A power-off protection device and method for a paper cup machine servo system

Abstract

This invention relates to a power failure protection device and method for a paper cup machine servo system, comprising the following steps: S1, converting AC mains power to DC power at the rated operating voltage, and monitoring the output voltage and current in real time; S2, sending a pre-charging command to control the capacitor bank to charge to a preset voltage upper limit, and performing current and temperature protection during charging; S3, parsing the servo motor speed command according to the production command, and driving the servo motor to run using the servo drive module; S4, continuously collecting the output voltage, and executing a power supply abnormality warning response when the output voltage is greater than the emergency voltage threshold and less than or equal to the warning voltage threshold, and executing a sudden power failure response when the output voltage is less than or equal to the emergency voltage threshold; S5, after the sudden power failure response, smoothly decelerating the servo motor to a stop according to a preset shutdown curve. The beneficial effect of this invention is that it switches to the energy storage module for power supply during a sudden power failure and stops the machine according to the preset shutdown curve, ensuring mold safety.

Description

Technical Field

[0001] This invention relates to the field of paper cup machine production equipment technology, specifically to a power failure protection device and method for a paper cup machine servo system. Background Technology

[0002] In the process of mass production of paper cups, paper cup machines need to drive key components such as die-cutting mechanism and forming mechanism to operate at high speed through servo system. The start-stop response speed and operation stability of servo motor directly determine product quality and production efficiency.

[0003] In existing technologies, the servo system of paper cup machines mostly uses AC mains power, which is rectified to power the servo drive module. When a sudden power failure occurs, the servo system loses power support, and the servo motor cannot achieve controllable stopping due to the lack of braking power source. This can lead to runaway phenomena, causing collisions of key components such as die-cutting blades and forming molds, resulting in mold damage and equipment downtime for maintenance. This not only increases production costs but also seriously affects production progress. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this application proposes a power failure protection device and method for a paper cup machine servo system. In the event of a sudden power failure, the device switches to an energy storage module for power supply and simultaneously stops the machine according to a preset shutdown curve. This solves the core problem of servo motor overrunning and crashing during a sudden power failure in a paper cup machine, ensuring mold safety, reducing equipment maintenance costs, and improving production continuity.

[0005] The following is the technical solution of the present invention: a power failure protection method for a paper cup machine servo system, comprising the following steps: S1. Convert AC mains power to DC power at the rated operating voltage and monitor the output voltage and current in real time; S2. Send a pre-charge command to control the capacitor bank to charge to the preset upper voltage limit, and perform current and temperature protection during the charging process; S3. Parse the servo motor speed command from the production command, and the servo drive module drives the servo motor to run. S4. Continuously collect the output voltage. When the output voltage is greater than the emergency voltage threshold and less than or equal to the warning voltage threshold, execute the power supply abnormality warning response. When the output voltage is less than or equal to the emergency voltage threshold, execute the sudden power outage response. S5. After a sudden power outage, the servo motor will smoothly decelerate to a stop according to the preset shutdown curve.

[0006] As a preferred embodiment of the present invention, in S4, the power supply anomaly warning response includes: Calculate the real-time load power of the servo motor; If the real-time load power is greater than the load power threshold, the servo motor will be controlled to reduce its speed. If the real-time load power is not greater than the load power threshold and the capacitor bank is in a charging state, then increase the target charging voltage of the capacitor bank.

[0007] As a preferred embodiment of the present invention, in S4, the sudden power outage response includes: When the output voltage remains below the emergency voltage threshold for a preset delay time, it is determined to be a sudden power outage; Send commands to switch to power supply from the energy storage module and to stop the system, and send a discharge command to the energy storage module; The energy storage module controls the capacitor bank to discharge.

[0008] As a preferred embodiment of the present invention, in S5, the preset shutdown curve includes: The curve shows how the servo motor linearly decelerates from its current speed to zero speed, with a deceleration time of 2 to 4 seconds.

[0009] As a preferred embodiment of the present invention, in S2, temperature protection during charging includes: When the capacitor temperature exceeds 45℃, start the cooling fan.

