Safety control system for heavy-load conveying line

Abstract

The utility model provides a safety control system for a heavy-load conveying line, which comprises a safety controller SC, a safety element group, an actuating mechanism module and a redundant power supply module, and input signals of safety elements such as a scram button and a safety light curtain are transmitted to the safety controller through two independent loops. Control instructions of double contactors and a frequency converter in the execution mechanism also adopt redundant output loops, and when any loop fails, the system can still maintain the safety function through a standby loop, so that the probability of system failure caused by a single point of failure is greatly reduced; a shielding sensor is further integrated on a safety light curtain R, the shielding sensor distinguishes personnel and materials through logic signals, the shutdown function of the safety light curtain is temporarily shielded when the materials pass through, and safety and production efficiency are effectively balanced; through the cooperative use of the safety controller SC and the safety element group and the design of the circuit, the system reaches the required safety certification level.

Description

TECHNICAL FIELD

[0001] The utility model relates to the safety control technical field, more specifically, relate to a heavy load conveying line safety control system. BACKGROUND

[0002] With the rapid development of industrial automation, heavy load conveying line is increasingly widely used in the fields of automobile manufacturing, heavy logistics, metallurgy, etc. This kind of conveying line usually needs to carry mass, high-speed material transportation, and its operation safety and reliability are directly related to production efficiency, equipment life and personnel safety.

[0003] The closest prior art is a kind of conveying line safety control system, with the authorization announcement number CN204347464U, it discloses including conveying line and the fence located in the conveying line outside, safety door is arranged on the fence, safety door switch for controlling the safety door switch state is arranged on the safety door, fence is provided with door switch control box, the door switch control box is provided with a plurality of control buttons for controlling the working state of conveying line, safety light curtain that crosses the conveying line is arranged on the conveying line, the safety light curtain, control button and safety door switch are connected with conveying controller through safety module, the output end of conveying controller is connected with conveying line and alarm.

[0004] The system relies on physical basic protection, for example, fence, safety door and safety light curtain linkage, but it is difficult to meet the increasing safety certification standards in industry, the safety certification level is insufficient, and it relies on ordinary PLC (programmable logic controller) to process safety signals, the input / output circuit is single path design, once the key components such as safety light curtain and emergency stop button fail, or the program is disturbed, the safety function may be completely invalid, leading to serious accidents, the single point failure risk is high.

[0005] Therefore, the utility model provides a kind of redundancy double circuit, based on safety controller, a kind of heavy load conveying line safety control system. UTILITY MODEL CONTENT

[0006] The utility model relates to the safety control technical field, more specifically, relate to a kind of heavy load conveying line safety control system.

[0007] To achieve the above object, the utility model provides a kind of heavy load conveying line safety control system, it is characterized by including:

[0008] Safety controller SC is configured to receive redundant input signals from a group of safety elements, and control the actuator module through redundant output circuit;

[0009] A safety component group, including an emergency stop button EMS, a safety light curtain R, and a pull cord switch, each of the safety components in the safety component group being connected to the safety controller SC through two independent circuits;

[0010] An actuator module, including a double contactor KM1, a double contactor KM2 connected in series, and a frequency converter INV with a safe torque off STO function;

[0011] The double contactor KM1 and the double contactor KM2 connected in series are respectively driven by two independent output terminals of the safety controller SC;

[0012] The frequency converter INV with the safe torque off STO function has a safety input terminal controlled by two independent output terminals of the safety controller SC;

[0013] A redundant power supply module provides double independent power supply for the safety controller SC and the safety component group.

[0014] In some embodiments, the safety light curtain R is configured as a four-level safety light curtain in a material passing area.

[0015] Further, the safety light curtain R is also integrated with a shielding sensor, which distinguishes between personnel and materials through a logic signal and temporarily shields the shutdown function of the safety light curtain when materials pass.

[0016] In some embodiments, the safety controller SC communicates with a general PLC through an industrial Ethernet or a field bus, forming a hierarchical control architecture, in which the safety controller SC independently processes safety logic and the general PLC is responsible for non-safety logic control.

[0017] In some embodiments, the electrical design of the redundant input circuit and the redundant output circuit meets the safety certification requirements of the PLd or PLe level in ISO13849-1, and the safety controller SC has a built-in fault self-diagnosis function to monitor the integrity of the circuit in real time.

[0018] In some embodiments, the safety component group further includes a limit switch, which is connected to the safety controller SC through a double circuit and forms a linkage logic with the emergency stop button EMS to trigger a multi-level safety response.

[0019] In some embodiments, the double contactors KM1 and KM2 in the actuator module adopt a mechanical interlocking design to ensure that the power output is forcibly cut off when any of the contactors KM1 and KM2 fails.

[0020] In some embodiments, the redundant power supply module includes two independent 24V DC power supplies, each of which is connected to the system in parallel through an isolation diode and automatically switches to a backup power supply when any power supply fails.

