Control method for preventing condensation water of explosion-proof electric roller

Abstract

The application provides a kind of anti-condensation control method of explosion-proof electric roller, relate to mechanical equipment control technical field.The method is applied to anti-condensation system, anti-condensation system includes cooling device and heating device, cooling device is connected with electric roller between proportional valve, method includes: obtaining the internal temperature of the electric roller to be controlled, internal humidity, wall temperature of the cooling water channel of electric roller and frequency converter operating state data;According to internal temperature and internal humidity, calculate current condensation point temperature;According to frequency converter operating state data, determine the working state of electric roller;In combination with working state, with wall temperature higher than current condensation point temperature and lower than preset maximum allowable temperature as target, control the start-stop of cooling device, the opening of proportional valve and the start-stop of heating device.The application can make electric roller normal operation without condensation, effectively improve the insulation performance of equipment, so as to ensure the safety of equipment.

Description

Technical Field

[0001] This invention relates to the field of mechanical equipment control technology, and in particular to a method for preventing condensation in an explosion-proof electric drum. Background Technology

[0002] In flammable and explosive workplaces such as mines, chemical plants, and petroleum plants, explosion-proof drive equipment is the core equipment to ensure production safety. Among them, explosion-proof water-cooled permanent magnet electric rollers have gradually become the mainstream choice for heavy-duty material conveying and power drive due to their high transmission efficiency, strong heat dissipation capacity, no additional transmission loss, and high explosion-proof rating.

[0003] When such equipment is shut down, in standby mode, operating under low load, or in high humidity environments, the wall temperature of the cooling water channel can drop rapidly and fall below the condensation point of the internal air. This causes condensation to form in the sealed cavity. The condensation adheres to the windings, terminals, and insulation surfaces, which continuously reduces the electrical insulation strength and eventually leads to insulation failure, causing short circuits, leakage, and other faults, thus affecting the safe and stable operation of the equipment. Summary of the Invention

[0004] This invention provides a method for controlling condensation in explosion-proof electric rollers to solve the problem that explosion-proof electric rollers are easily affected by condensation, leading to insulation failure and affecting equipment safety.

[0005] In a first aspect, embodiments of the present invention provide a method for controlling condensate in an explosion-proof electric drum, applied to an anti-condensation system. The anti-condensation system includes a cooling device and a heating device. A proportional valve is connected between the cooling device and the electric drum. The method includes: acquiring the internal temperature, internal humidity, wall temperature of the cooling water channel of the electric drum, and inverter operating status data of the electric drum to be controlled; calculating the current dew point temperature based on the internal temperature and internal humidity; determining the operating status of the electric drum based on the inverter operating status data; and, based on the operating status, controlling the start / stop of the cooling device, the opening degree of the proportional valve, and the start / stop of the heating device with the target of the wall temperature being higher than the current dew point temperature but lower than the preset maximum allowable temperature.

[0006] In one possible implementation, based on the working state, with the goal of the wall temperature being higher than the current dew point temperature but lower than the preset maximum allowable temperature, the start / stop of the cooling device, the opening degree of the proportional valve, and the start / stop of the heating device are controlled. This includes: when the electric drum is in operation, with the goal of the wall temperature being higher than the current dew point temperature but lower than the preset maximum allowable temperature, the start / stop of the cooling device and the opening degree of the proportional valve are controlled; when the electric drum is in a stopped state, with the goal of the wall temperature being higher than the current dew point temperature but lower than the preset maximum allowable temperature, the start / stop of the heating device is controlled.

[0007] In one possible implementation, the inverter operating status data includes the inverter operating current of the electric drum; when the electric drum is in operation, with the target of the wall temperature being higher than the current dew point temperature but lower than the preset maximum allowable temperature, the start / stop of the cooling device and the opening degree of the proportional valve are controlled, including: when the wall temperature is greater than or equal to the preset maximum allowable temperature, starting the cooling device, and calculating the current percentage based on the inverter operating current and the rated current of the electric drum as the flow section percentage of the proportional valve; adjusting the valve opening degree of the proportional valve based on the flow section percentage; and shutting off the cooling device when the wall temperature is lower than the preset maximum allowable temperature.

[0008] In one possible implementation, when the electric drum is in a stopped state, the heating device is controlled to start and stop with the goal of the wall temperature being higher than the current dew point temperature but lower than the preset maximum allowable temperature. This includes: when the wall temperature is lower than the current dew point temperature, starting the heating device to heat the wall of the cooling water channel of the electric drum; and when the wall temperature is higher than the current dew point temperature and the duration is greater than a first preset time, turning off the heating device.

[0009] In one possible implementation, the current dew point temperature is calculated based on the internal temperature and internal humidity, including: calculating the temperature compensation amount corresponding to the internal humidity; and subtracting the internal temperature from the temperature compensation amount to obtain the difference result as the current dew point temperature.

[0010] In one possible implementation, the temperature compensation amount corresponding to the internal humidity is calculated based on the internal humidity, including: calculating the corresponding basic compensation value based on the internal humidity and a preset nonlinear fitting relationship; and correcting the basic compensation value based on the fine-tuning coefficient corresponding to the internal temperature to obtain the temperature compensation amount.

