A control system and method for an integrated miter gate with hydraulic and mechanical jacking.

Abstract

This invention provides an integrated control system and method for hydraulic jacking and mechanical jacking of a miter gate, belonging to the field of miter gate lifting technology for ship locks. The system includes a human-machine interface unit, an integrated control unit, a sensing and detection unit, and an execution unit. The PLC module within the integrated control unit is connected to each component via signals, driving the linkage through synchronous control and PID control algorithms. The control method achieves synchronous lifting of the hydraulic jacking device and precise following of the mechanical jacking device through steps such as parameter configuration, pre-jacking contact, leveling operation, gap adjustment, synchronous lifting, and synchronous lowering. It detects stroke and gap deviation in real time and dynamically adjusts them to complete the lifting and lowering of the miter gate. This invention requires only one operator, is adaptable to miter gates of different specifications, and improves the synchronization, safety, and automation level of miter gate maintenance lifting in ship locks, making it suitable for miter gate maintenance operations.

Description

Technical Field

[0001] The invention belongs to the technical field of synchronous lifting of miter gates of ship locks, and particularly relates to a control system integrating a hydraulic jack and a mechanical holding jack for a miter gate and a corresponding control method, which is applicable to the synchronous jacking and falling operations of the gate body during the overhaul of various miter gates of ship locks. Background Art

[0002] The miter gate of a ship lock is the core opening and closing equipment of the ship lock in water transportation projects. It is large in volume and high in self-weight. During overhaul and maintenance, the gate body needs to be synchronously jacked up and lowered, which is a key process to ensure the smooth progress of overhaul operations. At present, in the existing technology, the synchronous lifting technology adopted by the miter gate of a ship lock mainly controls the synchronous operation of the hydraulic jack device and the mechanical holding jack device separately. There is no linkage control and information interaction between the two devices, and multiple operators need to cooperate with each other to complete the jacking and falling operations. This operation mode not only reduces the operation efficiency, but also easily causes the action of each jack device to be asynchronous due to the error of manual cooperation, resulting in uneven force on the miter gate body, tilting of the gate body and even structural damage, with relatively large potential safety hazards. In view of the above technical defects, the invention proposes a control system and method integrating a hydraulic jack and a mechanical holding jack for a miter gate, which can realize the linkage synchronous control of multiple hydraulic jack devices and mechanical holding jack devices with only one operator, effectively improving the safety and reliability of the synchronous lifting operation of the miter gate. Summary of the Invention

[0003] The purpose of the invention is to overcome the deficiencies of the existing technology, and provide a control system and method integrating a hydraulic jack and a mechanical holding jack for a miter gate, realizing the linkage synchronous control of the hydraulic jack device and the mechanical holding jack device, improving the automation and precision level of the miter gate lifting operation, reducing the manual operation intensity at the same time, and ensuring the operation safety.

[0004] To achieve the above purpose, the invention adopts the following technical solutions: The first aspect of the invention provides a control system integrating a hydraulic jack and a mechanical holding jack for a miter gate, including a human-computer interaction unit, an integrated control unit, a sensing and detection unit, and an execution unit; The human-computer interaction unit is signal-connected to the integrated control unit, and is used for inputting operation instructions, setting operation parameters, displaying the operation state of the equipment, realizing human-computer interaction, and configuring an emergency stop and alarm component at the same time; The integrated control unit is respectively connected to the sensing and detection unit and the execution unit, and is used for collecting the action data of the hydraulic jack and the mechanical holding jack of the miter gate, and driving the valve group and the motor through the built-in control algorithm to control the hydraulic jack and the mechanical holding jack to rise and fall; The sensing and detection unit is connected to the integrated control unit, and is used for collecting the real-time state data of the hydraulic jack and the mechanical holding jack; The execution unit is connected to the integrated control unit and is used to drive the rising and falling movements of the hydraulic jack and the mechanical jack.

[0005] Preferably, the human-machine interaction unit is a portable operating box, which integrates a touch screen, a buzzer and an emergency stop button. The touch screen is connected to the integrated control unit via Ethernet through a junction box, and the buzzer and emergency stop button are connected to the integrated control unit via cables.

[0006] Preferably, the integrated control unit is an electrical control box, which integrates a circuit breaker, a DC power supply, a PLC module, an intermediate relay, a servo driver, a reactor, and a terminal block. The electrical control box is installed on the pump station. The circuit breaker is connected to the DC power supply via a cable. The DC power supply is connected to the PLC module via a cable. The DC power supply is connected to the servo driver via a cable through the reactor. The PLC module is connected to the intermediate relay via a cable. The PLC module has built-in synchronous control algorithm and PID control algorithm. The intermediate relay is connected to the servo driver via communication. The servo driver provides adjustable power drive signals for the hydraulic jack and mechanical jack. The intermediate relay is connected to the terminal block. The terminal block is connected to the junction box. The PLC module is connected to the terminal block. The intermediate relay is connected to the buzzer and the emergency stop button via cables.

[0007] Preferably, the sensing and detection unit is an upper chamber pressure sensor and a lower chamber pressure sensor installed on the hydraulic jack, a displacement sensor installed at the bottom of the miter gate, a displacement sensor, a gap sensor, and a pressure sensor installed on the mechanical jack, and an oil level sensor installed on the pump station; the sensing and detection unit is connected to the electrical control box through a junction box.

[0008] Preferably, the execution unit comprises a solenoid valve, a hydraulic jack drive motor, a mechanical jack drive motor, a hydraulic pump, a pump station, a hydraulic jack, and a mechanical jack. The solenoid valve is connected to the electrical control box via a junction box, the hydraulic jack drive motor is connected to the electrical control box via a junction box, and the mechanical jack drive motor is connected to the servo driver via a junction box.

[0009] Preferably, the human-machine interface homepage has buttons for parameter setting, pre-top operation, leveling operation, gap adjustment operation, reference zero-position calibration, synchronous rising operation, synchronous falling operation, locking operation, maintenance operation, and fault and alarm information. Clicking a button will take you to the corresponding interface.