[0010] A power failure protection device for a paper cup machine servo system includes: The DC power supply module is used to convert AC power into DC voltage for the servo system, providing both operating power and charging power. The energy storage module is used to store electrical energy during normal operation and to quickly release electrical energy in the event of a sudden power outage. It is connected to the DC power supply module. The power failure detection module is used to monitor the output voltage and identify abnormal voltage conditions based on the output voltage, and is connected to the DC power supply module. The servo drive module is used to convert DC power into three-phase AC power for the servo motor and connects to the DC power supply module and the energy storage module. The execution module receives power output, completes the paper cup production process, and connects to the servo drive module.

[0011] As a preferred embodiment of the present invention, the energy storage module is provided with a heat dissipation unit that is attached to the capacitor bank. The heat dissipation unit includes a heat sink, a temperature sensor and a cooling fan.

[0012] As a preferred embodiment of the present invention, the DC power supply module includes a rectifier and filter unit, a voltage regulator unit, and an overcurrent protection unit, wherein the overcurrent protection unit is provided with a fuse and a current sensor.

[0013] The beneficial effects of this invention are: by designing a DC power supply module and an energy storage module, the power supply is switched to the energy storage module in the event of a sudden power outage. At the same time, the machine is stopped according to a preset shutdown curve, which solves the core problem of servo motor overrunning and crashing when the paper cup machine experiences a sudden power outage, ensuring mold safety, reducing equipment maintenance costs, and improving production continuity. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the device of the present invention; Figure 2 This is a flowchart of the method of the present invention; In the diagram: 1. DC power supply module; 2. Energy storage module; 3. Power failure detection module; 4. Servo drive module; 5. Execution module. Detailed Implementation

[0015] To make the technical problems solved by the present invention, the technical solutions adopted, and the technical effects achieved clearer, the technical solutions of the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0016] Example 1 like Figure 1 As shown, a power failure protection device for a paper cup machine servo system includes: DC power supply module 1 is used to convert AC power into DC voltage for the servo system, providing working power and charging power; Energy storage module 2 is used to store electrical energy during normal operation and to quickly release electrical energy in the event of a sudden power outage. It is connected to DC power supply module 1. The power failure detection module 3 is used to monitor the output voltage and identify abnormal voltage conditions based on the output voltage, and is connected to the DC power supply module 1; Servo drive module 4 is used to convert DC power into three-phase AC power for the servo motor and is connected to DC power supply module 1 and energy storage module 2. Execution module 5 is used to receive power output, complete the paper cup production process, and is connected to servo drive module 4; The main control module adjusts the control strategy based on the status data fed back from each module.

[0017] In this embodiment, the main control module adjusts the control strategy based on the status data fed back from each module. The main control module is connected to the DC power supply module 1, the energy storage module 2, the power failure detection module 3, and the servo drive module 4. After the system is powered on, it first completes a self-test, receives the production parameters from the paper cup machine's main controller, parses them, and sends running instructions to the servo drive module 4. At the same time, it receives the status data fed back from each module in real time and adjusts the control strategy accordingly.

[0018] In this embodiment, the DC power supply module 1 converts mains power into DC voltage for the servo system, providing continuous operating power for the servo drive module 4 and charging power for the energy storage module 2. The DC power supply module 1 includes a rectifier and filter unit, a voltage regulator unit, and an overcurrent protection unit, wherein the overcurrent protection unit is equipped with a fuse and a current sensor. The input terminal of the DC power supply module 1 is connected to the mains power, the output terminal of the rectifier and filter unit is connected to the input terminal of the voltage regulator unit, the output terminal of the voltage regulator unit is connected to both the servo drive module 4 and the energy storage module 2, and the overcurrent protection unit is connected in series between the output terminal of the voltage regulator unit and the load.

