A method for retrofitting an electrical control system of an electric shovel

Abstract

This application discloses a method for upgrading the electrical control system of an electric shovel. The electric shovel electrical control system includes an original master controller, a PLC, and an excitation regulating device. The original master controller is a potentiometer-type master controller. The upgrading method includes: replacing the original master controller with a target master controller, which includes a signal sensing module and a first industrial Ethernet communication module. The signal sensing module realizes magneto-electric signal conversion through the Hall effect. The first industrial Ethernet communication module is configured to transmit the control signal as a digital signal to the PLC; a second industrial Ethernet communication module is installed on the PLC to receive the digital signal transmitted by the first industrial Ethernet communication module; a signal analysis program is input into the PLC, which is configured to convert the digital signal into an analog signal that matches the excitation regulating device. This achieves contactless signal output from the master controller, solving the problem of frequent failures in the original system.

Description

Technical Field

[0001] This application relates to the field of electric locomotive control system technology, and in particular to a method for modifying the electrical control system of an electric shovel. Background Technology

[0002] Currently, electric shovels used in mining equipment, such as the WK-12C electric shovel currently in use at the Zhanihe open-pit mine, employ a potentiometer-type master controller for their electrical control system. This controller adjusts the voltage of a given control signal by changing the resistance of the potentiometer, thereby controlling the various actions of the shovel. The moving contact and the resistive element of this potentiometer-type master controller use a mechanical friction contact mechanism. Under the harsh conditions of high dust, strong vibration, and continuous operation in open-pit mines, this is prone to contact wear and resistive element aging, resulting in a short lifespan for the master controller. Regular maintenance, calibration, and replacement of parts by dedicated personnel are required. These problems not only significantly increase the workload of on-site equipment maintenance personnel and the cost of spare parts, but also easily lead to shovel downtime due to master controller failure, directly reducing equipment availability and affecting the continuity of open-pit mining production. Summary of the Invention

[0003] The summary section introduces a series of simplified concepts, which will be further explained in detail in the detailed description section. This section of the application is not intended to limit the key features and essential technical features of the claimed technical solution, nor is it intended to determine the scope of protection of the claimed technical solution.

[0004] This application aims to address at least one of the technical problems existing in the prior art or related technologies.

[0005] An embodiment of this application provides a method for modifying the electrical control system of an electric shovel. The electric shovel electrical control system includes an original master controller, a PLC, and an excitation regulating device. The original master controller is a potentiometer-type master controller. The modification method includes: replacing the original master controller with a target master controller. The target master controller includes a signal sensing module and a first industrial Ethernet communication module. The signal sensing module realizes magnetoelectric signal conversion through the Hall effect. The first industrial Ethernet communication module is configured to transmit the control signal as a digital signal to the PLC. A second industrial Ethernet communication module is installed on the PLC to receive the digital signal transmitted by the first industrial Ethernet communication module. A signal analysis program is input into the PLC. The signal analysis program is configured to convert the digital signal into an analog signal that matches the excitation regulating device.

[0006] For example, the target master controller further includes: an operating handle configured to receive external operations to generate movement; a signal sensing module including a magnet and a Hall element, one of which is connected to the operating handle and moves with the operating handle, the movement of the operating handle being configured to adjust the magnetic field at the position of the Hall element, the output terminal of the Hall element being used to output a control signal; and a signal processing module connected to the Hall element and a first industrial Ethernet communication module, configured to convert the control signal into a digital signal.

[0007] For example, the target master controller also includes a resilient reset member connected to the operating handle, the resilient reset member being configured to provide a force to reset the operating handle to an initial position; and / or, two operating handles are distributed on both sides of the operating seat of the electric shovel.

[0008] For example, the target master controller also includes a connection harness, which is connected to a second industrial Ethernet communication module via a plug-in structure.

[0009] For example, the steps of replacing the original master controller with a target master controller include: disassembling and separating the original master controller from the electric shovel's operating platform; fixing the adapter plate to the location of the original master controller on the operating platform; and installing the target master controller on the adapter plate.

