A PLC-based digital disassembly platform control method and system

Abstract

The application relates to the technical field of busbar cylinder dismounting, and discloses a PLC-based digital dismounting platform control method and system, wherein the method comprises the following steps: acquiring real-time bearing data of a plurality of support points of a replacement support device of a fault busbar cylinder, determining whether the support state of the replacement support device is safe, if yes, calibrating the levelness of a digital dismounting platform, supporting the fault busbar cylinder through the digital dismounting platform which meets the levelness calibration standard, then axially compressing the expansion joint of the fault busbar cylinder in a first direction to obtain a dismounting avoidance gap, and acquiring the compression displacement of the expansion joint; calculating a 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. Through the method and the corresponding system, the redundant process of removing adjacent units in the process of dismounting the fault busbar cylinder is avoided, and the efficiency and safety of repairing the fault busbar cylinder are improved.

Description

Technical Field

[0001] This invention relates to the field of busbar assembly and disassembly technology, and in particular to a PLC-based digital assembly and disassembly platform control method and system. Background Technology

[0002] In GIS busbars with phase-separated vertical stacking and GIS busbars with double busbars arranged vertically on the upper layer, when a fault occurs in the middle or lower busbar (such as insulator leakage or internal discharge), the conventional emergency repair method is to recover the SF6 gas from the faulty busbar drum, adjacent units, and the upper interfering units, and then use a crane to dismantle the interfering units that affect the hoisting of the faulty busbar drum one by one. After the problem is resolved, the busbars are reinstalled in sequence. The overall operation is difficult, involves many procedures, and is time-consuming, which can easily cause equipment incidents of level six or above.

[0003] To solve the above-mentioned operational problems, a digital disassembly and assembly platform is installed, and the faulty busbar cylinder is moved along the busbar axis and radial direction by controlling the digital disassembly and assembly platform. This eliminates the need to retrieve adjacent units. The process of controlling the digital disassembly and assembly platform to disassemble and assemble the busbar cylinder requires compressing the expansion joint to release disassembly space.

[0004] However, under normal operating conditions, the expansion joint is already in a pre-compressed position due to temperature changes. If the remaining compressible length is less than the space required for disassembly, it means that continued compression may cause it to exceed the maximum allowable working stroke, resulting in seal damage. Excessive compression may cause permanent deformation or crushing of internal sealing elements (such as rubber rings and graphite rings), leading to leakage in the busbar drum and generating huge additional stress on the connected busbar drum body and insulators, which may lead to equipment cracking. Summary of the Invention

[0005] Therefore, the purpose of this invention is to overcome the redundancy problem caused by the need to remove adjacent units and upper interfering units during the disassembly and assembly of faulty busbars in the prior art. It provides a PLC-based digital disassembly and assembly platform control method and system. By installing a digital disassembly and assembly platform and controlling its axial-radial movement, as well as controlling the compression force of the expansion joint while monitoring the radial offset of the expansion joint, the redundant process of removing adjacent units is avoided, and the expansion joint is safely and accurately compressed, thereby improving the efficiency and safety of emergency repairs.

[0006] Firstly, to solve the above-mentioned technical problems, the present invention provides a PLC-based digital disassembly and assembly platform control method, the method comprising: Step 1: acquiring real-time load-bearing data of multiple support points of the replacement support device for the faulty busbar drum, acquiring balance data based on the real-time load-bearing data, comparing the balance data with a balance threshold, and determining whether the support status of the replacement support device is safe based on the comparison result; if safe, proceeding to Step 2; Step 2: performing leveling calibration on the digital disassembly and assembly platform, and supporting the faulty busbar drum through the leveling calibration of the digital disassembly and assembly platform, proceeding to Step 3; Step 3: axially pressing along the first direction. Step 4: The expansion joint of the faulty busbar drum is compressed to obtain a disassembly and assembly clearance, and the compression displacement of the expansion joint is obtained; the dynamic pressure is calculated based on the compression displacement, and the expansion joint is compressed according to the dynamic pressure until the compression displacement reaches the target displacement; Step 5: The digital disassembly and assembly platform carrying the faulty busbar drum is driven to move a first distance in the opposite direction of the first direction toward the disassembly and assembly clearance, so that the faulty busbar drum is detached from the whole machine; wherein, the first distance is half of the target displacement; Step 6: The digital disassembly and assembly platform is driven to move in the radial direction of the faulty busbar drum, and the faulty busbar drum after being detached from the whole machine is lifted away by a hammock.

