Electric winch system with double brakes, control method and fault processing method

Abstract

The invention discloses an electric winch system with double brakes, a control method and a fault handling method, and belongs to the technical field of engineering machinery. The electric winch system comprises a supporting seat, a winding drum connected with the supporting seat, a winch speed reducer arranged in the winding drum, a brake I, a motor and a brake II; the brake I and the winch speed reducer are coaxially arranged through a shaft I; the motor is respectively connected with the brake I and the brake II, and the brake II and the motor are coaxially arranged through a shaft II; the shaft I is connected with the shaft II; the brake I is a main brake of the electric winch system and is used for being matched with the motor to brake the electric winch system; the brake II is an auxiliary brake of the electric winch system and is used for braking the electric winch system when the brake I or the motor breaks down. Starting and stopping of the winch are achieved through cooperation of the motor and the double-electromagnetic brake, and the phenomenon that heavy objects slide downwards when the winch is started or stopped and the motor breaks down can be prevented.

Description

Technical Field

[0001] The present invention relates to an electric hoisting system with double brakes, a control method and a fault handling method, belonging to the technical field of construction machinery. Background Art

[0002] Traditional cranes generally adopt a hydraulic hoisting system, and the start and stop of hoisting are achieved by the cooperation of the balance valve of the hoisting motor and the hydraulic brake. When hoisting starts, the pressure oil pushes the balance valve open, allowing the oil to flow into the motor. As the pressure increases, the brake opens, and the motor drives the hoisting mechanism to lift and lower. When hoisting stops, the balance valve closes under the action of the spring, preventing the oil in the motor from flowing, restricting the continued rotation of the drum due to the inertia of the load, and as the pressure decreases, the brake closes to lock the motor to prevent the heavy object from sliding down.

[0003] The hydraulic hoisting system has disadvantages such as low energy efficiency, slow response, and poor speed regulation. In recent years, with the continuous development of the electrification of the crane industry, some electrified cranes have begun to adopt an electric hoisting system. The existing electric hoisting system mainly uses an electric motor instead of a hydraulic motor, and the braking still uses a hydraulic system. The hydraulic braking system has a slow response and poor cooperation with the electric motor. In case of a serious fault of the electric motor, it cannot brake quickly, posing a safety hazard. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to overcome the defects of the prior art and provide an electric hoisting system with double brakes, a control method and a fault handling method.

[0005] To solve the above technical problems, the present invention is implemented by the following technical solutions.

[0006] In a first aspect, the present invention discloses an electric hoisting system with double brakes, including: a support seat, a drum connected to the support seat, and a hoisting speed reducer arranged in the drum; further including: a brake I, an electric motor, and a brake II; The brake I is coaxially arranged with the hoisting speed reducer through a shaft I; The electric motor is respectively connected to the brake I and the brake II, and the brake II is coaxially arranged with the electric motor through a shaft II; the shaft I and the shaft II are connected; The brake I is the main brake of the electric hoisting system, and is used to cooperate with the electric motor to brake the electric hoisting system; The brake II is the auxiliary brake of the electric hoisting system, and is used to brake the electric hoisting system when the brake I or the electric motor fails.

[0007] Further, the brake I is connected to the hoisting speed reducer through a spigot; both ends of the electric motor are respectively connected to the brake I and the brake II through spigots; the shaft I and the shaft II are connected by splines.

[0008] Further, the brake I is an electro-hydraulic proportional brake; the brake II is an electromagnetic switch brake.

[0009] In a second aspect, the present invention also discloses a control method for an electric hoisting system with a dual brake according to the first aspect, including: Obtaining the opening signal and the throttle signal of the hoisting control handle; Calculating the target motor speed A according to the handle opening signal and the throttle signal; Opening the brake II and controlling the motor to rotate at a preset initial speed B; Judging whether it is in the empty hook state according to the load weight monitored by the load limiter in real time, including: if so, when the motor torque rises to a certain fixed value C, controlling the brake I to be gradually opened; if not, when the motor torque rises to a percentage α of the motor torque value recorded at the previous moment, controlling the brake I to be opened proportionally, and when it is determined that the motor torque meets the requirement for lifting the heavy object after the brake I is opened proportionally, gradually opening the brake I; After the brake I is fully opened, controlling the motor to respond to the handle opening signal and the throttle signal and output the target speed A.

