Wireless sensing maintenance-free electric loading and unloading arm control system

Abstract

The application relates to the technical field of electric loading and unloading arms, and discloses a wireless-sensing and maintenance-free electric loading and unloading arm control system, which comprises a stand column and a control unit. A lengthened box is arranged at the top of the stand column, a process pipeline is connected to the top end of the lengthened box, rope wheels are arranged outside the lengthened box and the process pipeline, an outer arm driving mechanism is arranged at the bottom of the rope wheels, a supporting box is arranged at the bottom end of the lengthened box, an inner arm driving mechanism and a horizontal rotation driving mechanism are arranged between the supporting box and the stand column, and a three-dimensional joint is connected to the bottom end of the process pipeline. The ERC is arranged to be electrically controlled, so that the flexible start and stop of the three-dimensional joint and automatic alignment can be realized. During the docking process, the three-dimensional joint is in a linear movement mode, the docking time is shortened, the docking precision is improved, the docking is accelerated, meanwhile, the real-time data can be transmitted back by the explosion-proof servo electric cylinder, a monitoring closed loop is formed, and the safety during the use of the loading and unloading arm is improved.

Description

Technical Field

[0001] This invention relates to the field of electric loading arm technology, specifically to a wireless sensing, maintenance-free electric loading arm control system. Background Technology

[0002] Loading and unloading booms are rigid robotic arms used to safely and efficiently connect storage and transportation facilities with tank trucks, tank ships, and other transport vehicles for loading and unloading liquid or liquefied gas media, such as oil, chemicals, and LNG. Due to the demand for industrial automation and intelligent upgrades, electric loading and unloading booms use electric motors to replace manual or hydraulic systems, enabling fast, accurate, and labor-saving loading and unloading of liquids from the top and bottom of tank trucks / ship holds, and solving problems such as hydraulic oil leakage.

[0003] Application No. 201310718564.4 discloses a marine loading arm with a driver composed of an electric motor. Although it basically realizes the electric servo drive of the loading arm, accessories such as ERC still need to rely on hydraulics. In actual operation, there are still problems such as oil leakage and slow response. In actual operation, sensors need to be installed at different positions on the electric loading arm to achieve corresponding functions. The external cables of the sensors will wear down with the movement of the arm, which will eventually lead to insulation damage or poor contact, causing power outages or sensor failures, affecting the normal operation of the loading arm. At the same time, the wiring is cumbersome, requiring additional cable trays, occupying space, and increasing mechanical complexity and failure points. Summary of the Invention

[0004] In view of the shortcomings of existing electric loading arms mentioned in the background art, the present invention provides a wireless sensing maintenance-free electric loading arm control system, which has the advantages of good safety and convenient maintenance, and solves the technical problems mentioned in the background art.

[0005] This invention provides the following technical solution: a wireless sensing maintenance-free electric loading and unloading arm control system, comprising a column and a control unit: an extension box is installed on the top of the column, a process pipeline is connected to the top of the extension box, and a rope pulley is configured on the outside of the extension box and the process pipeline; an outer arm drive mechanism is provided at the bottom of the rope pulley; a support box is installed at the bottom of the extension box; an inner arm drive mechanism and a horizontal rotation drive mechanism are configured between the support box and the column; a three-dimensional joint is connected to the bottom of the process pipeline, and the three-dimensional joint includes a rotary joint, an ERC drive mechanism, a QCDC docking fine-tuning drive, a QCDC drive mechanism, and a pipe fitting; the electric loading and unloading arm control system is equipped with a sensor feedback system; and a locking mechanism is configured on the side of the bottom of the column near the outer arm drive mechanism.

[0006] Furthermore, the rope pulley has a lower rope pulley and an upper rope pulley. The lower rope pulley is located at the bottom of the support box, and the upper rope pulley is installed at the connection between the extended box and the process pipeline. The other end of the upper rope pulley is connected to the outside of the process pipeline, and the lower rope pulley and the upper rope pulley are connected by a rope.

