A synchronous car pressing method and system for a car presser hook of a car dumper
By collecting and processing distance, stroke, and pressure data of the car-pressing hook, and using control valves to control the hydraulic pipeline, the synchronous action of the car-pressing hook of the tipper is achieved, solving the problem of asynchronous car-pressing hooks in tipper equipment and improving the stability and control accuracy of the equipment.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- WUHAN POWER EQUIP WORKS
- Filing Date
- 2024-05-15
- Publication Date
- 2026-08-04
AI Technical Summary
Existing tippler equipment is prone to asynchrony during the action of the clamping hook, which leads to vehicle instability, structural damage and mechanical wear, and the adjustment is complicated and costly.
By collecting the distance, stroke, and pressure values of the car couplers, and controlling the on/off state of the hydraulic lines using control valves, the synchronous action of multiple car couplers is achieved. Data acquisition and processing are performed using laser rangefinders, pressure sensors, and rope encoders.
It achieves synchronized action of the coupler, reduces the risk of overturning, improves control accuracy, avoids abnormal misjudgment and uneven pressure, protects the vehicle structure, and reduces mechanical wear.
Smart Images
Figure CN118458412B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of tippler technology, and in particular to a method and system for synchronously pressing a tippler with a pressing hook. Background Technology
[0002] In the process of unloading materials such as coal and ore, tippler equipment mainly unloads railway open wagons and container wagons. The main working steps of the tippler equipment are pressing and aligning actions, that is, the hook pressing down on the top of the wagon vertically, and the aligning plate aligning with the side of the wagon horizontally. During the operation, due to the limitations of the mechanical structure and hydraulic system, the actions of different couplers may be inconsistent.
[0003] Inconsistent hook-operated movements can lead to vehicle instability during unloading, increasing the risk of tipper overturning. It can also cause uneven pressure on the vehicle, resulting in structural deformation or damage. Furthermore, it increases the burden on the tipper's transmission system, causing additional mechanical wear. The asynchronous hook-operated movements are primarily due to potential jamming between different hooks during operation. Additionally, because the system is hydraulically driven, the distance between the hydraulic station's oil pipes and the connecting pipes to the vehicle platform varies, causing inconsistent operating pressure and resulting in asynchronous movements.
[0004] Existing technologies mainly avoid the problem of asynchronous loading hooks by designing mechanical linkage structures or hydraulic synchronous shafts. However, these methods are complex to implement for different specifications and models of tippers and for different usage scenarios. They are also difficult to adjust and costly. Summary of the Invention
[0005] In view of this, the present invention proposes a method and system for synchronous pressing of car hooks in a tipper. By collecting the stroke of the pressing hook during its operation, the distance from the lowest position, and the internal oil pressure of the pressing cylinder, the synchronous pressing of the pressing hook is determined. Based on the determination result, the synchronous pressing action of multiple pressing hooks is achieved by independently switching on and off the oil circuit, so as to reduce the risk of tipping caused by asynchronous pressing hooks.
[0006] The technical solution of this invention is implemented as follows:
[0007] On one hand, the present invention provides a method for synchronously pressing a tippler using a pressing hook, based on a control valve and multiple pressing mechanisms. Each pressing mechanism includes a pressing cylinder and a pressing hook, the pressing cylinder and the pressing hook being drively connected. The control valve is connected to the hydraulic lines of each pressing cylinder, and is used to control the on / off state of the hydraulic lines of each pressing cylinder. The synchronous pressing method includes the following steps:
[0008] S1 collects the distance value of each pressing hook, the stroke value of the pressing cylinder, and the pressure value of the pressing cylinder. The distance value is the distance between the current position of the pressing hook and its lowest pressing position.
[0009] S2 sets standard distance values and standard stroke values based on the distance values of each pressing hook and the stroke values of each pressing cylinder. It compares each distance value with the standard distance value to obtain the corresponding distance comparison difference, and compares each stroke value with the standard stroke value to obtain the corresponding stroke comparison difference.
[0010] S3 controls the valves to adjust the pressing speed of each pressing coupler based on the obtained distance comparison difference and stroke comparison difference, until each pressing coupler presses onto the open wagon synchronously.
[0011] S4 sets a pressure standard value based on the pressure value of each hydraulic cylinder, compares each pressure value with the pressure standard value, and obtains the corresponding pressure comparison difference value.
[0012] S5 sets the normal pressure difference range. If the pressure difference of each pressing coupler is within the normal pressure difference range, the pressing action is determined to be completed. If there is a pressure difference that exceeds the normal pressure range among the pressure differences of each pressing coupler, the pressing action is determined to be incomplete.
[0013] Based on the above technical solution, preferably, in step S2, the distance values are arranged from smallest to largest, and the distance values of each hook are S1, S2, ..., S... n Then the distance from the standard value S p for:
[0014]
[0015] Where n represents the total number of couplers. This means rounding up n / 2. This means rounding down n / 2;
[0016] Arrange the stroke values from smallest to largest, and the stroke values for each coupler after arrangement are L1, L2, ..., L... n Then the standard value of the stroke L p for:
[0017]
[0018] Based on the above technical solutions, preferably, step S2 includes the following sub-steps:
[0019] S21 sets a standard distance value based on the distance value of each hook, and compares each distance value with the standard distance value to obtain the corresponding distance comparison difference.
