A collision prevention control system and control method for the trolley of a sludge filter press.

Abstract

This invention discloses an anti-collision control system and method for a sludge filter press's plate-lifting trolley. The system includes a trolley, a track, and an anti-collision control system. The trolley is slidably mounted on the track, which is mounted on the main body of the equipment. The anti-collision control system is mounted on the trolley, the track, and the control cabinet. The anti-collision control system also includes a PLC controller, a frequency converter, inductive switches, inductive switch brackets, stops, and relays. The function of this invention is to improve the mechanical reliability of the plate-lifting trolley system, achieve smooth reverse return, avoid head-on collisions, reduce the probability of component damage, lower maintenance costs, and save downtime required for maintenance. It also enhances control flexibility, allowing users to adjust the deceleration distance and hardware control logic according to site requirements, enabling the device to adapt to different operating conditions.

Description

Technical Field

[0001] This invention belongs to the field of filter press technology, and particularly relates to a collision prevention control system and control method for a sludge filter press pull plate trolley. Background Technology

[0002] Sludge filter presses, as solid-liquid separation equipment, are widely used in wastewater treatment, industrial production, and other fields. During operation, the plate-lifting trolley system is the core component for realizing the movement of filter plates and sludge unloading. In existing technologies, the plate-lifting trolley typically moves reciprocally along a track, and precise plate-lifting operation is achieved through PLC programming and frequency converter coordinated control.

[0003] In existing technologies, the pull-plate trolley system consists of a trolley, track, PLC controller, frequency converter, inductive switches, and stops. The workflow is as follows: 1. The trolley runs back and forth on the track, and the output current value of the frequency converter is controlled by PLC programming to realize the plate-pulling operation; 2. After the last filter plate is removed, the trolley moves to the end of the track and encounters an obstruction at the stop, generating an overcurrent signal that triggers the trolley to reverse. 3. The induction switch is installed on the front of the track facing the trolley, 2cm away from the stop. After detecting the trolley, the signal is input to the PLC, and the PLC outputs a deceleration signal to slow down the trolley, which eventually collides with the stop and reverses.

[0004] This method has the following drawbacks: First, it has low mechanical reliability and a very short deceleration distance of only 2cm. Furthermore, the induction switch is installed directly opposite the trolley, which inevitably causes the trolley to collide frequently with the stop and the induction switch during frequent reciprocating motion, resulting in mechanical damage to the trolley, the stop, and the induction switch, increasing maintenance costs and downtime. Second, the control adjustability is poor. Although the control logic can be optimized by modifying the PLC program, the equipment manufacturer does not provide PLC programming software. The control logic is closed by the manufacturer, and users cannot adjust the deceleration distance or control logic according to the on-site working conditions, making it difficult to adapt to different operating needs.

[0005] Therefore, the present invention provides a collision prevention control system and control method for the sludge filter press pull plate trolley. Summary of the Invention

[0006] To address the aforementioned technical problems, this invention discloses an anti-collision control system and method for the sludge filter press's pull-plate trolley. This system improves the mechanical reliability of the pull-plate trolley system, enables smooth reverse return, avoids head-on collisions, reduces the probability of component damage, lowers maintenance costs, and saves downtime required for maintenance. It also enhances control flexibility, allowing users to adjust the deceleration distance and hardware control logic according to on-site requirements, enabling the device to adapt to different operating conditions.

[0007] To achieve the above technical effects, the present invention provides a collision prevention control system for a sludge filter press pull-plate trolley, including a trolley, a track, and a collision prevention control system. The trolley is slidably mounted on the track, which is mounted on the main body of the equipment. The collision prevention control system is mounted on the trolley, the track, and the control cabinet. The collision prevention control system further includes a PLC controller, a frequency converter, an inductive switch, an inductive switch bracket, a stop block, and a relay. The PLC controller is located inside the control cabinet, the frequency converter is located inside the control cabinet and is electrically connected to the PLC controller, the inductive switch is mounted on the inductive switch bracket, the inductive switch bracket is located on the side of the track, the stop block is located above the inductive switch and at the end of the track, and the relay is located inside the control cabinet and is electrically connected to the inductive switch.

[0008] Preferably, the inductive switch bracket also includes a flat iron bracket, a mounting plate, an adjustment elongated hole, and a double-ended bolt. The L-shaped flat iron bracket is welded to the side of the equipment body and located between the rails. The mounting plate is located on the left side of the flat iron bracket. The adjustment elongated hole is located on the mounting plate. The hollow double-ended bolt is adjustable and located on the adjustment elongated hole by means of a nut. The inductive switch is located on the rear side of the double-ended bolt. The front side of the inductive switch is electrically connected to the relay via a cable.

[0009] Preferably, the inductive switch bracket is fixed on the side of the track at a distance of 5-10cm from the stop block.

