Crane electrical control system capable of balancing redundancy self-adaptive switching control

Abstract

The utility model discloses a crane electrical control system capable of balancing redundancy self-adaptive switching control, which relates to the technical field of automation control and comprises a control module, a main lifting redundancy module and a cart redundancy module. The main lifting redundancy module is provided with a main lifting unit and a standby lifting unit which are respectively used for controlling a main lifting mechanism of the crane and can send a signal to the control module when a fault occurs; the switching unit switches the main unit and the standby unit according to instructions of the control module and is connected between a power supply and wire inlet ends of the main unit and the standby unit. The wire outlet ends of the lifting main / standby units are connected with a driving circuit and a brake of the main lifting mechanism; the cart redundancy module comprises a cart main unit, a cart standby unit and a switching unit and is used for controlling a cart running mechanism and carrying out fault switching, and the leading-out ends of the cart main unit and the cart standby unit are connected with a driving circuit and a brake of the cart running mechanism; according to the utility model, single-point faults can be eliminated, real high availability is realized, and'zero 'intermittent uninterrupted production is realized.

Description

Technical Field

[0001] This utility model relates to the field of automation control technology in the iron and steel metallurgy industry, and in particular to a crane electrical control system with balanced redundancy adaptive switching control. Background Technology

[0002] In the current steel and metallurgical industry, to ensure production continuity, a redundant configuration of "one for use, one for backup" is commonly adopted for the drive control systems of critical equipment (such as cranes). However, this redundancy configuration usually has limitations, specifically: only the core voltage and speed regulating devices of the system (such as frequency converters, soft starters, etc.) are backed up, forming "device-level redundancy." That is, two sets of core drive devices are configured on-site, one operating as the primary system and the other as a backup system. When the primary core device fails, the control system switches to the backup core device to maintain equipment operation.

[0003] While the aforementioned "core device redundancy" scheme improves reliability to some extent, it suffers from a fundamental flaw: incomplete redundancy, amounting to "partial redundancy" or "pseudo-system redundancy." This scheme can only address failures of the core device itself, excluding numerous critical peripheral electrical devices (such as motor protectors, circuit breakers, contactors, braking units, and signal detection elements) connecting the core device to the actuator (e.g., the motor) from the redundancy system. These peripheral devices are also prone to failure, and the lack of peripheral device redundancy presents the following problems in actual production:

[0004] 1. The system reliability has a weak link effect: The reliability of the entire drive system is not determined by the most robust core redundant part, but by the weakest non-redundant link. Once any non-redundant peripheral device (such as a motor protector) fails, the entire system chain will be interrupted, causing the production mechanism it serves (such as a steel conveyor car or a sector drive) to stop.

[0005] 2. Long recovery time and huge economic losses: When a non-redundant electrical component (such as a motor protector) fails, the repair process is cumbersome. Repair personnel need to board the machine to inspect and diagnose the motor protector fault, then search for a spare part in the warehouse (assuming the warehouse has a spare), and then board the machine again to replace the motor protector. This entire process takes at least ten minutes. During this repair time, production is forcibly interrupted. For continuous casting and other continuous operations, even a few minutes of interruption can cause serious production accidents such as "casting interruption" or molten steel solidifying in the tundish or crystallizer, leading to equipment damage and economic losses ranging from tens of thousands to hundreds of thousands of yuan. If there are no spare parts in the warehouse, the downtime will extend to several days, resulting in even more severe losses.

[0006] 3. Severe impact on production efficiency and planning: Frequent unplanned downtime severely disrupts the production rhythm, reduces overall equipment efficiency (OEE), affects the timely delivery of orders, and has a continuous negative impact on the company's overall operating efficiency.

[0007] Therefore, the existing equipment redundancy cannot achieve true "uninterrupted production," and its reliability assurance has obvious shortcomings. Utility Model Content

[0008] This invention provides a crane electrical control system with balanced redundancy adaptive switching control to overcome the technical problems of low overall reliability, frequent unplanned shutdowns, and large economic losses due to production interruptions in existing redundant equipment systems.

[0009] To achieve the above objectives, the technical solution of this utility model is as follows:

[0010] A crane electrical control system with balanced redundancy adaptive switching control includes: a control module, a main hoisting redundancy module, and a trolley redundancy module;

[0011] Both the main hoisting redundancy module and the trolley redundancy module are electrically connected to the control module and are used to send hoisting fault signals and trolley fault signals to the control module, respectively, and to receive hoisting switching signals and trolley switching signals returned by the control module, thereby realizing the redundancy switching of the crane's electrical control system.

[0012] The main hoisting redundancy module includes a main hoisting unit, a standby hoisting unit, and a hoisting switching unit;

[0013] The main hoisting / standby unit is used to control the main hoisting mechanism of the crane and sends a fault signal to the control module when a fault occurs. The hoisting switching unit is used to receive the hoisting redundancy switching signal sent by the control module and to switch between the main hoisting unit and the standby hoisting unit.

[0014] Among them, the main hoisting unit and the standby hoisting unit are two independent electrical drive units with the same structure, each including: a first power circuit breaker, a first voltage regulating and speed regulating device, a first / second motor circuit breaker, a first / second motor protector, a first brake circuit breaker, a first / second brake contactor, and a first to a sixth rotor contactor.