[0011] In one possible implementation, the anti-condensation system further includes a wall temperature sensor, and internal temperature and humidity sensors for the electric drum. The internal temperature sensor includes a first internal temperature sensor and a second internal temperature sensor, the internal humidity sensor includes a first internal humidity sensor and a second internal humidity sensor, and the wall temperature sensor includes a first wall temperature sensor and a second wall temperature sensor. Before acquiring the internal temperature, internal humidity, wall temperature of the cooling water channel of the electric drum to be controlled, and inverter operating status data, the system further includes: averaging the temperature values ​​of the first internal temperature sensor and the second internal temperature sensor over a preset acquisition period to obtain the internal temperature; averaging the humidity values ​​of the first internal humidity sensor and the second internal humidity sensor over a preset acquisition period to obtain the internal humidity; and averaging the temperature values ​​of the first wall temperature sensor and the second wall temperature sensor over a preset acquisition period to obtain the wall temperature.

[0012] In one possible implementation, the inverter operating status data also includes an operating enable signal and a speed feedback signal; based on the inverter operating status data, the operating status of the electric drum is determined, including: when the operating enable signal is valid, the operating current is greater than a preset no-load current threshold, and the speed feedback signal is greater than a preset stationary speed threshold, the electric drum is determined to be in an operating state; when the operating enable signal is invalid, or the operating current is less than or equal to a preset no-load current threshold and the speed feedback signal is less than or equal to a preset stationary speed threshold, the electric drum is determined to be in a stopped state.

[0013] In one possible implementation, the anti-condensation system also includes a winding temperature sensor for the electric drum, and the method further includes: when the winding temperature of the electric drum is higher than a preset temperature protection threshold and the duration is greater than a second preset time, issuing an alarm signal and controlling the electric drum to stop running.

[0014] In one possible implementation, the anti-condensation system also includes a water supply bypass pipe; based on the working state, with the goal of the wall temperature being higher than the current condensation point temperature but lower than the preset maximum allowable temperature, the system controls the start and stop of the cooling device, the opening degree of the proportional valve, and the start and stop of the heating device, and also includes: when the opening degree of the proportional valve decreases or the cooling device stops running, the water supply bypass pipe maintains water flow.

[0015] This invention provides a method for preventing condensation in an explosion-proof electric drum. First, the current dew point temperature is calculated based on the internal temperature and humidity of the electric drum, quantifying the critical conditions for condensation formation and achieving precise condensation prevention. Then, considering the operating status of the electric drum, with the target wall temperature being higher than the dew point temperature but lower than the preset maximum allowable temperature, the cooling and heating devices are controlled to specifically adjust the wall temperature of the cooling water channels, ensuring the wall temperature remains within a reasonable range. This guarantees normal operation of the electric drum while preventing excessively low wall temperatures that could lead to condensation. Attached Figure Description

[0016] Figure 1 This is a flowchart illustrating the implementation of the anti-condensation control method for the explosion-proof electric drum provided in this embodiment of the invention. Figure 2 This is a schematic diagram of the water circulation of the explosion-proof electric drum provided in an embodiment of the present invention to prevent condensation. Figure 3 This is a cross-sectional schematic diagram of the explosion-proof drum motor provided in an embodiment of the present invention. Detailed Implementation

[0017] Explosion-proof water-cooled permanent magnet electric drums are widely used in the field of mining equipment, mainly providing the driving power source for the entire mining equipment.

[0018] Existing explosion-proof water-cooled permanent magnet electric drums are typically equipped only with explosion-proof breather valves. This reduces the temperature difference between the inside and outside of the motor connected to the electric drum, thereby reducing condensation. During operation, the explosion-proof water-cooled permanent magnet electric drum and the cooling device usually start simultaneously. When shutting down, the explosion-proof water-cooled permanent magnet electric drum stops immediately, while the cooling device stops after a 5-minute delay. Due to the harsh mining environment, especially underground, after the explosion-proof water-cooled permanent magnet electric drum has been running for a period of time, dust accumulates thickly, causing the explosion-proof breather valve to become clogged and malfunction. In actual production, frequent replacement of the one-way explosion-proof breather valve is required, which significantly impacts production time and subsequent maintenance. If the replacement process is not up to standard, the explosion-proof water-cooled permanent magnet electric drum will lose its explosion-proof performance, potentially leading to a production accident.

[0019] When the operating load is small, the temperature rise of the explosion-proof water-cooled permanent magnet electric drum is small. At the same time, the heat dissipation power of the cooling device remains unchanged, causing the internal water-cooled wall temperature to be lower than the condensation point temperature. A large amount of condensate will be generated inside the explosion-proof water-cooled permanent magnet electric drum. It will flow along the wall of the spiral cooling water channel to the lowest point inside the explosion-proof water-cooled permanent magnet electric drum and accumulate. Ultimately, this will cause the winding insulation of the explosion-proof water-cooled permanent magnet electric drum to fail, damaging the explosion-proof water-cooled permanent magnet electric drum.

[0020] Therefore, the anti-condensation control method for explosion-proof water-cooled permanent magnet electric drum in this embodiment of the invention aims to improve the safety of the explosion-proof water-cooled permanent magnet electric drum and reduce the risk of insulation failure and production accidents without damaging the explosion-proof structure of the explosion-proof water-cooled permanent magnet electric drum.

[0021] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0022] See Figure 1 The diagram illustrates the implementation flowchart of the anti-condensation water control method for the explosion-proof electric drum provided in this embodiment of the invention. The anti-condensation water control method for the explosion-proof electric drum is applied to an anti-condensation system, which includes a cooling device and a heating device. A proportional valve is connected between the cooling device and the electric drum.

