Automatic unhooking system adopting PLC redundancy control and control method thereof

Abstract

The invention discloses an automatic unhooking system adopting PLC redundancy control and a control method thereof, and relates to the field of hoisting engineering, and the automatic unhooking system comprises an execution mechanism which comprises an electric drive unit and a manual drive unit; the control module is arranged on the hook body and is electrically connected with the electric driving unit; the dual control module comprises a remote control unit and a local control unit; the state detection module is used for detecting the pulling force borne by the detacher; wherein the control module is configured to receive an instruction from the dual control module and a signal from the state detection module, and control the action of the execution mechanism based on a preset logic and a preset control priority; according to the automatic unhooking system, a multi-layer and multi-path redundancy control framework which takes a PLC as a core and integrates state detection, dual control and dual execution is constructed, and clear control priority logic is supplemented, so that the single-point failure risk of a traditional unhooking device is eliminated fundamentally.

Description

TECHNICAL FIELD

[0001] The present application relates to hoisting engineering technology, in particular to an automatic unhooking system adopting PLC redundant control and a control method thereof. BACKGROUND

[0002] In fishing, ocean engineering and port hoisting operations, the unhooking device is a key actuator for quickly releasing and separating the load (such as fishery catch, engineering components, hoisted cargo), and the reliability and immediacy of its action directly relate to the safety and efficiency of the entire operation system. In these high-dynamic and high-risk application scenarios, the operation environment is complex and changeable, often accompanied by adverse factors such as wind and waves, load swing, and sudden tension changes, which puts high requirements on the performance of the unhooking device.

[0003] However, the mainstream unhooking device products in service have exposed a core systematic disadvantage in the technical aspect: excessive dependence on a single control mode and the single-point failure risk it brings. Traditional unhooking devices generally use pure mechanical manual control or simple single-circuit electric control driving. This non-redundant design concept brings inherent safety hazards. In actual operations, especially in severe sea conditions or emergency working conditions, once the only control system fails - for example, the control circuit in the electric control system is interrupted due to vibration wear, the electromagnetic valve is stuck due to oil contamination or corrosion, the drive motor or power supply system fails - the entire unhooking device may be "stuck" and face the fatal risk of being unable to act when unhooking is urgently needed. At this time, the heavy load suspended cannot be released in time, which may cause equipment structural damage, cable rupture, and even loss of ship stability, resulting in serious safety accidents, exposing the ship and operating personnel to great danger.

[0004] Although some traditional devices attempt to design an emergency manual release mechanism as a backup, this manual method often requires the operator to risk approaching the unhooking device area under high load or dangerous conditions for high-risk operations. Its response process is slow, and in a tense emergency situation, the accuracy and success rate of the operation are difficult to guarantee, and the feasibility is very low in a high-dynamic and high-risk operation environment, and in essence, it cannot constitute a truly effective safety redundancy.

[0005] Therefore, there is an urgent need in the art for an unhooking system that can fundamentally overcome the single-point failure risk and has high reliability. The ideal solution should have multiple safety mechanisms built in to ensure that when any part of the main control system fails, there is still an independent and reliable backup means to achieve safe release of the load, thereby greatly improving the safety factor of the entire operation system. SUMMARY

[0006] The application aims to provide an automatic uncoupling system adopting PLC redundant control and a control method thereof to solve the single-point failure risk problem of the conventional uncoupler relying on a single control mode in the prior art.

[0007] To achieve the above-mentioned purpose, the application provides the following technical solutions.

