Energy-saving variable frequency door machine drive control system for passenger elevator

Abstract

This application provides an energy-saving variable frequency door operator drive control system for passenger elevators, relating to the field of elevator control technology. By integrating a real-time feedback unit for door operator position and speed, combined with an adaptive variable frequency control algorithm, this application can dynamically adjust the motor output torque and operating speed curves based on the actual running resistance of the door and the target position. This reduces the excess energy consumption of traditional door operators during acceleration and deceleration, lowering drive power consumption compared to existing door operator systems. Furthermore, when the elevator door is closed and there are no door opening / closing commands for an extended period, this application automatically puts the variable frequency drive module into a deep sleep state, retaining only the low-power wake-up circuit. Upon receiving a door opening / closing signal, it can quickly resume normal operation, reducing the static power consumption of the door operator system during elevator standby.

Description

Technical Field

[0001] This invention relates to the field of elevator control technology, and more specifically, to an energy-saving variable frequency door operator drive control system for passenger elevators. Background Technology

[0002] Currently, passenger elevator door operator drive systems mainly employ asynchronous motors combined with mechanical limit switches or simple frequency converters. During elevator operation, the door operator's start-stop and door opening / closing actions often rely on a fixed speed curve, lacking adaptive adjustment capabilities to load changes, door resistance, and usage frequency. This results in the motor still outputting significant torque even under light or no-load conditions, leading to energy waste. Furthermore, traditional control methods typically use mechanical stops to forcibly decelerate the door when it reaches its position, generating considerable noise and mechanical shock, and reducing the door operator's lifespan. Therefore, we propose an energy-saving variable frequency door operator drive control system for passenger elevators. Summary of the Invention

[0003] This invention provides an energy-saving variable frequency door operator drive control system for passenger elevators, comprising: The door operator drive motor is used to drive the elevator car door to perform the opening or closing action; The variable frequency drive module is electrically connected to the door operator's drive motor and is used to output a drive power supply with variable frequency and variable voltage to the motor. The door operator motion status detection unit is used to acquire the current position, speed and acceleration information of the door in real time; The main control unit is connected to the frequency converter drive module and the gantry crane motion status detection unit. The main control unit integrates the following: The adaptive speed curve generation module is used to dynamically generate a smooth speed curve from start-up, constant speed operation to deceleration and stop based on the current load state of the gate and the target position. The real-time power adjustment module is used to dynamically adjust the output frequency and voltage of the variable frequency drive module based on the real-time motion information fed back by the door machine motion status detection unit, so that the actual output torque of the motor matches the torque required for the door body movement. The standby and hibernation control module is used to output a hibernation command to the frequency converter drive module when it detects that the elevator door is completely closed and there is no door opening or closing command for more than a preset time threshold, thereby cutting off the main drive power and entering a low-power standby mode. A fast wake-up interface is used to reactivate the frequency converter drive module and restore the door operator drive within a preset wake-up time when an external door opening / closing signal is received in low-power standby mode.

[0004] As a preferred technical solution of this application, the door operator motion state detection unit is an encoder or a Hall sensor, which is installed on the door operator drive motor shaft or the door drive wheel to provide door displacement pulse signals to the main control unit, and the main control unit calculates the speed and acceleration values.

[0005] As a preferred technical solution of this application, the real-time power adjustment module further includes a light load current limiting unit. When the main control unit determines that the current door running resistance is lower than a preset threshold, the light load current limiting unit actively reduces the excitation current component output by the frequency converter drive module.

[0006] As a preferred technical solution of this application, the adaptive speed curve generation module stores at least three preset curve types, which correspond to normal load mode, light load fast mode and heavy load low speed mode respectively.

[0007] As a preferred technical solution of this application, it also includes a door resistance anomaly monitoring module. The door resistance anomaly monitoring module operates inside the main control unit and is used to compare the deviation between the actual drive current and the ideal current curve in real time during the door opening and closing process. When the deviation exceeds the set safety threshold and the duration is greater than N, it is determined that the door is stuck. The main control unit immediately controls the frequency conversion drive module to stop outputting positive torque and perform a reverse micro-opening action, and then tries to close the door again.

[0008] As a preferred technical solution of this application, the fast wake-up interface includes an edge-triggered wake-up circuit, which is connected to the door opening and closing command signal terminal of the elevator main control system. In low-power standby mode, the core processor of the main control unit enters a stop clock state. When the wake-up circuit detects a signal jump, it generates an interrupt signal to restart the core processor clock and restore the power supply to the frequency converter drive module.