[0010] Further, the step of when the motor torque rises to a percentage α of the motor torque value recorded at the previous moment, controlling the brake I to be opened proportionally, and when it is determined that the motor torque meets the requirement for lifting the heavy object after the brake I is opened proportionally, gradually opening the brake I, includes: After the brake I is opened proportionally, judging whether the motor speed change value △ is greater than 0 within the time t1. If △>0, controlling the brake I to be gradually opened; if △<0, controlling the brake I to be closed, and when the motor torque rises to α + 10% of the motor torque value recorded at the previous moment, controlling the brake I to be opened proportionally; And after the brake I is opened proportionally, judging whether the motor torque meets the requirement for lifting the heavy object, and gradually opening the brake I until it is satisfied.

[0011] Further, if △ = 0, it indicates that the brake I is not opened, and a fault that the brake I is not opened is sent to notify the driver to check and repair in time.

[0012] Further, it also includes: obtaining the zero opening signal of the hoisting control handle; After controlling the motor speed to decrease to zero according to the handle zero opening signal, controlling the motor to perform zero-speed hovering; Recording the motor torque value during successful zero-speed hovering, and controlling the brake II to be closed; After the brake II is closed, controlling the brake I to be gradually closed; After the brake I is closed, the control motor torque is adjusted to zero torque.

[0013] Further, the control motor performs zero-speed hovering, including: After performing zero-speed hovering, it is judged whether the zero-speed hovering time of the motor is greater than or equal to the preset time t2. If it is greater than or equal to the preset time t2, the average value of the motor torque values within the t2 time is recorded; if it is less than the preset time t2, the motor controller controls the motor to perform zero-speed hovering again until the zero-speed hovering time is greater than or equal to the preset time t2.

[0014] In a third aspect, the present invention also discloses a fault handling method for an electric winch system with double brakes according to the first aspect, including: Obtain the current fault type, and determine the fault level corresponding to the current fault type based on the fault levels set in advance from low to high according to the fault severity; Perform warning or brake closing processing according to the fault level.

[0015] Further, the fault levels include: Level 1 fault, used for faults that do not affect the normal operation of the motor, and only send a fault code for warning; Level 2 fault, used for faults that require power limitation for the motor to operate for a short time. Control the motor to operate with power limitation, and when the control handle returns to the middle position and the motor speed drops to 0, after the brake I and the brake II are closed, the electric winch system is not allowed to operate again; Level 3 fault, used for faults that the motor can be controlled for a short time. After controlling the motor speed to drop to 0, control the brake I to close; Level 4 fault, used for faults that the motor is completely out of control, and control the brake I and the brake II to close simultaneously.

[0016] The beneficial effects achieved by the present invention: The electric winch system, control method and fault handling method with double brakes of the present invention realize the start and stop of the winch through the cooperation of the motor and the double electromagnetic brakes, and can prevent the heavy object from sliding down during the start, stop and motor failure of the winch, improving the safety and reliability of the winch system. Classified into four categories for processing according to the fault severity, further improving the safety and reliability of the winch system. Brief Description of the Drawings

[0017] Figure 1 is the system structure schematic diagram of the present invention; Figure 2 is the system principle schematic diagram of the present invention; Figure 3 is the control method flow schematic diagram of the present invention.

[0018] In the figure: 1 - support base; 2 - drum; 3 - hoisting speed reducer; 4 - brake I; 5 - motor; 6 - brake II; 7 - shaft I; 8 - shaft II. Detailed implementation manner

[0019] The present invention will be further described below in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and cannot be used to limit the protection scope of the present invention.

[0020] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "transverse", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention. In addition, the terms "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the quantity of the indicated technical features. Thus, the features defined with "first", "second", etc. may explicitly or implicitly include one or more of such features. In the description of the present invention, unless otherwise stated, the meaning of "a plurality" is two or more.

