Wire winding machine alternating current energy-saving system for prestressed concrete cylinder pipe and three-stage pipe

Abstract

The invention provides an alternating-current energy-saving system of a wire winding machine for a prestressed steel cylinder concrete pipe and a three-stage pipe, and relates to the technical field of wire winding machine control. The energy-saving analysis and control module is used for monitoring and analyzing operation information of any frequency converter in the frequency converter group to obtain a working state corresponding to the frequency converter; when any frequency converter is in a power generation state, the electric energy generated by the inverter module is fed back to the direct current bus by controlling the working state of the inverter module. The direct-current bus is connected to the three-phase power supply in parallel, when the motor is in different working states, reasonable distribution and recovery of electric energy can be effectively achieved, the operation state of the frequency converter is accurately monitored and controlled in combination with the energy-saving analysis and control module, and the feedback power is reasonably calculated, so that the energy-saving efficiency is improved. The energy feedback device feeds back surplus electric energy to the three-phase power supply, so that energy waste is avoided, and the energy consumption of the system is further reduced.

Description

Technical Field

[0001] The invention relates to the technical field of wire winding machine control, in particular to an AC energy-saving system of a wire winding machine for a prestressed steel cylinder concrete pipe and a three-stage pipe. Background Art

[0002] In the field of construction engineering, concrete pipes such as prestressed concrete cylinder pipe (PCCP) and three-stage prestressed concrete pipe (SP) are widely used in urban water supply, drainage, water delivery and industrial water projects. These pipes face severe working conditions during long-term use, such as pressure from internal fluid, pressure from external soil, and impact and wear of water flow. With the increase of service time, the inner wall of the pipe will inevitably be damaged and worn, which will lead to the fall of cement debris, which not only reduces the water delivery efficiency of the pipe, but also seriously affects its structural integrity, greatly shortens the service life of the pipe, and poses a potential threat to the safety of pipeline operation. In order to deal with these problems, before the concrete pipe is put into use, it is an effective strengthening method to use a wire winding machine to evenly wrap the prestressed steel wire on its surface to form a mesh structure. In this way, the tensile strength of the concrete pipe can be significantly improved, and its ability to resist impact and wear can be enhanced, thereby extending the service life of the pipe and ensuring the long-term stable operation of the project.

[0003] As the core equipment for realizing this key process, the performance and operation status of the wire winding machine are directly related to the quality and production efficiency of concrete pipes. However, the existing wire winding machines have many problems that need to be solved in terms of energy configuration and system maintenance.

[0004] However, the existing winding machine has the following problems in its energy configuration during use:

[0005] 1. High power consumption, low power factor, and large harmonic interference. When the DC speed regulator is in a reversible operation state, the feedback power is fed back to the grid through the reverse group thyristor device. Due to manufacturing cost considerations and the complexity of control technology, the existing DC speed regulation device has not been specially optimized for the feedback of regenerated power to the grid. The size, frequency, phase sequence, phase and waveform of the feedback voltage are not equal to the grid voltage. Therefore, the DC speed regulation system has poor energy-saving effect and cannot effectively reduce the user's electricity cost.

[0006] Second, maintenance is inconvenient. At present, the wire winding machine adopts industrial computer + PLC + 590 speed regulator + stress detection, and the design of the electronic control system is too complicated. Therefore, it is necessary to provide an AC energy-saving system for prestressed steel cylinder concrete pipes and three-stage pipes. Summary of the invention

[0007] The present invention provides a prestressed steel cylinder concrete pipe and a three-stage pipe-use wire winding machine AC energy-saving system, which solves the problems raised in the above-mentioned background technology.

[0008] In order to solve the above technical problems, the present invention provides a prestressed steel cylinder concrete pipe and a three-stage pipe winding machine AC energy-saving system, which includes a device drive layer and a control logic layer; the device drive layer includes a frequency converter component, a three-phase power supply, a DC bus and an energy feedback device; the frequency converter component is connected in parallel to the three-phase power supply through a DC bus;

[0009] The control logic layer includes a time recording module, a motor analysis and control module, and an energy-saving analysis and control module; the time recording module is used to take the initial working moment of the winding machine as the first moment and the working end moment of the winding machine as the second moment; if there is no working end moment of the winding machine, the current moment is marked as the second moment; and the time area between the first moment and the second moment is marked as the working time zone;