[0023] In some embodiments, the explosion-proof electric drum is a drum drive device with its own motor, used in explosion-proof environments, and has an internal water-cooling channel. The cooling device supplies water to the electric drum to cool it and reduce the wall temperature. The heating device heats the walls of the cooling water channel to increase the wall temperature and prevent condensation. The proportional valve is an adjustable water valve used to control the flow rate of the cooling water.

[0024] The condensate control method for explosion-proof electric drum according to embodiments of the present invention includes: Step 101: Obtain the internal temperature, internal humidity, wall temperature of the cooling water channel of the electric drum to be controlled, and inverter operating status data.

[0025] In some embodiments, the internal temperature is the temperature of the air inside the cavity of the electric roller.

[0026] In some embodiments, the internal humidity is the humidity of the air inside the cavity of the electric roller.

[0027] In some embodiments, the wall temperature of the cooling water channel is the metal wall temperature of the cooling water channel inside the drum, and the cooling water channel is the location most prone to condensation.

[0028] In some embodiments, the inverter operating status data is an electrical signal reflecting whether the drum is working.

[0029] Step 102: Calculate the current condensation point temperature based on the internal temperature and internal humidity.

[0030] In some embodiments, the dew point temperature is the critical temperature at which air begins to condense, and condensation will occur when the wall temperature is below the dew point temperature.

[0031] As one possible implementation, step 102 can be specifically implemented as steps 1021-1022.

[0032] Step 1021: Calculate the temperature compensation amount corresponding to the internal humidity based on the internal humidity.

[0033] As one possible implementation, step 1021 can be specifically implemented as steps 11-12.

[0034] Step 11: Calculate the corresponding basic compensation value based on the internal humidity and the preset nonlinear fitting formula.

[0035] In some embodiments, the nonlinear fitting relationship is a pre-fitted mathematical formula or mapping relationship used to calculate the corresponding basic compensation value based on humidity. For example, the nonlinear fitting relationship is RH=a·e^(b·T), where RH is relative humidity (%), a is the fitting coefficient (a=132.87), e is the natural constant (e≈2.71828), b is the temperature coefficient (b=-0.0092), and T is the ambient temperature (°C).

[0036] In some embodiments, the base compensation value is a compensation value that is initially calculated based solely on the internal humidity.

[0037] In this embodiment, the compensation value is adaptively adjusted according to humidity changes, with a larger compensation amount for higher humidity, making the dew point calculation more consistent with actual working conditions.

[0038] Step 12: Correct the basic compensation value according to the fine-tuning coefficient corresponding to the internal temperature to obtain the temperature compensation amount.

[0039] In some embodiments, the fine-tuning factor is a correction factor determined based on the internal temperature, used to further refine the base compensation value. Table 1 shows the correspondence between internal temperature and correction factor.

[0040] Table 1 Correspondence between Temperature and Correction Factor

[0041] In some embodiments, the temperature compensation is a temperature correction value calculated based on humidity and temperature, used to calculate the final dew point temperature.

[0042] In this embodiment, the influence of temperature is introduced so that the compensation amount reflects the combined effect of temperature and humidity, further improving the accuracy of condensation point calculation and avoiding errors caused by relying solely on humidity.

[0043] In this embodiment, the effect of humidity on condensation is quantified as a temperature value, providing a correction basis for accurately calculating the dew point.

[0044] Step 1022: Calculate the difference between the internal temperature and the temperature compensation amount, and use the difference result as the current condensation point temperature.

[0045] In this embodiment, the condensation point is calculated by combining temperature and humidity. The calculation logic is simple and reliable, the physical meaning is clear, and the obtained dew point temperature is more accurate, providing the correct judgment threshold for subsequent anti-condensation control.

[0046] Step 103: Determine the working status of the electric drum based on the inverter's operating status data.

[0047] In some embodiments, the inverter operating status data also includes an operating enable signal and a speed feedback signal.

[0048] In some embodiments, the working state refers to the electric roller being in a running state or a stopped state.

[0049] In some embodiments, the operation enable signal is a command signal given by the frequency converter or control system that allows the electric drum to start operation, effectively indicating that the equipment is ready to operate.

[0050] In some embodiments, the speed feedback signal is a signal that reflects the actual speed of the electric drum, used to determine whether it is actually rotating.

[0051] As one possible implementation, step 103 can be specifically implemented as steps 1031-1032.

[0052] Step 1031: When the operation enable signal is valid, the operating current is greater than the preset no-load current threshold, and the speed feedback signal is greater than the preset stationary speed threshold, the working state of the electric drum is determined to be the operating state.

[0053] In some embodiments, the operating state is when the electric roller is working normally and the motor is rotating under load.

[0054] In some embodiments, the preset no-load current threshold is a pre-set current critical value used to distinguish whether the motor is unloaded or truly stopped.

[0055] In some embodiments, the preset static rotation speed threshold is a critical value close to zero rotation speed; if the speed is below this value, the drum is considered to be in a static state.

[0056] In this embodiment, multiple conditions are cross-verified to avoid misjudging the operating status; to prevent control errors caused by signal interference and motor vibration; and to provide reliable operating condition data for cooling control during operation.

