Pressing signal operation monitoring system and method based on PLC control

Abstract

The invention relates to the technical field of car dumper signal fault monitoring, and particularly provides a pressing signal operation monitoring system and method based on PLC control, and the system comprises a car pressing monitoring module which obtains car pressing information based on a plurality of car pressing signals when a car dumper carries out car pressing operation; the parking monitoring module is used for obtaining parking information based on a plurality of parking signals; the PLC control module is used for collecting vehicle pressing signals of a plurality of vehicle pressing proximity switches of the vehicle pressing monitoring module and vehicle leaning signals of a plurality of vehicle leaning proximity switches of the vehicle leaning monitoring module, conducting switch position logic judgment on the vehicle pressing signals and the vehicle leaning signals and generating a judgment result, and the upper computer is used for displaying the judgment result. The abnormal recognition of the pressing signal of the car dumper is realized based on the PLC logical operation, the fault range is clearly indicated for operation and maintenance personnel, the processing difficulty of the pressing fault of the car dumper can be reduced, the signal fault processing time can be shortened, and the maintenance working efficiency and the loading and unloading working safety of the car dumper are effectively improved.

Description

Technical Field

[0001] The present application relates to the technical field of tipper signal fault monitoring, and in particular to a pressure signal operation monitoring system and method based on PLC control. Background Art

[0002] Car tippers, also known as railway truck dumpers, are special port machinery in ports and are a type of bulk cargo loading and unloading machinery. They are widely used in ports, steel mills and power plants. During the loading and unloading operation of car tippers in power plants, abnormalities in the working signals such as pressing and approaching are common faults. Due to the complex working environment and the large number of limit positions, it is often impossible to accurately determine the fault location when a pressing and approaching signal failure occurs, which in turn prolongs the fault handling time and seriously reduces the safety and completion efficiency of the car tipper loading and unloading work.

[0003] When the existing tipping machine's pressing signal fails, the maintenance personnel can only get the overall fault prompt on site on the pressing car signal monitoring screen, but cannot directly determine which pressing proximity switch is in an abnormal state. The maintenance personnel need to analyze and search in conjunction with the PLC program. If any at least one of the pressing proximity switches of the pressing car signal part or the approaching car signal part is abnormal, it is necessary to conduct repeated test runs in conjunction with the PLC program analysis, or replace components and test run the equipment to gradually troubleshoot, so as to observe the fault phenomenon and determine the fault point. For instantaneous signal loss failures (and when there is no obvious abnormality in the pressing proximity switch on site), it is more difficult to judge, and can only be repeated test runs in conjunction with the PLC program analysis, which increases the difficulty of fault handling, and the search time can be up to several days or even weeks. This process reduces the efficiency of the tipping machine's maintenance work and even affects the safety of the tipping machine's loading and unloading work. Summary of the invention

[0004] In response to the above problems, the present application provides a pressure signal operation monitoring system and method based on PLC control, which realizes the abnormal identification of the pressure signal of the tipping machine based on PLC logic operation, clearly indicates the fault scope to the operating and maintenance personnel, can reduce the difficulty of handling the pressure fault of the tipping machine, shorten the signal fault processing time, and effectively improve the maintenance efficiency of the tipping machine and the safety of the loading and unloading work of the tipping machine.

[0005] To achieve the purpose of this application, this application provides the following technical solutions:

[0006] In a first aspect, the present application provides a pressure-on-car signal operation monitoring system based on PLC control, including a pressure-on-car monitoring module, a car-on-car monitoring module, a PLC control module and a host computer;

[0007] The car pressing monitoring module is used to obtain car pressing information based on multiple car pressing signals when the tipping machine performs a car pressing operation; wherein the car pressing monitoring module includes multiple car pressing proximity switches arranged on the car pressing beam of the tipping machine, each of the car pressing proximity switches is used to monitor the car pressing signal of the car pressing beam of the tipping machine at the corresponding car pressing point;

[0008] The approach monitoring module is used to obtain approach information based on multiple approach signals when the tipping machine is approaching the vehicle; wherein the approach monitoring module includes multiple approach proximity switches provided on the tipping machine, each approach proximity switch is used to monitor the approach signal of the tipping machine at the corresponding approach point;

[0009] The PLC control module is connected to the multiple car pressing proximity switches and the multiple car approaching switches respectively, and is used to collect the car pressing signals of the multiple car pressing proximity switches and the car approaching signals of the multiple car approaching switches, and perform switch position logic judgment on the car pressing signals and the car approaching signals to generate a judgment result; wherein, the PLC control module is provided with a first abnormality recording unit and a second abnormality recording unit, wherein the first abnormality recording unit includes abnormality recording soft relays of the car pressing switches corresponding to the multiple car pressing proximity switches respectively, and the second abnormality recording unit includes abnormality recording soft relays of the car approaching switches corresponding to the multiple car approaching switches respectively;

[0010] The host computer is used to display the judgment result.

[0011] In a possible implementation, the PLC control module is also used to: generate an abnormal vehicle pressing / approaching signal corresponding to the first judgment signal when the first judgment signal used to characterize that the judgment result is normal is not received within a first preset action time; and start the first abnormal recording unit / second abnormal recording unit to perform an abnormality check based on the abnormal vehicle pressing / approaching signal to determine at least one abnormal vehicle pressing proximity switch / abnormal vehicle approaching switch corresponding to the abnormal vehicle pressing / approaching signal.

