PLC (Programmable Logic Controller) controlled hydraulic group jacking automatic lifting system

Abstract

The invention relates to a PLC control hydraulic group jacking automatic lifting system, and relates to the technical field of engineering construction. Comprising an upper computer, a main controller, a sub-controller, a hydraulic control system and an execution component, the execution component is used for jacking and lifting the lifted component; the hydraulic control system is in communication connection with the execution component and used for controlling the execution component to act and obtaining oil pressure information of the execution component and lifting displacement information of the lifted component; the sub-controller is in communication connection with the hydraulic control system and is used for controlling the hydraulic control system and feeding back the operation condition of the hydraulic control system; the main controller is in communication connection with the sub-controllers and is used for controlling the sub-controllers; and the upper computer is in communication connection with the main controller, working parameters are set through an operation interface of the upper computer, and automatic continuous operation of the whole jacking and lifting automatic system is achieved. The hydraulic system has the characteristics of high oil pressure, long stroke, high speed increase, low fall-back, bidirectional movement, high precision, high safety and the like.

Description

Technical Field

[0001] The present invention relates to the technical field of engineering construction, and specifically to a PLC-controlled hydraulic group jack lifting automatic system. Background Art

[0002] In existing hydraulic lifting systems, the hydraulic hardware generally includes a hydraulic pump station, a hoist, and an oil circuit. Hydraulic lifting systems are widely used in fields such as heavy object lifting, engineering installation, and bridge construction. However, the existing hydraulic lifting technology has the following problems and limitations:

[0003] Insufficient lifting force monitoring accuracy: The main cylinder of traditional hydraulic hoists is usually only equipped with basic pressure sensors or completely relies on system pressure to calculate the lifting force, resulting in low monitoring accuracy of the lifting force. In precision construction or high-load scenarios, this inaccurate monitoring may cause lifting force deviation, thus affecting construction quality and even posing safety hazards.

[0004] Limited dynamic performance: The speed-up and fallback control capabilities of existing hydraulic hoists are poor. Especially during two-way movement (such as the switching between lifting and lowering), impacts or delays are likely to occur, making it difficult to meet the requirements of high-precision projects.

[0005] How to provide a PLC-controlled hydraulic group jack lifting automatic system with high precision and high safety has become an urgent technical problem for those skilled in the art to solve. Summary of the Invention

[0006] To solve at least one technical problem in the background art, the present invention provides a PLC-controlled hydraulic group jack lifting automatic system, which has the characteristics of high oil pressure, long stroke, high speed-up, low fallback, two-way movement, high precision, and high safety.

[0007] To achieve the above object, the present invention provides a PLC-controlled hydraulic group jack lifting automatic system, including: a host computer, a main controller, sub-controllers, a hydraulic control system, and an actuator;

[0008] The actuator is used to jack and lift the lifted member;

[0009] The hydraulic control system is communicatively connected to the actuator, and is used to control the actuator to act, and obtain the oil pressure information of the actuator and the lifting displacement information of the lifted member;

[0010] The sub-controller is communicatively connected to the hydraulic control system, and is used to control the hydraulic control system and feedback the operating status of the hydraulic control system;

[0011] The main controller is communicatively connected to the sub-controller, and is used to control each sub-controller;

[0012] The host computer is communicatively connected to the main controller, and the working parameters are set through the operation interface of the host computer to achieve the automatic and continuous operation of the entire top-lifting automatic system.

[0013] Further, the hydraulic control system includes an electrical control module, a hydraulic control module, a pressure sensor, and a position sensor; the electrical control module is communicatively connected to the actuator through the hydraulic control module, a pressure sensor is disposed inside the actuator, a lifted member is lifted on the actuator, the position sensor is installed on the lifted member, and both the pressure sensor and the position sensor are communicatively connected to the electrical control module, and are respectively used for obtaining the oil pressure information of the actuator and the lifting displacement information of the lifted member.

[0014] Further, the hydraulic control module includes an oil tank, a filter, a fixed-displacement pump, a relief valve, an electromagnetic directional valve, and a balance valve; the oil tank is sequentially connected to the fixed-displacement pump, the electromagnetic directional valve, the balance valve, and the oil inlet of the actuator through an oil inlet pipeline, and the oil outlet of the actuator is sequentially connected to the balance valve, the electromagnetic directional valve, the filter, and the oil tank through an oil return pipeline; a relief valve is disposed between the oil inlet pipeline at the outlet end of the fixed-displacement pump and the oil return pipeline at the inlet end of the filter.

