Detection device for unfreezing effect of wagon material
By designing a vehicle material thawing effect detection device, using probe rods and temperature sensors to monitor the depth of the frozen layer in real time, the problem of the thawing process in the existing technology cannot be monitored in real time, reducing energy waste and safety risks, and improving operational safety and production efficiency.
Patent Information
- Application Number
- CN202420749629.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-04-12
- Publication Date
- 2025-01-10
- Estimated Expiration
- 2034-04-12
AI Technical Summary
During the thawing of frozen raw materials in winter transportation, the existing technology cannot monitor the thawing effect in real time, resulting in waste of energy, equipment damage and high labor costs, and poses safety risks.
A vehicle material thawing effect detection device is designed, including a motor, reducer, torque coupling, probe rod, rack, gear, support wheel, mounting plate, limit switch and control unit, which is detected by probe rod and temperature sensor. The depth of the frozen layer is used, and the thawing progress is monitored in real time through the HMI human-computer interactive screen to avoid manual entry of the thawing library.
It realizes real-time monitoring of the thawing effect without manual entry into the thawing library, reduces the risk of energy waste and equipment damage, improves operational safety and production efficiency, and the device structure is simple and easy to maintain and use.
Smart Images
Figure CN222337145U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the field of material thawing, in particular to a vehicle skin material thawing effect detection device. Background Art
[0002] Metallurgical, coal and other enterprises in northern China purchase raw materials from outside, and most of them use train cars to transport raw materials. In winter, the temperature in the north is very low, and the raw materials have a lot of moisture inside. After freezing, the raw materials form frozen blocks in the train car, making it difficult to unload. Most of them put the train car in a thawing warehouse, burn gas in the thawing warehouse, and then use a fan to transport hot air through a pipeline to increase the temperature in the thawing warehouse to thaw the frozen materials in the car. The existing problems are: since the thawing effect cannot be observed in real time in the thawing warehouse, it needs to be estimated based on the experience of the operators. Because the frozen materials are greatly affected by external factors and the depth of the frozen layer is uncertain, the following adverse consequences will occur:
[0003] 1. The material is not completely thawed and needs secondary heating. The operator enters the thawing warehouse to measure the thawing effect. The operation time is 60 minutes, of which 15 minutes are used to release the gas in the thawing warehouse and 5 minutes are used to open the door of the thawing warehouse for testing. The secondary heating takes 40 minutes to reach the thawing temperature, resulting in energy waste and affecting production time;
[0004] 2. The material is completely thawed. Because the frozen layer of the material is shallow, it takes a longer time to heat it, which also causes energy waste. At the same time, if the material is overheated or the thawing time is blindly extended, it will cause damage to the train car.
[0005] Comprehensive analysis shows that under the current operation and inspection mode, energy waste, equipment damage, high labor costs and certain safety risks for operators will occur, which urgently needs improvement. Summary of the invention
[0006] The utility model aims to provide a device for detecting the thawing effect of car body materials, thereby improving the personal safety of operators and the use safety of train car body equipment.
[0007] To achieve the above purpose, the utility model is implemented through the following technical solutions:
[0008] A vehicle skin material thawing effect detection device comprises a motor, a reducer, a torque coupling, a probe rod, a rack, a gear, a support wheel, a mounting plate, a limit switch, and a control unit. The reducer and the gear are connected through the torque coupling, the gear is connected to the bearing seat, the motor is connected to the reducer, and the motor, the reducer, the torque coupling, the gear, and the bearing seat are on the same axis.
[0009] The probe rod is fixedly connected to the rack, the rack is meshed with the gear, the support wheel is installed on the bracket 2, the support wheel rolls with the rise and fall of the probe rod, a temperature sensor is arranged at the lower end of the probe rod, the reducer, the motor and the bracket 2 are arranged on the mounting plate, and the mounting plate is perpendicular to the bracket 2; the mounting plate is arranged on the roof of the thawing warehouse, and the probe rod passes through the mounting plate and the roof of the thawing warehouse and extends to the bottom of the thawing warehouse;
[0010] The motor, temperature sensor and limit switch are connected to the control unit.
