Mechanical transmission system operation protection control method and system

Abstract

This invention provides a method and system for protecting and controlling the operation of a mechanical transmission system, belonging to the field of mechanical transmission technology. The drive system drives the mechanical transmission system to operate. During operation, a loading system applies loads to each shaft of the mechanical transmission system. A lubrication system provides lubrication for the mechanical transmission system. A data acquisition system converts the acquired data and feeds it back to the control system. Based on the data feedback from the acquisition system, the control system controls the operating status of the drive system, lubrication system, and loading system, sends operating status commands to the host computer, and sets corresponding interlock protection mechanisms and alarm protection limits. Based on the set alarm protection limits, the control system determines whether to send an automatic stop command to the host computer. This effectively avoids phenomena such as dry running, torque overload, and over-speed operation caused by human error or equipment failure, ensuring stable operation of the mechanical transmission system and reducing the risk of malfunctions.

Description

Technical Field

[0001] This invention belongs to the field of mechanical transmission technology and relates to a method and system for protecting and controlling the operation of a mechanical transmission system. Background Technology

[0002] During gearbox verification testing, a mechanical transmission system is required to achieve gearbox operation, load application, and lubrication.

[0003] Mechanical transmission systems operate at high speeds and under heavy loads. Human error or equipment malfunction can easily lead to damage such as dry running, torque overload, and excessive speed. Therefore, during operation, mechanical transmission systems must simultaneously perform tasks such as equipment lubrication, torque loading, and motor drive. These systems are interconnected and influence each other. Summary of the Invention

[0004] To address the problems in existing technologies where dry running, torque overload, and excessive speed operation of mechanical transmission systems are caused by human error or equipment malfunction, thus failing to guarantee stable operation, this invention provides a protection and control method and system for mechanical transmission systems during operation. This effectively avoids dry running, torque overload, and excessive speed operation caused by human error or equipment malfunction, ensuring stable operation of the mechanical transmission system and reducing the risk of failure. This invention collects and monitors key parameters of the equipment's lubrication and loading systems, adds a PLC controller, and designs self-locking and interlocking protection programs for the mechanical, lubrication, and hydraulic systems in a programmed manner. Combining the operating characteristics of the mechanical transmission system, alarm, limitation, and shutdown schemes are designed in the program for relevant operating parameters and key parameters to achieve protective control of the operating state. The technical solution is as follows: In a first aspect, a mechanical transmission system operation protection and control system is provided, comprising: a drive system, a lubrication system, a loading system, a data acquisition system, and a control system; The mechanical transmission system and the drive system are connected by a coupling, while the loading system and the mechanical transmission system are directly rigidly connected. The drive system drives the mechanical transmission system to operate, and during operation, the loading system applies loads to each shaft of the mechanical transmission system. The lubrication system is connected to the mechanical transmission system through lubrication pipelines to provide lubrication for the mechanical transmission system. The data acquisition system is softly connected to the mechanical transmission system. The data acquisition system is installed on the lubrication system, loading system, and drive system. After converting the acquired data, the data acquisition system feeds it back to the control system. The control system is also softly connected to the data acquisition system. Based on the data fed back by the data acquisition system, the control system controls the operating status of the drive system, lubrication system, and loading system, sends operating status commands to the host computer, and sets corresponding interlock protection mechanisms and alarm protection limits. Based on the set alarm protection limits, the control system determines whether to send an automatic stop command to the host computer.

[0005] The interlock protection mechanism includes a speed and lubrication pressure interlock mechanism. The data acquisition system includes: a data acquisition module, programming software, sensors, and a host computer; the control system includes: a CPU module, a control module, a circuit breaker, a contactor, and programming software; the drive system includes a drive motor; and the lubrication system includes a lubrication pump. The sensor transmits the obtained drive motor speed signal and lubrication pressure signal to the acquisition module. After conversion, the acquisition module feeds the parameters back to the host computer via the communication bus. The host computer displays the drive motor speed and lubrication pressure through the programming software of the acquisition system and the control system, and synchronously transmits them to the CPU module of the control system. The CPU module interlocks the drive motor speed and lubrication pressure through the programming software of the control system. When the lubrication pressure is 0 or the lubrication pump is not started, the drive motor cannot start. Or, when the lubrication pressure suddenly drops to the lower limit, the drive motor stops running and transmits the interlock command to the contactor through the control module. The contactor opens and closes the circuit breaker, thereby realizing the start and stop of the drive motor and the lubrication pump.

