Lifting reduction gearbox cooling and lubricating system for crane and control method of lifting reduction gearbox cooling and lubricating system

Abstract

The invention discloses a lifting reduction gearbox cooling and lubricating system for a crane, which comprises a lubricating oil circuit communicated with a lubricating oil inlet and a lubricating oil outlet on a lifting reduction gearbox and used for circulating flow of lubricating oil; the cooling fan is used for dissipating heat and cooling the lubricating oil in the lifting reduction gearbox in the circulating flowing process; the lubricating oil pump motor is used for increasing the pressure of lubricating oil in the lifting reduction gearbox; the temperature sensor is used for collecting oil temperature data of lubricating oil in the lifting reduction gearbox; the liquid level sensor is used for collecting the liquid level of lubricating oil in the lifting reduction gearbox; the flow sensor is used for collecting the flow speed and flow of lubricating oil in the lifting reduction gearbox; the pressure difference indicator is used for collecting the pressure difference between the lubricating oil inlet and the lubricating oil outlet; and the main electric control PLC is used for acquiring the detection data and controlling the start and stop of the cooling fan and the lubricating oil pump motor according to the detection data result. According to the invention, cooling and lubrication of the lifting reduction gearbox mechanism of the container bridge crane can be realized.

Description

Technical Field

[0001] The invention relates to container port terminal loading and unloading operation technology, and more specifically, to a lifting reduction box cooling and lubrication system for a crane and a control method thereof. Background Art

[0002] For a long time, most of the domestic and foreign port container bridge cranes (referred to as: bridge cranes) have rarely been equipped with lubrication and cooling system devices on the lifting gearboxes. With the increasingly serious global greenhouse effect, the temperature is generally higher than before, especially in tropical countries, where the temperature in summer is as high as 50-60℃. The temperature in the bridge crane room during heavy-load operation is even higher, even exceeding 70℃. In these tropical countries, ports often have bridge cranes that have been working overloaded for several consecutive days. The lubricating oil inside the lifting gearbox cannot dissipate heat and cool, and the internal oil temperature is too high and boils and overflows from the gearbox, resulting in a decrease in the viscosity of the gear oil in the gearbox, a decrease in the lubrication and anti-wear effect, and a serious reduction in the service life of the lifting gearbox. For this reason, it is particularly urgent to add a lubrication and cooling system to the lifting gearbox of the bridge crane. Summary of the invention

[0003] In view of the defects existing in the prior art, the purpose of the present invention is to provide a cooling and lubrication system for a lifting reduction gearbox on a crane and a control method thereof, which can realize the cooling and lubrication of the lifting reduction gearbox mechanism of the container bridge crane and improve the efficiency of container loading and unloading operations.

[0004] To achieve the above object, the present invention adopts the following technical solution:

[0005] A first aspect of the present invention provides a cooling and lubricating system for a hoisting reduction gearbox on a crane, comprising:

[0006] The lubricating oil circuit is connected to the lubricating oil inlet and the lubricating oil outlet on the lifting reduction box and is used for the circulation of the lubricating oil;

[0007] A cooling fan, used for dissipating heat and cooling the lubricating oil during its circulation in the lifting reduction box;

[0008] A lubricating oil pump motor, used to increase the pressure of the lubricating oil in the lifting reduction box;

[0009] A temperature sensor, used for collecting oil temperature data of the lubricating oil in the lifting reduction box;

[0010] A liquid level sensor, used for collecting the liquid level of the lubricating oil in the lifting reduction box;

[0011] A flow sensor, used for collecting the flow rate and flow of the lubricating oil in the lifting reduction box;

[0012] A pressure difference transmitter, used for collecting the pressure difference between the lubricating oil inlet and the lubricating oil outlet;

[0013] The main electronic control PLC is used to obtain the detection data of the temperature sensor, the liquid level sensor, the flow sensor and the pressure difference transmitter, and to control the start and stop of the cooling fan and the lubricating oil pump motor based on the detection data results.

[0014] Preferably, the cooling fan comprises a housing, and a fan and a reducer arranged in the housing;

[0015] The fan is connected to the high-speed shaft of the reducer.