[0010] Preferably, in the human-machine interface, after entering the pre-lifting operation, leveling operation, gap adjustment operation, reference zero-point calibration, synchronous lifting operation, synchronous lowering operation, locking operation, and maintenance operation interface, it can display whether each hydraulic jack is selected, whether it is a reference jack, the real-time pressure value of the upper and lower chambers of each hydraulic jack, the actual stroke, the actual stroke relative to zero point, and the lifting force; it can display whether each mechanical jack is selected, the bearing pressure value of each mechanical jack, the gap value with the bottom of the door body, and the actual stroke; it can display the total lifting force, the actual stroke of the reference jack, and the stroke relative to zero point.

[0011] Preferably, in the human-machine interface, the fault and alarm information button interface can display real-time alarm information and reset the alarm information.

[0012] Preferably, in the sensing and detection unit, the upper chamber pressure sensor and the lower chamber pressure sensor of the hydraulic jack respectively detect the oil pressure in the upper and lower chambers of the hydraulic jack; the hydraulic jack displacement sensor is used to detect the bottom stroke of the miter gate body; the mechanical jack displacement sensor is used to detect the stroke of the mechanical jack screw; the mechanical jack gap sensor is used to detect the gap value between the top surface of the mechanical jack screw and the bottom of the miter gate; the mechanical jack pressure sensor is used to detect the pressure carried by the mechanical jack; and the oil level sensor is used to detect the oil level in the hydraulic oil tank.

[0013] Preferably, the number of hydraulic jacks and mechanical jacks can be independently selected according to the actual weight of the miter gate and the position of the gate. The integrated control unit can be adapted to hydraulic jacks and mechanical jacks with different numbers of points to achieve linkage and synchronous control.

[0014] Another aspect of this invention provides a method for collecting detection data from various sensing components through an integrated control unit, and combining this data with a preset control algorithm to control a servo driver to drive a motor. This enables the hydraulic jack and mechanical jacking to move in tandem according to preset parameters, achieving synchronous lifting and lowering of the miter gate. Furthermore, during the lifting and lowering process, the synchronousness and safety of the lifting and lowering process are ensured by real-time detection and dynamic parameter adjustment of the hydraulic jacking's movement deviation and the mechanical jacking's gap deviation. Specifically, the method includes the following steps: S1. System Start-up and Parameter Configuration: Complete the system wiring, turn on the power of the integrated control unit, enter the human-machine interaction unit parameter setting interface, input the operating parameters of each unit, set the system alarm threshold and shutdown threshold, select the number of hydraulic jacks and mechanical jacks, and select any hydraulic jack as the reference jack. S2, Pre-top Contact: Enter the pre-top operation interface of the human-machine interaction unit, set the pre-top lifting force of each hydraulic jack, set the lifting speed, start the pre-top operation, the integrated control unit drives the hydraulic jack to contact the V-shaped gate body according to the preset tightening force until the lifting force of the hydraulic jack reaches the preset tightening force, and controls the hydraulic jack servo motor to stop moving. When the pre-top action of all hydraulic jacks is finished, the system pre-top operation is completed. S3. Gate Leveling: Enter the leveling operation interface of the human-machine interaction unit, set the lifting stroke and lifting speed of each hydraulic jack, start the leveling operation, and the integrated control unit drives each hydraulic jack to lift synchronously according to the preset parameters until the stroke detection value of each hydraulic jack reaches the preset stroke, thus completing the leveling of the miter gate. S4. Gap Adjustment of the Top Protection: Enter the gap adjustment operation interface of the human-machine interaction unit, set the set value of each mechanical top protection gap and the action speed, start the gap adjustment operation, and the integrated control unit drives each mechanical top protection to lift according to the preset parameters until the gap sensor detects that the gap between the mechanical top protection and the bottom of the herringbone gate reaches the preset value, and controls the mechanical top protection servo motor to stop moving. S5, Reference Zero Position Calibration: Enter the reference zero position calibration interface of the human-machine interaction unit. Through the pre-top contact, gate body leveling, and top protection gap adjustment operations, the integrated control unit drives the hydraulic jack to lift the miter gate body to the posture required for maintenance, and starts the reference zero position calibration, calibrating the current position of the hydraulic jack as the system reference zero position. S6. One-key synchronous lifting: Enter the synchronous lifting interface of the human-machine interaction unit. Using the calibrated reference zero position, set the synchronous lifting stroke and synchronous lifting speed of the reference hydraulic jack, as well as the set value of the gap between each mechanical jack and the bottom of the V-shaped gate. Start the one-key synchronous lifting operation. The integrated control unit drives the reference jack to rise according to the preset parameters. The other hydraulic jacks adjust their posture in real time by detecting the stroke deviation from the reference hydraulic jack through displacement sensors. The integrated control unit dynamically adjusts the action parameters of the other hydraulic jacks through a preset control algorithm to ensure that the stroke deviation of each hydraulic jack is within the preset threshold range. At the same time, each mechanical jack detects the gap deviation between itself and the gate body in real time through gap sensors. The integrated control unit dynamically adjusts the action parameters of the mechanical jacks according to the deviation between the real-time gap and the set gap using a PID control algorithm to ensure that the gap deviation is within the preset threshold range, until the reference jack reaches the preset lifting stroke, and all jacks stop moving. The preset control algorithm for the synchronous lifting of the hydraulic jacks is as follows: the synchronization control target is the height difference, which is used as a feedback signal to adjust the motor speed. The reference cylinder runs at a given speed, and the other hydraulic jacks follow synchronously using a two-stage synchronization algorithm. The inflection point between the two stages of the synchronization algorithm can be set. When the height difference is less than the inflection point value of the synchronization algorithm, a linear adjustment strategy related to the height difference is adopted; when the height difference is greater than the inflection point value of the synchronization algorithm, a square root adjustment strategy related to the height difference is adopted, as detailed below: Hydraulic jack i The stroke height difference with the reference hydraulic jack is: Δh = S i - S 0; In the formula, Δh Hydraulic jack iThe difference in stroke height between the reference hydraulic jack and the reference hydraulic jack; S i Hydraulic jack i Travel relative to the reference zero point; S 0 represents the stroke of the reference hydraulic jack relative to the reference zero point; When | Δh| ≤ ΔS At 1 o'clock, the hydraulic jack i speed of ascent V i上 Adjusted to: ; When | Δh| > ΔS At 1 o'clock, the hydraulic jack i speed of ascent V i上 Adjusted to: ; In the formula, ΔS 1 represents the inflection point value for adjusting the strategy; V i上 Hydraulic jack i rate of ascent; V 0上 The set reference hydraulic jack lifting speed; h alarm This is the alarm threshold for the hydraulic jack height difference.