[0008] In a first aspect, the application provides an automatic uncoupling system adopting PLC redundant control, comprising an uncoupler, the uncoupler comprising a hook body and a claw hook joint, the claw hook joint comprising a main hook movably arranged on the hook body through a connecting plate one and a secondary hook movably arranged on the hook body through a connecting plate two, the main hook and the secondary hook cooperating with each other to realize locking or releasing, the system further comprising:

[0009] an actuator comprising an electric drive unit and a manual drive unit, for driving the main hook and the secondary hook to switch between the locking state and the releasing state;

[0010] a control module arranged on the hook body and electrically connected with the electric drive unit;

[0011] a dual control module comprising a remote control unit and a local control unit, the remote control unit and the local control unit being communicatively connected with the control module;

[0012] a state detection module for detecting the tension received by the uncoupler;

[0013] wherein the control module is configured to receive instructions from the dual control module and signals from the state detection module, and control the action of the actuator based on a preset logic and a predetermined control priority.

[0014] Further, the control module adopts a PLC programmable logic controller.

[0015] Further, the uncoupler further comprises a pressing head movably arranged at the rear end of the connecting plate two, the pressing head being respectively provided with a lever and a connecting rod, the connecting plate two at the front end of the lever being provided with a limiting rib, and the limiting rib and the connecting plate two being provided with an elastic member.

[0016] Further, the electric drive unit comprises a linear drive arranged on the hook body, the front end of the linear drive corresponding to the connecting rod.

[0017] Further, the manual drive unit comprises a pull rope arranged on the lever.

[0018] Further, the secondary hook is provided with at least two position detection modules, the position detection modules being electrically connected with the control module and used for detecting the relative position of the secondary hook and the main hook.

[0019] Further, the state detection module adopts a tension sensor, which is arranged on the connecting structure of the main hook and the hook body.

[0020] Further, the predetermined control priority is in descending order as follows: the operation of the hand drive unit, the emergency stop instruction of the local control unit, the manual unhooking instruction of the remote control unit, and the automatic unhooking instruction triggered by the control module according to the state detection module signal.

[0021] Further, the remote control unit is a human-machine interface (HMI) arranged in the cab, and the local control unit is an operation box arranged locally to the unhooker, and the signal of the operation box is directly connected to the control module.

[0022] In the second aspect, the application provides a control method for the automatic unhooking system, which comprises the following steps:

[0023] S1, acquiring the working state signal of the unhooker in real time through the state detection module;

[0024] S2, sending at least one of the control instruction from the dual control module and the working state signal to the control module;

[0025] S3, the control module judges according to the preset logic, and if the automatic unhooking condition is met or a valid unhooking instruction is received, the electric drive unit is controlled to act to drive the unhooker to the release state;

[0026] In any case, the current control process can be interrupted or covered by triggering the hand drive unit or the local control unit with higher priority to realize unhooking.

[0027] Compared with the prior art, the application provides an automatic unhooking system and a control method thereof using PLC redundant control, which fundamentally eliminates the single-point failure risk of the traditional unhooker by constructing a multi-level and multi-path redundant control architecture with PLC as the core, integrating state detection, dual control and dual execution, and assisting with clear control priority logic.

[0028] The control path redundancy provides three controllable electrical unhooking paths, i.e., remote control, local control and automatic control, and any one path failure does not affect the normal work of the remaining paths.

[0029] The execution mechanism redundancy provides a completely independent mechanical hand drive unit in addition to the electric drive unit; the unit does not depend on power, electronic components or PLC, and ensures that the unhooker can be forcibly unhooked through a physical way in the most extreme case of complete failure of the electric control system (such as power failure or controller damage), thereby providing ultimate safety guarantee.

[0030] Intelligent decision and safety priority: the introduction of PLC not only realizes automation, more importantly, it can coordinate the processing of multiple input signals, and strictly implement the safety logic of mechanical priority over electrical, local priority over remote, and emergency priority over normal; this priority management ensures that the system always moves in the safest direction in the case of complex or conflicting instructions. BRIEF DESCRIPTION OF DRAWINGS

[0031] In order to more clearly illustrate the technical solutions of the embodiments of the present application or the prior art, the drawings needed in the embodiments will be briefly introduced as follows. Obviously, the drawings in the following description are only some embodiments described in the present application, and other drawings can also be obtained by those skilled in the art based on these drawings.