[0015] Further, the fixed-displacement pump is electrically connected to a variable-frequency speed regulator.

[0016] Further, the hydraulic control system further includes an oil quantity distribution controller, an oil quantity distributor, and a flowmeter. The oil quantity distributor is electrically connected to the actuator, the oil quantity distributor is connected to the oil inlet of the actuator through a high-pressure oil pipe, a flowmeter is disposed at the oil inlet of the actuator, and the oil quantity distribution controller is respectively electrically connected to the oil quantity distributor and the flowmeter.

[0017] Further, the host computer includes an initialization module, a working condition control module, a monitoring and alarm module, and a data recording module;

[0018] The initialization module is used to read the calculation parameters and assign the relevant data to the variables of the host computer;

[0019] The working condition control module is used to control and monitor the lifting displacement. When there is a deviation in the lifting displacement, it is corrected through manual intervention. At the same time, the estimated lifting force value is calculated through the data fed back by the pressure sensor to detect the change of the lifting force data and ensure the safety of the construction;

[0020] The monitoring and alarm module alarms when there is a displacement during the lifting process, enabling the operator to intuitively discover the abnormalities during the operation of the system so as to handle the problems in a timely manner;

[0021] The data recording module is mainly used to record key parameters during the operation of the automatic top lifting system.

[0022] The beneficial effects of the present invention are:

[0023] High-precision lifting force monitoring: A pressure sensor is added to the main cylinder of the professional lifter to accurately monitor the lifting force in real time, and dynamically adjust the oil pressure through a closed-loop control system to ensure the stability and accuracy of the lifting force to meet the needs of high loads or precision construction.

[0024] Active safety protection: Equipped with a safety anchor, it is linked with the hydraulic system during the lifting process. Once an abnormality of the actuator is detected (such as a sudden drop in pressure or over-limit), the safety anchor can immediately act to lock the lifting position to prevent the heavy object from falling back. At the same time, the system can also be equipped with multiple adaptive sensors to further reduce the risk of misjudgment.

[0025] Optimize dynamic performance: By improving the oil circuit design, high-speed, low-fall bidirectional movement can be achieved, the impact during switching can be reduced, and the system response speed and stability can be improved.

[0026] Long stroke control optimization: high-precision sensors and pressure compensation technology are used to ensure uniformity of lifting force during long strokes and avoid loss of accuracy due to extended stroke. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a structural schematic diagram of the present invention;

[0028] Figure 2 It is a structural schematic diagram of the hydraulic control system of the present invention;

[0029] Figure 3 It is a structural schematic diagram of the hydraulic control module of the present invention;

[0030] Figure 4 It is a structural schematic diagram of the host computer of the present invention;

[0031] Figure 5 It is a connection block diagram of the flow distribution controller of the present invention.

[0032] Among them, in the figure: 1-oil tank, 2-oil filter, 3-metering pump, 4-overflow valve, 5-electromagnetic reversing valve, 6-balancing valve, 7-executing component. DETAILED DESCRIPTION

[0033] The technical solutions in the embodiments of the present invention are described clearly and completely below. 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.

[0034] It should be noted that the terms "first", "second", etc. in the description, claims and above-mentioned drawings of this application are used to distinguish similar objects, and do not necessarily describe a specific order or sequence. It should be understood that such data can be interchanged under appropriate circumstances for the embodiments of this application described herein. In addition, the terms "include" and "have" and any variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device that includes a series of steps or units does not necessarily have to be limited to those steps or units clearly listed, but may include other steps or units not clearly listed or inherent to these processes, methods, products or devices.

[0035] In this application, the orientation or positional relationship indicated by the terms "upper", "lower", "left", "right", "front", "rear", "top", "bottom", "inner", "outer", "middle", "vertical", "horizontal", "lateral", "longitudinal", etc. is based on the orientation or positional relationship shown in the drawings. These terms are mainly used to better describe this application and its embodiments, and are not used to limit that the indicated devices, elements or components must have a specific orientation or be constructed and operated in a specific orientation.

[0036] Moreover, in addition to being able to represent the orientation or positional relationship, some of the above terms may also be used to represent other meanings. For example, the term "upper" may also be used to represent a certain attachment relationship or connection relationship in some cases. For those of ordinary skill in the art, the specific meanings of these terms in this application can be understood according to specific circumstances.

