System for electrical control synchronization of three kinds of reels and cart of bridge type ship unloader

Abstract

The invention relates to the technical field of bridge type ship unloaders, and provides a bridge type ship unloader three-type reel and cart electrical control synchronization system comprising a PLC used for receiving and processing signals from sensors and outputting a control instruction according to a preset algorithm and control logic; the frequency converter is electrically connected with the PLC and used for receiving a control instruction of the PLC and adjusting the voltage, current and rotating speed of a cable drum motor according to the instruction so as to achieve winding and unwinding control over a power cable, a control cable and a water cable; through accurate control of the PLC and the frequency converter and real-time feedback of the incremental encoder and the absolute value encoder, accurate synchronization of the bridge type ship unloader power cable drum, the control cable drum, the water cable drum and cart operation can be achieved. Excessive abrasion and breakage caused by uneven tension of the power cable, the control cable and the water cable are avoided, and stability and safety of equipment operation are remarkably improved.

Description

Technical Field

[0001] The invention relates to the technical field of bridge-type ship unloaders, in particular to a system for synchronizing electrical control of three types of reels and a trolley of a bridge-type ship unloader. Background Art

[0002] During the operation of large-scale lifting equipment, especially bridge-type ship unloaders, power cables, control cables and water cables have different physical properties, so the weight and tension per unit length are different. The storage and release of the three cables on their respective reels in synchronization with the trolley is a crucial link. The three types of random-travel cables, power cables, control cables and water cables, not only need to be flexibly retracted and released with the movement of the equipment, but also need to ensure that the reels carrying the three types of cables can maintain stable tension and synchronization under various working conditions to avoid safety hazards such as excessive wear and breakage of the cables.

[0003] At present, the common cable reel technologies on the market mainly include elastic, heavy hammer, magnetic coupling and variable frequency cable reels. However, these technologies all have certain limitations. For example, elastic and heavy hammer cable reels mainly rely on the movement of the equipment to generate tension to retract and release the cable. This method easily leads to excessive cable tension, thereby shortening the service life of the cable. Although the magnetic coupling cable reel has the characteristics of constant tension, its technology is complex, the maintenance cost is high, and the rotor temperature is easy to rise, affecting the service life. Although the variable frequency cable reel has improved the control accuracy and stability of the cable reel to a certain extent, especially in large lifting equipment such as bridge ship unloaders, it is usually necessary to control the synchronous operation of multiple cable reels (such as power cables, water cables and control cables, etc.) at the same time. These cable reels not only have different specifications, but also need to maintain stable tension and synchronization under complex working conditions. Traditional control methods often fail to meet this demand, resulting in safety accidents such as excessive wear and breakage of cables.

[0004] To this end, those skilled in the art have proposed a system for synchronizing the electrical control of three types of reels of a bridge-type ship unloader with a trolley to solve the problems raised by the background technology. Summary of the invention

[0005] In order to solve the above technical problems, the present invention provides a system for synchronizing the electrical control of three types of reels of a bridge-type ship unloader with a trolley, so as to solve the problem that traditional control methods often fail to meet this demand, resulting in safety accidents such as excessive wear and breakage of cables.

[0006] A system for synchronizing the electrical control of three types of reels and a trolley of a bridge-type ship unloader, including a PLC controller for receiving and processing signals from various sensors and outputting control instructions according to a preset algorithm and control logic;

[0007] The frequency converter is electrically connected to the PLC controller, and is used to receive control instructions from the PLC controller, and adjust the voltage, current and speed of the cable drum motor according to the instructions to achieve cable retraction and extension control;

[0008] At least three cable drums, used to store and release power cables, water cables and control cables respectively. Each cable drum is electrically connected to a frequency converter to achieve independent control;

[0009] Incremental encoder, installed at the tail of the power cable drum / control power drum / water cable drum motor, is used to provide real-time feedback on the rotation frequency and speed of each drum motor, and send these signals to the inverter for closed-loop control;

[0010] The absolute encoder is installed at the tail of each reel shaft to provide real-time feedback of the rotation values ​​of the three types of reels and is connected to the PLC controller via Profibus DP or Profinet communication protocol so that the PLC can perform synchronous control calculations;

[0011] At least four rocker-type limit switches are provided, which are installed on the left and right sides of the three types of cable guides and the left and right over-tightening positions, respectively, to detect the guiding and over-tightening status of the cable and send these signals to the PLC controller;

[0012] The cam limiter is installed at the tail of the rotating shaft of the power cable reel, control power reel and water cable reel to detect the empty and full reel status of the three types of reels and send these signals to the system;

[0013] Among them, the PLC controller outputs corresponding control instructions to the frequency converter based on the received signals through analysis and calculation, adjusts the operation of the three types of drum motors, makes the rotation speed of the three types of drums synchronized with the travel speed of the trolley, and ensures the stability of the tension of the three types of cables: power cable, control cable and water cable.