[0032] Figure 1 System module block diagram provided for embodiment one of the present application;

[0033] Figure 2 Unhooker structure schematic diagram provided for embodiments one and two of the present application;

[0034] Figure 3 Claw hook joint structure schematic diagram provided for embodiments one and two of the present application.

[0035] Explanation of reference signs:

[0036] 1, hook body; 2, claw hook joint; 201, main hook; 202, auxiliary hook; 203, connecting plate one; 204, connecting plate two; 205, pressure head; 206, lever; 207, connecting rod; 3, linear actuator; 4, tension sensor; 5, controller. DETAILED DESCRIPTION

[0037] In order to enable those skilled in the art to better understand the technical solutions of the present application, the present application will be further described in detail below with reference to the drawings.

[0038] As shown in the accompanying Figure 1 to the accompanying Figure 3 drawings:

[0039] Embodiment one:

[0040] The present application provides an automatic unhooking system using PLC redundant control, comprising an unhooker, the unhooker comprising a hook body 1 and a claw hook joint 2, the claw hook joint 2 comprising a main hook 201 movably arranged on the hook body 1 through a connecting plate one 203, and an auxiliary hook 202 movably arranged on the hook body 1 through a connecting plate two 204, the main hook 201 and the auxiliary hook 202 cooperate with each other to realize locking or releasing, the system further comprises:

[0041] An actuating mechanism, including an electric drive unit and a manual drive unit, is configured to drive the main hook 201 and the auxiliary hook 202 to switch between the locked state and the released state.

[0042] A control module is arranged on the hook body 1 and electrically connected with the electric drive unit.

[0043] A dual control module, including a remote control unit and a local control unit, is in communication connection with the control module.

[0044] A state detection module is configured to detect the tension received by the unhooker.

[0045] The control module is configured to receive the instructions from the dual control module and the signals from the state detection module, and control the action of the actuating mechanism based on a preset logic and a predetermined control priority.

[0046] Specifically, the control module is a PLC programmable logic controller 5.

[0047] Specifically, the auxiliary hook 202 is provided with at least two position detection modules, which are electrically connected with the control module and configured to detect the relative position of the auxiliary hook 202 and the main hook 201.

[0048] Specifically, the state detection module is a tension sensor 4, which is arranged on the connecting structure of the main hook 201 and the hook body 1.

[0049] Specifically, the predetermined control priority is in descending order as follows: the operation of the manual drive unit, the emergency stop instruction of the local control unit, the manual unhooking instruction of the remote control unit, and the automatic unhooking instruction triggered by the control module according to the signals of the state detection module.

[0050] Specifically, the remote control unit is a human-machine interface HMI arranged in the cab, and the local control unit is an operation box arranged locally on the unhooker, and the signals thereof are directly connected to the control module.

[0051] Wherein:

[0052] The unhooker body is a mechanical bearing structure of the system, which is composed of a hook body 1, i.e., a main frame, and a claw hook joint 2. The claw hook joint 2 includes a main hook 201 and an auxiliary hook 202. The main hook 201 is movably connected to the hook body 1 through a connecting plate one 203, and the auxiliary hook 202 is movably connected to the hook body 1 through a connecting plate two 204. The main hook 201 and the auxiliary hook 202 are locked by the mutual buckling of their hook structures, and are used to hang loads, such as fishing catches and hoisting objects.

[0053] Actuator: including electric drive unit and hand drive unit. Electric drive unit as the main actuator, receiving electrical signal action; hand drive unit as an emergency actuator, providing a purely mechanical drive when the electric control fails. Both constitute a "electric + mechanical" redundant design.

[0054] Control module: in this embodiment, preferably using industrial PLC programmable logic controller 5, it is fixedly installed on the hook body 1. PLC and electric drive unit, state detection module and double control module are electrically connected through cable.

[0055] Double control module: including remote control unit and local control unit. Remote control unit is typically set in the ship's bridge HMI, the operator can remotely monitor the state and send "unhook" instruction. Local control unit is the operation box set beside the unhooker device, which is provided with at least emergency stop button and state indicator, and its signal is directly connected to PLC, ensuring quick and direct response.