[0015] The hoisting switching unit is connected between the power supply and the input terminals of the main hoisting unit and the standby hoisting unit; the output terminals of the main hoisting unit and the standby hoisting unit are both connected to the drive circuit and brake of the main hoisting mechanism.

[0016] The trolley redundancy module includes a trolley primary unit, a trolley backup unit, and a trolley switching unit.

[0017] The main / standby trolley unit is used to control the trolley traveling mechanism of the crane. In the event of a fault, it sends a fault signal to the control module. The trolley switching unit is used to receive the trolley redundancy switching signal sent by the control module and to switch between the main trolley unit and the standby trolley unit.

[0018] Among them, the main unit and the backup unit of the trolley are two independent electrical drive units with the same structure, both including: a second power circuit breaker, a second voltage regulating and speed regulating device, third to sixth motor circuit breakers, third to sixth motor protectors, a second brake circuit breaker and a third / fourth brake contactor.

[0019] The trolley switching unit is connected between the power supply and the input terminals of the trolley main unit and the trolley backup unit; the output terminals of the trolley main unit and the trolley backup unit are both connected to the drive circuit and brake of the trolley running mechanism.

[0020] Furthermore, the output terminal of the first power circuit breaker is connected to the input terminal of the first voltage regulating and speed regulating device, and the output terminal of the first voltage regulating and speed regulating device is connected to the input terminals of the first / second motor circuit breakers respectively; the first / second motor circuit breakers are connected to the first / second motor protectors respectively; the output terminals of the first / second motor protectors are connected to the first / second motors of the main hoisting mechanism respectively; one end of the first to sixth rotor contactors is connected to a common terminal; and the first brake circuit breaker is connected in series with the first / second brake contactors.

[0021] Furthermore, the drive circuit of the main hoisting mechanism includes a first motor drive branch and a second motor drive branch;

[0022] The first motor drive branch includes a first motor and a first resistor group connected in series in each winding circuit of the first motor in phases U, V, and W; the second motor drive branch includes a second motor and a second resistor group connected in series in each winding circuit of the second motor in phases U, V, and W; in the first resistor group and the second resistor group, the ends of the resistors connected in series in each phase winding are connected to each other to form a common connection point.

[0023] The first resistor group includes a first to a fourth resistor connected in series, and the second resistor group includes a fifth to a eighth resistor connected in series.

[0024] Furthermore, the hoisting main switching circuit and the hoisting backup switching circuit have the same structure, both including: a disconnect switch, a first / second motor switching contactor, a first to sixth rotor switching contactor, and a first brake switching contactor;

[0025] The incoming terminal of the disconnecting switch is connected to the power supply, and the outgoing terminals are connected to the incoming terminals of the first power circuit breaker and the first brake circuit breaker, respectively. The incoming terminals of the first / second motor switching contactor are connected to the outgoing terminals of the first / second motor protectors, respectively, and the outgoing terminals are connected to the first / second motors, respectively. One end of the first to sixth rotor switching contactors is connected to the other end of the first to sixth rotor switching contactors, respectively. The other end of the first rotor switching contactor is connected to the outgoing terminals of the first resistors of phases U, V, and W, respectively. The other end of the second rotor switching contactor is connected to the outgoing terminals of the fifth resistors of phases U, V, and W, respectively. The other end of the third rotor switching contactor is connected to the output terminal of the second resistor of phases U, V, and W; the other end of the fourth rotor switching contactor is connected to the output terminal of the sixth resistor of phases U, V, and W; the other end of the fifth rotor switching contactor is connected to the output terminal of the third resistor of phases U, V, and W; and the other end of the sixth rotor switching contactor is connected to the output terminal of the seventh resistor of phases U, V, and W. The input terminal of the first brake switching contactor is connected to the output terminal of the second brake contactor, and the output terminal is connected to the brake.

[0026] Furthermore, the disconnecting switch controls the closing state of the first / second motor switching contactor, the first to sixth rotor switching contactors, and the first brake switching contactor through auxiliary contacts.

[0027] Furthermore, the output terminal of the second power circuit breaker is connected to the input terminal of the second voltage regulating and speed regulating device, the output terminal of the second voltage regulating and speed regulating device is connected to the input terminals of the third to sixth motor circuit breakers, and the output terminals of the third to sixth motor circuit breakers are respectively connected to the input terminals of the third to sixth motor protectors; the second brake circuit breaker is connected in series with the third brake contactor and the fourth brake contactor.

[0028] Furthermore, the drive circuit of the trolley running mechanism includes the third to sixth motor drive branches with the same structure;

[0029] The third to sixth motor drive circuits include a drive motor and resistors. The U, V, and W phases of the drive motor output terminals are connected in series with a resistor, and the other ends of the resistors of each phase are connected to each other to form a common connection point.

[0030] Furthermore, the main switching circuit and the backup switching circuit of the large vehicle have the same structure, both including: power supply switching contactor, third to sixth motor switching contactor and second brake switching contactor.