[0006] Furthermore, the drive system also includes a coupling, a motor controller, and a potentiometer. The drive motor is rigidly connected to the coupling, the drive motor is flexibly connected to the motor controller via a cable, and the motor controller is flexibly connected to the potentiometer via a cable, thereby achieving stepless speed control.

[0007] Furthermore, the interlock protection mechanism also includes a start-stop interlock mechanism. The control logic of the start-stop interlock mechanism includes start control logic and stop control logic. The startup control logic is as follows: First, start the lubrication pump. The control system checks whether the lubrication pump has started and then checks whether the lubrication pressure has been established. If the lubrication pump has started and the lubrication pressure has been established, then start the loading pump of the loading system and check whether the loading pressure is abnormal. If there is no abnormality, then start the drive motor. If any of the above conditions are not met, the drive motor will not start. The stop control logic is as follows: first, stop the loading pump, check that the loading pressure is 0, then stop the drive motor, check that the drive motor speed is 0, and finally stop the lubrication pump.

[0008] The acquisition system converts the acquired lubrication pressure, loading pressure, and motor speed signals and feeds them back to the control system. When programming, the control system establishes an alarm protection subroutine and sets alarm protection limits. The alarm protection subroutine includes a drive motor speed protection program, a lubrication pressure protection program, a drive motor start-stop interlock protection program, and a loading pressure protection program. In the drive motor speed protection program, an upper limit control alarm value is set for the drive motor speed. If the upper limit control alarm value is exceeded, the host computer human-machine interface is instructed to flash the data color to trigger an alarm, and an automatic stop command is sent to the host computer to perform a protective stop. In the lubrication pressure protection program, a lower limit control alarm value for lubrication pressure is set. If the lubrication pressure is lower than the control alarm value, the host computer human-machine interface is instructed to flash the data color to trigger an alarm, and an automatic stop command is sent to the host computer to perform a protective stop. In the drive motor start-stop interlock protection program, a lower limit control alarm value for lubrication pressure is set. If the lubrication pressure is lower than the lower limit control alarm value before the drive motor starts, the drive motor cannot start; an automatic stop command is sent to the host computer to perform a protective stop. In the loading pressure protection program, the upper limit control alarm value of the outlet pressure of the plunger pump or motor of the loading system is set. If the upper limit control alarm value is exceeded, the host computer human-machine interface is instructed to flash the data color to trigger an alarm, and an automatic stop command is sent to the host computer to perform a protective stop. In the drive motor speed protection program, lubrication pressure protection program, and loading pressure protection program, when performing a protective shutdown, the load on the loading pump is first unloaded, then the drive motor speed is reduced to 0, and finally the lubrication pump is shut down.

[0009] The acquisition modules in the acquisition system are arranged according to the positions of the drive system, lubrication system, and loading system, and data transmission between the substations is carried out via a BUS bus.

[0010] The potentiometer outputs a resistance signal, which sends a control command to the host computer of the acquisition system through the programming software of the control system. The resistance signal is then output to the motor controller via the BUS bus. After receiving the resistance signal, the motor controller outputs the corresponding instructions to the drive motor, enabling the drive motor to perform speed increase, speed decrease, and speed stabilization operations, while feeding back the corresponding speed status to the host computer.

[0011] In a second aspect, a method for a mechanical transmission system operation protection and control system as described in any of the first aspects is provided, comprising: The drive system drives the mechanical transmission system to operate, and during operation, the loading system applies loads to each shaft of the mechanical transmission system; the lubrication system provides lubrication for the mechanical transmission system. The data acquisition system converts the acquired data and feeds it back to the control system; Based on the data feedback from the acquisition system, the control system controls the operating status of the drive system, lubrication system, and loading system, sends operating status commands to the host computer, and sets corresponding interlock protection mechanisms and alarm protection limits. Based on the set alarm protection limits, it determines whether to send an automatic stop command to the host computer.

[0012] The beneficial technical effects of the present invention are at least as follows: By employing interlocking protection between drive speed, lubrication, and loading, and limiting protection methods for lubrication pressure and load, the controllable operation of the mechanical transmission system is achieved. This effectively avoids phenomena such as dry running, torque overload, and over-speed operation caused by human error or equipment failure, ensuring stable operation of the mechanical transmission system and reducing the risk of failure. Attached Figure Description

[0013] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. The drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0014] Figure 1 This is a schematic diagram of the operation protection and control principle of the mechanical transmission system of the present invention; Figure 2 This is a schematic diagram of the drive motor speed control scheme of the present invention; Figure 3 This is a schematic diagram of the distributed substation layout of the data acquisition system of this invention. Detailed Implementation

[0015] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0016] The features and illustrative embodiments of various aspects of the present invention will now be described in detail. Numerous specific details are set forth in the following detailed description to provide a thorough understanding of the invention. However, it will be apparent to those skilled in the art that the invention may be practiced without requiring some of these specific details. The following description of embodiments is merely intended to provide a better understanding of the invention by illustrating examples of the invention. The invention is by no means limited to any specific setups and methods set forth below, but covers any improvements, substitutions, and modifications to structures, methods, and devices without departing from the spirit of the invention. Well-known structures and techniques are not shown in the drawings and the following description to avoid unnecessarily obscuring the invention.

