Torque mode and rotating speed mode combined electric winch system and control method thereof

Abstract

The invention discloses an electric winch system control method combining a torque mode and a rotating speed mode, which comprises the following steps of: when an assembly controller detects that the opening degree of a handle is greater than or less than 0, releasing the band-type brake of a motor; the electric angular speed and the torque of the motor rotor are detected in real time, and the current load torque is identified through a load torque identification algorithm; calculating a target torque according to the current load torque and the current reference torque coefficient; and adjusting the output torque of the motor according to the target torque until the rotating speed of the motor is reduced to a threshold rotating speed, and switching the motor into a rotating speed mode to maintain constant-speed operation. According to the control method provided by the invention, based on the reference torque MAP, the torque output of the motor can be dynamically adjusted at the start-stop time, and the torque ripple is effectively reduced, so that the impact on the motor, a driver and the whole system is reduced, the service life of the system is prolonged, and the overall stability of the system is also improved.

Description

Technical Field

[0001] The present invention relates to the technical field of winch control, and in particular to an electric winch system combining a torque mode with a speed mode and a control method thereof. Background Art

[0002] Energy consumption and environmental pollution have become a focus of attention worldwide. In the field of construction machinery, engineers face many challenges, such as low fuel efficiency, high fuel consumption, waste disposal and noise pollution. Especially in the winch system, there is a large amount of recoverable potential energy. Although the traditional hydraulic drive winch system is widely used, its energy recovery element (such as hydraulic accumulator) has a low energy density and cannot effectively recover a large amount of potential energy. Therefore, it has become an urgent need for the industry to introduce electric drive technology into the winch system and use high energy density batteries or capacitors and other energy storage elements to recover the potential energy released by the winch lowering to achieve the goals of energy saving, high efficiency and environmental protection.

[0003] At present, electric drive winch systems usually operate in motor speed mode. In this mode, the motor speed is precisely controlled and is suitable for applications that require a constant speed. However, this control mode will result in large torque pulsations at the start and stop of the winch system, which will impact the motor, drive, and even the entire system, thereby affecting its service life. In addition, in the face of working conditions that require constant fine-tuning, unstable start and stop in motor speed mode may lead to difficulties in position control. Another common control mode is torque mode, in which the output torque of the motor is precisely controlled and is suitable for applications that require precise torque control. Although the torque mode can solve the problem of large torque pulsations during start and stop, under the secondary rise condition, if the given torque cannot meet the load requirements, there is a risk of decline during startup, and the lifting speed of the winch cannot be effectively controlled.

[0004] The existing electric drive winch system has obvious deficiencies in both speed mode and torque mode. In speed mode, the torque pulsation problem at start and stop seriously affects the stability and service life of the system, especially under conditions that require frequent start and stop. This problem is more prominent. In torque mode, although torque pulsation can be reduced, under secondary rising conditions, if the given torque is not enough to meet the load demand, it is easy to cause system startup failure or decline, affecting the safety and reliability of the system. In addition, neither of these two modes can achieve precise position control under start-stop and fine-tuning conditions, which limits the scope of application of the system. Therefore, how to balance torque demand and position control to achieve stable, efficient and safe operation has become a technical problem that needs to be solved urgently. Summary of the invention

[0005] In view of the above defects or improvement needs of the prior art, the purpose of the present invention is to provide an electric winch system and a control method thereof that combines a torque mode with a speed mode. The control method uses a motor control algorithm to quickly and accurately identify the load torque size, and based on the reference torque MAP diagram, can dynamically adjust the torque output of the motor at the start and stop times, effectively reducing torque pulsation. This not only reduces the impact on the motor, the driver and the entire system, extends the service life of the system, but also improves the overall stability of the system. Although the traditional torque mode can reduce torque pulsation, it may not be able to meet the load requirements under the secondary rising condition, resulting in system startup failure or decline. However, the control method provided by the present invention monitors the handle opening signal, the motor speed torque signal and the load identification torque signal in real time through the assembly controller, and can flexibly switch the torque mode and the speed mode according to the actual working conditions, ensuring that accurate speed control can be achieved under different working conditions, thereby improving the controllability and flexibility of the system.