[0010] The motor analysis and control module is used to analyze the state information of any motor in the motor group in the working time zone to obtain the control analysis result corresponding to the motor; wherein the motor group includes a rotary motor, a stress motor, an upper plate motor and a lower plate motor, and the control analysis result includes the rotary adjustment value corresponding to the rotary motor, the output torque control value of the stress motor, and the speed compensation amount corresponding to the upper plate motor and the lower plate motor; any motor in the motor group is controlled to dynamically adjust the output of the corresponding inverter according to its corresponding control analysis result;

[0011] The energy-saving analysis and control module is used to monitor and analyze the operating information of any inverter in the inverter group to obtain the corresponding working status of the inverter; the working status includes power generation status, motoring status and energy balance status; when any inverter is in the power generation status, the electric energy generated by it is fed back to the DC bus by controlling the working status of the inverter module, and the bus voltage value of the electric energy generated by any inverter fed back to the DC bus is obtained, and the feedback power of the energy feedback device is analyzed according to the bus voltage value; the upper and lower limits of the bus voltage value of the DC bus are set, and when the bus voltage value is greater than the upper limit, it indicates excess electric energy and a feedback signal is generated; the feedback signal is used to trigger the start of the energy feedback device to feed back electric energy to the three-phase power supply according to its feedback power.

[0012] Preferably, the inverter assembly includes a first inverter, a second inverter, a third inverter, and a fourth inverter; the input end of any inverter in the inverter assembly is connected to a three-phase power supply, and any inverter in the inverter assembly is provided with a rectifier module and an inverter module; the output end of the first inverter is connected to a rotary motor, the output end of the second inverter is connected to a stress motor, the output end of the third inverter is connected to an upper disk motor, and the output end of the fourth inverter is connected to a lower disk motor; the input end of the energy feedback device is connected to a three-phase power supply, and the output end of the energy feedback device is connected to a DC bus.

[0013] Preferably, a first inductor and a second inductor are respectively provided between the first frequency converter and the second frequency converter and the DC bus; and an inductor is respectively provided between the first frequency converter, the second frequency converter, the third frequency converter, the fourth frequency converter and the three-phase power supply.

[0014] Preferably, fuses are respectively provided between the first frequency converter, the second frequency converter, the third frequency converter, the fourth frequency converter, the energy feedback device and the DC bus.

[0015] Preferably, a switch module is respectively provided between the first frequency converter, the second frequency converter, the third frequency converter, the fourth frequency converter, the energy feedback device and the three-phase power supply.

[0016] Preferably, the state information of the rotary motor in the motor group in the working time zone is analyzed, specifically:

[0017] For the rotary motor, a feedback signal of the actual speed of the rotary motor is received, and the difference between the actual speed of the rotary motor and its preset speed is calculated to obtain the actual speed difference; the actual speed difference at any collection time in the working time zone is obtained, and the actual speed difference in the working time zone is averaged to obtain the actual speed difference average;

[0018] The working time zone is equally divided into several working time zones, and the standard deviation of the actual transfer difference in the working time zones is calculated to obtain the partition actual transfer fluctuation value; the partition fluctuation threshold is set, and the partition actual transfer fluctuation value is compared with the partition fluctuation threshold. If the partition actual transfer fluctuation value is less than or equal to the partition fluctuation threshold, it means that the fluctuation amplitude of the working time zone is normal. On the contrary, if the partition actual transfer fluctuation value is greater than the partition fluctuation threshold, it means that the fluctuation amplitude of the working time zone is abnormal, and the working time zone is marked as an abnormal fluctuation zone; the number of abnormal fluctuation zones in the working time zone is recorded and marked as the abnormal wave number; the end time of the abnormal fluctuation zone is recorded, and the time difference of the end time zones of adjacent abnormal fluctuation zones is calculated to obtain the abnormal adjacent time; the standard deviation of the abnormal adjacent time in the working time zone is calculated to obtain the adjacent abnormal fluctuation value;

[0019] The actual rotation difference value, the actual rotation difference mean value, the abnormal wave number and the adjacent abnormal fluctuation value at the current time in the working time zone are weighted to obtain the rotation adjustment value corresponding to the rotary motor; the rotary motor adjusts the output of the first frequency converter according to the rotation adjustment value to control the rotation speed of the rotary motor.