[0056] State detection module: including tension sensor 4 for detecting load tension. The tension sensor 4 is preferably installed on the connection structure of the main hook 201 and the hook body 1, such as the connecting pin shaft of the connecting plate 203 and the hook body 1, so as to directly and accurately measure the tension of the load applied to the unhooker. In addition, the position detection module in this embodiment is two proximity switches set on the auxiliary hook 202, which are used to detect the "fully locked" position and "fully released" position of the auxiliary hook 202 relative to the main hook 201, and feed the signal back to the PLC.

[0057] Working principle: the core of this embodiment is its preset control logic and priority. The internal program of PLC sets clear control priority, from high to low: operation of hand drive unit > emergency stop instruction of local control unit > manual unhooking instruction of remote control unit > automatic unhooking instruction triggered by PLC according to state detection module signal.

[0058] Automatic unhooking process: tension sensor 4 monitors the load tension in real time and converts it into electrical signal to transmit to PLC. PLC compares the received tension value with the preset safety threshold, such as 110% of the maximum working load. Once the tension is determined to be out of limit, PLC will immediately send action instruction to electric drive unit such as electric push rod to drive the unhooker to release the load and realize overload protection.

[0059] Remote manual unhooking: the operator clicks the "unhook" button on the bridge HMI, and the PLC will first check whether the "fully locked" signal is valid after receiving the instruction, and then drive the electric drive unit to execute the unhooking action after confirming that there is no error.

[0060] Safety: Regardless of the state of the system, the highest priority local emergency stop and hand drive unit can interrupt the current process, ensuring that personnel have the final control in emergency situations.

[0061] The embodiment is directed to the general fishing and port hoisting scene, and the problems of low intelligent level and poor reliability of the traditional decoupler are fundamentally solved by introducing PLC intelligent judgment and multiple control redundancy, and the upgrade from "passive execution" to "active protection" is realized.

[0062] Embodiment two:

[0063] The embodiment is basically the same as the previous embodiment, and the difference is that the decoupler further comprises a pressure head 205 movably arranged at the rear end of the second connecting plate 204, and a lever 206 and a connecting rod 207 are arranged on the pressure head 205, respectively. A limiting rib is arranged on the second connecting plate 204 at the front end of the lever 206, and an elastic member is arranged between the limiting rib and the second connecting plate 204.

[0064] Specifically, the electric drive unit comprises a linear actuator 3 arranged on the hook body 1, and the front end of the linear actuator 3 corresponds to the connecting rod 207.

[0065] Specifically, the hand drive unit comprises a pull rope arranged on the lever 206.

[0066] Among them:

[0067] The electric drive unit comprises a linear actuator 3 fixedly arranged on the hook body 1, which is preferably a waterproof electric push rod. The front end of the push rod of the linear actuator 3 corresponds to the connecting rod 207 on the pressure head 205. In the power-on state, when the push rod is extended, it can push the connecting rod 207, and then drive the entire pressure head 205 to move.

[0068] The hand drive unit comprises a pull rope arranged on the lever 206. The other end of the pull rope leads to a position convenient for the operator to stand safely. On the hook body 1 near the pressure head 205, a limiting rib is also arranged, and an elastic member such as a compression spring is arranged between the limiting rib and the second connecting plate 204. The main function of the limiting rib is to keep the mechanism stable in the non-action state.

[0069] Working principle:

[0070] When the PLC issues the unhooking instruction, the linear driver 3, such as the push rod of the electric push rod, extends forward, pushes the connecting rod 207, and forces the connecting rod 207 to separate from the original locking fit of the hook body 1. The connecting rod 207 drives the lever 206 to rotate downward. Since the pressure head 205 is linked with the secondary hook 202 through the connecting plate 204, the rotation of the pressure head 205 drives the connecting plate 204 to swing through the limiting rib, which causes the secondary hook 202 to rotate upward and separate from the primary hook 201. At the same time, the primary hook 201 rotates downward under the action of the load gravity to open, realizing unhooking. At this time, the limiting rib and the elastic element play the roles of stroke limiting and buffering. After unhooking is completed, the "complete release" position detection module on the secondary hook 202 detects the signal and feeds back to the PLC, and the PLC immediately controls the electric push rod to stop moving.