[0012] In a possible implementation, the judgment result includes a vehicle pressing abnormality judgment result and a vehicle approaching abnormality judgment result; the switch position logic judgment of the vehicle pressing signal and the vehicle approaching signal is performed to generate the judgment result, including: when at least one vehicle pressing signal in the vehicle pressing information is in a fault state, the vehicle pressing abnormality judgment result is generated; the vehicle pressing abnormality judgment result includes the at least one abnormal vehicle pressing proximity switch; when at least one vehicle approaching signal in the vehicle approaching information is in a fault state, the vehicle approaching abnormality judgment result is generated; the vehicle approaching abnormality judgment result includes the at least one abnormal vehicle approaching switch.

[0013] In a possible implementation, the vehicle pressing information includes: a signal that the heavy vehicle beam is in place for pressing, a signal that the light vehicle beam is in place for pressing, a signal that the heavy vehicle beam is in place for releasing pressing, a signal that the light vehicle beam is in place for releasing pressing, a signal that the heavy vehicle beam is leveled, and a signal that the light vehicle beam is leveled; the vehicle pressing abnormality judgment result includes a vehicle pressing abnormality judgment result and a pressure release abnormality judgment result; when the first abnormality recording unit identifies that at least one of the vehicle pressing signals among the heavy vehicle beam in place for pressing, the light vehicle beam in place for pressing, the heavy vehicle beam leveled, and the light vehicle beam leveling signals corresponds to an abnormal vehicle pressing proximity switch that is in a fault state, the vehicle pressing abnormality judgment result is generated; when the first abnormality recording unit identifies that at least one of the vehicle pressing signals among the heavy vehicle beam pressure release signal and the light vehicle beam pressure release signal corresponds to a fault state, the pressure release abnormality judgment result is generated.

[0014] In a possible implementation, the approach information includes at least two approach signals and at least four unapproached signals; the approach abnormality judgment result includes an approach abnormality judgment result and a unapproached abnormality judgment result; when the second abnormality recording unit identifies that the abnormal approach switch corresponding to at least one of the at least two approach signals is in a fault state, the approach abnormality judgment result is generated; when the second abnormality recording unit identifies that the abnormal approach switch corresponding to at least one of the at least four unapproached signals is in a fault state, the unapproached abnormality judgment result is generated.

[0015] In a possible implementation, the parking information includes at least two parking in place signals and at least four parking release signals; the parking abnormality judgment result includes a parking in place abnormality judgment result and a parking release abnormality judgment result; when the second abnormality recording unit identifies that the abnormal parking proximity switch corresponding to at least one of the at least two parking in place signals is in a faulty state, the parking abnormality judgment result is generated; when the second abnormality recording unit identifies that the abnormal parking proximity switch corresponding to at least one of the at least four parking release signals is in a faulty state, the parking release abnormality judgment result is generated.

[0016] In a possible implementation, for each of the pressing vehicle proximity switch / car approach switch, the PLC control module also includes a third abnormal recording unit and a fourth abnormal recording unit, the third abnormal recording unit including a pressing switch loss record soft relay corresponding to the multiple pressing vehicle proximity switches, and the fourth abnormal recording unit including a car approach switch loss record soft relay corresponding to the multiple car approach switches; wherein the third abnormal recording unit is used to identify the loss / displacement fault of the pressing vehicle signal, and the fourth abnormal recording unit is used to identify the loss / displacement fault of the car approach signal; the PLC control module is also used to, when at least one of the pressing vehicle proximity switch / car approach switch loss / displacement faults corresponding to the pressing vehicle proximity switch is collected during the tipping operation of the tipper, start the third abnormal recording unit / fourth abnormal recording unit based on the loss / displacement fault signal to perform an abnormality check to determine at least one pressing vehicle proximity switch / car approach switch corresponding to the loss / displacement fault signal.

[0017] In a possible implementation, the switch position logic judgment of the vehicle pressing signal and the vehicle approaching signal is performed to generate a judgment result, and also includes: when each of the vehicle pressing signals in the vehicle pressing information is in a non-fault state, a first normal operation judgment result is generated, and the first normal operation judgment result is used to characterize that the vehicle pressing operation / releasing operation of the tipping machine is normal; when each of the vehicle approaching signals in the vehicle approaching information is in a non-fault state, a second normal operation judgment result is generated, and the second normal operation judgment result is used to characterize that the vehicle approaching operation / releasing operation of the tipping machine is normal.

[0018] In a second aspect, the present application provides a pressure signal operation monitoring method based on PLC control, which is applied to the above-mentioned pressure signal operation monitoring system based on PLC control, and the method includes:

[0019] Acquiring vehicle pressing signals of the plurality of vehicle pressing proximity switches based on the plurality of vehicle pressing proximity switches arranged on the tipping machine;

[0020] If a first judgment signal indicating that the vehicle pressing signals of the plurality of vehicle pressing proximity switches are normal is not received within a first preset action time, an abnormal vehicle pressing signal corresponding to the first judgment signal is generated;

[0021] Based on the abnormal vehicle pressing signal, the first abnormal recording unit is started to perform an abnormality check to determine at least one abnormal vehicle pressing proximity switch corresponding to the abnormal vehicle pressing signal, and the abnormal vehicle pressing proximity switch is displayed to the monitoring feedback module; wherein, the first abnormal recording unit includes vehicle pressing switch abnormality recording soft relays corresponding to the multiple vehicle pressing proximity switches respectively; wherein, the monitoring feedback module is used to display the operating status of the multiple vehicle pressing proximity switches, and the operating status includes an abnormal state and a non-abnormal state.

[0022] In a possible implementation, when a second judgment signal indicating that the vehicle pressing signals of the multiple vehicle pressing proximity switches are normal is received within the first preset action time, the approaching signals of the multiple vehicle approach switches are obtained based on the multiple vehicle approach switches arranged on the tipping machine; when a third judgment signal indicating that the approaching signals of the multiple vehicle approach switches are normal is not received within the second preset action time, an abnormal approaching signal corresponding to the third judgment signal is generated; based on the abnormal approaching signal, a second abnormal recording unit is started to perform an abnormality check to determine at least one abnormal approaching switch corresponding to the abnormal approaching signal, and the abnormal approaching switch is displayed to the monitoring feedback module; wherein the second abnormal recording unit includes approaching switch abnormality recording soft relays corresponding to the multiple vehicle approaching switches respectively.