[0020] S22 sets the normal distance difference range. If all distance comparison differences are within the normal distance difference range, return to step S1. If a certain distance comparison difference is not within the normal distance difference range, record the distance comparison difference as a distance anomaly and proceed to step S23.
[0021] S23 sets a standard stroke value based on the stroke value of each hydraulic cylinder, and compares each stroke value with the standard stroke value to obtain the corresponding stroke comparison difference.
[0022] S24 sets the normal range of travel difference. If the distance comparison difference of a certain pressing coupler is an abnormal distance value and the travel comparison difference is not within the normal range of travel difference, then the travel comparison difference is recorded as an abnormal travel value and proceeds to step S3; otherwise, it returns to step S1.
[0023] More preferably, in step S3, the step of controlling the valve to adjust the pressing speed of each pressing hook based on the obtained distance comparison difference value and stroke comparison difference value includes the following sub-steps:
[0024] S31 determines the distance comparison difference as the distance anomaly value and the travel comparison difference as the travel anomaly value of the pressure coupler;
[0025] S32 determines whether the distance difference of the pressing coupler is negative. If it is negative, the control valve disconnects the hydraulic line of the corresponding pressing cylinder. Otherwise, the control valve disconnects the hydraulic line of the corresponding pressing cylinder of other pressing couplers.
[0026] More preferably, the closing time T for the control valve to disconnect the hydraulic line of the corresponding press cylinder is:
[0027] T = (S p -S i ) / V
[0028] Where i is the distance comparison difference recorded as the distance anomaly value, and the travel comparison difference recorded as the travel anomaly value for the pressure coupler; Si is the distance value of the pressure coupler; S... p V represents the standard distance value, and V represents the operating speed of the coupler under normal pressure.
[0029] Based on the above technical solutions, preferably, step S4 includes the following sub-steps:
[0030] The pressure value sequence obtained by S41 is Q1, Q2, ..., Q n Take one pressure value from the pressure value series as the standard pressure value Q. i ;
[0031] S42 subtracts the standard pressure value Q from all pressure values in the pressure value series. iThe pressure difference for the corresponding pressure values is obtained, and a series of pressure difference values is obtained.
[0032] More preferably, step S5 includes the following sub-steps:
[0033] S51 sets the normal pressure difference range;
[0034] S52 determines whether each pressure comparison difference in the pressure comparison difference sequence is within the normal pressure difference range. If they are all within the normal pressure difference range, the pressing action is determined to be completed; otherwise, proceed to step S53.
[0035] S53 disconnects the hydraulic lines of all pressing cylinders by controlling the valve and stops the pressing operation.
[0036] Based on the above technical solutions, preferably, it is also based on a wagon-holding mechanism. The wagon-holding mechanism includes a wagon-holding plate and multiple wagon-holding cylinders. The output end of the wagon-holding cylinders is connected to the wagon-holding plate. The control valve is connected to the hydraulic lines of each wagon-holding cylinder. The control valve is used to control the on / off of the hydraulic lines of each wagon-holding cylinder. The synchronous wagon-holding method also includes step S6. After the wagon-holding action is completed, the wagon-holding cylinders push the wagon-holding plate to move towards the open wagon. During this process, the displacement distance of the output end of each wagon-holding cylinder is collected. Based on the displacement distance, the wagon-holding plate is made to flatly abut against the open wagon.
[0037] More preferably, step S6 includes the following sub-steps:
[0038] After the S61 pressing action is completed, the car-mounting cylinder pushes the car-mounting plate to move toward the open car, and during this process, the displacement distance of the output end of each car-mounting cylinder is collected.
[0039] S62 arranges the multiple displacement distances obtained from smallest to largest to form a displacement distance sequence;
[0040] S63 sets the normal range of displacement distance difference, subtracts the two endpoints in the displacement distance sequence, and determines whether the difference is within the normal range of displacement distance difference. If it is, the vehicle approach action is considered normal, and returns to step S61 until the vehicle approach action is completed. Otherwise, the difference is marked as an abnormal displacement value, and the process proceeds to step S64.
[0041] S64 adjusts the moving speed of the hydraulic cylinder output end by controlling the valve block according to the abnormal displacement value, and returns to step S61.
[0042] On the other hand, the present invention provides a tippler pressing hook synchronous pressing system for implementing the above-mentioned synchronous pressing method. The synchronous pressing system includes a control valve block, a laser rangefinder probe, a pressure sensor, and a rope encoder.
[0043] The control valve block is connected to each pressing cylinder, and the control valve block is used to control the opening and closing of the corresponding hydraulic oil pipes of the pressing cylinders;
[0044] The laser ranging probe is positioned outside the lowest point of the pressing coupler, with the detection end facing the direction of movement of the pressing coupler. The laser ranging probe is used to detect the distance value of the pressing coupler.
