A smart drive and safety control system for a rotary milking machine

Abstract

This invention relates to the field of automated livestock farming equipment technology, specifically to an intelligent drive and safety control system for a rotary milking machine. The drive module includes six identical frequency converters and six 1.1KW motors. The frequency converters are connected to the central control unit via the 485 communication protocol. Each frequency converter drives one motor, enabling forward and reverse rotation and speed control of the rotary table. The advantages of this invention are: efficient fault diagnosis: all hardware of the safety monitoring module is independently connected to the central control unit, allowing direct fault location via the human-machine interface module, eliminating the need for piecemeal troubleshooting and significantly reducing fault handling time; it supports temporary shielding of faulty hardware, reducing downtime losses. It also features an early warning mechanism: by real-time monitoring of motor current, frequency, speed, and load data, the system can predict the equipment's operating status in advance, enabling preventative maintenance, avoiding downtime caused by serious faults, and extending the equipment's service life.

Description

Technical Field

[0001] This invention relates to the field of automated livestock farming equipment technology, specifically to an intelligent drive and safety control system for a rotary milking machine. Background Technology

[0002] In modern livestock farming, rotary milking machines are widely used due to their high milking efficiency. The stability of their drive and safety control systems directly affects production efficiency and the safety of personnel and dairy cows. Existing rotary milking machine control systems mainly use circuit board (microcontroller) control and safety relay control, with all safety circuits connected in series, which has the following technical drawbacks:

[0003] Low efficiency in troubleshooting: Because the safety circuits are connected in series, when a fault occurs at a certain point, hardware needs to be checked one by one, which consumes a lot of time and results in excessive downtime.

[0004] Lack of equipment early warning mechanism: The existing system cannot monitor the motor operating status (such as current, frequency, load, etc.) in real time. There is no early warning when the motor is abnormal. It often stops only when a serious fault occurs, causing equipment damage and production interruption.

[0005] Hardware is closed and solidified: Most existing products are imported. In order to achieve a monopoly, manufacturers adopt closed hardware design and solidify the system, which does not support domestic substitution, resulting in high maintenance costs and poor compatibility.

[0006] Inadequate safety protection: There is a lack of comprehensive safety protection for scenarios such as cows entering and leaving, equipment collisions, and personnel operations, which poses safety hazards.

[0007] Therefore, developing an intelligent drive and safety control system with rapid fault diagnosis, equipment status early warning, comprehensive safety protection, and strong compatibility has become the key to solving existing technical problems. Summary of the Invention

[0008] This invention aims to solve the technical problems of existing rotary milking machine control systems, such as difficulty in troubleshooting, lack of early warning mechanisms, hardware encapsulation, and insufficient safety protection, and to provide a safe, reliable, easy-to-maintain, and highly intelligent drive and safety control system.

[0009] A smart drive and safety control system for a rotary milking machine, characterized in that it includes:

[0010] The central control unit uses an ABB industrial CPU to receive control commands, process safety monitoring signals, and drive control signals.

[0011] The drive module includes six frequency converters of the same model (VFD1.1, VFD1.2, VFD2.1, VFD2.2, VFD3.1, VFD3.2) and six 1.1KW motors. The frequency converters are connected to the central control unit via the 485 communication protocol. Each frequency converter drives one motor to realize the forward and reverse rotation and speed control of the turntable.

[0012] The safety monitoring module includes a cow entry and exit anti-pinch device, an inner / outer emergency stop switch, an inner / outer pull rope switch, an inner anti-collision switch, a cleaning positioning switch, a cleaning safety switch, and a safety interlock device. All safety hardware is independently connected to the central control unit to achieve independent monitoring of the safety status.

[0013] The human-machine interface module uses a field touch screen and communicates with the central control unit via a network cable. It is used to display motor operating parameters (current, frequency, speed, load), safety hardware status, and provides parameter adjustment, fault alarm, fault shielding and mode switching functions.

[0014] The emergency control module includes an emergency handheld device and a local control box. The emergency handheld device can be directly connected to the frequency converter to realize emergency forward and reverse control of the motor when the central control unit or human-machine interaction module fails. The local control box is used for operation control under normal working conditions.

[0015] As a further embodiment of the present invention, the central control unit is equipped with DI interfaces (DI1, DI2, DI3, etc.), DO interface (DO1) and a DC24V power supply circuit. It is connected to each module through terminal blocks (TB1.1, TB1.2, TB2.1, TB2.2, TB3.1, TB3.2). The power supply circuit is equipped with 10A and 5A circuit breakers (QF4, QF5) for overload protection.