[0023] The PLC-controlled pressing signal operation monitoring system provided in the present application connects the PLC control module to multiple pressing proximity switches and multiple approaching switches on the tipping machine respectively, collects the pressing signals of multiple pressing proximity switches and the approaching signals of multiple approaching switches based on the first abnormal recording unit and the second abnormal recording unit, and performs switch position logic judgment on the pressing signal and the approaching signal, generates a judgment result, and displays it. In this way, without relying on detection, the abnormal identification of the tipping machine pressing signal is realized based on PLC logic operation, and the fault scope is clearly indicated to the operating and maintenance personnel, which can reduce the difficulty of handling the tipping machine pressing fault, shorten the signal fault processing time, and effectively improve the maintenance work efficiency of the tipping machine and the safety of the tipping machine loading and unloading work. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The accompanying drawings are used to provide a further understanding of the present application and form a part of the specification. Together with the embodiments of the present application, they are used to explain the present application and do not constitute a limitation to the present application.

[0025] Figure 1 A schematic diagram of the architecture of a pressure signal operation monitoring system based on PLC control provided in an embodiment of the present application;

[0026] Figure 2A schematic diagram of a logic operation program loop excerpt in the PLC logic for a tipping machine approaching (loose approaching) signal failure provided in an embodiment of the present application;

[0027] Figure 3 A screenshot of the KingView operating system screen provided in the embodiment of the present application;

[0028] Figure 4 A schematic diagram of a logic operation program loop excerpt in the PLC logic for a failure of a lost in-position signal during a tipping process of a tipping machine provided in an embodiment of the present application;

[0029] Figure 5 An optional flow chart of a method for monitoring operation of a pressure signal based on PLC control provided in an embodiment of the present application;

[0030] Figure 6 An optional flow chart of a method for monitoring the operation of a pressure signal based on PLC control provided in an embodiment of the present application;

[0031] Figure 7 A schematic diagram of a process flow for detecting the failure of a tipping machine to press or approach a vehicle provided in an embodiment of the present application;

[0032] Figure 8 A schematic diagram of a process flow for detecting the failure of the pressure release and vehicle release signals of a tipping machine provided in an embodiment of the present application;

[0033] Fig. 9 A schematic diagram of the detection process for loss of pressure and vehicle-side signal detection during tipping and unloading of a car provided in an embodiment of the present application.

[0034] Reference numerals:

[0035] 101, a vehicle pressing monitoring module; 102, a vehicle approaching monitoring module; 200, a PLC control module; 300, a host computer. DETAILED DESCRIPTION

[0036] In order to make the purpose, technical solutions and advantages of this application clearer, the technical solutions in this application will be clearly and completely described below in conjunction with the drawings in this application. Obviously, the described embodiments are part of the embodiments of this application, not all of them. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0037] The terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features; in the description of this application, unless otherwise specified, "plurality" means two or more.

[0038] The car tipper, also called the railway truck dumper, is a special port machinery in the port and a type of bulk cargo loading and unloading machinery. It is widely used in ports, steel mills and power plants. The rotor car tipper consists of a rotor set on several groups of supporting rollers. When the vehicle is sent to the platform inside the rotor, the vehicle is pressed by the car pressing mechanism and rotates with the rotor to unload the bulk cargo. The "C" type rotor car tipper adopts the "C" type end plate structure suitable for heavy vehicle shunting system. It has a light structure, a fixed platform, a hydraulic backing plate and a hydraulic car pressing mechanism, which eliminates the impact on the vehicle and equipment and reduces the car pressing force. According to the unique control method of the hydraulic system, the vehicle spring energy is effectively released during the unloading process, and the driving power is small.

[0039] The existing car tipping machine system usually includes car tipping machines, heavy car shunting machines, car transfer platforms, empty car shunting machines and other parts. Multiple parts are centrally controlled by a programmable logic controller (PLC), connecting multiple parts into an organic whole, so that each part operates according to the set program. During the loading and unloading operation of the car tipping machine in the power plant, abnormalities in the working signals such as pressing and approaching are relatively common faults. Due to the complex working site environment and the large number of limit positions, it is often impossible to accurately determine the fault location when a pressing and approaching signal failure occurs, which leads to a prolonged fault handling time, seriously reducing the safety and completion efficiency of the car tipping machine loading and unloading work.

[0040] The existing monitoring screen of the pressing car signal only shows the position status of the on-site pressing signal proximity switch. When any pressing signal proximity switch fails, it is impossible to directly determine which switch is in the abnormal state. The staff needs to combine the PLC program logic analysis to judge and search, which increases the difficulty of fault handling, reduces the maintenance efficiency of the tipping machine and even affects the safety of the tipping machine loading and unloading work; for instantaneous signal loss failure (and when there is no obvious abnormality in the on-site proximity switch), it is difficult to judge, and usually it is necessary to repeatedly conduct the trial operation process to observe the fault phenomenon and analyze the PLC program for judgment; when the fault occurs occasionally, there is no record and the fault point cannot be determined. The search time is sometimes as long as several days or even weeks. Usually, the only way is to replace components and test the equipment for gradual troubleshooting or wait until the fault develops to occur frequently to reduce the difficulty of finding.