[0010] For example, before the step of fixing the adapter plate to the original location of the master controller on the operating console, the modification method further includes: processing the adapter plate according to the first mounting structure of the operating console and the second mounting structure of the target master controller; after the step of fixing the target master controller to the adapter plate, the modification method further includes: adjusting the operating stroke and reset gap of the operating handle.

[0011] For example, the modification method also includes: configuring a remote I / O station; and / or upgrading the operator's seat of the electric shovel.

[0012] For example, the steps of configuring a remote I / O station include: configuring a remote I / O station in the operator console of the electric shovel, wherein the remote I / O station is configured to collect signals from the target master controller and the buttons set on the operator console; and connecting the remote I / O station to a second industrial Ethernet communication module.

[0013] For example, the steps of upgrading the operator's seat of an electric shovel include: replacing the original operator's seat with a target operator's seat, wherein the target operator's seat is an air-suspended shock-absorbing seat and the original operator's seat is a fixed seat; wherein the air-suspended shock-absorbing seat integrates an integrated safety belt.

[0014] For example, the protection rating of the target master controller is IP67; the power supply voltage of the target master controller is DC 24V.

[0015] The method for modifying the electric shovel electrical control system provided in this application embodiment involves a target master controller whose signal sensing module achieves magnetoelectric signal conversion through the Hall effect. The first industrial Ethernet communication module of the target master controller is configured to transmit control signals as digital signals to the PLC. The target master controller, which adopts non-contact Hall technology and industrial Ethernet communication as its core technologies, replaces the original potentiometer-type master controller. A second industrial Ethernet communication module is added to the original PLC to receive the digital signals transmitted by the first industrial Ethernet communication module. A signal analysis program is input into the original PLC, and the signal analysis program is configured to convert the digital signals into analog signals that match the excitation adjustment device. Therefore, without altering the original electrical control system architecture—that is, without changing the original control panel or reconstructing the control logic—the master controller was modified to achieve contactless signal output, reducing the failure rate at its source and improving the anti-interference capability of signal transmission. This ultimately achieves a technological iteration of the electric shovel's electrical control system, solving the problems of difficult parts procurement, high maintenance costs, and frequent equipment downtime in existing technologies. It improves the equipment availability and production efficiency of electric shovels, while reducing construction difficulty, shortening the modification period, and lowering the modification cost, making it suitable for widespread application.

[0016] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, the following are specific embodiments of this application. Attached Figure Description

[0017] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this application. Furthermore, the same reference numerals denote the same parts throughout the drawings. Wherein: Figure 1 One of the flowcharts of the modification method of the electric shovel electrical control system provided in the embodiments of this application is shown. Detailed Implementation

[0018] The following description provides numerous specific details to offer a more thorough understanding of the technical solutions provided in this application. However, it will be apparent to those skilled in the art that the technical solutions provided in this application can be implemented without one or more of these details.

[0019] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms “comprising” and / or “including” are used in this specification, they indicate the presence of the stated features, integrals, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or combinations thereof.

[0020] Exemplary embodiments according to this application will now be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. It should be understood that these embodiments are provided so that the disclosure of this application is thorough and complete, and that the concept of these exemplary embodiments is fully conveyed to those skilled in the art.

[0021] This application provides a method for modifying the electrical control system of an electric shovel. The electric shovel electrical control system includes an original master controller, a PLC, and an excitation regulating device. The original master controller is a potentiometer-type master controller. A master controller is an operating electrical device used in an electrical control system to send command signals to the control circuit. Through manual operation, it controls the start, stop, speed adjustment, and reversing of the motor and actuator, and is a core operating component of construction machinery such as electric shovels and excavators. A potentiometer is a variable resistor-type master controller that changes the resistance value by sliding a moving contact on a resistive element, thereby regulating voltage and current. It is a core signal conversion component of traditional master controllers.

[0022] In the current electric shovel electrical control system, the original master controller was a potentiometer-type master controller. This potentiometer-type master controller has obvious defects in practical applications in open-pit mines, as follows: 1. The operation is not sensitive and there is a control delay. The original master controller's potentiometer moving contact and the resistor are in mechanical friction contact. After long-term operation, the contact wears and the contact gap increases, resulting in discontinuous resistance adjustment, lag in the output of the given signal voltage, delayed response of the electric shovel, and decreased operation accuracy.