[0031] The power supply switching contactor's input terminal is connected to the power supply, and its output terminal is connected to the input terminals of the second power circuit breaker and the second brake circuit breaker, respectively; one end of the third to sixth motor switching contactor is connected to the output terminal of the third to sixth motor protector, and the other end is connected to the input terminal of the third to sixth motor, respectively; the input terminal of the second brake switching contactor is connected to the output terminal of the fourth brake contactor, and its output terminal is connected to the brake.

[0032] Furthermore, the power supply switching contactor controls the closing state of the third to sixth motor switching contactors and the second brake switching contactor through auxiliary contacts.

[0033] Beneficial effects: This utility model provides a crane electrical control system with balanced redundancy adaptive switching control. Compared with the existing "equipment redundancy", this utility model has the following significant advantages:

[0034] 1. Eliminate single points of failure and achieve true high availability: This utility model does not back up a single device, but constructs two completely independent and fully functional drive units; when any component in the primary unit fails, it can quickly switch to the backup unit to start operation, thus significantly improving reliability.

[0035] 2. Achieving uninterrupted production with zero downtime: This invention features a redundant design for the drive unit. In the event of a fault, the fault switching process is completed instantaneously, ensuring that the production process is completely uninterrupted. This completely avoids major accidents such as "casting interruptions" caused by maintenance waiting time, directly preventing huge economic losses.

[0036] 3. Transforming "unplanned downtime" into "planned maintenance": Once the standby unit is operational, the faulty primary unit can be repaired offline at a leisurely pace. Maintenance personnel no longer need to perform emergency repairs under intense production pressure, allowing ample time for fault diagnosis and component replacement, significantly improving maintenance quality and safety. This transforms unplanned downtime into predictable, planned maintenance, greatly enhancing the scientific nature and stability of production management.

[0037] 4. Improve overall operational efficiency: By minimizing production interruptions, the company ensured on-time delivery of capacity and orders, improved overall equipment efficiency (OEE), and brought continuous and considerable economic benefits to the company, significantly enhancing its core competitiveness. Attached Figure Description

[0038] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0039] Figure 1 This is a system block diagram of a crane electrical control system with balanced redundancy adaptive switching control according to the present invention;

[0040] Figure 2 This is a single-line circuit diagram of the main lifting redundancy module of this utility model;

[0041] Figure 3 Wiring diagram for motor protector;

[0042] Figure 4 This is a single-line circuit diagram of the redundancy module for large vehicles of this utility model. Detailed Implementation

[0043] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0044] This embodiment provides a crane electrical control system with balanced redundancy adaptive switching control, such as... Figure 1 As shown, it includes: a control module, a main hoisting redundancy module, and a trolley redundancy module;

[0045] Both the main hoisting redundancy module and the trolley redundancy module are electrically connected to the control module and are used to send hoisting fault signals and trolley fault signals to the control module, respectively, and to receive hoisting switching signals and trolley switching signals returned by the control module, thereby realizing the redundancy switching of the crane's electrical control system.

[0046] The main hoisting redundancy module includes a main hoisting unit, a standby hoisting unit, and a hoisting switching unit;

[0047] The main hoisting / standby unit is used to control the main hoisting mechanism of the crane and sends a fault signal to the control module when a fault occurs. The hoisting switching unit is used to receive the hoisting redundancy switching signal sent by the control module and to switch between the main hoisting unit and the standby hoisting unit.

[0048] Among them, the main hoisting unit and the standby hoisting unit are two independent electrical drive units with the same structure, each including: a first power circuit breaker, a first voltage regulating and speed regulating device, a first / second motor circuit breaker, a first / second motor protector, a first brake circuit breaker, a first / second brake contactor, and a first to a sixth rotor contactor.

[0049] The hoisting switching unit is connected between the power supply and the input terminals of the main hoisting unit and the standby hoisting unit; the output terminals of the main hoisting unit and the standby hoisting unit are both connected to the drive circuit and brake of the main hoisting mechanism.

[0050] The trolley redundancy module includes a trolley primary unit, a trolley backup unit, and a trolley switching unit.

[0051] The main / standby trolley unit is used to control the trolley traveling mechanism of the crane. In the event of a fault, it sends a fault signal to the control module. The trolley switching unit is used to receive the trolley redundancy switching signal sent by the control module and to switch between the main trolley unit and the standby trolley unit.

[0052] Among them, the main unit and the backup unit of the trolley are two independent electrical drive units with the same structure, both including: a second power circuit breaker, a second voltage regulating and speed regulating device, third to sixth motor circuit breakers, third to sixth motor protectors, a second brake circuit breaker and a third / fourth brake contactor.

[0053] The trolley switching unit is connected between the power supply and the input terminals of the trolley main unit and the trolley backup unit; the output terminals of the trolley main unit and the trolley backup unit are both connected to the drive circuit and brake of the trolley running mechanism.

[0054] Specifically, the control module is a commonly used PLC system, which controls the switching units in the main hoisting redundancy module and the trolley redundancy module respectively;

[0055] For the main hoisting redundancy module, the PLC system is first manually controlled to send a hoisting switching signal to the hoisting switching unit, which then closes the corresponding switching circuit of the main hoisting unit. The main hoisting unit controls the main hoisting mechanism of the crane. When the main hoisting unit malfunctions, it sends a fault signal to the PLC system. Upon receiving the fault signal, the PLC system is manually controlled to send a hoisting switching signal to the hoisting switching unit. The hoisting switching unit then disconnects the corresponding switching circuit of the main hoisting unit and closes the corresponding switching circuit of the standby hoisting unit. The standby hoisting unit controls the main hoisting mechanism of the crane.

