Fault processing method for double-motor opening and closing door system of battery replacing station

Abstract

The invention discloses a fault processing method for a double-motor door opening and closing system of a battery swap station. The fault processing method comprises the following steps: step 1, receiving a vehicle pull-in signal; 2, after the vehicle enters the station and is in place; 3, the opening and closing door is opened, and the RGV replaces the battery pack of the vehicle; 4, after battery replacement is completed, the vehicle is driven away from the battery replacement station; and 5, door opening and closing error self-correction is conducted, the failure rate of the door opening and closing is reduced through motor brake clamping, double-motor synchronous error self-correction and the like, and operation safety is guaranteed.

Description

Technical Field

[0001] The present invention relates to the technical application field of battery swap stations, and in particular to a fault handling method for a dual-motor door opening and closing system of a battery swap station. Background Art

[0002] The battery compartment of the battery swap station stores a large number of batteries, which need to be frequently replaced and charged with the vehicle. The battery swap process is as follows: the battery is transferred from the vehicle to the battery swap compartment, and then transferred from the battery swap compartment back to the vehicle; in addition, the equipment in the battery swap station needs to be regularly maintained during daily use, so the battery swap channel needs to be used at a very high rate.

[0003] The existing battery replacement channel of the battery replacement station is equipped with an opening and closing door, which is switched open or closed so that the battery on the vehicle can be quickly replaced through the RGV.

[0004] The existing opening and closing doors have the following technical problems during use:

[0005] 1. The opening and closing doors are long-term affected by vehicle rolling, stones, and debris invading the tracks. The friction and resistance of the tracks on both sides change. When the doors are opened and closed at high speed, the two synchronous control motors of the opening and closing doors produce position errors due to different track resistance. When the error reaches a certain range, one side of the opening and closing door is pulled crooked and stuck, which eventually leads to overload of the opening and closing door servo system.

[0006] 2. In the process of entering and exiting the station, there are operational errors such as sudden acceleration, sudden deceleration, and wheel collision with guide rollers. The large torque on the wheel reacts on the opening and closing door, causing the position of the opening and closing door to change suddenly, causing the servo motor to run away.

[0007] 3. In order to achieve synchronization of the movement of the two motors when opening and closing the door, the synchronous control principle is adopted. When the motor on either side fails or is damaged, the entire set of opening and closing doors will not be able to participate in automatic power replacement.

[0008] In view of the above-mentioned technical problems, it is urgently necessary to provide a fault handling method for the dual-motor opening and closing door system of a battery swap station. Summary of the invention

[0009] In order to solve the above technical problems, the present invention provides a fault handling method for a dual-motor opening and closing door system of a battery swap station, which utilizes motor brake clamping and dual-motor synchronization error self-correction to reduce the opening and closing door failure rate and ensure safe operation.

[0010] The technical solution of the present invention is: a fault handling method for a dual-motor door opening and closing system of a battery swap station, comprising the following steps:

[0011] Step 1: Receive the vehicle entry signal;

[0012] Step 2: After the vehicle enters the station;

[0013] Step 3: The door is opened, and the RGV replaces the battery pack of the vehicle;

[0014] Step 4: After the battery swap is completed, the vehicle leaves the battery swap station;

[0015] Step 5: Self-correction of door opening and closing errors.

[0016] Furthermore, the step 1 also includes disconnecting the door opening and closing motor enable through the PLC and closing the brake.

[0017] Furthermore, the step 2 also includes sending the door opening and closing motor recovery enable through the PLC, and the brake is opened.

[0018] Furthermore, in step 3, during the opening process of the door, the PLC records the real-time torque of the two motors before and after the door, and enters the door health analysis mode after the power replacement is completed.

