Electric drive winch multiple safety control method and rotary drilling rig

Abstract

This invention discloses a multi-level safety control method for an electric-driven winch and a rotary drilling rig, belonging to the field of engineering machinery technology. The electric-driven winch includes a drive motor, a reducer, a first brake, a drum, a winch support, a second brake, and a control system. The multi-level safety control method for the electric-driven winch includes: real-time acquisition of drive motor operating data through the control system to determine whether the drive motor is operating normally; when an abnormal operation of the drive motor is detected, the control system sends a 0-speed braking command to the drive motor to actively reduce its speed; if the drive motor speed does not decrease or the decrease rate does not meet a preset threshold, the control system sends mechanical braking commands to the first and second brakes to mechanically brake them until the drive motor speed decreases to 0. This invention achieves rapid braking of the electric-driven winch in case of failure through a multi-level response strategy, improving the safety and stability of rotary drilling winch operations.

Description

Technical Field

[0001] This invention relates to a multi-safety control method for an electric-driven winch and a rotary drilling rig, belonging to the field of engineering machinery technology. Background Technology

[0002] As construction machinery products gradually move towards electrification, electric rotary drilling rigs, with their motor-driven winches, offer advantages over traditional hydraulic winches, including faster response, higher transmission efficiency, higher control precision, and potential energy recovery during drill rod lowering. They are widely used in building pile foundation construction, bridge foundation construction, and other scenarios. However, in actual operation, rotary drilling winches frequently endure complex conditions such as heavy-load lifting and lowering, drill bit bottoming impact, and sudden load changes. Under abnormal conditions such as power outages, signal failures, and brake failures, they are prone to safety risks such as slippage, stalling, overload, over-releasing, and braking impacts. These risks can damage the equipment structure (e.g., wire rope breakage, drum deformation, and reducer damage) and may even lead to personnel injuries or fatalities, seriously affecting construction safety and efficiency.

[0003] In existing technologies, the safety control of electric drive winches still has many problems: electric drive winches are prone to stalling, slippage and loss of control when lowered under heavy load or under sudden load changes. Existing safety control technologies mostly adopt single speed closed-loop control or single depth limit protection, and mostly use a single braking structure and single braking logic. The brake release and motor torque establishment are not synchronized, which can easily lead to problems such as slippage when the brake is released and impact when the brake is engaged. There is a lack of effective interlocking mechanisms and a lack of multi-dimensional and redundant safety constraint mechanisms. In addition, existing safety control technologies do not set graded response strategies for different fault levels. A single signal fault (motor disconnection, communication interruption) can easily cause safety protection failure. There is a lack of redundancy backup and fault graded processing capabilities, which makes it difficult to meet the high reliability and high safety operation requirements of rotary drilling rigs. Summary of the Invention

[0004] The purpose of this invention is to provide a multi-safety control method for electric-driven winches and a rotary drilling rig. The method involves configuring two brakes and a control system in the electric-driven winch to construct a multi-dimensional, redundant, and hierarchical safety control system. Through multi-level response strategies at the software and hardware levels, the method achieves rapid braking in case of electric-driven winch failure, solving the problems of single safety control, incomplete protection, and untimely response in existing electric-driven winch systems, thereby improving the safety and stability of rotary drilling winch operations.

[0005] To achieve the above objectives / to solve the above technical problems, the present invention is implemented using the following technical solution: On one hand, the present invention provides an electrically driven winch, comprising: The drive motor is used to output torque and drive the winch to rotate forward and backward; A speed reducer is used to reduce the high speed of the drive motor and apply the output torque of the drive motor to the drum. Brake 1 is used to cooperate with the reducer to slow down the speed and to brake according to the braking command; A drum is used to wind steel wire rope. It rotates under the output torque of a drive motor, causing the steel wire rope to move downwards or upwards. A winch support is used to place and secure the winch drum. Brake 2 is a rope reel that acts as a drum and brakes according to a braking command; The control system is used to collect the operating data of the drive motor, determine whether the drive motor is operating normally, and when an abnormality is detected in the drive motor, output the corresponding braking command according to the abnormality level to control the drive motor, brake one and / or brake two to perform electric drive hoist safety control.