[0006] According to a first aspect of the present invention, a method for controlling an electric hoisting system combining a torque mode and a speed mode is provided, which is implemented by using an electric hoisting system combining a torque mode and a speed mode, wherein the electric hoisting system comprises: an electric control handle, a host computer, an assembly controller, a motor driver, a permanent magnet synchronous motor, a hoisting reducer, a pilot oil supply hydraulic station, a displacement sensor and a three-phase AC power supply; the control method of the electric hoisting system comprises:

[0007] When the assembly controller detects that the handle opening is greater than or less than 0, the pilot oil supply hydraulic station supplies oil to the hydraulic brake inside the winch reducer to open the brake as a prerequisite for the winch lifting movement;

[0008] Release the motor brake, detect the electrical angular velocity and torque of the motor rotor in real time, and identify the current load torque through the load torque identification algorithm;

[0009] Calculating a target torque magnitude according to the current load torque magnitude and the current reference torque coefficient;

[0010] The output torque of the motor is adjusted according to the target torque until the motor speed drops to a threshold speed, and the motor is switched to a speed mode to maintain a constant speed.

[0011] Furthermore, when the assembly controller detects that the handle opening remains at 0, the motor continues to brake, and at the same time the pilot oil supply hydraulic station stops supplying oil to cause the internal brake of the winch reducer to lock, thereby preventing the winch from rising and falling.

[0012] Furthermore, when the winch needs to stop during the lifting process, an appropriate torque is given to the motor to reduce the lifting speed. When the speed drops to the threshold speed, it switches to the speed mode, the motor is braked, and at the same time, the motor is switched to the torque mode and the target torque is set to 0. Finally, the pilot oil supply hydraulic station is used to unload the oil pressure for braking.

[0013] Furthermore, it also includes: determining the current reference torque coefficient based on a reference torque coefficient curve diagram and according to the handle opening.

[0014] Furthermore, it also includes: determining the threshold speed based on a reference torque MAP curve diagram and according to the target torque size.

[0015] According to a second aspect of the present invention, there is provided an electric winch system combining a torque mode and a speed mode, which is implemented by applying the control method of the electric winch system combining a torque mode and a speed mode as described in the claim, comprising: an electric control handle, a host computer, an assembly controller, a motor driver, a permanent magnet synchronous motor, a winch reducer, a pilot oil supply hydraulic station, a displacement sensor and a three-phase AC power supply;

[0016] Furthermore, the motor driver and winch reducer are coaxially mechanically connected; the weight and the displacement sensor are hung on the winch reducer by ropes; the assembly controller is electrically connected to the host computer and the motor driver through the CAN bus respectively; the assembly controller is electrically connected to the pilot oil supply hydraulic station and the electric handle weak current; the motor is electrically connected to the power grid through the motor driver; and the pilot oil supply hydraulic station is connected to the oil circuit of the winch reducer brake device.

[0017] Furthermore, the assembly controller receives control signals from the host computer and the electric handle and feedback signals from the displacement sensor and the motor driver respectively; the motor driver receives control signals from the assembly controller; the motor driver receives feedback signals from the electric / generator; the pilot oil supply hydraulic station receives control signals from the assembly controller; and the winch reducer brake device receives pilot oil pressure from the pilot oil supply hydraulic station.

[0018] According to a second aspect of the present invention, there is provided an electronic device comprising a memory, a processor and a computer program stored in the memory and executable on the processor, wherein the processor implements the above-mentioned method for controlling an electric winch system combining a torque mode with a speed mode when loading and executing the computer program.

[0019] According to a second aspect of the present invention, there is provided a computer-readable storage medium, in which a computer program is stored, and the computer program is loaded and executed by a processor to implement the electric winch system control method combining a torque mode and a speed mode as claimed in the claim.

[0020] Beneficial effects of the present invention:

[0021] 1. The control method provided by the present invention utilizes the motor control algorithm to quickly and accurately identify the load torque size. Based on the reference torque MAP diagram, it can dynamically adjust the torque output of the motor at the start and stop times, effectively reducing the torque pulsation. This not only reduces the impact on the motor, the driver and the entire system, extends the service life of the system, but also improves the overall stability of the system.

[0022] 2. Although the traditional torque mode can reduce torque pulsation, it may not meet the load demand under the secondary rising condition, resulting in system startup failure or decline. The control method provided by the present invention monitors the handle opening signal, motor speed torque signal and load identification torque signal in real time through the assembly controller, and can flexibly switch the torque mode and speed mode according to the actual working conditions, ensuring accurate speed control under different working conditions, thereby improving the controllability and flexibility of the system.