[0011] A probe is arranged outside the temperature sensor, the probe is threadedly connected to the probe rod, and the probe is made of stainless steel.
[0012] The limit switch includes proximity switch 1 to proximity switch 3. Bracket 1 and bracket 3 are also arranged on the mounting plate. Bracket 1 is fixedly connected to bracket 2, and bracket 1 and bracket 2 are parallel to each other. Bracket 1 is sequentially arranged with proximity switch 1 and proximity switch 2 from top to bottom. Bracket 3 is arranged on one side of the gear, and proximity switch 3 is arranged on bracket 3.
[0013] The number of supporting wheels is not less than two, and the gears are convex and concave gears.
[0014] The control unit includes a digital input module, a digital output module, an analog input module, and a main circuit. The main circuit includes an overheating relay, a contactor, and a circuit breaker connected to the motor in sequence. The digital input module is connected to the limit switch, the normally open auxiliary contact of the overheating relay, and the normally open auxiliary contact of the contactor through a port. The digital output module is connected to the coil of the contactor through a port. The contactor includes a forward contactor and a reverse contactor connected in parallel. The analog input module is connected to the temperature sensor through a port.
[0015] The control unit also includes a communication module, and the communication module, the digital quantity input module, the digital quantity output module, and the analog quantity input module are connected through ports.
[0016] The control unit adopts slave PLC.
[0017] Proximity switch 1 is used to detect the upper limit position of the probe rod, proximity switch 2 is used to detect the lower limit position of the probe rod, and proximity switch 3 is used to detect the number of rotating teeth of the gear.
[0018] Compared with the prior art, the beneficial effects of the utility model are:
[0019] 1. A temperature sensor is set at the lower end of the probe rod, the analog input module is connected to the temperature sensor, the slave PLC is connected to the master PLC through the communication module, and the HMI human-machine interaction screen is connected to the master PLC. The operator can check the detection data of the temperature sensor at any time through the HMI human-machine interaction screen in the operation room, without entering the thawing warehouse to measure the thawing effect. The structure is simple, the operation is convenient, and it is easy to implement;
[0020] 2. The car skin material thawing effect detection device adopts motor-reducer-torque coupling-gear-rack transmission, which has low requirements on the working environment, is easy to disassemble and repair, and has low production cost;
[0021] 3. The support wheel is installed on the second bracket. The support wheel rolls with the rise and fall of the probe rod to ensure that the probe rod will not deviate when it moves at the set position;
[0022] 4. The digital output module is connected to the coil of the motor contactor through the port. The operator can operate the motor start and stop through the buttons on the HMI human-machine interaction screen, and check the equipment operation and start and stop status at any time. It is easy to operate and query;
[0023] 5. A probe is set outside the temperature sensor to prevent the temperature sensor from directly contacting the frozen layer of frozen materials during movement. The probe is threadedly connected to the probe rod to facilitate disassembly by maintenance personnel;
[0024] 6. The gear is connected to the bearing seat, and the gear is fixed using the bearing seat, which has a simple structure and is safe and stable. BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Figure 1 It is a front view of a device for detecting the thawing effect of car body materials.
[0026] Figure 2 It is a side view of a device for detecting the thawing effect of car body materials.
[0027] Figure 3 yes Figure 1 Enlarged view of part I.
[0028] Figure 4 It is a schematic diagram of the structure of a device for detecting the thawing effect of car skin materials.
[0029] Figure 5 It is a schematic diagram of the assembly structure of proximity switch three.
[0030] Figure 6 Schematic diagram of the principle of the digital input module of the slave PLC in the embodiment.
[0031] Figure 7 Schematic diagram of the principle of the digital output module of the slave PLC in the embodiment.