[0006] In conjunction with the first aspect, furthermore, the drum, reducer, and drive motor are coaxially connected, wherein the reducer has a reduction structure inside, and the reduction structure is distributed along the circumference of the borehole center along the axial direction of the drum.

[0007] In conjunction with the first aspect, furthermore, the axial connection between the reducer and the drive electrode adopts a flange stop fit and is fixedly connected by bolts around the flange.

[0008] In conjunction with the first aspect, furthermore, brake one is built into the reducer, and brake two is installed on the winch bracket; the number of brake one and brake two is one or more sets.

[0009] Secondly, the present invention provides a multi-safety control method for an electrically driven hoist, comprising: During the operation of the electric drive hoist, the control system collects the working data of the drive motor in real time to determine whether the working status of the drive motor is normal. When an abnormal operating state of the drive motor is detected, the abnormality level of the drive motor is determined based on the drive motor operating data. Based on the abnormality level of the drive motor, the control system outputs the corresponding braking command to control the drive motor, brake one and / or brake two for electric drive hoist safety control.

[0010] In conjunction with the second aspect, the abnormality levels of the drive motor further include: Level 1 - abnormal motor speed, Level 2 - abnormal motor disconnection, and Level 3 - abnormal system high voltage.

[0011] In conjunction with the second aspect, furthermore, when an abnormal speed of the Level 1 motor is detected, the control system sends a speed control command to the drive motor and issues an audible and visual alarm. Based on the response signal of the drive motor, determine whether the speed of the drive motor is controllable; If the speed of the drive motor is controllable, the control system sends a 0-speed braking command to the drive motor to control the drive motor to actively reduce its speed. At the same time, the control system sends a mechanical braking command to brake one and brake two to control brake one and brake two to perform mechanical braking until the speed of the drive motor drops to 0. If the drive motor speed is uncontrollable, the control system sends mechanical braking commands to brake one and brake two to control brake one and brake two to perform mechanical braking until the drive motor speed drops to 0.

[0012] In conjunction with the second aspect, furthermore, when a Level 2 motor disconnection anomaly is detected, the active speed reduction program built into the motor driver is activated, and an audible and visual alarm is triggered. If the drive motor speed decreases, wait for the drive motor speed to drop to 0, and then send a mechanical braking command to brake one and brake two through the control system to control brake one and brake two to perform mechanical braking. If the drive motor speed increases or remains constant, the control system sends a mechanical braking command to brake one and brake two to control brake one and brake two to perform mechanical braking until the drive motor speed drops to 0.

[0013] In conjunction with the second aspect, furthermore, when a high-voltage anomaly is detected in the Level 3 system, the control system sends a 0-speed braking command to the drive motor to control the drive motor to actively reduce its speed. At the same time, the control system sends a mechanical braking command to brake one and brake two to control brake one and brake two to perform mechanical braking until the drive motor speed drops to 0, and then issues an audible and visual alarm.

[0014] Thirdly, the present invention provides a rotary drilling rig, the rotary drilling rig including the electric drive winch provided in the first aspect, the rotary drilling rig employing the multiple safety control method provided in the second aspect to perform safety control on the electric drive winch.

[0015] Compared with the prior art, the beneficial effects achieved by the present invention are as follows: This invention proposes a multi-layered safety control method for electric-driven winches and a rotary drilling rig. It improves the hardware structure of the electric-driven winch by incorporating at least two brakes to enhance braking effectiveness in case of winch malfunctions. Regarding safety control strategies, this invention introduces both software and hardware control to identify real-time faults in the electric-driven winch system, such as stalling, communication failure, and high-voltage anomalies. Different safety control strategies are implemented based on the severity of the fault, accompanied by audible and visual alarms. This method can actively decelerate the motor and trigger both the built-in primary brake and the external hydraulic clamp secondary brake for mechanical braking. Through the coordinated control of safety strategies and dual-redundant mechanical braking, this invention ensures controllable winch speed or complete stoppage, achieving heavy-load safety protection. This invention constructs a multi-dimensional, redundant, and hierarchical safety control system, solving problems such as single-layered safety control, incomplete protection, and communication failure in existing electric-driven winch systems. It effectively improves the safety and stability of rotary drilling winch operations and prevents accidents. Attached Figure Description