[0007] Furthermore, the outer boom drive mechanism, inner boom drive mechanism, and horizontal slewing drive mechanism are all driven by servo explosion-proof motors, and are equipped with reducers and corresponding slewing bearing gears. After receiving a signal command, the motor amplifies the torque through the reducer and transmits it to the gears of the slewing bearing to complete the action.

[0008] Furthermore, the bottom of the three-dimensional connector is equipped with a quick connector flange, and the three-dimensional connector is self-balancing. The ERC drive mechanism and the QCDC drive mechanism are both explosion-proof servo electric cylinder drives. The QCDC docking fine-tuning drive includes an electronic control unit, a servo motor, a reduction transmission mechanism, and a sensor.

[0009] Furthermore, the locking mechanism includes a locking mechanism drive, a locking handle, and a locking chain. The locking mechanism drive is a servo explosion-proof electric cylinder with a built-in brake. The top of the locking mechanism drive is equipped with a locking handle, and the middle of the locking handle is connected to a locking chain. The locking mechanism drive moves downward to pull the locking handle, thereby enabling the locking chain to achieve the locking function.

[0010] Furthermore, a valve position monitoring sensor is configured on the side of the three-dimensional connector. When the loading and unloading task needs to be interrupted, the ERC drive mechanism drives the valve body to rotate and feeds back a signal. The valve position monitoring sensor detects the valve position, and the monitoring system compares and calculates the electric cylinder signal with the sensor signal to dynamically compensate the overall mechanism.

[0011] Furthermore, the sensing feedback system is a self-powered wireless sensor array. The sensors are installed at the corresponding installation positions in the electric loading and unloading arm control system. In the prior art, the installation positions are specified, so they will not be described in detail. The sensors are driven by vibration, temperature difference, or force capture to generate electricity. The system monitors the process parameters such as air tightness, pressure difference, pressure, flow rate, and temperature, as well as the real-time force, driving force, bearing capacity, positioning status, and ERC valve position of key components such as the grippers, slewing bearings, adjustable outriggers, and locking mechanisms. This avoids the problems of power outages or sensor failures caused by the aging and wear of traditional cable structures, ensuring the normal operation of the loading and unloading arm. At the same time, it avoids the problems of cumbersome wiring, the need for additional cable trays, space occupation, and increased mechanical complexity and failure points.

[0012] The present invention has the following beneficial effects: 1. By setting the ERC to electronic control, this invention can realize flexible start and stop and automatic alignment of the three-dimensional joint. During the docking process, the three-dimensional joint moves in a linear mode, which shortens the docking time, improves the docking accuracy, and accelerates the docking. At the same time, the explosion-proof servo electric cylinder can transmit real-time data back to form a monitoring closed loop, which improves the safety of the loading and unloading arm during use.

[0013] 2. This invention sets the sensors of the sensing feedback system of the loading arm control system as a self-powered wireless sensor array, eliminating the need for external batteries and signal cables. It achieves long-term maintenance-free operation by generating electricity through vibration, temperature difference, or force capture. It can perform real-time online monitoring of process parameters such as air tightness, pressure difference, pressure, flow rate, and temperature, as well as the real-time force, driving force, bearing capacity, positioning status, and ERC valve position of key components such as jaws, slewing bearings, adjustable outriggers, and locking mechanisms. This avoids the problems of power outages or sensor failures caused by the aging and wear of traditional cable structures, ensuring the normal operation of the loading arm. At the same time, it avoids the problems of cumbersome wiring, the need for additional cable trays, space occupation, and increased mechanical complexity and failure points.