[0016] As a further aspect of the present invention, the human-computer interaction module has a fault location function. When the safety hardware fails, the corresponding location is displayed in red and a text prompt pops up, while the fault information is recorded. It supports the operation of shielding faulty hardware, and the faulty component can be temporarily shielded after password verification to ensure the continuous operation of the system.

[0017] As a further embodiment of the present invention, the anti-pinch device in the safety monitoring module includes an inlet forward / reverse anti-pinch switch, an inlet forward / reverse anti-pinch cup switch, an outlet forward / reverse anti-pinch switch, an outlet forward anti-pinch cup switch, and a reverse anti-pinch system. All anti-pinch signals are transmitted to the central control unit in real time to achieve rapid shutdown in abnormal situations.

[0018] As a further embodiment of the present invention, the frequency converter of the drive module supports speed regulation. The system speed regulation frequency can be set through the human-machine interaction module, with a range of 0-50HZ. The central control unit can realize early warning judgment of the equipment operating status by monitoring the motor current and load data.

[0019] As a further embodiment of the present invention, the system also includes a secondary control circuit, which is equipped with a safety control relay (KM1), a switching power supply and a secondary control circuit power switch (SP1) to realize independent power supply and safety protection for the control circuit.

[0020] The beneficial effects of this invention are:

[0021] Highly efficient troubleshooting: All hardware components of the safety monitoring module are independently connected to the central control unit. The fault location can be directly located through the human-machine interface module, eliminating the need for individual troubleshooting and significantly reducing fault handling time. It also supports temporary shielding of faulty hardware, reducing downtime losses.

[0022] It has an early warning mechanism: by monitoring motor current, frequency, speed and load data in real time, it can judge the equipment operating status in advance, realize preventive maintenance, avoid downtime caused by serious failures, and extend the service life of the equipment.

[0023] High compatibility: It adopts an open hardware design, and the central control unit and frequency converter are both selected from highly versatile industrial-grade products, supporting domestic substitution and reducing maintenance and procurement costs.

[0024] Comprehensive safety protection: Equipped with all-round safety protection components, covering all critical scenarios such as cow entry and exit, equipment collisions, and personnel operation. Through real-time communication and rapid response of the central control unit, the safety of personnel, cows, and equipment is ensured.

[0025] Easy to operate: The human-machine interface is intuitive and supports operations such as parameter adjustment, mode switching and fault handling. It is also equipped with a local operation box and an emergency handheld device to meet the operational needs under different working conditions and improve the practicality of the system.

[0026] Obviously, based on the above description of the present invention, and according to common technical knowledge and conventional methods in the field, various other modifications, substitutions or alterations can be made without departing from the basic technical concept of the present invention.

[0027] The following detailed embodiments further illustrate the above-described content of the present invention. However, this should not be construed as limiting the scope of the present invention to the following examples. All technologies implemented based on the above-described content of the present invention fall within the scope of the present invention. Attached Figure Description

[0028] Figure 1This is a schematic diagram of the low-voltage power distribution control principle structure of the present invention;

[0029] Figure 2 This is a schematic diagram of the power distribution structure of the PLC system of the present invention. Detailed Implementation

[0030] The present invention is illustrated below with specific embodiments, which are not intended to limit the scope of the invention.

[0031] like Figure 1-2 As shown, an intelligent drive and safety control system for a rotary milking machine includes a central control unit, a drive module, a safety monitoring module, a human-machine interaction module, and an emergency control module. The modules work together to achieve intelligent drive and safety protection for the rotary milking machine.

[0032] Central Control Unit: As the core of the system, it adopts an ABB industrial CPU, featuring high reliability and strong substitutability. It is equipped with DI and DO interfaces and a DC 24V power supply circuit. It communicates with the inverters of the drive modules via the 485 communication protocol, receives control commands from the human-machine interface module and the local control box, processes signals from the safety monitoring module, and outputs drive control signals. The central control unit is connected to each module via terminal blocks, and the power supply circuit is equipped with a circuit breaker for overload protection, ensuring stable system operation.