[0020] Preferably, the state information of the stress motor in the motor group in the working time zone is analyzed, specifically:

[0021] For the stress motor, the tension feedback value of the wire winding is obtained through the tension sensor, and the tension feedback value is calculated by the difference between the target tension value required by the current wire winding process to obtain the tension error value;

[0022] Obtain the proportional coefficient, integral coefficient and differential coefficient of the stress motor, and calculate the proportional control amount by combining the proportional coefficient and the tension error value; calculate the integral control amount by combining the integral coefficient and the tension error value; calculate the differential control amount by combining the differential coefficient and the tension error value; add the proportional, integral and differential control amounts to obtain the output torque control value of the stress motor; adjust the output of the second inverter according to the output torque control value to control the output torque of the stress motor.

[0023] Preferably, the state information of the upper disk motor and the lower disk motor in the motor group in the working time zone is analyzed, and the specific process is:

[0024] Obtain the motor positions of the upper plate motor and the lower plate motor fed back by the encoder, and calculate the position deviation value between the upper plate motor and the lower plate motor;

[0025] Proportional control is used to calculate the speed compensation amount according to the position deviation value;

[0026] For the upper plate motor, if the speed compensation is greater than zero, it means that the upper plate motor is ahead of the lower plate motor. The third frequency converter is controlled to reduce the output frequency according to the speed compensation to reduce the speed of the upper plate motor. On the contrary, if the speed compensation is less than zero, the third frequency converter is controlled to increase the output frequency according to the speed compensation to increase the speed of the upper plate motor.

[0027] For the lower disc motor, the control logic is opposite to that of the upper disc motor; if the speed compensation amount is greater than zero, the fourth frequency converter is controlled to increase the output frequency according to the speed compensation amount to increase the speed of the lower disc motor; if the speed compensation amount is less than zero, the fourth frequency converter is controlled to reduce the output frequency according to the speed compensation amount to reduce the speed of the lower disc motor.

[0028] Preferably, the operation information of any inverter in the inverter group is analyzed to obtain the corresponding working state of the inverter, specifically:

[0029] Obtain the operating information of any inverter in the inverter group, including input voltage, output voltage, input current, and output current; for any inverter, use the power calculation formula to calculate the input power Pin and output power Pout of the inverter according to the input current and input voltage, output current, and output voltage corresponding to the inverter; where U and I represent voltage and current respectively; compare the output power with the input power:

[0030] When Pout>Pin, it means the corresponding inverter is in power generation state;

[0031] When Pout<Pin, it means the corresponding inverter is in the electric state;

[0032] When Pout=Pin, it indicates that the corresponding inverter is in an energy balance state.

[0033] Preferably, the feedback power of the energy feedback device is analyzed according to the bus voltage value, specifically:

[0034] Obtain the bus voltage value at any time in the working time zone, and calculate the difference between the bus voltage value and the upper limit of the bus voltage value to obtain a real-time feedback value;

[0035] The mean and standard deviation of all real-time feedback values ​​in the working time zone are calculated to obtain the feedback mean and feedback fluctuation value; the real-time feedback value, feedback mean and feedback fluctuation value are weighted to obtain the final feedback power.

[0036] Compared with the related art, the prestressed steel cylinder concrete pipe and the three-stage pipe winding machine AC energy-saving system provided by the present invention have the following beneficial effects:

[0037] 1. The present invention connects the DC bus in parallel to the three-phase power supply. When the motor is in different working states, it can effectively realize the reasonable distribution and recovery of electric energy. It combines the energy-saving analysis and control module to accurately monitor and control the operating state of the inverter, and through reasonable calculation of the feedback power, the energy feedback device feeds back the excess electric energy to the three-phase power supply, avoiding energy waste and further reducing the energy consumption of the system.

[0038] 2. The present invention implements precise control of the rotation, stress, upper plate and lower plate motors through the motor analysis and control module. The rotation motor speed, stress motor tension, and upper plate and lower plate motor synchronous movement can all be precisely controlled to improve the winding quality and production efficiency, and ensure stable product quality.

[0039] 3. Compared with the traditional complex electronic control system that uses industrial computer + PLC + 590 speed regulator + stress detection and has non-universal control software, this solution adopts a relatively simple layered architecture (device driver layer and control logic layer). The functions of each module are clear and work well together, reducing hardware complexity and software incompatibility issues, making it easier for technicians to quickly locate and solve problems, reducing downtime, reducing maintenance difficulty and cost, and facilitating unified equipment management. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 A circuit diagram of the AC energy-saving system for the prestressed steel cylinder concrete pipe and the three-stage pipe winding machine provided by the present invention;

[0041] Figure 2 The schematic diagram of the AC energy-saving system for the prestressed steel cylinder concrete pipe and the three-stage pipe winding machine provided by the present invention.

