Digital disassembly and assembly platform control method and system based on PLC

Abstract

The invention relates to the technical field of bus cylinder disassembly and assembly, and discloses a PLC-based digital disassembly and assembly platform control method and system.The method comprises the steps that real-time bearing data of multiple supporting points of a fault bus cylinder replacement supporting device are obtained, whether the supporting state of the replacement supporting device is safe or not is judged, and if yes, the replacement supporting device is started; carrying out levelness calibration on a digital disassembly and assembly platform, supporting the faulty bus cylinder by the digital disassembly and assembly platform after the levelness calibration reaches the standard, then axially compressing a telescopic joint of the faulty bus cylinder along a first direction to obtain a disassembly and assembly avoidance gap, and obtaining compression displacement of the telescopic joint; and dynamic pressure is calculated according to the compression displacement, and the expansion joint is compressed according to the dynamic pressure until the compression displacement reaches target displacement. Through the method and the corresponding system, the redundant process of dismounting the adjacent units in the process of dismounting the faulty bus cylinder is avoided, and the efficiency and the safety of repairing the faulty bus cylinder are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of busbar cylinder disassembly and assembly, in particular to a PLC-based digital disassembly and assembly platform control method and system. BACKGROUND

[0002] In a GIS busbar arranged in a phase-separated vertical stack, and a GIS busbar with a double-busbar arrangement on the upper layer, when a fault occurs in the middle and lower busbars (such as insulation sub leakage, internal discharge, etc.), the conventional emergency repair method is to recover the fault busbar cylinder, the SF6 gas in the adjacent unit, and the SF6 gas in the upper interfering unit, and then use a crane to remove the interfering units one by one that affect the hoisting of the fault busbar cylinder, and then sequentially reassemble after the processing is completed. The overall operation is difficult, the process is complex, and it takes a long time, which is prone to cause six-level and above equipment events.

[0003] To solve the above operation problems, a digital disassembly and assembly platform is installed, and the digital disassembly and assembly platform is controlled to move the fault busbar cylinder along the axial and radial directions of the busbar. In this way, there is no need to recover the adjacent unit. The process of controlling the digital disassembly and assembly platform to disassemble and assemble the busbar cylinder needs to compress the expansion joint to release the disassembly space.

[0004] However, under normal operating conditions, the expansion joint is in a certain pre-compressed position due to temperature changes. If the remaining compressible length is less than the required space for disassembly, it means that further compression will likely exceed the maximum allowable working stroke, causing seal damage. Excessive compression can cause permanent deformation or crushing of internal sealing elements (such as rubber rings and graphite rings), leading to leakage of the busbar cylinder, and generating a large additional stress on the busbar cylinder body and insulators connected thereto, which can cause the equipment to crack. SUMMARY

[0005] Therefore, the purpose of the present application is to overcome the problem of redundant processes caused by the need to remove adjacent units and upper interfering units during the disassembly and assembly of the fault busbar cylinder in the prior art. A PLC-based digital disassembly and assembly platform control method and system is provided. By installing a digital disassembly and assembly platform and controlling its axial-radial movement, and monitoring the radial displacement of the expansion joint while controlling the compression force of the compression expansion joint, the redundant process of removing adjacent units is avoided, safe and precise compression of the expansion joint is achieved, and the repair efficiency and safety are improved.

[0006] In a first aspect, to solve the above technical problems, the present application provides a PLC-based digital disassembly platform control method, which comprises the following steps: Step 1: acquiring real-time bearing data of a plurality of support points of a fault busbar cylinder replacement support device, acquiring balance degree data based on the real-time bearing data, comparing the balance degree data with a balance degree threshold, and determining whether the support state of the replacement support device is safe according to the comparison result; if yes, Step 2 is performed; Step 2: calibrating the levelness of the digital disassembly platform, supporting the fault busbar cylinder by the digital disassembly platform that has passed the levelness calibration, and performing Step 3; Step 3: axially compressing the expansion joint of the fault busbar cylinder in a first direction to obtain a disassembly avoidance gap, and acquiring the compression displacement of the expansion joint; calculating the dynamic pressure according to the compression displacement, and compressing the expansion joint until the compression displacement reaches a target displacement according to the dynamic pressure; Step 4: driving the digital disassembly platform carrying the fault busbar cylinder to move a first distance in the opposite direction of the first direction to the disassembly avoidance gap, so that the fault busbar cylinder is separated from the whole machine; wherein the first distance is half of the target displacement; and Step 5: driving the digital disassembly platform to move in the radial direction of the fault busbar cylinder, and lifting off the fault busbar cylinder separated from the whole machine by a hammock.

