Furnace area hydraulic station servo energy-saving control system

Abstract

The invention belongs to the technical field of workshop hydraulic control, and discloses a furnace area hydraulic station servo energy-saving control system which comprises a servo permanent magnet synchronous motor, a synchronous servo driver, a pressure sensor, a touch screen, a double-closed-loop control module and a constant power control module. By the adoption of the hydraulic servo system, the energy-saving effect is achieved, the system can adjust pressure and flow according to actual requirements, it is ensured that the pressure is stable, and the requirements of various production working conditions are met. And the servo system adopts closed-loop rotating speed control, so that the repetitive precision of the motion position and the product consistency are improved, and the anti-interference capability is relatively strong. The system is stable in operation, low in noise and weak in vibration, the rotating speed and the action efficiency are improved through the constant power control module, and the system cost is optimized. In addition, the system integrates various protection functions, the reliability of the equipment is enhanced, the service life of the equipment is prolonged, and the maintenance requirement is reduced.

Description

Technical Field

[0001] The present invention belongs to the field of workshop hydraulic control technology, and in particular relates to a servo energy-saving control system for a furnace hydraulic station. Background Art

[0002] Energy and energy conservation are receiving increasing attention. The metallurgical industry is a typical high-energy-consuming industry. The energy-saving design and transformation of hydraulic systems in the metallurgical industry has become a major topic of concern for hydraulic technicians, with power consumption of hydraulic systems being one of their key performance indicators.

[0003] The original design of the hydraulic station in the furnace area consisted of a variable displacement piston pump coupled with an asynchronous motor. For asynchronous motors, the entire loading process is subject to a constantly changing load state. Currently, however, the vast majority of hydraulic systems utilize an asynchronous motor coupled with a fixed displacement pump (or variable displacement pump). The motor delivers a constant flow rate at a rated speed, but at certain stages of the production process, only minimal flow rate is required (such as maintaining pressure). Excess hydraulic oil flows back to the tank through a relief valve. Furthermore, the motor continues to rotate at high speed during the waiting or pressure-maintaining phases of the hydraulic station, resulting in significant energy waste. Summary of the Invention

[0004] In view of this, the present invention provides a servo energy-saving control system for a furnace area hydraulic station to solve the above problems.

[0005] In order to solve the above technical problems, the present invention provides a servo energy-saving control system for a furnace hydraulic station, comprising:

[0006] Servo permanent magnet synchronous motor, servo permanent magnet synchronous motor is used to drive the hydraulic pump;

[0007] Synchronous servo drive, the synchronous servo drive is connected to the servo permanent magnet synchronous motor and is used to control the speed of the servo permanent magnet synchronous motor;

[0008] Pressure sensor: The pressure sensor is set in the pipeline of the hydraulic system to detect the actual system pressure;

[0009] Touch screen, which is used to set system pressure and flow parameters and control the operating status of the servo permanent magnet synchronous motor in real time;

[0010] Dual closed-loop control module, which includes a speed closed-loop module and a pressure closed-loop module, is used to accurately control the speed of the servo permanent magnet synchronous motor to match the actual pressure requirements;

[0011] Constant power control module, the constant power control module is used to increase the speed of the servo permanent magnet synchronous motor to increase the movement speed and allow the selection of smaller pumps and motors.

[0012] As an optional method, the dual closed-loop control module achieves precise control of the servo permanent magnet synchronous motor by setting the corresponding relationship between the pressure threshold and the motor speed.

[0013] As an optional method, the constant power control module keeps the motor output power constant by adjusting the voltage and current of the motor under different motor loads.

[0014] As an optional manner, a protection module is also included, which includes but is not limited to short circuit protection, overcurrent protection, overvoltage protection and undervoltage protection.

[0015] As an optional method, the touch screen has a custom parameter setting function.

[0016] As an optional method, in the dual closed-loop control module, the control accuracy of the pressure closed-loop module is ±0.1 bar.

[0017] As an optional method, the constant power control module monitors the motor load in real time and adjusts the motor voltage and current to ensure that the motor operates in the high-efficiency area.

[0018] As an optional method, the protection module is also used for motor overheat protection. When the motor temperature exceeds the preset value, the motor speed is automatically reduced or shut down.