[0045] The detection end of the pressure sensor is connected to the hydraulic cylinder of the press to detect the pressure value inside the hydraulic cylinder;
[0046] The pull-rope encoder is fixed on the hydraulic cylinder of the pressing machine, and the pull-rope end is fixed to the output end of the hydraulic cylinder of the pressing machine. The pull-rope encoder is used to detect the stroke value of the hydraulic cylinder of the pressing machine.
[0047] The tipper and tipper coupler synchronous tipping method and system of the present invention have the following advantages over the prior art:
[0048] (1) By collecting the distance value of each pressing hook, the stroke value of the pressing cylinder and the pressure value of the pressing cylinder, and setting the corresponding standard value according to the stroke value and distance value, it is determined whether the distance value and stroke value of a single pressing hook are abnormal values. Then, based on the abnormal value, it is determined whether the corresponding pressing hook needs to be adjusted by controlling the valve and the adjustment time is determined, so that each pressing hook can realize the synchronous pressing action of multiple pressing hooks through independent oil circuit opening and closing, so as to reduce the risk of overturning caused by asynchronous pressing hooks;
[0049] (2) By using both distance and stroke values for judgment, the accuracy of data detection can be avoided due to material falling during the unloading process, thereby avoiding abnormal misjudgment of the car hook, reducing the impact of erroneous data, and improving control accuracy. At the same time, by using the median average to select the standard distance value of the car hook and the standard stroke value of the car cylinder, the difference between the end values can be avoided, which would affect the accuracy of the adjustment.
[0050] (3) By collecting the pressure value of the pressing cylinder and processing each pressure value, and then setting a pressure standard value for comparison, it is possible to avoid the situation where the pressure of a single pressing hook is too high or too low during the pressing process, which would affect the tilting operation of the material. This not only prevents the damage to open wagons or containers caused by excessive pressing hook pressure, but also prevents the risk of overturning caused by insufficient pressing hook pressure. Attached Figure Description
[0051] 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 only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0052] Figure 1 This is a schematic diagram illustrating the steps of the tipper and car-pressing coupler synchronous pressing method of the present invention;
[0053] Figure 2 This is a schematic diagram of the installation of the laser ranging probe in the tipper pressing coupler synchronous pressing system of the present invention. Detailed Implementation
[0054] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.
[0055] like Figure 1 As shown, the present invention discloses a method for synchronously pressing a wagon with a wagon hook, which is based on control valves and multiple pressing mechanisms. Each pressing mechanism includes a pressing cylinder and a pressing hook, which are connected in a transmission manner. The control valves are connected to the hydraulic lines of each pressing cylinder and are used to control the on / off state of the hydraulic lines of each pressing cylinder. A wagon tipper is a large mechanical device used to unload bulk materials from open railway wagons. It is a loading and unloading machine that can tilt or overturn rail vehicles to unload materials. It is suitable for ports with large transport volumes and industrial sectors such as metallurgy, coal, and thermal power. The wagon tipper includes a rotor, a tipping platform, and a pressing system. The pressing system includes a pressing mechanism and a support mechanism. The pressing mechanism is used to press the top of the open wagon or container, pressing it onto the tipping platform. The support mechanism provides lateral support to the vehicle. The rotor drives the tipping platform to rotate, thus unloading the materials transported by the vehicle, causing the materials to fall into the pit of the wagon tipper.
[0056] Existing tipplers typically have eight pressing mechanisms per tippler, with each pressing hook driven by a pressing cylinder. This embodiment will be described using a tippler with eight pressing hooks.
[0057] Specifically, the synchronous pressing method includes steps S1-S6.
[0058] Step S1: Collect the distance value of each pressing hook, the stroke value of the pressing cylinder, and the pressure value of the pressing cylinder. The distance value is the distance between the current position of the pressing hook and its lowest pressing position.
[0059] On a tipper, both the pressing hook and the pressing cylinder are mounted on the pressing arm. A slide rail is also installed on the pressing arm. The pressing hook slides on the slide rail with its sliding direction toward the tipping platform. The pressing cylinder is fixed inside the pressing arm. The output end of the pressing cylinder is then connected to the pressing hook for transmission. The pressing hook on the pressing arm has a maximum raised position and a minimum lowered position, which are determined by the stroke of the hydraulic cylinder or the length of the slide rail.
[0060] In this embodiment, there are eight pressing mechanisms, and correspondingly eight pressing hook distance values, hydraulic cylinder stroke values, and hydraulic cylinder pressure values are collected. The pressing mechanisms are associated with the corresponding distance, stroke, and pressure values. The data can be recorded in a table format during the collection process, which will facilitate subsequent retrieval and viewing by maintenance personnel.
[0061] Step S2: Based on the distance value of each pressing hook and the stroke value of each pressing cylinder, set the distance standard value and stroke standard value respectively. Compare each distance value with the distance standard value to obtain the corresponding distance comparison difference. Compare each stroke value with the stroke standard value to obtain the corresponding stroke comparison difference.