[0037] In addition, the terms "install", "set", "be provided with", "connect", "be connected", "be sleeved" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection or an electrical connection; it can be directly connected, or indirectly connected through an intermediate medium, or there can also be internal communication between two devices, elements or components. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0038] As Figure 1 shown, the present invention provides a PLC-controlled hydraulic group jack lifting automatic system, including: a host computer, a main controller, a sub-controller, a hydraulic control system and an execution component;

[0039] The execution component is used to lift the lifted member, and a hydraulic jack can be used as the execution component;

[0040] The hydraulic control system is communicatively connected to the execution component, and is used to control the action of the execution component, and obtain the oil pressure information of the execution component and the lifting displacement information of the lifted member;

[0041] The sub-controller is communicatively connected to the hydraulic control system, and is used for controlling the hydraulic control system and feeding back the operation status of the hydraulic control system;

[0042] The main controller is communicatively connected to the sub-controller and is used for controlling each sub-controller;

[0043] The upper computer is communicatively connected to the main controller, and working parameters are set through the operation interface of the upper computer to realize the automatic continuous operation of the entire top-lifting automatic system.

[0044] The rated working pressure of the system reaches 35 MPa (higher than the mainstream level of 25 MPa). While meeting the requirements of large-tonnage lifting, it reduces the size and weight of the hydraulic jacks; the stroke of the main cylinder is 400 mm (higher than the mainstream level of 300 mm), greatly improving the lifting speed.

[0045] Reference Figure 2 , considering the diversity of projects, the number and specifications of hydraulic jacks used in different projects vary. To maximize the utilization rate of equipment, the hydraulic control system of the present invention is designed with a modular concept. The hydraulic control system includes an electrical control module, a hydraulic control module, a pressure sensor, and a position sensor; the electrical control module is communicatively connected to the execution component through the hydraulic control module. A pressure sensor is arranged inside the execution component, and a lifted component is lifted on the execution component. The position sensor is installed on the lifted component, and both the pressure sensor and the position sensor are communicatively connected to the electrical control module, and are respectively used for obtaining the oil pressure information of the execution component and the lifting displacement information of the lifted component. The hydraulic control system can realize the automation and intelligence of hydraulic hardware, form a closed-loop control through high-precision displacement sensors and oil pressure sensors, effectively monitor the entire process of structural lifting, and ensure construction safety. Each control point can realize the synchronous control and collaborative control of displacement and force, with flexible functions, can cover a variety of application scenarios, and can customize system functions according to project characteristics and requirements.

[0046] In this embodiment, a pump station can be used as a basic unit. Each pump station contains four sub-pumps and can control four lifting points. When facing different projects, only the number of pump stations and the number and specifications of hydraulic jacks connected to the pump stations need to be reasonably combined, reducing the complexity of the system hardware. When a subsequent pump station fails, the faulty equipment can be quickly repaired and replaced.

[0047] According to the engineering load characteristics, the following combination schemes can be adopted:

[0048]

[0049] Reference Figure 3, the hydraulic control module includes an oil tank 1, a filter 2, a fixed-displacement pump 3, a relief valve 4, a solenoid-operated directional valve 5, and a balance valve 6; the oil tank 1 is successively connected to the inlet of the fixed-displacement pump 3, the solenoid-operated directional valve 4, the balance valve 5, and the inlet of the actuator 7 through an oil inlet pipeline, and the outlet of the actuator is successively connected to the balance valve 6, the solenoid-operated directional valve 5, the filter 2, and the oil tank 1 through an oil return pipeline; a relief valve 4 is provided between the oil inlet pipeline at the outlet end of the fixed-displacement pump 3 and the oil return pipeline at the inlet end of the filter 2. The fixed-displacement pump 3 is electrically connected to a variable-frequency speed regulator.

[0050] During the lifting process of the steel truss, operations such as cylinder extension, cylinder retraction, and pressure holding of the jacks need to be achieved. The hydraulic circuit corresponding to each traction point mainly includes three circuits: a speed control circuit, a pressure holding circuit, and a unloading circuit.