[0015] S7. Mechanical Locking: Enter the mechanical locking interface of the human-machine interaction unit, set the mechanical top locking action speed, start the mechanical locking operation, and the integrated control unit drives each mechanical top to perform locking movements until the integrated control unit detects an overload signal in the power drive component of the mechanical top, controls each mechanical top to automatically stop its action, and completes the locking and fixing of the mechanical top. S8. One-key synchronous descent: Enter the synchronous descent interface of the human-machine interaction unit. Using the calibrated reference zero position, set the synchronous rising stroke, synchronous rising speed, synchronous falling stroke, synchronous falling speed of the reference hydraulic jack, the set value of the gap between each mechanical jack and the bottom of the miter gate, and the gap adjustment action speed. Start one-key synchronous descent. The integrated control unit drives the reference hydraulic jack to rise according to the set synchronous rising stroke. The other hydraulic jacks rise synchronously according to the synchronous control algorithm. When the reference hydraulic jack reaches the synchronous rising stroke, the miter gate locking state is released, and the hydraulic jack stops moving. Then, the mechanical jack automatically enters the jack gap adjustment operation and rises according to the set gap adjustment action speed. When the gap between the mechanical jack and the bottom of the miter gate reaches the preset value, the mechanical jack stops moving. Then, the reference hydraulic jack falls according to the preset parameters. The other hydraulic jacks and mechanical jacks repeat the deviation detection and dynamic adjustment logic of step S6 to ensure that the actions of each unit are synchronized until the reference jack reaches the preset falling stroke, and all jacks stop moving. The preset control algorithm for the synchronous descent of the hydraulic jacks is as follows: the synchronization control target is the height difference, which is used as a feedback signal to adjust the motor speed. The reference cylinder runs at a given speed, and the other hydraulic jacks follow synchronously using a two-stage synchronization algorithm. The inflection point between the two stages of the synchronization algorithm can be set. When the height difference is less than the inflection point value of the synchronization algorithm, a linear adjustment strategy related to the height difference is adopted; when the height difference is greater than the inflection point value of the synchronization algorithm, a square root adjustment strategy related to the height difference is adopted, as detailed below: When | Δh| ≤ ΔS At 1 o'clock, the hydraulic jack i Falling speed V i下 Adjusted to: ; When | Δh| > ΔS At 1 o'clock, the hydraulic jack i Falling speed V i下 Adjusted to: ; In the formula, Δh Hydraulic jack i The difference in stroke height between the reference hydraulic jack and the reference hydraulic jack; ΔS 1 represents the inflection point value for adjusting the strategy; V i下 Hydraulic jack i Falling speed; V 0下 The set reference hydraulic jack descent speed; h alarm This is the alarm threshold for the hydraulic jack height difference.

[0016] S9. Maintenance Operation: The action parameters of any one or more hydraulic jacks and mechanical jacks can be set individually through the human-machine interaction unit. The integrated control unit drives the selected hydraulic jacks and mechanical jacks to independently complete the lifting and lowering actions according to the preset parameters, which can meet the local adjustment needs of the miter gate maintenance.

[0017] Preferably, in steps S6 and S8, the action deviation threshold of the hydraulic jack and the gap deviation threshold between the mechanical jack and the gate can be flexibly adjusted by the human-machine interaction unit according to the specifications and maintenance requirements of the miter gate; in step S7, the locking movement speed parameter of the mechanical jack can be set independently by the human-machine interaction unit. The preset parameters include one or more of the following: the action speed, stroke, clamping force, and gap value of each unit. All preset parameters can be modified and reset in real time through the human-machine interaction unit.

[0018] Preferably, during any of the operations in steps S1-S9, when the integrated control unit detects that the detection data of any sensor component exceeds the alarm threshold, the integrated control unit immediately triggers the buzzer alarm component to remind the operator to strengthen monitoring; when the emergency stop component of the human-machine interaction unit is triggered, or when the integrated control unit detects that the detection data of any sensor component exceeds the stop threshold, the integrated control unit immediately triggers the alarm component and controls all hydraulic jacks and mechanical jacks to stop their actions, thereby realizing the emergency safety protection of the system; The preset control algorithm includes one or a combination of synchronous control algorithm and PID control algorithm; the action deviation is the height difference between various points at the bottom of the door or the travel deviation between the top and bottom.

[0019] This invention discloses an integrated control system and method for the hydraulic jacking and mechanical support of a miter gate. Addressing the technical shortcomings of existing miter gate lifting technologies, such as separate control of the hydraulic jacking and mechanical support, lack of linkage and interaction, high requirements for manual coordination, and poor synchronization and safety, this invention achieves automation, precision, and safety in the synchronous lifting operation of the miter gate through a modular system structure design and integrated linkage control logic. Compared with existing technologies, it has the following significant advantages: 1. This invention divides the system into a hierarchical structure of human-machine interaction unit, integrated control unit, sensing and detection unit, and execution unit. Each unit functions independently but works in conjunction with each other. The number of hydraulic jacking and mechanical jacking points can be independently selected according to the actual weight of the miter gate and the position of the top gate. The integrated control unit can adapt to execution units with different numbers of points to achieve precise linkage and synchronous control, meet the maintenance and lifting needs of miter gates of different specifications of ship locks such as small, medium and large, and solve the problem of single adaptability of traditional systems.

[0020] 2. This invention uses an integrated control unit as its core, integrating synchronous control algorithms and PID control algorithms. Through various sensing components, it collects real-time data on the pressure of the hydraulic jack, the stroke data of each point on the miter gate, and the stroke, clearance, and contact pressure data of the mechanical jack. This enables information interaction and action linkage between hydraulic jacks and between hydraulic jacks and mechanical jacks. It abandons the traditional mode of separate operation of two sets of devices and multi-person collaborative operation. Only one person needs to complete all operations through the human-machine interaction unit. It realizes one-button linkage control of the hydraulic jack and mechanical jack for raising and lowering, which greatly reduces the intensity of manual operation and improves work efficiency.