[0023] 2. Frequent parts replacement and high maintenance costs. The high dust and strong vibration conditions in open-pit mines accelerate the wear and tear of mechanical friction, significantly shortening the normal service life of potentiometers and contacts. Faults such as poor contact and open circuits are prone to occur, requiring monthly inspections and replacement of core components approximately every 3 months, resulting in a large amount of spare parts consumption.

[0024] 3. Low equipment uptime affects production continuity. The master controller is the core component of electric shovel operation. Its failure will directly cause the electric shovel to be unable to operate normally. Moreover, the replacement of parts requires machine downtime (a single replacement takes about 2 to 4 hours). The number of unplanned downtimes increases, the effective working time of the equipment decreases, and the uptime decreases.

[0025] 4. Complete replacement is too costly, while partial upgrades offer no fundamental improvement. Complete replacement involves directly purchasing a new, fully-fledged electrical control system for the electric shovel, replacing the existing system entirely. This includes replacing all core components such as the master controller, PLC, and excitation regulator. Replacing the entire system with a new one requires significant investment and adaptation to the shovel's mechanical structure, resulting in a long construction period. Partial component upgrades involve purchasing original or compatible parts to replace frequently failing components (such as potentiometers and contacts) in the existing electrical control system, preserving the original system's overall architecture and control logic. However, since partial upgrades only replace worn parts without altering the core "mechanical friction contact" design, the root cause of the problem remains unresolved, leading to continued high failure and maintenance rates.

[0026] 5. Unstable spare parts procurement channels. The Siemens electrical control system originally used with the electric shovel has been discontinued. There is a shortage of original parts required for partial upgrades, and the procurement cycle can be as long as 1 to 3 months. This can easily lead to situations where there are no spare parts available after a failure, resulting in the electric shovel being down for a long time.

[0027] In view of this, such as Figure 1 As shown in the embodiment of this application, a method for modifying the electrical control system of an electric shovel is provided. The modification method includes the following steps.

[0028] Step S110: Replace the original master controller with a target master controller. The target master controller includes a signal sensing module and a first industrial Ethernet communication module. The signal sensing module realizes the conversion of magnetoelectric signals through the Hall effect. The first industrial Ethernet communication module is configured to transmit the control signal as a digital signal to the PLC.

[0029] In this embodiment, a target master controller replaces the original master controller. That is, the master controller of the modified electric shovel electrical control system is the target master controller. The signal sensing module of the target master controller achieves magneto-electric signal conversion through the Hall effect. Specifically, the core technology of the target master controller is non-contact Hall technology, which achieves contactless signal output through the magneto-electric conversion of the Hall element. This eliminates the mechanical friction contact design of the original master controller, eradicating the potential for contact wear and poor contact at the source, reducing the failure rate of the master controller, achieving maintenance-free operation throughout its lifespan, and improving the reliability, maintainability, and overall production efficiency of the electric shovel electrical control system.

[0030] The first industrial Ethernet communication module of the target master controller is configured to transmit control signals to the PLC as digital signals. That is, the target master controller uses industrial Ethernet communication to communicate with the PLC. Using industrial Ethernet for digital signal transmission provides significantly better anti-interference capabilities than the original analog voltage signal transmission, ensuring stable signal output even in the strong electromagnetic interference environment of open-pit mines. This optimizes the signal transmission method of the master controller, enhances signal anti-interference capabilities, ensures the continuity and stability of the given signal output, and improves the action response speed and accuracy of the electric shovel operation.

[0031] Step S120: Install a second industrial Ethernet communication module on the PLC to receive digital signals transmitted by the first industrial Ethernet communication module.

[0032] In this embodiment, PLC refers to the PLC in the original electrical control system. By adding a second industrial Ethernet communication module to the PLC, the target master controller and the original PLC can communicate smoothly using the industrial Ethernet communication method, so that there is no need to replace the entire PLC, which helps to save on transformation costs.

[0033] Specifically, a second industrial Ethernet communication module, such as a PROFINET communication module, can be added to the existing PLC's communication interface to complete the communication protocol matching between the target master controller and the PLC, set communication baud rate, address and other parameters, and ensure the stability of digital signal transmission.