[0033] The drive module consists of six frequency converters and six 1.1kW motors, with each frequency converter driving one motor. The frequency converter models include VFD1.1, VFD1.2, VFD2.1, VFD2.2, VFD3.1, and VFD3.2. The frequency converters receive control signals from the central control unit to achieve forward and reverse rotation and speed regulation of the motors. Speed ​​regulation is set through the human-machine interface module, with a frequency range of 0-50Hz. Simultaneously, the frequency converters collect real-time data on motor current, frequency, speed, and load, feeding this data back to the central control unit to provide data support for equipment status early warning.

[0034] Safety monitoring module: Includes comprehensive safety protection components, including internal emergency stop switch, external emergency stop switch, internal pull rope switch, external pull rope switch, internal anti-collision switch 1, internal anti-collision switch 2, cleaning positioning switch, cleaning safety switch, and various anti-pinch devices. All safety hardware is independently connected to the DI interface of the central control unit, avoiding the difficulty of troubleshooting caused by series connections. The anti-pinch devices cover all key positions for cow entry and exit, achieving comprehensive protection for personnel and cows, and can quickly trigger a stop command in abnormal situations.

[0035] Human-Machine Interface Module: Employs a field touchscreen that communicates with the central control unit via network cable, providing an intuitive operating interface. It can display real-time motor operating parameters (current, frequency, speed, load) and the status of all safety hardware (green for normal, red for fault). When a fault occurs, the corresponding location turns red and a text prompt appears, recording the fault information for subsequent maintenance. It supports parameter adjustment, mode switching (forward, reverse, cleaning mode), and fault masking. Fault masking requires password verification to prevent accidental operation.

[0036] Emergency control module: includes an emergency handheld controller and a local control box. The local control box is used for operation and control under normal working conditions, and is equipped with normal forward rotation, normal reverse rotation, normal stop, and reset buttons. The emergency handheld controller can be directly connected to the frequency converter. When the central control unit or human-machine interface module fails, the motor can be directly controlled to rotate forward and reverse through the emergency handheld controller to ensure continuous milking operations.

[0037] Auxiliary circuit: The system is equipped with a secondary control circuit, including a safety control relay (KM1), a switching power supply, a secondary control circuit power switch (SP1), and circuit breakers (QF4, QF5), to achieve independent power supply and overload protection for the control circuit, thereby improving the safety and stability of the system. Detailed Implementation

[0038] The present invention will be further described in detail below with reference to specific embodiments: The intelligent drive and safety control system for the rotary milking machine in this embodiment has the following hardware configuration: Central control unit: adopts ABB industrial CPU, configured with DI1, DI2, DI3 and other DI interfaces and DO1 interface, DC24V power supply; Drive module: six frequency converters (VFD1.1, VFD1.2, VFD2.1, VFD2.2, VFD3.1, VFD3.2), six 1.1KW motors; Safety monitoring module: internal emergency stop switch, external emergency stop switch, internal pull rope switch, external pull rope switch, internal anti-collision switch 1, internal anti-collision switch 2, and clearing switch. Cleaning positioning switch, cleaning safety switch, inlet forward / reverse anti-pinch switch, inlet forward / reverse anti-pinch cup switch, outlet forward / reverse anti-pinch switch, outlet forward anti-pinch cup switch, reverse anti-pinch system; Human-machine interface module: Samkoon touch screen; Emergency control module: emergency handheld device, local operation box; Auxiliary components: terminal blocks (TB1.1, TB1.2, TB2.1, TB2.2, TB3.1, TB3.2), circuit breakers (QF4-10A, QF5-5A, QF2.1-6A), safety control relay (KM1), switching power supply, secondary control circuit power switch (SP1).

[0039] The system works as follows:

[0040] Normal operating mode: Upon power connection, the secondary control circuit power is turned on via SP1, the central control unit is powered on and initialized, and the inverter establishes a 485 communication connection with the central control unit. The operator issues forward, reverse, or speed adjustment commands via the local control box or human-machine interface module. After receiving the commands, the central control unit sends control signals to the corresponding inverter, driving the motor to run, and the turntable rotates at the set speed. At this time, the human-machine interface module displays the current, frequency, speed, and load data of each motor in real time, and all safety hardware statuses are displayed in green.

[0041] Safety Monitoring and Fault Handling: When a safety hardware component (such as internal anti-collision switch 1) is triggered or malfunctions, its corresponding signal is transmitted to the central control unit via the DI interface. The central control unit immediately issues a stop command, the inverter stops outputting, and the turntable stops rotating. Simultaneously, the corresponding point on the human-machine interface module turns red and displays the message "Internal anti-collision switch 1 malfunction," recording the time and status of the malfunction. After logging in with a password, operators can select to disable the malfunctioning hardware according to the actual situation, and the system resumes operation. The malfunctioning component can be replaced during subsequent maintenance.