[0007] Preferably, the method further includes: obtaining the initial length and maximum allowable compression length of the expansion joint; measuring the actual length of the expansion joint before axially compressing it; 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; if the remaining compressible length is greater than the disassembly clearance, then axially compressing the expansion joint is performed.

[0008] Preferably, axial compression of the expansion joint of the faulty busbar includes: obtaining the force-displacement curve of the expansion joint; calculating the target displacement based on the disassembly clearance and the compressed length, and obtaining the dynamic pressure by combining the target displacement and the force-displacement curve; and driving a 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 includes: real-time monitoring of the actual pressure output by the servo motor; calculating the deviation value between the dynamic pressure and the actual pressure; inputting the deviation value into a 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 to the servo motor.

[0010] Preferably, 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.

[0011] Preferably, the safety index is calculated based on the radial offset in the following manner:

[0012] ,

[0013] 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.

[0014] Preferably, the method involves obtaining balance data based on real-time load-bearing 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. This includes: obtaining the maximum and minimum load-bearing values ​​from the real-time load-bearing data, where 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, then the support status of the replacement support device is determined to be safe; otherwise, the support status of the replacement support device is determined to be unsafe.

[0015] Secondly, to solve the above-mentioned technical problems, this invention also proposes a PLC-based digital disassembly and assembly platform control system. The system includes: a module for determining whether a replacement support device is stable, used to acquire real-time load-bearing data of multiple support points of the replacement support device for the faulty busbar, acquire balance data based on the real-time load-bearing data, compare the balance data with a balance threshold, and determine whether the support status of the replacement support device is safe based on the comparison result. If safe, a level calibration module is invoked; a level calibration module is used to perform level calibration on the digital disassembly and assembly platform. After the level calibration is passed, the digital disassembly and assembly platform supports the faulty busbar, and a compression expansion joint module is invoked; the compression expansion joint module... The system includes a digital disassembly and assembly platform for axially compressing the expansion joint of the faulty busbar along a first direction to obtain a disassembly and assembly clearance, and for obtaining the compression displacement of the expansion joint; calculating dynamic pressure based on the compression displacement, and compressing the expansion joint according to the dynamic pressure until the compression displacement reaches a target displacement; an axial movement module for driving the digital disassembly and assembly platform carrying the faulty busbar along the opposite direction of the first direction to move a first distance toward the disassembly and assembly clearance, so that the faulty busbar is detached from the whole machine; wherein, the first distance is half of the target displacement; and a radial movement module for driving the digital disassembly and assembly platform to move along the radial direction of the faulty busbar, and lifting the faulty busbar after it has been detached from the whole machine by a hammock.

[0016] Preferably, the compression expansion joint module includes: 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.

[0017] Preferably, 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 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. The above technical solution of the present invention has the following advantages compared with the prior art:

[0018] The present invention discloses a PLC-based digital disassembly and assembly platform control method. By installing a digital disassembly and assembly platform and controlling its axial-radial movement, as well as controlling the compression force of the expansion joint and monitoring the radial offset of the expansion joint, redundant procedures for disassembling adjacent units are avoided, and safe and precise compression of the expansion joint is achieved, thereby improving emergency repair efficiency and safety.

[0019] Among them, by judging the balance of the support, the fall and deformation of the busbar drum caused by the imbalance of the temporary support were avoided. Although the original fixed support can achieve balanced load bearing, it will directly block the horizontal radial translation path of the faulty busbar drum and become an obstacle to disassembly. Therefore, it is necessary to replace it with a temporary support first to make room for disassembly.

[0020] By calibrating the levelness of the digital assembly / disassembly platform, the risk of basic deviations in subsequent compression and movement was eliminated.

[0021] By precisely controlling the force during the compression process of the busbar expansion joint, permanent deformation caused by excessive compression of the expansion joint can be avoided.