[0009] As a preferred technical solution of this application, the frequency converter drive module integrates a DC bus voltage monitoring unit; the DC bus voltage monitoring unit is connected to the main control unit and is used to collect the DC bus voltage value of the frequency converter in real time; when the main control unit determines that the door machine is in a deceleration regenerative braking state and the bus voltage rises to the preset voltage upper limit value, it controls the frequency converter drive module to feed the regenerative energy back to the DC common bus of the elevator control cabinet.

[0010] As a preferred technical solution of this application, the standby sleep control module is equipped with a hierarchical sleep strategy. The hierarchical sleep strategy includes: when the elevator door is closed and the continuous time without door opening or closing commands reaches a first preset threshold, the system enters a shallow sleep state, shuts down the output of the frequency converter drive module but keeps the core processor of the main control unit running; when the continuous time without commands reaches a second preset threshold greater than the first preset threshold, the system enters a deep sleep state, shuts down the core processor of the main control unit and the frequency converter drive module, and keeps the wake-up circuit of the fast wake-up interface working.

[0011] As a preferred technical solution of this application, the main control unit is also provided with a door operator operation learning module. After the elevator completes its first installation or maintenance, the door operator operation learning module automatically performs self-learning operation: controlling the door operator to complete a complete door opening and closing cycle at a reference speed, recording the motor current value and running time corresponding to each stroke position during the process, and generating a personalized reference speed curve and a reference current curve; during subsequent normal operation, the real-time power adjustment module performs energy consumption optimization adjustment based on the personalized reference curve.

[0012] As a preferred technical solution of this application, the main control unit is a single-chip microcomputer, which is also equipped with a door operator operation energy consumption recording unit to accumulate the power consumption of each door opening and closing cycle, and upload it to the building energy management platform through the elevator main control system.

[0013] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This application integrates a real-time feedback unit for the position and speed of the gate operator, combined with an adaptive frequency conversion control algorithm, which can dynamically adjust the output torque and running speed curve of the motor according to the actual running resistance of the gate and the target position, thereby reducing the excess energy consumption of the traditional gate operator during the acceleration and deceleration phases and reducing the driving power consumption compared with the existing gate operator system. 2. When the elevator door is closed and there is no door opening or closing command for a long time, this application automatically puts the frequency converter drive module into a deep sleep state, keeping only the low-power wake-up circuit working. When the door opening or closing signal is received, it can quickly resume normal working mode, reducing the static power consumption of the door machine system during elevator standby. 3. This invention adopts a sensorless vector control strategy and an automatic optimization function for light load current, eliminating the need for additional mechanical door zone limit switches. This reduces hardware costs and maintenance workload, avoids control failures caused by switch aging or jamming, and improves the operational reliability and service life of the door operator system. Attached Figure Description

[0014] Figure 1 A schematic diagram of the energy-saving variable frequency door operator drive control system for passenger elevators provided in this application; Figure 2A schematic diagram showing the connection between the gantry crane motion state detection unit and the gantry crane drive motor and frequency converter drive module provided in this application; Figure 3 A flowchart for abnormal door resistance monitoring and jamming handling provided in this application; Figure 4 A flowchart of the self-learning process of the gantry crane operation learning module provided in this application. Detailed Implementation

[0015] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. 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 should fall within the scope of protection of the present invention.

[0016] It should be noted that, unless otherwise specified, the embodiments and features and technical solutions in the present invention can be combined with each other.

[0017] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0018] For an example, please refer to... Figures 1-4 An energy-saving variable frequency door operator drive control system for passenger elevators includes: The door operator drive motor is used to drive the elevator car door to perform the opening or closing action; The variable frequency drive module is electrically connected to the door operator's drive motor and is used to output a drive power supply with variable frequency and variable voltage to the motor. The door operator motion status detection unit is used to acquire the current position, speed and acceleration information of the door in real time; The main control unit is connected to the frequency converter drive module and the gantry crane motion status detection unit. The main control unit integrates the following: The adaptive speed curve generation module is used to dynamically generate a smooth speed curve from start-up, constant speed operation to deceleration and stop based on the current load state of the gate and the target position. The real-time power adjustment module is used to dynamically adjust the output frequency and voltage of the variable frequency drive module based on the real-time motion information fed back by the door machine motion status detection unit, so that the actual output torque of the motor matches the torque required for the door body movement. The standby and hibernation control module is used to output a hibernation command to the frequency converter drive module when it detects that the elevator door is completely closed and there is no door opening or closing command for more than a preset time threshold, thereby cutting off the main drive power and entering a low-power standby mode. The fast wake-up interface is used to reactivate the frequency converter drive module and restore the door operator drive within a preset wake-up time when an external door opening / closing signal is received in low-power standby mode.