[0016] Preferably, the liquid level sensor is a tuning fork type liquid level sensor.

[0017] Preferably, a one-way valve and a ball valve are provided on the lubricating oil circuit.

[0018] Preferably, the main electronic control PLC adopts Siemens S series.

[0019] The second aspect of the present invention provides a control method for a cooling and lubrication system of a hoisting reduction gearbox on a crane based on the first aspect of the present invention;

[0020] During the heavy-load operation of the bridge crane, when the temperature sensor detects that the oil temperature in the lifting reduction box reaches the high temperature setting value, the main electronic control PLC controls to start the cooling fan and the lubricating oil pump motor to start the lubricating oil circulation. After a delay of N seconds, the main electronic control PLC detects whether the flow sensor has a flow signal. If there is no flow signal, the main electronic control PLC prompts an alarm.

[0021] When the temperature sensor detects that the oil temperature in the lifting reduction box reaches the low temperature setting value, the main electric control PLC controls to stop the cooling fan and the lubricating oil pump motor. After a delay of N seconds, the main electric control PLC detects that the contact signal of the flow sensor is disconnected. If the contact signal is not disconnected, the main electric control PLC prompts an alarm.

[0022] When the temperature sensor detects that the oil temperature in the lifting reduction box reaches the upper limit high temperature setting value, the main electronic control PLC prompts a fault alarm and the bridge crane immediately stops operating.

[0023] When the temperature sensor detects that the oil temperature in the lifting reduction box reaches the lower limit low temperature setting value, the cooling and lubrication system of the lifting reduction box stops working.

[0024] Preferably, when the pressure difference detected by the pressure difference transmitter reaches a set value, the contacts of the pressure difference transmitter will close and output a feedback signal, and the main electronic control PLC will prompt to clean or replace the filter element of the filter.

[0025] The present invention provides a cooling and lubricating system for a lifting reduction gearbox on a crane and a control method thereof, which are particularly suitable for any container bridge crane equipment at port terminals in highly tropical countries and regions. The system can realize the cooling and lubrication of the lifting reduction gearbox mechanism of the container bridge crane, improve the efficiency of container loading and unloading operations, and solve the problem that the oil in the existing lifting reduction gearbox overflows from the reduction gearbox after boiling due to excessively high oil temperature, resulting in a decrease in the viscosity of the gear oil in the reduction gearbox, a decrease in the lubrication and anti-wear effect, and a serious reduction in the service life of the lifting reduction gearbox. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a structural schematic diagram of the cooling and lubrication system of the lifting reduction box of the present invention;

[0027] Figure 2 It is a schematic diagram of the working principle of the cooling and lubrication system of the lifting reduction box of the present invention;

[0028] Figure 3 It is a schematic diagram of the electrical control of the operation of the cooling and lubrication system of the lifting reduction box of the present invention, (a) is the electrical control schematic diagram of the main electronic control PLC, (b) is the PLC logic control schematic diagram of the cooling fan, (c) is the PLC logic control schematic diagram of the lubricating oil pump motor, (d) is the PLC logic control schematic diagram of the temperature sensor, (e) is the PLC logic control schematic diagram of the liquid level sensor, (f) is the PLC logic control schematic diagram of the flow sensor, and (g) is the PLC logic control schematic diagram of the pressure difference transmitter. DETAILED DESCRIPTION

[0029] In order to better understand the above technical solution of the present invention, the technical solution of the present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0030] Combination Figure 1 As shown, the present invention provides a cooling and lubricating system for a hoisting reduction gearbox on a crane, comprising:

[0031] In order to achieve better heat dissipation and cooling effect for the lifting reduction gearbox 100, a cooling fan 101 is arranged on the lubricating oil path 109 of the lubricating oil outlet for heat dissipation and cooling of the lubricating oil during the circulation process. The cooling fan includes a housing, and a fan and a reducer installed in the housing; the fan is connected to the high-speed shaft of the reducer.

