Three-way push rod control system and method based on integration of multiple protection functions

Abstract

The invention provides a three-way push rod control system and method based on integration of multiple protection functions, the system integrates multiple protection mechanisms of overcurrent, torque and actuation time, a mechanical limiting trigger module is arranged at the tail end of a push rod reversing path, and when a limiting switch fails, a push rod moves to a prefabricated position and then abuts against the limiting switch, and the mechanical limiting trigger module is connected with the mechanical limiting trigger module. The motor load is forced to increase; the data acquisition module synchronously acquires a motor operation current signal, a push rod operation torque signal and a push rod action signal, and the overcurrent protection module, the torque protection module and the action time protection module cope with abnormal working conditions according to respective shutdown conditions. Through cooperation of multi-dimensional protection, the problem that the motor cannot be stopped due to faults of the limiting switch is solved, various potential risks such as moment overrun and action timeout are covered, and all-directional safety protection of the three-way push rod and the motor is achieved.

Description

Technical Field

[0001] This invention relates to the field of coal conveying equipment protection technology, and in particular to a three-way push rod control system and method based on multiple protection functions. Background Technology

[0002] In existing coal conveying systems, the three-way valve is a key component for material reversal, and its operation relies on a motor-driven push rod to switch the position of the valve core or baffle. The three-way valve's position signal is usually fed back by a limit switch. When the limit switch detects that the three-way valve has reached the designated position, the control box issues a stop command to stop the motor.

[0003] However, in actual operation, limit switches are prone to failure due to dust accumulation, mechanical wear, or circuit faults. When a limit switch fails, the motor cannot receive a stop signal and will continue to output torque to drive the push rod, eventually causing the push rod to break due to overload. A broken push rod not only requires significant manpower and resources for replacement and repair but also disrupts the coal conveying system, severely impacting production continuity and stability. Summary of the Invention

[0004] This invention provides a three-way push rod control system and method based on multiple protection functions, which solves the problem in the prior art where the three-way motor cannot stop due to limit switch failure.

[0005] On the one hand, the present invention provides a three-way actuator control system based on multiple protection functions, comprising:

[0006] The execution module includes a three-way motor and a three-way push rod driven by the three-way motor to realize three-way reversal;

[0007] The data acquisition module is used to acquire the operating current signal of the three-way motor, the operating torque signal of the three-way push rod, and the action signal of the three-way push rod starting to move;

[0008] A mechanical limit trigger module is located at the end of the reversing direction movement path of the three-way push rod, and is used to abut against the three-way push rod when the three-way push rod moves to the pre-set position, thereby increasing the load on the three-way motor.

[0009] An overcurrent protection module is used to instantly cut off the power supply to the three-way motor when the operating current signal exceeds the overcurrent threshold within a first time window.

[0010] Calculate the current-time integral value of the operating current signal within the second time window. When the current-time integral value is greater than the preset thermal accumulation threshold, cut off the power supply to the three-way motor.

[0011] A torque protection module is used to cut off the power supply to the three-way motor when the operating torque signal exceeds a preset torque threshold.

[0012] An action time protection module is used to start timing after the three-way push rod receives the action signal. If the three-way push rod does not stop running within a preset protection time, the power supply to the three-way motor is cut off.

[0013] Optionally, the overcurrent protection module further includes an operating condition identification unit;

[0014] The operating condition identification unit is used for:

[0015] Obtain operating parameters that characterize the system load state;

[0016] Based on the operating parameters, the overcurrent threshold and the heat accumulation threshold are dynamically adjusted.

[0017] Specifically, when a high-load condition is detected, the overcurrent threshold and thermal accumulation threshold are increased accordingly to allow the three-way motor to output greater torque within a safe range.

[0018] Optionally, the overcurrent protection module further includes a fault diagnosis unit;

[0019] The fault diagnosis unit is used for:

[0020] Extract the harmonic component characteristics of the operating current signal;

[0021] The harmonic component characteristics are matched with a pre-stored fault feature library to obtain the matching degree; the fault feature library includes at least the feature patterns corresponding to mechanical jamming, bearing wear, and intermittent short circuit of coil.

[0022] When the matching degree is greater than the preset confidence level, the corresponding fault warning signal is output.

[0023] Optionally, it further includes a predictive protection module; the predictive protection module includes:

[0024] Historical operation database is used to associate and store historical current data, historical operating parameters and corresponding fault diagnosis results;

[0025] The current trend prediction unit is used to call the historical operation database and perform time-series analysis on the operation current signal based on machine learning algorithms to generate current change trends.

[0026] The forward-looking intervention unit is used to issue a speed reduction or torque limiting command to the three-way motor when the predicted current in the current change trend is greater than the overcurrent threshold and the fault diagnosis unit does not output the fault warning signal.

[0027] Optionally, the duration of the first time window is 0.05-0.1 seconds, and the duration of the second time window is 1-3 seconds; the heat accumulation threshold is set based on the rated heating power and insulation heat resistance level of the three-way motor, and the heat accumulation threshold is positively correlated with the duration of the second time window.