[0019] Furthermore, the door operator motion status detection unit is an encoder or Hall sensor, installed on the door operator drive motor shaft or door drive wheel, used to provide door displacement pulse signals to the main control unit, which calculates the speed and acceleration values. Encoders and Hall sensors are mature high-precision detection components that can convert mechanical motion into electrical signals, with high transmission efficiency, small error, and are suitable for the operating environment of elevator door operators, and can work stably for a long time to ensure the accurate execution of control commands.

[0020] Furthermore, the real-time power adjustment module also includes a light-load current limiting unit. When the main control unit determines that the current door operating resistance is lower than a preset threshold, the light-load current limiting unit actively reduces the excitation current component output by the frequency converter drive module, so that the motor operates in a low-flux energy-saving state. Specifically, the preset threshold can be set based on experience. For example, for common passenger elevator door operators, the rated torque of the motor is about 5-8 N·m, and the preset threshold is usually set at about 2 N·m-3 N·m. When the motor is lightly loaded, the required torque is small, and excessive excitation current will be converted into heat energy waste. The light-load current limiting unit dynamically adjusts the excitation current by accurately judging the door resistance, so that the motor operates in the best energy-saving state, which does not affect the normal operation of the door and can minimize power consumption.

[0021] Furthermore, the adaptive speed curve generation module stores at least three preset curve types, corresponding to normal load mode, light load fast mode, and heavy load low speed mode, respectively. The main control unit automatically selects the matching curve type based on the current rise rate when the gate is first started. The current rise rate when the gate is started is positively correlated with the load size. The main control unit can quickly determine the load type through this parameter and match the corresponding speed curve to ensure that the gate machine always operates in the optimal state, taking into account efficiency, energy saving, and safety.

[0022] Furthermore, it also includes a door resistance anomaly monitoring module. This module operates within the main control unit and is used to compare the deviation between the actual drive current and the ideal current curve in real time during door opening and closing. When the deviation exceeds a set safety threshold and lasts for a duration greater than N (N is set according to the actual situation, for example, 100 milliseconds), it is determined that the door is stuck. The main control unit immediately controls the frequency converter drive module to stop outputting positive torque and perform a reverse micro-opening action, and then tries to close the door again. When the door is stuck, the required drive torque will increase significantly, and the corresponding drive current will deviate from the ideal curve. By monitoring the current deviation, the stuck state can be accurately identified, and a reverse micro-opening measure can be taken in time, which protects the motor and the door, ensures the safety of passengers, and avoids safety hazards caused by stuckness.

[0023] Furthermore, the fast wake-up interface includes an edge-triggered wake-up circuit, which is connected to the door opening / closing command signal terminal of the elevator main control system. In low-power standby mode, the core processor of the main control unit enters a stop clock state. When the wake-up circuit detects a signal transition, it generates an interrupt signal to restart the core processor clock and restore power supply to the frequency converter drive module. The edge-triggered method is sensitive to signal transitions and can quickly capture door opening / closing commands. The interrupt signal can immediately activate the core processor without waiting for the system to fully restart. The stop clock of the core processor can cut off its redundant power consumption, leaving only the wake-up circuit to work, achieving the dual effect of "low-power standby + fast wake-up".

[0024] Furthermore, the variable frequency drive module integrates a DC bus voltage monitoring unit; the DC bus voltage monitoring unit is connected to the main control unit and is used to collect the DC bus voltage value of the variable frequency drive in real time; when the main control unit determines that the door operator is in a deceleration regenerative braking state and the bus voltage rises to the preset voltage upper limit value, it controls the variable frequency drive module to feed the regenerative energy back to the DC common bus of the elevator control cabinet for use by other power-consuming units of the elevator, such as lighting; it can recover the electrical energy generated during the deceleration regenerative braking of the door operator, realize energy recycling, further reduce the overall energy consumption of the elevator, and reduce energy waste.