[0021] 3. This invention selects a benchmark lifting unit to monitor and dynamically adjust the movement deviation of the remaining hydraulic jacks in real time, ensuring that the movement deviation of each hydraulic jack is always within a preset threshold range. At the same time, it monitors and dynamically adjusts the gap deviation between the mechanical jack and the gate body in real time, achieving precise tracking of the gate body by the mechanical jack. This effectively avoids uneven force on the gate body and gate tilting caused by asynchronous movement of each jacking device, ensuring that the V-shaped gate maintains a horizontal posture during lifting and lowering, thus improving the safety of the gate structure.

[0022] 4. The system of this invention is equipped with multiple safety protections, including emergency stop, abnormal alarm, and threshold stop. During the entire operation, if the emergency stop component is triggered or the sensor component detects abnormal data, the integrated control unit can immediately trigger an alarm and control all execution units to stop operating. At the same time, the mechanical jacking achieves automatic locking and fixing of the gate through overload signals, forming a dual safety protection of hydraulic jacking and mechanical jacking. From the perspective of control logic and execution action, it eliminates safety hazards such as gate tilting and device malfunction, and greatly improves the safety and reliability of the V-gate maintenance and lifting operation.

[0023] 5. All operating parameters, alarm thresholds, shutdown thresholds, and action thresholds of this invention can be flexibly set and modified in real time through the human-machine interface unit. Locking speed, deviation thresholds, etc., can be adjusted according to the specifications of the miter gate and maintenance requirements. At the same time, it supports independent local maintenance and adjustment of one or more hydraulic jacks and mechanical jacks, meeting the diverse operational needs in the miter gate maintenance process. Moreover, the connection method of each unit of the system is simple and reliable, the sensor components are reasonably laid out, the detection data is accurate, and the later maintenance is convenient, which has strong industrial applicability.

[0024] 6. This invention establishes a unified position reference for synchronous lifting by means of benchmark zero-position calibration. Combined with closed-loop control logic of deviation detection, dynamic adjustment, linkage execution, and threshold protection, it realizes fully automated control of the entire process from parameter configuration, pre-top contact, gate leveling to synchronous lifting, mechanical locking, and synchronous descent. No manual intervention is required to adjust the actions of each device. This solves the problems of low operational accuracy and poor synchronization caused by human error in traditional technology, and promotes the intelligent development of lock miter gate lifting technology. Attached Figure Description

[0025] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0026] Figure 1 This is a system layout diagram of the present invention.

[0027] Figure 2 This is the wiring diagram for the present invention.

[0028] Figure 3 This is a diagram showing the internal layout of the electrical control box of the present invention.

[0029] Figure 4 This is a block diagram of the electronic control system of the present invention.

[0030] Figure 5 This is a flowchart of the hydraulic jacking pre-jacking action control process of the present invention.

[0031] Figure 6 This is a flowchart of the hydraulic jacking leveling action control of the present invention.

[0032] Figure 7 This is a flowchart of the mechanical top clearance adjustment control action of the present invention.

[0033] Figure 8 This is a flowchart of the one-click linkage synchronous rising control process of the present invention.

[0034] Figure 9 This is a flowchart of the one-click linkage synchronous falling control process of the present invention.

[0035] Figure 10 This is a flowchart of the mechanical top-locking action control of the present invention.

[0036] The diagram shows: 11. Handheld control box; 12. Touch screen; 13. Buzzer; 14. Emergency stop button; 2. Electrical control box; 21. Circuit breaker; 22. DC power supply; 23. PLC module; 24. Intermediate relay; 25. Servo driver; 26. Reactor; 27. Terminal block; 28. Junction box; 31. Upper chamber pressure sensor; 32. Lower chamber pressure sensor; 33. Displacement sensor; 34. Displacement sensor; 35. Gap sensor; 36. Pressure sensor; 37. Oil level sensor mounted on the oil tank; 41. Solenoid valve; 42. Servo motor; 43. Servo motor; 44. Hydraulic pump; 45. Pump station; 46. Hydraulic jack; 47. Mechanical jack. Detailed Implementation

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and 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.

[0038] The integrated hydraulic and mechanical jacking control system and its control method for the miter gate of this invention, through the coordinated operation of a human-machine interface unit, an integrated control unit, a sensing and detection unit, and an execution unit, combined with a preset control algorithm, achieve synchronous raising and lowering of the miter gate during maintenance. The following is in conjunction with the appendix... Figure 1-5 Through two typical embodiments, four-point synchronization and six-point synchronization, the system structure and control flow of the present invention are described in detail, and the feasibility and adaptability of the present invention in engineering practice are verified.

[0039] Example 1 Control system and control method for a four-point synchronous integrated miter gate with hydraulic and mechanical jacking: This embodiment is applicable to the maintenance and lifting operations of miter gates in small, medium, and large ship locks. These miter gates weigh approximately 80-1000 tons, have large dimensions, and require high stress resistance, necessitating a four-point synchronous lifting method to ensure gate level. One execution unit is installed at each of the four preset top positions at the bottom corners of the miter gate. Centralized linkage control is achieved through one electrical control box 2, two hydraulic pump stations 45, and four sensor detection units. A portable operating box 11 serves as the remote human-machine interface. The overall system layout is as follows: Figure 1 As shown, the connection relationship of the electronic control system is as follows: Figure 4 As shown.

[0040] 1.1 System Composition and Connection Relationships: The integrated hydraulic and mechanical jacking control system of this embodiment includes a portable operating box 11, an electrical control box 2, a hydraulic pump station 45, four hydraulic jacks 46, four mechanical jacks 47, four sets of sensor detection units, four sets of valve group units 4, four sets of motor units 42, and four sets of motor units 43. The system is assembled using fully autonomous and controllable products. The specific configuration and connection relationship of each component are as follows: 1. Human-Machine Interface Unit: A portable control box 11 is adopted, which integrates a touch screen 12, a buzzer 13, and an emergency stop button 14. The touch screen 12 and the PLC module 23 in the control box 2 establish a high-speed signal connection via Ethernet, which can efficiently realize parameter setting and data interaction; the buzzer 13 and the emergency stop button 14 are rigidly connected to the control box 2 via cables to ensure reliable transmission of alarm signals and emergency stop commands, and ensure operational safety.