[0057] Step 1032: When the operation enable signal is invalid, or the operating current is less than or equal to the preset no-load current threshold and the speed feedback signal is less than or equal to the preset stationary speed threshold, the working state of the electric drum is determined to be the stopped state.

[0058] In some embodiments, the stopped state is a state in which the electric roller stops and the motor does not work.

[0059] In this embodiment, the shutdown state is accurately identified to ensure that the anti-condensation heating logic is entered; the heating is not accidentally started when the machine is in a false shutdown or under light load and low speed, which is energy-saving and reliable; the operating condition is clearly judged to prevent the cooling and heating logic from being confused.

[0060] In this embodiment, adaptive control based on operating conditions is implemented, with heat dissipation emphasized during operation and condensation prevention emphasized during shutdown, resulting in a more rational logic.

[0061] Step 104: Based on the working status, with the goal of the wall temperature being higher than the current condensation point temperature but lower than the preset maximum allowable temperature, control the start and stop of the cooling device, the opening degree of the proportional valve, and the start and stop of the heating device.

[0062] In some embodiments, the preset maximum allowable temperature is the upper limit of the wall temperature to prevent the motor from overheating and the insulation from being damaged.

[0063] In some embodiments, the start / stop of the cooling device is to control the start and stop of the cooling device for cooling the wall surface.

[0064] In some embodiments, the opening degree of the proportional valve is used to adjust the cooling water flow rate, thereby achieving precise control of the wall temperature.

[0065] As one possible implementation, step 104 can be specifically implemented as steps 1041-1042.

[0066] Step 1041: When the electric drum is in operation, the cooling device is started and stopped and the opening degree of the proportional valve is controlled with the goal of the wall temperature being higher than the current condensation point temperature but lower than the preset maximum allowable temperature.

[0067] In some embodiments, inverter operating status data includes the inverter operating current of the electric drum.

[0068] For example, the inverter operating current is the working current output by the inverter to the electric drum, which reflects the size of the motor load.

[0069] As one possible implementation, step 1041 can be specifically implemented as steps 21-23.

[0070] Step 21: When the wall temperature is greater than or equal to the preset maximum allowable temperature, start the cooling device and calculate the current percentage based on the inverter operating current and the rated current of the electric drum, which is used as the flow section percentage of the proportional valve.

[0071] In some embodiments, the current percentage characterizes the load weight.

[0072] In some embodiments, the flow section percentage is the proportion of the cross-sectional area of ​​the proportional valve opening to the total flow area, corresponding to the valve opening degree.

[0073] In this embodiment, the electric roller is cooled in a timely manner to prevent the wall temperature from exceeding the limit and to ensure the safety of the motor insulation and structure. Load-following flow regulation is achieved; a larger load results in a larger cooling flow, and a smaller load results in a smaller flow, leading to more precise temperature control and greater energy savings.

[0074] Step 22: Adjust the valve opening degree of the proportional valve according to the percentage of the flow cross section.

[0075] In some embodiments, the valve opening degree is the size of the proportional valve opening, which directly determines the amount of cooling water flow.

[0076] In this embodiment, the cooling intensity is precisely controlled so that the wall temperature can be quickly stabilized within the target range, without overheating or condensation due to excessive cooling.

[0077] Step 23: When the wall temperature is lower than the preset maximum allowable temperature, turn off the cooling device.

[0078] In some embodiments, unnecessary cooling is avoided, energy consumption is reduced, and the wall temperature is prevented from being excessively cooled below the condensation point, thus preventing condensation from occurring at the source.

[0079] In this embodiment, adaptive control based on operating conditions is implemented to avoid unreasonable control caused by applying a single set of logic to all operating conditions, thereby improving the accuracy of temperature control. This ensures that the wall temperature does not exceed the limit, allowing for reliable motor operation; simultaneously, it ensures that the wall temperature does not fall below the dew point, preventing condensation during operation; thus achieving a balance between heat dissipation and condensation prevention.

[0080] Step 1042: When the electric drum is in a stopped state, control the heating device to start and stop with the goal of the wall temperature being higher than the current condensation point temperature but lower than the preset maximum allowable temperature.

[0081] As one possible implementation, step 1042 can be specifically implemented as steps 31-32.

[0082] Step 31: When the wall temperature is lower than the current dew point temperature, start the heating device to heat the wall of the cooling water channel of the electric drum.

[0083] In this embodiment, the wall temperature is rapidly increased to above the condensation point temperature, preventing condensation from forming at the source and avoiding internal dampness, corrosion, and insulation degradation.

[0084] Step 32: When the wall temperature is higher than the current condensation point temperature and the duration is longer than the first preset time, turn off the heating device.

[0085] In some embodiments, the first preset time is a pre-set delay time used to prevent the heating device from frequently starting and stopping.

[0086] In this embodiment, the wall temperature is ensured not to rise briefly and then fall rapidly, making the anti-condensation effect more reliable; To avoid frequent start-ups and shutdowns of the heater when the wall temperature fluctuates slightly around the dew point, thus extending the heater's lifespan and reducing energy consumption.

[0087] In this embodiment, the shutdown state is specifically designed to prevent condensation from forming on the wall surface due to excessively low temperatures; cooling is not activated to avoid energy waste; it is highly targeted, and the anti-condensation effect is more direct and effective.

[0088] In some embodiments, the anti-condensation system also includes a water supply bypass pipe.