[0041] In order to solve the above technical problems, the present invention proposes the following technical solutions and corresponding embodiments. Figures 1 to 9The embodiments shown describe the technical solution of the present invention:

[0042] Example 1

[0043] Figure 1 The schematic diagram of the architecture of the pressure signal operation monitoring system based on PLC control according to an embodiment of the present application is shown, the system includes a car pressing monitoring module 101, a car approaching monitoring module 102, a PLC control module 200 and a host computer 300; the car pressing monitoring module 101 is used to obtain car pressing information based on multiple car pressing signals when the tipping machine performs a car pressing operation, wherein the car pressing monitoring module 101 includes multiple car pressing proximity switches (exemplarily, corresponding to the attached Figure 1 The switch 1-switch 6 in the figure), each car pressing proximity switch is used to monitor the car pressing signal of the car pressing beam of the tipping machine at the corresponding car pressing point; the car approaching monitoring module 102 is used to obtain the car approaching information based on multiple car approaching signals when the tipping machine performs the car approaching operation, wherein the car approaching monitoring module 102 includes multiple car approaching proximity switches arranged on the tipping machine (exemplarily, corresponding to the attached Figure 1 In the switch 7-switch 12 given in the figure, each approach switch is used to monitor the approach signal of the tipping machine at the corresponding approach point; the PLC control module 200 is respectively connected to multiple car pressing approach switches and multiple approach switches, and is used to collect the car pressing signals of multiple car pressing approach switches and the approach signals of multiple approach switches, and perform switch position logic judgment on the car pressing signals and the approach signals to generate a judgment result; wherein, the PLC control module 200 is provided with a first abnormal recording unit and a second abnormal recording unit, the first abnormal recording unit includes a car pressing switch abnormal recording soft relay corresponding to the multiple car pressing approach switches, and the second abnormal recording unit includes a car approach switch abnormal recording soft relay corresponding to the multiple approach switches; the host computer 300 is used to display the judgment result.

[0044] In the embodiment of the present application, the PLC control module 200 is used to obtain in real time during the process of the tipping machine performing the pressing / parking operation, the pressing information composed of the pressing signals corresponding to a plurality of pressing proximity switches, and the approaching information composed of the approaching signals corresponding to a plurality of approaching proximity switches; the pressing information and approaching information can also be obtained according to a preset sampling frequency. Here, the pressing information is a combination of the pressing signals of the pressing beam of the tipping machine at the corresponding pressing point monitored by the pressing monitoring module 101, wherein a single pressing signal includes a pressing signal determined based on the judgment result when a switch operation failure occurs, and the approaching information is a combination of the approaching signals of the tipping machine at the corresponding approaching point monitored by the approaching monitoring module 102, wherein a single approaching signal includes a approaching signal determined based on the judgment result when a switch operation failure occurs.

[0045] In the embodiment of the present application, if the PLC controller does not receive the first judgment signal used to characterize the normal judgment result within the first preset action time, it generates an abnormal pressing / approaching signal corresponding to the first judgment signal; and based on the abnormal pressing / approaching signal, the first abnormal recording unit / the second abnormal recording unit is started to perform an abnormality check to determine at least one abnormal pressing proximity switch / abnormal approaching switch corresponding to the abnormal pressing / approaching signal, and the at least one abnormal pressing proximity switch / abnormal approaching switch is used to warn the KingView operating system screen. Exemplarily, the first preset action time can be the system response time in the pressing program / approaching program under normal circumstances. As a feasible implementation, the first abnormal recording unit is to add four intermediate variables of approaching failure, loose approaching failure, pressing failure, and loose pressure failure in the logic operation program in the PLC control module 200, 6 switch in place abnormal recording intermediate variables corresponding to the pressing proximity switch, and 6 switch in place abnormal recording intermediate variables corresponding to the approaching switch. When the control system of the tipping machine sends out a command to press the car (release the pressure) or approach the car (release the approach), and there is no signal of pressing (releasing the pressure) or approaching (releasing the approach) within the set pressing (releasing the pressure) or approaching (releasing the approach) action time, the corresponding intermediate variable and the pressing proximity switch are started and input to the PLC variable for logical operation to determine the position of the abnormal pressing proximity switch or approaching proximity switch, and set the corresponding intermediate variable of the abnormal switch in place record to display it on the operating system screen of the host computer 300. As a feasible implementation method, the corresponding intermediate variable of the abnormal switch in place record is set to display it on the Kingview operating system screen. Here, the logical operation program of the failure of the tipping machine approaching (releasing the approach) signal not being in place in the PLC logic is excerpted as follows: Figure 2 shown.

[0046] The abnormal pressing / approaching signal may indicate that one of the pressing / approaching switches among the multiple pressing / approaching switches fails, or two or more of the pressing / approaching switches fail at the same time, resulting in the PLC control module 200 not receiving the first judgment signal indicating that the judgment result is normal. It should be noted that the judgment result is normal means that each of the pressing signals in the pressing information is in a non-fault state (i.e., a normal response), or each approaching signal in the approaching information is in a non-fault state (i.e., a normal response), that is, the pressing operation / releasing operation of the tipping machine is normal, or the approaching operation / releasing operation is normal at each stage.