[0032] The lubricating oil pump motor 102 is used to increase the pressure of the lubricating oil in the lifting reduction box 100, ensuring that the lubricating oil can effectively reach the various parts of the lifting reduction box 100 that need lubrication, thereby reducing the heat and wear generated by friction and protecting the lifting reduction box 100 from damage. The design and performance of the lubricating oil pump motor 102 directly affect the efficiency of the entire lubrication system, and play an important role in ensuring the efficient and stable operation of mechanical equipment.

[0033] The temperature sensor 103 uses analog temperature signals to collect the oil temperature data of the lubricating oil in the lifting reduction box 100 in real time. The output signal is 4-20MA, linearly changing, and the temperature measurement range is -xx℃--+xx℃, -xx℃ corresponds to analog 4mA, +xx℃ corresponds to analog 20mA, supports RS485 communication, and outputs signals to the main electronic control PLC. It can measure the oil temperature in real time and display the specific temperature value, making it convenient and intuitive to see the actual temperature of the lifting reduction box 100.

[0034] The liquid level sensor 104 is a tuning fork type liquid level sensor, which causes the vibration of the tuning fork through the resonance of the piezoelectric crystal, and determines the liquid level of the lubricating oil in the lifting reduction box 100 by detecting the change in the vibration frequency of the tuning fork. The liquid level sensor 104 is mainly used to detect the low oil level on the lifting reduction box 100, and adopts a switch quantity passive contact.

[0035] The flow sensor 105 is designed based on the principle of heat exchange. The probe of the flow sensor 105 has a built-in heating module and a thermal sensing module. The thermal conduction of the flow switch is closely related to the flow rate of the medium. During measurement, heat is emitted by the heating module. When there is no medium flowing in the lubricating oil circuit, the heat received by the thermal sensing module is a fixed value. When there is medium flowing in the lubricating oil circuit, the heat received by the thermal sensing module will change with the flow rate of the medium. The thermal sensing module converts the temperature difference signal into an electrical signal, and then converts it into a corresponding standard analog signal or contact signal output through a processor. The flow switch displays and controls the flow rate of the medium through this signal, and monitors and controls the speed and size of the lubricating oil flow in the lifting reduction box 100.

[0036] The differential pressure transmitter 106 triggers signals based on changes in pressure difference, and is mainly used to monitor and alarm pressure changes in the cooling lubrication system. When the pressure difference in the cooling lubrication system exceeds a preset value, the differential pressure transmitter 106 will send a signal to prompt the operator to perform corresponding maintenance or adjustments. The differential pressure transmitter 106 is usually connected to the lubricating oil inlet and lubricating oil outlet of the lifting reduction box 100 to monitor the pressure difference between the lubricating oil inlet / outlet. When the cooling lubrication system is running, impurities gradually accumulate on the filter element of the lubricating oil inlet / outlet, causing the pressure difference between the lubricating oil inlet / outlet to increase. Once the pressure difference reaches the preset threshold, the mechanical or electronic components inside the differential pressure transmitter 106 will be triggered to generate electrical signals or mechanical actions. After the differential pressure transmitter 106 is triggered, the signal is transmitted to the control system or alarm device to prompt the operator to perform necessary maintenance or replace the filter element and other operations.

[0037] The lubricating oil circuit 109 is connected to the lubricating oil inlet and the lubricating oil outlet on the lifting reduction box 100 and is used for the circulation of the lubricating oil.

[0038] The main electronic control PLC is used to obtain the detection data of the temperature sensor 103, the liquid level sensor 104, the flow sensor 105 and the pressure difference transmitter 106, and control the start and stop of the cooling fan 101 and the lubricating oil pump motor 102 based on the detection data results.

[0039] A one-way valve 107 is provided on the lubricating oil circuit 109. A manual one-way valve is used to control the opening and closing of the lubricating oil circuit 109. The manual one-way valve ensures that the lubricating oil can only flow in one direction and cannot flow in the reverse direction. When the lubricating oil flows in the forward direction, due to the pressure difference of the fluid, the valve core of the one-way valve 107 will be pressed and pushed open, thereby opening the one-way valve 107 and allowing the lubricating oil to pass through. When the lubricating oil flows in the reverse direction, the valve core of the one-way valve 107 will be affected by the upstream pressure and automatically closed to prevent the fluid from flowing in the reverse direction.