[0034] Step S130: Input the signal parsing program into the PLC. The signal parsing program is configured to convert digital signals into analog signals that match the excitation regulating device.

[0035] In this embodiment, the PLC refers to the PLC in the original electrical control system. By inputting a signal analysis program into the PLC, the digital signal can be converted into an analog signal that matches the excitation adjustment device, thus achieving precise control of the electric shovel's movement. This eliminates the need to reconstruct the original PLC's control logic, ensuring that the original operating habits of the electric shovel remain unchanged, facilitating operator use, simplifying operator training after the modification, reducing training costs, and making it suitable for widespread application.

[0036] Specifically, a simple signal parsing program can be written into the existing PLC to convert the digital signals transmitted by the target master controller into analog signals that match the existing excitation regulation device. Specifically, the analog signals can be voltage-type analog signals from 0V to 10V and current-type analog signals from 4mA to 20mA.

[0037] The method for modifying the electric shovel electrical control system provided in this application embodiment involves a target master controller whose signal sensing module achieves magnetoelectric signal conversion through the Hall effect. The first industrial Ethernet communication module of the target master controller is configured to transmit control signals as digital signals to the PLC. The target master controller, which adopts non-contact Hall technology and industrial Ethernet communication as its core technologies, replaces the original potentiometer-type master controller. A second industrial Ethernet communication module is added to the original PLC to receive the digital signals transmitted by the first industrial Ethernet communication module. A signal analysis program is input into the original PLC, and the signal analysis program is configured to convert the digital signals into analog signals that match the excitation adjustment device. Therefore, without altering the original electrical control system architecture—that is, without changing the original control panel or reconstructing the control logic—the master controller was modified to achieve contactless signal output, reducing the failure rate at its source and improving the anti-interference capability of signal transmission. This ultimately achieves a technological iteration of the electric shovel's electrical control system, solving the problems of difficult parts procurement, high maintenance costs, and frequent equipment downtime in existing technologies. It improves the equipment availability and production efficiency of electric shovels, while reducing construction difficulty, shortening the modification period, and lowering the modification cost, making it suitable for widespread application.

[0038] In some embodiments provided in this application, the target master controller further includes: an operating handle configured to receive external operations to generate movement; a signal sensing module including a magnet and a Hall element, one of which is connected to the operating handle and moves with the operating handle, the movement of the operating handle being configured to adjust the magnetic field at the position of the Hall element, and the output terminal of the Hall element being used to output a control signal; and a signal processing module connected to the Hall element and a first industrial Ethernet communication module, configured to convert the control signal into a digital signal.

[0039] This embodiment provides the specific structure of the target master controller. The target master controller includes an operating handle, a signal sensing module, a signal conversion module, and a first industrial Ethernet communication module. The signal sensing module includes a magnet and a Hall element. One of the magnet and the Hall element is connected to the operating handle, while the other can be fixed to the main body of the electric shovel. When the operator moves the operating handle, it causes the handle to move, which in turn moves the magnet or Hall element mounted on the handle, thereby adjusting the magnetic field at the location of the Hall element. This allows the Hall element to output a control signal. The signal processing module converts the control signal into a digital signal, and the first industrial Ethernet communication module transmits the digital signal to the second industrial Ethernet module, and then to the PLC. Thus, through the magnetoelectric conversion of the Hall element, contactless output of the control signal can be achieved. This process eliminates any mechanical friction contact parts, fundamentally eliminating the potential for contact wear and poor contact. It can meet the harsh working conditions of high dust, strong vibration, and continuous operation in open-pit mines, reducing the failure rate of the target master controller, extending its service life, and reducing maintenance frequency. Meanwhile, the use of industrial Ethernet for digital signal transmission provides a much stronger anti-interference capability than the original analog voltage transmission, ensuring stable signal output in the strong electromagnetic interference environment of open-pit mines.

[0040] In the above embodiments, there can be two operating handles, which can be distributed on both sides of the electric shovel's operating seat. That is, the target master controller adopts a split design of left and right operating handles to adapt to the two-handed operating habits of electric shovel operators.