[0010] Preferably, the stop also includes an angle steel base, a baffle, an mounting elongated hole, and a round steel stop head. The angle steel base is welded to the side of the equipment body, the baffle is detachably connected to the front of the angle steel base, the mounting elongated hole is set on the baffle and connected by bolts, and the round steel stop head is welded to the right side of the baffle.

[0011] Preferably, the relay is also provided with four contact outputs, which are respectively connected to different input terminals and control circuits of the PLC controller: the first output is connected to the manual operation circuit; the second output is connected to the automatic control circuit; the third output is connected to the automatic control circuit; and the fourth output is connected to the reverse return control circuit.

[0012] Based on the above technical solution, the present invention also provides a control method for the anti-collision control system of the sludge filter press pull plate trolley, which specifically includes the following steps: S1: Position adjustment stage, subject of execution: operator; object: induction switch and bracket; triggering condition: on-site working conditions; execution action: loosen the bolt of the adjustment hole, move the induction switch to 5-10cm away from the stop and tighten it, and install the bracket on the side of the track. S2: Signal detection phase; Executor: Inductive switch; Object: Car; Triggering condition: Car moves into the detection range of the inductive switch; Execution action: The inductive switch is triggered and outputs a detection signal. S3: Signal conversion and expansion stage; Execution subject: relay; Object: detection signal; Triggering condition: inductive switch closed; Execution action: relay coil is energized and activated, expanding the single-channel signal into four-channel contact signal output. S4: Logic control stage; executing subject: PLC controller; object: relay contact signal; triggering condition: the second deceleration contact, the third stop contact, and the fourth reversal contact of the relay close in sequence; executing action: the PLC receives deceleration, stop, and reversal commands according to its built-in logic. S5: Smooth execution phase; Executing subject: frequency converter and trolley; Object: frequency converter output current; Triggering condition: receiving PLC instruction; Execution action: the frequency converter first outputs deceleration current, then outputs reversing current, so that the trolley smoothly reverses and returns.

[0013] Compared with the prior art, the beneficial effects of the present invention are as follows: This device provides a collision prevention control system and method for the trolley of a sludge filter press. By setting an adjustable inductive switch bracket and control system, the mechanical reliability of the trolley system is improved, achieving smooth reverse return, avoiding head-on collisions, reducing the probability of component damage, lowering maintenance costs, and saving downtime required for maintenance. It also enhances control flexibility, allowing users to adjust the deceleration distance and hardware control logic according to site requirements, enabling the device to adapt to different operating conditions. Attached Figure Description

[0014] Figure 1 This is the circuit diagram of the present invention before modification; Figure 2 This is the modified circuit diagram of the present invention; Figure 3 This is a front view of the mounting structure of the inductive switch bracket and the stop block in this invention; Figure 4 This is an isometric view of the mounting structure of the inductive switch bracket and the stop block in this invention; Figure 5 This is a schematic diagram of the modified structure of the present invention; The attached diagram lists the components represented by each number as follows: 1. Track; 2. Equipment body; 3. Induction switch; 4. Induction switch bracket; 5. Stop block; 6. Flat iron bracket; 7. Mounting plate; 8. Adjustment elongated hole; 9. Double-ended bolt; 10. Angle steel base; 11. Baffle; 12. Mounting elongated hole; 13. Round steel stop head. Detailed Implementation

[0015] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0016] like Figures 1 to 5 As shown The prior art in this embodiment has the following problems: The inventors have found the following defects in the prior art: 1. Low mechanical reliability, the deceleration distance is too short, and the trolley inevitably collides frequently with the stop and the inductive switch during frequent reciprocating motion, causing mechanical damage to the trolley, the stop and the inductive switch, increasing maintenance costs and downtime; 2. Poor control adjustability, the control logic is closed by the manufacturer, and users cannot adjust the deceleration distance or control logic according to the on-site working conditions, making it difficult to adapt to different operating requirements; Therefore, the inventor provides a collision prevention control system for a sludge filter press pull plate trolley, including a trolley, a track 1, and a collision prevention control system. The trolley (not shown in the figure) is slidably mounted on the track 1, and the track 1 is mounted on the main body 2 of the equipment. The collision prevention control system is mounted on the trolley, the track 1, and the control cabinet. The collision prevention control system also includes a PLC controller, a frequency converter, an inductive switch 3, an inductive switch bracket 4, a stop block 5, and a relay. The PLC controller (not shown in the figure) is mounted inside the control cabinet (not shown in the figure), the frequency converter (not shown in the figure) is mounted inside the control cabinet and is electrically connected to the PLC controller, the inductive switch 3 is mounted on the inductive switch bracket 4, the inductive switch bracket 4 is mounted on the side of the track 1, the stop block is mounted above the inductive switch 3 and located at the end of the track 1, and the relay (not shown in the figure) is mounted inside the control cabinet and is electrically connected to the inductive switch 3.