[0089] For example, a water supply bypass pipe is a small-diameter pipe connected in parallel with a proportional valve. The water supply bypass pipe allows a small amount of water to circulate without passing through the proportional valve.

[0090] As one possible implementation, step 104 can also be further processed as follows: When the opening degree of the proportional valve decreases or the cooling device stops operating, water flow is maintained through the water supply bypass pipe.

[0091] In some embodiments, water circulation means that cooling water flows slowly within the pipes and drum water-cooling channels to prevent stagnant water from forming.

[0092] In this embodiment, even after the proportional valve is closed or cooling stops, a small amount of water flow is maintained in the bypass to prevent localized water temperature from dropping below the condensation point, thus structurally eliminating condensation. Continuous micro-flow allows for more uniform wall temperature, preventing localized low-temperature zones and further improving anti-condensation reliability. Maintaining only micro-flow eliminates the need for high-flow-rate cooling, thus avoiding excessive energy consumption and solving the problem of condensation caused by stagnant water.

[0093] In this embodiment, the wall temperature is always higher than the condensation point temperature, eliminating the generation of condensate at the source; the wall temperature is always lower than the maximum allowable temperature, ensuring that the motor does not overheat and operates normally; at the same time, it achieves the dual effects of anti-condensation and safe operation, with closed-loop and stable control.

[0094] This invention provides a method for preventing condensation in an explosion-proof electric drum. First, the current dew point temperature is calculated based on the internal temperature and humidity of the electric drum, quantifying the critical conditions for condensation formation and achieving precise condensation prevention. Then, considering the operating status of the electric drum, with the target wall temperature being higher than the dew point temperature but lower than the preset maximum allowable temperature, the cooling and heating devices are controlled to specifically adjust the wall temperature of the cooling water channels, ensuring the wall temperature remains within a reasonable range. This guarantees normal operation of the electric drum while preventing excessively low wall temperatures that could lead to condensation.

[0095] In some embodiments, the anti-condensation system further includes a wall temperature sensor, and an internal temperature sensor and an internal humidity sensor for the electric roller. The internal temperature sensor includes a first internal temperature sensor and a second internal temperature sensor, the internal humidity sensor includes a first internal humidity sensor and a second internal humidity sensor, and the wall temperature sensor includes a first wall temperature sensor and a second wall temperature sensor.

[0096] For example, the wall temperature sensor is a sensor that collects the wall temperature of the cooling water channel of the electric drum.

[0097] For example, the internal temperature sensor is a sensor that collects the air temperature inside the cavity of the electric drum.

[0098] For example, the first internal temperature sensor and the second internal temperature sensor are two independently configured sensors used to acquire internal temperature.

[0099] For example, the internal humidity sensor is a sensor that collects the humidity of the air inside the cavity of the motorized drum. The first internal humidity sensor and the second internal humidity sensor are two independent humidity acquisition sensors.

[0100] As one possible implementation, the control method further includes steps A11-A13 before step 101.

[0101] Step A11: The internal temperature is obtained by averaging the temperature values ​​of the first internal temperature sensor and the second internal temperature sensor during a preset acquisition period.

[0102] In this embodiment, the impact of single sensor errors, drift, or malfunctions is reduced; the accuracy of internal temperature acquisition is improved, making subsequent dew point calculations more accurate.

[0103] Step A12: Calculate the average of the humidity values ​​from the preset collection period of the first internal humidity sensor and the preset collection period of the second internal humidity sensor to obtain the internal humidity.

[0104] In this embodiment, the reliability of humidity data is improved, and errors in condensation point calculation due to humidity measurement deviations are avoided.

[0105] Step A13: Calculate the average of the temperature values ​​from the preset acquisition period of the first wall temperature sensor and the preset acquisition period of the second wall temperature sensor to obtain the wall temperature.

[0106] In this embodiment, the wall temperature measurement is more stable and accurate; it avoids malfunctions in cooling or heating due to the abnormality of a single sensor, ensuring reliable temperature control.

[0107] In some embodiments, before calculating the mean in steps A11, A12, and A13, the data is filtered first, and the mean of the filtered data is calculated to improve the accuracy of the data.

[0108] In some embodiments, the anti-condensation system further includes a winding temperature sensor for the electric roller.

[0109] For example, a winding temperature sensor is a sensor installed near the windings of an electric drum motor to detect the temperature of the motor coils in real time.

[0110] As one possible implementation, the control method can also perform the following processing: When the winding temperature of the electric drum exceeds the preset temperature protection threshold and the duration exceeds the second preset time, an alarm signal is issued and the electric drum is controlled to stop running.

[0111] In some embodiments, the preset temperature protection threshold is a pre-set maximum safe temperature allowed by the motor windings; exceeding this temperature may result in burnout or insulation failure.

[0112] In some embodiments, the second preset time is a pre-set delay time used to avoid false protection caused by instantaneous temperature fluctuations.

[0113] In some embodiments, the second preset time is 10 seconds.

[0114] In some embodiments, the alarm signal is an audible and visual alarm.

[0115] In this embodiment, in addition to the anti-condensation water control, an over-temperature protection function for the motor winding is added. This function can monitor the motor temperature in real time and accurately, and will delay alarm and shut down the machine when there is a risk of overheating. This not only avoids motor damage, but also improves the safety and reliability of the entire electric drum operation.