[0056] For the redundant trolley module, switching is performed through the PLC system. When the driver selects the manual switching knob on the control panel and selects the trolley main unit, the PLC system sends a trolley switching signal to the trolley switching unit. The trolley switching unit controls the corresponding switching circuit of the trolley main unit to close. At this time, the trolley main unit controls the crane's trolley traveling mechanism. When the driver selects the manual switching knob on the control panel and selects the trolley standby unit, the PLC system sends a trolley switching signal to the trolley switching unit. The trolley switching unit controls the corresponding switching circuit of the trolley main unit to open and the corresponding switching circuit of the trolley standby unit to close. At this time, the trolley standby unit controls the crane's trolley traveling mechanism.

[0057] When the operator selects the automatic switching knob on the control panel, the main trolley unit is initially selected by default. If any electrical component in the main trolley unit fails, causing the trolley mechanism to malfunction, the main trolley unit sends a fault signal to the PLC. At this point, the operator returns the trolley handle to zero, and the trolley switching unit automatically controls the operation. The corresponding switching circuit of the main trolley unit disconnects, and the corresponding switching circuit of the trolley backup unit closes, allowing subsequent operations to proceed through the backup unit. If any electrical component in the backup unit fails within ten minutes of automatic switching, the system will not automatically switch back to the main trolley unit. For safety and contactor lifespan considerations, if the backup system fails within ten minutes of automatic switching to the backup unit, a ten-minute wait is required before automatically switching back to the main trolley unit. If the main trolley unit also fails at this time, the system will not switch back to the backup unit until the crane is powered on again and the trolley mechanism enters the initialization state, at which point it will switch back to the main trolley unit.

[0058] In a specific embodiment, such as Figure 2 As shown, the main hoisting unit and the standby hoisting unit have the same structure, both including: a first power circuit breaker, a first voltage regulating and speed regulating device, a first / second motor circuit breaker, a first / second motor protector, a first brake circuit breaker, a first / second brake contactor, and first to sixth rotor contactors;

[0059] The output terminal of the first power circuit breaker is connected to the input terminal of the first voltage regulating and speed regulating device, and the output terminal of the first voltage regulating and speed regulating device is connected to the input terminals of the first / second motor circuit breaker respectively; the first / second motor circuit breaker is connected to the first / second motor protector respectively; the output terminals of the first / second motor protector are connected to the first / second motor of the main hoisting mechanism respectively; one end of the first to sixth rotor contactors is connected to a common terminal; the first brake circuit breaker is connected in series with the first / second brake contactor.

[0060] Specifically, to distinguish between the main hoisting unit and the standby hoisting unit, the main hoisting unit and the standby hoisting unit use different names to label the components in the circuit, such as... Figure 2 As shown:

[0061] The hoisting main unit includes: a main first power circuit breaker 1Q1A, a main first voltage regulating and speed regulating device 1U1A, a main first / second motor circuit breaker 1Q11A / 1Q12A, a main first / second motor protector 1F1A / 1F2A, a main first brake circuit breaker 1Q7A, a main first / second brake contactor 1KM71A / 1KM72A; and main first to sixth rotor contactors 1KM421A / 1KM422A / 1KM411A / 1KM412A / 1KM401A / 1KM402A.

[0062] The hoisting backup unit includes: a backup first power circuit breaker 1Q1B, a backup first voltage regulating and speed regulating device 1U1B, a backup first / second motor circuit breaker 1Q11B / 1Q12B, a backup first / second motor protector 1F1B / 1F2B, a backup first brake circuit breaker 1Q7B, a backup first / second brake contactor 1KM71B / 1KM72B, and backup first to sixth rotor contactors 1KM421B / 1KM422B / 1KM411B / 1KM412B / 1KM401B / 1KM402B;

[0063] Figure 2 The circuit diagram shows that each device has three phases: U, V, and W. The devices are connected by three lines. To simplify the circuit, it is simplified to a single line connection in the diagram, which is represented by three diagonal lines drawn on the line.

[0064] Figure 3 The diagram below shows the wiring of the motor protector. Taking 1F1A as an example, the U-phase / V-phase / W-phase outgoing cables pass through current transformers CT1 / CT2 / CT3 respectively. The secondary side outgoing cables of each current transformer are connected to the corresponding terminals of the motor protector. In this solution, the model of the motor protector is MMP31SS. This model of motor protector is connected to the motor circuit breaker through an external current transformer, which is common knowledge to those skilled in the art. Therefore, the specific connection relationship will not be described in detail.

[0065] In a specific embodiment, such as Figure 2 As shown, the drive circuit of the main hoisting mechanism includes a first motor drive branch and a second motor drive branch.

[0066] The first motor drive branch includes a first motor and a first resistor group connected in series in each winding circuit of the first motor in phases U, V, and W; the second motor drive branch includes a second motor and a second resistor group connected in series in each winding circuit of the second motor in phases U, V, and W; in the first resistor group and the second resistor group, the ends of the resistors connected in series in each phase winding are connected to each other to form a common connection point.