[0021] In the description of the present invention, it should be noted that unless otherwise clearly defined and limited, the terms "installation", "connection", and "connection" 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 directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood through specific situations.

[0022] Embodiment 1. This embodiment introduces an electric hoisting system with double brakes, as Figure 1 shown, including a support base 1, a drum 2, a hoisting speed reducer 3, a brake I 4, a motor 5, and a brake II 6. Among them, the support base 1 is connected to the drum 2, and the hoisting speed reducer 3 is arranged in the drum 2; the brake I 4 is coaxial with the hoisting speed reducer 3 (shaft I 7) and is connected to the hoisting speed reducer 3 through a spigot, and can reliably brake the hoisting speed reducer 3; the motor 5 is connected to the brake I 4 through a spigot; the brake II 6 is coaxial with the motor 5 (shaft II 8) and is connected to the motor 5 through a spigot, and can reliably brake the motor 5; the shaft I 7 and the shaft II 8 are connected by splines.

[0023] The brake I4 is an electro-hydraulic proportional brake that can adjust the braking force proportionally through electrical signals. This brake has advantages such as fast response and wear resistance. It is the main brake of the system and can cooperate with the motor to achieve braking of the hoisting system. The brake II6 is a switch-type brake. When powered on, the electromagnet attracts the armature to open, and when powered off, the spring presses the brake disc to achieve braking. This brake has a fast response and low cost. It is the auxiliary brake of the system and can achieve braking of the hoisting system when the brake I or the motor fails. It is a safety redundancy design that can further improve the safety of the system.

[0024] Embodiment 2, based on the same inventive concept as Embodiment 1, this embodiment introduces a control method for an electric hoisting system with dual brakes, as Figure 2 and Figure 3 shown, including: When the driver pushes or pulls the hoisting control handle forward or backward, the handle opening signal and the throttle signal are transmitted to the vehicle body controller.

[0025] The vehicle body controller calculates the target motor speed A based on the handle opening signal and the throttle signal.

[0026] The vehicle body controller controls the brake II to open. After the brake II opens, the vehicle body controller sends the speed control mode and a small initial speed B (such as 10 rpm) to the motor controller.

[0027] The vehicle body controller determines whether it is in the empty hook state by the load weight monitored in real time by the force limiter (force limiter weight ≤ hook weight). If it is in the empty hook state, when the motor torque rises to a certain fixed value C (this value can be determined by calibration), the vehicle body controller controls the brake I to gradually open; if it is not in the empty hook state, when the motor torque rises to a certain percentage α (such as 80%) of the motor torque value recorded at the previous moment, the vehicle body controller controls the brake I to open proportionally.

[0028] After the brake I opens proportionally, it is judged within the time t1 whether the change value △ of the motor speed is greater than 0. If △>0, it indicates that the motor torque can meet the requirement of lifting the heavy object, and the vehicle body controller controls the brake I to gradually open; if △<0, it indicates that the motor torque cannot meet the requirement of lifting the heavy object, and the vehicle body controller controls the brake I to close. When the motor torque rises to α + 10% of the motor torque value recorded at the previous moment, the vehicle body controller controls the brake I to open proportionally; if △ = 0, it indicates that the brake I has not opened, and the vehicle body controller sends a fault that the brake I has not opened to notify the driver to check and repair in time.

[0029] After the brake I gradually opens, the vehicle body controller sends the target speed A to the motor controller, and the motor starts to respond to the handle opening signal and the throttle signal.

[0030] When the driver returns the winch control handle to the neutral position, the zero-opening signal of the handle is transmitted to the vehicle body controller.

[0031] Based on the zero-opening signal of the handle, the vehicle body controller sends the speed control mode and the target speed zero to the motor controller.

[0032] After the motor controller controls the motor speed to decrease to zero, it controls the motor to hover at zero speed (the core of the motor controller controlling the motor to hover at zero speed is to achieve the cancellation of external torque through closed-loop feedback control and maintain the dynamic balance state with the speed being zero; the motor speed is zero, and the output torque is equal in magnitude and opposite in direction to the torque formed by the heavy object suspended on the winch).