[0116] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.

[0117] Example: Two humidity sensors are arranged at the end of the explosion-proof water-cooled permanent magnet electric drum winding, with the two sensors spaced 180° apart, to measure the humidity of the internal space environment.

[0118] Two temperature sensors are arranged at the end of the explosion-proof water-cooled permanent magnet electric drum winding, with the two sensors spaced 180° apart, to measure the ambient temperature of the internal space.

[0119] Two temperature sensors are arranged on the wall of the internal cooling water channel of the explosion-proof water-cooled permanent magnet electric drum, with the two sensors spaced 180° apart, to measure the internal wall temperature.

[0120] Install a proportional valve at the outlet of the cooling device, and add a bypass pipe between the outlet and the proportional valve, with the other end of the pipe leading back to the cooling device water tank.

[0121] The serial port of the programmable controller is connected to the serial port of the explosion-proof water-cooled permanent magnet electric drum inverter via a twisted pair cable. Communication is established using the Modbus RTU protocol to read the inverter's operating current and status words.

[0122] Read the humidity sensor data at the end of the explosion-proof water-cooled permanent magnet electric drum winding, i.e., the humidity data of the internal space, and take the average value after filtering: RH=(RH 11 +RH 12 +RH 13 +RH 14 +RH 15 +RH 21 +RH 22 +RH 23 +RH 24 +RH 25 ) / 10 Wherein, RH: average ambient humidity; RH 11 : Humidity value of the first data collection cycle of the first spatial humidity sensor; RH 12 : Humidity value of the first spatial humidity sensor during the second data acquisition cycle; RH 13 : Humidity value of the first spatial humidity sensor in the third data acquisition cycle; RH 14 : Humidity value of the first spatial humidity sensor in the fourth data collection cycle; RH 15 : Humidity value of the fifth data collection cycle of the first spatial humidity sensor; RH 21 : Humidity value of the first data acquisition cycle of the second space humidity sensor; RH 22 : Humidity value of the second sampling period of the second spatial humidity sensor; RH 23 : Humidity value of the second spatial humidity sensor during the third data acquisition cycle; RH 24 : Humidity value of the second space humidity sensor in the fourth data collection cycle; RH 25 The humidity value from the fifth data collection cycle of the second spatial humidity sensor. (Example:) Figure 2 As shown, 1 is the water tank, 2 is the heat exchanger, 3 is the drum motor, 4 is the one-way proportional valve, and 5 is the water pump. The drum motor contains a heating element. The cooling system includes a water tank, water pump, one-way proportional valve, and heat exchanger; the heating element is the heating element within the drum motor. Cooling water enters the electric drum from the water tank via the water pump and proportional valve to absorb heat, then dissipates heat through the heat exchanger before returning to the water tank; when the machine is stopped, the heating element heats the wall surface to prevent condensation. Figure 3 As shown, 31 is the first waterway wall temperature sensor, 31' is the second waterway wall temperature sensor, 32 is the first space temperature sensor, 32' is the second space temperature sensor, 33 is the first space humidity sensor, and 33' is the second space humidity sensor.

[0123] Read the temperature sensor data at the end of the explosion-proof water-cooled permanent magnet electric drum winding, i.e., the internal space temperature data, and take the average value after filtering: T=(T 11 +T 12 +T 13 +T 14 +T 15 +T 21 +T 22 +T 23 +T 24 +T 25 ) / 10 Where T: average temperature of the space; T 11 : Temperature value of the first acquisition cycle of the first spatial temperature sensor; T 12 : Temperature value of the first spatial temperature sensor in the second acquisition cycle; T 13 : Temperature value of the third acquisition cycle of the first spatial temperature sensor; T 14 : Temperature value of the fourth acquisition cycle of the first space temperature sensor; T 15 : Temperature value of the fifth acquisition cycle of the first space temperature sensor; T 21 : Temperature value of the first acquisition cycle of the second space temperature sensor; T 22 : Temperature value of the second acquisition cycle of the second space temperature sensor; T 23 : Temperature value of the second space temperature sensor in the third acquisition cycle; T 24 : Temperature value of the fourth acquisition cycle of the second space temperature sensor; T 25 Temperature value of the fifth acquisition cycle of the second space temperature sensor.

[0124] Read the temperature sensor data from the internal wall surface of the explosion-proof water-cooled permanent magnet electric drum, filter the data, and then take the average value. TW=(TW 11 +TW 12 +TW 13 +TW 14 +TW 15 +TW 21 +TW 22 +TW 23 +TW 24 +TW 25 ) / 10 Where TW: average temperature of the cooling water channel wall; TW 11: Temperature value of the first acquisition cycle of the first wall surface temperature sensor; TW 12 : Temperature value of the second acquisition cycle of the first wall temperature sensor; TW 13 : Temperature value of the first wall surface temperature sensor in the third acquisition cycle; TW 14 : Temperature value of the first wall surface temperature sensor in the fourth acquisition cycle; TW 15 : Temperature value of the fifth acquisition cycle of the first wall temperature sensor; TW 21 : Temperature value of the second wall temperature sensor in the first acquisition cycle; TW 22 : Temperature value of the second acquisition cycle of the second wall temperature sensor; TW 23 : Temperature value of the second wall temperature sensor in the third acquisition cycle; TW 24 : Temperature value of the second wall temperature sensor in the fourth acquisition cycle; TW 25 Temperature value of the second wall surface temperature sensor in the fifth acquisition cycle.