[0007] Preferably, the method further comprises: acquiring an initial length and a maximum allowable compression length of the expansion joint; measuring the actual length of the expansion joint before axially compressing the expansion joint; calculating the compressed length of the expansion joint based on the initial length and the actual length, and calculating the remaining compressible length based on the maximum allowable compression length and the compressed length; and if the remaining compressible length is greater than the disassembly avoidance gap, axially compressing the expansion joint.

[0008] Preferably, axially compressing the expansion joint of the fault busbar cylinder comprises: acquiring a force-displacement curve of the expansion joint; calculating the target displacement based on the disassembly avoidance gap and the compressed length, obtaining the dynamic pressure based on the target displacement and the force-displacement curve; and driving the servo motor to axially compress the expansion joint according to the dynamic pressure.

[0009] Preferably, driving the servo motor to axially compress the expansion joint according to the dynamic pressure comprises: monitoring the actual pressure output by the servo motor in real time; calculating a deviation value between the dynamic pressure and the actual pressure; inputting the deviation value into a PID control algorithm to calculate an adjustment amount of the output force of the servo motor, and outputting the adjustment amount of the output force to the servo motor.

[0010] Preferably, in the process of compressing the expansion joint, the radial offset of the expansion joint during compression is acquired, a safety index is calculated based on the radial offset, and if the safety index is less than a preset safety threshold, Step 4 is performed; otherwise, an alarm is given.

[0011] Preferably, the safety index is calculated based on the radial offset according to the following manner: wherein, represents the safety index, represents the measured radial offset of the jth sampling; represents the ideal radial offset of the jth sampling; m represents the total number of sampling points; represents the preset radial offset value.

[0012] Preferably, the balance degree data is obtained based on the real-time bearing data, the balance degree data is compared with a preset balance degree threshold, and whether the support state of the replacement support device is safe is determined according to the comparison result, including: obtaining the maximum bearing value and the minimum bearing value in the real-time bearing data, and the balance degree data is the difference between the maximum bearing value and the minimum bearing value; if the balance degree data is less than the preset balance degree threshold, it is determined that the support state of the replacement support device is safe; otherwise, it is determined that the support state of the replacement support device is unsafe.

[0013] The second aspect, to solve the above technical problems, the present application also proposes a kind of digital disassembly platform control system based on PLC, the system includes: whether the module of judging replacement support device is stable, for obtaining the real-time bearing data of multiple support points of replacement support device of fault bus cylinder, balance degree data is obtained based on real-time bearing data, balance degree data and balance degree threshold are compared, and whether the support state of the replacement support device is safe is determined according to the comparison result, if safe, horizontal calibration module is called;Horizontal calibration module is used for horizontal calibration to digital disassembly platform, and the digital disassembly platform after horizontal calibration standard is supported to the fault bus cylinder, and compression telescopic joint module is called;Compression telescopic joint module is used for compressing telescopic joint of the fault bus cylinder in the first direction axial to obtain disassembly avoidance gap, and the compression displacement of the telescopic joint is obtained;Dynamic pressure is calculated according to the compression displacement, and the telescopic joint is compressed according to the dynamic pressure until the compression displacement reaches target displacement;Axial movement module is used for driving the digital disassembly platform carrying the fault bus cylinder to move a first distance in the opposite direction of the first direction to the disassembly avoidance gap, so that the fault bus cylinder is separated from whole machine;Wherein, the first distance is half of the target displacement;Radial movement module is used for driving the digital disassembly platform to move in the radial direction of fault bus cylinder, and the fault bus cylinder after being separated from whole machine is lifted off by hammock.

[0014] ​Preferably, the compression expansion joint module comprises: an initial length acquisition module for acquiring an initial length and a maximum allowable compression length of the expansion joint; an actual length measurement module for measuring an actual length of the expansion joint before axial compression of the expansion joint; a remaining compressible length calculation module for calculating a compressed length of the expansion joint based on the initial length and the actual length, and calculating a remaining compressible length based on the maximum allowable compression length and the compressed length; and a compression execution module for performing axial compression of the expansion joint if the remaining compressible length is greater than the disassembly avoidance gap.

[0015] Preferably, the compression execution module comprises: a curve acquisition module for acquiring a force-displacement curve of the expansion joint; a dynamic pressure acquisition module for calculating the target displacement based on the disassembly avoidance gap and the compressed length, and obtaining the dynamic pressure in combination with the target displacement and the force-displacement curve; and a compression driving module for driving the servo motor to axially compress the expansion joint according to the dynamic pressure. The PLC-based digital disassembly platform control method can avoid redundant procedures of disassembling adjacent units, realize safe and accurate compression of the expansion joint, and improve repair efficiency and safety.