[0019] In this embodiment, the energy storage module 2 stores electrical energy during normal operation and rapidly releases it during a sudden power outage. The energy storage module 2 includes a capacitor bank, an energy storage management unit, and a heat dissipation unit. The energy storage management unit is equipped with a voltage detection circuit, a current detection circuit, a charging control switch, and a discharging control switch. The heat dissipation unit is equipped with a temperature sensor, a heat sink, and a cooling fan. The charging input terminal of the energy storage management unit is connected to a voltage regulator unit, and the discharging output terminal is connected to a servo drive module 4. The output terminals of the voltage detection circuit and the current detection circuit are connected to the main control module. The heat dissipation unit and the capacitor bank are mounted in close contact, and the cooling fan is controlled by the main control module.

[0020] In this embodiment, the power failure detection module 3 is used to monitor the input or output voltage of the DC power supply module 1, identify abnormal conditions such as power failure and voltage drop, and convert the detection signal into a digital signal to feed back to the main control module. The power failure detection module 3 is equipped with a voltage sampling circuit, a signal comparison circuit, and a delay trigger circuit. The input terminal of the voltage sampling circuit is connected to the regulated output terminal of the DC power supply module 1, the input terminal of the signal comparison circuit is connected to the output terminal of the voltage sampling circuit, the input terminal of the delay trigger circuit is connected to the output terminal of the signal comparison circuit, and the output terminal of the delay trigger circuit is connected to the signal input terminal of the main control module.

[0021] In this embodiment, the servo drive module 4 is used to convert the DC power provided by the DC power supply module 1 or the energy storage module 2 into three-phase AC power for the servo motor. The servo drive module 4 includes a drive chip, an inverter, and a main / backup power switching circuit. The main power input terminal of the servo drive module 4 is connected to the regulated output terminal of the DC power supply module 1, and the backup power input terminal of the servo drive module 4 is connected to the discharge output terminal of the energy storage module 2. The main / backup power switching circuit is connected in series between the input terminals of the main power supply and the backup power supply and the drive chip, and converts the DC power from the main power supply and the backup power supply into three-phase AC power for the servo motor through the inverter. During normal operation, the main / backup power switching circuit connects to the main power supply, driving the servo motor to run. In the event of a sudden power failure, it receives a switching command from the main control module, and the main / backup power switching circuit switches to the backup power supply of the energy storage module 2, controlling the motor to decelerate and stop.

[0022] In this embodiment, the execution module 5 receives the power output from the servo drive module 4 and converts the rotational motion of the servo motor into the motion of the execution component through the transmission assembly to complete the paper cup production process. The execution module 5 includes a servo motor, a transmission assembly, and an execution component. The input end of the servo motor is connected to the output end of the servo drive module 4, the output end of the servo motor is connected to the transmission assembly, and the transmission assembly is connected to the execution component.

[0023] Example 2 like Figure 2 As shown, a power failure protection method for a paper cup machine servo system includes the following steps: S1. Convert AC mains power to DC power at the rated operating voltage and monitor the output voltage and current in real time; S2. Send a pre-charge command to control the capacitor bank to charge to the preset upper voltage limit, and perform current and temperature protection during the charging process; S3. Parse the servo motor speed command according to the production command, and the servo drive module 4 drives the servo motor to run. S4. Continuously collect the output voltage. When the output voltage is greater than the emergency voltage threshold and less than or equal to the warning voltage threshold, execute the power supply abnormality warning response. When the output voltage is less than or equal to the emergency voltage threshold, execute the sudden power outage response. S5. After a sudden power outage, the servo motor will smoothly decelerate to a stop according to the preset shutdown curve.

[0024] In step S1, the AC mains power is converted to DC power at the rated operating voltage, and the output voltage and current are monitored in real time, including the following steps: S101. The AC mains power is converted into DC power with rated operating voltage through the DC power supply module 1 to power the servo drive module 4. When connected to AC power, the rectifier and filter unit converts the AC voltage into a pulsating DC voltage, and the voltage regulator unit stabilizes the DC voltage at the rated operating voltage of the servo system.

[0025] S102. Real-time monitoring of output voltage and current; The system monitors the output voltage and feeds it back to the main control module. If the voltage deviates from the preset range, the main control module transmits a command to the voltage regulator unit to adjust the voltage. It also monitors the output current. When the current exceeds the threshold, the fuse blows or the main control module is triggered to cut off the power supply to avoid overload damage.