[0028] Optionally, the fault diagnosis unit is further configured to:

[0029] When the fault warning signal is output, the current waveform segment corresponding to the harmonic component characteristics is recorded synchronously, and the current waveform segment is associated with the fault warning signal and stored in the fault feature library.

[0030] Optionally, the data acquisition module includes a main current sensor and a backup current sensor; the main current sensor and the backup current sensor are connected in parallel to the power supply circuit of the three-way motor;

[0031] The overcurrent protection module also includes a signal verification unit;

[0032] The signal verification unit is used to: compare the operating current signals output by the main current sensor and the backup current sensor; when the deviation between the two operating current signals is greater than a preset deviation, generate a sensor fault alarm and switch to the backup sensor to collect the signal.

[0033] Optionally, the prospective intervention unit is further configured to:

[0034] After issuing a speed reduction or torque limiting command, monitor the rate of change of the operating current signal;

[0035] If the rate of change is greater than a preset safety threshold, an acceleration trigger signal is sent to the overcurrent protection module to instantly cut off the power supply to the three-way motor.

[0036] Optionally, it also includes an environmental sensing module; the environmental sensing module is connected to the overcurrent protection module.

[0037] The environmental sensing module is used to: collect environmental parameters of the three-way motor; the environmental parameters include the temperature, humidity and dust concentration of the operating environment.

[0038] The overcurrent protection module is also used to: correct the overcurrent threshold and the thermal accumulation threshold based on the environmental parameters.

[0039] On the other hand, the present invention also provides a three-way push rod control method based on multiple protection functions, including:

[0040] The operating current signal, operating torque signal, and action signal of the three-way motor as well as the start of movement of the three-way push rod are collected. The three-way motor drives the three-way push rod to move along the reversing direction to realize the three-way reversing.

[0041] The operating current signal is monitored within a first time window. If the value is greater than the overcurrent threshold, the power supply to the three-way motor is instantly cut off.

[0042] Calculate the current-time integral value of the operating current signal within the second time window. If the current-time integral value is greater than the preset thermal accumulation threshold, then cut off the power supply to the three-way motor.

[0043] When the operating torque signal exceeds the preset torque threshold, the power supply to the three-way motor is cut off;

[0044] After the three-way push rod receives the action signal, a timer is started. If the three-way push rod does not stop running within the preset protection time, the power supply to the three-way motor is cut off.

[0045] When the three-way push rod moves to the pre-set position, the mechanical limit trigger module set at the end of its reversing direction movement path abuts against the three-way push rod, which increases the load of the three-way motor and causes the operating current signal to rise.

[0046] On the other hand, the present invention also provides an electronic device, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the program to implement the three-way push rod control method based on multiple protection functions as described above.

[0047] On the other hand, the present invention also provides a non-transitory computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the three-way push rod control method based on multiple protection functions as described above.

[0048] On the other hand, the present invention also provides a computer program product, including a computer program that, when executed by a processor, implements the three-way push rod control method based on multiple protection functions as described above.

[0049] This invention provides a three-way push rod control system and method integrating multiple protection functions. The system integrates multiple protection mechanisms including overcurrent, torque, and action time. A mechanical limit trigger module is located at the end of the push rod's reversing path. When the limit switch fails, the push rod moves to a pre-set position and abuts against it, forcing an increase in motor load. A data acquisition module simultaneously collects motor operating current signals, push rod operating torque signals, and push rod action signals. Overcurrent protection, torque protection, and action time protection modules respond to abnormal operating conditions according to their respective shutdown conditions. Through the synergy of multi-dimensional protection, not only is the problem of motor failure due to limit switch malfunction solved, but it also covers multiple potential risks such as torque over-limit and action timeout, achieving comprehensive safety protection for the three-way push rod and motor. Attached Figure Description

[0050] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0051] Figure 1 This is one of the schematic diagrams of a three-way push rod control system based on multiple protection functions provided in the embodiments of the present invention;

[0052] Figure 2 This is the second schematic diagram of a three-way push rod control system based on multiple protection functions provided in this embodiment of the invention;

[0053] Figure 3 This is a schematic diagram of the overcurrent protection module provided in an embodiment of the present invention;

[0054] Figure 4 This is a schematic diagram of the structure of the electronic device provided in an embodiment of the present invention. Detailed Implementation

[0055] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0056] Figure 1 This is one of the schematic diagrams of a three-way push rod control system based on multiple protection functions provided in the embodiments of the present invention.

[0057] like Figure 1 As shown, the three-way push rod control system based on multiple protection functions provided in this embodiment of the invention includes:

[0058] The execution module 110 includes a three-way motor and a three-way push rod driven by the three-way motor to realize three-way reversal.