[0042] Numbers in the figure: 1. first frequency converter; 2. second frequency converter; 3. third frequency converter; 4. fourth frequency converter; 5. energy feedback device; 6. three-phase power supply; 7. rotary motor; 8. stress motor; 9. upper plate motor; 10. lower plate motor; 11. DC bus; 12. first inductor; 13. second inductor; 14. fuse. DETAILED DESCRIPTION

[0043] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0044] The terms used in this disclosure are for the purpose of describing specific embodiments only and are not intended to limit the disclosure. The singular forms of "class", "group" and "the" used in this disclosure and the appended claims are also intended to include plural forms unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to and includes any or all possible combinations of one or more associated listed items.

[0045] It should be understood that although the terms first, second, third, etc. may be used in the present disclosure to describe various information, such information should not be limited to these terms. These terms are only used to distinguish the same type of information from each other. For example, without departing from the scope of the present disclosure, the first information may also be referred to as the second information, and similarly, the second information may also be referred to as the first information. Depending on the context, the word "if" as used herein may be interpreted as "at the time of" or "when" or "in response to determining".

[0046] Please refer to Figure 1-Figure 2 The AC energy-saving system of the prestressed steel cylinder concrete pipe and the three-stage pipe winding machine includes a device drive layer and a control logic layer; the device drive layer includes a frequency converter component, a three-phase power supply 6, a DC bus 11 and an energy feedback device 5; the frequency converter component is connected in parallel to the three-phase power supply 6 through the DC bus 11;

[0047] The control logic layer includes a time recording module, a motor analysis and control module, and an energy-saving analysis and control module; the time recording module is used to take the initial working moment of the winding machine as the first moment and the working end moment of the winding machine as the second moment; if there is no working end moment of the winding machine, the current moment is marked as the second moment; and the time area between the first moment and the second moment is marked as the working time zone;

[0048] The motor analysis and control module is used to analyze the state information of any motor in the motor group in the working time zone to obtain the control analysis result corresponding to the motor; wherein the motor group includes a rotary motor 7, a stress motor 8, an upper plate motor 9 and a lower plate motor 10, and the control analysis result includes a rotary adjustment value corresponding to the rotary motor 7, an output torque control value of the stress motor 8, and a speed compensation amount corresponding to the upper plate motor 9 and the lower plate motor 10; any motor in the motor group is controlled to dynamically adjust the output of the corresponding inverter according to its corresponding control analysis result;

[0049] The energy-saving analysis and control module is used to monitor and analyze the operation information of any inverter in the inverter group, and obtain the corresponding working state of the inverter; the working state includes power generation state, motoring state and energy balance state; when any inverter is in the power generation state, the electric energy generated by it is fed back to the DC bus 11 by controlling the working state of the inverter module, and the bus voltage value U of any inverter fed back to the DC bus 11 is obtained. dc , according to the bus voltage value U dc Analyze the feedback power of the energy feedback device; set the upper limit value U of the bus voltage of the DC bus max With the lower limit value U min , when the bus voltage value U dc Greater than the upper limit U max , indicating excess electric energy, generating a feedback signal; the feedback signal is used to trigger the energy feedback device 5 to feed back electric energy to the three-phase power supply 6 according to its feedback power.

[0050] In the present application, the inverter assembly includes a first inverter 1, a second inverter 2, a third inverter 3, and a fourth inverter 4; the input end of any inverter in the inverter assembly is connected to a three-phase power supply 6, and any inverter in the inverter assembly is provided with a rectifier module and an inverter module; the output end of the first inverter 1 is connected to a rotary motor 7, the output end of the second inverter 2 is connected to a stress motor 8, the output end of the third inverter 3 is connected to an upper disk motor 9, and the output end of the fourth inverter 4 is connected to a lower disk motor 10; the input end of the energy feedback device 5 is connected to the three-phase power supply 6, and the output end of the energy feedback device 5 is connected to a DC bus 11.

[0051] In the present application, a first inductor 12 and a second inductor 13 are respectively arranged between the first inverter 1 and the second inverter 2 and the DC bus 11; inductors are respectively arranged between the first inverter 1, the second inverter 2, the third inverter 3, the fourth inverter 4 and the three-phase power supply 6.