[0016] Figure 1 The diagram shown is a structural schematic of an electrically driven winch provided in an embodiment of the present invention; Figure 2 The diagram shows the steps of a multi-safety control method for an electric winch provided in an embodiment of the present invention. Detailed Implementation

[0017] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the embodiments of the present invention and the specific features in the embodiments are detailed descriptions of the technical solution of the present invention, rather than limitations thereof. In the absence of conflict, the embodiments of the present invention and the technical features in the embodiments can be combined with each other. Example

[0018] This embodiment describes an improved electrically driven winch, the structure of which is as follows: Figure 1 As shown, it mainly includes a drive motor 1, a reducer 2, a brake 1 3, a drum 4, a winch support 5, a brake 2 6, and a control system (not shown in the figure). In addition, it also includes a winch rope presser, shaft end support, standard parts, and accessories.

[0019] The drum, reducer, shaft end support, and other components are assembled on the winch support to form the main winch structure. The drum, reducer, and drive motor are coaxially connected. Specifically, the reducer has a reduction structure inside, distributed along the circumference of the borehole center along the drum axis. The drive motor is rigidly or flexibly connected to the reducer. In this invention, the drive motor is used to transmit torque and drive the winch to rotate forward and backward. The reducer is used to reduce the high speed of the drive motor and convert it into a huge torque acting on the drum. The drum is used to wind the wire rope and rotates under the torque, driving the wire rope downward or upward. Brake 1 is built into the reducer and is used to cooperate with the reducer to decelerate and brake. Brake 2 is installed on the winch support and hugs the drum as a rope reel during operation to brake.

[0020] The control system is electrically connected to the drive motor, reducer, brake one, and brake two. During the operation of the electric drive hoist, the control system outputs drive commands to control the drive motor to rotate forward or backward, realizing the wire rope lowering and lifting functions. Simultaneously, the control system identifies faults in the electric drive hoist system in real time, such as stalling, communication failure, and high-voltage anomalies, and executes corresponding safety control strategies and issues audible and visual alarms according to the level of abnormality. This invention, through safety strategies and dual-redundant mechanical braking coordinated control, ensures that the hoisting speed is controllable or stationary, achieving heavy-load safety protection.

[0021] In this embodiment of the invention, the drive motor and the reducer are axially fitted using a flange stop, and are primarily fixed by bolts around the flange. There can be multiple sets of drive motors and reducers, each corresponding to the previous one and of the same quantity.

[0022] Both brake one and brake two are used to perform necessary braking operations during winch operation. Brake one is directly built into the reducer to achieve primary braking, while brake two is set on the winch support to achieve secondary braking. Through multi-stage mechanical forced braking, the problem of loss of control caused by winch failure can be better avoided, thereby improving the safety and stability of rotary drilling winch operation.

[0023] The structure of brake one and brake two is not limited; any existing brake structure can be used, and there can be multiple sets of brakes. Preferably, brake one is a friction pad brake, and brake two is a hydraulic caliper brake. Example

[0024] Based on the electrically driven winch described in Embodiment 1, this embodiment introduces a multi-safety control method for electrically driven winches, such as... Figure 2 As shown, the main steps include the following: Step 1: Before the electric drive hoist starts working, the system performs a self-test to determine whether the current electric drive hoist system is normal, including but not limited to whether the connections of each module in the system are normal and whether the built-in parameters of the system are normal. If the system is normal, the electric drive hoist starts working. If the system is abnormal, a system abnormality alarm is triggered, and the system continues working only after the abnormality is resolved.

[0025] Step 2: During the operation of the electric hoist, the control system collects the working data of the drive motor in real time to determine whether the working status of the drive motor is normal. The working status of the drive motor includes stationary, lifting and lowering. The hoist can perform corresponding actions according to the handle command. When an abnormal working status of the drive motor is detected, the safety control stage is entered.

[0026] Step 3: In the safety control phase, firstly, the software control cycle is shortened to improve the system response time, enabling the electric hoisting system to quickly react to abnormalities. Then, the abnormality level of the drive motor is determined based on the drive motor's operating data. In this embodiment of the invention, the drive motor mainly includes three abnormality levels: Level 1 - abnormal motor speed, Level 2 - abnormal motor disconnection, and Level 3 - abnormal system high voltage. Levels 1-3 are from low to high.