[0023] 3. The control method provided by the present invention avoids the speed runaway phenomenon that may occur when operating in the normal torque mode by optimizing the control method, ensuring the safe and reliable operation of the system under complex working conditions. Especially under working conditions that require frequent start-stop and fine-tuning, the dynamic response speed and stability of the system are significantly improved, effectively preventing mechanical shock and vibration, and improving the safety of operation.

[0024] 4. The winch system provided by the present invention uses three-phase electricity as the energy source of the system. At the same time, the potential energy released when the winch descends can be recovered to the power grid for reuse, realizing effective energy recovery and reuse. This not only reduces the energy consumption of the system and improves the energy utilization efficiency, but also meets the requirements of the national energy conservation and emission reduction development plan, and has important environmental protection significance.

[0025] 5. The control method provided by the present invention avoids unnecessary energy waste and improves the operating efficiency of the system through precise torque and speed control. At the same time, it reduces torque pulsation and mechanical impact, reduces system wear, prolongs the service life of the system, and reduces maintenance costs.

[0026] Additional aspects and advantages of the present application will be partially given in the following description, which will become apparent from the following description, or will be understood through the practice of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The above and / or additional aspects and advantages of the present application will become apparent and easily understood from the following description of the embodiments in conjunction with the accompanying drawings, in which:

[0028] Figure 1 This is a flow chart of a method for controlling an electric winch system combining a torque mode and a speed mode in an embodiment of the present invention;

[0029] Figure 2 It is a schematic diagram of an electric winch system combining a torque mode and a speed mode according to an embodiment of the present invention;

[0030] Figure 3 is a schematic diagram of a load torque identification synovial observer in an embodiment of the present invention;

[0031] Figure 4 is a schematic diagram of a reference torque coefficient curve in an embodiment of the present invention;

[0032] Figure 5 It is a schematic diagram of a reference torque MAP curve in an embodiment of the present invention. DETAILED DESCRIPTION

[0033] The present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It is to be understood that the specific embodiments described herein are only used to explain the present invention, rather than to limit the present invention. It should also be noted that, for ease of description, only parts related to the present invention, rather than all structures, are shown in the accompanying drawings.

[0034] Those skilled in the art will appreciate that, unless otherwise stated, the singular forms "a", "an", "said" and "the" used herein may also include plural forms. It should be further understood that the term "comprising" used in the specification of the present application refers to the presence of the features, integers, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or combinations thereof.

[0035] It will be understood by those skilled in the art that, unless otherwise defined, all terms (including technical terms and scientific terms) used herein have the same meaning as the general understanding of those skilled in the art to which this application belongs. It should also be understood that terms such as those defined in general dictionaries should be understood to have the same meaning as in the context of the prior art, and will not be interpreted with an idealized or overly formal meaning unless specifically defined as in the embodiments of this application.

[0036] The present invention provides an electric winch system combining a torque mode with a speed mode and a control method thereof. The control method utilizes a motor control algorithm to quickly and accurately identify the load torque size, and based on a reference torque MAP diagram, can dynamically adjust the torque output of the motor at the start and stop times, thereby effectively reducing torque pulsation. This not only reduces the impact on the motor, the driver, and the entire system, extends the service life of the system, but also improves the overall stability of the system. Although the traditional torque mode can reduce torque pulsation, it may not be able to meet the load requirements under secondary rising conditions, resulting in system startup failure or decline. However, the control method provided by the present invention monitors the handle opening signal, the motor speed torque signal, and the load identification torque signal in real time through the assembly controller, and can flexibly switch the torque mode and the speed mode according to the actual working conditions, ensuring that accurate speed control can be achieved under different working conditions, thereby improving the controllability and flexibility of the system.

[0037] Embodiment 1:

[0038] like Figure 1 As shown, this embodiment provides an electric winch system, including an electric control handle, a host computer, an assembly controller, a motor driver, a motor / generator, a winch reducer, a weight, a pilot oil supply hydraulic station, a displacement sensor, and three-phase alternating current;

[0039] Preferably, in this embodiment, the motor driver and the winch reducer are coaxially mechanically connected; the weight and the displacement sensor are hung on the winch reducer through a rope; the assembly controller is electrically connected to the host computer and the motor driver through the CAN bus; the assembly controller is electrically connected to the pilot oil supply hydraulic station and the electric handle weak current; the motor / generator is electrically connected to the power grid through the motor driver; the pilot oil supply hydraulic station is connected to the oil circuit of the winch reducer brake device;