[0052] In the present application, fuses 14 are respectively provided between the first frequency converter 1 , the second frequency converter 2 , the third frequency converter 3 , the fourth frequency converter 4 , the energy feedback device 5 and the DC bus 11 .

[0053] In the present application, switch modules are respectively arranged between the first frequency converter 1 , the second frequency converter 2 , the third frequency converter 3 , the fourth frequency converter 4 , the energy feedback device 5 and the three-phase power supply 6 .

[0054] In this application, the state information of the rotary motor 7 in the motor group in the working time zone is analyzed, specifically:

[0055] For the rotary motor 7, a feedback signal of the actual speed of the rotary motor 7 is received, and the actual speed of the rotary motor 7 is calculated to differ from the preset speed to obtain the actual rotation difference G1; the actual rotation difference at any acquisition time in the working time zone is obtained, and the actual rotation difference in the working time zone is averaged to obtain the actual rotation difference average G2;

[0056] The working time zone is equally divided into several working time zones, and the standard deviation of the actual transfer difference in the working time zones is calculated to obtain the partition actual transfer fluctuation value; the partition fluctuation threshold is set, and the partition actual transfer fluctuation value is compared with the partition fluctuation threshold. If the partition actual transfer fluctuation value is less than or equal to the partition fluctuation threshold, it means that the fluctuation amplitude of the working time zone is normal. On the contrary, if the partition actual transfer fluctuation value is greater than the partition fluctuation threshold, it means that the fluctuation amplitude of the working time zone is abnormal, and the working time zone is marked as an abnormal fluctuation partition; the number of abnormal fluctuation partitions in the working time zone is recorded and marked as the abnormal wave number G3; the end time of the abnormal fluctuation partition is recorded, and the time difference between the end time zones of adjacent abnormal fluctuation partitions is calculated to obtain the abnormal adjacent time; the standard deviation of the abnormal adjacent time in the working time zone is calculated to obtain the adjacent abnormal fluctuation value G4;

[0057] The actual rotation difference value, actual rotation difference mean value, abnormal wave number and adjacent abnormal fluctuation value most recently at the current moment in the working time zone are weighted, and the rotation adjustment value G corresponding to the rotary motor 7 is obtained using the formula G=G1×g1+G2×g2+G3×g3+G4×g4; wherein g1, g2, g3, and g4 respectively represent the weights corresponding to the actual rotation difference value, the actual rotation difference mean value, the abnormal wave number and the adjacent abnormal fluctuation value; the rotary motor 7 adjusts the output of the first inverter 1 according to the rotation adjustment value to control the rotation speed of the rotary motor 7.

[0058] In this application, the state information of the stress motor 8 in the motor group in the working time zone is analyzed, specifically:

[0059] For the stress motor 8, the tension feedback value of the wire winding is obtained through the tension sensor, and the tension feedback value is calculated by difference with the target tension value required by the current wire winding process to obtain the tension error value e;

[0060] Obtain the proportional coefficient, integral coefficient, and differential coefficient of the stress motor 8, and calculate the proportional control value u by combining the proportional coefficient and the tension error value. P , the formula is: P =K P ×e; where K P Represents the proportionality coefficient, K P It is set according to the current tension error value;

[0061] Calculate the integral coefficient and the tension error value to get the integral control value u I , the formula is: Among them, K I represents the integral coefficient, er represents the tension error value as a function of the time variable r, dr represents the small increment of the time variable r, t represents the time in the working time zone, It represents the integration operation of the tension error function er with respect to the time variable r from time 0 to time t;

[0062] The differential coefficient and the tension error value are calculated to obtain the differential control value u D , the formula is: Among them, K D represents the differential coefficient, de represents the small change in the tension error value e, and dt represents the small change in time t. Indicates the rate of change of tension error value e with time t;

[0063] The proportional, integral and differential control quantities are added together to obtain the output torque control value of the stress motor 8; the output of the second frequency converter 2 is adjusted according to the output torque control value to control the output torque of the stress motor 8.