[0040] A ball valve 108 is provided on the lubricating oil circuit 109, which is used when inspecting the cooling lubrication system to prevent the lubricating oil from splashing out during the inspection. The ball valve 108 is closed manually and opened manually after the inspection is completed.

[0041] Combination Figure 2 As shown, the present invention also provides a control method for the cooling and lubrication system of the lifting reduction box based on the present invention.

[0042] When the lifting reduction box 100 is working, the running gears continuously throw the splashing oil mist to the tooth surfaces of the gears and the raceways of each rolling bearing to meet the lubrication and heat dissipation requirements of each friction surface.

[0043] When the cooling and lubricating system of the lifting reduction box of the present invention is working, the lubricating oil is firstly drawn out from the oil tank of the lifting reduction box 100, firstly purified by the filter element at the lubricating oil outlet, and then cooled by the cooling fan 101, and then the lubricating oil is sent to the reduction box to achieve the effects of lubrication, cooling, sealing, etc.

[0044] During the heavy-load operation of the bridge crane, when the temperature sensor 103 detects that the oil temperature in the lifting reduction box 100 reaches the high temperature setting value (the value can be adjusted according to the actual start and stop frequency of the cooling and lubrication system), the main electronic control PLC controls the start of the cooling fan 101 and the lubricating oil pump motor 102 to start the lubricating oil circulation. After a delay of N seconds, the main electronic control PLC detects whether the flow sensor 105 has a flow signal. If there is no flow signal, the main electronic control PLC prompts an alarm.

[0045] When the temperature sensor 103 detects that the oil temperature in the lifting reduction box 100 reaches the low temperature setting value (the value can be adjusted according to the actual start and stop frequency of the cooling and lubrication system), the main electronic control PLC controls to stop the cooling fan 101 and the lubricating oil pump motor 102. After a delay of N seconds, the main electronic control PLC detects that the contact signal of the flow sensor 105 is disconnected. If the contact signal is not disconnected, the main electronic control PLC prompts an alarm.

[0046] When the temperature sensor 103 detects that the oil temperature in the lifting reduction box 100 reaches the upper limit high temperature setting value, the main electronic control PLC prompts an alarm.

[0047] When the temperature sensor 103 detects that the oil temperature in the lifting reduction box 100 reaches the lower limit low temperature setting value, the cooling and lubrication system of the lifting reduction box stops working.

[0048] After long-term use, the filter element of the lubricating oil inlet / outlet filter will be clogged. When the pressure difference detected by the pressure difference transmitter 106 reaches the set value, the contact of the pressure difference transmitter 106 will close and output a feedback signal, and the main electronic control PLC will prompt to clean or replace the filter element of the filter.

[0049] The main electric control PLC adopts Siemens SIMATIC S-XX series, CPU adopts CPUXX-X, PN / DP, and is equipped with I / O expansion modules. The communication protocol adopts PROFINET. The signals of the temperature sensor 103, liquid level sensor 104, flow sensor 105 and pressure difference transmitter 106 of the cooling and lubrication system enter the main electric control PLC and participate in the electrical control of the host. Figure 3 As shown in (a).

[0050] When the main electric control PLC detects that the temperature monitored by the temperature sensor 103 in real time exceeds the analog signal of XX℃ (X000), this signal is transmitted to the relay coil "Hoist Gearbox cooling on" of the cooling fan 101 to start the cooling fan 101; when the main electric control PLC detects that the temperature monitored by the temperature sensor 103 in real time exceeds the analog signal of the set value of XX℃ (X000), the host system issues an "Alarm" alarm. When the temperature reaches the limit of the set value of XX℃, the main electric control PLC immediately reports a "fault", cuts off the control, and the bridge crane stops operating. When the main electric control PLC detects that the temperature monitored by the temperature sensor 103 in real time is lower than the analog signal of XX℃ (X000), this signal is transmitted to the relay coil "Hoist Gearbox coolingoff" of the cooling fan 101, disconnects the Q161.3 "o_MainHoistGearBoxCooling SystemCooling Fanonorder" control loop, disconnects the cooling fan 101, and stops the cooling system. Figure 3 as shown in (b).