[0032] In the figure: 1-motor 2-reducer 3-proximity switch three 4-gear 5-bracket three 6-bracket two 7-proximity switch two 8-proximity switch one 9-bracket one 10-rack 11-support wheel 12-torque coupling 13-bearing seat 14-temperature sensor 15-probe 16-probe rod 17-thawing room. DETAILED DESCRIPTION
[0033] [Example 1]
[0034] See Figures 1 to 4 , a vehicle skin material thawing effect detection device, including a motor 1, a reducer 2, a torque coupling 12, a probe rod 16, a rack 10, a gear 4, a support wheel 11, a mounting plate, a limit switch, and a control unit. The reducer 2 and the gear 4 are connected through the torque coupling 12, the gear 4 is connected to the bearing seat 13, the motor 1 is connected to the reducer 2, the motor 1, the reducer 2, the torque coupling 12, the gear 4, and the bearing seat 13 are on the same axis; the probe rod 16 is welded with the rack 10, the rack 10 is meshed with the gear 4, the gear 4 is a convex and concave gear 4, the support wheel 11 is installed on the bracket 2 6, the number of the support wheels 11 is not less than two, and the support wheel 11 rolls with the rise and fall of the probe rod 16 (the installation principle of the support wheel 11: the force direction of the rack 10 on the probe rod 16 is when the gear 4 is driven, the action surface of the normal force will be parallel to the end surface, and this component has only circumferential force and radial force. The support wheel 4 is installed above and below the force point of the gear, which can ensure that the probe rod 16 is The probe 16 is provided with a temperature sensor 14 at the lower end, and a probe 15 is provided outside the temperature sensor 14. The probe 15 is threadedly connected to the probe 16, and the probe 15 is made of stainless steel; the reducer 2, the motor 1, and the bracket 26 are arranged on the mounting plate, and the mounting plate is perpendicular to the bracket 26; the mounting plate is arranged on the roof of the thawing warehouse 17, and the probe 16 extends to the bottom of the thawing warehouse through the mounting plate and the roof of the thawing warehouse; the limit switch includes a proximity switch 8 to a proximity switch 3 3, and a bracket 1 9 and a bracket 3 5 are also arranged on the mounting plate. The bracket 1 9 is fixedly connected to the bracket 2 6, and the bracket 1 9 and the bracket 2 6 are parallel to each other. The bracket 1 9 is provided with a proximity switch 1 8 and a proximity switch 2 7 from top to bottom in sequence, and the bracket 3 5 is arranged on one side of the gear 4, and the bracket 3 5 is provided with a proximity switch 3 3; the proximity switch 1 8 is used to detect the upper limit position of the probe 16, and the proximity switch 2 7 is used to detect the lower limit position of the probe 16.
[0035] See Figure 6 and Figure 7The control unit includes a digital input module, a digital output module, an analog input module, a communication module, and a main circuit. The communication module, the digital input module, the digital output module, and the analog input module are connected through a port. The main circuit includes an overheating relay, a contactor, and a circuit breaker connected to the motor 1 in sequence. The digital input module is connected to the limit switch, the normally open auxiliary contact of the overheating relay, and the normally open auxiliary contact of the contactor through a port. The digital output module is connected to the coil of the contactor through a port. The contactor includes a forward contactor and a reverse contactor. The analog input module is connected to the temperature sensor 14 through a port. The control unit adopts a slave PLC. The slave PLC realizes data communication with the master PLC through a communication module. The HMI human-computer interaction screen is connected to the communication module of the master PLC through a port. The operator can operate the start and stop of the motor 1 through the HMI human-computer interaction screen and check the equipment operation status at any time.