[0064] In this application, the status information of the upper disk motor 9 and the lower disk motor 10 in the motor group in the working time zone is analyzed, and the specific process is:

[0065] Obtain the motor positions of the upper plate motor 9 and the lower plate motor 10 fed back by the encoder, and calculate the position deviation value Δθ between the upper plate motor 9 and the lower plate motor 10, as expressed by the formula: Δθ=θ1-θ2; θ1 and θ2 represent the motor positions of the upper plate motor 9 and the lower plate motor 10 respectively;

[0066] The speed compensation Δv is calculated according to the position deviation value using the proportional control method, and the formula is: Δv = Kp × Δθ; where Kp represents the proportional coefficient, and the value of the proportional coefficient is determined according to the motor performance, load characteristics, and the system's requirements for synchronization accuracy;

[0067] For the upper plate motor 9, if the speed compensation amount is greater than zero, it means that the upper plate motor position is ahead of the lower plate motor 10, and the third frequency converter 3 is controlled to reduce the output frequency according to the speed compensation amount to reduce the rotation speed of the upper plate motor 9; on the contrary, if the speed compensation amount is less than zero, the third frequency converter is controlled to increase the output frequency according to the speed compensation amount to increase the rotation speed of the upper plate motor 9;

[0068] For the lower disk motor 10, the control logic is opposite to that of the upper disk motor 9; if the speed compensation amount is greater than zero, the fourth frequency converter 4 is controlled to increase the output frequency according to the speed compensation amount to increase the rotational speed of the lower disk motor 10; if the speed compensation amount is less than zero, the fourth frequency converter 4 is controlled to reduce the output frequency according to the speed compensation amount to reduce the rotational speed of the lower disk motor 10.

[0069] In this application, the operation information of any inverter in the inverter group is analyzed to obtain the corresponding working state of the inverter, specifically:

[0070] Obtain the operation information of any inverter in the inverter group, including input voltage, output voltage, input current, and output current; for any inverter, use the power calculation formula P=UI according to the input current and input voltage, output current, and output voltage corresponding to the inverter to calculate the input power Pin and output power Pout of the inverter respectively; where U and I represent voltage and current respectively; compare the output power with the input power:

[0071] When Pout>Pin, it means the corresponding inverter is in power generation state;

[0072] When Pout<Pin, it means the corresponding inverter is in the electric state;

[0073] When Pout=Pin, it indicates that the corresponding inverter is in an energy balance state.

[0074] In this application, according to the bus voltage value U dcAnalyze the feedback power of the energy feedback device, specifically:

[0075] Obtain the bus voltage value at any time in the working time zone, calculate the difference between the bus voltage value and the upper limit of the bus voltage value to obtain the real-time feedback value Y1;

[0076] The mean and standard deviation of all real-time feedback values ​​in the working time zone are calculated to obtain the feedback mean Y2 and the feedback fluctuation value Y3; the real-time feedback value, feedback mean and feedback fluctuation value are weighted, and the final feedback power Y is obtained using the formula Y=Y1×a1+Y2×a2+Y3×a3; wherein a1, a2 and a3 represent the weights corresponding to the real-time feedback value, feedback mean and feedback fluctuation value, respectively.

[0077] Those skilled in the art will readily appreciate other embodiments of the present invention after considering the specification and practicing the invention disclosed herein. This application is intended to cover any variations, uses or adaptations of the present invention that follow the general principles of the present invention and include common knowledge or customary techniques in the art that are not disclosed in this disclosure. The specification and examples are to be considered exemplary only, and the true scope and spirit of the present invention are indicated by the following claims.

[0078] It should be understood that the present invention is not limited to the exact construction that has been described above and shown in the drawings and that various modifications and changes may be made without departing from the scope thereof. The scope of the present invention is limited only by the appended claims.