[0062] Step S21: Based on the distance values of each hook, set a standard distance value, and compare each distance value with the standard distance value to obtain the corresponding distance comparison difference.
[0063] There are several ways to select the standard distance value. You can use the average of all distance values or choose one of the eight distance values directly as the standard distance value.
[0064] To avoid excessive differences in the end values affecting the adjustment accuracy, this embodiment uses the median average as the standard distance value. Specifically, the distance values are arranged from smallest to largest, and the distance values for each hook are S1, S2, ..., S... n Then the distance from the standard value S p for:
[0065]
[0066] Where n represents the total number of couplers. This means rounding up n / 2. This means rounding down n / 2.
[0067] The eight distance values are arranged in ascending order, and the fourth and fifth distance values are selected. The average of the two distance values is used as the standard distance value. The distance comparison difference is the difference between the distance value and the standard distance value. The eight corresponding distance comparison differences can be calculated in this way.
[0068] In addition, if the number of couplings is odd, such as nine couplings, the distance between the fourth and sixth couplings will be selected, and the average of the two distances will be taken.
[0069] Step S22: Set the normal distance difference range. If all distance comparison differences are within the normal distance difference range, return to step S1. If a distance comparison difference is not within the normal distance difference range, record the distance comparison difference as a distance anomaly and proceed to step S23.
[0070] In a specific example, if one of the eight distance values is selected as the standard distance value, assuming the selected distance value is S1, then we have -10<(S2-S1)<10, -10<(S3-S1)<10, -10<(S4-S1)<10, -10<(S5-S1)<10, -10<(S6-S1)<10, -10<(S7-S1)<10, -10<(S8-S1)<10, where (-10, 10) is the normal range of distance difference in cm. The normal range of distance difference is set to a 20cm interval because the distance value selected as the standard distance value may be the minimum distance value, and a larger range needs to be set between it and the maximum distance value to ensure that no incorrect adjustment is made within the allowable accuracy.
[0071] In this embodiment, the median mean is preferably used as the standard distance value. In a specific example, -5<(S2-S1)<5, -5<(S3-S1)<5, -5<(S4-S1)<5, -5<(S5-S1)<5, -5<(S6-S1)<5, -5<(S7-S1)<5, -5<(S8-S1)<5, where (-5, 5) is the normal range of distance difference, in cm. Since the median mean is selected as the standard distance value, there is no situation where the difference between the extreme values is too large and affects the misjudgment of the pressure value. Therefore, the normal range of distance difference can be set within 10cm, which can effectively improve the judgment accuracy.
[0072] If any of the eight distance comparison differences are not within the normal distance difference range, it means that the downward pressing distance of each pressing coupler is within the allowable error range. In this case, it is necessary to return to step S1 to continue the data acquisition operation. If there are any, the corresponding distance values are recorded as distance anomalies, and the pressing couplers with distance anomalies are marked. The stroke values of the pressing couplers with distance anomalies are sent to the next step for stroke value determination.
[0073] Step S23: Based on the stroke value of each hydraulic cylinder, set the stroke standard value, and compare each stroke value with the stroke standard value to obtain the corresponding stroke comparison difference value.
[0074] Before determining the travel value, it is necessary to determine the travel standard value. The method is the same as that for determining the distance standard value. The average value of all travel values can be used, or one of the eight travel values can be selected directly as the travel standard value.
[0075] To avoid excessive differences in the endpoint values affecting the adjustment accuracy, this embodiment uses the median average as the standard stroke value. Specifically, the stroke values are arranged from smallest to largest, and the stroke values of each hydraulic cylinder after arrangement are L1, L2, ..., L... n Then the standard value of the stroke L p for:
[0076]
[0077] The eight stroke values are arranged in ascending order, and the fourth and fifth stroke values are selected. The average of the two stroke values is used as the stroke standard value. The stroke comparison difference is the difference between the stroke value and the stroke standard value. Based on this method, the stroke comparison difference corresponding to the coupler with abnormal distance values in step S22 can be calculated. It should be noted that in this step, it is not necessary to calculate the stroke comparison difference for couplers with normal distance comparison differences.
[0078] Step S24: Set the normal range of stroke difference. If the distance comparison difference of a certain pressing coupler is an abnormal value and the stroke comparison difference is not within the normal range of stroke difference, then record the stroke comparison difference as an abnormal value and proceed to step S3; otherwise, return to step S1.
[0079] In this step, if the distance comparison difference of a certain pressing coupler is an abnormal value and the stroke comparison difference is an abnormal value, it is determined that the pressing coupler needs to be adjusted and the subsequent steps are performed. If the distance comparison difference is an abnormal value but the stroke comparison difference is within the normal range of stroke difference, it means that the pressing coupler is not abnormal. Correspondingly, if all pressing couplers are not abnormal, return to step S1 to continue to check various data. If at least one pressing coupler is abnormal, step S3 needs to be performed.