[0036] The working process is as follows:
[0037] When the motor 1 rotates, the gear 4 is driven to rotate, and the gear 4 rotates to drive the rack 10 to rise and fall, thereby driving the probe 16 to rise and fall. The probe 16 is used to detect the depth of the frozen layer of the thawed material in the train car, which specifically includes the following steps:
[0038] S1, obtain the lifting distance of the probe rod 16 through the proximity switch 3
[0039] See Figure 5 , the proximity switch 3 is aligned with the protruding part of the gear 4, and the diameter of the detection head of the proximity switch 3 is smaller than the distance P between the adjacent protruding parts of the gear 4. The proximity switch 3 is used to detect the number of protruding parts of the gear 4 when the gear 4 rotates, which is the number of rotating teeth of the gear. The lifting distance formula of the probe rod 16 is:
[0040] L=L1*n / p①
[0041] In formula ①, L represents the height of the probe rod 16 when it is lowered. When the probe rod 16 is at the upper limit position, L=0. L1 represents the length of the rack. n represents the number of teeth of the rotating gear detected by the proximity switch. p represents the number of teeth of the rack on the probe rod 16.
[0042] L1=3000mm, p=190, n=1, according to formula ①, L=15.8mm, that is, the proximity switch 3 detects a signal once, and the probe rod 16 rises and falls by 15.8mm;
[0043] S2, the digital input module of the PLC is connected to the limit switch of the main door of the thawing warehouse through the port;
[0044] S3, start the motor 1, the probe rod 16 moves vertically downward to the surface of the thawed material in the train car and then continues to move downward. When the probe 15 encounters the frozen layer of the unthawed material, the resistance encountered by the probe 15 is greater than the set value of the torque coupling 12, and the reducer 2 is separated from the gear 4 through the torque coupling 12, and the probe rod 16 stops its downward movement;
[0045] S4, after the probe rod 16 stops descending, the PLC receives that the number of rotations of the gear 4 is zero, the motor 1 continues to run idling until time T1 and then stops, and after stopping until time T2, step S3 is repeated until the probe rod 16 descends to the set height from the bottom of the train car, and the probe rod 16 is lifted and returned to the original position at the upper end;
[0046] S5. During the execution of step S3 and step S4, the door of the thawing warehouse is opened, the PLC receives the limit switch action of the door of the thawing warehouse, and the probe rod 16 is lifted and returned to the original position at the upper end.
[0047] First, before operation, the operator determines that the probe rod is in the upper limit position through the HMI human-machine interactive screen. Secondly, operate the button on the screen of the HMI human-machine interactive screen to the automatic control position. After operating the start button of the screen, the device starts the vertical movement of the probe rod downward to the surface of the thawed material and continues to move downward. If the material is not thawed well and the surface resistance is greater than the set value of the torque coupling, the probe rod stops moving downward, the motor reducer idles, and after idling for 5S, the motor is powered off. After 20MIN, the motor automatically starts and repeats the above movement until the probe rod runs to 300MM from the bottom of the car and stops the above control. The screen on the HMI human-machine interactive screen prompts that the thawing is completed, and the probe rod automatically returns to the upper end position. During this period, if there is a device failure, the screen will display a fault prompt, and the operator will notify the maintenance personnel to handle it. During this operation, the temperature sensor detects and feedbacks the internal temperature of the material in real time on the operation screen. At the same time, if the door of the thawing warehouse is opened, the probe rod interlocking protection starts to automatically return to the original position and the upper limit position of the probe rod to prevent the car body from moving and damaging the device. After the detection work is completed, the operator operates the screen conversion button to the manual position and disconnects the power button.