Claims

1. Prestressed steel cylinder concrete pipe and three-stage pipe wire winding machine AC energy saving system, characterized in that, It comprises a device drive layer and a control logic layer; the device drive layer comprises a frequency converter component, a three-phase power supply (6), a DC bus (11) and an energy feedback device (5); the frequency converter component is connected in parallel to the three-phase power supply (6) via the DC bus (11); The control logic layer includes a time recording module, a motor analysis and control module, and an energy-saving analysis and control module; the time recording module is used to take the initial working moment of the winding machine as the first moment and the working end moment of the winding machine as the second moment; if there is no working end moment of the winding machine, the current moment is marked as the second moment; and the time area between the first moment and the second moment is marked as the working time zone; The motor analysis and control module is used to analyze the state information of any motor in the motor group in the working time zone to obtain the control analysis result corresponding to the motor; wherein the motor group includes a rotary motor (7), a stress motor (8), an upper plate motor (9) and a lower plate motor (10); the control analysis result includes a rotary adjustment value corresponding to the rotary motor (7), an output torque control value of the stress motor (8), and a speed compensation amount corresponding to the upper plate motor (9) and the lower plate motor (10); any motor in the motor group is controlled to dynamically adjust the output of the corresponding inverter according to the corresponding control analysis result; The energy-saving analysis and control module is used to monitor and analyze the operation information of any inverter in the inverter group to obtain the corresponding working state of the inverter; the working state includes power generation state, motoring state and energy balance state; when any inverter is in the power generation state, the electric energy generated by it is fed back to the DC bus (11) by controlling the working state of the inverter module, and the bus voltage value of the electric energy generated by any inverter fed back to the DC bus (11) is obtained, and the feedback power of the energy feedback device is analyzed according to the bus voltage value; the upper limit and lower limit of the bus voltage value of the DC bus are set, and when the bus voltage value is greater than the upper limit, it indicates that there is excess electric energy, and a feedback signal is generated; the feedback signal is used to trigger the energy feedback device (5) to feed back electric energy to the three-phase power supply (6) according to its feedback power.

2. The AC energy-saving system for prestressed steel cylinder concrete pipe and three-stage pipe winding machine according to claim 1 is characterized in that: The inverter assembly comprises a first inverter (1), a second inverter (2), a third inverter (3), and a fourth inverter (4); the input end of any inverter in the inverter assembly is connected to a three-phase power supply (6), and any inverter in the inverter assembly is provided with a rectifier module and an inverter module; the output end of the first inverter (1) is connected to a rotary motor (7), the output end of the second inverter (2) is connected to a stress motor (8), the output end of the third inverter (3) is connected to an upper plate motor (9), and the output end of the fourth inverter (4) is connected to a lower plate motor (10); the input end of the energy feedback device (5) is connected to the three-phase power supply (6), and the output end of the energy feedback device (5) is connected to a DC bus (11).

3. The AC energy-saving system for prestressed steel cylinder concrete pipe and three-stage pipe winding machine according to claim 2 is characterized in that: A first inductor (12) and a second inductor (13) are respectively arranged between the first frequency converter (1) and the second frequency converter (2) and the DC bus (11); and an inductor is respectively arranged between the first frequency converter (1), the second frequency converter (2), the third frequency converter (3), the fourth frequency converter (4) and the three-phase power supply (6).

4. The AC energy-saving system for prestressed steel cylinder concrete pipe and three-stage pipe winding machine according to claim 2 is characterized in that: Fuses (14) are respectively provided between the first frequency converter (1), the second frequency converter (2), the third frequency converter (3), the fourth frequency converter (4), the energy feedback device (5) and the DC bus (11).

5. The AC energy-saving system for prestressed steel cylinder concrete pipe and three-stage pipe winding machine according to claim 2 is characterized in that: Switch modules are respectively provided between the first frequency converter (1), the second frequency converter (2), the third frequency converter (3), the fourth frequency converter (4), the energy feedback device (5) and the three-phase power supply (6).

6. The AC energy-saving system for prestressed steel cylinder concrete pipe and three-stage pipe winding machine according to claim 1 is characterized in that: The state information of the rotary motor (7) in the motor group in the working time zone is analyzed, specifically: For the rotary motor (7), a feedback signal of the actual rotation speed of the rotary motor (7) is received, and the actual rotation speed of the rotary motor (7) is calculated to be different from the preset rotation speed to obtain an actual rotation difference; the actual rotation difference at any collection time in the working time zone is obtained, and the actual rotation difference in the working time zone is averaged to obtain an actual rotation difference average; The working time zone is equally divided into several working time zones, and the standard deviation of the actual transfer difference in the working time zones is calculated to obtain the actual transfer fluctuation value of the partition; Set a partition fluctuation threshold, compare the partition actual fluctuation value with the partition fluctuation threshold, if the partition actual fluctuation value is less than or equal to the partition fluctuation threshold, it means that the fluctuation range of the working time zone is normal, on the contrary, if the partition actual fluctuation value is greater than the partition fluctuation threshold, it means that the fluctuation range of the working time zone is abnormal, and the working time zone is marked as an abnormal fluctuation partition; record the number of abnormal fluctuation partitions in the working time zone and mark it as the abnormal wave number; Record the end time of the abnormal fluctuation partition, and calculate the time difference between the end time zones of adjacent abnormal fluctuation partitions to obtain the abnormal adjacent time; The standard deviation of abnormal adjacent times in the working time zone is calculated to obtain the adjacent abnormal fluctuation value; The actual rotation difference value, the actual rotation difference mean value, the abnormal wave number and the adjacent abnormal fluctuation value at the current time in the working time zone are weighted to obtain a rotation adjustment value corresponding to the rotary motor (7); the rotary motor (7) adjusts the output of the first frequency converter (1) according to the rotation adjustment value to control the rotation speed of the rotary motor (7).