[0051] When the main electric control PLC detects that the temperature monitored by the temperature sensor 103 in real time exceeds the analog signal of XX℃ (X000), this signal is transmitted to the relay coil "Hoist Gearbox cooling on" of the cooling fan 101, and the lubricating oil pump motor 102 receives the "Hoist Gearbox cooling on" operation command; at the same time, the Q161.2 "o_MainHoistGearBoxCooling SystemPumpOnOrder" control loop is also connected, and the lubricating oil pump motor 102 is started to run when other conditions are met, such as Figure 3 as shown in (c).

[0052] The temperature sensor 103 collects analog temperature signals and collects the oil temperature changes in the lifting gearbox 100 in real time. The output signal is 4-20mA, linear change, temperature measurement range: -XX℃--+XX℃, -XX℃ corresponds to analog 4mA, +XX℃ corresponds to analog 20mA, supports RS485 communication, and outputs signals to the main electric control PLC. It can measure the oil temperature in real time and display the specific temperature value, which is convenient and intuitive to see the actual temperature of the gearbox. When the temperature monitored by the main electric control PLC exceeds XX℃ (X000), the analog signal is transmitted to the relay coil "Hoist Gearbox cooling on" of the cooling fan 101 to start the cooling fan 101; when the temperature monitored by the main electric control PLC is lower than XX℃ (X000), the analog signal is transmitted to the relay coil "Hoist Gearbox cooling on" of the cooling fan 101. off” to disconnect the cooling fan 101 and stop the cooling system; when the temperature detected by the main electric control PLC exceeds the analog signal of the set value of XX℃ (X000), the host system will issue an "Alarm" alarm. When the temperature reaches the limit of the set value of XX℃, the main electric control PLC will immediately report a "fault" fault, cut off the control, and the bridge crane will stop working. Figure 3 as shown in (d).

[0053] The liquid level sensor 104 adopts a tuning fork type liquid level sensor, which causes the vibration of the tuning fork through the resonance of the piezoelectric crystal, and determines the liquid level by detecting the change in the vibration frequency of the tuning fork. This type of liquid level sensor is mainly used to detect the low oil level on the bridge crane lifting reducer 100, and adopts a switch passive contact. When the oil level is within the normal range, a switch "1" signal is given to the main electronic control PLC, and the PLC control loop of the cooling and lubrication system "Hoist gearbox cooling system ok" is connected, and the cooling and lubrication system works normally. When the oil level is lower than the normal value, a switch "0" signal is given to the main electronic control PLC, and the PLC control loop of the cooling and lubrication system "Hoist gearbox cooling system ok" is cut off, and the cooling and lubrication system stops working. Figure 3 As shown in (e).

[0054] The flow sensor 105 adopts a thermal conductivity flow switch designed based on the principle of heat exchange. The probe has a built-in heating module and a heat-sensing module. The heat conduction of the flow switch is closely related to the flow rate of the medium. During measurement, the heating module emits heat. If there is no medium flowing in the circulating oil circuit 109, the heat received by the heat-sensing module is a fixed value. When there is medium flowing, the heat received by the heat-sensing module will change with the flow rate of the medium. The heat-sensing module converts this temperature difference signal into an electrical signal, and then converts it into a corresponding standard analog signal or contact signal output through the processor. The flow switch displays and controls the flow rate of the medium through this signal, and monitors and controls the speed and size of the lubricating oil flowing in the lifting reduction box 100. The flow switch sets the upper and lower limits of the flow according to the actual flow. If the flow reaches this limit, the flow switch will send a signal to the main electronic control PLC, and the cooling and lubrication system will stop or start. When the flow rate of the lubricating oil is greater than the set starting flow rate, a switch value "1" signal is output, the PLC control loop of "Hoist gearbox cooling system ok" is connected, and the cooling and lubrication system works normally. When the flow rate of the lubricating oil is less than the starting flow rate, a switch value "0" signal is output, the PLC control loop of "Hoist gearbox cooling system ok" is disconnected, and the cooling and lubrication system stops working. Figure 3 As shown in (f).