[0041] 2. Integrated Control Unit: An electrical control box 2 is used, integrating a PLC module 23 and eight servo drives 25. The PLC module 6 is a Nanda Aotuo NJ300 series PLC, and the servo drives 25 are Huada SBF-AL201 servo drives. The PLC module 23 and the eight servo drives 25 communicate via an RS485 bus network. The PLC module 23 has built-in synchronous control and PID control algorithms, enabling it to output precise power drive signals. The servo drives 25 provide adjustable frequency conversion power to the hydraulic servo motor 42 and the mechanical jacking servo motor 43, ensuring precise operation of each actuator.

[0042] 3. Sensing and Detection Unit: Four identical hydraulic jacking devices 7 are used, each equipped with one upper chamber pressure sensor 31, one lower chamber pressure sensor 32, and one absolute wire-type displacement sensor 33. The upper chamber pressure sensor 31 is model MB300 (0-20MPa), the lower chamber pressure sensor 32 is model MB300 (0-70MPa), and the absolute wire-type displacement sensor 33 is model CLMS1-JA2AB012000. Four identical mechanical jacking devices 8 are also provided, each equipped with a mechanical jacking servo motor 43, a gap sensor 35, a screw top pressure sensor 36, and a magnetostrictive displacement sensor 34. The mechanical jacking gap sensor 35 is model LSM-5mm, the screw top pressure sensor 36 is model HS-TH3T-500t, and the magnetostrictive displacement sensor 34 is a Nadu GB series heavy-duty displacement sensor with a range of 1000mm. All pressure sensors 31 and 32, displacement sensors 33 and 34, gap sensor 35, and screw top pressure sensor 36 are connected to the electrical control box 2 via cables. The detection data is uploaded in real time to ensure that the control end can keep track of the status of the hydraulic jack and mechanical jacking.

[0043] 4. Motor Unit: Hydraulic jack servo motor 42, model 130ST-M14615LMBB, with a power of 2.3kW; mechanical jack servo motor 43, model 80ST-M03330LFB, with a power of 1.0kW. Servo motors 42 and 43 are connected to the integrated control unit servo driver 25 to drive the hydraulic pump and mechanical gears.

[0044] The wiring relationships of each component are as follows: Figure 4 As shown, all signals from the sensing and execution components are aggregated to the PLC module 23, which then uniformly completes data acquisition, processing, and control command output to achieve coordinated control of the entire system and ensure that the actions of each unit are coordinated.

[0045] 1.2 Control Method Implementation Steps: Based on the above system, the synchronous lifting and lowering control method for the miter gate of the lock in this embodiment is strictly implemented according to steps S1-S9. The specific engineering implementation parameters and operation process are as follows: S1. System Start-up and Parameter Configuration: First, turn on the main power of the electrical control box 2. Input the operating parameters through the touch screen 12 of the portable operation box 11: set the size of the hydraulic jack, the maximum pressure value of the upper and lower chambers, the pump displacement value, the operating speed of the mechanical jacking device 47 (200-1900 r / min), and the setting value of the gap between the mechanical jacking device and the gate body (3 mm); set the system alarm threshold: the height difference between any two hydraulic jacking devices 46 is ≥1 mm, and the gap between the mechanical jacking device 47 and the gate body is ≥4.5 mm or ≤1.5 mm; select 4 hydraulic jacking points and 4 mechanical jacking points according to the weight of the gate body and the distribution of the jacking positions, and select the hydraulic jacking device at the lower left corner of the miter gate as the reference jacking unit to provide a reference for subsequent synchronous actions.

[0046] S2, Pre-top contact: Set the pre-top clamping force to 10t on the touch screen 12 and click the "Pre-top start" command; after receiving the command, the PLC module 23 controls the hydraulic jack servo motor 42 to drive the plunger pump 44 to supply oil, and the four hydraulic jack devices 46 synchronously and slowly lift until the lifting force of each jack reaches 10t. The PLC module 23 immediately issues a stop command, and the hydraulic jack devices 46 stop moving, completing the flexible contact of the door body, effectively avoiding damage to the door body or devices caused by hard contact.

[0047] S3. Gate Leveling: Based on the required posture of the gate body, set the lifting stroke and lifting speed (8mm / min) of each hydraulic jacking device 46 on the touch screen 12, and click "Leveling Start"; PLC module 23 controls the four hydraulic jacking devices 46 to lift synchronously, and each absolute pull-wire displacement sensor 33 detects the stroke in real time and feeds it back to the control terminal. When the stroke detection value of all hydraulic jacking devices 46 reaches their respective set stroke, the control terminal issues a stop command to stop the lifting operation and complete the leveling of the V-shaped gate body.

[0048] S4. Adjustment of the gap between the mechanical top protection device 8 and the door body: Set the gap setting value of 3mm and the rising speed of 8mm / min on the touch screen 12, and click "Start Gap Adjustment"; PLC module 23 controls the 4 mechanical top protection devices 8 to lift synchronously, and detects the gap with the door body in real time through the gap sensor 35. When the gap detection value of all mechanical top protection devices 47 reaches 3mm, the mechanical top protection devices 47 stop moving, and the pre-adjustment of the top protection gap is completed, which is ready for the subsequent synchronous following action.

[0049] S5. Zero-position calibration: When the miter gate body is raised to the required elevation and horizontal position for maintenance, and after confirming that the gap between the four mechanical jacking devices 47 and the bottom of the gate body is stable at 3mm, click "Zero-position calibration" on the touch screen 12 to set the current position of all hydraulic jacking devices 46 as the system's zero-position, providing a unified position reference standard for subsequent synchronous lifting.

[0050] S6. One-key synchronous lifting: On the touch screen 12, set the synchronous lifting stroke of the reference lifting unit to 650mm, the lifting speed to 8mm / min, and the synchronous lifting gap setting value of the mechanical jacking device 47 to 3mm, and click "One-key synchronous lifting start"; the reference lifting unit first accelerates to 8mm / min and then rises at a constant speed. The other three hydraulic jacking devices 46 detect the stroke deviation from the reference lifting unit in real time through the absolute wire displacement sensor 33. The PLC module 23 dynamically adjusts the lifting speed of the other hydraulic jacking devices 46 through the synchronous control algorithm. This ensures that the height difference between any two hydraulic jacking devices 46 is within 1mm; at the same time, the four mechanical jacking devices 47 detect the gap between themselves and the gate body in real time through the gap sensor 35, and the PLC module 23 dynamically adjusts the speed of the mechanical jacking servo motor 43 through the PID control algorithm to ensure that the gap between the mechanical jacking device and the gate body deviates from the set gap within 1mm; when the stroke detection value of the reference jacking unit reaches 500mm, all hydraulic jacking devices 46 and mechanical jacking devices 47 immediately stop operating, and the synchronous jacking is completed, and the miter gate body is stably stopped at the maintenance elevation.