[0014] Preferably, the PLC controller also receives real-time feedback signals from an incremental encoder and an absolute encoder, which respectively represent the rotation frequency and rotation speed of the cable drum motor and the rotation value of the cable drum; receives signals from a rocker limit switch and a cam limit switch to detect the guiding state, over-tightening state of the cable, and the empty and full states of the cable drum; processes all the above received signals according to a preset algorithm and control logic, and outputs precise control instructions to the frequency converter accordingly;

[0015] The PLC controller preferably adopts a programmable logic controller of ABB brand or other compatible brands, which has high-speed data processing capability and powerful control functions to ensure rapid system response and stable operation.

[0016] Preferably, the frequency converter is electrically connected to the PLC controller and receives control instructions from the PLC controller in real time;

[0017] According to the control instructions received, the voltage, current and speed of the motor connected to each cable drum are accurately adjusted to achieve accurate retraction and release control of power cables, control cables and water cables;

[0018] The frequency converter adopts a model that is fully compatible with the PLC controller, ensuring that accurate speed and torque control can be achieved, thereby ensuring the smooth and efficient operation of the cable drum motor.

[0019] Preferably, the incremental encoder and the absolute encoder can provide real-time feedback of the rotation state of the cable reel motor, including the rotation frequency and speed, and the precise rotation value of the cable reel;

[0020] The incremental encoder is installed at the tail of the cable drum motor, sending real-time rotation data to the frequency converter to participate in the closed-loop control process;

[0021] The absolute encoder is installed at the tail of the cable drum shaft and is connected to the PLC controller through communication protocols such as Profi nbus DP or Profi net, providing the PLC with the precise rotation value required for synchronous control calculations.

[0022] Preferably, at least four rocker-type limit switches are also included, which are respectively installed on the left and right sides and the left and right over-tightening positions of the three types of cable guides, for real-time monitoring of the cable guiding condition and over-tightening state, and timely feeding back relevant signals to the PLC controller;

[0023] The cam limit device is installed at the tail of the rotating shaft of the power cable reel, control cable reel and water cable reel. It is used to accurately detect the empty and full status of the cable reel and send this key status information to the system for timely processing and adjustment.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] 1. Through the precise control of the PLC controller and the frequency converter, as well as the real-time feedback of the incremental encoder and the absolute encoder, the present invention can achieve precise synchronization between the cable drum and the trolley operation. This not only avoids excessive wear and breakage of the cable due to uneven tension, but also significantly improves the stability and safety of the equipment operation.

[0026] 2. This system integrates a touch screen, fault alarm and diagnosis module, and remote monitoring module, allowing users to easily monitor the system's operating status, adjust parameters in a timely manner, and quickly locate and repair faults when they occur. This not only improves the intelligence and automation level of the equipment, but also reduces dependence on manual operation and improves work efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic diagram of the system flow structure of the present invention. DETAILED DESCRIPTION

[0028] The following is a further detailed description of the embodiments of the present invention in conjunction with the accompanying drawings and examples. The following examples are used to illustrate the present invention but are not intended to limit the scope of the present invention.

[0029] As attached Figure 1 As shown:

[0030] Embodiment 1: According to Figure 1 As shown, the present invention provides a system for electrical control synchronization of three types of reels and a trolley of a bridge-type ship unloader, including a PLC controller for receiving and processing signals from various sensors and outputting control instructions according to a preset algorithm and control logic;

[0031] The frequency converter is electrically connected to the PLC controller, and is used to receive control instructions from the PLC controller, and adjust the voltage, current and speed of the cable drum motor according to the instructions to achieve cable retraction and extension control;

[0032] At least three cable drums, used to store and release power cables, water cables and control cables respectively. Each cable drum is electrically connected to a frequency converter to achieve independent control;

[0033] Incremental encoder, installed at the tail of the power cable drum / control power drum / water cable drum motor, is used to provide real-time feedback on the rotation frequency and speed of each drum motor, and send these signals to the inverter for closed-loop control;

[0034] The absolute encoder is installed at the tail of each reel shaft to provide real-time feedback of the rotation values ​​of the three types of reels and is connected to the PLC controller via Profibus DP or Profinet communication protocol so that the PLC can perform synchronous control calculations;

[0035] At least four rocker-type limit switches are provided, which are installed on the left and right sides of the three types of cable guides and the left and right over-tightening positions, respectively, to detect the guiding and over-tightening status of the cable and send these signals to the PLC controller;

[0036] The cam limiter is installed at the tail of the rotating shaft of the power cable reel, control power reel and water cable reel to detect the empty and full reel status of the three types of reels and send these signals to the system;