[0014] 3. This invention adopts a fully electric servo drive scheme, eliminating the hydraulic station, hydraulic cylinders, and high-pressure pipelines. It uses servo motors, servo cylinders, and precision mechanical transmission mechanisms to complete all actions such as horizontal rotation of the loading and unloading arm, lifting and telescopic movement of the inner and outer arms, locking mechanism, blind flange opening and closing, QCDC rotation fine adjustment, and ERC emergency disengagement. It achieves millimeter-level positioning accuracy and millisecond-level response speed. With dual closed-loop control of position and torque, it has functions such as flexible start and stop, automatic alignment, overload protection, and power failure self-locking. It can avoid the leakage problems caused by hydraulics, reduce energy consumption, and improve production safety. Attached Figure Description

[0015] Figure 1 A schematic diagram of the overall structure of the invention; Figure 2 This is a schematic diagram of the drive structure of the loading and unloading arm in this invention; Figure 3 This is a schematic diagram of the three-dimensional connector drive structure in this invention; Figure 4 This is a schematic diagram of the locking mechanism in this invention; Figure 5 This is a partial structural diagram of the locking mechanism in this invention; Figure 6 This is a schematic diagram of the valve position monitoring system in this invention.

[0016] In the diagram: 1. Outer arm drive mechanism; 2. Lower rope pulley; 3. Support box; 4. Inner arm drive mechanism; 5. Extension box; 6. Process pipeline; 7. Upper rope pulley; 8. Three-dimensional joint; 81. Rotary joint; 82. ERC drive mechanism; 83. QCDC docking fine-tuning drive; 84. QCDC drive mechanism; 9. Horizontal rotation drive mechanism; 10. Column; 11. Locking mechanism drive; 12. Locking handle; 13. Locking chain; 14. Valve position monitoring sensor. Detailed Implementation

[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] Please see Figure 1 A wireless sensing, maintenance-free electric loading and unloading boom control system includes a column 10 and a control unit. The control unit uses a PLC controller as its core, in conjunction with servo drivers, position sensors, and torque sensors, forming a closed-loop control system of "command input - signal acquisition - logic processing - action output - feedback adjustment". Operators input work commands (such as slewing angle, inner and outer boom rotation, docking coordinates, etc.) through an operation panel (or host computer), and the command signals are transmitted to the PLC controller. The position sensors collect the angle and displacement data of each boom in real time, and the torque sensors collect the thrust / torque data of the servo cylinders, feeding back the real-time operating data to the PLC controller to form position, force, and torque data. The system features dual closed-loop feedback; the PLC controller compares and analyzes input commands and feedback data, and generates corresponding control signals through preset control algorithms, such as PID adjustment algorithms and flexible docking algorithms, which are then transmitted to each servo driver; after receiving the control signals, the servo drivers adjust the speed, direction, and output torque of the servo motors to drive each electric drive unit to coordinate actions and achieve precise movement of the loading and unloading arm; at the same time, the controller can achieve synchronous control of multiple boom sections to ensure consistent rotation, lifting, and extension actions; the controller receives real-time operating data from sensor feedback, and if displacement deviation, torque overload, or other issues occur, it immediately adjusts the control signals to correct the action deviations, ensuring operational accuracy and equipment safety.

[0019] Please see Figure 1An extension box 5 is installed on the top of the column 10. A process pipeline 6 is connected to the top of the extension box 5. Rope pulleys are configured on the outside of the extension box 5 and the process pipeline 6. The rope pulleys include a lower rope pulley 2 and an upper rope pulley 7. The lower rope pulley 2 is located at the bottom of the support box 3. The upper rope pulley 7 is installed at the connection between the extension box 5 and the process pipeline 6, and the other end of the upper rope pulley 7 is connected to the outside of the process pipeline 6. The lower rope pulley 2 and the upper rope pulley 7 are connected by a rope. An outer arm drive mechanism 1 is set at the bottom of the rope pulleys. A support box 3 is installed at the bottom of the extension box 5. An inner arm drive mechanism 4 and a horizontal rotation drive mechanism 9 are configured between the support box 3 and the column 10. Electric loading and unloading arm control system. Equipped with a sensor feedback system, which is a self-powered wireless sensor array, the system primarily generates electricity to drive the sensors through vibration, temperature difference, or force capture. It provides real-time online monitoring of process parameters such as air tightness, differential pressure, pressure, flow rate, and temperature, as well as the real-time force, driving force, bearing capacity, positioning status, and ERC valve position of key components such as grippers, slewing bearings, adjustable outriggers, and locking mechanisms. This avoids the problems of power outages or sensor failures caused by the aging and wear of traditional cable structures, ensuring the normal operation of the loading and unloading arm. At the same time, it avoids the problems of cumbersome wiring, the need for additional cable trays, space occupation, and increased mechanical complexity and potential failure points.