[0051] S7. Mechanical Locking: Click "Locking Start" on the touch screen 12 and set the locking speed to 8mm / min; PLC module 23 controls 4 mechanical top protection devices 47 to perform locking motion at a low and uniform speed, and the screw slowly presses against the bottom of the V-shaped gate body; when the servo driver 25 detects an overload signal in the mechanical top protection servo motor 43 and the current exceeds 1.2 times the rated value, it determines that the gate body has been locked, and PLC module 23 immediately issues a stop command, and all mechanical top protection devices 47 stop rising, forming a rigid support for the mechanical top protection, which together with the hydraulic top constitutes a double top protection of hydraulic + mechanical, further ensuring the stability of the gate body.

[0052] S8. One-key synchronous descent: After the miter gate maintenance is completed, set the synchronous lifting stroke of the reference lifting unit to 10mm, the synchronous lifting speed to 6mm / min, the synchronous descent stroke to 650mm, and the descent speed to 6mm / min on the touch screen 12, as well as the synchronous descent gap setting of the mechanical jacking device 47 to 3mm and the gap adjustment speed to 6mm / min. Click "One-key synchronous descent start". The reference lifting unit first accelerates to 6mm / min and then rises at a constant speed. The other three hydraulic jacking devices 46 rise synchronously according to the synchronous control algorithm until the reference hydraulic jacking reaches the synchronous lifting stroke, releasing the miter gate locking state and stopping the hydraulic jacking. Subsequently, the mechanical jacking automatically enters the jacking gap adjustment operation, according to the set gap. The gap adjustment mechanism rises at a speed of 6 mm / min. When the gap between the mechanical support and the bottom of the miter gate reaches the preset value of 3 mm, the mechanical support stops. The reference lifting unit accelerates to 6 mm / min and then falls at a constant speed. The other three hydraulic lifting devices 46 repeat the stroke deviation detection and dynamic adjustment logic of S6 to ensure that the height difference between any two hydraulic lifting devices 46 is within 1 mm. The four mechanical support devices 47 repeat the gap deviation detection and dynamic adjustment logic of S6 to ensure that the gap deviation between the mechanical support and the gate body and the set gap is within 1 mm. When the stroke detection value of the reference lifting unit returns to the system reference zero position, all hydraulic lifting devices 46 and mechanical support devices 47 stop operating, and the miter gate body smoothly falls back to the initial position.

[0053] S9. Local maintenance and adjustment: If there is a local positional deviation after the door is reset, the hydraulic jacking device 46 or mechanical jacking device 47 that needs to be adjusted can be selected individually through the touch screen 12. The single adjustment stroke and adjustment speed of 8mm / min are set according to the door posture requirements. Click the "Individual Action" command, and the PLC module 23 controls the selected unit to independently complete the lifting action, so as to realize the local fine adjustment of the door and meet the reset accuracy requirements after maintenance.

[0054] In all the above operating steps, if the emergency stop button 14 is triggered, or if the detection data collected by the PLC module 23 of any sensor component exceeds the stop threshold, the buzzer 13 will immediately emit a continuous alarm sound. At the same time, the PLC module 23 will issue an emergency stop command within 0.5 seconds, and all hydraulic jacks and mechanical jacks will stop all actions, realizing the emergency safety protection of the system and minimizing safety risks.

[0055] Example 2 Control system and control method for six-point synchronous integrated miter gate with hydraulic and mechanical jacking: This embodiment is applicable to the maintenance and lifting operations of miter gates in ultra-large ship locks. These miter gates weigh 1000-1300 tons and have a compact structure. Three hydraulic pump stations, 45 sets of sensors, and 6 sets of actuators are installed at the preset top gate positions on both the left and right sides of the bottom of the miter gate. The overall system layout and electrical control logic are consistent with Embodiment 1, and the wiring relationships are as follows: Figure 2 As shown.

[0056] 2.1 System Composition and Adaptability Adjustment: The system component configuration in this embodiment is basically the same as that in Embodiment 1, with only the following adaptation adjustments: 1. Six sets of actuators are installed at the bottom of each miter gate. Centralized linkage control is achieved through one set of electrical control box, two or three sets of hydraulic pump stations, and four or five sets of sensor detection units, which simplifies the power drive configuration and reduces energy consumption. 2. The hydraulic jack servo motor model is 130ST-M15025LFB, with a power adjusted to 3.8kW. The mechanical jack servo motor model is 130ST-M15025LFB, with a power adjusted to 3.8kW.

[0057] The models, connections, and sensor configurations of the remaining components are the same as in Embodiment 1. The PLC module 23 of the integrated control unit can be directly adapted to the linkage control of 12 points without modifying the built-in algorithm, which fully verifies the adaptability of the flexible selection of points in this invention and enables the system configuration to be flexibly adjusted according to the door specifications.

[0058] 2.2 Control method implementation steps: The control method in this embodiment is completely consistent with steps S1-S9 of embodiment 1. The only difference is that in the parameter configuration step of S1, 6 hydraulic jacking points and 6 mechanical jacking points are selected, and the hydraulic jacking device 46 on the left side of the miter gate is selected as the reference jacking unit. In the synchronous jacking step of S6 and the synchronous descent step of S8, it is only necessary to control the height difference of the 6 hydraulic jacking devices 46 to be ≤1mm and the gap between the 6 mechanical jacking devices 47 and the gate body to always be 3mm, so as to meet the lifting accuracy requirements of the ultra-large miter gate.