[0051] 1. Speed control circuit

[0052] During the lifting process of the steel truss, the required lifting displacements at each lifting point may be different. To ensure the smooth operation of the steel truss lifting process, it is required that each lifting point completes its respective target displacement within the same time. To achieve this function, the system uses a combination of a fixed-displacement pump, a motor, and a frequency converter to adjust the lifting speed. The supply frequency is adjusted by the frequency converter to change the motor speed, thereby achieving the control of the oil pump flow rate.

[0053] 2. Pressure holding circuit

[0054] When an unexpected situation occurs at the construction site and the system suspends operation, it is necessary to hold the pressure of the jacks to prevent the lifting cables from slipping. The pressure holding circuit is realized through a balance valve. When the system needs to hold the pressure, the balance valve is in the left position, and the check valve is used to prevent the pressure oil in the jack cylinder from flowing back.

[0055] 3. Unloading circuit

[0056] When the single stroke reaches the target displacement, the jack needs to be unloaded. At this time, the solenoid-operated directional valve switches the working position to change the flow direction of the pressure oil, and the throttle valve is used to control the flow rate during unloading to form a back pressure to ensure the smooth progress of the oil return process.

[0057] The displacement of the steel truss lifting is often much larger than the stroke of the hydraulic jack. Therefore, the hydraulic jack needs to continuously reverse the cylinder multiple times to meet the requirements of the lifting displacement. The hydraulic control system connects the hydraulic jack to the oil circuit of the pump station and controls the pump station through the upper computer, which can achieve continuous non-stop reverse cylinder of multiple traction points, without investing too much manpower, and can ensure the coordination and synchronization of each traction point.

[0058] Reference Figure 5, the hydraulic control system further includes an oil quantity distribution controller, an oil quantity distributor, and a flowmeter. The oil quantity distributor is electrically connected to the execution component. The oil quantity distributor is connected to the oil inlet of the execution component through a high-pressure oil pipe. A flowmeter is provided at the oil inlet of the execution component. The oil quantity distribution controller is electrically connected to the oil quantity distributor and the flowmeter respectively. The oil quantity distributor is used to read the dynamic oil quantity information of the execution component, generate a control instruction according to a preset program, and adjust the opening and closing of the gates of each oil supply line in the oil quantity distributor to control the optimization of the initial oil supply quantity on the oil circuits of each three-stage double-acting self-fitting hydraulic jack; the oil quantity distributor is also used to read the dynamic oil quantity information on the oil circuits after the initial oil supply quantity optimization of each execution component, perform dynamic analysis according to a preset program and generate conclusion information, and send the information data to the oil quantity distribution controller in real time. The information data includes dynamic oil quantity information conclusion information, oil quantity distribution information of each oil circuit, and the opening and closing status of the oil circuit. The oil quantity distribution controller is used to receive the information data. Thus, it is ensured that the oil supply quantities between each execution component are consistent, realizing the dynamic oil quantity information cyclic processing and systematic oil supply balance from the whole to the part. Once the total oil quantities inside each execution component are balanced with each other, the jacking displacements of the piston cylinders of each execution component will also be consistent, thereby accurately ensuring the synchronism of the jacking strokes of each execution component and the displacement of the beam body during the jacking process.

[0059] Reference Figure 4 , the upper computer is an important platform for the operator to control the system. Its operation interface is simple and intuitive. It can not only monitor the data status and send lower-level instructions, but also perform relatively complex data calculations. The upper computer includes an initialization module, a working condition control module, a monitoring and alarm module, and a data recording module; the initialization module is used to read the calculation parameters and assign relevant data to the variables of the upper computer; the working condition control module is used to control and monitor the lifting displacement. When there is a deviation in the lifting displacement, it is corrected through manual intervention. At the same time, the data fed back by the pressure sensor is calculated through corresponding calculations to calculate and estimate the lifting force value to detect the change of the lifting force data and ensure the safety of the construction; the monitoring and alarm module alarms when there is a displacement during the lifting process, enabling the operator to intuitively discover the abnormal situation during the operation of the system so as to handle the problem in time; the data recording module is mainly used to record the key parameters during the operation of the top lifting automatic system.

[0060] The present invention can achieve high-precision lifting force monitoring: a pressure sensor is added to the main cylinder of the professional lifter to accurately monitor the lifting force in real time, and the oil pressure is dynamically adjusted through a closed-loop control system to ensure the stability and accuracy of the lifting force, meeting the requirements of high-load or precision construction.