[0022] By controlling the axial movement of the digital disassembly and assembly platform carrying the faulty busbar, a disassembly and assembly clearance is formed to avoid scraping or colliding with adjacent units due to improper position control during the disassembly and assembly of the faulty busbar, which could cause damage to adjacent units.

[0023] Next, the digital dismantling platform carrying the faulty busbar is moved radially so that the crane can lift the faulty busbar away. Attached Figure Description

[0024] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings, wherein...

[0025] Figure 1 This is a flowchart of a PLC-based digital disassembly and assembly platform control method in a preferred embodiment of the present invention;

[0026] Figure 2 This is a schematic diagram of the process of disassembling a faulty busbar cylinder using a PLC-based digital disassembly and assembly platform in a preferred embodiment of the present invention.

[0027] Figure 3 This is a system block diagram of a PLC-based digital disassembly and assembly platform control system according to a preferred embodiment of the present invention. Detailed Implementation

[0028] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments described are not intended to limit the present invention.

[0029] It should be noted that for 500kV GIS busbars with a "phase-separated vertical stacked arrangement" structure and 220kV GIS busbars with a "double busbars arranged vertically on the upper layer" structure, if a fault occurs in the middle or lower layer busbars (such as insulator leakage or internal discharge), the conventional emergency repair method is to recover the SF6 gas from the faulty unit, adjacent units, and the upper interfering units, and then use a crane to remove the interfering units that affect the hoisting of the faulty unit one by one. After the problem is resolved, the units are reinstalled in sequence. The overall operation is difficult, involves many procedures, and is time-consuming, which can easily cause equipment incidents of level 6 or above.

[0030] The solution of this invention is to install a digital disassembly and assembly platform under the faulty busbar of the GIS busbar with a "phase-separated vertical stacked arrangement" structure. The digital disassembly and assembly platform supports the faulty busbar and controls the axial and radial movement of the digital disassembly and assembly platform to drive the faulty busbar to move, without having to remove the interfering busbar above the faulty busbar.

[0031] Example 1: Refer to Figure 1As shown, this embodiment of the invention provides a PLC-based digital disassembly and assembly platform control method, including: Step 1: Acquiring real-time load-bearing data of multiple support points of a replacement support device for a faulty busbar drum; acquiring balance data based on the real-time load-bearing data; comparing the balance data with a balance threshold; and determining whether the support status of the replacement support device is safe based on the comparison result. If safe, proceed to Step 2; Step 2: Performing leveling calibration on the digital disassembly and assembly platform; after the leveling calibration is passed, the digital disassembly and assembly platform supports the faulty busbar drum; proceed to Step 3; Step 3: Axially compressing the faulty busbar drum along a first direction. The expansion joint of the cylinder is used to obtain a disassembly and assembly clearance, and the compression displacement of the expansion joint is obtained; the dynamic pressure is calculated based on the compression displacement, and the expansion joint is compressed 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 cylinder to move a first distance in the opposite direction of the first direction toward the disassembly and assembly clearance, so that the faulty busbar cylinder 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 cylinder, and lift the faulty busbar cylinder after it is detached from the whole machine by a hammock.

[0032] Figure 2 The diagram shows the process of disassembling a faulty busbar using a PLC-based digital disassembly and assembly platform. Step (1) involves removing the fixed support and installing a temporary support; step (2) involves installing the temporary support and then installing the digital disassembly and assembly platform; step (3) involves compressing the expansion joint to release the disassembly space; step (4) involves the digital disassembly and assembly platform moving axially to separate the faulty busbar; and step (5) involves the digital disassembly and assembly platform moving radially to lift the faulty busbar.

[0033] In specific application scenarios, pressure sensors are installed at each support point of the replacement support device. The sensors communicate with the PLC via data lines to collect the load-bearing data of each support point in real time (sampling frequency 10Hz), and the balance is calculated based on the following method:

[0034] Balance = (Maximum load-bearing capacity of each support point - Minimum load-bearing capacity of each support point) / Average load-bearing capacity of each support point.