[0037] Among them, the PLC controller outputs corresponding control instructions to the frequency converter based on the received signal through analysis and calculation, and adjusts the operation of the three types of drum motors to synchronize the rotation speed of the three types of drums with the travel speed of the trolley, ensuring the stability of the tension of the three types of cables: power cable, control cable, and water cable;

[0038] Among them, the PLC controller outputs corresponding control instructions to the frequency converter according to the received signal through analysis and calculation, adjusts the operation of the cable drum motor, synchronizes the rotation speed of the cable drum with the travel speed of the trolley, and ensures the stability of the cable tension. The PLC controller uses ABB brand or other compatible brand programmable logic controller as the control center of the system, which is responsible for receiving and processing signals from various sensors and outputting control instructions according to the preset algorithm and control logic. The frequency converter is connected to the PLC controller through the communication interface, receives control instructions and adjusts the voltage, current and speed of the cable drum motor. Each cable drum is equipped with an independent frequency converter to achieve precise control.

[0039] The PLC controller also receives real-time feedback signals from the incremental encoder and the absolute encoder, which respectively represent the rotation frequency and speed of the cable drum motor and the rotation value of the cable drum; receives signals from the rocker limit switch and the cam limit switch to detect the guiding state, over-tightening state of the cable and the empty and full states of the cable drum; processes all the above received signals according to the preset algorithm and control logic, and outputs precise control instructions to the frequency converter accordingly;

[0040] The PLC controller preferably adopts a programmable logic controller of ABB brand or other compatible brands, which has high-speed data processing capability and powerful control functions to ensure rapid system response and stable operation.

[0041] The frequency converter is electrically connected to the PLC controller and receives control instructions from the PLC controller in real time;

[0042] According to the control instructions received, the voltage, current and speed of the motor connected to each cable drum are accurately adjusted to achieve accurate retraction and release control of power cables, control cables and water cables;

[0043] The frequency converter adopts a model that is fully compatible with the PLC controller to ensure accurate speed and torque control, thereby ensuring the smooth and efficient operation of the cable drum motor. The incremental encoder and absolute encoder can provide real-time feedback on the rotation state of the cable drum motor, including the rotation frequency and speed, as well as the precise rotation value of the cable drum.

[0044] The incremental encoder is installed at the tail of the cable reel motor, and sends the real-time rotation data to the frequency converter to participate in the closed-loop control process; the absolute encoder is installed at the tail of the cable reel shaft, and is connected to the PLC controller through communication protocols such as Profi nbus DP or Profi inet, providing the PLC with the precise rotation value required for synchronous control calculations. It also includes at least four rocker limit switches, which are installed on the left and right sides and left and right over-tightening positions of three types of cable guides, respectively, to monitor the cable guidance and over-tightening status in real time, and promptly feed back relevant signals to the PLC controller; the cam limit device is installed at the tail of the power cable reel, control cable reel and water cable reel shaft, to accurately detect the empty and full reel status of the cable reel, and send these key status information to the system for timely processing and adjustment.

[0045] Working principle: When the trolley starts to run, the PLC controller receives the running signal and direction information of the trolley. According to the running direction and speed of the trolley, the PLC controller calculates the rotation speed and direction of the cable reel, and outputs control instructions to the frequency converter. The frequency converter adjusts the voltage, current and speed of the cable reel motor according to the received control instructions, so that the cable reel starts to reel in or release the cable. The incremental encoder feeds back the rotation frequency and speed of the motor to the frequency converter in real time to achieve closed-loop control and ensure the stable operation of the cable reel motor. The absolute encoder feeds back the rotation value of the cable reel to the PLC controller in real time for accurate calculation of synchronous control. The rocker limit switch and cam limit respectively detect the cable's guidance, over-tightening state, and empty and full reel states, and send signals to the PLC controller for corresponding processing. The PLC controller performs intelligent control through internal algorithms based on all received signals to ensure that the rotation speed of the cable reel is synchronized with the travel speed of the trolley. The touch screen displays the system's working status, parameter settings and fault diagnosis information in real time, and allows users to make necessary adjustments and control operations.

[0046] The standard parts used in the present invention can all be purchased from the market, and the special-shaped parts can be customized according to the description and the drawings. The specific connection methods of each part adopt conventional means such as mature bolts, rivets, welding, etc. in the prior art. The machinery, parts and equipment all adopt conventional models in the prior art, and the circuit connection adopts the conventional connection method in the prior art, which will not be described in detail here. The contents not described in detail in this specification belong to the prior art known to professional and technical personnel in this field.

[0047] In the description of the present invention, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. "Multiple" means two or more, unless otherwise clearly and specifically defined.

