Self-adaptive floating energy-saving control system of continuous ship unloader

Abstract

The invention discloses a self-adaptive floating energy-saving control system of a continuous ship unloader, relates to the technical field of ship unloader structures, and solves the problems that an existing ship unloader adopts a conventional control mode, completely depends on hydraulic pressure to overcome the gravity of mechanisms such as a cantilever crane and control the cantilever crane, energy consumption is large, and the requirement for driving structures such as a motor is high. The front end of the horizontal arm frame is connected with a vertical arm frame, the vertical arm frame comprises a discharging driving device, the rear end of the horizontal arm frame is connected with a balance weight, and the weight and / or the position of the balance weight are / is set according to the material counter-acting force borne by the vertical arm frame, so that the front-section moment of the horizontal arm frame is larger than the rear-section moment of the horizontal arm frame. And the horizontal arm frame drives the vertical arm frame to move downwards. Through the force arm principle and the hydraulic control principle, gravitational potential energy is effectively utilized for automatic displacement material taking, the principle is simple, energy consumption is small, and the energy-saving effect during working is improved.

Description

Technical Field

[0001] This invention relates to the field of ship unloader structure technology, and in particular to an adaptive floating energy-saving control system for a continuous ship unloader. Background Art

[0002] Continuous unloaders are port loading and unloading equipment that uses continuous conveying devices such as screws, chain buckets, or pneumatic conveyors to lift bulk materials. They are characterized by high efficiency, environmental friendliness, and low maintenance. The equipment adopts a fully enclosed structure design, realizing dust-free transfer of materials from the ship's hold to the dock conveying system, reducing dust emissions by more than 90% compared to traditional grab unloaders. Its material handling mechanism uses screw blades (screw type) or chain buckets (chain bucket type) to perform material grabbing, and is equipped with an automatic sinking feed head to achieve full-load operation.

[0003] However, existing ship unloaders use conventional control methods, relying entirely on hydraulics to overcome the gravity of the boom and other mechanisms and to control the boom. This consumes a lot of energy and places high demands on the drive structure, such as the motor. Summary of the Invention

[0004] The purpose of this invention is to provide an adaptive floating energy-saving control system for a continuous ship unloader. By utilizing the lever arm principle and hydraulic control principle, it effectively uses gravitational potential energy for automatic displacement and material handling. The principle is simple and the energy consumption is low, thus improving the energy-saving effect during operation.

[0005] The above-mentioned technical objective of the present invention is achieved through the following technical solution: An adaptive floating energy-saving control system for a continuous ship unloader includes a body with a horizontal boom hinged to it. A vertical boom is connected to the front end of the horizontal boom, and the vertical boom includes a material unloading drive device therein. A counterweight is connected to the rear end of the horizontal boom. The weight and / or position of the counterweight are set according to the material reaction force on the vertical boom, so that the torque of the front section of the horizontal boom is greater than the torque of the rear section, and the horizontal boom drives the vertical boom downward.

[0006] Furthermore, a horizontal boom cylinder is hinged between the machine body and the horizontal boom, and the large and / or small chambers of the horizontal boom cylinder are connected to a speed regulating valve for limiting the flow rate.

[0007] Furthermore, the upper end of the vertical boom is hinged to the horizontal boom, and the vertical boom tends to remain vertical under its own weight.

[0008] Furthermore, a vertical boom cylinder is hinged between the vertical boom and the horizontal boom, and the large and / or small chambers of the vertical boom cylinder are connected to a speed regulating valve for limiting the flow rate.

[0009] Furthermore, the large and small chambers of the vertical arm cylinder are respectively connected to speed regulating valves for limiting flow. The other ends of the two speed regulating valves are connected to port X. Hydraulic oil enters the large and small chambers of the vertical arm cylinder through port X, connecting the two.

[0010] Furthermore, a distance detection device is connected to the vertical boom, and the embedment depth of the vertical boom is obtained based on the distance detection device.

[0011] Furthermore, after the vertical boom's embedment depth is reduced to the lower limit of the preset warning range, the opening of the speed regulating valve at the horizontal boom cylinder is increased; after the vertical boom's embedment depth is increased to the upper limit of the preset warning range, the opening of the speed regulating valve at the horizontal boom cylinder is reduced.