[0017] like Figure 1As shown, an embodiment of the present invention provides a mechanical transmission system operation protection and control system, including: a drive system 2, a lubrication system 5, a loading system 6, a data acquisition system 4, and a control system 3; Mechanical transmission system 1 and drive system 2 are connected by a coupling. Loading system 6 is directly rigidly connected to mechanical transmission system 1. Drive system 2 drives mechanical transmission system to operate. During operation, loading system 6 applies loads to each shaft of mechanical transmission system. Lubrication system 5 is connected to mechanical transmission system 1 through lubrication pipelines to provide lubrication for mechanical transmission system 1. The data acquisition system 4 is softly connected to the mechanical transmission system 1. The data acquisition system 4 is installed on the lubrication system 5, the loading system 6, and the drive system 2. The data acquisition system 4 converts the acquired data and feeds it back to the control system 3. The control system 3 is softly connected to the data acquisition system 4. Based on the data fed back by the data acquisition system 4, the control system 3 controls the operation status of the drive system 2, the lubrication system 5, and the loading system 6, sends the operation status command to the host computer, and sets the corresponding interlock protection mechanism and alarm protection limit value. Based on the set alarm protection limit value, it determines whether to send an automatic stop command to the host computer.

[0018] The drive system is the power source for the transmission system. It uses an AC or DC motor to draw power from the power grid to realize the operation of the mechanical transmission system. The lubrication system is used to lubricate and cool the gears and bearings during the operation of the mechanical transmission system; The loading system is used to apply loads to each shaft during the operation of the mechanical transmission system; The data acquisition system is used to collect and convert various status parameters during the operation of mechanical transmission systems and equipment, and transmit them to the control system and host computer.

[0019] In one embodiment, the interlock protection mechanism includes a rotational speed and lubrication pressure interlock mechanism. The data acquisition system 4 includes: a data acquisition module, a communication bus, programming software, sensors, and a host computer; the control system 3 includes: a CPU module, a control module, a circuit breaker, a contactor, and programming software; the drive system 2 includes a drive motor; and the lubrication system includes a lubrication pump. The sensor transmits the acquired drive motor speed and lubrication pressure signals to the acquisition module. After conversion, the acquisition module feeds the parameters back to the host computer via the communication bus. The host computer displays the drive motor speed and lubrication pressure through the programming software of the acquisition system and the control system, and synchronously transmits them to the CPU module of the control system. The CPU module interlocks the drive motor speed and lubrication pressure through the programming software of the control system. When the lubrication pressure is 0 or the lubrication pump is not started, the drive motor cannot start, or the lubrication pressure suddenly drops to the lower limit, the drive motor stops running. This interlock design of speed and lubrication pressure is used to prevent dry running of the mechanical transmission system. The interlock command is transmitted to the control module, and then to the contactor. The contactor's on / off state controls the circuit breaker, thereby realizing the start and stop of the drive motor and lubrication pump.

[0020] Furthermore, the drive system also includes a coupling, a motor controller, and a potentiometer. The drive motor is rigidly connected to the coupling, the drive motor is flexibly connected to the motor controller via a cable, and the motor controller is flexibly connected to the potentiometer via a cable, achieving stepless speed control. See also Figure 2 The potentiometer outputs a resistance signal, which sends a control command to the host computer of the acquisition system 4 through the programming software of the control system 3. The resistance signal is then output to the motor controller via the BUS bus. After receiving the resistance signal, the motor controller outputs the corresponding instructions to the drive motor, enabling the drive motor to perform speed increase, speed decrease, and speed stabilization operations, while simultaneously feeding back the corresponding speed status to the host computer.

[0021] In one embodiment, the lubrication system further includes a lubricating oil tank, a motor, a gear pump or screw pump, an oil filter, oil tank piping, and a lubrication pressure sensor; The loading system includes: a loading tank, a loading pump, a control valve, a relief valve, an adapter, a coupling, a gearbox, and a plunger pump or motor, the plunger pump or motor outlet pressure, and the plunger pump or motor outlet flow rate.