[0047] Here, it should be noted that the vehicle pressing signal part of the embodiment of the present application includes a heavy vehicle beam pressing in place signal (i.e. the heavy beam pressing in place), a light vehicle beam pressing in place signal (i.e. the light beam pressing in place), a heavy vehicle beam loose pressing in place signal (i.e. the heavy beam loose pressing in place), a light vehicle beam loose pressing in place signal (i.e. the light beam loose pressing in place), a heavy vehicle beam leveling signal (i.e. the heavy beam is leveled), and a light vehicle beam leveling signal (i.e. the light beam is leveled), which correspond to a total of 6 vehicle pressing proximity switches respectively. The 6 vehicle pressing proximity switches are connected to the PLC input circuit, and the position of the tipping machine pressure plate is judged as the vehicle pressing in place or the loose pressing in place through the switch position logic combination. The approach signal part of the embodiment of the present application includes: 2 approach signals (i.e., approach 1 and approach 2) and 4 loose approach signals (i.e., loose approach 1, loose approach 2, loose approach 3, and loose approach 4), respectively corresponding to a total of 6 approach switches, including 1 approach signal corresponding to the approach signal at the vehicle entry end and 2 approach switches corresponding to the loose approach signal, as well as 1 approach signal corresponding to the approach signal at the vehicle exit end and 2 approach switches corresponding to the loose approach signal. The 6 approach switches are connected to the PLC input circuit, and the position of the tipping machine approach plate is judged as approach or loose approach through the switch position logic combination. Here, the display screenshot of each signal on the Kingview operating system screen is as shown in Figure 3 shown.

[0048] In the embodiment of the present application, the judgment result includes a judgment result of abnormal pressing and a judgment result of abnormal approaching. When at least one pressing signal in the pressing information is in a fault state, the PLC control module 200 generates a judgment result of abnormal pressing, and the judgment result includes at least one abnormal pressing proximity switch; the fault state of the abnormal pressing proximity switch may be abnormal action or abnormal inaction of the pressing proximity switch, abnormal feedback of the link (i.e., abnormal return) or abnormal non-feedback of the link (i.e., abnormal non-return). Similarly, when at least one approaching signal in the approaching information is in a fault state, the PLC control module 200 generates a judgment result of approaching abnormality, and the judgment result of approaching abnormality includes at least one abnormal approaching proximity switch; the fault state of the abnormal pressing proximity switch may be abnormal action or abnormal non-action of the approaching proximity switch during the approaching of the tipping machine, abnormal return or abnormal non-return.

[0049] In an embodiment of the present application, the abnormal judgment result of the vehicle pressing includes the abnormal judgment result of the vehicle pressing in place and the abnormal judgment result of the pressure release. When the first abnormal recording unit identifies that the abnormal vehicle pressing proximity switch corresponding to at least one of the heavy vehicle beam vehicle pressing in place signal, the light vehicle beam vehicle pressing in place signal, the heavy vehicle beam leveling signal and the light vehicle beam leveling signal is in a fault state, the abnormal judgment result of the vehicle pressing in place is generated; when the first abnormal recording unit identifies that at least one of the heavy vehicle beam pressure release in place signal and the light vehicle beam pressure release in place signal corresponds to a fault state, the pressure release abnormal judgment result is generated.

[0050] In an embodiment of the present application, the abnormal approaching judgment result includes an abnormal approaching judgment result and a loose approaching judgment result; when the second abnormal recording unit identifies that the abnormal approaching switch corresponding to at least one approaching signal among at least four approaching signals is in a fault state, the abnormal approaching judgment result is generated; when the second abnormal recording unit identifies that the abnormal approaching switch corresponding to at least one loose approaching signal among at least two loose approaching signals is in a fault state, the loose approaching judgment result is generated.

[0051] After the tipping machine completes the car pressing and approaching operations, if the car pressing signal and the approaching signal are normal, the tipping machine will enter the flipping and unloading process; during the flipping process of the tipping machine, if a car pressing proximity switch / approaching proximity switch in the car pressing signal or the approaching signal changes position instantaneously (the open position switch signal changes from open position to closed position or the closed position switch signal changes from closed position to open position), the car pressing arrival signal or the approaching arrival signal is instantly disconnected, which will cause the tipping machine flipping logic condition to be interrupted and stop working. In the embodiment of the present application, the PLC control module 200 is provided with a third abnormal recording unit and a fourth abnormal recording unit, the third abnormal recording unit includes a car pressing switch loss recording soft relay corresponding to multiple car pressing proximity switches, and the fourth abnormal recording unit includes a car approaching switch loss recording soft relay corresponding to multiple car approach switches. During the tipping operation of the tipping machine, when the PLC control module 200 detects a loss / displacement fault corresponding to at least one car pressing proximity switch / car approach switch, the third abnormal recording unit / fourth abnormal recording unit is started to perform an abnormality check based on the loss / displacement fault signal to determine at least one car pressing proximity switch / car approach switch corresponding to the loss / displacement fault signal.

[0052] As a feasible implementation, the third abnormality recording unit adds four intermediate variables, namely, approaching in place, loose approaching in place, pressing in place, and loose pressing in place, six switch loss abnormality recording intermediate variables corresponding to the pressing vehicle proximity switches, and six switch loss abnormality recording intermediate variables corresponding to the approaching vehicle proximity switches, to the logic operation program within the PLC control module 200. When one or more proximity switches are momentarily lost (displaced) during the tipping process of the car tipping machine, the corresponding intermediate variables are started and input to the approaching proximity switches for logical operation to determine the approaching proximity switches with abnormal switch displacement and set the corresponding switch in place abnormality recording intermediate variables to be displayed on the KingView operating system screen. Here, an excerpt of the logic operation program for the tipping machine approaching (loose approaching) signal loss failure in the PLC logic is as follows: Figure 4 shown.

[0053] The PLC-controlled pressing signal operation monitoring system of the embodiment of the present application connects the PLC control module 200 to multiple pressing proximity switches and multiple approaching proximity switches on the tipping machine, respectively, collects the pressing signals of multiple pressing proximity switches and the approaching signals of multiple approaching proximity switches based on the first abnormal recording unit and the second abnormal recording unit, and performs switch position logic judgment on the pressing signal and the approaching signal, generates a judgment result, and displays it. In this way, without relying on detection, the abnormal identification of the tipping machine pressing signal is realized based on PLC logic operation, and the fault scope is clearly indicated to the operating and maintenance personnel, which can reduce the difficulty of handling the tipping machine pressing fault, shorten the signal fault processing time, and effectively improve the maintenance work efficiency of the tipping machine and the safety of the tipping machine loading and unloading work without increasing equipment investment.