[0019] As an optional method, the servo permanent magnet synchronous motor and the synchronous servo drive are connected through a high-speed data interface to achieve fast data transmission and precise control of the motor.

[0020] As an optional method, the synchronous servo drive is connected to multiple groups of servo permanent magnet synchronous motors.

[0021] The beneficial effects of the present invention are:

[0022] This invention achieves energy savings by employing a hydraulic servo system. The system can adjust pressure and flow according to actual needs, ensuring stable pressure and meeting the requirements of various production conditions. The servo system uses closed-loop speed control, which improves the repeatability of motion positions and product consistency, and has strong anti-interference capabilities. The system operates smoothly with low noise and low vibration. The constant power control module improves speed and motion efficiency, optimizing system costs. In addition, the system integrates multiple protection functions, enhancing the reliability and service life of the equipment and reducing maintenance requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 This is a schematic diagram of the structure of a servo energy-saving control system provided by an embodiment of the present invention.

[0024] Reference numerals and their corresponding relationships:

[0025] 1-Integrated touch screen, 2-Servo control cabinet, 3-Pressure transmitter, 4-Servo motor, 51-Oil supply pipe, 52-Oil return pipe, 53-Hydraulic oil tank. DETAILED DESCRIPTION

[0026] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention is further described in detail below in conjunction with specific implementation methods.

[0027] This embodiment provides a servo energy-saving control system for a furnace area hydraulic station, including a servo permanent magnet synchronous motor for driving a hydraulic pump; a synchronous servo driver connected to the servo permanent magnet synchronous motor for controlling the speed of the motor; a pressure sensor arranged in the pipeline of the hydraulic system to detect the actual system pressure; a touch screen for setting system pressure and flow parameters and controlling the operating status of the servo permanent magnet synchronous motor in real time; a dual closed-loop control module, including a speed closed loop and a pressure closed loop, for accurately controlling the speed of the servo permanent magnet synchronous motor to match the actual pressure requirement; a constant power control module for increasing the motor speed, improving the action speed, and allowing the selection of smaller pumps and motors; and a protection function for increasing the service life of the equipment and reducing maintenance costs.

[0028] See also Figure 1 In an optional scenario, the integrated touch screen 1 of this embodiment is set on the servo control cabinet 2, and the servo control tube is connected to multiple groups of servo motors 4. A pressure transmitter is set on each servo motor 4 for detection. The servo motor 4 is also connected to an oil supply pipe 51 and a hydraulic oil tank 53 provided with an oil return pipe 52 to form a circulation system. This system not only significantly improves the energy utilization efficiency of the hydraulic station and reduces unnecessary energy waste. It can achieve more precise hydraulic control and improve production accuracy and speed. By implementing this embodiment, metal processing enterprises can significantly reduce energy consumption. At the same time, because the system can quickly respond to pressure changes, the processing accuracy of metal products is improved, and production efficiency is also improved, providing strong technical support for the green production and sustainable development of enterprises.

[0029] Preferably, this embodiment cancels the PLC centralized acquisition control mode and adopts the Kunlun Tongtai integrated touch screen 1. The touch screen network port is used to perform MODBUS TCP communication with the host computer to achieve remote control. The touch screen's built-in RS485 port is used to read and write signals, collect information from 6 servo drives and 6 smart meters, and write the set pressure parameters to save them to the servo drive. The servo drive's built-in analog acquisition port is used to collect the pressure of the pressure transmitter directly to the servo drive, and the servo motor 4 is controlled to start and stop according to the pressure size according to the servo drive parameter setting. The touch screen is specifically the Kunlun Tongtai integrated touch screen 1. Through the Kunlun Tongtai integrated touch screen 1, the operator can intuitively monitor and adjust the system parameters, improving the convenience and accuracy of operation. In actual applications, in the furnace area hydraulic station of the steel plant, the operator can quickly respond to production needs, adjust the system pressure and flow, and ensure the continuity and stability of the production process. The Kunlun Tongtai integrated touch screen 1 has a friendly operation interface and quick response, allowing operators to focus more on monitoring the production process, reducing production interruptions and equipment damage caused by improper operation, and further improving production efficiency and equipment safety.