[0071] When the ship is powered off or the electric control system fails, the operator can rush to the equipment and pull the pull rope. The pull rope pulls the lever 206, and the lever 206 directly drives the pressure head 205 to rotate and separate from the hook body 1. The subsequent mechanical linkage process is consistent with the electrically driven unhooking, and finally the forced unhooking is realized. The key is that the push rod of the linear driver 3 and the connecting rod 207 are not rigidly connected, but have a "corresponding" relationship, that is, the push rod can push the connecting rod 207, but when the pull rope pulls the lever 206, it will not drive the push rod, which makes the hand drive unit and the electric drive unit independent of each other at the mechanical level and do not interfere with each other, ensuring that when the electric drive system fails completely, the mechanical release channel is still unobstructed.

[0072] The embodiment refines the mechanical transmission system composed of the lever 206, the connecting rod 207, and the pull rope, providing an absolutely reliable physical unhooking path for emergency situations. This design is particularly suitable for marine engineering operation scenarios with extremely high safety requirements, such as offshore wind power facility hoisting, where any electric control failure should not result in the disastrous consequences of being unable to release the load in an emergency.

[0073] Embodiment three:

[0074] The embodiment provides a control method for the automatic unhooking system, comprising:

[0075] S1, acquiring the working state signal of the unhooking device in real time through the state detection module;

[0076] Specifically, after the system is powered on, the working state signal of the unhooking device is acquired in real time and continuously through the state detection module, including the load tension value and the locking / release state. The state detection module includes a tension sensor 4 and a position detection module including a proximity switch.

[0077] S2, sending at least one of the control instruction from the dual control module and the working state signal to the control module;

[0078] Specifically: at least one of the control instructions (instructions of the remote HMI or local emergency stop signal) from the dual control system and the working state signal in step S1 is sent to the PLC controller 5.

[0079] S3, the control module judges according to a preset logic, and if the automatic unhooking condition is met or a valid unhooking instruction is received, the electric drive unit is controlled to act to drive the unhooking device to a release state.

[0080] In any case, the current control process can be interrupted or overridden by triggering the hand drive unit or the local control unit with higher priority to achieve unhooking.

[0081] This step includes multiple parallel or serial judgment paths, specifically:

[0082] Path one (automatic mode): the PLC continuously compares the tension sensor 4 signal with the preset threshold. If the automatic unhooking condition (such as tension overrun) is met, the electric drive unit is immediately controlled to act to drive the unhooking device to a release state.

[0083] Path two (remote manual mode): if a valid manual unhooking instruction is received from the remote HMI, the PLC will first verify the "complete locking" signal and then execute unhooking after confirmation.

[0084] Path three (highest priority intervention): this is an independent channel throughout. In any case, regardless of what instruction the PLC is processing, as soon as the local control unit's emergency stop signal is detected or the hand drive unit is physically operated (such as the pull rope being pulled), the system will immediately interrupt or override the current process, and give priority to unhooking action or enter a safe state.

[0085] Working principle: the essence of this control method lies in its condition triggering and priority interrupt mechanism. It not only realizes basic remote control and automation, but more importantly, it builds a "safety net".

[0086] In fishing, when the net load suddenly increases (such as hitting an obstacle), the system can instantly automatically release to avoid capsizing the ship or damaging the equipment.

[0087] In port hoisting, if the load is about to collide with the ship or the wharf, the operator can quickly start the emergency release in the cab or on site to prevent the accident from expanding.

[0088] The "in any case" can achieve unhooking through higher priority, which is the last line of defense for all possible failure modes (such as program runaway, single sensor false alarm, etc.), ensuring the ultimate safety of the system.