[0019] Furthermore, the door opening and closing health analysis mode includes:

[0020] During the battery replacement process, confirm whether the maximum torque of the motor exceeds the maximum threshold of 60%:

[0021] When the maximum torque of the motor exceeds 60%, the PLC reports to the upper computer that the torque of the single motor is over the limit, and checks whether the motor, gear and roller are abnormal. The upper computer generates a maintenance work order and sends it to the maintenance personnel for inspection;

[0022] When the maximum torque of the motor does not exceed 60, confirm whether the torque difference between the front and rear synchronous motors exceeds 20% and lasts for more than 2s:

[0023] When the torque difference of the motor exceeds 20% and lasts for more than 2s, the PLC reports the imbalance between the torques of the synchronous motors to the upper computer and checks the motor inertia ratio setting and track. The upper computer generates a maintenance work order and sends it to the maintenance personnel for inspection;

[0024] When the torque difference of the motor does not exceed 20%, it indicates that the door opening and closing is normal.

[0025] Furthermore, step 3 also includes fault redundancy during the opening process of the opening and closing door. When a single-side motor of the opening and closing door fails, the two motors are contacted in a synchronous control state, and the normal motor independently maintains operation at a low speed to open or close the opening and closing door.

[0026] Furthermore, if a door opening and closing shaft failure occurs during automatic power replacement, first try to reset the fault. If the fault cannot be reset, check the installation location of the faulty door opening and closing motor and choose to block the motor on the HMI touch screen.

[0027] After the PLC detects that the faulty motor has been shielded, it automatically resets the alarm and immediately releases the synchronous coupling state between the two motors for opening and closing the door;

[0028] The PLC automatically disconnects the faulty motor enabling device and releases the brake of the faulty motor. At the same time, the PLC automatically modifies the motor speed of another normal door opening and closing to 1 / 3 of the automatic operation speed of the door opening and closing.

[0029] Continue to complete the battery replacement and go to step 4, waiting for maintenance personnel to inspect.

[0030] Furthermore, the step 4 also includes closing the opening and closing door, disconnecting the opening and closing door motor enable through the PLC, and closing the brake.

[0031] Furthermore, in step 5, the self-correction of the opening and closing door error is to automatically detect whether the current position of the motors on the front and rear sides of the opening and closing door is within the error range of 5 mm when the power swap station is initialized;

[0032] When the current position error of the motor on the front and rear sides is less than 5mm, the self-test passes and waits for the next power replacement;

[0033] When the current position error of the motor on the front and rear sides is greater than 5mm, the self-reset correction step is performed.

[0034] Furthermore, the self-resetting correction step includes:

[0035] S1: The two motors for opening and closing doors run at a low speed 100mm relative to the opening direction of the door;

[0036] S2: The front door motor performs the origin search action and runs at a low speed in the direction of the door closing. The rear door motor follows the movement at the same speed and in the same direction. After hitting the front door origin position sensor, the front and rear door motors stop at the same time. The PLC sets the current position of the front door motor to 0, and the front door servo motor correction is completed.

[0037] S3: The two motors for opening and closing the door run again at a low speed relative to the opening direction of the door to a position of 100 mm;

[0038] S4: The rear door motor performs the origin search action and runs at a low speed in the direction of the door closing. The front door motor follows the movement at the same speed and in the same direction. After hitting the rear door origin position sensor, the front and rear door servo motors stop at the same time. The PLC sets the current position of the rear door motor to 0, and the door servo motors are fully corrected.

[0039] The beneficial technical effects of the present invention are:

[0040] 1. When the vehicle is moving, the brake holding brake ensures the stability of the opening and closing door, and the position of the opening and closing door will not be offset due to external factors such as sudden braking, emergency stopping, and wheel collision of the vehicle.

[0041] 2. The detection of dual motor torque further ensures the stability of the opening and closing door during use, and avoids overload of the opening and closing door servo system caused by deformation of the opening and closing door due to external environmental factors, foreign objects on the guide rails, etc.

[0042] 3. The fault redundancy setting prevents one of the motors from being unusable when an abnormality occurs.

[0043] 4. The setting of self-reset correction further ensures the stability of opening and closing doors.