[0020] Please see Figure 5 A locking mechanism is provided on the bottom of the column 10 near the outer arm drive mechanism 1. The locking mechanism includes a locking mechanism drive 11, a locking handle 12, and a locking chain 13. The locking mechanism drive 11 is a servo explosion-proof electric cylinder. The motor has a built-in brake and is also used with a positioning pin for secondary fixation, which can increase the locking strength. The top of the locking mechanism drive 11 is equipped with a locking handle 12. The middle of the locking handle 12 is connected to the locking chain 13. When the locking mechanism drive 11 moves down, it pulls the locking handle 12 to move, so that the locking chain 13 can achieve the locking function.

[0021] Please see Figure 2 The outer arm drive mechanism 1, the inner arm drive mechanism 4, and the horizontal slewing drive mechanism 9 are all driven by servo explosion-proof motors, and are equipped with reducers and corresponding slewing bearing gears. After receiving the signal command, the motor amplifies the torque through the reducer and transmits it to the gears of the slewing bearing to complete the action. It can achieve millimeter-level positioning accuracy and millisecond-level response speed. With the dual closed-loop control of position and torque, it has functions such as flexible start and stop, automatic alignment, overload protection, and power failure self-locking.

[0022] Please see Figure 3-4The bottom end of the process pipeline 6 is connected to a three-dimensional connector 8, which includes a rotary joint 81, an ERC drive mechanism 82, a QCDC docking fine-tuning drive 83, a QCDC drive mechanism 84, and pipe fittings. There are three rotary joints 81, which connect to the corresponding pipe fittings. The bottom end of the three-dimensional connector 8 is equipped with a quick connector flange, and the three-dimensional connector 8 is self-balancing. The ERC drive mechanism 82 and the QCDC drive mechanism 84 are both explosion-proof servo electric cylinder drives. The QCDC docking fine-tuning drive 83 includes an electronic control unit, a servo motor, a reduction transmission mechanism, and a sensor.

[0023] Please see Figure 6 The side of the three-dimensional connector 8 is equipped with a valve position monitoring sensor 14. When the loading and unloading task needs to be interrupted, the ERC drive mechanism 82 drives the valve body to rotate and feeds back a signal. The valve position monitoring sensor 14 detects the valve position, and the monitoring system compares and calculates the electric cylinder signal with the sensor signal to dynamically compensate the overall mechanism.

[0024] The method of use (working principle) of this invention is as follows: The control system sends a signal, and after the motor receives the signal command, the torque is amplified by the reducer and transmitted to the gear of the slewing bearing, thereby completing the action. With the cooperation of position and torque dual closed-loop control, functions such as flexible start and stop, automatic alignment, overload protection, and power failure self-locking are realized. The output of the horizontal slewing drive mechanism 9 drives the extension box 5, process pipeline 6 and other related accessories to rotate horizontally after passing through the reducer and the slewing bearing gear. Similarly, the inner arm drive mechanism 4 drives the inner arm to move, while the lower rope wheel 2 and the upper rope wheel 7 control the deflection angle of the process pipeline 6. The quick-connect flange is always vertical and docks with the ship's flange under the control and drive of the electric loading arm control system. At the same time, the explosion-proof servo cylinder transmits real-time data back to form a monitoring closed loop and ultimately realizes the operation of the loading arm. Meanwhile, the system is equipped with a self-powered wireless sensor array that generates electricity through vibration, temperature difference or force capture to achieve maintenance-free operation. It performs full-process online monitoring of process parameters such as air tightness, differential pressure, pressure, flow rate, and temperature of the electric loading arm, as well as the real-time force, driving force, bearing capacity, positioning status and ERC valve position of key components such as jaws, slewing bearings, adjustable outriggers, and locking mechanisms.