[0048] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0049] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may mean that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. Moreover, a first feature being "above", "above" or "above" a second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being "below", "below" or "below" a second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0050] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example" or "some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in a suitable manner in any one or more embodiments or examples. In addition, those skilled in the art may combine and combine different embodiments or examples and features of different embodiments or examples described in this specification without contradiction.

[0051] In the drawings of the embodiments disclosed in the present invention, only the structures related to the embodiments disclosed in the present invention are involved, and other structures can refer to the general design. In the absence of conflict, the same embodiment and different embodiments of the present invention can be combined with each other.

[0052] Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments, or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A system for synchronous electrical control of three types of reels and trolleys of a bridge-type ship unloader, characterized in that: It includes a PLC controller for receiving and processing signals from various sensors and outputting control instructions according to preset algorithms and control logic; The frequency converter is electrically connected to the PLC controller, and is used to receive control instructions from the PLC controller, and adjust the voltage, current and speed of the cable drum motor according to the instructions to achieve cable retraction and extension control; At least three cable drums, used to store and release power cables, water cables and control cables respectively. Each cable drum is electrically connected to a frequency converter to achieve independent control; Incremental encoder, installed at the tail of the power cable drum / control power drum / water cable drum motor, is used to provide real-time feedback on the rotation frequency and speed of each drum motor, and send these signals to the inverter for closed-loop control; The absolute encoder is installed at the tail of each reel shaft to provide real-time feedback of the rotation values ​​of the three types of reels and is connected to the PLC controller via the Profinbus DP or Profinet communication protocol so that the PLC can perform synchronous control calculations; At least four rocker-type limit switches are provided, which are installed on the left and right sides of the three types of cable guides and the left and right over-tightening positions, respectively, to detect the guiding and over-tightening status of the cable and send these signals to the PLC controller; The cam limiter is installed at the tail of the rotating shaft of the power cable reel, control power reel and water cable reel to detect the empty and full reel status of the three types of reels and send these signals to the system; Among them, the PLC controller outputs corresponding control instructions to the frequency converter based on the received signals through analysis and calculation, adjusts the operation of the three types of drum motors, makes the rotation speed of the three types of drums synchronized with the travel speed of the trolley, and ensures the stability of the tension of the three types of cables: power cable, control cable and water cable.

2. A system for synchronous electrical control of three types of reels and trolleys of a bridge-type ship unloader as claimed in claim 1, characterized in that: The PLC controller also receives real-time feedback signals from the incremental encoder and the absolute encoder, which respectively represent the rotation frequency and speed of the cable drum motor and the rotation value of the cable drum; receives signals from the rocker limit switch and the cam limit switch to detect the guiding state, over-tightening state of the cable and the empty and full states of the cable drum; processes all the above received signals according to the preset algorithm and control logic, and outputs precise control instructions to the frequency converter accordingly; The PLC controller preferably adopts a programmable logic controller of ABB brand or other compatible brands, which has high-speed data processing capability and powerful control functions to ensure rapid system response and stable operation.

3. A system for synchronous electrical control of three types of reels and trolleys of a bridge-type ship unloader as claimed in claim 1, characterized in that: The frequency converter is electrically connected to the PLC controller and receives control instructions from the PLC controller in real time; According to the control instructions received, the voltage, current and speed of the motor connected to each cable drum are accurately adjusted to achieve accurate retraction and release control of power cables, control cables and water cables; The frequency converter adopts a model that is fully compatible with the PLC controller, ensuring that accurate speed and torque control can be achieved, thereby ensuring the smooth and efficient operation of the cable drum motor.

4. A system for synchronous electrical control of three types of reels and trolleys of a bridge-type ship unloader as claimed in claim 1, characterized in that: The incremental encoder and absolute encoder can provide real-time feedback on the rotation state of the cable drum motor, including the rotation frequency and speed, as well as the precise rotation value of the cable drum; The incremental encoder is installed at the tail of the cable drum motor, sending real-time rotation data to the frequency converter to participate in the closed-loop control process; The absolute encoder is installed at the tail of the cable drum shaft and is connected to the PLC controller via communication protocols such as Profinbus DP or Profinet, providing the PLC with the precise rotation value required for synchronous control calculations.

5. A system for synchronous electrical control of three types of reels and trolleys of a bridge-type ship unloader as claimed in claim 1, characterized in that: It also includes at least four rocker-type limit switches, which are respectively installed on the left and right sides and the left and right over-tightening positions of the three types of cable guides, for real-time monitoring of the cable guiding conditions and over-tightening conditions, and timely feeding back relevant signals to the PLC controller; The cam limit device is installed at the tail of the rotating shaft of the power cable reel, control cable reel and water cable reel. It is used to accurately detect the empty and full status of the cable reel and send this key status information to the system for timely processing and adjustment.

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