[0022] In one embodiment, the interlock protection mechanism further includes a start-stop interlock mechanism, the control logic of which includes start control logic and stop control logic. The startup control logic is as follows: First, start the lubrication pump. The control system 3 checks whether the lubrication pump has started and then checks whether the lubrication pressure has been established. If the lubrication pump has started and the lubrication pressure has been established, start the loading pump of the loading system and check whether the loading pressure is abnormal. If there is no abnormality, start the drive motor. If any of the above conditions are not met, the drive motor cannot start. The stop control logic is as follows: first, stop the loading pump, check that the loading pressure is 0, then stop the drive motor, check that the drive motor speed is 0, and finally stop the lubrication pump.

[0023] In one embodiment, the acquisition system 4 converts the acquired lubrication pressure, loading pressure and motor speed signals and feeds them back to the control system 3. When programming, the control system 3 establishes an alarm protection subroutine and sets alarm protection limit values. The alarm protection subroutine includes a drive motor speed protection program, a lubrication pressure protection program, a drive motor start-stop interlock protection program, and a loading pressure protection program. In the drive motor speed protection program, an upper limit control alarm value is set for the drive motor speed. If the upper limit control alarm value is exceeded, the host computer human-machine interface is instructed to flash the data color to trigger an alarm. An automatic stop command is sent to the host computer to perform a protective stop. First, the load of the loading pump is unloaded, then the drive motor speed is reduced to 0, and finally the lubrication pump is shut down.

[0024] In the lubrication pressure protection program, a lower limit control alarm value for lubrication pressure is set. If the pressure is lower than the control alarm value, the host computer human-machine interface is instructed to flash the data color to trigger an alarm. An automatic stop command is sent to the host computer to perform a protective stop. First, the load of the loading pump is unloaded, then the speed of the drive motor is reduced to 0, and finally the lubrication pump is shut down.

[0025] In the drive motor start-stop interlock protection program, a lower limit control alarm value for lubrication pressure is set. If the lubrication pressure is lower than the lower limit control alarm value before the drive motor starts, the drive motor cannot start; an automatic stop command is sent to the host computer to perform a protective stop. In the loading pressure protection program, the upper limit control alarm value of the outlet pressure of the plunger pump or motor of the loading system is set. If the upper limit control alarm value is exceeded, the host computer human-machine interface is instructed to flash the data color to trigger an alarm, and an automatic stop command is sent to the host computer to perform a protective stop. First, the load of the loading pump is unloaded, then the speed of the drive motor is reduced to 0, and finally the lubrication pump is shut down.

[0026] In one embodiment, the acquisition modules in the acquisition system are arranged according to the positions of the drive system, lubrication system, and loading system. Data transmission between the substations is achieved via a BUS bus. See [link to relevant documentation]. Figure 3 .

[0027] The above description merely illustrates embodiments of the present invention and is quite specific and detailed; however, it should not be construed as limiting the scope of the patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the scope of protection of the present invention. Furthermore, any parts of the present invention not described in detail are conventional techniques.

Claims

1. A mechanical transmission system operation protection and control system, characterized in that, include: Drive system, lubrication system, loading system, data acquisition system, control system; The mechanical transmission system and the drive system are connected by a coupling, while the loading system and the mechanical transmission system are directly rigidly connected. The drive system drives the mechanical transmission system to operate, and during operation, the loading system applies loads to each shaft of the mechanical transmission system. The lubrication system is connected to the mechanical transmission system through lubrication pipelines to provide lubrication for the mechanical transmission system. The data acquisition system is softly connected to the mechanical transmission system. The data acquisition system is installed on the lubrication system, loading system, and drive system to convert the acquired data and feed it back to the control system. The control system is softly connected to the data acquisition system. Based on the data fed back from the data acquisition system, the control system controls the operating status of the drive system, lubrication system, and loading system, sends operating status commands to the host computer, and sets corresponding interlock protection mechanisms and alarm protection limits. Based on the set alarm protection limits, the control system determines whether to send an automatic stop command to the host computer.