[0080] It should be noted that the use of both distance and travel values for judgment is because the falling of materials during the unloading process may affect the accuracy of data detection. In addition, the use of dual judgment detection can effectively avoid abnormal misjudgment of the coupler, reduce the impact of erroneous data, and improve control accuracy.
[0081] Step S3: Based on the obtained distance comparison difference and stroke comparison difference, control the valve to adjust the pressing speed of each pressing coupler until each pressing coupler presses onto the open wagon synchronously.
[0082] The pressure coupler that needs adjustment can be determined by comparing the distance difference and the stroke difference, along with the required adjustment distance. Based on this, the synchronous alignment of all pressure couplers can be achieved within the allowable error range using control valves. Specifically, this step includes sub-steps S31-S32.
[0083] Step S31: Determine the distance comparison difference as the distance anomaly value and the travel comparison difference as the travel anomaly value of the pressure hook.
[0084] The pressure coupler determined in this step is the pressure coupler marked in step S24 above. There is at least one of them. In actual operation, each pressure coupler has a corresponding number. Abnormal pressure couplers can be identified directly by marking the corresponding number.
[0085] Step S32: Determine whether the distance difference of the pressing coupler is negative. If it is negative, disconnect the hydraulic line of the corresponding pressing cylinder by the control valve. Otherwise, disconnect the hydraulic line of the corresponding pressing cylinder of other pressing couplers by the control valve.
[0086] When the distance comparison difference is negative, it indicates that the distance between the corresponding pressing hook and the lowest position is less than the distance standard value corresponding to the pressing hook position, that is, the pressing speed is too fast. After the distance comparison difference of the pressing hook is an abnormal value, it is necessary to disconnect the pressing cylinder of the pressing mechanism through the control valve. Conversely, when the distance comparison difference is positive, it is necessary to disconnect the pressing cylinder of other pressing mechanisms through the control valve to synchronize all pressing hooks.
[0087] In one specific embodiment, it is also possible for two or more pressing couplers to be abnormal at the same time, with both positive and negative distance comparison differences. In this case, the same logic is used to adjust the abnormal pressing couplers simultaneously so that they can be pressed down synchronously.
[0088] Regarding the disconnection time of the control valve, the closing time T of the hydraulic line of the corresponding press cylinder disconnected by the control valve is:
[0089] T = (S p -S i ) / V
[0090] Where i is the distance comparison difference recorded as the distance anomaly value, and the travel comparison difference recorded as the travel anomaly value for the pressure coupler; Si is the distance value of the pressure coupler; S... p V represents the standard distance value, and V represents the operating speed of the coupler under normal pressure.
[0091] The operating speed V of the coupler under normal pressure is determined by the set oil supply pressure, thus yielding the adjustment time S for abnormal coupler operation. p -S iThat is, the negative of the corresponding distance comparison difference. When the distance comparison difference is negative, then S p -S i If the distance difference is positive, the resulting T will also be positive. Conversely, if the distance difference is positive, then T will be negative. When T is negative, it is necessary to adjust the stop-T time of other couplings.
[0092] Through continuous cyclic adjustments, each car coupler can be synchronously pressed down onto the open wagon or container within the allowable error range.
[0093] Step S4: Based on the pressure values of each hydraulic cylinder, set the pressure standard value, compare each pressure value with the pressure standard value, and obtain the corresponding pressure comparison difference value.
[0094] The pressure value sequence obtained by S41 is Q1, Q2, ..., Q n Take one pressure value from the pressure value series as the standard pressure value Q. i .
[0095] When determining pressure values, the pressure values cannot be adjusted, making the median-based method unsuitable. Only the relative differences between the pressure values need to be considered. To facilitate system calculations, one of the eight pressure values can be directly selected as the standard pressure value Q. i ,
[0096] S42 subtracts the standard pressure value Q from all pressure values in the pressure value series. i The pressure difference for the corresponding pressure values is obtained, and a series of pressure difference values is obtained.
[0097] The obtained pressure difference values can be sorted into a series according to the number of the pressure coupler to facilitate the identification of abnormal pressure couplers when the pressure value is abnormal in the future.
[0098] Step S5: Set the normal pressure difference range. If the pressure difference of each pressing coupler is within the normal pressure difference range, the pressing action is determined to be completed. If there is a pressure difference that exceeds the normal pressure range among the pressure differences of each pressing coupler, the pressing action is determined to be incomplete.
[0099] By measuring the pressure of each clamping hook, it can be directly determined whether the clamping hook has fully clamped the vehicle body to be overturned. Only after the clamping hook has fully clamped can the next step be carried out. This step specifically includes sub-steps S51-S53.
[0100] Step S51: Set the normal pressure difference range.
[0101] The normal pressure range needs to be set according to the actual operation of the tipper. Since the pressure value detected in this embodiment is the hydraulic oil pressure inside the hydraulic cylinder, the actual detected value is the pressure value. In a specific embodiment, the normal pressure difference range can be set to (-2, 2), with the unit being MPa.