[0017] Furthermore, the inductive switch bracket 4 also includes a flat iron bracket 6, a mounting plate 7, an adjustment elongated hole 8, and a double-ended bolt 9. The L-shaped flat iron bracket 6 is welded to the side of the equipment body 2 and located between the rails 1. The mounting plate 7 is located on the left side of the flat iron bracket 6. The adjustment elongated hole 8 is located on the mounting plate 7. The hollow double-ended bolt 9 is adjustablely located on the adjustment elongated hole 8 by means of a nut. The inductive switch 3 is located on the rear side of the double-ended bolt 9. The front side of the inductive switch 3 is electrically connected to the relay via a cable. Furthermore, the induction switch bracket 4 is fixed to the side of the track 1 at a distance of 5-10cm from the stop block 5; The induction switch 3 is bolted into the adjustment hole 8 and can be adjusted back and forth along the direction of the adjustment hole 8 to achieve flexible adjustment of the deceleration distance. According to the equipment usage in the production workshop, the optimal buffer distance adjustment range is 5-10cm. During implementation, a scale can be set above the adjustment hole 8 for reference during adjustment. At the same time, the bracket installation position has been changed from the front of the original track 1 to the side of the track 1, which completely avoids the trolley from colliding with the induction switch 3 head-on, extends the buffer distance, and reduces mechanical damage.

[0018] Furthermore, the stop block also includes an angle steel base 10, a baffle 11, an mounting elongated hole 12, and a round steel stop head 13. The angle steel base 10 is welded to the side of the equipment body, the baffle 11 is detachably connected to the front side of the angle steel base 10, the mounting elongated hole 12 is provided on the baffle 11 and connected by bolts, and the round steel stop head 13 is welded to the right side of the baffle 11. The baffle 11 on the block can also be adjusted to a limited extent on the angle steel base 10 through the mounting elongated hole 12, in order to cooperate with the adjustment of the inductive switch 3.

[0019] Furthermore, the relay is also equipped with four contact outputs, which are respectively connected to different input terminals and control circuits of the PLC controller: the first output is connected to the manual operation circuit; the second output is connected to the automatic control circuit; the third output is connected to the automatic control circuit; and the fourth output is connected to the reverse return control circuit. The relay is expanded to have four contact outputs, which are connected to different input terminals and control circuits of the PLC controller: the first output is connected to the manual operation circuit to realize the trolley stop control when it reaches the position; the second output is connected to the automatic control circuit to realize the trolley deceleration control when it reaches the position; the third output is connected to the automatic control circuit to realize the trolley stop control when it reaches the position; and the fourth output is connected to the reverse return control circuit to realize the trolley reverse return control when it reaches the position.

[0020] Based on the above technical solution, the present invention also provides a collision prevention control system for the sludge filter press pull plate trolley, which specifically includes the following steps: S1: Position adjustment stage, subject of execution: operator; object: induction switch 3 and bracket; triggering condition: on-site working conditions; execution action: loosen the bolt of adjustment long hole 8, move induction switch 3 to a distance of 55-10cm from the stop and tighten it, bracket is installed on the side of track 1; S2: Signal detection phase, executing subject: inductive switch 3; object: trolley; triggering condition: the trolley moves into the detection range of inductive switch 3; executing action: inductive switch 3 is triggered and outputs a detection signal; S3: Signal conversion and expansion stage; Execution subject: relay; Object: detection signal; Triggering condition: induction switch 3 is closed; Execution action: the relay coil is energized and closes, expanding the single-channel signal into a four-channel contact signal output. S4: Logic control stage; executing subject: PLC controller; object: relay contact signal; triggering condition: the second deceleration contact, the third stop contact, and the fourth reversal contact of the relay close in sequence; executing action: the PLC receives deceleration, stop, and reversal commands according to its built-in logic. S5: Smooth execution phase; Executing subject: frequency converter and trolley; Object: frequency converter output current; Triggering condition: receiving PLC instruction; Execution action: the frequency converter first outputs deceleration current, then outputs reversing current, so that the trolley smoothly reverses and returns.

[0021] S1 is the physical basis for achieving collision avoidance; its termination condition is the bolt being tightened and fixed; the result is that the buffer distance is set to 5-10cm and avoids frontal collisions; thus, hard collisions can be avoided. S2's function is to sense the vehicle's position; the termination condition is when the vehicle leaves the detection range; the result is the emission of an electrical signal; it can serve as an early warning system. The function of S3 is to realize signal branching; the termination condition is relay de-energization; the result is the output of four independent control signals; it can break through the PLC's closure and realize hardware logic redistribution. S4 is responsible for issuing decisions; the termination condition is the completion of PLC output; the result is the sequential issuance of deceleration, stop, and reverse commands; this step can provide the prerequisites for smooth control. The function of S5 is to perform the final execution; the termination condition is that the trolley reverses and leaves the sensing area; the result is that the trolley smoothly changes direction; the purpose is to completely eliminate mechanical impact damage.