[0030] The dual closed-loop control module achieves precise control of the servo permanent magnet synchronous motor by setting a corresponding relationship between pressure thresholds and motor speed. This allows the system to precisely adjust motor speed based on actual pressure requirements, avoiding the pressure fluctuations common in traditional hydraulic systems and improving system stability and reliability. This ensures stable pressure during machining and enhances part processing accuracy.

[0031] Preferably, the constant power control module maintains the motor output power constant by adjusting the motor voltage and current under different motor loads. The application of the constant power control module enables the system to maintain efficient operation of the motor under different loads, avoids the decline in motor efficiency due to load changes, can significantly improve the working efficiency of the equipment, and reduce operating costs. The application of the constant power control module enables this embodiment to maintain stable working efficiency when performing high-intensity, high-load operations, reduces downtime caused by motor overload, improves the continuous operation capability of the equipment, and reduces operating costs.

[0032] Preferably, the protection functions of this embodiment include short-circuit protection, overcurrent protection, overvoltage protection, and undervoltage protection. The addition of these protection functions can effectively prevent damage to the motor and hydraulic pump under abnormal circumstances, extend the service life of the equipment, reduce production interruptions caused by equipment failures, enable the workshop to promptly detect and prevent equipment failures during the production process, reduce production delays and economic losses caused by abnormal equipment downtime, and provide guarantees for stable production and safety management of the enterprise.

[0033] Preferably, the touch screen has a custom parameter setting function. The custom parameter setting function enables the operator to flexibly adjust system parameters according to different production requirements, thereby improving the adaptability and flexibility of the system.

[0034] Preferably, in one implementation, the pressure closed loop in the dual closed-loop control module has a control accuracy of ±0.1 bar. This high-precision pressure control ensures the hydraulic system remains stable under various operating conditions, improving the controllability and consistency of the production process.

[0035] The constant power control module allows the system to automatically select the optimal speed and pump model under different operating conditions. This technology enables the system to automatically match the most appropriate operating state while maintaining constant output power, improving the system's intelligence and energy efficiency.

[0036] Optimally, the protection function monitors the operating status of the motor and hydraulic pump in real time through a built-in intelligent monitoring circuit. This intelligent monitoring circuit promptly detects anomalies in equipment operation, enabling preventive measures to be taken to avoid equipment failure. The touch screen features data recording and analysis capabilities, saving system operating parameters. The addition of data recording and analysis capabilities enables the system to store and analyze operating data over the long term, providing data support for equipment maintenance and optimization. During equipment maintenance and fault diagnosis, problems can be quickly located, reducing downtime and improving equipment availability and production efficiency. Long-term data analysis can identify patterns in equipment operation and potential problems, allowing for proactive maintenance measures, reducing production delays caused by equipment failures, and improving equipment reliability and enterprise production efficiency.

[0037] Preferably, the synchronous servo drive can dynamically adjust the speed of the servo permanent magnet synchronous motor according to actual needs. The ability to dynamically adjust the motor speed enables the system to quickly respond to changes in production needs, thereby improving the response speed and flexibility of the system. The pressure sensor adopts a high-precision sensor, and its range covers the operating pressure range of the system. The high-precision pressure sensor can ensure that the system maintains accurate control under various pressure ranges, thereby improving the stability and reliability of the system. When the servo motor 4 reaches the pressure, it slows down to maintain the pressure, and when it is lower than the pressure, it speeds up and increases the pressure, which is suitable for large and small flow conditions. When the pressure reaches the set pressure, the servo controller runs at the set low speed to maintain the pressure (the lowest speed is the shortest pressure response time required for this working condition, and the pressure motor can stop when the pressure is reached without the response time length requirement).

[0038] In addition, the constant power control module monitors the motor load in real time and adjusts the motor voltage and current to ensure that the motor operates in the high-efficiency zone. The protection function of this embodiment also includes motor overheat protection. When the motor temperature exceeds the preset value, the system automatically reduces the motor speed or shuts down. The addition of the motor overheat protection function can effectively prevent damage to the motor due to overheating, extend the service life of the motor, and reduce maintenance costs. In industrial applications in high-temperature environments, such as steelmaking and casting, it can ensure that the motor operates within a safe temperature range, ensuring the continuity and stability of the production process.