[0059] The execution module 110 mainly consists of a three-way motor and a three-way push rod, which are rigidly connected. The three-way motor acts as the power source, converting the rotary motion into the linear reciprocating motion of the three-way push rod through a reducer, lead screw, or gear. This drives the valve core or reversing baffle inside the three-way equipment to deflect, enabling the material to switch between different flow directions such as left-hand, right-hand, or straight-through. In the coal conveying system, the execution module 110 directly determines the reversing response speed and positioning accuracy of the three-way equipment. Its operating status, through linkage with the subsequent mechanical limit trigger module 130 and data acquisition module 120, becomes the key triggering basis for the system's protection logic. When the three-way push rod reaches its limit position, the mechanical action of the three-way push rod will indirectly reflect the change in the load of the three-way motor, providing physical triggering conditions for overcurrent protection.

[0060] The data acquisition module 120 is used to acquire the operating current signal of the three-way motor, the operating torque signal of the three-way push rod, and the action signal of the three-way push rod starting to move.

[0061] The data acquisition module 120 includes a current sensor connected in series to the main power circuit of the three-way motor. For example, the current sensor can be installed between the circuit breaker and the contactor of the three-way motor in the control box. The current sensor can collect the operating current signal during the operation of the three-way motor. The current sensor converts the high current signal of the motor into a processable raw signal according to a fixed transformation ratio. The signal conditioning circuit then filters, amplifies, and linearizes the collected raw signal to eliminate the influence of power grid interference or instantaneous pulses on signal accuracy. The collected operating current signal is continuously transmitted to the overcurrent protection module 140 as an electrical parameter to determine whether the motor is overloaded or stalled.

[0062] In addition, detecting the operating torque signal can prevent the tee push rod from getting stuck during operation or from being damaged or the motor insulation from being damaged when other protections fail. The collected operating torque signal can be used to determine whether the tee push rod is operating within the designed torque range, thereby protecting the equipment safety.

[0063] By collecting the action signal of the T-joint actuator starting to move, protection can be provided for T-joint actuators at different strokes. For example, during the initial installation and commissioning phase, the running time of the T-joint actuator can be calculated by measuring the distance between the strokes of two actuators. A time protection function can then be added to the logic. If the T-joint fails to stop within a reasonable time after receiving the action signal, exceeding the protection time, the T-joint motor will immediately stop. On-site inspection and confirmation are required. If the T-joint motor is fault-free, it can resume operation after resetting; otherwise, maintenance work is necessary. The current, torque, and time protections work together and are mutually redundant, increasing the safety and reliability of the T-joint actuator operation, significantly reducing the equipment failure rate, and improving operational reliability.

[0064] The mechanical limit trigger module 130 is located at the end of the reversing direction movement path of the three-way push rod. It is used to abut against the three-way push rod when the three-way push rod moves to the pre-set position, thereby increasing the load on the three-way motor.

[0065] The mechanical limit trigger module 130 is fixedly installed at the end of the movement path of the three-way push rod in the reversing direction. There is one set for each reversing direction. For example, one mechanical limit trigger module 130 is set at the end of the left and right reversing directions. The installation position of the mechanical limit trigger module 130 is precisely matched with the design limit stroke of the three-way push rod to ensure that the three-way push rod can abut against the mechanical limit trigger module 130 when it moves to the preset position.

[0066] When a traditional limit switch fails, the three-way push rod is forced to stop moving by mechanical obstruction. When the three-way push rod comes into contact with the limit trigger module, the motor load will increase sharply due to the obstruction of movement, which will lead to a significant increase in the operating current.

[0067] The overcurrent protection module 140 is used for:

[0068] When the operating current signal exceeds the overcurrent threshold within the first time window, the power supply to the three-way motor is instantly cut off.

[0069] Calculate the current-time integral value of the operating current signal within the second time window. When the current-time integral value exceeds the preset thermal accumulation threshold, cut off the power supply to the three-way motor.

[0070] The overcurrent protection module 140 provides safety protection for the motor and push rod through a preset dual protection logic. The first level of protection is instantaneous overcurrent protection. When the operating current signal is detected to exceed the preset overcurrent threshold within the first time window, a trip signal is immediately output to cut off the motor power supply, preventing the push rod from breaking due to instantaneous overload. The second level of protection is thermal accumulation overcurrent protection. An integral algorithm is used to calculate the current-time integral value of the operating current signal within the second time window. The current-time integral value is positively correlated with the heat generation of the motor. When the current-time integral value exceeds the thermal accumulation threshold, the motor power supply will still be cut off even if the operating current signal has not reached the current threshold, preventing the motor from being damaged by overheating of the coil due to prolonged slight overload.

[0071] The torque protection module 170 is used to cut off the power supply to the three-way motor when the operating torque signal exceeds a preset torque threshold.