[0033] The vehicle body controller determines whether the zero-speed hovering time of the motor is greater than or equal to the preset time t2. If it is greater than or equal to the preset time t2, the vehicle body controller records the average value of the motor torque value within the t2 time; if it is less than the preset time t2, the motor controller controls the motor to perform zero-speed hovering again until the zero-speed hovering time is greater than or equal to the preset time t2.

[0034] After recording the motor torque value, the vehicle body controller controls Brake II to close. After Brake II closes, the vehicle body controller controls Brake I to close gradually.

[0035] After Brake I closes, the vehicle body controller sends the torque control mode and the target torque zero to the motor controller.

[0036] Embodiment 3, based on the same inventive concept as other embodiments, this embodiment introduces a fault handling method for an electric winch system with double brakes, including: For the faults of the electric winch system, the present invention classifies and processes them into four categories according to the severity of the faults. Specifically as follows: For faults that do not affect the normal operation of the motor, such as over-temperature warning faults and active discharge faults, they are defined as level one, and the vehicle body controller only sends fault codes for warning.

[0037] For faults where the motor can run for a short time and power needs to be limited, such as over-temperature faults and over-current faults, they are defined as level two. The vehicle body controller sends the power limit value to the motor controller, and the motor controller controls the motor to operate with limited power. And when the control handle returns to the neutral position, the motor speed decreases to 0, and the winch system is not allowed to run again after the brake closes.

[0038] For faults where the motor is controllable for a short time, such as resolver faults and stall faults, they are defined as level three. The vehicle body controller sends the target speed 0 to the motor controller. After the motor speed decreases to 0, it controls Brake I to close.

[0039] For faults where the motor is completely out of control, such as the through-fault of power transistors and the overvoltage fault of the bus hardware, they are defined as level four, and the body controller controls the simultaneous closing of Brake I and Brake II.

[0040] Those skilled in the art should understand that the embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of an entirely hardware embodiment, an entirely software embodiment, or an embodiment combining software and hardware aspects. Moreover, the present invention can take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk memory, CD-ROM, optical memory, etc.) containing computer-usable program code.

[0041] The present invention is described with reference to the flowcharts and / or block diagrams of methods, devices (systems), and computer program products according to the embodiments of the present invention. It should be understood that each flow and / or block in the flowchart and / or block diagram can be implemented by computer program instructions, and the combination of the flows and / or blocks in the flowchart and / or block diagram can also be implemented. These computer program instructions can be provided to the processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing devices to generate a machine, so that the instructions executed by the processor of the computer or other programmable data processing devices generate means for implementing the specified functions in Figure 1 one flow or multiple flows and / or blocks Figure 1 one block or multiple blocks.

[0042] These computer program instructions can also be stored in a computer-readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer-readable memory generate a manufactured article including instruction means, and the instruction means implements the specified functions in Figure 1 one flow or multiple flows and / or blocks Figure 1 one block or multiple blocks.

[0043] These computer program instructions can also be loaded onto a computer or other programmable data processing device, so that a series of operation steps are executed on the computer or other programmable device to generate a computer-implemented process, and thus the instructions executed on the computer or other programmable device provide steps for implementing the specified functions in Figure 1 one flow or multiple flows and / or blocks Figure 1 one block or multiple blocks.

[0044] The above are only the preferred embodiments of the present invention. It should be noted that for those of ordinary skill in the art, without departing from the technical principle of the present invention, several improvements and deformations can be made, and these improvements and deformations should also be regarded as the protection scope of the present invention.

Claims

1. An electric hoisting system with double brakes, comprising: A support base, a drum connected to the support base, and a hoisting speed reducer disposed in the drum, characterized in that it further includes: a brake I, a motor, and a brake II; The brake I and the hoisting speed reducer are coaxially arranged through a shaft I; The motor is respectively connected to the brake I and the brake II, and the brake II and the motor are coaxially arranged through a shaft II; the shaft I and the shaft II are connected; The brake I is the main brake of the electric hoisting system, and is used to cooperate with the motor to brake the electric hoisting system; The brake II is the auxiliary brake of the electric hoisting system, and is used to brake the electric hoisting system when the brake I or the motor fails.