[0041] In some embodiments provided in this application, the target master controller further includes an elastic reset member connected to the operating handle. The elastic reset member is configured to provide a force to the operating handle to reset it to its initial position. Therefore, after the operating handle is moved, it can automatically reset to its initial position under the action of the elastic reset member. The initial position can also be the zero point position of the operating handle, which can reduce or avoid the possibility of misoperation of the operating handle and improve operating accuracy.

[0042] Specifically, the elastic reset component can be a spring, tension spring, torsion spring, sheet spring, or other elastic component.

[0043] In some embodiments provided in this application, the target master controller further includes a connection harness, which is connected to a second industrial Ethernet communication module via a plug-in structure.

[0044] In this embodiment, the connecting harness is an integrated harness that comes with the target master controller from the factory. The end of the connecting harness is provided with a plug-in. This plug-in and the mating part at the location of the second industrial Ethernet communication module on the PLC form a plug-in structure, so that the connecting harness can be connected to the second industrial Ethernet communication module on the PLC through the plug-in structure formed by the plug-in and the mating part. The operation is simple, no on-site wiring is required, the modification operation is simplified, and the modification efficiency is improved.

[0045] Furthermore, both ends of the connecting harness can be equipped with plug-ins. The plug-in at the first end forms a plug-in structure with the mating component at the location of the first industrial Ethernet communication module on the target master controller, allowing the first end of the connecting harness to interface with the first industrial Ethernet communication module through the plug-in structure formed by the plug-in and mating component. Similarly, the plug-in at the second end forms a plug-in structure with the mating component at the location of the second industrial Ethernet communication module on the PLC to achieve interface between the connecting harness and the second industrial Ethernet communication module.

[0046] In the above embodiment, the target master controller is powered by DC 24V, which is a safe 24VDC power supply, adapting to the safety power supply requirements of mining equipment, reducing the risk of electric shock to operators and improving operational safety.

[0047] Furthermore, the target master controller has an IP67 protection rating. The IP67 protection rating of the target master controller has dustproof, waterproof and vibration-resistant performance, and can directly adapt to the harsh working conditions of high dust and water spray in open mines without the need for additional protective devices, further improving the inherent safety of equipment operation.

[0048] In some embodiments provided in this application, the step of replacing the original master controller with a target master controller includes: The original master controller and the electric shovel's operating platform were disassembled and separated. Fix the adapter plate to the original location of the master controller on the control panel; Install the target master controller on the adapter board.

[0049] In this embodiment, the original master controller and the electric shovel's operating platform are detachably connected, and the target master controller is mounted on the operating platform via an adapter plate. Further, during the modification process, the original master controller is first disassembled from the operating platform. Then, the adapter plate is fixed to the operating platform at the location of the original master controller. Next, the target master controller is installed on the adapter plate, thereby fixing the target master controller to the operating platform and replacing the original master controller.

[0050] Specifically, the original master controller and the electric shovel's operating platform can be detachably connected via bolts or plug-in structures. The original master controller and the electric shovel's operating platform can be disassembled and separated by removing the bolts or by dragging with external force.

[0051] The adapter plate can be fixed to the original master controller installation position on the control panel using bolts or plug-in structures. The target master controller can be detachably installed on the adapter plate using bolts or plug-in structures to complete the mechanical installation and facilitate subsequent maintenance operations.

[0052] Furthermore, the disassembly and assembly process of the master controller, which involves removing the original master controller, installing the adapter board, and installing the target master controller, takes approximately 1 to 2 hours per disassembly and assembly, which is more than 50% shorter than replacing the original parts. This reduces the modification time and minimizes the impact on normal production.

[0053] In some embodiments provided in this application, before the step of fixing the adapter board to the original location of the master controller on the console, the modification method further includes: processing the adapter board according to the first mounting structure of the console and the second mounting structure of the target master controller.

[0054] In this embodiment, the first mounting structure of the operating console can be used for the installation of the original master controller and the operating console, while the second mounting structure of the target master controller can be used for the installation of the target master controller with other components. During the fabrication of the adapter board, the adapter board is fabricated according to the first mounting structure of the operating console and the second mounting structure of the target master controller, so that the adapter board can match the first and second mounting structures. This facilitates the reliable, accurate, and secure fixing of the adapter board to the operating console, and allows the target master controller to be reliably, accurately, and securely fixed to the adapter board. Simultaneously, seamless installation of the target master controller on the existing operating console is achieved without modifying the operating console structure, reducing modification costs and construction difficulty.