[0072] The torque protection module 170 is a protection unit for the output torque of the three-way motor. It monitors the torque signal output by the three-way motor driving the push rod during operation. This signal is directly acquired by a torque sensor installed on the motor output shaft or the push rod transmission chain, or indirectly calculated based on an algorithm relating motor current and speed. When the detected operating torque signal exceeds the torque threshold, regardless of whether the current reaches the overcurrent protection condition, a cut-off signal is immediately output to the motor control circuit to forcibly stop the motor, preventing the push rod from deforming or breaking due to continuous excessive force. This, together with the overcurrent protection, forms a dual physical quantity protection system of current and torque, further covering overload risks under different operating conditions.

[0073] The action time protection module 180 is used to start timing after the three-way push rod receives the action signal. If the three-way push rod does not stop running within the preset protection time, the power supply to the three-way motor will be cut off.

[0074] When the action time protection module 180 receives the reversing command from the three-way push rod, the built-in timer immediately starts timing, while simultaneously monitoring the operating status of the three-way push rod in real time. The preset protection time of the action time protection module 180 is determined based on the normal reversing time of the three-way equipment under maximum load and most severe operating conditions. If the preset protection time is reached and the push rod has not stopped running, it is determined to be an abnormal situation such as limit switch failure or torque / current protection failure, and the motor is immediately forced to stop. The function of the action time protection module 180 is to supplement protection from the time dimension, avoid the risk of the push rod running indefinitely due to the failure of a single protection mechanism, and form a multi-level protection closed loop.

[0075] In some embodiments, such as Figure 3 As shown, the overcurrent protection module 140 also includes a working condition identification unit 1401;

[0076] The operating condition identification unit 1401 is used for:

[0077] Obtain operating parameters that characterize the system load status.

[0078] Based on operating parameters, the overcurrent threshold and thermal accumulation threshold are dynamically adjusted.

[0079] Specifically, when high load conditions are detected, the overcurrent threshold and thermal accumulation threshold are increased accordingly to allow the three-way motor to output greater torque within a safe range.

[0080] Specifically, the operating condition identification unit 1401 collects operating condition parameters reflecting the load of the three-way motor and the three-way push rod through sensors. These operating condition parameters include, but are not limited to, the material flow rate of the coal conveying system, the material moisture content, the operating speed of the three-way push rod, and the input voltage and power factor of the three-way motor. By acquiring these operating condition parameters, the actual operating conditions of the three-way motor can be revealed. For example, when the material flow rate is high and the moisture content is high, the resistance required for the push rod to reverse the material is greater, and the three-way motor is under high load. Changes in the operating condition parameters directly reflect the dynamic fluctuations of the load.

[0081] When dynamically adjusting the overcurrent and heat accumulation thresholds based on operating parameters, the operating condition identification unit 1401 matches the collected operating parameters with a preset operating condition classification model to determine the load level of the three-way motor. When a high-load condition is identified, such as when the material flow rate exceeds the preset threshold or the push rod speed drops below the set range due to increased resistance, the operating current of the three-way motor will naturally be higher than that of a normal load condition because it needs to output greater torque to overcome the larger load. If a fixed threshold is still used, it may lead to false triggering of protection. Therefore, the operating condition identification unit 1401 will increase the overcurrent and heat accumulation thresholds accordingly based on a preset safety algorithm. For example, the overcurrent threshold is increased from 1.5 times the rated current of the three-way motor to 1.8 times, and the heat accumulation threshold is increased from 100% to 120%. This avoids unnecessary shutdowns under high loads and ensures that the increase does not exceed the safe bearing limit of the three-way motor and the three-way push rod by limiting the increase. This achieves dynamic protection that can be adjusted as needed, making the overcurrent protection logic more in line with the load changes of the actual operating scenario.

[0082] In some embodiments, such as Figure 3 As shown, the overcurrent protection module 140 also includes a fault diagnosis unit 1402;

[0083] Fault diagnosis unit 1402 is used for:

[0084] Extract the harmonic component characteristics of the operating current signal.

[0085] The harmonic component characteristics are matched with a pre-stored fault feature library to obtain the matching degree; the fault feature library includes at least the feature modes corresponding to mechanical jamming, bearing wear, and intermittent short circuit of coil.

[0086] When the matching degree is greater than the preset confidence level, the corresponding fault warning signal is output.

[0087] Specifically, the fault diagnosis unit 1402 performs frequency domain analysis on the operating current signal transmitted by the data acquisition module 120, decomposing the time-varying current waveform into the fundamental wave and various harmonics, and extracting the harmonic component characteristics. These harmonic component characteristics include the amplitude proportion, phase offset, and harmonic distortion rate of each harmonic. These characteristics directly reflect abnormal operating states of the three-way motor and the three-way push rod. For example, mechanical jamming can cause periodic fluctuations in the load of the three-way motor, corresponding to harmonic components of specific frequencies; intermittent short circuits in the coil can distort the current waveform, leading to a significant increase in the amplitude of higher harmonics.