[0016] Wherein, by judging the support balance degree, the collapse and deformation of the bus barrel caused by unbalanced temporary support are avoided, the original fixed support can realize balanced bearing, but will directly block the horizontal radial translation path of the faulty bus barrel and become a disassembly obstacle, therefore, the temporary support needs to be replaced first to create operation space for disassembly; By calibrating the levelness of the digital disassembly platform, the risk of subsequent compression and movement is eliminated; By accurately controlling the force during compression of the expansion joint of the bus barrel, permanent deformation of the expansion joint caused by excessive compression is avoided; By controlling the axial movement of the digital disassembly platform carrying the faulty bus barrel to form a disassembly avoidance gap, the damage to the adjacent unit caused by improper position control and collision with the adjacent unit during disassembly of the faulty bus barrel is avoided; Then, by controlling the radial movement of the digital disassembly platform carrying the faulty bus barrel, the crane can be lifted away from the faulty bus barrel. BRIEF DESCRIPTION OF DRAWINGS

[0017] In order to make the content of the present application more easily understood, the present application will be further described in detail below according to specific embodiments of the present application and in conjunction with the drawings, wherein, Figure 1A flow chart of a PLC-based digital disassembly platform control method in a preferred embodiment of the present application; Figure 2 A process schematic diagram of a PLC-based digital disassembly platform disassembling a faulty bus cylinder in a preferred embodiment of the present application; Figure 3 A system block diagram of a PLC-based digital disassembly platform control system in a preferred embodiment of the present application. DETAILED DESCRIPTION

[0018] The present application will be further described below in conjunction with the drawings and specific embodiments, so that those skilled in the art can better understand the present application and implement it. The embodiments are not intended to limit the present application.

[0019] It should be noted that for the 500kV GIS bus with the structure of "separate-phase vertical stacking arrangement" and the 220kV GIS bus with the structure of "double-bus arranged on the upper layer", if the middle and lower layer buses are faulty (insulator gas leakage, internal discharge, etc.), the conventional emergency repair method is: after recovering the SF6 gas of the faulty unit, the adjacent unit and the upper interfering unit, the interfering units affecting the faulty unit are removed one by one using a crane, and after the processing is completed, they are reassembled in turn. The overall operation is difficult, the process is long, and it is easy to cause a six-level or above equipment event.

[0020] The scheme of the embodiment of the present application installs a digital disassembly platform under the faulty bus cylinder of the GIS bus with the structure of "separate-phase vertical stacking arrangement", supports the faulty bus cylinder through the digital disassembly platform, controls the axial and radial movement of the digital disassembly platform to drive the movement of the faulty bus cylinder, and does not need to remove the upper interfering bus cylinder of the faulty bus cylinder.

[0021] Embodiment one: refer to Figure 1As shown, the embodiment of the present application provides a PLC-based digital disassembly platform control method, which comprises the following steps: step one: acquiring real-time bearing data of a plurality of support points of a replacement support device of a faulty busbar cylinder, acquiring balance degree data based on the real-time bearing data, comparing the balance degree data with a balance degree threshold, and determining whether the support state of the replacement support device is safe according to the comparison result, and if safe, executing step two; step two: calibrating the levelness of the digital disassembly platform, supporting the faulty busbar cylinder through the digital disassembly platform that has passed the levelness calibration, and executing step three; step three: axially compressing the expansion joint of the faulty busbar cylinder in a first direction to obtain a disassembly avoidance gap, and acquiring the compression displacement of the expansion joint; calculating the dynamic pressure according to the compression displacement, and compressing the expansion joint according to the dynamic pressure until the compression displacement reaches a target displacement; step four: driving the digital disassembly platform carrying the faulty busbar cylinder to move a first distance in the opposite direction of the first direction to the disassembly avoidance gap, so that the faulty busbar cylinder is separated from the whole machine; wherein the first distance is half of the target displacement; step five: driving the digital disassembly platform to move in the radial direction of the faulty busbar cylinder, and lifting off the faulty busbar cylinder that has been separated from the whole machine through a hammock.

[0022] Figure 2 As shown is a process schematic diagram of the PLC-based digital disassembly platform disassembling a faulty busbar cylinder, wherein step (1) is to remove the fixed support and install a temporary support, step (2) is to install the digital disassembly platform after installing the temporary support; step (3) is to compress the expansion joint and release the disassembly space; step (4) is to axially move the digital disassembly platform and separate the faulty busbar cylinder; and step (5) is to radially move the digital disassembly platform and lift off the faulty busbar cylinder.