[0012] Furthermore, the torque of the front section of the horizontal boom is obtained based on the weight and position of the front section of the horizontal boom, the weight and position of the vertical boom, and the material reaction force and position acting on the vertical boom. The torque of the rear section of the horizontal boom is obtained based on the weight and position of the rear section of the horizontal boom and the weight and position of the counterweight.

[0013] Furthermore, the weight and position of the counterweight are preset to ensure that the torque at the front of the horizontal boom is greater than a fixed value at the rear.

[0014] Furthermore, the counterweight is slidably connected to the horizontal boom along the length of the horizontal boom, and the torque of the rear section of the horizontal boom is adjusted by the displacement of the counterweight.

[0015] In summary, the present invention has the following beneficial effects: Based on the lever arm principle: when L1*F1>L2*F2, the horizontal arm will tilt towards the ship's hold, driving the vertical arm to automatically enter the unloaded material. In the actual system construction, G1 and F are matched and designed to effectively utilize gravitational potential energy for automatic displacement and material handling. The principle is simple and consumes little energy, thus improving the energy-saving effect during operation. The adaptive floating energy-saving control system effectively utilizes gravitational potential energy for automatic material displacement through the lever arm principle and hydraulic control principle. Its design concept is simple yet advanced and reasonable. Its control logic and distribution are simple and practical. Moreover, the components used in the system construction are all mature and reliable products. The design principle meets the requirements of the application site and is very easy to promote. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of an adaptive floating energy-saving control system for a continuous ship unloader according to the present invention; Figure 2 This is a schematic diagram of the hydraulic control principle in the adaptive floating energy-saving control system for a continuous ship unloader of the present invention; Figure 3 yes Figure 2Control diagram of the hydraulic oil output section; Figure 4 yes Figure 2 Control diagram of the vertical arm hydraulic cylinder section; Figure 5 yes Figure 2 A schematic diagram of the control system for the hydraulic cylinder section of the horizontal arm.

[0017] In the diagram, 1. Distance detection device; 2. Vertical boom cylinder; 3. Horizontal boom cylinder; 4. Counterweight; 5. Horizontal boom; 6. Vertical boom; 7. Unloading drive device; 1.3. New power source; 16. Control valve group; 24. First functional valve group; 27. Second functional valve group; 27.4a. First oil replenishing valve; 27.4b. Second oil replenishing valve; 27.8. First cylinder pressure holding valve; 27.9. Second cylinder pressure holding valve; 27.7a. First adaptive opening valve; 27.7b. Second adaptive opening valve; 27.3a. First adaptive speed regulating valve; 27.3b. Second adaptive speed regulating valve. Detailed Implementation

[0018] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. These embodiments do not constitute a limitation of the present invention. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this application.

[0019] An adaptive floating energy-saving control system for a continuous ship unloader, such as Figure 1 As shown, the machine includes a body with a horizontal boom 5 hinged to it, and the hinge point is located in the middle of the body, dividing the horizontal boom 5 into a front end and a rear end. The front end of the horizontal boom 5 is connected to a vertical boom 6, and the vertical boom 6 includes a material unloading drive device 7 (the material unloading drive device 7 is existing technology, such as using spiral blades to perform material gripping, etc., which will not be described in detail here). The rear end (tail end) of the horizontal boom 5 is connected to a counterweight 4. In this embodiment, a horizontal boom cylinder 3 is hinged between the machine body and the horizontal boom 5, and the upper end of the vertical boom 6 is hinged to the horizontal boom 5. The vertical boom 6 tends to maintain a vertical state under its own weight. A vertical boom cylinder 2 is hinged between the vertical boom 6 and the horizontal boom 5.