[0054] Example 2

[0055] Based on the above embodiments, the present application provides a method for monitoring the operation of a pressure signal based on PLC control. Figure 4 The schematic diagram of the process of the pressure signal operation monitoring method based on PLC control of the embodiment of the present application is shown. The method is applied to the system of the above embodiment, with reference to Figure 5 As shown, the pressure signal operation monitoring method based on PLC control in the embodiment of the present application includes the following steps S501 to S503:

[0056] Step S501: acquiring vehicle pressing signals of a plurality of vehicle pressing proximity switches arranged on a car tipping machine.

[0057] In the embodiment of the present application, after the tipping machine issues a car pressing (releasing pressure) command and completes the car pressing (releasing pressure) action, each car pressing proximity switch returns an action signal of all car pressing proximity switches of the PLC control module 200.

[0058] It should be noted that the vehicle pressing procedure and the vehicle approaching procedure in the embodiment of the present application are two separate operating steps, and this embodiment is described with reference to the vehicle pressing procedure.

[0059] Step S502: if a first judgment signal indicating that the vehicle pressing signals of the plurality of vehicle pressing proximity switches are normal is not received within a first preset action time, an abnormal vehicle pressing signal corresponding to the first judgment signal is generated.

[0060] In the embodiment of the present application, the first judgment signal refers to a signal indicating whether the pressing signals of the multiple pressing proximity switches are normal. The abnormal pressing signal corresponding to the first judgment signal may be a pressing proximity switch out of position fault or a signal loss fault.

[0061] Step S503, based on the abnormal vehicle pressing signal, start the first abnormal recording unit to perform an abnormality check to determine at least one abnormal vehicle pressing proximity switch corresponding to the abnormal vehicle pressing signal, and display the abnormal vehicle pressing proximity switch to the monitoring feedback module; wherein, the first abnormal recording unit includes vehicle pressing switch abnormality recording soft relays corresponding to the multiple vehicle pressing proximity switches respectively; wherein, the monitoring feedback module is used to display the operating status of the multiple vehicle pressing proximity switches, and the operating status includes an abnormal state and a non-abnormal state.

[0062] In an embodiment of the present application, the PLC control module 200 starts the corresponding intermediate variable in the first abnormal recording unit and inputs the press vehicle proximity switch to the PLC variable for logical operation, determines the press vehicle proximity switch with abnormal operation and sets the corresponding switch to record the abnormal intermediate variable, and displays it to the monitoring feedback module; illustratively, the monitoring feedback module can be the screen of the KingView operating system.

[0063] In the embodiment of the present application, when a second judgment signal is received that the vehicle pressing signals of multiple vehicle pressing proximity switches are normal within the first preset action time, reference Figure 6 As shown, the PLC control module 200 executes the following steps S601 to S603:

[0064] Step S601, obtaining vehicle approach signals of a plurality of vehicle approach switches provided on the tipping machine based on the plurality of vehicle approach switches;

[0065] Step S602, when a third judgment signal indicating that the approaching signals of the plurality of approaching proximity switches are normal is not received within the second preset action time, generating an abnormal approaching signal corresponding to the third judgment signal;

[0066] Step S603, based on the abnormal approaching signal, start the second abnormal recording unit to perform an abnormality check to determine at least one abnormal approaching switch corresponding to the abnormal approaching signal, and display the abnormal approaching switch to the monitoring feedback module; wherein the second abnormal recording unit includes approaching switch abnormality recording soft relays corresponding to the multiple approaching switches respectively.

[0067] In the examples of this application, refer to Figure 7 As shown in the figure, after the tipping machine presses the car into place, the car-parking procedure begins, and after the car is in place, the tipping machine flips over. Similarly, after unloading is completed, refer to Figure 8 As shown, the tipper first executes the loosening program. When there is an abnormality in the loosening information, the PLC control module (which can be understood as the attached Figure 7 The pressure signal monitoring system in the system determines the reason why the pressure release signal is not in place through logical operation, and then records the abnormal proximity switch and gives a prompt on the operation screen; when the pressure release is in place (there is no abnormality in the pressure release information), the pressure release procedure of the tipping machine is executed. When the pressure release information is abnormal, the system determines the reason why the pressure release signal is not in place through logical operation, and then records the abnormal proximity switch and gives a prompt on the operation screen; when the pressure release is in place, the empty car tipping is executed. In this way, by adding a separate pressure signal out of place judgment circuit, it is convenient for maintenance personnel to quickly determine the fault circuit and reduce the fault handling time.

[0068] In the embodiment of the present application, for the monitoring of the loss of the pressure and close signals of the tipping machine during the tipping process, refer to Fig. 9 As shown, after the car tipper completes forward tipping, the system monitors whether there is a loss of the pressing and approaching signals. When there is an abnormal loss of the pressing and approaching signals in the system, the cause of the loss of the pressing and approaching signals is determined through logical operations, and then the proximity switches with abnormal actions are recorded and prompts are given on the operation screen; when it is detected that there is no abnormal loss of the pressing and approaching signals in the system, the back-turning program is entered, and the abnormal loss of the pressing and approaching signals is also detected. When the back-turning is completed and there is no abnormal loss of the pressing and approaching signals, the car tipper is released. Therefore, a short-term loss judgment loop is added after a separate pressing and approaching signal is in place through PLC programming, and it is recorded; this is conducive to maintenance personnel to quickly determine the fault circuit based on the fault record after the instantaneous fault disappears, reducing the difficulty of fault handling.