[0059] In actual engineering implementation, the synchronous lifting and lowering process of this embodiment showed no deviation exceeding the threshold throughout the entire process. The horizontal deviation of the gate during the lifting and lowering process was ≤1mm, and there was no displacement of the gate after mechanical locking, fully meeting the maintenance and lifting requirements of the miter gate of the ultra-large ship lock. Moreover, only one operator is needed to complete all operations through a portable control box 1, which improves the work efficiency by more than 80% compared with the traditional manual collaborative mode, significantly reducing labor costs and operational intensity.

[0060] Example Description The two embodiments described above are typical application scenarios in actual engineering. The integrated hydraulic jacking and mechanical jacking control system of the present invention can be further equipped with more synchronous jacking points, such as 8 points, according to the maintenance needs of large ship lock miter gates. It only requires increasing the number of hydraulic jacking devices 46 and mechanical jacking devices 47, and adapting the number of hydraulic pump stations 10, motors 51 and 52, solenoid valves 41, and sensor detection units. The PLC module 23 of the integrated control unit can be directly adapted to the linkage control of different numbers of points without redesigning the control logic. The core deviation detection-dynamic adjustment-linkage synchronization logic of the control method remains unchanged. It only requires flexibly adjusting the action threshold and operating parameters according to the specifications and weight of the miter gate to meet the maintenance lifting and lowering needs of different ship lock miter gates.

[0061] All components of the system of this invention are commercially available conventional industrial parts, which are easy to process, assemble and deploy. The control method is fully automated and does not require manual intervention to adjust the device. In engineering practice, it has the characteristics of being easy to implement, easy to operate, highly accurate and safe. It can completely replace the traditional separate control mode of hydraulic jacking and mechanical jacking, and greatly improve the automation level and safety and reliability of the maintenance and lifting operation of the miter gate of the ship lock.

Claims

1. A control system for integrated hydraulic miter gate hoist and mechanical backstop, characterized by, It includes a human-computer interaction unit, an integrated control unit, a sensing and detection unit, and an execution unit; The human-machine interaction unit is connected to the integrated control unit for inputting operation commands, setting operating parameters, displaying the device's operating status, and realizing human-machine interaction. It is also equipped with emergency stop and alarm components. The integrated control unit is connected to the sensing and detection unit and the execution unit respectively. It is used to collect the action data of the hydraulic jack and mechanical jack of the miter gate, and drive the motor to control the hydraulic jack and mechanical jack to rise and fall through the built-in control algorithm. The sensing and detection unit is connected to the integrated control unit and is used to collect real-time status data of the hydraulic jack and the mechanical jack. The execution unit is connected to the integrated control unit and is used to drive the rising and falling movements of the hydraulic jack and the mechanical jack.

2. The integrated control system for hydraulic miter gate hoist and mechanical backstop of claim 1, wherein, The human-machine interaction unit is a portable operation box (11), which integrates a touch screen (12), a buzzer (13) and an emergency stop button (14). The touch screen (12) is connected to the integrated control unit (2) via Ethernet through a junction box (28), and the buzzer (13) and the emergency stop button (14) are connected to the integrated control unit (2) via cables.

3. The integrated control system for hydraulic jacks and mechanical jacks of miter gates according to claim 2, characterized in that, The integrated control unit is an electrical control box (2), which integrates a circuit breaker (21), a DC power supply (22), a PLC module (23), an intermediate relay (24), a servo driver (25), a reactor (26), and a terminal block (27). The electrical control box (2) is installed on the pump station (45). The circuit breaker (21) is connected to the DC power supply (22) by cable. The DC power supply (22) is connected to the PLC module (23) by cable. The DC power supply (22) is connected to the servo driver (25) by cable through the reactor (26). The PLC module (23) is connected to the intermediate relay (24), the servo driver (25), the reactor (26), and the terminal block (27). The relay (24) is connected by a cable. The PLC module (23) has built-in synchronous control algorithm and PID control algorithm. The intermediate relay (24) is connected to the servo driver (25) for communication. The servo driver (25) provides adjustable power drive signals for the hydraulic jack (46) and mechanical jack (47). The intermediate relay (24) is connected to the terminal block (27). The terminal block (27) is connected to the junction box (28). The PLC module (23) is connected to the terminal block (27). The intermediate relay (24) is connected to the buzzer (13) and the emergency stop button (14) by a cable.

4. The integrated control system for hydraulic jacks and mechanical jacks of miter gates according to claim 2, characterized in that, The sensing and detection unit includes an upper chamber pressure sensor (31) and a lower chamber pressure sensor (32) installed on the hydraulic top (46). The sensing and detection unit includes a displacement sensor (33). The pull wire end of the displacement sensor (33) is hung at the bottom of the miter gate to measure the displacement of the bottom of the miter gate when it rises or falls. The sensing and detection unit includes a displacement sensor (34), a gap sensor (35), and a pressure sensor (36) installed on the mechanical top (47), and an oil level sensor (37) installed on the pump station (45). The sensing and detection unit is connected to the electrical control box (2) through a junction box (28).

5. The integrated hydraulic jacking and mechanical jacking control system for a herringbone gate according to claim 3, characterized in that, The execution unit includes a solenoid valve (41), a hydraulic jack drive motor (42), a mechanical jack drive motor (43), a hydraulic pump (44), a pump station (45), a hydraulic jack (46), and a mechanical jack (47). The solenoid valve (41) is connected to the electrical control box (2) through a junction box (28), the hydraulic jack drive motor (42) is connected to the servo driver (25) through a junction box (28), and the mechanical jack drive motor (43) is connected to the servo driver (25) through a junction box (28).

6. The integrated hydraulic jacking and mechanical jacking control system for a herringbone gate according to claim 2, characterized in that, The human-machine interaction unit includes a human-machine operation interface. The home page of the human-machine operation interface has buttons for parameter setting, pre-top operation, leveling operation, gap adjustment operation, reference zero position calibration, synchronous rise operation, synchronous fall operation, locking operation, maintenance operation, and fault and alarm information. Clicking the button will take you to the corresponding interface. The human-machine interface allows users to enter various operation interfaces, including pre-lifting, leveling, gap adjustment, reference zero-position calibration, synchronous lifting, synchronous lowering, locking, and maintenance. Each interface displays whether each hydraulic jack is selected, whether it is the reference jack, the real-time pressure values ​​of the upper and lower chambers of each hydraulic jack, the actual stroke of the bottom of the miter gate, the actual stroke relative to zero, and the lifting force. It also displays whether each mechanical jack is selected, the bearing pressure value of each mechanical jack, the gap value with the bottom of the gate, and the actual stroke of the mechanical jack. Finally, it displays the total lifting force of all hydraulic jacks, the actual stroke of the reference jack, and the stroke relative to zero. The human-machine interface allows users to access the fault and alarm information button interface, which displays real-time alarm information and allows users to reset alarm information.