[0044] The above description is only an overview of the technical solution of the present invention. In order to more clearly understand the technical means of the present invention and implement it according to the contents of the specification, the following is a detailed description of the preferred embodiments of the present invention in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 is a schematic diagram of a power exchange platform of the present invention;

[0046] Figure 2 It is a schematic diagram of the overall structure of the present invention;

[0047] Figure 3 This is a schematic diagram of the brake holding state process of the present invention;

[0048] Figure 4 It is a schematic diagram of the process flow of the self-correction of the door opening and closing error of the present invention;

[0049] Figure 5 It is a schematic diagram of the double motor fault redundancy process for opening and closing doors of the present invention;

[0050] Figure 6 It is a schematic diagram of the health analysis process of the door opening and closing of the present invention. DETAILED DESCRIPTION

[0051] In order to more clearly understand the technical means of the present invention and implement it according to the contents of the specification, the specific implementation methods of the present invention are further described in detail below in conjunction with the drawings and examples. The following examples are used to illustrate the present invention but are not used to limit the scope of the present invention.

[0052] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the numbers used in this way can be interchanged where appropriate, so as to describe the embodiments of the present application described herein.

[0053] In the description of the present invention, it should be noted that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", etc. indicate directions or positional relationships based on the directions or positional relationships described in the embodiments and shown in the accompanying drawings, or are directions or positional relationships in which the inventive product is usually placed when used. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore should not be understood as a limitation on the present invention.

[0054] like Figure 1 As shown, the present invention specifically relates to a fault handling method for a dual-motor door opening and closing system of a battery swap station, comprising the following steps:

[0055] Step 1: Receive the vehicle entry signal;

[0056] The step 1 also includes disconnecting the door opening and closing motor enable through the PLC and closing the brake.

[0057] Step 2: After the vehicle enters the station;

[0058] The step 2 also includes sending the door opening and closing motor recovery enable through the PLC, and the brake is opened.

[0059] Step 3: The door is opened, and the RGV replaces the battery pack of the vehicle;

[0060] In step 3, during the opening process of the door, the PLC records the real-time torque of the two motors before and after the door, and enters the door health analysis mode after the power replacement is completed.

[0061] Furthermore, the door opening and closing health analysis mode includes:

[0062] During the battery replacement process, confirm whether the maximum torque of the motor exceeds the maximum threshold of 60%:

[0063] When the maximum torque of the motor exceeds 60%, the PLC reports to the upper computer that the torque of the single motor is over the limit, and checks whether the motor, gear and roller are abnormal. The upper computer generates a maintenance work order and sends it to the maintenance personnel for inspection;

[0064] When the maximum torque of the motor does not exceed 60, confirm whether the torque difference between the front and rear synchronous motors exceeds 20% and lasts for more than 2s:

[0065] When the torque difference of the motor exceeds 20% and lasts for more than 2s, the PLC reports the imbalance between the torques of the synchronous motors to the upper computer and checks the motor inertia ratio setting and track. The upper computer generates a maintenance work order and sends it to the maintenance personnel for inspection;

[0066] When the torque difference of the motor does not exceed 20%, it indicates that the door opening and closing is normal.

[0067] Furthermore, step 3 also includes fault redundancy during the opening process of the opening and closing door. When a single-side motor of the opening and closing door fails, the two motors are contacted in a synchronous control state, and the normal motor independently maintains operation at a low speed to open or close the opening and closing door.

[0068] If a door opening and closing shaft failure occurs during automatic power replacement, try to reset the fault first. If the fault cannot be reset, check the installation location of the faulty door opening and closing motor and choose to block the motor on the HMI touch screen.

[0069] After the PLC detects that the faulty motor has been shielded, it automatically resets the alarm and immediately releases the synchronous coupling state between the two motors for opening and closing the door;

[0070] The PLC automatically disconnects the faulty motor enabling device and releases the brake of the faulty motor. At the same time, the PLC automatically modifies the motor speed of another normal door opening and closing to 1 / 3 of the automatic operation speed of the door opening and closing.

