroneously. The control system provided by this invention requires three conditions to be met simultaneously when controlling the opening of the pressure beam: the electronic control system receives electrical signals from the proximity switch and the time relay, and simultaneously receives a signal indicating that the tipper body has rotated to between 0° and α2. In addition to setting the hardware conditions such as the proximity switch and the master controller, a time relay control process is also designed into the electronic control system, which improves the reliability of the control system. The three conditions for the electronic control system to control the opening of the pressure beam include non-contact induction (proximity switch), time control (time relay), and electronic control conditions of the hydraulic system (solenoid valve and relief valve). Compared with the control program of existing tippers, this invention further improves the system. The multi-condition control provides better protection and prevents the car body from falling off the tipper during the rotation process due to the accidental opening of the pressure beam.

[0053] This invention can be applied to the safety of C-type tippler systems and the safety of open railway wagons. It solves the problem of wagons falling off due to accidental movement of the pressure beam during tipping, and solves the problem of equipment and wagon damage caused by wagon falling off. Ultimately, it improves the safety, economy and reliability of tippler system operation.

[0054] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A tipper control system for preventing car bodies from falling off during tipping, characterized in that, This includes proximity switches, proximity switch sensing elements, time relays, master controllers, hydraulic systems, and electrical control systems. The proximity switch, the time relay, and the master controller are all electrically connected to the electronic control system. The proximity switch is installed on the ground foundation platform at the entrance or exit of the tippler body. The proximity switch sensing element is installed at the entrance or exit of the tippler body. When the tippler body is in the zero position, the proximity switch sensing element corresponds to the position of the proximity switch. The sensing range between the proximity switch and the proximity switch sensing element is between 0° and α1 when the tippler body rotates. α1 represents the preset allowable rotation angle of the tippler body when the pressure beam opens during the process of the electronic control system controlling the tippler body to rotate to the maximum angle and then return to the zero position. The proximity switch is used to send the electrical signal generated by the proximity switch sensing element to the electronic control system. The master controller is installed on the tippler body and is used to detect the tippler body's tilting angle and send the corresponding electrical signal to the electronic control system; The time relay is used to start timing after the tipper body is flipped to the maximum angle, and to send an electrical signal to the electronic control system when the preset timing duration T is reached, where T represents the time required for the tipper body to return from the maximum angle to α1; The hydraulic system includes a hydraulic pump, a solenoid valve, a relief valve, and a drive cylinder for driving the tipper beam; the outlet of the hydraulic pump is connected to the inlet of the drive cylinder via the relief valve, and the solenoid valve is used to control the operation of the drive cylinder. The hydraulic pump, the solenoid valve, and the relief valve are electrically connected to the electronic control system. During the process of the tippler body flipping to its maximum angle and returning to the zero position, the electronic control system controls the solenoid valve to open according to the electrical signals sent by the proximity switch and the time relay, and controls the hydraulic pump and the relief valve to open according to the electrical signal sent by the master controller when the tippler body flips to between 0° and α2, so that the drive cylinder can drive the tippler pressing beam to perform the opening action. α2 represents the preset flipping angle of the tippler body when the hydraulic pump starts and the relief valve opens during the process of the electronic control system controlling the tippler body to flip to its maximum angle and return to the zero position, and α2 > α1.

2. The tipper control system for preventing car bodies from falling off during tipping, as described in claim 1, is characterized in that, The tilting angle of the main body of the tipper is 0° to 165°, α1 is 27°, T is 36s, and α2 is 45°.

3. The tipper control system for preventing car bodies from falling off during tipping, as described in claim 1, is characterized in that, The electronic control system controls the time relay to start timing based on the electrical signal sent by the master controller that the tipper body has flipped to its maximum angle.

4. The tipper control system for preventing car bodies from falling off during tipping, as described in claim 1, is characterized in that, The electrical control system includes a PLC controller, and the proximity switch, the time relay, the master controller, the hydraulic oil pump, the solenoid valve, and the relief valve are electrically connected to the PLC controller.

5. A tipper control method for preventing car bodies from falling off during tipping, characterized in that, The control system described in any one of claims 1-4 specifically includes the following steps: S1: The electronic control system controls the tipper body to start flipping from the zero position. When the tipper body flips to the maximum angle, the electronic control system controls the tipper body to start returning and simultaneously controls the time relay to start timing. S2: When the electronic control system receives an electrical signal from the master controller indicating that the tipper body has flipped to between 0° and α2, it controls the hydraulic oil pump and the overflow valve to open and start supplying hydraulic oil to the hydraulic cylinder. S3: When the tipper body flips to between 0° and α1, the proximity switch and the proximity switch sensing iron generate an electrical signal and send it to the electronic control system; when the timing duration of the time relay reaches T, it sends an electrical signal to the electronic control system. S4: When the electronic control system receives the electrical signals sent by the proximity switch and the time relay, it controls the solenoid valve to open, so that the hydraulic cylinder starts and uses the hydraulic oil provided by the hydraulic pump to drive the tipper beam to perform the opening action.

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