[0067] The first resistor group includes a first to a fourth resistor connected in series, and the second resistor group includes a fifth to a eighth resistor connected in series.

[0068] Specifically, to simplify the circuit, Figure 2 Only one set of resistors is connected to the motor. In the actual circuit, the U, V, and W phases of the first motor (motor #1) and the second motor (motor #2) are each connected to a set of resistors. The first to fourth resistors are 1R41, 1R31, 1R21, and 1R11, respectively, and the fifth to eighth resistors are 1R42, 1R32, 1R22, and 1R12, respectively.

[0069] In a specific embodiment, such as Figure 2 As shown, the hoisting main switching circuit and the hoisting standby switching circuit have the same structure, both including: a disconnect switch, a first / second motor switching contactor, a first to sixth rotor switching contactor, and a first brake switching contactor;

[0070] The incoming terminal of the disconnecting switch is connected to the power supply, and the outgoing terminals are connected to the incoming terminals of the first power circuit breaker and the first brake circuit breaker, respectively. The incoming terminals of the first / second motor switching contactor are connected to the outgoing terminals of the first / second motor protectors, respectively, and the outgoing terminals are connected to the first / second motors, respectively. One end of the first to sixth rotor switching contactors is connected to the other end of the first to sixth rotor switching contactors, respectively. The other end of the first rotor switching contactor is connected to the outgoing terminals of the first resistors of phases U, V, and W, respectively. The other end of the second rotor switching contactor is connected to the outgoing terminals of the fifth resistors of phases U, V, and W, respectively. The other end of the third rotor switching contactor is connected to the output terminal of the second resistor of phases U, V, and W; the other end of the fourth rotor switching contactor is connected to the output terminal of the sixth resistor of phases U, V, and W; the other end of the fifth rotor switching contactor is connected to the output terminal of the third resistor of phases U, V, and W; and the other end of the sixth rotor switching contactor is connected to the output terminal of the seventh resistor of phases U, V, and W. The input terminal of the first brake switching contactor is connected to the output terminal of the second brake contactor, and the output terminal is connected to the brake.

[0071] Specifically, to distinguish between the main hoisting switching circuit and the standby hoisting switching circuit, different names are used to label the components in each circuit, such as... Figure 2 As shown:

[0072] The hoisting main switching circuit includes: main disconnect switch 1Q1C, main first / second motor switching contactor 1KM11C / 1KM12C, main first to sixth rotor switching contactor 1KM412C / 1KM422C / 1KM411C / 1KM421C / 1KM410C / 1KM420C, and main first brake switching contactor 1KM71C;

[0073] The hoisting backup switching circuit includes: backup isolating switch 1Q2C, backup first / second motor switching contactor 1KM21C / 1KM22C; backup first to sixth rotor switching contactors 1KM512C / 1KM522C / 1KM511C / 1KM521C / 1KM510C / 1KM520C, and backup first brake switching contactor 1KM72C;

[0074] Among them, the main / standby disconnecting switches 1Q1C / 1Q2C control the opening and closing of other devices in the switching circuit through auxiliary contacts, which is a conventional technical means in this field, and therefore will not be described in detail.

[0075] In the driving circuit, the resistors are connected in series. Therefore, the output terminal of the first resistor is the end where the first resistor is connected to the second resistor, the output terminal of the second resistor is the end where the second resistor is connected to the third resistor, the output terminal of the third resistor is the end where the third resistor is connected to the fourth resistor, the output terminal of the fifth resistor is the end where the fifth resistor is connected to the sixth resistor, the output terminal of the sixth resistor is the end where the sixth resistor is connected to the seventh resistor, and the output terminal of the seventh resistor is the end where the seventh resistor is connected to the eighth resistor.

[0076] In this scheme, four brakes are provided. The main / standby first brake switching contactors 1KM71C / 1KM72C are connected to the four brakes, and the main / standby disconnect switches are connected to the 380V power supply.

[0077] This solution's main hoisting redundancy module enables manual and rapid switching between the main and backup hoisting units. If any electrical component in the main hoisting unit fails, disconnect switches 1Q1C and 1Q2C can be manually switched to achieve the transition between the two units. The specific usage process of the main hoisting redundancy module is as follows:

[0078] During normal operation, 1Q1A, 1Q11A, 1Q12A, and 1Q7A in the main hoisting unit are in the closed state, and 1Q1B, 1Q11B, 1Q12B, and 1Q7B in the standby hoisting unit are also in the closed state.

[0079] Selection of main hoisting unit: Manually operate the main isolating switch 1Q1C to close and the standby isolating switch 1Q2C to open. Control the switching circuit via the auxiliary contact of 1Q1C to engage 1KM11C, 1KM12C, 1KM412C, 1KM422C, 1KM411C, 1KM421C, 1KM410C, 1KM420C, and 1KM71C, while disengaging 1KM21C, 1KM22C, 1KM512C, 1KM522C, 1KM511C, 1KM521C, 1KM510C, 1KM520C, and 1KM72C. At this time, the main hoisting unit is selected to work.