[0071] Continue to complete the battery replacement and go to step 4, waiting for maintenance personnel to inspect.

[0072] Step 4: After the battery swap is completed, the vehicle leaves the battery swap station;

[0073] The step 4 also includes closing the door, disconnecting the door motor enable through the PLC, and closing the brake.

[0074] Step 5: Self-correction of door opening and closing errors.

[0075] In step 5, the self-correction of the opening and closing door error is to automatically detect whether the current position of the motor on the front and rear sides of the opening and closing door is within the error range of 5 mm when the power swap station is initialized;

[0076] When the current position error of the motor on the front and rear sides is less than 5mm, the self-test passes and waits for the next power replacement;

[0077] When the current position error of the motor on the front and rear sides is greater than 5mm, the self-reset correction step is performed.

[0078] Furthermore, the self-resetting correction step includes:

[0079] S1: The two motors for opening and closing doors run at a low speed 100mm relative to the opening direction of the door;

[0080] S2: The front door motor performs the origin search action and runs at a low speed in the direction of the door closing. The rear door motor follows the movement at the same speed and in the same direction. After hitting the front door origin position sensor, the front and rear door motors stop at the same time. The PLC sets the current position of the front door motor to 0, and the front door servo motor correction is completed.

[0081] S3: The two motors for opening and closing the door run again at a low speed relative to the opening direction of the door to a position of 100 mm;

[0082] S4: The rear door motor performs the origin search action and runs at a low speed in the direction of the door closing. The front door motor follows the movement at the same speed and in the same direction. After hitting the rear door origin position sensor, the front and rear door servo motors stop at the same time. The PLC sets the current position of the rear door motor to 0, and the door servo motors are fully corrected.

[0083] In addition, safety edge anti-collision strips are installed on the left side, lower left side, right side and lower right side of the opening and closing door.

[0084] When the safety edge-touching anti-collision strip of the opening and closing door is triggered, for example, if the power exchange mechanism interferes, the opening and closing door squeezes foreign objects, or other mechanisms collide with the opening and closing door, the corresponding safety edge-touching anti-collision strip sensor immediately triggers a rising edge signal to the PLC; upon receiving the safety edge-touching anti-collision strip sensor signal, the PLC immediately stops all currently running mechanisms and alarms to prompt the triggering anti-collision strip position.

[0085] The above embodiments are only specific implementation methods of the present invention, which are used to illustrate the technical solutions of the present invention rather than to limit them. The protection scope of the present invention is not limited thereto. Although the present invention has been described in detail with reference to the aforementioned embodiments, ordinary technicians in the field should understand that any technician familiar with the technical field can still modify the technical solutions recorded in the aforementioned embodiments within the technical scope disclosed by the present invention, or can easily think of changes, or make equivalent replacements for some of the technical features therein; and these modifications, changes or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be covered within the protection scope of the present invention.

Claims

1. A fault handling method for a dual-motor door opening and closing system of a battery swap station, characterized in that: The following steps are involved: Step 1: Receive the vehicle entry signal; Step 2: After the vehicle enters the station; Step 3: The door is opened, and the RGV replaces the battery pack of the vehicle; Step 4: After the battery swap is completed, the vehicle leaves the battery swap station; Step 5: Self-correction of door opening and closing errors.

2. The fault handling method for the dual-motor door opening and closing system of a battery swap station according to claim 1 is characterized in that: The step 1 also includes disconnecting the door opening and closing motor enable through the PLC and closing the brake.

3. The fault handling method for the dual-motor door opening and closing system of a battery swap station according to claim 1 is characterized in that: The step 2 also includes sending the door opening and closing motor recovery enable through the PLC, and the brake is opened.