[0027] Step 4: When an abnormal motor speed is detected in Level 1, the control system sends a speed control command to the drive motor and displays a "Level 1 Motor Speed ​​Abnormality" alarm on the display. The control system obtains the response signal from the drive motor and determines whether the drive motor speed is controllable based on the response signal.

[0028] If the drive motor speed is controllable, the control system sends a 0-speed braking command to the drive motor to control the drive motor to actively reduce its speed. At the same time, the control system sends mechanical braking commands to brake one and brake two to control brake one and brake two to perform mechanical braking at the hardware level. With the cooperation of hardware and software, the drive motor speed is reduced to 0, thus completing the safety control of the electric drive winch and avoiding the more serious consequences caused by winch stall.

[0029] If the drive motor speed is uncontrollable, it is no longer possible to reduce the speed of the drive motor through software control. Only hardware forced braking can be performed. The control system sends mechanical braking commands to brake one and brake two to control brake one and brake two to perform mechanical braking until the drive motor speed drops to 0.

[0030] Step 5: The control system controls the operation of the drive motor by controlling the motor driver inside the drive motor. When the control system and the motor driver do not receive a signal from each other for a period of time (time length N), it indicates that the communication connection between the control system and the motor driver is broken, which is regarded as a detection of Level 2 - Motor disconnection abnormality. The present invention sets an active speed reduction program inside the motor driver. When the motor driver does not receive a signal from the control system for N consecutive time, the active speed reduction program is started, and the motor driver reduces the speed of the drive motor, and displays the alarm "Level 2 - Motor disconnection abnormality" on the display.

[0031] If the active deceleration program can run normally and the drive motor speed decreases, then wait for the drive motor speed to drop to 0. At this time, the drive motor is in a stalled state. Since there is a risk of stall function failure due to the drive motor being stalled for a long time, this invention sends mechanical braking commands to brake one and brake two through the control system to control brake one and brake two to perform mechanical braking, so as to avoid the motor restarting and causing danger after the stall function fails.

[0032] If the active deceleration program fails to operate normally, and the drive motor speed increases or remains unchanged, it is necessary to send mechanical braking commands to brake one and brake two through the control system to control brake one and brake two to perform mechanical braking until the drive motor speed drops to 0. In this case, "Level 2 - Drive Motor Abnormal" and "Level 2 - Motor Driver Abnormal" alarms can be displayed on the monitor so that technicians can understand the situation in time.

[0033] Step 6: When a Level 3 system high voltage abnormality is detected, the control system sends a 0-speed braking command to the drive motor to control the drive motor to actively reduce its speed. At the same time, the control system sends a mechanical braking command to brake one and brake two to control brake one and brake two to perform mechanical braking until the drive motor speed drops to 0, and displays a "Level 3 system high voltage abnormality" alarm on the display.

[0034] The multiple safety control strategies of this invention can control the drive motor to actively reduce speed at the software level and control the two-stage brakes to perform mechanical forced braking at the hardware level, which can effectively improve the comprehensiveness and timeliness of the abnormal response of the electric drive hoist.

[0035] During the safety control phase, the present invention first performs anomaly detection on the power supply of the high-voltage system; if the high-voltage system is normal, it further determines whether the drive motor has stalled or lost connection; and prioritizes handling faults with higher fault registration to improve system safety. Example

[0036] This embodiment describes a rotary drilling rig that includes the electric drive winch described in Embodiment 1, and the electric drive winch can be safely controlled using the method described in Embodiment 2.

[0037] In summary, this invention improves the hardware structure of the electric hoist by incorporating at least two brakes to enhance braking performance in case of hoist malfunction. Regarding safety control strategies, this invention introduces both software and hardware control to identify real-time faults in the electric hoist system, such as stalling, communication failure, and high-voltage anomalies. Safety control strategies are implemented according to the severity of the fault, triggering audible and visual alarms. This involves both pre-programmed safety procedures to actively decelerate the motor and sequentially triggering the built-in primary brake of the reducer and the external hydraulic caliper secondary brake. Through the coordinated control of safety strategies and dual redundant mechanical brakes, the hoist speed is ensured to be controllable or stationary, achieving heavy-load safety protection.