[0025] Furthermore, the standby hibernation control module has a hierarchical hibernation strategy, which includes: when the elevator door is closed and the continuous time without door opening / closing commands reaches a first preset threshold, the system enters a shallow hibernation state, shutting down the output of the frequency converter drive module but keeping the core processor of the main control unit running; when the continuous time without commands reaches a second preset threshold greater than the first preset threshold, the system enters a deep hibernation state, simultaneously shutting down the core processor of the main control unit and the frequency converter drive module, while keeping the wake-up circuit of the fast wake-up interface working. The first preset threshold is set within the range of 5 to 15 seconds to prevent repeated sleep wake-ups caused by frequent door opening and closing for a short period of time after the elevator door is closed; the second preset threshold is set within the range of 60 to 300 seconds, and is at least 6 times the first preset threshold, to achieve deep energy saving when there is no operation for a long time. For example, if the first preset threshold is set to 10 seconds and the second preset threshold is set to 120 seconds, when the elevator door is completely closed and there is no door opening or closing command for 10 consecutive seconds, the system shuts down the output of the frequency converter drive module, while the core processor of the main control unit continues to run. At this time, the static power consumption of the system is about 2 watts. If there is still no command for 120 consecutive seconds, the system shuts down the clock of the core processor of the main control unit and the power supply of the frequency converter drive module, and only keeps the edge trigger wake-up circuit working. At this time, the static power consumption drops to below 0.1 watts. In elevator operation, there are situations where doors open and close frequently in a short period of time (such as during peak hours). Shallow sleep mode can respond quickly to commands and avoid repeated wake-ups that consume more energy. When there is no operation for a long time, deep sleep mode can cut off all redundant power supplies and retain only the wake-up function to achieve extreme energy saving. At the same time, the threshold setting conforms to the actual usage patterns of elevators, improving the practicality of the strategy.

[0026] Furthermore, the main control unit is also equipped with a door operator operation learning module. After the elevator completes its initial installation or maintenance, the door operator operation learning module automatically performs self-learning operation: controlling the door operator to complete a complete door opening and closing cycle at a reference speed, recording the motor current value and running time corresponding to each stroke position during the process, and generating personalized reference speed curve and reference current curve; during subsequent normal operation, the real-time power adjustment module optimizes energy consumption based on the personalized reference curve; different elevators have different door weights, mechanical resistance, and installation precision, and a general reference curve cannot be adapted to multiple scenarios. Self-learning collects data through actual operation and generates a reference curve that fits the current equipment, making power adjustment more targeted and further improving energy saving effect and operational stability.

[0027] Furthermore, the main control unit is a microcontroller, which also has an internal door operator energy consumption recording unit to accumulate the power consumption of each door opening and closing cycle and upload it to the building energy management platform through the elevator main control system. The microcontroller has the advantages of small size, low power consumption and precise control, which is suitable for the control requirements of the elevator door operator. The energy consumption record can quantify the energy saving effect, provide data basis for subsequent energy saving optimization, and upload it to the building management platform for centralized management and control, so as to realize refined energy management.

[0028] After elevator installation or maintenance, the system automatically activates the door operator learning module to complete a full door opening and closing cycle and generate a personalized baseline curve. During normal operation, the door operator motion status detection unit collects door position, speed, and acceleration information in real time. The main control unit matches the corresponding speed curve through the adaptive speed curve generation module. The real-time power adjustment module adjusts the output of the frequency converter drive module based on feedback information to match the motor torque with the door's requirements. Under light load, the light load current limiting unit reduces the excitation current to achieve energy saving. After the door closes, the standby sleep control module enters shallow or deep sleep mode based on the time without command. During low-power standby, the quick wake-up interface responds to door opening and closing commands at any time, waking up the system to resume operation. During operation, the door resistance anomaly monitoring module monitors and automatically handles jamming in real time. The DC bus voltage monitoring unit recovers regenerative energy and avoids overvoltage risks. The energy consumption recording unit accumulates energy consumption and uploads it to the building energy management platform. The entire process requires no manual intervention; only periodic maintenance of the sensors and modules is needed.

[0029] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0030] Obviously, the embodiments described above are merely some embodiments of the present invention, not all embodiments. The accompanying drawings show preferred embodiments of the present invention, but do not limit the patent scope of the present invention. The present invention can be implemented in many different forms; rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing specific embodiments, or make equivalent substitutions for some of the technical features. Any equivalent structures made using the content of this specification and drawings, directly or indirectly applied to other related technical fields, are similarly within the patent protection scope of this invention.