[0023] In a specific application scenario, a pressure sensor is installed at each support point of the replacement support device, the sensor communicates with the PLC through a data line, and real-time bearing data (sampling frequency 10 Hz) of each support point is collected. The balance degree is calculated based on the following method: Balance degree = (maximum bearing value of each support point - minimum bearing value of each support point) / average bearing value of each support point.

[0024] The calculated balance degree is compared with the threshold value to determine whether the support state is safe, including adjusting the height of each support point until the balance degree is less than the threshold value if the balance degree exceeds the threshold value. Through real-time bearing collection and balance degree calculation of multiple support points, it is avoided that the support device is deformed due to overload of a single support point (such as the bearing of a certain support point far exceeding that of other points), or the busbar cylinder is tilted due to uneven support, thereby ensuring the structural safety of the disassembly process from the source.

[0025] Two orthogonal electronic levels (measurement range ±0.5, accuracy 0.001°) are installed on the platform table of the digital disassembly and assembly platform. The level real-time feedbacks the levelness data of the table until the levelness calibration meets the standard, ensuring that the platform supports the bus cylinder uniformly and avoiding additional stress due to inclination. The horizontal accuracy of the digital disassembly and assembly platform directly affects the accuracy of subsequent telescopic joint compression direction and displacement control. Precise levelness calibration of the digital disassembly and assembly platform ensures uniform stress on the bus cylinder during support and avoids local pressure damage to the bus cylinder (such as deformation of the flange sealing surface of the bus cylinder) caused by platform inclination.

[0026] Subsequently, the telescopic joint is axially compressed in the first direction to form a gap, providing sufficient space for the bus cylinder to be disassembled and avoided. The radial displacement is continuously monitored during the compression process, and it is converted into a safety index. The smaller the safety index, the better the structural stability; on the contrary, the larger the safety index, the worse the structural stability. When the safety index is greater than the safety threshold, the disassembly and assembly are immediately stopped and an alarm is given. Calculating the safety index can identify risks such as deformation and jamming caused by improper stress in advance; real-time monitoring of radial displacement and safety index quantification can identify the risk of radial deformation during telescopic joint compression in advance; the triggering of the alarm mechanism can terminate the dangerous operation in time to avoid the expansion of the fault (such as telescopic joint damage leading to bus cylinder falling), and improve the risk controllability of the disassembly and assembly process.

[0027] On the basis of the above embodiment, it also includes: obtaining the initial length and the maximum allowed compression length of the telescopic joint; before axially compressing the telescopic joint, measuring the actual length of the telescopic joint, calculating the compressed length of the telescopic joint based on the initial length and the actual length, calculating the remaining compressible length based on the maximum allowed compression length and the compressed length; if the remaining compressible length is greater than the disassembly and assembly avoidance gap, then axially compressing the telescopic joint is performed.

[0028] In a specific application scenario, the expansion joint nameplate contains the working pressure, compensation range and maximum allowable compression length. First, the initial length of the expansion joint is obtained, which is the nominal length of the expansion joint under no stress condition. The maximum allowable compression length is the limit compression value determined by product design or material characteristics. The expansion joint nameplate contains the maximum allowable compression length. Before actual operation, the actual length of the expansion joint at this moment is obtained through displacement sensors or laser range finders and other measurement means to reflect the current expansion state. Because the expansion joint itself absorbs the thermal expansion and contraction of the busbar cylinder caused by temperature changes, vibration or installation errors, prevents the busbar cylinder from breaking or leaking due to excessive stress, and the compressed length indicates the deformation tolerance consumed by the expansion joint. Based on the maximum allowable compression length and the compressed length, the remaining compressible length is calculated, and the remaining compressible length = maximum allowable compression length - compressed length. The greater the remaining amount, the lower the risk of the structure. Compare the remaining compressible length with the required disassembly clearance. If the remaining compressible length is greater than or equal to the disassembly clearance, the axial compression operation is allowed; if not, it is refused to execute, prompting the adjustment scheme or taking the standby disassembly path to prevent the expansion joint from exceeding the design compression limit and causing damage. Preventing structural damage, avoiding permanent deformation, seal failure or material fatigue cracks caused by excessive compression of the expansion joint, ensuring that the expansion joint always operates within the design allowable strain range; improving disassembly safety, obtaining clear feasibility before compression operation, reducing the probability of accidents; preventing equipment jamming and part breakage caused by misoperation.