[0020] like Figure 1As shown, the weight and / or position of the counterweight 4 are set according to the reaction force of the material on the vertical boom 6, so that the torque of the front section of the horizontal boom 5 is greater than that of the rear section, and the horizontal boom 5 drives the vertical boom 6 downward. The weight of the counterweight 4 can be changed by disassembly or other means, or the counterweight 4 can be set to slide along the length of the horizontal boom 5 and connected to the horizontal boom 5. Through a linear drive device such as a winch or hydraulic cylinder, in conjunction with the guide rail, the linear sliding of the counterweight 4 can be realized, so as to adjust the torque of the rear section of the horizontal boom 5 by the displacement of the counterweight 4. Specifically, the horizontal boom 5 uses the hinge point on the machine body as the fulcrum. According to the balance condition of the lever structure: power × power arm = resistance × resistance arm (L1*F1=L2*F2), the torque L1*F1 of the front section of the horizontal boom 5 is obtained from the weight G3 and position of the front section of the horizontal boom 5, the weight G2 and position of the vertical boom 6, and the material reaction force F and position of the vertical boom 6. The torque L2*F2 of the rear section of the horizontal boom 5 is obtained from the weight G4 and position of the rear section of the horizontal boom 5 and the weight G1 and position of the counterweight 4. When L1*F1 > L2*F2, the horizontal arm will tilt towards the hold, automatically driving the vertical boom 6 into the unloaded material. Based on the above principle, since G3, G4, etc. are fixed values, and the material reaction force F changes due to differences in material density, material type, degree of compaction, etc., the only easily adjustable variables are the weight G1 and position of the counterweight 4. Therefore, in the actual system construction of this embodiment, the weight G1 and / or position of the counterweight 4 are matched according to the material reaction force F. For the reaction force F (which can be pre-measured and calculated, or sensed in real time by setting pressure sensors and other devices), by replacing or adding or removing the counterweight 4 and the drive movement of the counterweight 4, the weight and position of the counterweight 4 can be preset and adjusted so that the torque of the front section of the horizontal boom 5 is greater than a fixed value or a fixed ratio of the torque of the rear section. This causes the horizontal boom 5 and the vertical boom 6 to tilt towards the material in the hull compartment by their own weight, and the suction head connected to the vertical boom will automatically be buried in the material being retrieved. This fixed value should not be too large to reduce the risk of stalling.

[0021] like Figure 2 As shown, since L1*F1 > L2*F2, the tilting speed and burial depth are uncontrollable in the free state, which will lead to operational risks. In order to solve the above risks, this embodiment has also made further improvements to the hydraulic control part of the vertical arm cylinder 2 and the horizontal arm cylinder. like Figure 3 As shown, based on the original hydraulic control, a limiting oil circuit for the vertical arm cylinder 2 and the horizontal arm cylinder has been added to prevent them from stalling. The limiting oil circuit includes a new power source 1.3. The new power source 1.3 and the power source in the original hydraulic control oil circuit are connected to the control valve group 16. The control valve group 16 includes a first control valve Y3 and a second control valve Y4, both of which are two-position three-way valves. One side of each valve is connected to the oil inlet passage and the oil return passage, and the other side is connected to the control passage. This allows the two control passages to receive or return oil through the corresponding control valves. The valves can also be set to have on / off functions. The two oil return passages are connected to the oil tank, and the two oil inlet passages are connected to the main oil inlet passage. The main oil inlet passage is connected to the new power source 1.3 and the power source in the original hydraulic control oil circuit through two corresponding check valves, respectively, to realize the oil inlet and return of the new limiting oil circuit. It can also be realized through the power source in the original hydraulic control oil circuit.