2. The system according to claim 1, characterized in that, The interlock protection mechanism includes a speed and lubrication pressure interlock mechanism. The data acquisition system includes: a data acquisition module, programming software, sensors, and a host computer; the control system includes: a CPU module, a control module, a circuit breaker, a contactor, and programming software; the drive system includes a drive motor; and the lubrication system includes a lubrication pump. The sensor transmits the obtained drive motor speed signal and lubrication pressure signal to the acquisition module. After conversion, the acquisition module feeds the parameters back to the host computer via the communication bus. The host computer displays the drive motor speed and lubrication pressure through the programming software of the acquisition system and the control system, and synchronously transmits them to the CPU module of the control system. The CPU module interlocks the drive motor speed and lubrication pressure through the programming software of the control system. When the lubrication pressure is 0 or the lubrication pump is not started, the drive motor cannot start. Or, when the lubrication pressure suddenly drops to the lower limit, the drive motor stops running and transmits the interlock command to the contactor through the control module. The contactor opens and closes the circuit breaker, thereby realizing the start and stop of the drive motor and the lubrication pump.

3. The system according to claim 2, characterized in that, The drive system also includes a coupling, a motor controller, and a potentiometer. The drive motor is rigidly connected to the coupling, the drive motor is flexibly connected to the motor controller via a cable, and the motor controller is flexibly connected to the potentiometer via a cable, thereby achieving stepless speed control.

4. The system according to claim 3, characterized in that, The interlock protection mechanism also includes a start-stop interlock mechanism. The control logic of the start-stop interlock mechanism includes start control logic and stop control logic. The startup control logic is as follows: First, start the lubrication pump. The control system checks whether the lubrication pump has started and then checks whether the lubrication pressure has been established. If the lubrication pump has started and the lubrication pressure has been established, then start the loading pump of the loading system and check whether the loading pressure is abnormal. If there is no abnormality, then start the drive motor. If any of the above conditions are not met, the drive motor will not start. The stop control logic is as follows: first, stop the loading pump, check that the loading pressure is 0, then stop the drive motor, check that the drive motor speed is 0, and finally stop the lubrication pump.

5. The system according to claim 4, characterized in that, The acquisition system converts the acquired lubrication pressure, loading pressure, and motor speed signals and feeds them back to the control system. When programming, the control system establishes an alarm protection subroutine and sets alarm protection limit values. The alarm protection subroutine includes a drive motor speed protection program, a lubrication pressure protection program, a drive motor start-stop interlock protection program, and a loading pressure protection program. In the drive motor speed protection program, an upper limit control alarm value is set for the drive motor speed. If the upper limit control alarm value is exceeded, the host computer human-machine interface is instructed to flash the data color to trigger an alarm, and an automatic stop command is sent to the host computer to perform a protective stop. In the lubrication pressure protection program, a lower limit control alarm value for lubrication pressure is set. If the lubrication pressure is lower than the control alarm value, the host computer human-machine interface is instructed to flash the data color to trigger an alarm, and an automatic stop command is sent to the host computer to perform a protective stop. In the drive motor start-stop interlock protection program, a lower limit control alarm value for lubrication pressure is set. If the lubrication pressure is lower than the lower limit control alarm value before the drive motor starts, the drive motor cannot start; an automatic stop command is sent to the host computer to perform a protective stop. In the loading pressure protection program, the upper limit control alarm value of the outlet pressure of the plunger pump or motor of the loading system is set. If the upper limit control alarm value is exceeded, the host computer human-machine interface is instructed to flash the data color to trigger an alarm, and an automatic stop command is sent to the host computer to perform a protective stop. In the drive motor speed protection program, lubrication pressure protection program, and loading pressure protection program, when performing a protective shutdown, the load on the loading pump is first unloaded, then the drive motor speed is reduced to 0, and finally the lubrication pump is shut down.

6. The system according to claim 2, characterized in that, The acquisition modules in the acquisition system are arranged according to the positions of the drive system, lubrication system, and loading system, and data transmission between the substations is carried out via a BUS bus.

7. The system according to claim 3, characterized in that, The potentiometer outputs a resistance signal, which sends a control command to the host computer of the acquisition system through the programming software of the control system. The resistance signal is then output to the motor controller via the BUS bus. After receiving the resistance signal, the motor controller outputs the corresponding instructions to the drive motor, enabling the drive motor to perform speed increase, speed decrease, and speed stabilization operations, while simultaneously feeding back the corresponding speed status to the host computer.

8. A method for the operation protection and control system of a mechanical transmission system as described in any one of claims 1 to 7, characterized in that, include: The drive system drives the mechanical transmission system to operate, and during operation, the loading system applies loads to each shaft of the mechanical transmission system. The lubrication system provides lubrication for the mechanical transmission system; The data acquisition system converts the acquired data and feeds it back to the control system; Based on the data feedback from the acquisition system, the control system controls the operating status of the drive system, lubrication system, and loading system, sends operating status commands to the host computer, and sets corresponding interlock protection mechanisms and alarm protection limits. Based on the set alarm protection limits, it determines whether to send an automatic stop command to the host computer.

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