[0102] Step S52: Determine whether each pressure difference in the pressure difference series is within the normal pressure difference range. If they are all within the normal pressure difference range, the pressing action is completed; otherwise, proceed to step S53.
[0103] Once the pressing action is completed, step S6 can be entered to allow the tipper to perform subsequent actions. Otherwise, since the hydraulic cylinder cannot be adjusted such as oil return during the pressing process, step S53 needs to be entered to handle the abnormality through other means.
[0104] Step S53: Disconnect the hydraulic lines of all pressing cylinders by controlling the valve and stop the pressing operation.
[0105] After the clamping coupler contacts the car body, it will continuously increase the pressure to a certain level, so that the pressure applied by each clamping coupler to the car body can clamp the fully loaded car body. During the continuous pressure increase, the pressure value should gradually equalize within a certain range. If the pressure value is abnormal, it indicates that there is a problem with the system, and manual inspection and maintenance of the clamping mechanism and corresponding hydraulic pipelines are required.
[0106] Step S6: After the pressing action is completed, the car-mounting cylinder pushes the car-mounting plate to move towards the open wagon. During this process, the displacement distance of the output end of each car-mounting cylinder is collected. Based on the displacement distance, the car-mounting plate is made to flatten and fit against the open wagon.
[0107] On the tipper, the car-applying mechanism includes a car-applying plate and multiple car-applying cylinders. The output end of each car-applying cylinder is connected to the car-applying plate. The control valve is connected to the hydraulic lines of each car-applying cylinder and is used to control the on / off state of the hydraulic lines of each car-applying cylinder. In this embodiment, since a single-tilting tipper is used for illustration, the single-tilting tipper typically has four car-applying cylinders. The car-applying cylinders and the car-pressing cylinders have the same asynchronous problem. To reduce the impact of the asynchronous car-applying cylinders, step S6 can be used. Specifically, step S6 includes sub-steps S61-S64.
[0108] Step S61: After the pressing action is completed, the car-mounting cylinder pushes the car-mounting plate to move towards the open car, and during this process, the displacement distance of the output end of each car-mounting cylinder is collected.
[0109] Since the number of approach cylinders is relatively small and their impact on unloading operations is not as great as that of the pressing cylinders, only the displacement distance at the output end of the approach cylinders is collected to determine the synchronous approach.
[0110] Step S62: Arrange the obtained multiple displacement distances from smallest to largest to form a displacement distance sequence.
[0111] Step S63: Set the normal range of displacement distance difference, subtract the two endpoints in the displacement distance sequence, and determine whether the difference is within the normal range of displacement distance difference. If it is, the vehicle approach action is considered normal, and return to step S61 until the vehicle approach action is completed. Otherwise, mark the difference as an abnormal displacement value and proceed to step S64.
[0112] Since the number of approach cylinders is usually half that of the pressing cylinders, in this embodiment, the displacement distance of the four approach cylinders can be directly reduced from large to small to determine whether the maximum difference distance is within the normal range. If the maximum difference is within this range, it indicates that the other two approach cylinders are normal, that is, the approach action is normal, until they are completely close to the vehicle body. Conversely, it indicates that the two cylinders with the largest difference are abnormal, and then adjustments can be made through step S64.
[0113] Step S64: Based on the abnormal displacement value, adjust the moving speed of the output end of the car-mounted hydraulic cylinder by controlling the valve block, and return to step S61.
[0114] In this step, based on the abnormal displacement value, the hydraulic cylinder that is moving too fast can be adjusted by controlling the valve block to disconnect the oil circuit until it is synchronized with other hydraulic cylinders. At the same time, the displacement distance of this hydraulic cylinder will no longer be the maximum value. At this point, the process can be repeated in step S61 to make a cyclic judgment, so that each hydraulic cylinder can be continuously adjusted during the moving process to complete the synchronized moving.
[0115] The tipper hook synchronous pressing system of the present invention is used to realize the above-mentioned synchronous pressing method. The synchronous pressing system includes a control valve block, a laser rangefinder probe, a pressure sensor and a rope encoder.
[0116] The control valve block is connected to each pressing cylinder. The control valve block is used to control the opening and closing of the corresponding hydraulic oil pipes of the pressing cylinder. The number of control valve blocks can be set to multiple, or a single valve block can be set to multiple channels, thereby connecting the pressing cylinder and the approach cylinder on the tipper. The control valve block can form multiple control units according to the internal channels. Each control unit can be directly opened and closed electrically or pneumatically. When the control unit is opened, the corresponding hydraulic line is connected. When the control unit is closed, the corresponding hydraulic line is disconnected, thereby realizing the on and off control of the cylinder.