[0125] To determine if there is an over-temperature fault in the winding, if the temperature of the explosion-proof water-cooled permanent magnet electric drum winding continues to exceed the upper limit of the winding temperature protection threshold for 10 seconds, an audible and visual alarm will be issued immediately, and the enable signal of the explosion-proof water-cooled permanent magnet electric drum inverter will be interrupted, and the transmission system will stop.

[0126] The current condensation point temperature is calculated as follows: TD = T - [(100 - RH) / 5] Where TD: condensation point temperature; T: average ambient temperature; RH: average ambient humidity.

[0127] Determine whether the internal wall temperature TW of the explosion-proof water-cooled permanent magnet electric drum is greater than the condensation point temperature TD; compare whether the status word is 1 to determine whether the explosion-proof water-cooled permanent magnet electric drum is in operation.

[0128] When the explosion-proof water-cooled permanent magnet electric drum is in operation, the status word is equal to 1.

[0129] If the internal wall temperature TW of the explosion-proof water-cooled permanent magnet electric drum is greater than the dew point temperature TD, the cooling device should be turned on immediately. Based on the ratio of the current operating current of the explosion-proof water-cooled permanent magnet electric drum inverter to the rated current of the explosion-proof water-cooled permanent magnet electric drum, the proportional valve should be opened. The percentage opening of the proportional valve is calculated as follows: VO = IOUT / IN * 100% Wherein, VO: proportional valve opening percentage; IOUT: current operating current of the explosion-proof water-cooled permanent magnet electric drum inverter; IN: rated current of the explosion-proof water-cooled permanent magnet electric drum.

[0130] If the internal wall temperature TW of the explosion-proof water-cooled permanent magnet electric drum is less than or equal to the dew point temperature TD, immediately shut down the cooling device.

[0131] When the explosion-proof water-cooled permanent magnet electric drum is in a stopped state, the status word is not equal to 1.

[0132] If the internal wall temperature TW of the explosion-proof water-cooled permanent magnet electric drum is greater than the condensation point temperature TD, immediately turn off the heating belt.

[0133] If the internal wall temperature TW of the explosion-proof water-cooled permanent magnet electric drum is less than or equal to the dew point temperature TD, the heating belt should be turned on immediately.

[0134] Compared with existing technologies, this invention eliminates the need for explosion-proof breather valves, ensuring the integrity of the explosion-proof structure of the explosion-proof water-cooled permanent magnet electric drum and improving safety. It also optimizes the heat dissipation process of the explosion-proof water-cooled permanent magnet electric drum by adjusting the opening degree of the proportional valve to control the water supply of the cooling device according to the actual heat dissipation. This ensures that the temperature rise of the explosion-proof water-cooled permanent magnet electric drum is controlled at a normal level and that no condensation occurs inside, thus avoiding the problem of winding insulation damage caused by condensation.

[0135] The newly added winding end humidity sensor and temperature sensor can detect the temperature and humidity of the internal space and calculate the accurate condensation point temperature. By controlling the start and stop of the cooling device and heating belt, the wall temperature of the internal cooling water channel that may produce condensation is always kept within a reasonable range, which ensures the normal operation of the electric drum and avoids the formation of condensation due to excessively low wall temperature.

[0136] Since most of the water pumps in the cooling system are fixed-frequency motors, adding a frequency converter and replacing the fixed-frequency water pump windings with variable-frequency windings would be too costly. Adding a proportional valve and a water supply bypass pipe is more economical. By controlling the opening of the proportional valve, the heat dissipation power of the cooling system is always synchronized with the heat dissipation of the explosion-proof water-cooled permanent magnet electric drum, and the temperature rise is stably controlled within a reasonable range. Excess cooling water flows back to the cooling system water tank through the water supply bypass pipe, further protecting the fixed-frequency water pump from overload.

[0137] The newly added programmable controller is responsible for the acquisition and processing of data for the entire system, and controls the cooling device, the proportional valve of the cooling device, and the heating belt according to the control process flow to ensure the stability of the system operation.

[0138] The following are device embodiments of the present invention. For details not described in detail, please refer to the corresponding method embodiments described above.

[0139] In the above embodiments, the descriptions of each embodiment have their own emphasis. Parts not detailed or described in a particular embodiment can be referred to in the relevant descriptions of other embodiments. Unless otherwise specified or in conflict with logic, the terminology and / or descriptions between different embodiments are consistent and can be referenced interchangeably. Technical features in different embodiments can be combined to form new embodiments based on their inherent logical relationships.

[0140] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be included within the protection scope of the present invention.

Claims

1. A method for controlling condensate in an explosion-proof electric drum, characterized in that, The method, applied to an anti-condensation system including a cooling device and a heating device, wherein a proportional valve is connected between the cooling device and the electric drum, comprises: Acquire the internal temperature, internal humidity, wall temperature of the cooling water channel of the electric drum to be controlled, and inverter operating status data; Calculate the current dew point temperature based on the internal temperature and the internal humidity; The working status of the electric drum is determined based on the inverter's operating status data; Based on the aforementioned operating state, with the goal of the wall temperature being higher than the current condensation point temperature but lower than the preset maximum allowable temperature, the start / stop of the cooling device, the opening degree of the proportional valve, and the start / stop of the heating device are controlled.