[0040] Preferably, in this embodiment, the assembly controller receives control signals from the upper computer and the electric handle respectively; the assembly controller receives feedback signals from the displacement sensor and the motor driver respectively; the motor driver receives the control signal from the assembly controller; the motor driver receives the feedback signal from the electric / generator; the pilot oil supply hydraulic station receives the control signal from the assembly controller; the winch reducer brake device receives the pilot oil pressure from the pilot oil supply hydraulic station;

[0041] Preferably, in this embodiment, the input signal of the assembly controller includes the input signal of other systems of the vehicle, and the present invention patent only relates to the signal related to the control of the winch drive system;

[0042] Preferably, in this embodiment, the motor / generator is a permanent magnet synchronous motor.

[0043] Embodiment 2:

[0044] like Figure 2 As shown, an embodiment of the present invention provides a method for controlling an electric winch system that combines a torque mode with a speed mode. The method detects the handle signal, the motor speed torque signal, and the load identification torque signal in real time through the assembly controller to determine the motion state of the winch system. During the winch lifting process, different torques or speeds are given according to the handle opening signal. The specific workflow of the system control method includes:

[0045] S100, when the assembly controller detects that the handle opening is greater than or less than 0, the pilot oil supply hydraulic station supplies oil to the hydraulic brake inside the winch reducer to open the brake as a prerequisite for the winch lifting movement;

[0046] S200, releasing the motor holding brake, detecting the electrical angular velocity and torque of the motor rotor in real time, and identifying the current load torque through a load torque identification algorithm;

[0047] S300, calculating a target torque according to the current load torque and the current reference torque coefficient;

[0048] S400, adjusting the output torque of the motor according to the target torque until the motor speed drops to a threshold speed, and the motor is switched to a speed mode to maintain a constant speed.

[0049] Preferably, when the assembly controller detects that the handle opening remains at 0, the motor continues to brake, and at the same time, the pilot oil supply hydraulic station does not supply oil to lock the internal brake of the winch reducer to prevent the winch from lifting. When the winch needs to stop during lifting, the motor is given an appropriate torque to reduce the lifting speed. When the speed is reduced to the threshold speed, it is switched to the speed mode, the motor brakes, and at the same time the motor is switched to the torque mode and the target torque is set to 0. Finally, the pilot oil supply hydraulic station is used to release the oil pressure for braking.

[0050] like Figure 3 As shown, the embodiment of the present invention provides a load torque identification algorithm, which can detect the electrical angular velocity and torque of the motor rotor in real time, identify the load torque through the sliding mode observer, and provide support and basis for the implementation of the control method. Through this algorithm, the system can quickly and accurately identify the load torque and use it as the basic torque value.

[0051] like Figure 4 As shown, an embodiment of the present invention provides a reference torque coefficient curve diagram, based on which the current reference torque coefficient can be determined according to the handle opening.

[0052] Preferably, the relationship between the handle opening and the reference torque coefficient can be determined through the reference torque coefficient curve. It can be seen from the figure that as the handle opening increases, the reference torque coefficient increases in a concave form. This growth form reduces the system power and battery discharge power requirements, but can improve the stability and energy saving of the winch start and stop moments, which is in line with the current improvement direction of winches in the market.

[0053] like Figure 5 As shown, an embodiment of the present invention provides a reference torque MAP curve diagram, which can determine the threshold speed according to the target torque size based on the reference torque MAP curve diagram; the reference torque MAP diagram is formulated to set the performance characteristics of the motor under different torque and speed conditions, and on this basis, a suitable torque expected value is input into the motor driver to drive the winch to perform lifting and lowering movements.

[0054] An embodiment of the present invention also provides an electronic device, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor implements the above-mentioned electric winch system control method combining a torque mode with a speed mode when loading and executing the computer program.

[0055] An embodiment of the present invention further provides a computer-readable storage medium, in which a computer program is stored. The computer program is loaded and executed by a processor to implement the electric winch system control method combining a torque mode and a speed mode as claimed in the claim.