[0055] Specifically, an adapter plate can be fabricated based on the installation dimensions of the target master controller and the opening dimensions of the existing control panel. The adapter plate has mounting holes matching the target master controller and fixing holes matching the existing control panel, allowing for seamless installation of the target master controller on the existing control panel without altering its structure. Specifically, the adapter plate can be made of stainless steel, but other materials are also acceptable. The thickness of the adapter plate can be 5mm, or other sizes, to adapt to the high dust conditions of open-pit mines.

[0056] In some embodiments provided in this application, after the step of fixing the target master controller to the adapter board, the modification method further includes: adjusting the operating stroke and reset gap of the operating handle.

[0057] In this embodiment, after the target master controller is fixed to the operating table via the adapter plate, the operating stroke and reset gap of the operating handle can be adjusted to ensure that the operating handle operates smoothly without jamming and resets accurately.

[0058] Specifically, the operating handle can be moved to various operating positions to observe for any jamming or interference. Then, the operating handle can be released to observe whether it can accurately return to its initial position under the action of the reset elastic element. If the operating handle jams or cannot accurately return to its initial position, the positions of the adapter plate and the target master controller can be adjusted.

[0059] In some embodiments provided in this application, the modification method further includes: configuring a remote I / O station.

[0060] In this embodiment, by configuring a remote I / O station, centralized acquisition and transmission of various operation signals can be achieved, which helps to improve the stability of signal transmission and reduces cable wiring, thereby reducing the risk of cable faults.

[0061] In the above embodiments, the steps for configuring a remote I / O station include: A remote I / O station is configured in the control panel of the electric shovel. The remote I / O station is configured to collect signals from the target master controller and the buttons on the control panel. Connect the remote I / O station to the second industrial Ethernet communication module.

[0062] In this embodiment, a remote I / O station is configured in the control panel, such as a Siemens ET200 remote I / O station. The signals from the target master controller and each button on the control panel are centrally connected to the remote I / O station, and then communicated with the PLC's second industrial Ethernet communication module through industrial Ethernet communication. This can significantly reduce the cabling in the control room, reduce the risk of cable faults, and facilitate troubleshooting later.

[0063] In some embodiments provided in this application, the modification method further includes: upgrading the operator's seat of the electric shovel.

[0064] In this embodiment, upgrading the operator's seat of the electric shovel can improve the operator's work comfort and safety.

[0065] In the above embodiments, the steps for upgrading the operator's seat of the electric shovel include: The original operating seat is replaced with a target operating seat, which is an air-suspended shock-absorbing seat, while the original operating seat is a fixed seat; the air-suspended shock-absorbing seat integrates an integrated seat belt.

[0066] Because the original operating chair was a fixed chair without a shock-absorbing structure, and the seat was rigidly connected to the base with only simple padding, vibrations were directly transmitted, easily causing operator fatigue and back injuries during prolonged operation. Therefore, this embodiment replaces the original fixed chair with an air-suspended shock-absorbing chair. The air-suspended shock-absorbing chair features an ergonomic design that conforms to the curves of the waist, back, and legs, providing multi-directional adjustment functions (height, fore-aft position, backrest angle, armrest position) to accommodate operators of different body types. Equipped with an air suspension shock absorption system, the air-suspended shock-absorbing chair can dynamically adjust damping, effectively filtering vibrations during electric shovel operation, reducing operator fatigue during prolonged operation, improving operator comfort, and making it suitable for widespread application.

[0067] The seat integrates a one-piece safety belt, which is fixed to the seat frame to prevent the operator's body from shifting when the electric shovel moves sharply, thus improving operational safety.