[0048] The utility model provides a temperature sensor at the lower end of the probe rod, an analog input module is connected to the temperature sensor, a slave station PLC is connected to the master station PLC through a communication module, an HMI human-machine interaction screen is connected to the master station PLC, an operator can check the detection data of the temperature sensor at any time through the HMI human-machine interaction screen in the operation room, and does not need to enter the thawing warehouse to measure the thawing effect, the structure is simple, the operation is convenient, and it is easy to implement; the car skin material thawing effect detection device adopts a motor-reducer-torque coupling-gear-rack transmission, has low requirements on the working environment, is easy to disassemble and repair, and has low production cost; the support wheel is installed on the second bracket The support wheel rolls with the rise and fall of the probe rod to ensure that the probe rod will not deviate when moving to the set position; the digital output module is connected to the coil of the motor contactor through the port, and the operator can operate the motor start and stop through the buttons on the HMI human-machine interaction screen, and check the equipment operation and start and stop status at any time. The operation is convenient and the query is convenient; a probe is set on the outside of the temperature sensor to prevent the temperature sensor from directly contacting the frozen layer of the frozen material during movement. The probe is threadedly connected to the probe rod, which is convenient for maintenance personnel to disassemble; the gear is connected to the bearing seat, and the bearing seat is used when the gear is fixed. The structure is simple, safe and stable.
Claims
1. A device for detecting the thawing effect of car skin materials, characterized in that: It includes a motor, a reducer, a torque coupling, a probe rod, a rack, a gear, a support wheel, a mounting plate, a limit switch, and a control unit. The reducer and the gear are connected through the torque coupling, the gear is connected to the bearing seat, the motor is connected to the reducer, and the motor, the reducer, the torque coupling, the gear, and the bearing seat are on the same axis; The probe rod is fixedly connected to the rack, the rack is meshed with the gear, the support wheel is installed on the bracket 2, the support wheel rolls with the rise and fall of the probe rod, a temperature sensor is arranged at the lower end of the probe rod, the reducer, the motor and the bracket 2 are arranged on the mounting plate, and the mounting plate is perpendicular to the bracket 2; the mounting plate is arranged on the roof of the thawing warehouse, and the probe rod passes through the mounting plate and the roof of the thawing warehouse and extends to the bottom of the thawing warehouse; The motor, temperature sensor and limit switch are connected to the control unit.
2. A vehicle skin material thawing effect detection device according to claim 1, characterized in that: The temperature sensor is provided with a probe outside, the probe is threadedly connected to the probe rod, and the probe is made of stainless steel.
3. A vehicle skin material thawing effect detection device according to claim 1, characterized in that: The limit switch includes proximity switch 1 to proximity switch 3. Bracket 1 and bracket 3 are also arranged on the mounting plate. Bracket 1 is fixedly connected to bracket 2, and bracket 1 and bracket 2 are parallel to each other. Bracket 1 is sequentially arranged with proximity switch 1 and proximity switch 2 from top to bottom. Bracket 3 is arranged on one side of the gear, and proximity switch 3 is arranged on bracket 3.
4. A vehicle skin material thawing effect detection device according to claim 1, characterized in that: The number of the supporting wheels is not less than two, and the gears are convex and concave gears.
5. A vehicle skin material thawing effect detection device according to claim 1, characterized in that: The control unit includes a digital input module, a digital output module, an analog input module, and a main circuit. The main circuit includes an overheating relay, a contactor, and a circuit breaker connected to the motor in sequence. The digital input module is connected to the limit switch, the normally open auxiliary contact of the overheating relay, and the normally open auxiliary contact of the contactor through a port. The digital output module is connected to the coil of the contactor through a port. The contactor includes a forward contactor and a reverse contactor connected in parallel. The analog input module is connected to the temperature sensor through a port.
6. A vehicle skin material thawing effect detection device according to claim 5, characterized in that: The control unit also includes a communication module, and the communication module, the digital quantity input module, the digital quantity output module, and the analog quantity input module are connected through ports.
7. A vehicle skin material thawing effect detection device according to claim 5, characterized in that: The control unit adopts a slave PLC.
8. A vehicle skin material thawing effect detection device according to claim 3, characterized in that: The proximity switch 1 is used to detect the upper limit position of the probe rod, the proximity switch 2 is used to detect the lower limit position of the probe rod, and the proximity switch 3 is used to detect the number of rotating teeth of the gear.