[0088] The characteristic cycles of harmonic components are obtained, and these characteristics are matched with a pre-stored fault feature library to obtain the matching degree. The fault feature library is constructed based on historical fault data of the three-way equipment and laboratory simulated fault test data. The library pre-stores harmonic feature templates corresponding to typical faults such as mechanical jamming, bearing wear, and intermittent coil short circuits. For example, the template for mechanical jamming is a 5th harmonic amplitude exceeding 8% and an 11th harmonic phase shift greater than 15°; the template for bearing wear is a 3rd harmonic distortion rate exceeding 5% and periodic fluctuations in the fundamental amplitude.

[0089] The fault diagnosis unit 1402 uses a preset similarity algorithm, such as the Euclidean distance algorithm or the cosine similarity algorithm, to calculate the similarity between the harmonic component features and each fault template in the library. The higher the matching degree, the closer the current operating state is to the corresponding fault mode.

[0090] When the matching degree is greater than the preset confidence level, the corresponding fault warning signal is output. The preset confidence level is a threshold set based on the fault identification accuracy requirement. If the matching degree between a certain fault template and the real-time feature exceeds the threshold, the fault diagnosis unit 1402 determines that the equipment may have this type of fault, and then outputs a warning signal containing the fault type, matching degree value, current harmonic component characteristics and fault occurrence timestamp. The warning signal can be transmitted to the human-machine interface for audio-visual prompts, or uploaded to the remote monitoring platform so that maintenance personnel can locate the fault type in time and take maintenance measures to avoid the fault from further expanding and causing the push rod to break or the motor to burn out.

[0091] In some embodiments, such as Figure 2 As shown, the three-way push rod control system based on multiple protection functions provided in this embodiment of the invention also includes a predictive protection module 150; the predictive protection module 150 includes:

[0092] Historical operation database 1501 is used to associate and store historical current data, historical operating parameters and corresponding fault diagnosis results.

[0093] The historical operation database 1501 employs a distributed storage architecture to ensure efficient storage and rapid retrieval of large amounts of historical data. The historical operation database 1501 not only records the current changes of the equipment under different operating conditions, but also provides detailed annotations of the specific parameters at the time of each fault, offering data support for subsequent fault prediction.

[0094] The current trend prediction unit 1502 is used to call the historical operation database 1501 and perform time-series analysis on the operating current signal based on machine learning algorithms to generate current change trends.

[0095] When the current trend prediction unit 1502 starts working, it first calls historical data similar to the current operating condition from the historical operating database 1501 as a reference sample, and then uses machine learning algorithms suitable for time series signal analysis, such as using a long short-term memory network to perform dynamic time series modeling on the operating current signal transmitted by the data acquisition module 120. The long short-term memory network will capture the short-term fluctuation pattern and long-term change trend of the current signal, and combine the correlation pattern of current change → fault occurrence in historical samples to generate the current change trend curve and the corresponding predicted current value within a preset time period in the future.

[0096] The forward-looking intervention unit 1503 is used to issue a speed reduction or torque limiting command to the three-way motor when the predicted current in the current change trend is greater than the overcurrent threshold and the fault diagnosis unit 1402 does not output a fault warning signal.

[0097] The proactive intervention unit 1503 performs a dual judgment on the prediction results and the fault diagnosis status. When the predicted current value in the current change trend is greater than the overcurrent threshold and the fault diagnosis unit 1402 does not output a fault warning signal, the identified mechanical jamming, coil short circuit and other clear faults are ruled out. It is determined to be a potential overload risk and immediately sends a speed reduction or torque limiting command to the drive unit of the three-way motor. By reducing the motor speed, the push rod running speed is reduced, or the motor output torque is directly limited to suppress the current from continuing to rise from the source and avoid the predicted current from reaching the overcurrent threshold to trigger the shutdown. This achieves predictive protection that intervenes in advance before the fault occurs, which reduces unnecessary shutdowns and further reduces the risk of push rod overload breakage.

[0098] In some embodiments, the duration of the first time window is 0.05-0.1 seconds, and the duration of the second time window is 1-3 seconds; the heat accumulation threshold is set based on the rated heating power and insulation heat resistance level of the three-way motor, and the heat accumulation threshold is positively correlated with the duration of the second time window.

[0099] The system employs a first time window to capture instantaneous changes in the operating current signal, enabling rapid identification of short circuits or overloads in the three-way motor. The second time window analyzes the long-term trend of the current signal to assess the motor's continuous operating status and potential heat accumulation risks. In practical applications, adjusting the duration of both the first and second time windows optimizes the system's response speed and diagnostic accuracy. Furthermore, the heat accumulation threshold setting must comprehensively consider the actual operating conditions and safety requirements of the three-way motor, ensuring the system effectively prevents equipment damage caused by overheating without becoming overly sensitive or failing to detect overheating.

[0100] In some embodiments, the fault diagnosis unit 1402 is further configured to:

[0101] When a fault warning signal is output, the current waveform segment corresponding to the harmonic component characteristics is recorded synchronously, and the current waveform segment is associated with the fault warning signal and stored in the fault feature library.