7. The integrated hydraulic jacking and mechanical jacking control system for a herringbone gate according to claim 6, characterized in that, In the sensing and detection unit, the upper chamber pressure sensor and lower chamber pressure sensor of the hydraulic jack respectively detect the oil pressure in the upper and lower chambers of the hydraulic jack; the hydraulic jack displacement sensor is used to detect the bottom stroke of the miter gate body; the mechanical jack displacement sensor is used to detect the stroke of the mechanical jack screw; the mechanical jack gap sensor is used to detect the gap value between the top surface of the mechanical jack screw and the bottom of the miter gate; the mechanical jack pressure sensor is used to detect the pressure borne by the mechanical jack; and the oil level sensor is used to detect the oil level in the hydraulic oil tank. The number of hydraulic jacks and mechanical jacks is independently selected based on the actual weight of the miter gate and the position of the gate. An integrated control unit is used to adapt to different numbers of hydraulic jacks and mechanical jacks to achieve linkage and synchronous control.

8. A control method for a control system based on the integrated miter gate hydraulic jacking and mechanical jacking control system according to any one of claims 1-7, characterized in that, The integrated control unit collects data from the sensor detection unit and combines it with a preset control algorithm to control the servo driver to drive the motor, achieving synchronous lifting and lowering of the hydraulic jack and the mechanical jacking mechanism. It also enables real-time detection and dynamic adjustment of hydraulic jack movement deviations and mechanical jacking clearance deviations. Specifically, this includes: S1. Connect the system and power it on. Enter the parameter setting interface of the human-machine interaction unit, input the operating parameters, set the alarm threshold and shutdown threshold, select the number of hydraulic jacks and mechanical protection jacks, and select the reference jack. S2. Enter the pre-lifting operation interface, set the lifting force and lifting speed, start the pre-lifting, the integrated control unit drives the hydraulic jack to contact the door body until the lifting force reaches the standard, and controls the hydraulic jack servo motor to stop. S3. Enter the leveling operation interface, set the lifting stroke and lifting speed, start leveling, and the integrated control unit drives the hydraulic jack to lift synchronously until the stroke is met; S4. Enter the gap adjustment operation interface, set the gap value and action speed, start the gap adjustment, the integrated control unit drives the mechanical jacking to lift until the gap meets the standard, and controls the mechanical jacking servo motor to stop. S5. Enter the reference zero-position calibration interface, raise the door to the maintenance posture, and calibrate the current position of the hydraulic jack as the system reference zero position; S6. Enter the synchronous jacking interface, using the reference zero position as a reference, set the reference jacking stroke, jacking speed and jacking gap value, and start synchronous jacking; the integrated control unit drives the reference jacking to run, the other hydraulic jacks are adjusted in real time according to the stroke deviation, and the mechanical jacking is adjusted in real time according to the gap deviation using PID control, until the reference jacking stroke reaches the standard, all jacks stop. The hydraulic jack synchronous lifting adopts a two-stage synchronous algorithm, using the height difference as feedback to adjust the speed. When |Δh|≤ΔS1, the adjustment is linear; when |Δh|>ΔS1, the adjustment is square root. S7. Enter the mechanical locking interface, set the locking speed, start locking, the integrated control unit drives the mechanical top locking, and stops when an overload signal is detected; S8. Enter the synchronous descent interface. Using the reference zero position as a reference, set the reference top's rising and falling stroke and speed, as well as the top protection gap value and adjustment speed, and start synchronous descent. The integrated control unit first drives the reference top to rise to the set stroke, releases the lock, adjusts the mechanical top protection to the set gap, and then drives the reference top to fall. The remaining hydraulic tops and mechanical top protections operate synchronously according to the aforementioned logic until the reference top stroke reaches the target, at which point all tops stop. The hydraulic jack synchronous descent adopts a two-stage synchronous algorithm, using the height difference as feedback to adjust the rotation speed. When |Δh|≤ΔS1, the adjustment is linear; when |Δh|>ΔS1, the adjustment is square root. S9. The parameters of one or more hydraulic jacks and mechanical jacks can be set through the human-machine interaction unit, and the integrated control unit can drive them to lift and lower independently.

9. The control method of the integrated miter gate hydraulic jacking and mechanical jacking control system according to claim 8, characterized in that, The two-stage synchronization algorithm in S6 specifically includes: Hydraulic jack i The stroke height difference with the reference hydraulic jack is: Δh = S i - S 0； In the formula, S i Hydraulic jack i Travel relative to the reference zero point; S 0 represents the stroke of the reference hydraulic jack relative to the reference zero point; When | Δh| ≤ ΔS 1 o'clock: ； When | Δh| > ΔS 1 o'clock: ； In the formula, ΔS 1 represents the inflection point value for adjusting the strategy; V i上 Hydraulic jack i Real-time ascent speed; V 0上 The set reference hydraulic jack lifting speed; h alarm The set alarm threshold for hydraulic jack height difference; The two-stage synchronization algorithm in S8 specifically includes: When | Δh| ≤ ΔS 1 o'clock: ； When | Δh| > ΔS 1 o'clock: ； In the formula, ΔS 1 represents the inflection point value for adjusting the strategy; V i下 Hydraulic jack i Falling speed; V 0下 The set reference hydraulic jack descent speed; h alarm The alarm threshold for the height difference of each hydraulic jack is set.

10. The control method of the integrated miter gate hydraulic jacking and mechanical jacking control system according to claim 8, characterized in that, In steps S6 and S8, the hydraulic jacking action deviation threshold and the mechanical jacking and gate body gap deviation threshold can be flexibly adjusted through the human-machine interaction unit according to the V-gate specifications and maintenance requirements. In step S7, the mechanical locking motion speed parameters can be set independently through the human-machine interface unit; the preset parameters include one or more of the following: motion speed, stroke, tightening force, and gap value. All preset parameters can be modified and reset in real time through the human-machine interface unit.

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