4. The fault handling method for the dual-motor door opening and closing system of a battery swap station according to claim 1 is characterized in that: In step 3, during the opening process of the door, the PLC records the real-time torque of the two motors before and after the door, and enters the door health analysis mode after the power replacement is completed.

5. The fault handling method for the dual-motor door opening and closing system of a battery swap station according to claim 4 is characterized in that: The health analysis mode of the opening and closing door includes: During the battery replacement process, confirm whether the maximum torque of the motor exceeds the maximum threshold of 60%: When the maximum torque of the motor exceeds 60%, the PLC reports to the upper computer that the torque of the single motor is over the limit, and checks whether the motor, gear and roller are abnormal. The upper computer generates a maintenance work order and sends it to the maintenance personnel for inspection; When the maximum torque of the motor does not exceed 60, confirm whether the torque difference between the front and rear synchronous motors exceeds 20% and lasts for more than 2s: When the torque difference of the motor exceeds 20% and lasts for more than 2s, the PLC reports the imbalance between the torques of the synchronous motors to the upper computer and checks the motor inertia ratio setting and track. The upper computer generates a maintenance work order and sends it to the maintenance personnel for inspection; When the torque difference of the motor does not exceed 20%, it indicates that the door opening and closing is normal.

6. The fault handling method for the dual-motor door opening and closing system of a battery swap station according to claim 1, characterized in that: The step 3 also includes fault redundancy during the opening process of the door. When a single-side motor of the door fails, the two motors are in synchronous control state, and the normal motor maintains independent operation at a low speed to open or close the door.

7. The fault handling method for the dual-motor door opening and closing system of a battery swap station according to claim 6 is characterized in that: If a door opening and closing shaft failure occurs during automatic power replacement, try to reset the fault first. If the fault cannot be reset, check the installation location of the faulty door opening and closing motor and choose to block the motor on the HMI touch screen. After the PLC detects that the faulty motor has been shielded, it automatically resets the alarm and immediately releases the synchronous coupling state between the two motors for opening and closing the door; The PLC automatically disconnects the faulty motor enabling device and releases the brake of the faulty motor. At the same time, the PLC automatically modifies the motor speed of another normal door opening and closing to 1 / 3 of the automatic operation speed of the door opening and closing. Continue to complete the battery replacement and go to step 4, waiting for maintenance personnel to inspect.

8. The fault handling method for the dual-motor door opening and closing system of a battery swap station according to claim 1, characterized in that: The step 4 also includes closing the door, disconnecting the door motor enable through the PLC, and closing the brake.

9. The fault handling method for the dual-motor door opening and closing system of a battery swap station according to claim 1, characterized in that: In step 5, the self-correction of the opening and closing door error is to automatically detect whether the current position of the motor on the front and rear sides of the opening and closing door is within the error range of 5 mm when the power swap station is initialized; When the current position error of the motor on the front and rear sides is less than 5mm, the self-test passes and waits for the next power replacement; When the current position error of the motor on the front and rear sides is greater than 5mm, the self-reset correction step is performed.

10. The fault handling method for the dual-motor door opening and closing system of a battery swap station according to claim 9, characterized in that: The self-resetting correction step comprises: S1: The two motors for opening and closing doors run at a low speed 100mm relative to the opening direction of the door; S2: The front door motor performs the origin search action and runs at a low speed in the direction of the door closing. The rear door motor follows the movement at the same speed and in the same direction. After hitting the front door origin position sensor, the front and rear door motors stop at the same time. The PLC sets the current position of the front door motor to 0, and the front door servo motor correction is completed. S3: The two motors for opening and closing the door run again at a low speed relative to the opening direction of the door to a position of 100 mm; S4: The rear door motor performs the origin search action and runs at a low speed in the direction of the door closing. The front door motor follows the movement at the same speed and in the same direction. After hitting the rear door origin position sensor, the front and rear door servo motors stop at the same time. The PLC sets the current position of the rear door motor to 0, and the door servo motors are fully corrected.

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