[0022] like Figure 4 and Figure 5 As shown, the large and small chambers of the horizontal arm cylinder 3 are respectively connected to a speed regulating valve for limiting the flow rate; similarly, the large and small chambers of the vertical arm cylinder 2 are also respectively connected to a speed regulating valve for limiting the flow rate, controlling the oil discharge speed of the cylinder and preventing stalling. The large and small chambers of the vertical boom cylinder 2 are respectively connected to speed regulating valves (first adaptive speed regulating valve 27.3a and second adaptive speed regulating valve 27.3b) used to limit the flow rate. The other ends of the two speed regulating valves are connected to port X. Hydraulic oil enters the large and small chambers of the vertical boom cylinder 2 through port X, connecting the two to allow the vertical boom 6 to be in a free state and always remain vertical under its own weight. In some embodiments, the horizontal boom cylinder 3 also adopts the above structure to achieve tilting material picking under the setting of counterweight 4. Specifically, in this embodiment, the horizontal arm cylinder 3 is equipped with a first functional valve group 24, and the vertical arm cylinder 2 is equipped with a second functional valve group 27 to realize the control of the corresponding cylinders. The control principles of the first functional valve group 24 and the second functional valve group 27 are the same or similar. Taking the second functional valve group 27 as an example, the original hydraulic control oil circuit is connected to the large chamber and small chamber of the horizontal arm cylinder 3 through port A and port B respectively. Port A and port B can achieve unidirectional oil replenishment through the first oil replenishing valve 27.4a and the second oil replenishing valve 27.4b respectively, and achieve pressure holding through the first cylinder pressure holding valve 27.8 and the second cylinder pressure holding valve 27.9. It can also achieve the original hydraulic control mode through other hydraulic control methods. Specifically, the two control paths of the newly added limiting oil circuit are respectively connected to port X at the corresponding oil cylinder. After passing through port X, the hydraulic oil enters the first adaptive opening valve 27.7a and the second adaptive opening valve 27.7b (in this embodiment, they are hydraulically controlled check valves). The other end of the first adaptive opening valve 27.7a is connected to the first adaptive speed regulating valve 27.3a, and the other end of the first adaptive speed regulating valve 27.3a is connected to the small chamber of the vertical arm oil cylinder 2. The other end of the second adaptive opening valve 27.7b is connected to the second adaptive speed regulating valve 27.3b, and the other end of the second adaptive speed regulating valve 27.3b is connected to the large chamber of the vertical arm oil cylinder 2 (in this embodiment, the adaptive speed regulating valve is a two-position two-way valve to realize the disconnection or speed limiting opening of the oil circuit).

[0023] like Figure 1 As shown, a distance detection device 1 is connected to the vertical boom 6. The distance detection device 1 detects the height H1. The embedment depth H of the vertical boom 6 is calculated based on the preset total height H2. After the large and small chambers of the horizontal boom cylinder 3 are connected, the horizontal boom 5 will automatically shift and drive the vertical boom into the unloaded material under the condition that L1*F1 > L2*F2. In this working state, the above-mentioned PLC records the embedment depth H as a control signal to participate in the overall control. When the embedment depth H of the vertical boom 6 decreases to the lower limit of the preset warning range, the PLC sends a large current signal to increase the opening of the speed regulating valve at the horizontal boom cylinder 3, thereby increasing the flow rate of the horizontal boom cylinder 3 and increasing the horizontal descent speed. This allows the horizontal boom 5 to move more quickly to compensate for the decrease in the value of H. Conversely, when the embedment depth H of the vertical boom 6 increases to the upper limit of the preset warning range, the opening of the speed regulating valve at the horizontal boom cylinder 3 is reduced. The increase or decrease of the opening can be set in a gradient or can be set according to the specific value of H.

[0024] Working principle: Once the vertical boom 6 is above the material to be unloaded, the unloading drive device 7 is activated, and the unloading system begins to work. The unloading efficiency is judged based on the current or pressure at the unloading drive device 7 (motor or hydraulic pump) to determine whether the unloading efficiency has reached the optimal state. If the optimal state is reached, the PLC records the embedment depth H, and sends a signal to control the start of the new power source 1.3. After the pressure sensor in the control valve group 16 detects the pressure signal, it feeds back to the PLC. The PLC sends a command to energize the first control valve Y3. The pressurized oil enters the second functional valve group 27 through the first control valve Y3, and then enters the first adaptive opening valve 27.7a and the second adaptive opening valve 27.7b through port X. The two adaptive valves open, and the PLC sends an analog signal to the first adaptive speed regulating valve 27.3a and the second adaptive speed regulating valve 27.7b. Two adaptive speed regulating valves 27.7b are connected, enabling the vertical arm cylinder 2 to open and close its large and small chambers. The first adaptive speed regulating valve 27.3a and the second adaptive speed regulating valve 27.7b achieve different opening degrees under the control of the current magnitude, limiting the flow of the large and small chambers and preventing stalling. After the large and small chambers of the vertical arm cylinder 2 are connected, the first cylinder pressure holding valve 27.8 and the second cylinder pressure holding valve 27.9 are short-circuited and lose their pressure holding effect, and the vertical arm 6 is in a free state, always remaining vertical under its own weight. The PLC sends a control signal to energize and turn on the second control valve Y4 in the control valve group 16. Control oil enters the first functional valve group 24 to control the horizontal boom cylinder 3. Its control method is the same as the control method of the vertical boom cylinder 2 mentioned above. Under the condition that L1*F1>L2*F2, the horizontal boom 5 and the vertical boom 6 tilt towards the material in the ship's cargo hold by their own weight. The suction head connected to the vertical boom will automatically bury itself into the material to be picked up for unloading.