[0038] This invention constructs a multi-dimensional, redundant, and hierarchical safety control system, which solves the problems of single safety control, incomplete protection, and communication failure in existing electric-driven winches. It can effectively improve the safety and stability of rotary drilling winch operations and prevent safety accidents.

[0039] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0040] The embodiments of the present invention have been described above with reference to the accompanying drawings. However, the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the present invention without departing from the spirit and scope of the claims. All of these forms are within the protection scope of the present invention.

Claims

1. An electrically driven winch, characterized in that, include: The drive motor is used to output torque and drive the winch to rotate forward and backward; A speed reducer is used to reduce the high speed of the drive motor and apply the output torque of the drive motor to the drum. Brake 1 is used to cooperate with the reducer to slow down the speed and to brake according to the braking command; A drum is used to wind steel wire rope. It rotates under the output torque of a drive motor, causing the steel wire rope to move downwards or upwards. A winch support is used to place and secure the winch drum. Brake 2 is a rope reel that acts as a drum and brakes according to a braking command; The control system is used to collect the operating data of the drive motor, determine whether the drive motor is operating normally, and when an abnormality is detected in the drive motor, output the corresponding braking command according to the abnormality level to control the drive motor, brake one and / or brake two to perform electric drive hoist safety control.

2. The electrically driven winch according to claim 1, characterized in that, The drum, reducer, and drive motor are coaxially connected. The reducer has a reduction structure inside, which is distributed along the circumference of the borehole center along the drum axis.

3. The electrically driven winch according to claim 1, characterized in that, The reducer and drive electrode are axially fitted with a flange stop and fixedly connected by bolts around the flange.

4. The electrically driven winch according to claim 1, characterized in that, Brake 1 is built into the reducer, and brake 2 is installed on the winch support; there may be one or more sets of brake 1 and brake 2.

5. A multi-safety control method based on the electrically driven hoist of claim 1, characterized in that, include: During the operation of the electric drive hoist, the control system collects the working data of the drive motor in real time to determine whether the working status of the drive motor is normal. When an abnormal operating state of the drive motor is detected, the abnormality level of the drive motor is determined based on the drive motor operating data. Based on the abnormality level of the drive motor, the control system outputs the corresponding braking command to control the drive motor, brake one and / or brake two for electric drive hoist safety control.

6. The multiple security control method according to claim 5, characterized in that, The abnormality levels of the drive motor include: Level 1 - abnormal motor speed, Level 2 - abnormal motor disconnection, and Level 3 - abnormal system high voltage.

7. The multiple security control method according to claim 6, characterized in that, When an abnormal motor speed is detected in Level 1, the control system sends a speed control command to the drive motor and issues an audible and visual alarm. Based on the response signal of the drive motor, determine whether the speed of the drive motor is controllable; If the speed of the drive motor is controllable, the control system sends a 0-speed braking command to the drive motor to control the drive motor to actively reduce its speed. At the same time, the control system sends a mechanical braking command to brake one and brake two to control brake one and brake two to perform mechanical braking until the speed of the drive motor drops to 0. If the drive motor speed is uncontrollable, the control system sends mechanical braking commands to brake one and brake two to control brake one and brake two to perform mechanical braking until the drive motor speed drops to 0.

8. The multiple security control method according to claim 6, characterized in that, When a Level 2 motor disconnection anomaly is detected, the motor driver's built-in active speed reduction program is activated, and an audible and visual alarm is triggered. If the drive motor speed decreases, wait for the drive motor speed to drop to 0, and then send a mechanical braking command to brake one and brake two through the control system to control brake one and brake two to perform mechanical braking. If the drive motor speed increases or remains constant, the control system sends a mechanical braking command to brake one and brake two to control brake one and brake two to perform mechanical braking until the drive motor speed drops to 0.

9. The multiple security control method according to claim 6, characterized in that, When a Level 3 high-voltage anomaly is detected, the control system sends a 0-speed braking command to the drive motor to actively reduce its speed. At the same time, the control system sends mechanical braking commands to brake one and brake two to mechanically brake them until the drive motor speed drops to 0, and then issues an audible and visual alarm.

10. A rotary drilling rig, characterized in that, The rotary drilling rig includes an electrically driven winch as described in any one of claims 1-4, and the rotary drilling rig employs a multi-safety control method as described in any one of claims 5-9 to perform safety control on the electrically driven winch.

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