[0102] The fault feature database employs a hierarchical storage structure, categorized by motor model, fault type, and occurrence time. Recorded current waveform segments contain complete cycle harmonic distribution data, with a sampling frequency of at least 10kHz to ensure the integrity of feature details. When recurring similar waveform segments are detected, a correlation analysis process is automatically triggered. By comparing harmonic phase shifts and amplitude attenuation characteristics in historical data, it determines whether there are potential equipment aging trends. Stored fault warning signals include timestamps and ambient temperature parameters, providing multi-dimensional analysis basis for subsequent fault mode identification.

[0103] In some embodiments, the data acquisition module 120 includes a main current sensor and a backup current sensor; the main current sensor and the backup current sensor are connected in parallel to the power supply circuit of the three-way motor.

[0104] The overcurrent protection module 140 also includes a signal verification unit.

[0105] The signal verification unit is used to compare the operating current signals output by the main current sensor and the backup current sensor. When the deviation between the two operating current signals is greater than the preset deviation, a sensor fault alarm is generated and the system switches to the backup sensor to collect the signal.

[0106] By setting up a main current sensor and a backup current sensor, dual monitoring of the operating current of the three-way motor is achieved, effectively avoiding protection failure caused by the failure of a single sensor.

[0107] The signal verification unit first synchronously acquires two sets of operating current signals output by the main current sensor and the backup current sensor. Since the two sensors are connected in parallel to the same power circuit, the two sets of operating current signals are current data with high consistency, providing a basis for comparison for signal verification.

[0108] Next, the signal verification unit dynamically compares the two sets of acquired signals using a preset deviation calculation algorithm. The preset deviation is set to 5%, specifically determined based on the accuracy level of the sensor. This preset deviation serves as the basis for judging whether the current sensor is working properly. When the calculated deviation between the two sets of signals is less than or equal to the preset deviation, the main current sensor is considered to be in normal acquisition status, and the signal verification unit defaults to transmitting the signal from the main current sensor to the overcurrent protection module 140. If the deviation is greater than the preset deviation, a fault alarm signal is generated, containing the sensor fault type, the current deviation values ​​of the two sets of signals, and the fault occurrence timestamp. Furthermore, when the deviation is greater than the preset deviation, a signal switching mechanism is activated, cutting off the signal transmission link of the main sensor and switching the signal from the backup current sensor to the input signal of the overcurrent protection module 140, ensuring uninterrupted current monitoring.

[0109] The signal verification unit directly compensates for the current signal loss or distortion that may be caused by a single sensor failure by real-time verification and intelligent switching of the dual sensor signals. This ensures that even if the main sensor fails due to component aging, loose wiring, or other reasons, reliable current monitoring can still be maintained through the backup sensor, providing stable data input for the overcurrent protection module 140 and improving the safety redundancy of the control system.

[0110] In some embodiments, the forward intervention unit 1503 is further configured to:

[0111] After issuing a speed reduction or torque limiting command, monitor the rate of change of the operating current signal.

[0112] If the rate of change is greater than the preset safety threshold, an acceleration trigger signal is sent to the overcurrent protection module 140 to instantly cut off the power supply to the three-way motor.

[0113] The forward-looking intervention unit 1503 can continuously collect the operating current signal during the operation of the three-way motor at a preset sampling frequency. The collected operating current signal will be calculated by subtracting the current signal values ​​at adjacent sampling times according to a preset algorithm, and combined with the time interval, the rate of change of the operating current signal will be obtained.

[0114] If the calculated rate of change exceeds a preset safety threshold, an acceleration trigger signal is sent to the overcurrent protection module 140 to instantly cut off the power supply to the three-way motor. Specifically, after issuing a speed reduction or torque limiting command, the system can promptly detect abnormal current fluctuations by monitoring the rate of change of the operating current signal in real time. Once the rate of change exceeds the preset safety threshold, the proactive intervention unit 1503 reacts quickly by sending an acceleration trigger signal to the overcurrent protection module 140. This acceleration trigger signal causes the overcurrent protection module 140 to immediately activate and instantly cut off the power supply to the three-way motor, effectively preventing equipment damage or safety accidents caused by excessive current, and further improving the system's safety and reliability.

[0115] In some embodiments, such as Figure 2 As shown, the three-way push rod control system based on multiple protection functions provided in this embodiment of the invention also includes an environmental sensing module 160; the environmental sensing module 160 is connected to the overcurrent protection module 140.

[0116] The environmental sensing module 160 is used to collect environmental parameters of the three-way motor; the environmental parameters include the temperature, humidity and dust concentration of the operating environment.

[0117] Specifically, the environmental sensing module 160 integrates a temperature sensor, a humidity sensor, and a dust concentration sensor. The environmental sensing module 160 is installed near the three-way motor and at key locations within the equipment's operating area to collect environmental parameters in real time. Temperature reflects the motor's heat dissipation environment; higher temperatures result in lower heat dissipation efficiency. Humidity is related to the insulation performance of electrical components; excessive humidity may accelerate circuit aging. Dust concentration affects the heat dissipation capacity of the motor's heat sink; dust accumulation can block heat dissipation channels. The collected environmental parameters are continuously transmitted to the overcurrent protection module 140 via signal lines.