[0025] The control method in this embodiment utilizes the self-weight of the boom, achieving automatic material handling and displacement using only a small flow control oil circuit. The energy consumed during automatic displacement is calculated as q = (P*Q / 600) / 0.94. In some embodiments, the adaptive opening valve at the horizontal boom cylinder 3 controls a flow rate of 10L and a pressure of 30bar, resulting in an energy consumption of 0.78kW. However, without the adaptive floating energy-saving control system, a motor (75kW) needs to be started in the existing hydraulic control oil circuit during material handling, with an operating power of approximately (180*100 / 600) / 0.94 = 40kW, significantly reducing energy consumption.

[0026] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art can make various modifications or equivalent substitutions to the present invention within the scope of its essence and protection. Such modifications or equivalent substitutions should also be considered to fall within the protection scope of the present invention.

Claims

1. An adaptive floating energy-saving control system for a continuous ship unloader, characterized in that: The device includes a body with a horizontal boom hinged to it. The front end of the horizontal boom is connected to a vertical boom, which includes a material unloading drive device. The rear end of the horizontal boom is connected to a counterweight. The weight and / or position of the counterweight are set according to the material reaction force on the vertical boom, so that the torque of the front section of the horizontal boom is greater than that of the rear section, and the horizontal boom drives the vertical boom downward.

2. The adaptive floating energy-saving control system for a continuous ship unloader according to claim 1, characterized in that: A horizontal boom cylinder is hinged between the machine body and the horizontal boom, and the large and / or small chambers of the horizontal boom cylinder are connected to a speed regulating valve for limiting the flow rate.

3. The adaptive floating energy-saving control system for a continuous ship unloader according to claim 1 or 2, characterized in that: The upper end of the vertical boom is hinged to the horizontal boom, and the vertical boom tends to remain vertical under its own weight.

4. The adaptive floating energy-saving control system for a continuous ship unloader according to claim 3, characterized in that: A vertical boom cylinder is hinged between the vertical boom and the horizontal boom, and the large and / or small chambers of the vertical boom cylinder are connected to a speed regulating valve for limiting the flow rate.

5. The adaptive floating energy-saving control system for a continuous ship unloader according to claim 4, characterized in that: The large and small chambers of the vertical arm cylinder are respectively connected to speed regulating valves for limiting flow. The other end of the two speed regulating valves is connected to port X. Hydraulic oil enters the large and small chambers of the vertical arm cylinder through port X, connecting the two.

6. The adaptive floating energy-saving control system for a continuous ship unloader according to claim 1, characterized in that: The vertical boom is connected to a distance detection device, and the embedment depth of the vertical boom is obtained based on the distance detection device.

7. The adaptive floating energy-saving control system for a continuous ship unloader according to claim 6, characterized in that: After the vertical boom's embedment depth is reduced to the lower limit of the preset warning range, the opening of the speed regulating valve at the horizontal boom cylinder is increased; after the vertical boom's embedment depth is increased to the upper limit of the preset warning range, the opening of the speed regulating valve at the horizontal boom cylinder is decreased.

8. The adaptive floating energy-saving control system for a continuous ship unloader according to claim 1, characterized in that: The torque of the front section of the horizontal boom is obtained based on the weight and position of the front section of the horizontal boom, the weight and position of the vertical boom, and the material reaction force and position acting on the vertical boom. The torque of the rear section of the horizontal boom is obtained based on the weight and position of the rear section of the horizontal boom and the weight and position of the counterweight.

9. The adaptive floating energy-saving control system for a continuous ship unloader according to claim 1 or 8, characterized in that: The weight and position of the counterweight are preset to ensure that the torque at the front of the horizontal boom is greater than a fixed value at the rear.

10. The adaptive floating energy-saving control system for a continuous ship unloader according to claim 9, characterized in that: The counterweight is slidably connected to the horizontal boom along the length of the horizontal boom, and the torque of the rear section of the horizontal boom is adjusted by the displacement of the counterweight.

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