[0035] The calculated balance is compared with a threshold to determine the safety of the support status. If the balance exceeds the threshold, the height of each support point is adjusted until the balance is less than the threshold. By collecting the load on multiple support points in real time and calculating the balance, the deformation of the support device due to overload of a single support point (such as the load on a support point being much greater than that on other points) or the tilting of the busbar due to uneven support is avoided, thus ensuring the structural safety of the disassembly and assembly process from the source.

[0036] The digital assembly / disassembly platform is equipped with two orthogonally arranged electronic levels (measuring range ±0.5°, accuracy 0.001°). These levels provide real-time feedback on the platform's levelness until calibration is achieved. This ensures uniform force distribution when the platform supports the busbar drum, preventing additional stress caused by tilting. The levelness accuracy of the digital assembly / disassembly platform directly affects the accuracy of subsequent expansion joint compression direction and displacement control. Precise levelness calibration of the digital assembly / disassembly platform ensures uniform force distribution when supporting the busbar drum, preventing localized pressure damage to the busbar drum caused by platform tilting (such as deformation of the busbar drum's flange sealing surface).

[0037] Subsequently, the expansion joint is axially compressed along the first direction to create a gap, providing sufficient space for disassembly and clearance of the busbar drum. During compression, radial offset is continuously monitored and converted into a safety index. A smaller safety index indicates better structural stability; conversely, a larger safety index indicates poorer structural stability. Disassembly and assembly are immediately stopped and an alarm is triggered when the safety index exceeds a safety threshold. Calculating the safety index allows for early detection of risks such as deformation and jamming due to improper stress. Real-time monitoring of radial offset and quantification of the safety index identify radial deformation risks during expansion joint compression. The alarm mechanism promptly terminates dangerous operations, preventing escalation of faults (such as expansion joint damage leading to busbar drum collapse), and improving the controllability of risks during disassembly and assembly.

[0038] Based on the above embodiments, the method further includes: obtaining the initial length and maximum allowable compression length of the expansion joint; before axially compressing the expansion joint, measuring the actual length of the expansion joint, calculating the already 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 already compressed length; if the remaining compressible length is greater than the disassembly and assembly clearance, then axially compressing the expansion joint is performed.

[0039] In specific application scenarios, the nameplate of the expansion joint includes the working pressure, compensation range, and maximum allowable compression length. First, the initial length of the expansion joint is obtained; this initial length is the nominal length of the expansion joint under no-stress conditions. The maximum allowable compression length is the ultimate compression value determined by product design or material properties. The nameplate of the expansion joint includes the maximum allowable compression length. Before actual operation, the actual length of the expansion joint at this moment is obtained using measurement methods such as displacement sensors or laser rangefinders to reflect its current expansion and contraction state. This is because the expansion joint itself absorbs the thermal expansion and contraction of the busbar caused by temperature changes, vibration, or installation errors, preventing the busbar from cracking or leaking due to excessive stress. The compressed length indicates the deformation tolerance that the expansion joint has already consumed. Based on the maximum allowable compression length and the compressed length, the remaining compressible length is calculated: Remaining compressible length = Maximum allowable compression length - Compressed length. The larger the margin, the lower the structural risk. The remaining compressible length is compared with the required disassembly / assembly clearance. If the remaining compressible length is greater than or equal to the disassembly / assembly clearance, axial compression is permitted. If it is insufficient, the operation is rejected, and an adjustment plan or alternative disassembly / assembly path is suggested 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 caused by over-compression of the expansion joint, ensuring that the expansion joint always operates within the design-allowed strain range; it improves disassembly / 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.

[0040] In one embodiment of the present invention, axial compression of the expansion joint of the faulty busbar includes: obtaining the force-displacement curve of the expansion joint; calculating the target displacement based on the disassembly clearance and the compressed length, and obtaining the dynamic pressure by combining the target displacement and the force-displacement curve; and driving a servo motor to axially compress the expansion joint according to the dynamic pressure.