[0029] In one embodiment of the present application, the expansion joint of the faulty busbar cylinder is axially compressed, including: obtaining the force-displacement curve of the expansion joint; calculating the target displacement based on the disassembly clearance and the compressed length; obtaining the dynamic pressure by combining the target displacement and the force-displacement curve; and driving the servo motor to axially compress the expansion joint according to the dynamic pressure.

[0030] In a specific application scenario, the force-displacement relationship is established, the force of the telescopic joint under different compression amounts is tested in advance, the force-displacement curve reflecting the elastic properties of the telescopic joint is obtained, the horizontal coordinate of the curve is displacement, the vertical coordinate is reaction force, the target displacement is calculated, and two factors need to be considered during actual assembly: a) disassembly clearance → space left for facilitating insertion or disassembly of parts; b) compressed length → deformation amount of the telescopic joint in the pre-assembly state, target displacement = compressed length + displacement amount required to compensate for the installation gap; according to the force-displacement curve, the vertical coordinate value corresponding to the horizontal coordinate of the target displacement is found, which is the dynamic pressure required by the telescopic joint under the deformation amount, and the dynamic pressure changes with the target displacement, which can accurately reflect the stress state of the telescopic joint during installation. The force-displacement curve and the real-time calculated dynamic pressure make the compression process controllable, avoid damage caused by excessive compression, and prevent sealing failure caused by insufficient compression. The servo motor is controlled by the calculation model, and manual judgment of force is not required, which greatly reduces the dependence on manual experience and operation risk. The service life of the telescopic joint is prolonged, the compression ratio of the telescopic joint is reasonably controlled, stress concentration and material fatigue are reduced, and the operation reliability and service life are improved.

[0031] In one embodiment of the present application, the servo motor is driven according to the dynamic pressure to axially compress the telescopic joint, including: monitoring the actual pressure output by the servo motor in real time; calculating the deviation value between the dynamic pressure and the actual pressure; inputting the deviation value into the PID control algorithm to calculate the adjustment amount of the output force of the servo motor, and outputting the adjustment amount of the output force of the servo motor to the servo motor.

[0032] In a specific application scenario, the force sensor installed on the servo motor actuator (such as an electric cylinder) continuously collects and feeds back the actual output pressure to the controller, forming the feedback link of the digital disassembly platform. The calculation unit of the controller compares the target dynamic pressure calculated from the compression displacement with the actual pressure monitored in real time, calculates the real-time pressure deviation value, and the deviation value reflects the gap between the current output force and the expected value. The deviation value is sent as input into the PID (proportional-integral-derivative) control algorithm. The PID controller will comprehensively consider the current deviation (proportion P), the accumulation of historical deviation (integral I), and the trend of deviation (derivative D), and perform high-speed and complex calculations to finally calculate the precise output force adjustment required to eliminate the deviation. The calculated adjustment is output to the servo motor driver in the form of a control signal (such as voltage or pulse command); the driver drives the servo motor to accurately increase or decrease the output force by the corresponding amount, thereby achieving constant force or precise pressure according to the predetermined curve on the telescopic joint. This process is repeated continuously, forming a dynamic and continuous closed-loop control loop. Using the PID closed-loop control algorithm, the system can respond immediately to small deviations in pressure and make compensations, overcoming the problem of inaccurate pressure control caused by factors such as internal friction, oil temperature changes, and voltage fluctuations in open-loop control or manual operation. This ensures the accuracy of the compression displacement, and the differential (D) element in the PID algorithm can predict the trend of the deviation and suppress overshoot or oscillation of the pressure in advance; the integral (I) element can eliminate static errors. This makes the entire compression process extremely smooth and smooth, avoiding the impact or damage to precision components (such as telescopic bellows) caused by sudden changes or fluctuations in pressure, greatly improving the reliability of the operation and the safety of the equipment; and achieving automatic pressure control without the need for manual intervention and experience-based adjustments.

[0033] In one embodiment of the present application, a safety index is calculated based on the radial offset, including: obtaining the radial offset of the busbar cylinder, calculating the safety index based on the radial offset: ,

[0034] wherein, represents the safety index, represents the measured radial offset of the jth sampling; represents the ideal radial offset of the jth sampling; m represents the total number of sampling points; represents the preset radial offset value.