[0056] It should be understood that, although the steps in the flowchart of the accompanying drawings are displayed in sequence as indicated by the arrows, these steps are not necessarily executed in sequence in the order indicated by the arrows. Unless otherwise specified herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, at least a part of the steps in the flowchart of the accompanying drawings may include multiple sub-steps or multiple stages, and these sub-steps or stages are not necessarily executed at the same time, but can be executed at different times, and their execution order is not necessarily sequential, but can be executed in turn or alternately with other steps or at least a part of the sub-steps or stages of other steps.

[0057] The above description is only a partial implementation method of the present application. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present application. These improvements and modifications should also be regarded as the scope of protection of the present application.

Claims

1. A method for controlling an electric winch system combining a torque mode and a speed mode, characterized in that: The electric winch system is realized by using a torque mode and a speed mode. The electric winch system includes: an electric control handle, a host computer, an assembly controller, a motor driver, a motor / generator, a winch reducer, a pilot oil supply hydraulic station, a weight, a displacement sensor and a three-phase AC power supply; the control method of the electric winch system includes: S100, when the assembly controller detects that the handle opening is greater than or less than 0, the pilot oil supply hydraulic station supplies oil to the hydraulic brake inside the winch reducer to open the brake as a prerequisite for the winch lifting movement; S200, releasing the motor holding brake, detecting the electrical angular velocity and torque of the motor rotor in real time, and identifying the current load torque through a load torque identification algorithm; S300, calculating a target torque according to the current load torque and the current reference torque coefficient; S400, adjusting the output torque of the motor according to the target torque until the motor speed drops to a threshold speed, and the motor is switched to a speed mode to maintain a constant speed.

2. The electric winch system control method combining a torque mode and a speed mode according to claim 1, characterized in that: When the assembly controller detects that the handle opening remains at 0, the motor continues to brake, and at the same time the pilot oil supply hydraulic station stops supplying oil to cause the internal brake of the winch reducer to lock, preventing the winch from rising and falling.

3. The electric winch system control method combining a torque mode and a speed mode according to claim 1, characterized in that: When the winch needs to stop during the lifting process, the motor is given an appropriate torque to reduce the lifting speed. When the speed drops to the threshold speed, it switches to speed mode, the motor is braked, and at the same time the motor is switched to torque mode and the target torque is set to 0. Finally, the pilot oil supply hydraulic station is used to unload the oil pressure for braking.

4. A method for controlling an electric winch system combining a torque mode and a speed mode according to any one of claims 1 to 3, characterized in that: Also includes: The current reference torque coefficient is determined based on a reference torque coefficient curve diagram and according to the handle opening.

5. A method for controlling an electric winch system combining a torque mode and a speed mode according to any one of claims 1 to 3, characterized in that: This includes: The threshold speed is determined based on a reference torque MAP curve map and in accordance with the target torque magnitude.

6. An electric hoisting system combining a torque mode and a speed mode, which is implemented by applying a control method for an electric hoisting system combining a torque mode and a speed mode as claimed in any one of claims 1 to 4, characterized in that: include: Electric control handle, host computer, assembly controller, motor driver, permanent magnet synchronous motor, winch reducer, pilot oil supply hydraulic station, displacement sensor and three-phase AC power supply.

7. The electric winch system combining a torque mode and a speed mode according to claim 6, characterized in that: The motor driver is coaxially mechanically connected to the winch reducer; the weight and the displacement sensor are hung on the winch reducer by ropes; the assembly controller is electrically connected to the host computer and the motor driver respectively through the CAN bus; the assembly controller is weakly electrically connected to the pilot oil supply hydraulic station and the electric control handle; the motor is electrically connected to the power grid through the motor driver; the pilot oil supply hydraulic station is connected to the oil circuit of the winch reducer brake device.

8. The electric winch system combining a torque mode and a speed mode according to claim 6, characterized in that: The assembly controller receives control signals from the host computer and the electric handle and feedback signals from the displacement sensor and the motor driver respectively; the motor driver receives control signals from the assembly controller; the motor driver receives feedback signals from the electric / generator; the pilot oil supply hydraulic station receives control signals from the assembly controller; the winch reducer brake device receives pilot oil pressure from the pilot oil supply hydraulic station.

9. An electronic device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that: When the processor loads and executes the computer program, an electric winch system control method combining a torque mode and a speed mode according to any one of claims 1 to 5 is implemented.

10. A computer-readable storage medium, characterized in that: The computer-readable storage medium stores a computer program, which is loaded and executed by a processor to implement a method for controlling an electric winch system combining a torque mode and a speed mode according to any one of claims 1 to 5.

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