[0039] Optionally, the servo permanent magnet synchronous motor and the synchronous servo driver in this embodiment are connected via a high-speed data interface, enabling rapid data transmission and precise motor control. The use of a high-speed data interface improves the efficiency of data transmission within the system and ensures accurate and real-time motor control.

[0040] Through the above scheme, this embodiment significantly improves the energy efficiency of the hydraulic system and reduces energy consumption by utilizing a servo permanent magnet synchronous motor and a synchronous servo drive, combined with a dual closed-loop control module and a constant power control module. In practical applications, the system can automatically adjust the motor speed according to load changes, avoiding the overflow phenomenon common in traditional hydraulic systems and reducing energy waste. Furthermore, the high-precision pressure sensor and touch screen human-machine interaction design make the system operation more intuitive and simple, improving control accuracy and response speed. The addition of protection functions further ensures the stable operation of the equipment, extends its service life, and reduces maintenance costs. Overall, this system offers significant advantages in improving work efficiency, energy conservation and emission reduction, and equipment protection, making it suitable for energy-saving renovation and optimization upgrades of various furnace hydraulic stations. Furthermore, the system can be flexibly configured and adjusted according to different industrial environments and production needs, with wide applicability and strong scalability. It is an important technical means to achieve intelligent, efficient, and green production in modern industrial production.

[0041] The above are merely preferred embodiments of the present invention. It should be noted that the above preferred embodiments should not be construed as limiting the present invention, and the scope of protection of the present invention should be determined by the scope defined in the claims. Persons skilled in the art will appreciate that improvements and modifications may be made without departing from the spirit and scope of the present invention, and such improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A servo energy-saving control system for a furnace hydraulic station, characterized in that: include: A servo permanent magnet synchronous motor, wherein the servo permanent magnet synchronous motor is used to drive a hydraulic pump; A synchronous servo driver, connected to the servo permanent magnet synchronous motor, for controlling the rotational speed of the servo permanent magnet synchronous motor; A pressure sensor is provided in a pipeline of the hydraulic system and is used to detect actual system pressure; A touch screen, the touch screen being used to set system pressure and flow parameters and to control the operating state of the servo permanent magnet synchronous motor in real time; A dual closed-loop control module, comprising a speed closed-loop module and a pressure closed-loop module, for precisely controlling the speed of the servo permanent magnet synchronous motor to match actual pressure requirements; A constant power control module is used to increase the rotation speed of the servo permanent magnet synchronous motor to increase the movement speed and allow the selection of smaller pumps and motors.

2. A furnace area hydraulic station servo energy-saving control system according to claim 1, characterized in that: The dual closed-loop control module achieves precise control of the servo permanent magnet synchronous motor by setting the corresponding relationship between the pressure threshold and the motor speed.

3. A furnace area hydraulic station servo energy-saving control system according to claim 1, characterized in that: The constant power control module keeps the motor output power constant by adjusting the voltage and current of the motor under different motor loads.

4. A furnace area hydraulic station servo energy-saving control system according to claim 1, characterized in that: It also includes a protection module, which includes but is not limited to short circuit protection, overcurrent protection, overvoltage protection and undervoltage protection.

5. A furnace area hydraulic station servo energy-saving control system according to claim 1, characterized in that: The touch screen has a custom parameter setting function.

6. A furnace area hydraulic station servo energy-saving control system according to claim 1, characterized in that: In the dual closed-loop control module, the control accuracy of the pressure closed-loop module is ±0.1 bar.

7. A furnace area hydraulic station servo energy-saving control system according to claim 1, characterized in that: The constant power control module monitors the motor load in real time and adjusts the voltage and current of the motor to ensure that the motor operates in a high-efficiency area.

8. A furnace area hydraulic station servo energy-saving control system according to claim 4, characterized in that: The protection module is also used for motor overheat protection. When the motor temperature exceeds a preset value, the motor speed is automatically reduced or the motor is shut down.

9. A furnace area hydraulic station servo energy-saving control system according to claim 1, characterized in that: The servo permanent magnet synchronous motor and the synchronous servo driver are connected via a high-speed data interface to achieve fast data transmission and precise control of the motor.

10. A furnace area hydraulic station servo energy-saving control system according to claim 1, characterized in that: The synchronous servo driver is connected to a plurality of groups of the servo permanent magnet synchronous motors.

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