[0118] The overcurrent protection module 140 is also used to: correct the overcurrent threshold and thermal accumulation threshold based on environmental parameters.

[0119] Specifically, when the ambient temperature exceeds the preset reference temperature, the resistance of the motor coil increases with the temperature, and the heat generated under the same current increases significantly. If the original overcurrent threshold is maintained at this time, the motor is likely to overheat and burn out. Therefore, the overcurrent protection module 140 will automatically reduce the overcurrent threshold and reduce the heat accumulation threshold proportionally, thereby limiting the motor current by tightening the protection threshold.

[0120] When the dust concentration exceeds the preset concentration threshold, the motor's heat dissipation capacity decreases, and overheating can be caused by a prolonged medium current. Therefore, the overcurrent protection module 140 will shorten the second time window and trigger thermal protection in advance by reducing the heat accumulation calculation time.

[0121] In a favorable environment with low humidity and low dust, the overcurrent protection module 140 will appropriately relax the threshold to avoid unnecessary protection actions.

[0122] Based on the same general inventive concept, this invention also protects a three-way push rod control method integrating multiple protection functions. The three-way push rod control method integrating multiple protection functions provided by this invention will be described below. The three-way push rod control method integrating multiple protection functions described below can be referred to in correspondence with the three-way push rod control system integrating multiple protection functions described above.

[0123] This invention also provides a three-way push rod control method based on multiple protection functions, including:

[0124] The system collects the operating current signal, operating torque signal, and the action signal of the three-way push rod starting to move. The three-way motor drives the three-way push rod to move along the reversing direction to realize the three-way reversing.

[0125] Monitor the value of the operating current signal within the first time window. If the value exceeds the overcurrent threshold, the power supply to the three-way motor is cut off instantly.

[0126] Calculate the current-time integral value of the operating current signal within the second time window. If the current-time integral value is greater than the preset thermal accumulation threshold, then cut off the power supply to the three-way motor.

[0127] When the operating torque signal exceeds the preset torque threshold, the power supply to the three-way motor is cut off;

[0128] The timing starts after the three-way push rod receives the action signal. If the three-way push rod does not stop running within the preset protection time, the power supply to the three-way motor is cut off.

[0129] When the three-way push rod moves to the pre-set position, the mechanical limit trigger module set at the end of its reversing direction movement path abuts against the three-way push rod, which increases the load on the three-way motor and causes the operating current signal to rise.

[0130] Figure 4 This is a schematic diagram of the structure of the electronic device provided in an embodiment of the present invention.

[0131] like Figure 4As shown, the electronic device may include a processor 410, a communication interface 420, a memory 430, and a communication bus 440. The processor 410, communication interface 420, and memory 430 communicate with each other via the communication bus 440. The processor 410 can call logic instructions from the memory 430 to execute a three-way pushrod control method integrating multiple protection functions.

[0132] Furthermore, the logical instructions in the aforementioned memory 430 can be implemented as software functional units and, when sold or used as independent products, can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, essentially, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0133] On the other hand, the present invention also provides a computer program product, which includes a computer program that can be stored on a non-transitory computer-readable storage medium. When the computer program is executed by a processor, the computer is able to execute the three-way push rod control method based on multiple protection functions provided by the above methods.

[0134] In another aspect, the present invention also provides a non-transitory computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, is implemented to perform the three-way push rod control method based on multiple protection functions provided by the above methods.

[0135] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs. Those skilled in the art can understand and implement this without any creative effort.

[0136] Through the above description of the embodiments, those skilled in the art can clearly understand that each embodiment can be implemented by means of software plus necessary general-purpose hardware platforms, and of course, it can also be implemented by hardware. Based on this understanding, the above technical solutions, in essence or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, magnetic disk, optical disk, etc., and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute the methods described in the various embodiments or some parts of the embodiments.

[0137] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A three-way push rod control system based on integration of multiple protection functions, characterized by, The method comprises the following steps: An execution module comprises a three-way motor and a three-way push rod driven by the three-way motor to realize three-way reversing; A data acquisition module is used to acquire an operating current signal of the three-way motor, an operating torque signal of the three-way push rod, and a motion signal of the three-way push rod starting to move; A mechanical limit triggering module is arranged at the end of the moving path in the reversing direction of the three-way push rod, and is used to abut against the three-way push rod when the three-way push rod moves to a preset position, so that the load of the three-way motor is increased; An overcurrent protection module is used to instantaneously cut off the power supply of the three-way motor when the operating current signal is greater than an overcurrent threshold value within a first time window; An integral value of the operating current signal within a second time window is calculated, and the power supply of the three-way motor is cut off when the integral value is greater than a preset thermal accumulation threshold value; A torque protection module is used to cut off the power supply of the three-way motor when the operating torque signal exceeds a preset torque threshold value; An action time protection module is used to start timing after the three-way push rod receives the motion signal, and the power supply of the three-way motor is cut off if the three-way push rod does not stop operating within a preset protection time.