[0089] The control method of the embodiment deeply integrates the redundancy design of hardware and the intelligent judgment of software, forms a complete solution suitable for high dynamic and high risk operation environment, and significantly improves the safety boundary and intelligent level of operation.

[0090] The above has described certain exemplary embodiments of the present application by way of illustration only, and it is needless to say that the described embodiments can be modified in various ways without departing from the spirit and scope of the present application for those skilled in the art. Therefore, the above drawings and descriptions are illustrative in nature and should not be understood as limiting the scope of protection of the claims of the present application.

Claims

1. An automatic unhooking system employing PLC redundant control, comprising an unhooking device, the unhooking device comprising a hook body (1) and a claw hook joint (2), the claw hook joint (2) comprising a main hook (201) movably mounted on the hook body (1) via a connecting plate one (203), and a secondary hook (202) movably mounted on the hook body (1) via a connecting plate two (204), the main hook (201) and the secondary hook (202) cooperating to achieve locking or releasing, characterized in that, The system also includes: The actuator, including an electric drive unit and a manual drive unit, is used to drive the main hook (201) and the auxiliary hook (202) to switch between a locked state and a released state; The control module is mounted on the hook body (1) and is electrically connected to the electric drive unit; The dual control module includes a remote control unit and a local control unit, both of which are communicatively connected to the control module. A status detection module is used to detect the tension applied to the unhooker; The control module is configured to receive instructions from the dual control module and signals from the status detection module, and control the action of the actuator based on preset logic and predetermined control priority.

2. The automatic unhooking system using PLC redundant control according to claim 1, characterized in that, The control module adopts a PLC programmable logic controller (5).

3. The automatic unhooking system using PLC redundant control according to claim 1, characterized in that, The unhooking device also includes a pressure head (205) movably disposed at the rear end of the connecting plate two (204). The pressure head (205) is provided with a lever (206) and a connecting rod (207). A limiting rib is provided on the connecting plate two (204) at the front end of the lever (206). An elastic element is provided between the limiting rib and the connecting plate two (204).

4. The automatic unhooking system using PLC redundant control according to claim 3, characterized in that, The electric drive unit includes a linear actuator (3) disposed on the hook body (1), the front end of which corresponds to the connecting rod (207).

5. An automatic unhooking system employing PLC redundant control according to claim 3, characterized in that, The hand-drive unit includes a pull rope mounted on a lever (206).

6. An automatic unhooking system employing PLC redundant control according to claim 1, characterized in that, The auxiliary hook (202) is provided with at least two position detection modules, which are electrically connected to the control module and are used to detect the relative position of the auxiliary hook (202) and the main hook (201).

7. An automatic unhooking system employing PLC redundant control according to claim 1, characterized in that, The status detection module uses a tension sensor (4), which is located on the connection structure between the main hook (201) and the hook body (1).

8. An automatic unhooking system employing PLC redundant control according to claim 1, characterized in that, The predetermined control priorities, from highest to lowest, are: operation of the manual drive unit, emergency stop command of the local control unit, manual uncoupling command of the remote control unit, and automatic uncoupling command triggered by the control module based on the status detection module signal.

9. An automatic unhooking system employing PLC redundant control according to claim 1, characterized in that, The remote control unit is a human-machine interface (HMI) located in the cab, and the local control unit is an operation box located locally on the decoupling device, whose signals are directly connected to the control module.

10. A control method for the automatic unhooking system according to any one of claims 1-9, characterized in that, include: S1. The working status signal of the unhooker is acquired in real time through the status detection module; S2. Send at least one of the control command from the dual control module and the working status signal to the control module; S3. The control module makes a judgment based on preset logic. If the automatic unhooking condition is met or a valid unhooking command is received, the control module controls the electric drive unit to operate and drives the unhooker to the release state. In any case, the current control flow can be interrupted or overridden by triggering the higher-priority manual drive unit or local control unit to achieve decoupling.

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