[0080] Selection of hoisting standby unit: Manually operate the standby isolating switch 1Q2C to close and the main isolating switch 1Q1C to open. Control the switching circuit through the auxiliary contact of 1Q2C to engage 1KM21C, 1KM22C, 1KM512C, 1KM522C, 1KM511C, 1KM521C, 1KM510C, 1KM520C, and 1KM72C, while 1KM11C, 1KM12C, 1KM412C, 1KM422C, 1KM411C, 1KM421C, 1KM410C, 1KM420C, and 1KM71C are disengaged. At this time, the hoisting standby unit is selected to work.

[0081] In a specific embodiment, such as Figure 4 As shown, the main unit and the backup unit of the trolley have the same structure, both including: a second power circuit breaker, a second voltage regulating and speed regulating device, third to sixth motor circuit breakers, third to sixth motor protectors, a second brake circuit breaker and a third / fourth brake contactor;

[0082] The output terminal of the second power circuit breaker is connected to the input terminal of the second voltage regulating and speed regulating device, the output terminal of the second voltage regulating and speed regulating device is connected to the input terminals of the third to sixth motor circuit breakers, and the output terminals of the third to sixth motor circuit breakers are respectively connected to the input terminals of the third to sixth motor protectors; the second brake circuit breaker is connected in series with the third brake contactor and the fourth brake contactor.

[0083] Specifically, to distinguish between the main unit and the backup unit for the trolley, the main unit and the backup unit use different names to label the components in the circuit, such as... Figure 4 As shown:

[0084] The main unit for the trolley includes: main second power circuit breaker 4Q1A, main second voltage regulating and speed regulating device 4U1A, main third to sixth motor circuit breakers 4Q11A / 4Q12A / 4Q13A / 4Q14A, main third to sixth motor protectors 4F1A / 4F2A / 4F3A / 4F4A, main second brake circuit breaker 4Q7A, and main third / fourth brake contactors 4KM71A / 4KM72A;

[0085] The main trolley backup unit includes: backup second power circuit breaker 4Q1B, backup second voltage regulating and speed regulating device 4U1B, backup third to sixth motor circuit breakers 4Q11B / 4Q12B / 4Q13B / 4Q14B, backup third to sixth motor protectors 4F1B / 4F2B / 4F3B / 4F4B, backup second brake circuit breaker 4Q7B, and backup third / fourth brake contactors 4KM71B / 4KM72B;

[0086] Similar to the main lifting redundancy module, Figure 4 This is a single-line circuit diagram of the redundant module for the large vehicle. Each device includes three phases: U, V, and W, and the devices are connected to each other through three lines.

[0087] In a specific embodiment, the drive circuit of the trolley running mechanism includes the third to sixth motor drive branches with the same structure;

[0088] The third to sixth motor drive circuits include a drive motor and resistors. The U, V, and W phases of the drive motor output terminals are connected in series with a resistor, and the other ends of the resistors of each phase are connected to each other to form a common connection point.

[0089] Specifically, to simplify the circuit, Figure 4 Only one resistor is connected to the motor. In the actual circuit, the U, V, and W phases of the third motor (motor #3), fourth motor (motor #4), fifth motor (motor #5), and sixth motor (motor #6) are each connected to a resistor. The third motor is connected in series with the ninth resistor 4R1, the fourth motor is connected in series with the tenth resistor 4R2, the fifth motor is connected in series with the eleventh resistor 4R3, and the sixth motor is connected in series with the twelfth resistor 4R4. The other ends of each resistor are connected to each other to form a common connection point.

[0090] In a specific embodiment, such as Figure 4 As shown, the main switching circuit and the backup switching circuit of the large vehicle have the same structure, both including: power supply switching contactor, third to sixth motor switching contactor and second brake switching contactor;

[0091] The power supply switching contactor's input terminal is connected to the power supply, and its output terminal is connected to the input terminals of the second power circuit breaker and the second brake circuit breaker, respectively; one end of the third to sixth motor switching contactor is connected to the output terminal of the third to sixth motor protector, and the other end is connected to the input terminal of the third to sixth motor, respectively; the input terminal of the second brake switching contactor is connected to the output terminal of the fourth brake contactor, and its output terminal is connected to the brake.

[0092] Specifically, to distinguish between the main switching circuit and the standby switching circuit for heavy vehicles, different names are used to label the components in each circuit, such as... Figure 4 As shown:

[0093] The main switching circuit for the large vehicle includes: main power supply switching contactor 4KM01C, main third to sixth motor switching contactors 4KM11C / 4KM12C / 4KM13C / 4KM14C; and main second brake switching contactor 4KM71C.

[0094] The backup switching circuit for the main vehicle includes: backup power supply switching contactor 4KM02C; backup third to sixth motor switching contactors 4KM21C / 4KM22C / 4KM23C / 4KM24C; and backup second brake switching contactor 4KM72C.

[0095] The main / standby power supply switching contactor controls the opening and closing of other devices in the switching circuit through auxiliary contacts, which is a conventional technical means in this field and therefore will not be described in detail.

[0096] In this scheme, four brakes are provided. The main / standby second brake switching contactors 4KM71C / 4KM72C are connected to the four brakes, and the power supply switching contactor is connected to the 380V power supply.