2. The electric hoisting system with double brakes according to claim 1, characterized in that The brake I is connected to the hoisting speed reducer through a spigot; Both ends of the motor are respectively connected to the brake I and the brake II through spigots; The shaft I and the shaft II are connected by splines.

3. The electric hoisting system with double brakes according to claim 1, characterized in that The brake I is an electro-hydraulic proportional brake; The brake II is an electromagnetic switch type brake.

4. A control method for an electric hoisting system with a double brake according to any one of claims 1-3, characterized in that, It includes: Obtain the opening signal and the throttle signal of the hoisting control handle; Calculate the target speed A of the motor according to the handle opening signal and the throttle signal; Open the brake II and control the motor to rotate at a preset initial speed B; Judge whether it is in the empty hook state according to the lifting weight monitored by the load limiter in real time, including: if so, when the motor torque rises to a certain fixed value C, control the brake I to gradually open; if not, when the motor torque rises to a percentage α of the motor torque value recorded at the previous moment, control the brake I to open proportionally, and when it is determined that the motor torque meets the requirement of lifting the heavy object after the brake I opens proportionally, gradually open the brake I; After the brake I is fully opened, control the motor to respond to the handle opening signal and the throttle signal and output the target speed A.

5. The control method according to claim 4, wherein When the motor torque rises to a percentage α of the motor torque value recorded at the previous moment, control the brake I to open proportionally, and when it is determined that the motor torque meets the requirement of lifting the heavy object after the brake I opens proportionally, gradually open the brake I, including: After the brake I opens proportionally, judge whether the change value △ of the motor speed is greater than 0 within the time t1. If △>0, control the brake I to gradually open; if △<0, control the brake I to close. When the motor torque rises to α + 10% of the motor torque value recorded at the previous moment, control the brake I to open proportionally; And after the brake I opens proportionally, judge whether the motor torque meets the requirement of lifting the heavy object, and gradually open the brake I until it is met.

6. The control method according to claim 5, wherein If △ = 0, it indicates that the brake I is not opened, send a fault that the brake I is not opened, and notify the driver to check and repair in time.

7. The control method according to claim 4, characterized in that It also includes: Obtain the zero opening signal of the hoisting control handle; After controlling the motor speed to decrease to zero according to the handle zero opening signal, control the motor to perform zero-speed hovering; Record the motor torque value when successful zero-speed hovering is performed, and control the brake II to close; After the brake II is closed, control the brake I to gradually close; After the brake I is closed, the control motor torque is adjusted to zero torque.

8. The control method according to claim 7, wherein The control motor performs zero-speed hovering, including: After performing zero-speed hovering, it is judged whether the zero-speed hovering time of the motor is greater than or equal to the preset time t2. If it is greater than or equal to the preset time t2, the average value of the motor torque values within the t2 time is recorded; if it is less than the preset time t2, the motor controller controls the motor to perform zero-speed hovering again until the zero-speed hovering time is greater than or equal to the preset time t2.

9. A fault handling method for an electric hoisting system with a double brake according to any one of claims 1-3, characterized in that, Including: Obtain the current fault type, and determine the fault level corresponding to the current fault type based on the fault levels set in advance from low to high according to the fault severity; Perform warning or brake closing processing according to the fault level.

10. The fault handling method according to claim 9, wherein The fault levels include: Level 1 fault, used for faults that do not affect the normal operation of the motor, and only send a fault code for warning; Level 2 fault, used for faults that require power limitation for the motor to run for a short time. Control the motor to run with power limitation, and when the control handle returns to the middle position and the motor speed drops to 0, after the brake I and the brake II are closed, the electric hoisting system is not allowed to run again; Level 3 fault, used for faults that are controllable by the motor for a short time. After controlling the motor speed to drop to 0, control the brake I to close; Level 4 fault, used for faults where the motor is completely out of control. Control the brake I and the brake II to close simultaneously.

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