[0117] like Figure 2As shown in the figure, 1 is the hydraulic cylinder for pressing the car, 2 is the car hook for pressing the car, and 3 is the laser ranging probe. The laser ranging probe is located on the outside of the lowest position of the car hook for pressing the car, and the detection end faces the direction of movement of the car hook for pressing the car. The laser ranging probe is used to detect the distance value of the car hook for pressing the car. Specifically, it emits a short pulse laser beam through a built-in laser. After the laser beam contacts the car hook for pressing the car, it returns and is received by the receiver inside the laser ranging probe. The probe measures the time delay between emitting the laser pulse and receiving the reflected light, that is, the time that the laser takes from emission to reception. Based on the speed of light and the time delay, the distance between the target object and the probe can be determined, thereby detecting the distance between the current position of the car hook for pressing the car and its lowest position on the slide, realizing the detection of the distance value. Specifically, when the car hook for pressing the car moves, the laser sensor reads the distance change value and transmits it to the PLC control system through Ethernet communication. The distance between the car hook for pressing the car and the laser sensor is S = U x B, where S is the distance, U is the sensor voltage signal, and B is the proportional parameter. The distance value is calculated by the program. The preferred model of the laser rangefinder is OM70-P1000.HV0500.VI, with a specific detection range of 100-1000mm.
[0118] The detection end of the pressure sensor is connected to the hydraulic cylinder of the press to detect the pressure value inside the cylinder. Specifically, a detection port connected to the inside of the cylinder is set on the hydraulic cylinder. A miniature high-pressure hose is connected to the external part of the detection port. The detection end of the pressure sensor is connected through the hose, so that the pressure sensor can detect the oil pressure inside the cylinder. The preferred model of the pressure sensor is LABOM, with a detection range of 0-400 bar, where 1 bar = 0.1 MPa.
[0119] The pull-rope encoder is fixed to the hydraulic cylinder of the pressing machine, with the pull-rope end fixed to the output end of the cylinder. The encoder is used to detect the stroke value of the cylinder. Specifically, when the cylinder actuates, the encoder reads the stroke change value and transmits it to the PLC control system via Ethernet communication. The internal stroke is L = I x A, where L is the stroke, I is the sensor current signal, and A is a proportional parameter. The stroke value is calculated by the program. The preferred model of the pull-rope encoder is KS30, with a specific detection range of 0-1000mm.
[0120] By combining the rope sensor stroke detection algorithm, the laser sensor distance detection algorithm, and the stroke and distance range comparison algorithm, when the logic determines that a certain oil cylinder or a certain pressing coupler is moving too fast, the start and stop of the individual valve in the oil circuit is controlled to realize the cyclic start and stop of the valve, control the flow, and achieve the effect of synchronizing the pressing coupler.
[0121] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. A method for synchronously pressing a car with a tipper and its coupler, characterized in that, The synchronous pressing method is implemented based on control valves and multiple pressing mechanisms. Each pressing mechanism includes a pressing cylinder and a pressing hook, which are connected in a driving manner. The control valves are connected to the hydraulic lines of each pressing cylinder and are used to control the on / off state of the hydraulic lines of each pressing cylinder. The synchronous pressing method includes the following steps: S1 collects the distance value of each pressing hook, the stroke value of the pressing cylinder, and the pressure value of the pressing cylinder. The distance value is the distance between the current position of the pressing hook and its lowest pressing position. S2 sets standard distance values and standard stroke values based on the distance values of each pressing hook and the stroke values of each pressing cylinder. It compares each distance value with the standard distance value to obtain the corresponding distance comparison difference, and compares each stroke value with the standard stroke value to obtain the corresponding stroke comparison difference. S3 controls the valves to adjust the pressing speed of each pressing coupler based on the obtained distance comparison difference and stroke comparison difference, until each pressing coupler presses onto the open wagon synchronously. S4 sets a pressure standard value based on the pressure value of each hydraulic cylinder, compares each pressure value with the pressure standard value, and obtains the corresponding pressure comparison difference value. S5 sets the normal pressure difference range. If the pressure difference of each pressing coupler is within the normal pressure difference range, the pressing action is determined to be completed. If there is a pressure difference that exceeds the normal pressure range among the pressure differences of each pressing coupler, the pressing action is determined to be incomplete.
2. The method for synchronously pressing a car with a tipper and its coupler as described in claim 1, characterized in that, In step S2, the distance values are arranged from smallest to largest, and the distance values of each hook are S1, S2, ..., S... n Then the distance from the standard value S p for: Where n represents the total number of couplers. This means rounding up n / 2. This means rounding down n / 2; Arrange the stroke values from smallest to largest, and the stroke values for each coupler after arrangement are L1, L2, ..., L... n Then the standard value of the stroke L p for:
3. The method for synchronously pressing a car with a tipper and coupler as described in claim 1, characterized in that, Step S2 includes the following sub-steps: S21 sets a standard distance value based on the distance value of each hook, and compares each distance value with the standard distance value to obtain the corresponding distance comparison difference. S22 sets the normal distance difference range. If all distance comparison differences are within the normal distance difference range, return to step S1. If a certain distance comparison difference is not within the normal distance difference range, record the distance comparison difference as a distance anomaly and proceed to step S23. S23 sets a standard stroke value based on the stroke value of each hydraulic cylinder, and compares each stroke value with the standard stroke value to obtain the corresponding stroke comparison difference. S24 sets the normal range of travel difference. If the distance comparison difference of a certain pressing coupler is an abnormal distance value and the travel comparison difference is not within the normal range of travel difference, then the travel comparison difference is recorded as an abnormal travel value and proceeds to step S3; otherwise, it returns to step S1.