2. The method for preventing condensation in an explosion-proof electric drum according to claim 1, characterized in that, The method of controlling the start / stop of the cooling device, the opening degree of the proportional valve, and the start / stop of the heating device, in conjunction with the operating state and with the goal of the wall temperature being higher than the current dew point temperature but lower than the preset maximum allowable temperature, includes: When the electric drum is in operation, the cooling device is controlled to start / stop and the opening degree of the proportional valve with the goal that the wall temperature is higher than the current condensation point temperature but lower than the preset maximum allowable temperature. When the electric drum is in a stopped state, the heating device is controlled to start and stop with the goal of the wall temperature being higher than the current condensation point temperature but lower than the preset maximum allowable temperature.

3. The method for preventing condensation in an explosion-proof electric drum according to claim 2, characterized in that, The inverter operating status data includes the inverter operating current of the electric drum; When the electric drum is in operation, controlling the start / stop of the cooling device and the opening degree of the proportional valve with the goal of the wall temperature being higher than the current dew point temperature but lower than the preset maximum allowable temperature includes: When the wall temperature is greater than or equal to the preset maximum allowable temperature, the cooling device is activated, and the current percentage is calculated based on the inverter operating current and the rated current of the electric drum, which is used as the flow section percentage of the proportional valve. The valve opening degree of the proportional valve is adjusted according to the percentage of the flow cross section; When the wall temperature is lower than the preset maximum allowable temperature, the cooling device is turned off.

4. The method for preventing condensation in an explosion-proof electric drum according to claim 2, characterized in that, When the electric drum is in a stopped state, the heating device is controlled to start and stop with the goal of the wall temperature being higher than the current dew point temperature but lower than the preset maximum allowable temperature, including: When the wall temperature is lower than the current dew point temperature, the heating device is activated to heat the wall of the cooling water channel of the electric drum. When the wall temperature is higher than the current condensation point temperature and the duration is longer than a first preset time, the heating device is turned off.

5. The method for controlling condensate in an explosion-proof electric drum according to any one of claims 1-4, characterized in that, The calculation of the current dew point temperature based on the internal temperature and the internal humidity includes: Based on the internal humidity, the temperature compensation amount corresponding to the internal humidity is calculated; The difference between the internal temperature and the temperature compensation amount is calculated to obtain the difference result, which is used as the current condensation point temperature.

6. The method for preventing condensation in an explosion-proof electric drum according to claim 5, characterized in that, The step of calculating the temperature compensation amount corresponding to the internal humidity based on the internal humidity includes: Based on the internal humidity and a preset nonlinear fitting formula, the corresponding basic compensation value is calculated. The basic compensation value is corrected based on the fine-tuning coefficient corresponding to the internal temperature to obtain the temperature compensation amount.

7. The method for preventing condensation in an explosion-proof electric drum according to claim 1, characterized in that, The anti-condensation system also includes a wall temperature sensor, and an internal temperature sensor and an internal humidity sensor for the electric roller. The internal temperature sensor includes a first internal temperature sensor and a second internal temperature sensor, the internal humidity sensor includes a first internal humidity sensor and a second internal humidity sensor, and the wall temperature sensor includes a first wall temperature sensor and a second wall temperature sensor. Before acquiring data on the internal temperature and humidity of the motorized drum to be controlled, the wall temperature of the cooling water channels of the motorized drum, and the operating status of the frequency converter, the following steps are also included: The internal temperature is obtained by averaging the temperature values ​​of the first internal temperature sensor and the second internal temperature sensor during a preset sampling period. The internal humidity is obtained by averaging the humidity values ​​from the preset sampling period of the first internal humidity sensor and the humidity values ​​from the preset sampling period of the second internal humidity sensor. The wall temperature is obtained by averaging the temperature values ​​of the first wall temperature sensor and the second wall temperature sensor during a preset sampling period.

8. The method for preventing condensation in an explosion-proof electric drum according to claim 1, characterized in that, The inverter operating status data also includes an operating enable signal and a speed feedback signal; Determining the operating status of the electric drum based on the inverter operating status data includes: When the operation enable signal is valid, the operating current is greater than the preset no-load current threshold, and the speed feedback signal is greater than the preset stationary speed threshold, the working state of the electric drum is determined to be the operating state. When the operation enable signal is invalid, or the operating current is less than or equal to the preset no-load current threshold and the speed feedback signal is less than or equal to the preset stationary speed threshold, the working state of the electric drum is determined to be a stopped state.

9. The method for preventing condensation in an explosion-proof electric drum according to claim 1, characterized in that, The anti-condensation system also includes a winding temperature sensor for the electric drum, and the method further includes: When the winding temperature of the electric drum exceeds a preset temperature protection threshold and the duration exceeds a second preset time, an alarm signal is issued and the electric drum is controlled to stop running.

10. The method for preventing condensation in an explosion-proof electric drum according to claim 1, characterized in that, The anti-condensation system also includes a water supply bypass pipeline; The method of controlling the start / stop of the cooling device, the opening degree of the proportional valve, and the start / stop of the heating device, in conjunction with the aforementioned working state and with the goal of the wall surface temperature being higher than the current dew point temperature but lower than the preset maximum allowable temperature, further includes: When the opening degree of the proportional valve decreases or the cooling device stops operating, water flow is maintained through the water supply bypass pipe.

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