[0041] In specific application scenarios, a force-displacement relationship is established. The force on the expansion joint under different compression levels is tested beforehand to obtain a force-displacement curve reflecting the elastic characteristics of the expansion joint. The horizontal axis of the curve represents displacement, and the vertical axis represents reaction force. Target displacement calculation requires consideration of two factors during actual assembly: a) disassembly clearance – space left for easy insertion or removal of components; b) compressed length – the deformation already generated by the expansion joint in its pre-assembled state. Target displacement = compressed length + displacement required to compensate for installation clearance. Based on the force-displacement curve, the vertical axis value is found on the horizontal axis corresponding to the target displacement. This value represents the dynamic pressure that needs to be applied to the expansion joint at that deformation level. This dynamic pressure changes with the target displacement, accurately reflecting the stress state of the expansion joint during installation. The force-displacement curve and the real-time calculated dynamic pressure ensure precise control of the compression process, avoiding damage caused by over-compression and preventing seal failure due to insufficient compression. The servo motor is controlled by the calculation model, eliminating the need for manual judgment of force magnitude, significantly reducing reliance on manual experience and operational risks. Extend the life of expansion joints by rationally controlling the compression ratio of expansion joints, reducing stress concentration and material fatigue, and improving operational reliability and service life.

[0042] In one embodiment of the present invention, the servo motor is driven to axially compress the expansion joint according to the dynamic pressure, comprising: real-time monitoring of the actual pressure output by the servo motor; calculating the deviation value between the dynamic pressure and the actual pressure; inputting the deviation value into a 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 to the servo motor.

[0043] In specific application scenarios, force sensors installed on servo motor actuators (such as electric cylinders) continuously collect and feed back the actual output pressure to the controller, forming the feedback loop of the digital disassembly and assembly platform. The controller's calculation unit compares the target dynamic pressure calculated from the compression displacement with the real-time monitored actual pressure to calculate the real-time pressure deviation value. This deviation value reflects the difference between the current output force and the expected value. This deviation value is fed as input into the PID (Proportional-Integral-Derivative) control algorithm. The PID controller integrates three factors: the current deviation (proportional P), the accumulation of historical deviations (integral I), and the trend of deviation changes (derivative D), performing high-speed and complex calculations to ultimately calculate the precise output force adjustment amount required to eliminate this deviation. The calculated adjustment amount 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 precisely increase or decrease its output force by the corresponding amount, thereby achieving constant force or precise pressure application according to a predetermined curve on the expansion joint. This process is continuous, forming a dynamic and continuous closed-loop control loop. Employing a PID closed-loop control algorithm, this system can react instantly to and compensate for minute pressure deviations, overcoming the inaccuracies in pressure control caused by factors such as system friction, oil temperature changes, and voltage fluctuations in open-loop control or manual operation. It achieves high-precision, adaptive adjustment of dynamic pressure, ensuring accurate compression displacement. The derivative (D) term in the PID algorithm anticipates the trend of deviation changes, suppressing pressure overshoot or oscillations in advance; the integral (I) term eliminates static errors. This makes the entire compression process extremely smooth and stable, avoiding impacts or damage to precision components (such as expansion joint bellows) caused by sudden pressure changes or vibrations, greatly improving operational reliability and equipment safety; and achieving automated pressure control without manual intervention or experience-based adjustments.

[0044] In one embodiment of the present invention, calculating a safety index based on the radial offset includes: obtaining the radial offset of the busbar drum, and calculating a safety index based on the radial offset.

[0045] ,

[0046] 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.