[0025] 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.

[0026] 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 wireless sensing, maintenance-free electric loading and unloading arm control system, comprising a column (10) and a control unit, characterized in that: An extension box (5) is installed on the top of the column (10). A process pipeline (6) is connected to the top of the extension box (5). A rope wheel is arranged on the outside of the extension box (5) and the process pipeline (6). An outer arm drive mechanism (1) is provided at the bottom of the rope wheel. A support box (3) is installed at the bottom of the extension box (5). An inner arm drive mechanism (4) and a horizontal rotation drive mechanism (9) are arranged between the support box (3) and the column (10). A three-dimensional joint (8) is connected to the bottom of the process pipeline (6). The three-dimensional joint (8) includes a rotary joint (81), an ERC drive mechanism (82), a QCDC docking fine-tuning drive (83), a QCDC drive mechanism (84), and pipe fittings. The electric loading and unloading arm control system is equipped with a sensor feedback system. A locking mechanism is arranged on the side of the bottom of the column (10) near the outer arm drive mechanism (1).

2. The wireless sensing maintenance-free electric loading and unloading arm control system according to claim 1, characterized in that: The rope wheel has a lower rope wheel (2) and an upper rope wheel (7). The lower rope wheel (2) is located at the bottom of the support box (3). The upper rope wheel (7) is installed at the connection between the extension box (5) and the process pipeline (6). The other end of the upper rope wheel (7) is connected to the outside of the process pipeline (6). At the same time, the lower rope wheel (2) and the upper rope wheel (7) are connected by a rope.

3. The wireless sensing maintenance-free electric loading and unloading arm control system according to claim 1, characterized in that: The outer arm drive mechanism (1), inner arm drive mechanism (4) and horizontal slewing drive mechanism (9) are all driven by servo explosion-proof motors and equipped with reducers and corresponding slewing bearing gears. After the motor receives the signal command, the torque is amplified by the reducer and then transmitted to the gear of the slewing bearing to complete the action.

4. The wireless sensing maintenance-free electric loading and unloading arm control system according to claim 1, characterized in that: The bottom of the three-dimensional connector (8) is equipped with a quick connector flange, and the three-dimensional connector (8) is self-balancing. The ERC drive mechanism (82) and the QCDC drive mechanism (84) are both explosion-proof servo electric cylinder drives. The QCDC docking fine-tuning drive (83) includes an electric control unit, a servo motor, a speed reduction transmission mechanism, and a sensor.

5. The wireless sensing maintenance-free electric loading and unloading arm control system according to claim 1, characterized in that: The locking mechanism includes a locking mechanism drive (11), a locking handle (12), and a locking chain (13). The locking mechanism drive (11) is a servo explosion-proof electric cylinder with a built-in brake. The top of the locking mechanism drive (11) is equipped with a locking handle (12), and the middle of the locking handle (12) is connected to the locking chain (13). The locking mechanism drive (11) moves down to pull the locking handle (12) to make the locking chain (13) achieve the locking function.

6. The wireless sensing maintenance-free electric loading and unloading arm control system according to claim 1, characterized in that: The three-dimensional connector (8) is equipped with a valve position monitoring sensor (14) on its side. When the loading and unloading of fluid needs to be interrupted, the ERC drive mechanism (82) drives the valve body to rotate and feeds back a signal. The valve position monitoring sensor (14) detects the valve position and the monitoring system compares and calculates the electric cylinder signal with the sensor signal to dynamically compensate the overall mechanism.

7. The wireless sensing maintenance-free electric loading and unloading arm control system according to claim 1, characterized in that: The sensing feedback system is a self-powered wireless sensor array. It mainly generates electricity through vibration, temperature difference or force capture to drive the sensors to work. It performs real-time online monitoring of process parameters such as air tightness, pressure difference, pressure, flow rate, temperature, as well as key components such as chucks, slewing bearings, adjustable outriggers, locking mechanisms, and ERC valve positions.

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