7. The AC energy-saving system for prestressed steel cylinder concrete pipe and three-stage pipe winding machine according to claim 1 is characterized in that: The state information of the stress motor (8) in the motor group in the working time zone is analyzed, specifically: For the stress motor (8), a tension feedback value of the wire winding is obtained through a tension sensor, and the tension feedback value is calculated by difference with the target tension value required by the current wire winding process to obtain a tension error value; Obtaining the proportional coefficient, integral coefficient, and differential coefficient of the stress motor (8), and calculating the proportional control amount by using the proportional coefficient and the tension error value; The integral control amount is obtained by calculating the integral coefficient and the tension error value; The differential coefficient and the tension error value are calculated to obtain the differential control amount; The proportional, integral and differential control quantities are added together to obtain an output torque control value of the stress motor (8); The output of the second frequency converter (2) is adjusted according to the output torque control value to control the output torque of the stress motor (8).

8. The AC energy-saving system for prestressed steel cylinder concrete pipe and three-stage pipe winding machine according to claim 1 is characterized in that: The state information of the upper plate motor (9) and the lower plate motor (10) in the motor group in the working time zone is analyzed. The specific process is as follows: Obtaining the motor positions of the upper plate motor (9) and the lower plate motor (10) fed back by the encoder, and calculating the position deviation value between the upper plate motor (9) and the lower plate motor (10); Proportional control is used to calculate the speed compensation amount according to the position deviation value; For the upper plate motor (9), if the speed compensation amount is greater than zero, it means that the upper plate motor is ahead of the lower plate motor (10), and the third frequency converter is controlled to reduce the output frequency according to the speed compensation amount to reduce the rotation speed of the upper plate motor (9); on the contrary, if the speed compensation amount is less than zero, the third frequency converter is controlled to increase the output frequency according to the speed compensation amount to increase the rotation speed of the upper plate motor (9); For the lower plate motor (10), the control logic is opposite to that of the upper plate motor (9); if the speed compensation amount is greater than zero, the fourth frequency converter (4) is controlled to increase the output frequency according to the speed compensation amount to increase the rotation speed of the lower plate motor (10); If the speed compensation amount is less than zero, the fourth frequency converter (4) is controlled to reduce the output frequency according to the speed compensation amount, so as to reduce the rotation speed of the lower plate motor (10).

9. The AC energy-saving system for prestressed steel cylinder concrete pipe and three-stage pipe winding machine according to claim 1, characterized in that: Analyze the operating information of any inverter in the inverter group to obtain the corresponding working status of the inverter, specifically: Obtain the operation information of any inverter in the inverter group, including input voltage, output voltage, input current, and output current; for any inverter, use the power calculation formula P=UI according to the input current and input voltage, output current, and output voltage corresponding to the inverter to calculate the input power Pin and output power Pout of the inverter respectively; where U and I represent voltage and current respectively; compare the output power with the input power: When Pout>Pin, it means the corresponding inverter is in power generation state; When Pout<Pin, it means the corresponding inverter is in the electric state; When Pout=Pin, it indicates that the corresponding inverter is in an energy balance state.

10. The AC energy-saving system for prestressed steel cylinder concrete pipe and three-stage pipe winding machine according to claim 1, characterized in that: The feedback power of the energy feedback device is analyzed according to the bus voltage value, specifically: Obtain the bus voltage value at any time in the working time zone, and calculate the difference between the bus voltage value and the upper limit of the bus voltage value to obtain a real-time feedback value; The mean and standard deviation of all real-time feedback values ​​in the working time zone are calculated to obtain the feedback mean and feedback fluctuation value; the real-time feedback value, feedback mean and feedback fluctuation value are weighted to obtain the final feedback power.

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