[0047] In specific application scenarios, radial offset refers to the deviation of a specific monitoring point from the theoretical center axis in the radial plane (i.e., the plane perpendicular to the axis) during the assembly and disassembly of the busbar. The theoretical center axis is the baseline for calculation, defined as a straight line connecting the centers of the flanges at both ends of the busbar when it is ideally aligned and unstressed. The specific monitoring point is selected at the location where the expected deformation is greatest. During the axial compression of the expansion joint, high-precision displacement sensors (such as laser rangefinders or machine vision systems) sample at a fixed frequency to continuously acquire a series of discrete data points of measured radial offset. The ideal radial offset represents the radial offset of a busbar that is installed, aligned, and without internal interference under ideal conditions during pure axial compression. By monitoring the radial offset and determining the safety index, the problem of excessive radial misalignment of the expansion joint is intercepted in real time, avoiding yielding deformation of the expansion joint and preventing damage to the busbar caused by uncontrolled compression. The core of the formula is to calculate the root mean square error between the measured sequence and the ideal sequence. The deviation between the measured value and the ideal value at each sampling point is calculated. All deviations are squared (to eliminate the influence of positive and negative signs and amplify abnormal errors), summed, and then averaged to obtain the mean square error (MSE). The calculated safety index directly reflects the instability and abnormality of radial offset during the entire compression process. The smaller the ε value, the smoother and closer the compression process is to the ideal state, and the lower the risk. The larger the ε value, the more obvious the radial runaway, jamming, or interference, triggering an alarm. The evaluation dimensions are more comprehensive, from static values ​​to dynamic processes: Compared with traditional methods that only monitor the instantaneous or final offset at a certain moment, this scheme evaluates all behaviors during the entire compression process. Even if the final offset is small, severe jitter or trend deviations occurring during the process will be effectively captured, greatly improving the accuracy of risk identification and early warning capabilities. It has strong anti-interference capabilities and a low false alarm rate: Due to the use of root mean square calculation and sequence alignment, this algorithm is not sensitive to instantaneous false alarms or noise signals from a single sensor (because individual abnormal points are averaged out), but it is very sensitive to persistent, genuine abnormal patterns. This effectively filters out accidental interference, reduces the probability of false alarms in the system, and improves reliability.

[0048] In one embodiment of the present invention, balance data is obtained based on real-time load-bearing data, the balance data is compared with a preset balance threshold, and the support status of the replacement support device is determined to be safe based on the comparison result. This includes: obtaining the maximum load-bearing value and the minimum load-bearing value in the real-time load-bearing data, wherein the balance data is the difference between the maximum load-bearing value and the minimum load-bearing value; 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 determined to be unsafe.

[0049] Example 2: This embodiment of the invention provides a PLC-based digital disassembly and assembly platform control system, referring to... Figure 3 As shown, the system includes: a module for determining whether the replacement support device is stable; acquiring real-time load-bearing data of multiple support points of the replacement support device for the faulty busbar drum; acquiring balance data based on the real-time load-bearing data; comparing the balance data with a balance threshold; and determining whether the support status of the replacement support device is safe based on the comparison result. If safe, a level calibration module is invoked. The level 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 a compression expansion joint module is invoked. The compression expansion joint module is used to axially compress the faulty busbar drum along a first direction. An expansion joint is used to obtain a disassembly and assembly clearance, and the compression displacement of the expansion joint is obtained; dynamic pressure is calculated based on the compression displacement, and the expansion joint is compressed 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, so that the faulty busbar is detached from the whole machine; wherein, the first distance is half of the target displacement; a radial movement module is used to drive the digital disassembly and assembly platform to move along the radial direction of the faulty busbar, and to lift the faulty busbar after it is detached from the whole machine by a hammock.

[0050] In specific application scenarios, real-time load-bearing data acquisition and balance calculation at multiple support points prevent deformation of the support device due to overload of a single support point (e.g., the load on one support point far exceeds that of other points), or tilting of the busbar due to uneven support, thus ensuring structural safety during the disassembly and assembly process from the source. Precise level calibration of the digital disassembly and assembly platform ensures uniform force distribution during busbar support, preventing localized pressure damage to the busbar due to platform tilt (e.g., deformation of the busbar flange sealing surface). Dynamic pressure calculation based on stiffness coefficient enables precise control of the expansion joint compression force, preventing damage to expansion joint seals due to over-compression (e.g., rupture of rubber seals) or insufficient clearance due to insufficient clearance (preventing detachment from the machine). The combination of target displacement setting and real-time monitoring ensures that the clearance meets disassembly and assembly requirements, improving the accuracy of expansion joint compression operations. Real-time monitoring of radial offset and quantification of safety index identify radial deformation risks during expansion joint compression in advance. The triggering of the alarm mechanism can promptly terminate dangerous operations, preventing the escalation of faults (e.g., busbar falling due to expansion joint damage), thus improving the controllability of risks during the disassembly and assembly process.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] 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.

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