[0035] In a specific application scenario, the radial offset refers to the offset distance of a specific monitoring point of the busbar cylinder relative to a theoretical center axis in a radial plane (i.e., a plane perpendicular to the axis) during the disassembly process of the busbar cylinder; the theoretical center axis is a reference line calculated and defined as a straight line connecting the centers of the flanges at both ends of the busbar cylinder in an ideal centering and unstressed state, and the specific monitoring point is selected at the position where the deformation is expected to be the largest; during the axial compression of the expansion joint, a high-precision displacement sensor (such as a laser range finder or a machine vision system) is used to sample at a fixed frequency to continuously obtain a series of discrete data points of the actual radial offset, and the ideal radial offset represents the radial offset of a well-installed and centered busbar cylinder without internal interference when it is purely axially compressed in an ideal state. The radial offset monitoring and safety index determination can real-time intercept the problem of excessive radial skew of the expansion joint, avoid yield deformation of the expansion joint, and prevent damage to the busbar cylinder caused by uncontrolled compression. The core of the formula is to calculate the root mean square error between the actual sequence and the ideal sequence, and the difference The deviation of the actual value and the ideal value at each sampling point is calculated, all deviations are squared (to eliminate the positive and negative signs and amplify abnormal errors), summed and averaged to obtain the mean square error (MSE), and the safety index calculated directly reflects the instability and abnormality of the radial offset during the entire compression process. The smaller the value of ε, the more stable the compression process, the closer to the ideal state, and the lower the risk. The larger the value of ε, the more obvious the radial movement, the more obvious the jamming or interference, and the more likely the alarm is triggered. The evaluation dimension is more comprehensive, from static value to dynamic process: compared with the traditional method of only monitoring the instantaneous offset or the final offset at a certain moment, this scheme evaluates the entire behavior during the compression process. Even if the final offset is not large, but the severe jitter or trend deviation during the process will also be effectively captured, greatly improving the accuracy and early warning ability of risk identification. The anti-interference ability is strong, and the false alarm rate is low: since the root mean square calculation and sequence comparison are used, this algorithm is not sensitive to the instantaneous false alarm or noise signal of a single sensor (because individual abnormal points will be averaged out), but it is very sensitive to persistent and real abnormal patterns. This effectively filters accidental interference, reduces the false alarm probability of the system, and improves the reliability.

[0036] In an embodiment of the present application, the equalization degree data is obtained based on real-time bearing data, the equalization degree data and the preset equalization degree threshold value are compared, and whether the support state of the replacement support device is safe is determined according to the comparison result, including: obtaining the maximum bearing value and the minimum bearing value in the real-time bearing data, the equalization degree data is the difference between the maximum bearing value and the minimum bearing value; if the equalization degree data is less than the preset equalization degree threshold value, it is determined that the support state of the replacement support device is safe; otherwise, it is determined that the support state of the replacement support device is unsafe.

[0037] Embodiment two, the embodiment of the application provides a kind of digital disassembly and assembly platform control system based on PLC, refer to Figure 3 As shown in the figure, the system includes: judging whether the replacement support device is stable module, obtains the real-time bearing data of the plurality of support points of the fault bus cylinder replacement support device, obtains the balance degree data based on the real-time bearing data, compares the balance degree data and balance degree threshold, and judges whether the support state of the replacement support device is safe according to the comparison result, if safe, then call the horizontal calibration module;Horizontal calibration module, for horizontal calibration of digital disassembly and assembly platform, the digital disassembly and assembly platform after horizontal calibration standard supports the fault bus cylinder, calls the compression telescopic joint module;Compression telescopic joint module, for axial compression of the telescopic joint of the fault bus cylinder along the first direction to obtain disassembly avoidance gap, and obtains the compression displacement of the telescopic joint;According to the compression displacement, calculate dynamic pressure, compress the telescopic joint according to the dynamic pressure until the compression displacement reaches the target displacement;Axial movement module, for driving the digital disassembly and assembly platform carrying the fault bus cylinder to move a first distance in the opposite direction of the first direction to the disassembly avoidance gap, so that the fault bus cylinder is separated from the whole machine;Wherein, the first distance is half of the target displacement;Radial movement module, for driving the digital disassembly and assembly platform to move along the radial direction of the fault bus cylinder, and the fault bus cylinder after being separated from the whole machine is lifted off by hammock.

[0038] In specific application scenarios, through real-time bearing collection and balance degree calculation of multiple support points, it is avoided that the support device is deformed due to overload of a single support point (such as the bearing of a certain support point far exceeds that of other points), or the bus cylinder is inclined due to uneven support, thus ensuring the structural safety of the disassembly process from the source;Precise horizontal calibration of digital disassembly and assembly platform ensures that the bus cylinder is supported evenly, and avoids that the bus cylinder is locally pressed and damaged (such as deformation of the flange sealing surface of the bus cylinder) due to inclination of the platform;Dynamic pressure calculation based on stiffness coefficient realizes precise control of telescopic joint compression force, avoids damage of telescopic joint sealing element (such as rupture of rubber sealing ring) due to excessive compression, or insufficient compression leading to insufficient avoidance gap (unable to separate from the whole machine);Target displacement setting combined with real-time monitoring ensures that the avoidance gap meets the disassembly requirement, and improves the precision of telescopic joint compression operation;Real-time monitoring of radial offset and safety index quantification identifies the risk of radial deformation in the telescopic joint compression process in advance;The triggering of alarm mechanism can terminate the dangerous operation in time, avoid the expansion of fault (such as telescopic joint damage leading to bus cylinder falling), and improve the risk controllability of disassembly process.