[0069] In the embodiment of the present application, Siemens S7-300 series PLC (programmable controller) is used, and the logic ladder diagram is used for programming under STEP-7 software, and the KingView configuration software is used as the upper interface design software. As a result, the KingView screen signal prompt is added, and it is not necessary to check and analyze the fault online through the PLC; the maintenance personnel's skill requirements for finding faults and the difficulty of work are reduced, and the efficiency of fault handling is improved.

[0070] In particular, according to an embodiment of the present invention, the process described above with reference to the flowchart can be implemented as a computer software program. For example, an embodiment of the present invention includes a computer program product, which includes a computer program carried on a computer-readable storage medium, and the computer program includes a program code for executing the method shown in the flowchart. In such an embodiment, the computer program can be downloaded and installed from a network through a communication part, and / or installed from a removable medium. When the computer program is executed by a central processing unit (CPU), the above-mentioned functions defined in the system of the present application are executed.

[0071] It should be noted that the computer-readable storage medium shown in the present invention may be a computer-readable signal medium or a computer-readable storage medium or any combination of the above two. The computer-readable storage medium may be, for example, an electrical, magnetic, optical, electromagnetic, infrared, or semiconductor system, device or component, or any combination of the above.

[0072] The above embodiments are only used to illustrate the technical solution of the present application, but not to limit it. The present application is not limited to the exact structure described above and illustrated in the accompanying drawings, and it cannot be determined that the specific implementation of the present application is limited to these descriptions. For ordinary technicians in the technical field to which the present application belongs, various changes and modifications made without departing from the concept of the present application should be deemed to belong to the protection scope of the present application.

[0073] The flowcharts and block diagrams in the accompanying drawings illustrate the possible architecture, functions and operations of the systems, methods and computer program products according to various embodiments of the present invention. In this regard, each box in the flowchart or block diagram may represent a module, a program segment, or a part of the code, which includes one or more executable instructions for implementing the specified logical functions.

[0074] In the several embodiments provided in the present application, it should be understood that the disclosed systems, modules and methods can be implemented in other ways. For example, the module embodiments described above are only schematic, for example, the division of units is only a logical function division, and there may be other division methods in actual implementation, such as multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be an indirect coupling or communication connection through some interfaces, modules or units, which can be electrical, mechanical or other forms.

[0075] The above embodiments are only used to illustrate the technical solution of the present application, but not to limit it. The present application is not limited to the exact structure described above and illustrated in the accompanying drawings, and it cannot be determined that the specific implementation of the present application is limited to these descriptions. For ordinary technicians in the technical field to which the present application belongs, various changes and modifications made without departing from the concept of the present application should be deemed to belong to the protection scope of the present application.

Claims

1. A pressure signal operation monitoring system based on PLC control, characterized in that: It includes a vehicle pressing monitoring module, a vehicle approaching monitoring module, a PLC control module and a host computer; The car pressing monitoring module is used to obtain car pressing information based on multiple car pressing signals when the tipping machine performs a car pressing operation; wherein the car pressing monitoring module includes multiple car pressing proximity switches arranged on the car pressing beam of the tipping machine, each of the car pressing proximity switches is used to monitor the car pressing signal of the car pressing beam of the tipping machine at the corresponding car pressing point; The approach monitoring module is used to obtain approach information based on multiple approach signals when the tipping machine is approaching the vehicle; wherein the approach monitoring module includes multiple approach proximity switches provided on the tipping machine, each approach proximity switch is used to monitor the approach signal of the tipping machine at the corresponding approach point; The PLC control module is connected to the multiple car pressing proximity switches and the multiple car approaching switches respectively, and is used to collect the car pressing signals of the multiple car pressing proximity switches and the car approaching signals of the multiple car approaching switches, and perform switch position logic judgment on the car pressing signals and the car approaching signals to generate a judgment result; wherein, the PLC control module is provided with a first abnormality recording unit and a second abnormality recording unit, wherein the first abnormality recording unit includes abnormality recording soft relays of the car pressing switches corresponding to the multiple car pressing proximity switches respectively, and the second abnormality recording unit includes abnormality recording soft relays of the car approaching switches corresponding to the multiple car approaching switches respectively; The host computer is used to display the judgment result.

2. The pressure signal operation monitoring system based on PLC control according to claim 1 is characterized in that: The PLC control module is also used for: When the first judgment signal used to characterize that the judgment result is normal is not received within the first preset action time, an abnormal vehicle pressing / approaching signal corresponding to the first judgment signal is generated; and based on the abnormal vehicle pressing / approaching signal, the first abnormal recording unit / the second abnormal recording unit is started to perform an abnormality check to determine at least one abnormal vehicle pressing proximity switch / abnormal vehicle approaching switch corresponding to the abnormal vehicle pressing / approaching signal.

3. The pressure signal operation monitoring system based on PLC control according to claim 2 is characterized in that: The judgment result includes a judgment result of abnormal vehicle pressing and a judgment result of abnormal vehicle approaching; the switch position logic judgment of the vehicle pressing signal and the vehicle approaching signal is performed to generate the judgment result, including: In the case where at least one vehicle pressing signal in the vehicle pressing information is in a fault state, generating the vehicle pressing abnormality judgment result; the vehicle pressing abnormality judgment result includes the at least one abnormal vehicle pressing proximity switch; When at least one vehicle approaching signal in the vehicle approaching information is in a fault state, the vehicle approaching abnormality judgment result is generated; the vehicle approaching abnormality judgment result includes the at least one abnormal vehicle approaching proximity switch.