[0097] In this solution, the trolley redundancy module can achieve manual or automatic switching between the main / standby units of the trolley. The specific usage process is as follows:

[0098] Manual switching of the main trolley unit: When the driver selects the manual switching knob on the control panel and selects the main trolley unit, 4KM01C / 4KM11C / 4KM12C / 4KM13C / 4KM14C / 4KM71C will be engaged, and 4KM02C / 4KM21C / 4KM22C / 4KM23C / 4KM24C / 4KM72C will be disengaged. At this time, the main trolley unit is selected to work. When the driver operates the trolley handle, the trolley motor can be controlled through the main trolley unit.

[0099] Manual switching of the trolley backup unit: When the driver selects the manual switching knob on the control panel and selects the trolley backup unit, 4KM02C / 4KM21C / 4KM22C / 4KM23C / 4KM24C / 4KM72C will be engaged, and 4KM01C / 4KM11C / 4KM12C / 4KM13C / 4KM14C / 4KM71C will be disengaged. At this time, the trolley mechanism selects the trolley backup unit to work. When the driver operates the trolley handle, the trolley motor can be controlled through the trolley backup unit.

[0100] Automatic switching mode: When the driver selects the automatic switching knob on the control panel, the system initially selects the main unit of the trolley to work. At this time, 4KM01C / 4KM11C / 4KM12C / 4KM13C / 4KM14C / 4KM71C are engaged, and 4KM02C / 4KM21C / 4KM22C / 4KM23C / 4KM24C / 4KM72C are disengaged. When the driver operates the trolley handle, the trolley motor can be controlled through the main unit of the trolley.

[0101] When any electrical component in the main unit of the trolley malfunctions, causing the trolley mechanism to malfunction, the driver returns the trolley handle to zero. At this time, the system automatically controls the operation of each switching contactor: 4KM02C / 4KM21C / 4KM22C / 4KM23C / 4KM24C / 4KM72C engage, and 4KM01C / 4KM11C / 4KM12C / 4KM13C / 4KM14C / 4KM71C disengage. At this time, the trolley mechanism automatically selects the trolley backup unit to work. When the driver operates the trolley handle again, the trolley motor can be controlled through the trolley backup unit.

[0102] If any electrical component in the trolley backup unit fails within ten minutes of automatic switching, the system will not automatically switch back to the trolley main unit. For safety and to ensure the lifespan of each switching contactor, if the trolley backup unit fails within ten minutes of automatic switching, a ten-minute wait is required before automatically switching back to the trolley main unit. If the trolley main unit also fails at this time, the system will not switch back to the backup unit until the crane is powered on again and the trolley mechanism enters the initialization state, at which point it will switch back to the trolley main unit.

[0103] The control logic set is common to those skilled in the art, and implementing this control logic through a PLC system is a conventional technique for those skilled in the art; therefore, no specific steps will be described.

[0104] Because the switching contactors 4KM01C / 4KM11C / 4KM12C / 4KM13C / 4KM14C and 4KM02C / 4KM21C / 4KM22C / 4KM23C / 4KM24C are large in size and cannot be directly controlled by PLC output, the PLC output first controls the relay, and then the relay controls the operation of each switching contactor. This is a common technique used by those skilled in the art, so the connection relationship will not be specifically described. Those skilled in the art will know how to use PLC for control.

[0105] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the utility model 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 or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. A crane electrical control system with balanced redundancy adaptive switching control, characterized in that, include: Control module, main hoisting redundancy module and trolley redundancy module; Both the main hoisting redundancy module and the trolley redundancy module are electrically connected to the control module and are used to send hoisting fault signals and trolley fault signals to the control module, respectively, and to receive hoisting switching signals and trolley switching signals returned by the control module, thereby realizing the redundancy switching of the crane's electrical control system. The main hoisting redundancy module includes a main hoisting unit, a standby hoisting unit, and a hoisting switching unit; The main hoisting / standby unit is used to control the main hoisting mechanism of the crane and sends a fault signal to the control module when a fault occurs. The hoisting switching unit is used to receive the hoisting redundancy switching signal sent by the control module and to switch between the main hoisting unit and the standby hoisting unit. Among them, the main hoisting unit and the standby hoisting unit are two independent electrical drive units with the same structure, each including: a first power circuit breaker, a first voltage regulating and speed regulating device, a first / second motor circuit breaker, a first / second motor protector, a first brake circuit breaker, a first / second brake contactor, and a first to a sixth rotor contactor. The hoisting switching unit is connected between the power supply and the input terminals of the main hoisting unit and the standby hoisting unit; the output terminals of the main hoisting unit and the standby hoisting unit are both connected to the drive circuit and brake of the main hoisting mechanism. The trolley redundancy module includes a trolley primary unit, a trolley backup unit, and a trolley switching unit. The main / standby trolley unit is used to control the trolley traveling mechanism of the crane. In the event of a fault, it sends a fault signal to the control module. The trolley switching unit is used to receive the trolley redundancy switching signal sent by the control module and to switch between the main trolley unit and the standby trolley unit. Among them, the main unit and the backup unit of the trolley are two independent electrical drive units with the same structure, both including: a second power circuit breaker, a second voltage regulating and speed regulating device, third to sixth motor circuit breakers, third to sixth motor protectors, a second brake circuit breaker and a third / fourth brake contactor. The trolley switching unit is connected between the power supply and the input terminals of the trolley main unit and the trolley backup unit; the output terminals of the trolley main unit and the trolley backup unit are both connected to the drive circuit and brake of the trolley running mechanism.