[0039] In one embodiment of the present invention, a PLC-based digital disassembly and assembly platform control system includes a compression expansion joint module comprising: an initial length acquisition module for acquiring the initial length and maximum allowable compression length of the expansion joint; an actual length measurement module for measuring the actual length of the expansion joint before axial compression; a remaining compressible length calculation module for calculating the already compressed length of the expansion joint based on the initial length and actual length, and calculating the remaining compressible length based on the maximum allowable compression length and the already compressed length; and a compression execution module for performing axial compression on the expansion joint if the remaining compressible length is greater than the disassembly and assembly clearance.

[0040] In specific application scenarios, if the remaining compressible length is greater than or equal to the disassembly and assembly clearance, axial compression operation is permitted; if it is insufficient, the operation is rejected, prompting for adjustment or an alternative disassembly and assembly path to prevent damage caused by the expansion joint exceeding its design compression limit. This prevents structural damage, avoiding permanent deformation, seal failure, or material fatigue cracks in the expansion joint due to over-compression, ensuring that the expansion joint always operates within the design-allowed strain range; it improves disassembly and assembly safety by obtaining a clear feasibility assessment before compression operation, reducing the probability of accidents; and it prevents equipment jamming and component breakage due to misoperation.

[0041] In one embodiment of the present invention, the compression execution module includes: a curve acquisition module for acquiring the force-displacement curve of the expansion joint; a dynamic pressure acquisition module for calculating the target displacement based on the disassembly and assembly clearance and the compressed length, and obtaining the dynamic pressure by combining the target displacement and the force-displacement curve; and a compression drive module for driving a servo motor to axially compress the expansion joint according to the dynamic pressure.

[0042] In specific applications, the force-displacement curve and real-time calculated dynamic pressure ensure precise control of the compression process, preventing damage from over-compression and sealing failure from under-compression. The servo motor is controlled by the computational model, eliminating the need for manual force assessment and significantly reducing reliance on human experience and operational risks. This extends the lifespan of the expansion joint, allows for reasonable control of the compression ratio, reduces stress concentration and material fatigue, and improves operational reliability and service life.

[0043] The PLC-based digital disassembly and assembly platform control system described in this embodiment of the invention is used to implement the PLC-based digital disassembly and assembly platform control method in Embodiment 1 above. Both are based on the same inventive concept and have the same technical effects, which will not be repeated here.

[0044] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0045] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0046] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0047] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0048] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A PLC-based digital disassembly and assembly platform control method, characterized in that, The method includes: Step 1: Obtain real-time load data of multiple support points of the replacement support device for the faulty busbar drum, obtain balance data based on the real-time load data, compare the balance data with the balance threshold, and determine whether the support status of the replacement support device is safe based on the comparison result. If it is safe, proceed to Step 2. Step 2: Perform a leveling calibration on the digital disassembly and assembly platform. Once the leveling calibration is passed, the digital disassembly and assembly platform supports the faulty busbar. Proceed to Step 3. Step 3: Axially compress the expansion joint of the faulty busbar along the first direction to obtain a disassembly and assembly clearance, and obtain the compression displacement of the expansion joint; calculate the dynamic pressure based on the compression displacement, and compress the expansion joint according to the dynamic pressure until the compression displacement reaches the target displacement; Step 4: Drive the digital disassembly and assembly platform carrying the faulty busbar to move a first distance in the opposite direction of the first direction toward the disassembly and assembly clearance gap, so that the faulty busbar is detached from the whole machine; wherein, the first distance is half of the target displacement; Step 5: Drive the digital disassembly and assembly platform to move along the radial direction of the faulty busbar drum, and use a hammock to lift the faulty busbar drum away from the whole machine.

2. The PLC-based digital disassembly and assembly platform control method according to claim 1, characterized in that, Also includes: Obtain the initial length and maximum allowable compression length of the expansion joint; Before axially compressing the expansion joint, measure the actual length of the expansion joint; The compressed length of the expansion joint is calculated based on the initial length and the actual length, and the remaining compressible length is calculated based on the maximum allowable compressed length and the compressed length. If the remaining compressible length is greater than the disassembly clearance, then axial compression of the expansion joint is performed.