[0055] The main function of the differential pressure transmitter 106 is: when the filter is unobstructed, the pressure difference between the lubricating oil inlet and the lubricating oil outlet is very small. However, when there are too many impurities deposited and the filter element of the filter is blocked, the pressure difference between the lubricating oil inlet and the lubricating oil outlet will gradually increase (the inlet pressure increases and the outlet pressure decreases). When the pressure difference reaches a certain value, the spring in the differential pressure transmitter 106 will be compressed, and the contact of the differential pressure transmitter 106 will be disconnected to output a feedback signal "0" to the main electronic control PLC, disconnecting the "Hoist gearbox cooling system ok" control loop, and the cooling and lubricating system stops working, reminding the maintenance personnel to clean or replace the filter element of the filter, such as Figure 3 As shown in (g).

[0056] Those skilled in the art should recognize that the above embodiments are only used to illustrate the present invention, and are not intended to limit the present invention. As long as they are within the spirit of the present invention, any changes or modifications to the above embodiments will fall within the scope of the claims of the present invention.

Claims

1. A cooling and lubrication system for a hoisting reduction gearbox on a crane. It is characterized in that include: The lubricating oil circuit is connected to the lubricating oil inlet and the lubricating oil outlet on the lifting reduction box and is used for the circulation of the lubricating oil; A cooling fan, used for dissipating heat and cooling the lubricating oil during its circulation in the lifting reduction box; A lubricating oil pump motor, used to increase the pressure of the lubricating oil in the lifting reduction box; A temperature sensor, used for collecting oil temperature data of the lubricating oil in the lifting reduction box; A liquid level sensor, used for collecting the liquid level of the lubricating oil in the lifting reduction box; A flow sensor, used for collecting the flow rate and flow of the lubricating oil in the lifting reduction box; A pressure difference transmitter, used for collecting the pressure difference between the lubricating oil inlet and the lubricating oil outlet; The main electronic control PLC is used to obtain the detection data of the temperature sensor, the liquid level sensor, the flow sensor and the pressure difference transmitter, and to control the start and stop of the cooling fan and the lubricating oil pump motor based on the detection data results.

2. The cooling and lubrication system for a hoisting reduction gearbox on a crane according to claim 1, Features: The cooling fan comprises a housing, and a fan and a reducer arranged in the housing; The fan is connected to the high-speed shaft of the reducer.

3. The cooling and lubricating system for a hoisting reduction gearbox on a crane according to claim 1, Features: The liquid level sensor is a tuning fork type liquid level sensor.

4. The cooling and lubricating system for a hoisting reduction gearbox on a crane according to claim 1, Features: A one-way valve and a ball valve are arranged on the lubricating oil circuit.

5. The cooling and lubricating system for a hoisting reduction gearbox on a crane according to claim 1, Features: The main electric control PLC adopts Siemens S series.

6. A control method for a cooling and lubrication system of a hoisting reduction gearbox on a crane based on any one of claims 1 to 5, Features: During the heavy-load operation of the bridge crane, when the temperature sensor detects that the oil temperature in the lifting reduction box reaches the high temperature setting value, the main electronic control PLC controls to start the cooling fan and the lubricating oil pump motor to start the lubricating oil circulation. After a delay of N seconds, the main electronic control PLC detects whether the flow sensor has a flow signal. If there is no flow signal, the main electronic control PLC prompts an alarm. When the temperature sensor detects that the oil temperature in the lifting reduction box reaches the low temperature setting value, the main electric control PLC controls to stop the cooling fan and the lubricating oil pump motor. After a delay of N seconds, the main electric control PLC detects that the contact signal of the flow sensor is disconnected. If the contact signal is not disconnected, the main electric control PLC prompts an alarm. When the temperature sensor detects that the oil temperature in the lifting reduction box reaches the upper limit high temperature setting value, the main electric control PLC prompts an alarm; When the temperature sensor detects that the oil temperature in the lifting reduction box reaches the lower limit low temperature setting value, the cooling and lubrication system of the lifting reduction box stops working.

7. The control method according to claim 6, Features: When the pressure difference detected by the pressure difference transmitter reaches the set value, the contact of the pressure difference transmitter will close and output a feedback signal, and the main electronic control PLC will prompt to clean or replace the filter element of the filter.

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