2. The crane electrical control system with balanced redundancy adaptive switching control according to claim 1, characterized in that, The output terminal of the first power circuit breaker is connected to the input terminal of the first voltage regulating and speed regulating device, and the output terminal of the first voltage regulating and speed regulating device is connected to the input terminals of the first / second motor circuit breaker respectively; the first / second motor circuit breaker is connected to the first / second motor protector respectively; the output terminals of the first / second motor protector are connected to the first / second motor of the main hoisting mechanism respectively; one end of the first to sixth rotor contactors is connected to a common terminal; the first brake circuit breaker is connected in series with the first / second brake contactor.

3. The crane electrical control system with balanced redundancy adaptive switching control according to claim 2, characterized in that, The drive circuit of the main hoisting mechanism includes a first motor drive branch and a second motor drive branch; The first motor drive branch includes a first motor and a first resistor group connected in series in each winding circuit of the first motor in phases U, V, and W; the second motor drive branch includes a second motor and a second resistor group connected in series in each winding circuit of the second motor in phases U, V, and W; in the first resistor group and the second resistor group, the ends of the resistors connected in series in each phase winding are connected to each other to form a common connection point. The first resistor group includes a first to a fourth resistor connected in series, and the second resistor group includes a fifth to a eighth resistor connected in series.

4. The crane electrical control system with balanced redundancy adaptive switching control according to claim 3, characterized in that, The hoisting main switching circuit and the hoisting backup switching circuit have the same structure, both including: a disconnect switch, a first / second motor switching contactor, a first to sixth rotor switching contactor, and a first brake switching contactor; The incoming terminal of the disconnecting switch is connected to the power supply, and the outgoing terminal is connected to the incoming terminals of the first power circuit breaker and the first brake circuit breaker, respectively; the incoming terminal of the first / second motor switching contactor is connected to the outgoing terminal of the first / second motor protector, and the outgoing terminal is connected to the first / second motor, respectively. One end of each of the first to sixth rotor switching contactors is connected to the other end of the first to sixth rotor switching contactors respectively. The other end of the first rotor switching contactor is connected to the output terminal of the first resistor of phases U, V, and W respectively. The other end of the second rotor switching contactor is connected to the output terminal of the fifth resistor of phases U, V, and W respectively. The other end of the third rotor switching contactor is connected to the output terminal of the second resistor of phases U, V, and W. The other end of the fourth rotor switching contactor is connected to the output terminal of the sixth resistor of phases U, V, and W. The other end of the fifth rotor switching contactor is connected to the output terminal of the third resistor of phases U, V, and W. The other end of the sixth rotor switching contactor is connected to the output terminal of the seventh resistor of phases U, V, and W. The input terminal of the first brake switching contactor is connected to the output terminal of the second brake contactor, and the output terminal is connected to the brake.

5. A crane electrical control system with balanced redundancy adaptive switching control according to claim 4, characterized in that, The disconnecting switch controls the closing state of the first / second motor switching contactor, the first to sixth rotor switching contactors, and the first brake switching contactor through auxiliary contacts.

6. A crane electrical control system with balanced redundancy adaptive switching control according to claim 1, characterized in that, The output terminal of the second power circuit breaker is connected to the input terminal of the second voltage regulating and speed regulating device, the output terminal of the second voltage regulating and speed regulating device is connected to the input terminals of the third to sixth motor circuit breakers, and the output terminals of the third to sixth motor circuit breakers are respectively connected to the input terminals of the third to sixth motor protectors; the second brake circuit breaker is connected in series with the third brake contactor and the fourth brake contactor.

7. A crane electrical control system with balanced redundancy adaptive switching control according to claim 6, characterized in that, The drive circuit of the trolley traveling mechanism includes the third to sixth motor drive branches with the same structure; The third to sixth motor drive circuits include a drive motor and resistors. The U, V, and W phases of the drive motor output terminals are connected in series with a resistor, and the other ends of the resistors of each phase are connected to each other to form a common connection point.

8. A crane electrical control system with balanced redundancy adaptive switching control according to claim 7, characterized in that, The main switching circuit and the backup switching circuit of the large vehicle have the same structure, both including: power supply switching contactor, third to sixth motor switching contactor and second brake switching contactor; The power supply switching contactor's input terminal is connected to the power supply, and its output terminal is connected to the input terminals of the second power circuit breaker and the second brake circuit breaker, respectively; one end of the third to sixth motor switching contactor is connected to the output terminal of the third to sixth motor protector, and the other end is connected to the input terminal of the third to sixth motor, respectively; the input terminal of the second brake switching contactor is connected to the output terminal of the fourth brake contactor, and its output terminal is connected to the brake.

9. A crane electrical control system with balanced redundancy adaptive switching control according to claim 8, characterized in that, The power supply switching contactor controls the closing state of the third to sixth motor switching contactors and the second brake switching contactor through auxiliary contacts.

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