[0068] After modification using the electric shovel electrical control system modification method provided in this application embodiment, the overall control logic of the electric shovel operation is as follows: The operator operates the control handle of the target master controller. The Hall element of the signal sensing module generates a contactless control signal through magneto-electric conversion. The signal processing module converts the control signal into a digital signal. The first industrial Ethernet communication module sends the digital signal to the PLC through PROFINET communication. After parsing the signal, the PLC outputs an analog signal to the excitation regulating device. The excitation regulating device adjusts the action of the electric shovel actuator to achieve precise control of the electric shovel. At the same time, the remote I / O station completes the centralized acquisition and transmission of various operation signals to ensure the stability of signal transmission.

[0069] The method for modifying the electric shovel's electrical control system provided in this application has the following technical advantages compared to the prior art: I. Direct Economic Benefits 1. Save on spare parts and maintenance costs. The target master controller adopts non-contact Hall technology, which is maintenance-free throughout its life cycle and eliminates the need to purchase spare parts such as potentiometers and contacts. It is estimated that it can save RMB 160,000 in spare parts procurement costs annually. At the same time, it eliminates the need for regular maintenance and calibration work, which can reduce the working hours of dedicated maintenance personnel each year.

[0070] 2. Reduce unplanned downtime losses: After the upgrade, the failure rate of the target master controller is reduced to 0.12%, completely eliminating unplanned downtime caused by master controller failure, which can reduce downtime losses by about 370,000 yuan per year.

[0071] 3. Reduced renovation costs: This solution is a partial upgrade and renovation, which does not require a complete replacement of the electrical control system. The renovation cost is only 1 / 20 of the overall replacement, and the construction period is short (the renovation of a single electric shovel takes about 8 hours, which can be completed during equipment maintenance), without affecting normal production.

[0072] II. Improved Production Efficiency 1. Improve equipment availability: After the upgrade, the number of unplanned downtimes of the electric shovel due to master controller failure was 0, and the effective working time of the equipment increased significantly. The availability of the WK-12C electric shovel increased from 85% to over 95%.

[0073] 2. Improved operational efficiency and accuracy: The new master controller has zero signal transmission delay, the electric shovel's action response speed is increased by 30%, the operational accuracy is improved, and the ineffective operation is effectively reduced. The daily mining volume of a single electric shovel can be increased by about 8% to 10%.

[0074] III. Improved User Experience and Security 1. Improved operational comfort: The air-suspended shock-absorbing seat effectively filters vibrations, and the ergonomic design reduces operator fatigue, making it suitable for 24-hour continuous operation in open-pit mines.

[0075] 2. Improved operational safety: 24VDC safe voltage power supply reduces the risk of electric shock to operators, the integrated safety belt in the seat reduces body displacement, and the IP67 protection-rated master controller is adapted to the harsh working conditions of open-pit mines, further enhancing the inherent safety of equipment operation.

[0076] IV. Technical and Management Benefits 1. Achieve technological iteration of electrical control system: This solution abandons the traditional mechanical friction contact control design and introduces non-contact Hall technology and PROFINET industrial Ethernet communication to realize the digital transmission of electric shovel control signals, completing the technological upgrade from "analog control" to "digital control".

[0077] 2. Promote the intelligent transformation of equipment: During the transformation process, the PLC communication module was upgraded and the remote I / O station was configured, laying the hardware foundation for the intelligent monitoring and remote control of the electric shovel's electrical control system; at the same time, an electronic health record for the electric shovel equipment was established (100% electronic rate), realizing refined management of equipment maintenance.

[0078] 3. Establishing enterprise standards with promotional value: This solution is compatible with the WK-12C electric shovel and can be further extended to the master controller upgrade of other models of electric shovels and excavators in open-pit mines. At the same time, based on this solution, an enterprise standard, "Intelligent Electric Shovel PLC System Operation and Maintenance Specification", can be formed to improve the overall intelligence level of the mine and lay a technical foundation for the research and development and application of unmanned electric shovels.

[0079] 4. Solve the problem of parts procurement: The target master controller is a domestically adapted product with stable procurement channels and short delivery cycle, which completely solves the problem of difficult and long procurement cycle of the original Siemens system parts.

[0080] 5. Multi-component collaborative optimization: By combining the transformation of the master controller with the configuration of remote I / O stations and the upgrade of air-suspended seats, a synergistic effect of "hardware upgrade + signal optimization + improved user experience" is achieved, ensuring the integrity and practicality of the transformation.