Claims

1. A passenger elevator energy-saving variable frequency door machine drive control system, characterized in that, include: The door operator drive motor is used to drive the elevator car door to perform the opening or closing action; The variable frequency drive module is electrically connected to the door operator's drive motor and is used to output a drive power supply with variable frequency and variable voltage to the motor. The door operator motion status detection unit is used to acquire the current position, speed and acceleration information of the door in real time; The main control unit is connected to the frequency converter drive module and the gantry crane motion status detection unit. The main control unit integrates the following: The adaptive speed curve generation module is used to dynamically generate a smooth speed curve from start-up, constant speed operation to deceleration and stop based on the current load state of the gate and the target position. The real-time power adjustment module is used to dynamically adjust the output frequency and voltage of the variable frequency drive module based on the real-time motion information fed back by the door machine motion status detection unit, so that the actual output torque of the motor matches the torque required for the door body movement. The standby and hibernation control module is used to output a hibernation command to the frequency converter drive module when it detects that the elevator door is completely closed and there is no door opening or closing command for more than a preset time threshold, thereby cutting off the main drive power and entering a low-power standby mode. A fast wake-up interface is used to reactivate the frequency converter drive module and restore the door operator drive within a preset wake-up time when an external door opening / closing signal is received in low-power standby mode.

2. The passenger elevator energy-saving variable frequency door machine drive control system according to claim 1, characterized in that, The door operator motion state detection unit is an encoder or Hall sensor, installed on the door operator drive motor shaft or door drive wheel, used to provide door displacement pulse signals to the main control unit, which calculates the speed and acceleration values.

3. The passenger elevator energy-saving variable frequency door machine drive control system according to claim 1, characterized in that, The real-time power adjustment module also includes a light load current limiting unit. When the main control unit determines that the current door operating resistance is lower than a preset threshold, the light load current limiting unit actively reduces the excitation current component output by the frequency converter drive module.

4. The passenger elevator energy-saving variable frequency door machine drive control system according to claim 1, characterized in that, The adaptive speed curve generation module stores at least three preset curve types, corresponding to normal load mode, light load fast mode and heavy load low speed mode, respectively.

5. The energy-saving variable frequency door operator drive control system for passenger elevators according to claim 1, characterized in that, It also includes a door resistance anomaly monitoring module, which operates inside the main control unit. This module is used to compare the deviation between the actual drive current and the ideal current curve in real time during the door opening and closing process. When the deviation exceeds the set safety threshold and the duration is greater than N, it is determined that the door is stuck. The main control unit immediately controls the frequency converter drive module to stop outputting positive torque and perform a reverse micro-opening action, and then tries to close the door again.

6. The energy-saving variable frequency door operator drive control system for passenger elevators according to claim 1, characterized in that, The fast wake-up interface includes an edge-triggered wake-up circuit, which is connected to the door opening and closing command signal terminal of the elevator main control system. In low-power standby mode, the core processor of the main control unit enters a stop clock state. When the wake-up circuit detects a signal jump, it generates an interrupt signal to restart the core processor clock and restore the power supply to the frequency converter drive module.

7. The passenger elevator energy-saving variable frequency door machine drive control system according to claim 1, characterized in that, The variable frequency drive module integrates a DC bus voltage monitoring unit; the DC bus voltage monitoring unit is connected to the main control unit and is used to collect the DC bus voltage value of the variable frequency drive in real time; when the main control unit determines that the door machine is in a deceleration regenerative braking state and the bus voltage rises to the preset voltage upper limit value, it controls the variable frequency drive module to feed the regenerative energy back to the DC common bus of the elevator control cabinet.

8. The passenger elevator energy-saving variable frequency door machine drive control system according to claim 1, characterized in that, The standby sleep control module has a hierarchical sleep strategy, which includes: when the elevator door is closed and the continuous time without door opening / closing commands reaches a first preset threshold, the system enters a shallow sleep state, shutting down the output of the frequency converter drive module but keeping the core processor of the main control unit running; when the continuous time without commands reaches a second preset threshold greater than the first preset threshold, the system enters a deep sleep state, simultaneously shutting down the core processor of the main control unit and the frequency converter drive module, while keeping the wake-up circuit of the fast wake-up interface working.

9. The passenger elevator energy-saving variable frequency door machine drive control system according to claim 1, characterized in that, The main control unit is also equipped with a door operator operation learning module. After the elevator completes its first installation or maintenance, the door operator operation learning module automatically performs self-learning operation: controlling the door operator to complete a complete door opening and closing cycle at a reference speed, recording the motor current value and running time corresponding to each stroke position during the process, and generating personalized reference speed curve and reference current curve. During normal operation, the real-time power adjustment module optimizes energy consumption based on the personalized baseline curve.

10. The passenger elevator energy-saving variable frequency door machine drive control system according to claim 1, characterized in that, The main control unit is a microcontroller, which also has a door operator energy consumption recording unit inside, used to accumulate the power consumption of each door opening and closing cycle, and upload it to the building energy management platform through the elevator main control system.

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