[0022] The working principle of this invention is as follows: The trolley runs on track 1 to pick up the pull plate. When it reaches the detection range of inductive switch 3, switch 3 is triggered and sends a signal to the relay. The relay coil is energized and opens, expanding the single-channel signal into a four-channel contact signal output. The second contact inputs a deceleration signal to the PLC controller, and the fourth contact inputs a reverse trigger signal to the PLC controller. The PLC controller outputs deceleration, stop, and reverse control commands sequentially to the frequency converter according to its built-in logic. After receiving the commands, the frequency converter adjusts its output current, causing the trolley to decelerate first and then smoothly reverse back. Throughout the entire process, the trolley does not need to collide with or stall against stop 5, and it also avoids a head-on collision with inductive switch 3, thus achieving smooth reversal.

[0023] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0024] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A collision prevention control system for a sludge filter press pull-plate trolley, comprising a trolley, a track, and a collision prevention control system, wherein the trolley is slidably mounted on the track, the track is mounted on the main body of the equipment, and the collision prevention control system is respectively mounted on the trolley, the track, and the control cabinet, characterized in that: The aforementioned anti-collision control system also includes a PLC controller, a frequency converter, an induction switch, an induction switch bracket, a stop block, and a relay. The PLC controller is installed inside the control cabinet, the frequency converter is installed inside the control cabinet and is electrically connected to the PLC controller, the induction switch is installed on the induction switch bracket, the induction switch bracket is installed on the side of the track, the stop block is installed above the induction switch and located at the end of the track, and the relay is installed inside the control cabinet and is electrically connected to the induction switch.

2. The anti-collision control system for the sludge filter press pull-plate trolley according to claim 1, characterized in that: The inductive switch bracket also includes a flat iron bracket, a mounting plate, an adjustment elongated hole, and a double-ended bolt. The L-shaped flat iron bracket is welded to the side of the equipment body and located between the rails. The mounting plate is located on the left side of the flat iron bracket. The adjustment elongated hole is located on the mounting plate. The hollow double-ended bolt is adjustable and located on the adjustment elongated hole by a nut. The inductive switch is located on the rear side of the double-ended bolt. The front side of the inductive switch is electrically connected to the relay via a cable.

3. The anti-collision control system for the sludge filter press pull-plate trolley according to claim 1, characterized in that: The inductive switch bracket is fixed to the side of the track at a distance of 5-10cm from the stop block.

4. The anti-collision control system for the sludge filter press pull-plate trolley according to claim 1, characterized in that: The stop block also includes an angle steel base, a baffle plate, an mounting elongated hole, and a round steel stop head. The angle steel base is welded to the side of the equipment body, the baffle plate is detachably connected to the front side of the angle steel base, the mounting elongated hole is set on the baffle plate and connected by bolts, and the round steel stop head is welded to the right side of the baffle plate.

5. The anti-collision control system for the sludge filter press pull-plate trolley according to claim 1, characterized in that: The relay is also equipped with four contact outputs, which are respectively connected to different input terminals and control circuits of the PLC controller: the first output is connected to the manual operation circuit; the second output is connected to the automatic control circuit; the third output is connected to the automatic control circuit; and the fourth output is connected to the reverse return control circuit.

6. A control method for a collision prevention control system for a sludge filter press pull-plate trolley according to any one of claims 1 to 5, characterized in that: Specifically, the following steps are included: S1: Position adjustment stage, subject of execution: operator; object: induction switch and bracket; triggering condition: on-site working conditions; execution action: loosen the bolt of the adjustment hole, move the induction switch to 5-10cm away from the stop and tighten it, and install the bracket on the side of the track. S2: Signal detection phase; Executor: Inductive switch; Object: Car; Triggering condition: Car moves into the detection range of the inductive switch; Execution action: The inductive switch is triggered and outputs a detection signal. S3: Signal conversion and extension stage, executed by relay; Object: Detection signal; Triggering condition: Inductive switch closed; Execution action: Relay coil energized and engaged, expanding the single-channel signal into a four-channel contact signal output; S4: Logic control stage, execution subject: PLC controller; Object: Relay contact signal; Triggering condition: The second deceleration contact, the third stop contact, and the fourth reverse contact of the relay close sequentially; Execution action: The PLC receives deceleration, stop, and reverse commands according to its built-in logic; S5: Smooth execution phase, execution entities: frequency converter and trolley; Object: Inverter output current; Triggering condition: Receiving PLC command; Execution action: The inverter first outputs deceleration current, then outputs reversing current, so that the trolley can smoothly reverse and return.

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