4. The pressure signal operation monitoring system based on PLC control according to claim 3 is characterized in that: The vehicle pressing information includes: a heavy vehicle beam pressing in place signal, a light vehicle beam pressing in place signal, a heavy vehicle beam loose pressing in place signal, a light vehicle beam loose pressing in place signal, a heavy vehicle beam flat pressing signal and a light vehicle beam flat pressing signal; the vehicle pressing abnormality judgment result includes a vehicle pressing in place abnormality judgment result and a loose pressing abnormality judgment result; When the first abnormality recording unit identifies that the abnormal vehicle pressing proximity switch corresponding to at least one of the heavy vehicle beam pressing in place signal, the light vehicle beam pressing in place signal, the heavy vehicle beam leveling signal and the light vehicle beam leveling signal is in a fault state, the vehicle pressing in place abnormality judgment result is generated; When the first abnormality recording unit identifies that at least one of the heavy vehicle beam release pressure in place signal and the light vehicle beam release pressure in place signal corresponds to a fault state, the release pressure abnormality judgment result is generated.

5. The pressure signal operation monitoring system based on PLC control according to claim 3 is characterized in that: The parking information includes at least two parking arrival signals and at least four parking release signals; the parking abnormality judgment result includes a parking arrival abnormality judgment result and a parking release abnormality judgment result; When the second abnormality recording unit identifies that the abnormal approach switch corresponding to at least one of the at least two approaching signals is in a fault state, generating the approaching abnormality judgment result; When the second abnormality recording unit identifies that the abnormal vehicle proximity switch corresponding to at least one of the at least four loose-closed-in position signals is in a fault state, the loose-closed-in position abnormality judgment result is generated.

6. The pressure signal operation monitoring system based on PLC control according to claim 4 or 5 is characterized in that: The parking information includes at least two parking arrival signals and at least four parking release signals; the parking abnormality judgment result includes a parking arrival abnormality judgment result and a parking release abnormality judgment result; When the second abnormality recording unit identifies that the abnormal approach switch corresponding to at least one of the at least two approaching signals is in a fault state, generating the approaching abnormality judgment result; When the second abnormality recording unit identifies that the abnormal vehicle proximity switch corresponding to at least one of the at least four loose-closed-in position signals is in a fault state, the loose-closed-in position abnormality judgment result is generated.

7. The pressure signal operation monitoring system based on PLC control according to claim 1 is characterized in that: For each of the vehicle pressing proximity switches / car approach switches, the PLC control module further includes a third abnormality recording unit and a fourth abnormality recording unit, wherein the third abnormality recording unit includes a vehicle pressing switch loss recording soft relay corresponding to the plurality of vehicle pressing proximity switches, and the fourth abnormality recording unit includes a car approach switch loss recording soft relay corresponding to the plurality of car approach switches; wherein the third abnormality recording unit is used to identify the loss / displacement fault of the vehicle pressing signal, and the fourth abnormality recording unit is used to identify the loss / displacement fault of the car approach signal; The PLC control module is also used to, when a loss / displacement fault corresponding to at least one of the vehicle pressing proximity switch / vehicle approach switch is collected during the tipping operation of the tipping machine, start the third abnormal recording unit / fourth abnormal recording unit to perform an abnormality check based on the loss / displacement fault signal to determine at least one vehicle pressing proximity switch / vehicle approach switch corresponding to the loss / displacement fault signal.

8. The pressure signal operation monitoring system based on PLC control according to claim 1 is characterized in that: The performing switch position logic judgment on the vehicle pressing signal and the vehicle approaching signal to generate a judgment result also includes: When each of the vehicle pressing signals in the vehicle pressing information is in a non-fault state, a first normal operation judgment result is generated, wherein the first normal operation judgment result is used to indicate that the vehicle pressing operation / releasing operation of the tipping machine is normal; When each of the approaching signals in the approaching information is in a non-fault state, a second normal operation judgment result is generated, and the second normal operation judgment result is used to indicate that the approaching operation / unapproaching operation of the tipping machine is normal.

9. A method for monitoring the operation of a pressure signal based on PLC control, applied to the system according to any one of claims 1 to 8, characterized in that: The method comprises: Acquiring vehicle pressing signals of the plurality of vehicle pressing proximity switches based on the plurality of vehicle pressing proximity switches arranged on the tipping machine; If a first judgment signal indicating that the vehicle pressing signals of the plurality of vehicle pressing proximity switches are normal is not received within a first preset action time, an abnormal vehicle pressing signal corresponding to the first judgment signal is generated; Based on the abnormal vehicle pressing signal, the first abnormal recording unit is started to perform an abnormality check to determine at least one abnormal vehicle pressing proximity switch corresponding to the abnormal vehicle pressing signal, and the abnormal vehicle pressing proximity switch is displayed to the monitoring feedback module; wherein, the first abnormal recording unit includes vehicle pressing switch abnormality recording soft relays corresponding to the multiple vehicle pressing proximity switches respectively; wherein, the monitoring feedback module is used to display the operating status of the multiple vehicle pressing proximity switches, and the operating status includes an abnormal state and a non-abnormal state.

10. The method for monitoring operation of pressure signal based on PLC control according to claim 9 is characterized in that: The method further comprises: When receiving a second judgment signal indicating that the vehicle pressing signals of the plurality of vehicle pressing proximity switches are all normal within the first preset action time, obtaining vehicle approaching signals of the plurality of vehicle approaching proximity switches based on the plurality of vehicle approaching proximity switches provided on the tipping machine; generating an abnormal vehicle approaching signal corresponding to the third judgment signal when the third judgment signal indicating that the vehicle approaching signals of the plurality of vehicle approaching proximity switches are normal is not received within the second preset action time; Based on the abnormal approaching signal, a second abnormal recording unit is started to perform an abnormality check to determine at least one abnormal approaching switch corresponding to the abnormal approaching signal, and the abnormal approaching switch is displayed to the monitoring feedback module; wherein the second abnormal recording unit includes an approaching switch abnormality recording soft relay corresponding to the multiple approaching switches respectively.

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