[0081] In this application, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance; the term "multiple" refers to two or more unless otherwise expressly defined. The terms "install," "connect," "link," and "fix" should be interpreted broadly. For example, "connect" can mean a fixed connection, a detachable connection, or an integral connection; "link" can mean a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0082] In the description of this application, it should be understood that the terms "upper", "lower", "left", "right", "front", "rear", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or unit referred to must have a specific orientation or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0083] In the description of this specification, the terms "one embodiment," "some embodiments," "specific embodiment," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0084] The above are merely preferred embodiments of this application and are not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A method for modifying the electrical control system of an electric shovel, characterized in that, The electric shovel's electrical control system includes the original master controller, PLC, and excitation adjustment device. The original master controller is a potentiometer-type master controller. The modification method includes: The original master controller is replaced by a target master controller, which includes a signal sensing module and a first industrial Ethernet communication module. The signal sensing module realizes magnetoelectric signal conversion through the Hall effect, and the first industrial Ethernet communication module is configured to transmit the control signal as a digital signal to the PLC. A second industrial Ethernet communication module is installed on the PLC to receive the digital signals transmitted by the first industrial Ethernet communication module. A signal analysis program is input into the PLC, and the signal analysis program is configured to convert the digital signal into an analog signal that matches the excitation regulating device.

2. The method for modifying the electrical control system of an electric shovel according to claim 1, characterized in that, The target master controller also includes: An operating handle, configured to receive external operations to generate movement; The signal sensing module includes a magnet and a Hall element. One of the magnet and the Hall element is connected to the operating handle and moves with the operating handle. The movement of the operating handle is configured to adjust the magnetic field at the position of the Hall element. The output terminal of the Hall element is used to output the control signal. A signal processing module is connected to the Hall element and the first industrial Ethernet communication module, and is configured to convert the control signal into the digital signal.

3. The method for modifying the electrical control system of an electric shovel according to claim 2, characterized in that, The target master controller further includes a resilient reset element connected to the operating handle, the resilient reset element being configured to provide a force to the operating handle to reset it to an initial position; and / or The two operating handles are located on both sides of the operating seat of the electric shovel.

4. The method for modifying the electrical control system of an electric shovel according to claim 1, characterized in that, The target master controller also includes a connection harness, which is connected to the second industrial Ethernet communication module via a plug-in structure.

5. The method for modifying the electrical control system of an electric shovel according to claim 1, characterized in that, The step of replacing the original master controller with a target master controller includes: Disassemble and separate the original master controller from the operating platform of the electric shovel; Fix the adapter plate to the original master controller location on the operating console; The target master controller is installed on the adapter board.

6. The method for modifying the electrical control system of an electric shovel according to claim 5, characterized in that, Before the step of fixing the adapter plate to the original master controller location on the operating console, the modification method further includes: processing the adapter plate according to the first mounting structure of the operating console and the second mounting structure of the target master controller; After the step of fixing the target master controller to the adapter board, the modification method further includes: adjusting the operating stroke and reset gap of the operating handle.

7. The method for modifying the electrical control system of an electric shovel according to any one of claims 1 to 6, characterized in that, The modification method also includes: Configure remote I / O stations; and / or, Upgrade the operator's seat of the electric shovel.

8. The method for modifying the electrical control system of an electric shovel according to claim 7, characterized in that, The steps for configuring the remote I / O station include: A remote I / O station is configured in the control panel of the electric shovel. The remote I / O station is configured to collect signals from the target master controller and the buttons on the control panel. The remote I / O station is connected to the second industrial Ethernet communication module.

9. The method for modifying the electrical control system of an electric shovel according to claim 7, characterized in that, The steps for upgrading the operating seat of the electric shovel include: The original operating seat is replaced with a target operating seat, which is an air-suspended shock-absorbing seat, and the original operating seat is a fixed seat; The air-suspended shock-absorbing seat integrates a one-piece seat belt.

10. The method for modifying the electrical control system of an electric shovel according to any one of claims 1 to 6, characterized in that, The protection level of the target master controller is IP67; The target master controller is powered by DC 24V.

Images