[0026] In step S2, a pre-charge command is sent to control the capacitor bank to charge to a preset upper voltage limit, and current and temperature protection is performed during the charging process, including the following steps: S201, Send pre-charge command; A pre-charge command is sent to the energy storage management unit of energy storage module 2. The energy storage management unit closes the charging control switch, and the capacitor bank begins charging through DC power supply module 1.

[0027] S202. Current and temperature protection are performed during charging; The current detection circuit monitors the charging current. If the charging current exceeds the maximum surge current, the energy storage management unit reduces the charging current to prevent the capacitor bank from being overcharged. At the same time, the temperature sensor of the heat dissipation unit monitors the capacitor temperature. When the temperature exceeds 45°C, the cooling fan is activated to dissipate heat from the capacitor bank.

[0028] S203, Control the capacitor bank to charge to the preset upper voltage limit; When the terminal voltage of the capacitor bank reaches the preset upper limit, the voltage detection circuit sends a feedback signal to the main control module, disconnects the charging control switch, and stops the capacitor charging.

[0029] In step S3, the servo motor speed command is parsed from the production command, and the servo drive module 4 drives the servo motor to run, including the following steps: S301. Parse the servo motor speed command based on the production command; After receiving the production instruction, the paper cup machine parses the production speed in the production instruction into the rotation speed instruction of the servo motor, and sends the rotation speed instruction to the servo drive module 4.

[0030] S302, servo drive module 4 drives the servo motor to run; After receiving the speed command, the servo drive module 4 keeps the main power supply connected and converts the DC power into three-phase AC power through the inverter. After receiving the three-phase AC power, the servo motor starts to run and performs the paper cup production process through the transmission component and the execution component.

[0031] In step S4, the output voltage is continuously collected. When the output voltage is greater than the emergency voltage threshold and less than or equal to the warning voltage threshold, a power supply abnormality warning response is executed. When the output voltage is less than or equal to the emergency voltage threshold, a sudden power outage response is executed, including the following steps: S401, Continuously acquire the output voltage of DC power supply module 1; The voltage sampling circuit of the power failure detection module 3 continuously collects the output voltage of the DC power supply module 1, amplifies it, and transmits it to the signal comparator.

[0032] S402. Compare the collected output voltage with the preset warning voltage threshold and emergency voltage threshold: S4021. When the output voltage is greater than the emergency voltage threshold and less than or equal to the warning voltage threshold, execute the power supply abnormality warning response. If the output voltage is greater than the emergency voltage threshold and less than or equal to the warning voltage threshold, it is determined as a power supply abnormality warning. The load torque and speed are collected, and the load power of the servo motor is calculated based on the load torque and speed. If the load power is greater than the set load power threshold, the speed of the servo motor is reduced by 10%; if the load power is less than or equal to the load power threshold, the servo motor maintains the current speed. If the energy storage module 2 is charging, the charging voltage of the capacitor bank of the energy storage module 2 is increased by 10%.

[0033] S4022. When the output voltage is less than or equal to the emergency voltage threshold, execute the emergency power failure response. If the output voltage is less than or equal to the emergency voltage threshold, it is determined to be a sudden power failure. The signal comparator outputs a low-level signal, and the delay trigger circuit starts timing. After the timing ends, the delay trigger circuit sends a power failure signal to the main control module. After receiving the power failure signal, the main control module sends a power switching command to the servo drive module 4 and a discharge command to the energy storage module 2. After receiving the power switching command, the main power switching circuit of the servo drive module 4 disconnects the main power supply and switches to the backup power supply of the energy storage module 2, and supplies power to the servo drive module 4 through the backup power supply. After receiving the discharge command, the energy storage management unit of energy storage module 2 closes the discharge control switch to switch to discharge mode. The capacitor bank outputs DC power to servo drive module 4 according to the preset discharge current. The DC power is converted into three-phase AC power by the inverter, and servo drive module 4 stops.