[0061] Active safety protection: Configure a safety anchor, which is linked with the hydraulic system during the lifting process. Once an abnormality of the executing component is detected (such as a sudden drop or overlimit of pressure), the safety anchor can act immediately to lock the lifting position and prevent the heavy object from falling back. At the same time, the system can also be equipped with multiple adapted sensors to further reduce the risk of misjudgment.

[0062] Optimize dynamic performance: By improving the oil circuit design, achieve two-way movement with high acceleration and low fallback, reduce the impact during switching, and enhance the system response speed and stability.

[0063] Long-stroke control optimization: Adopt high-precision sensors and pressure compensation technology to ensure the uniformity of the lifting force during long strokes and avoid the accuracy degradation caused by the extension of the stroke.

[0064] The above is only a preferred embodiment of the present invention, and does not impose any limitation on the technical scope of the present invention. Therefore, any minor modifications, equivalent changes and decorations made to the above embodiments based on the technical essence of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. A PLC-controlled hydraulic group jacking-up automatic system, characterized in that, Including: A host computer, a main controller, sub - controllers, a hydraulic control system, and an execution component; The execution component is used to jack up the lifted component; The hydraulic control system is communicatively connected to the execution component, and is used to control the actions of the execution component, and acquire the oil pressure information of the execution component and the lifting displacement information of the lifted component; The sub - controller is communicatively connected to the hydraulic control system, and is used to control the hydraulic control system and feedback the operating condition of the hydraulic control system; The main controller is communicatively connected to the sub - controller, and is used to control each sub - controller; The host computer is communicatively connected to the main controller, and sets working parameters through the operation interface of the host computer to realize the automatic continuous operation of the entire jack - up automatic system.

2. The PLC-controlled hydraulic group jack lifting automatic system according to claim 1, characterized in that, The hydraulic control system includes an electrical control module, a hydraulic control module, a pressure sensor, and a position sensor; the electrical control module is communicatively connected to the execution component through the hydraulic control module, a pressure sensor is arranged inside the execution component, the execution component jacks up the lifted component, the position sensor is installed on the lifted component, and both the pressure sensor and the position sensor are communicatively connected to the electrical control module, and are respectively used to acquire the oil pressure information of the execution component and the lifting displacement information of the lifted component.

3. The PLC-controlled hydraulic group jack lifting automatic system according to claim 2, wherein, The hydraulic control module includes an oil tank, a filter, a fixed - displacement pump, a relief valve, an electromagnetic directional valve, and a balance valve; the oil tank is sequentially connected to the fixed - displacement pump, the electromagnetic directional valve, the balance valve, and the oil inlet of the execution component through an oil inlet pipeline, and the oil outlet of the execution component is sequentially connected to the balance valve, the electromagnetic directional valve, the filter, and the oil tank through an oil return pipeline; a relief valve is arranged between the oil inlet pipeline at the outlet end of the fixed - displacement pump and the oil return pipeline at the inlet end of the filter.

4. The PLC-controlled hydraulic group jack lifting automatic system according to claim 3, characterized in that, The fixed - displacement pump is electrically connected to a variable - frequency speed regulator.

5. The PLC-controlled automatic hydraulic group jacking system according to claim 4, wherein The hydraulic control system further includes an oil quantity distribution controller, an oil quantity distributor, and a flowmeter. The oil quantity distributor is electrically connected to the execution component, the oil quantity distributor is connected to the oil inlet of the execution component through a high - pressure oil pipe, a flowmeter is arranged at the oil inlet of the execution component, and the oil quantity distribution controller is electrically connected to both the oil quantity distributor and the flowmeter respectively.

6. The PLC-controlled hydraulic group jack lifting automatic system according to claim 5, wherein, The host computer includes an initialization module, a working condition control module, a monitoring and alarm module, and a data recording module; The initialization module is used to realize the reading of calculation parameters and assign relevant data to the variables of the host computer; The working condition control module is used to realize the control and monitoring of the lifting displacement. When there is a deviation in the lifting displacement, it is corrected through manual intervention. At the same time, through the data fed back by the pressure sensor, the estimated lifting force value is calculated through corresponding calculations to detect the change of the lifting force data and ensure the safety of construction; The monitoring and alarm module gives an alarm when there is a displacement during the lifting process, enabling the operator to intuitively discover the abnormal situation during the operation of the system so as to handle the problem in time; The data recording module is mainly used to record the key parameters during the operation of the jack - up automatic system.

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