2. The three-way push rod control system based on integration of multiple protection functions according to claim 1, characterized in that, The overcurrent protection module further comprises a working condition recognition unit; The working condition recognition unit is used to: acquire a working condition parameter representing the load state of the system; dynamically adjust the overcurrent threshold value and the thermal accumulation threshold value based on the working condition parameter; wherein, when a high load working condition is identified, the overcurrent threshold value and the thermal accumulation threshold value are correspondingly increased to allow the three-way motor to output greater torque within a safe range.

3. The three-way push rod control system based on integration of multiple protection functions according to claim 1, characterized in that, The overcurrent protection module further comprises a fault diagnosis unit; The fault diagnosis unit is used to: extract a harmonic component feature of the operating current signal; match the harmonic component feature with a pre-stored fault feature library to obtain a matching degree; the fault feature library at least includes feature patterns corresponding to mechanical jamming, bearing wear, and coil intermittent short circuit; output a corresponding fault warning signal when the matching degree is greater than a preset confidence level.

4. The three-way push rod control system based on integration of multiple protection functions according to claim 1, characterized in that, Further comprising a predictive protection module; the predictive protection module comprises: a historical operation database used to store historical current data, historical working condition parameters, and corresponding fault diagnosis results in association; a current trend prediction unit used to call the historical operation database and perform time series analysis on the operating current signal based on a machine learning algorithm to generate a current change trend; a forward-looking intervention unit used to issue a speed reduction or torque limitation instruction to the three-way motor when the predicted current in the current change trend is greater than the overcurrent threshold value and the fault diagnosis unit does not output the fault warning signal.

5. The three-way push rod control system based on integration of multiple protection functions according to claim 1, characterized in that, The duration of the first time window is 0.05-0.1 seconds, and the duration of the second time window is 1-3 seconds; the thermal accumulation threshold value is set based on the rated heat generating power and the insulation heat resistance level of the three-way motor, and the thermal accumulation threshold value is positively correlated with the duration of the second time window.

6. The three-way push rod control system based on integration of multiple protection functions according to claim 3, characterized in that, The fault diagnosis unit is further used to: When the fault early warning signal is output, a current waveform segment corresponding to the harmonic component feature is recorded synchronously, and the current waveform segment is stored in association with the fault early warning signal in the fault feature library.

7. The three-way push rod control system based on integration of multiple protection functions according to claim 1, characterized in that, The data acquisition module comprises a main circuit current sensor and a backup current sensor; the main circuit current sensor and the backup current sensor are connected in parallel to a power supply loop of the three-way motor; The overcurrent protection module further comprises a signal verification unit; The signal verification unit is configured to: compare running current signals output by the main circuit current sensor and the backup current sensor, and generate a sensor fault alarm and switch to the backup sensor for signal acquisition when a deviation between the two running current signals is greater than a preset deviation.

8. The three-way push rod control system based on integration of multiple protection functions according to claim 4, characterized in that, The prospective intervention unit is further configured to: monitor a change rate of the running current signal after the speed reduction or torque limitation instruction is issued; if the change rate is greater than a preset safety threshold, send an acceleration trigger signal to the overcurrent protection module to instantaneously cut off the power supply of the three-way motor.

9. The three-way push rod control system based on integration of multiple protection functions according to claim 1, characterized in that, The environment perception module is further connected to the overcurrent protection module. The environment perception module is configured to: acquire environment parameters of the three-way motor; the environment parameters comprise temperature, humidity and dust concentration parameters of the running environment. The overcurrent protection module is further configured to: correct the overcurrent threshold and the thermal accumulation threshold based on the environment parameters.

10. A three-way push rod control method based on integration of a plurality of protection functions, characterized by The method comprises: acquiring a running current signal, a running torque signal and a movement signal of the three-way push rod of the three-way motor, and driving the three-way push rod to move in a reversing direction to realize three-way reversing; monitoring a value of the running current signal in a first time window, and instantaneously cutting off the power supply of the three-way motor if the value is greater than an overcurrent threshold; calculating a current time integral value of the running current signal in a second time window, and cutting off the power supply of the three-way motor if the current time integral value is greater than a preset thermal accumulation threshold; cutting off the power supply of the three-way motor when the running torque signal exceeds a preset torque threshold; starting timing after the three-way push rod receives the movement signal, and cutting off the power supply of the three-way motor if the three-way push rod does not stop running within a preset protection time; wherein, when the three-way push rod moves to a preset position, a mechanical limit trigger module arranged at the end of the moving path in the reversing direction of the three-way push rod abuts against the three-way push rod, so that the load of the three-way motor increases and causes the running current signal to rise.

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