[0034] In step S5, after the sudden power failure response, the servo motor is smoothly decelerated to a stop according to the preset shutdown curve, including: After the servo drive module 4 switches to energy storage power supply, it receives a stop command from the main control module. The stop command includes a preset stop curve, which linearly decelerates the motor from the current speed to 0 rpm in 3 seconds. The servo drive module 4 gradually reduces the frequency of the output AC power according to the shutdown curve to avoid shutdown impact.

[0035] In this invention, by designing a DC power supply module 1 and an energy storage module 2, the power supply is switched to the energy storage module 2 during a sudden power outage. At the same time, the machine is stopped according to a preset shutdown curve, which solves the core problem of servo motor overrunning and crashing when the paper cup machine experiences a sudden power outage, ensuring mold safety, reducing equipment maintenance costs, and improving production continuity.

[0036] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Clearly, those skilled in the art can make various alterations and variations to the invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of equivalents of the invention, the invention is also intended to include these modifications and variations.

Claims

1. A power failure protection method for a paper cup machine servo system, characterized in that, Includes the following steps: S1. Convert AC mains power to DC power at the rated operating voltage and monitor the output voltage and current in real time; S2. Send a pre-charge command to control the capacitor bank to charge to the preset upper voltage limit, and perform current and temperature protection during the charging process; S3. Parse the servo motor speed command from the production command, and the servo drive module drives the servo motor to run. S4. Continuously collect the output voltage. When the output voltage is greater than the emergency voltage threshold and less than or equal to the warning voltage threshold, execute the power supply abnormality warning response. When the output voltage is less than or equal to the emergency voltage threshold, execute the sudden power outage response. S5. After a sudden power outage, the servo motor will smoothly decelerate to a stop according to the preset shutdown curve.

2. The power failure protection method for a paper cup machine servo system according to claim 1, characterized in that, In S4, the power supply anomaly warning response includes: Calculate the real-time load power of the servo motor; If the real-time load power is greater than the load power threshold, the servo motor will be controlled to reduce its speed. If the real-time load power is not greater than the load power threshold and the capacitor bank is in a charging state, then increase the target charging voltage of the capacitor bank.

3. The power failure protection method for a paper cup machine servo system according to claim 1, characterized in that, In S4, the emergency power outage response includes: When the output voltage remains below the emergency voltage threshold for a preset delay time, it is determined to be a sudden power outage; Send commands to switch to power supply from the energy storage module and to stop the system, and send a discharge command to the energy storage module; The energy storage module controls the capacitor bank to discharge.

4. The power failure protection method for a paper cup machine servo system according to claim 1, characterized in that, In S5, the preset shutdown curves include: The curve shows how the servo motor linearly decelerates from its current speed to zero speed, with a deceleration time of 2 to 4 seconds.

5. The power failure protection method for a paper cup machine servo system according to claim 1, characterized in that, In S2, temperature protection is implemented during charging, including: When the capacitor temperature exceeds 45℃, start the cooling fan.

6. A power failure protection device for a paper cup machine servo system, applicable to the power failure protection method for a paper cup machine servo system as described in any one of claims 1-5, characterized in that, include: The DC power supply module is used to convert AC power into DC voltage for the servo system, providing both operating power and charging power. The energy storage module is used to store electrical energy during normal operation and to quickly release electrical energy in the event of a sudden power outage. It is connected to the DC power supply module. The power failure detection module is used to monitor the output voltage and identify abnormal voltage conditions based on the output voltage, and is connected to the DC power supply module. The servo drive module is used to convert DC power into three-phase AC power for the servo motor and connects to the DC power supply module and the energy storage module. The execution module receives power output, completes the paper cup production process, and connects to the servo drive module.

7. The power failure protection device for a paper cup machine servo system according to claim 6, characterized in that, The energy storage module is equipped with a heat dissipation unit that is attached to the capacitor bank. The heat dissipation unit includes a heat sink, a temperature sensor, and a cooling fan.

8. The power failure protection device for a paper cup machine servo system according to claim 6, characterized in that, The DC power supply module includes a rectifier and filter unit, a voltage regulator unit, and an overcurrent protection unit. The overcurrent protection unit is equipped with a fuse and a current sensor.

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