[0042] Emergency Operation Mode: When the central control unit or human-machine interface module malfunctions, the operator can use an emergency handheld device to directly connect to the frequency converter and control the motor operation through the forward, stop, and reverse buttons on the emergency handheld device to ensure that the milking operation can proceed normally.

[0043] Preventive maintenance: The central control unit continuously monitors the motor's current and load data. When the data exceeds the normal range, the human-machine interface module issues an early warning, allowing operators to promptly check the equipment and perform preventive maintenance to avoid malfunctions.

[0044] The system in this embodiment effectively solves the defects of the prior art by centrally controlling the central control unit, providing comprehensive protection through the safety monitoring module, intelligent monitoring through the human-machine interaction module, and redundant design of the emergency control module, thereby improving the operational safety, stability, and ease of maintenance of the rotary milking machine.

[0045] Application areas

[0046] This invention is applicable to the drive control of all rotary milking machines and can be widely used in large-scale dairy farms, livestock breeding cooperatives, and other similar settings, especially suitable for breeding scenarios with high requirements for equipment operational stability, safety, and maintenance efficiency. Furthermore, the hardware configuration of this system can be customized to meet the actual needs of the farm, demonstrating strong adaptability.

[0047] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0048] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention's specification and drawings under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

[0049] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An intelligent drive and safety control system for a rotary milking machine, characterized in that, include: The central control unit uses an ABB industrial CPU to receive control commands, process safety monitoring signals, and drive control signals. The drive module includes six frequency converters of the same model and six 1.1KW motors. The frequency converters are connected to the central control unit via the 485 communication protocol. Each frequency converter drives one motor to realize the forward and reverse rotation and speed control of the turntable. The safety monitoring module includes a cow entry and exit anti-pinch device, an inner / outer emergency stop switch, an inner / outer pull rope switch, an inner anti-collision switch, a cleaning positioning switch, a cleaning safety switch, and a safety interlock device. All safety hardware is independently connected to the central control unit to achieve independent monitoring of the safety status. The human-machine interaction module uses a field touch screen and communicates with the central control unit via a network cable. It is used to display motor operating parameters and safety hardware status, and provides parameter adjustment, fault alarm, fault shielding and mode switching functions. The emergency control module includes an emergency handheld device and a local control box. The emergency handheld device can be directly connected to the frequency converter to realize emergency forward and reverse control of the motor when the central control unit or human-machine interaction module fails. The local control box is used for operation control under normal working conditions.

2. The intelligent drive and safety control system for the rotary milking machine according to claim 1, characterized in that, The central control unit is equipped with a DI interface, a DO interface and a DC24V power supply circuit. It is connected to each module through a terminal block. The power supply circuit is equipped with 10A and 5A circuit breakers for overload protection.

3. The intelligent drive and safety control system for the rotary milking machine according to claim 1, characterized in that, The human-computer interaction module has a fault location function. When the safety hardware fails, the corresponding point is displayed in red and a text prompt pops up, while the fault information is recorded. It supports the operation of blocking faulty hardware. After password verification, the faulty component can be temporarily blocked to ensure the continuous operation of the system.

4. The intelligent drive and safety control system for the rotary milking machine according to claim 1, characterized in that, The anti-pinch device in the safety monitoring module includes an inlet forward / reverse anti-pinch switch, an inlet forward / reverse anti-pinch cup switch, an outlet forward / reverse anti-pinch switch, an outlet forward anti-pinch cup switch, and a reverse anti-pinch system. All anti-pinch signals are transmitted to the central control unit in real time to achieve rapid shutdown in case of abnormality.

5. The intelligent drive and safety control system for the rotary milking machine according to claim 1, characterized in that, The inverter of the drive module supports speed regulation. The system speed regulation frequency can be set through the human-machine interaction module, with a range of 0-50HZ. The central control unit monitors the motor current and load data to realize early warning judgment of the equipment operating status.

6. The intelligent drive and safety control system for the rotary milking machine according to claim 1, characterized in that, The system also includes a secondary control circuit, which is equipped with a safety control relay, a switching power supply, and a power switch for the secondary control circuit, to achieve independent power supply and safety protection for the control circuit.

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