4. The method for synchronously pressing a car with a tipper and coupler as described in claim 3, characterized in that, In step S3, the step of controlling the valve to adjust the pressing speed of each pressing hook based on the obtained distance comparison difference and stroke comparison difference includes the following sub-steps: S31 determines the distance comparison difference as the distance anomaly value and the travel comparison difference as the travel anomaly value of the pressure coupler; S32 determines whether the distance difference of the pressing coupler is negative. If it is negative, the control valve disconnects the hydraulic line of the corresponding pressing cylinder. Otherwise, the control valve disconnects the hydraulic line of the corresponding pressing cylinder of other pressing couplers.
5. The method for synchronously pressing a car with a tipper and its coupler as described in claim 4, characterized in that, The closing time T for the control valve to disconnect the hydraulic line of the corresponding press cylinder is: T=(S p -S i ) / V Where i is the distance comparison difference recorded as the distance anomaly value, and the travel comparison difference recorded as the travel anomaly value for the pressure coupler; Si is the distance value of the pressure coupler; S... p V represents the standard distance value, and V represents the operating speed of the coupler under normal pressure.
6. The method for synchronously pressing a car with a tipper and its coupler as described in claim 1, characterized in that, Step S4 includes the following sub-steps: The pressure value sequence obtained by S41 is Q1, Q2, ..., Q n Take one pressure value from the pressure value series as the standard pressure value Q. i ; S42 subtracts the standard pressure value Q from all pressure values in the pressure value series. i The pressure difference for the corresponding pressure values is obtained, and a series of pressure difference values is obtained.
7. The method for synchronously pressing a car with a tipper and coupler as described in claim 6, characterized in that, Step S5 includes the following sub-steps: S51 sets the normal pressure difference range; S52 determines whether each pressure comparison difference in the pressure comparison difference sequence is within the normal pressure difference range. If they are all within the normal pressure difference range, the pressing action is determined to be completed; otherwise, proceed to step S53. S53 disconnects the hydraulic lines of all pressing cylinders by controlling the valve and stops the pressing operation.
8. The method for synchronously pressing a car with a tipper and its coupler as described in claim 1, characterized in that, It is also based on a wagon-holding mechanism, which includes a wagon-holding plate and multiple wagon-holding cylinders. The output end of the wagon-holding cylinders is connected to the wagon-holding plate. The control valve is connected to the hydraulic lines of each wagon-holding cylinder. The control valve is used to control the on / off of the hydraulic lines of each wagon-holding cylinder. The synchronous wagon-holding method also includes step S6. After the wagon-holding action is completed, the wagon-holding cylinders push the wagon-holding plate to move toward the open wagon. During this process, the displacement distance of the output end of each wagon-holding cylinder is collected. Based on the displacement distance, the wagon-holding plate is made to flatly abut against the open wagon.
9. The method for synchronously pressing a car with a tipper and its coupler as described in claim 8, characterized in that, Step S6 includes the following sub-steps: After the S61 pressing action is completed, the car-mounting cylinder pushes the car-mounting plate to move toward the open car, and during this process, the displacement distance of the output end of each car-mounting cylinder is collected. S62 arranges the multiple displacement distances obtained from smallest to largest to form a displacement distance sequence; S63 sets the normal range of displacement distance difference, subtracts the two endpoints in the displacement distance sequence, and determines whether the difference is within the normal range of displacement distance difference. If it is, the vehicle approach action is considered normal, and returns to step S61 until the vehicle approach action is completed. Otherwise, the difference is marked as an abnormal displacement value, and the process proceeds to step S64. S64 adjusts the moving speed of the hydraulic cylinder output end by controlling the valve block according to the abnormal displacement value, and returns to step S61.
10. A tippler pressing coupler synchronous pressing system, characterized in that, For implementing the synchronous pressing method according to any one of claims 1-9, the synchronous pressing system includes a control valve block, a laser ranging probe, a pressure sensor, and a rope encoder, wherein... The control valve block is connected to each pressing cylinder, and the control valve block is used to control the opening and closing of the corresponding hydraulic oil pipes of the pressing cylinders; The laser ranging probe is positioned outside the lowest point of the pressing coupler, with the detection end facing the direction of movement of the pressing coupler. The laser ranging probe is used to detect the distance value of the pressing coupler. The detection end of the pressure sensor is connected to the hydraulic cylinder of the press to detect the pressure value inside the hydraulic cylinder; The pull-rope encoder is fixed on the hydraulic cylinder of the pressing machine, and the pull-rope end is fixed to the output end of the hydraulic cylinder of the pressing machine. The pull-rope encoder is used to detect the stroke value of the hydraulic cylinder of the pressing machine.