3. The PLC-based digital disassembly and assembly platform control method according to claim 2, characterized in that, Axial compression of the expansion joint of the faulty busbar includes: Obtain the force-displacement curve of the expansion joint; The target displacement is calculated based on the disassembly clearance and the compressed length, and the dynamic pressure is obtained by combining the target displacement and the force-displacement curve. The expansion joint is axially compressed by a servo motor driven by the dynamic pressure.

4. The PLC-based digital disassembly and assembly platform control method according to claim 3, characterized in that, The axial compression of the telescopic joint is driven by the dynamic pressure-driven servo motor, including: Real-time monitoring of the actual pressure output by the servo motor; Calculate the deviation between the dynamic pressure and the actual pressure; The deviation value is input into the PID control algorithm to calculate the adjustment amount of the output force of the servo motor, and the adjustment amount of the output force is output to the servo motor.

5. The PLC-based digital disassembly and assembly platform control method according to claim 1, characterized in that, Also includes: During the compression of the expansion joint, the radial offset of the expansion joint during the compression process is obtained, and a safety index is calculated based on the radial offset. If the safety index is less than a preset safety threshold, step four is executed; otherwise, an alarm is triggered.

6. The PLC-based digital disassembly and assembly platform control method according to claim 5, characterized in that, The safety index is calculated based on the radial offset in the following manner: ， in, Indicates the safety index. This represents the measured radial offset during the j-th sampling. This represents the ideal radial offset for the j-th sample; m represents the total number of sampling points. This indicates the preset radial offset value.

7. A PLC-based digital disassembly and assembly platform control method according to claim 1, comprising: acquiring balance data based on real-time load data, comparing the balance data with a preset balance threshold, and determining whether the support status of the replacement support device is safe based on the comparison result, including: Obtain the maximum and minimum load-bearing values ​​from the real-time load-bearing data, whereby the balance data is the difference between the maximum and minimum load-bearing values. If the balance data is less than the preset balance threshold, the support status of the replacement support device is determined to be safe. Otherwise, the support status of the replacement support device is deemed unsafe.

8. A PLC-based digital disassembly and assembly platform control system, characterized in that, The system includes: The module for determining whether the replacement support device is stable is used to obtain real-time load data of multiple support points of the replacement support device for the faulty busbar drum, obtain balance data based on the real-time load data, compare the balance data with the balance threshold, and determine whether the support status of the replacement support device is safe based on the comparison result. If it is safe, the horizontal calibration module is called. The horizontal calibration module is used to calibrate the level of the digital disassembly and assembly platform. After the level calibration is passed, the digital disassembly and assembly platform supports the faulty busbar drum and calls the compression expansion joint module. The compression expansion joint module is used to axially compress the expansion joint of the faulty busbar cylinder along a first direction to obtain a disassembly and assembly clearance, and to obtain the compression displacement of the expansion joint; calculate the dynamic pressure based on the compression displacement, and compress the expansion joint according to the dynamic pressure until the compression displacement reaches the target displacement; An axial movement module is used to drive the digital disassembly and assembly platform carrying the faulty busbar to move a first distance in the opposite direction of the first direction toward the disassembly and assembly clearance gap, so that the faulty busbar is detached from the whole machine; wherein, the first distance is half of the target displacement; The radial movement module is used to drive the digital disassembly and assembly platform to move along the radial direction of the faulty busbar drum, and to lift the faulty busbar drum away from the whole machine by a hammock.

9. A PLC-based digital disassembly and assembly platform control system according to claim 8, characterized in that, The compression expansion joint module includes: An initial length acquisition module is used to acquire the initial length and maximum allowable compression length of the expansion joint; The module for measuring the actual length of the expansion joint is used to measure the actual length of the expansion joint before axial compression. The module for calculating the remaining compressible length calculates the compressed length of the expansion joint based on the initial length and the actual length, and calculates the remaining compressible length based on the maximum allowable compressible length and the compressed length; The compression module is used to perform axial compression on the expansion joint if the remaining compressible length is greater than the disassembly and assembly clearance.

10. A PLC-based digital disassembly and assembly platform control system according to claim 9, characterized in that, The compression execution module includes: The curve acquisition module is used to acquire the force-displacement curve of the expansion joint; The dynamic pressure module is used to calculate the target displacement based on the disassembly and assembly clearance and the compressed length, and the dynamic pressure is obtained by combining the target displacement and the force-displacement curve. A drive compression module is used to drive a servo motor to axially compress the expansion joint according to the dynamic pressure.

Images