[0021] The utility model discloses a heavy load conveying line safety control system, including safety controller SC, safety element group, actuating mechanism module, redundancy power module, through the input signal of emergency stop button, safety light curtain and so on safety element is transmitted to safety controller through two independent loops, the control instruction of double contactor, frequency converter in actuating mechanism also adopts redundancy output loop, when any loop failure, system still can maintain safety function through spare loop, the probability of system failure caused by single point failure is reduced greatly, through the shielding sensor that still has in safety light curtain R, shielding sensor distinguishes personnel and material through logic signal, temporarily shields the shutdown function of safety light curtain when material passes, effectively balances safety and production efficiency, through the cooperation of safety controller SC and safety element group and the design of circuit, make the system reach required safety authentication level. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 It is a heavy load conveying line safety control system's structural schematic diagram of the utility model.

[0023] Figure 2 It is a heavy load conveying line safety control system's working principle step diagram of the utility model.

[0024] Figure 3 It is a heavy load conveying line safety control system's circuit diagram of the utility model.

[0025] Figure 4 It is a heavy load conveying line safety control system's partial amplification circuit diagram of the utility model.

[0026] Figure 5 It is a heavy load conveying line safety control system's partial amplification circuit diagram of the utility model.

[0027] Figure 6 It is a heavy load conveying line safety control system's partial amplification circuit diagram of the utility model.

[0028] Figure 7 It is a heavy load conveying line safety control system's contactor control circuit diagram of the utility model.

[0029] Figure 8 It is a heavy load conveying line safety control system's frequency converter control circuit diagram of the utility model.

[0030] The following specific embodiment will further illustrate the utility model in conjunction with the above-mentioned drawing. Specific embodiment

[0031] The following examples are described to assist in the understanding of the present application, the examples are not and should not be interpreted in any way to limit the protection scope of the present application.

[0032] In the following description, those skilled in the art will understand that they can be described as individual functional units (which can include sub-units), but those skilled in the art will recognize that various components or parts thereof can be divided into individual components, or can be integrated together (including integrated into a single system or component).

[0033] At the same time, the connection between the components or systems is not intended to be limited to direct connection, on the contrary, the data between these components can be modified, reformatted, or otherwise changed by intermediate components. In addition, additional or fewer connections can be used. It should also be noted that the terms "coupled", "connected", or "input" should be understood to include direct connections, indirect connections through one or more intermediate devices, and wireless connections.

[0034] Embodiment 1:

[0035] As shown in Figure 1 , it is a structural schematic diagram of a heavy load conveying line safety control system.

[0036] A heavy load conveying line safety control system, characterized in that it comprises:

[0037] A safety controller SC configured to receive redundant input signals from a safety element group and control an actuator module through a redundant output loop;

[0038] A safety element group comprising an emergency stop button EMS, a safety light curtain R, and a pull rope switch, each safety element in the safety element group being connected to the safety controller SC through two independent loops;

[0039] An actuator module comprising a series-connected double contactor KM1, a double contactor KM2, and a frequency converter INV with a safety torque off STO function,

[0040] The series-connected double contactor KM1 and double contactor KM2 are respectively driven by two independent output terminals of the safety controller SC; the safety input terminal of the frequency converter INV with the safety torque off STO function is controlled by two independent output terminals of the safety controller SC;

[0041] A redundant power supply module providing double independent power supply for the safety controller SC and the safety element group.

[0042] The safety light curtain R is configured as a four-stage safety light curtain in the material passing area.

[0043] The safety light curtain R is also integrated with a shielding sensor, which distinguishes between personnel and materials through a logic signal and temporarily shields the shutdown function of the safety light curtain when materials pass.

[0044] The safety controller SC and the common PLC communicate through industrial Ethernet or field bus, forming a hierarchical control architecture, wherein the safety controller SC independently processes safety logic, and the common PLC is responsible for non-safety logic control.

[0045] The electrical design of the redundant input circuit and the redundant output circuit meets the safety certification requirements of PLd or PLe level in ISO13849-1, and the safety controller SC has a built-in fault self-diagnosis function to monitor the circuit integrity in real time.

[0046] The safety element group also includes a limit switch, which is connected to the safety controller SC through a double circuit and forms a linkage logic with the emergency stop button EMS, triggering a multi-stage safety response.

[0047] The double contactors KM1 and KM2 in the actuator module adopt a mechanical interlocking design, which ensures that the power output is forcibly cut off when any of the contactors KM1 and KM2 fails.

[0048] The redundant power module includes two independent 24V DC power supplies, each of which is connected to the system in parallel through an isolation diode, and automatically switches to the standby power supply when any power supply fails.

[0049] As Figure 2 As shown in the working principle step diagram of the heavy-load conveying line safety control system, the working principle of the utility model is:

[0050] Step 1: System initialization and redundant circuit self-checking. When the system starts, the safety controller SC performs self-checking on the redundant circuits of the input / output terminals: checks whether the double-circuit signals of the emergency stop button, safety light curtain and other safety elements are normal; verifies whether the redundant output circuits of the double contactors (KM1, KM2) or the frequency converter INV are connected; confirms that the redundant power module (double 24VDC) supplies stable power. If any circuit fails, the system triggers an alarm and prohibits starting until the fault is eliminated.

[0051] Step 2: Real-time monitoring of safety signals. The input end redundant acquisition, the signals of the emergency stop button, safety light curtain, pull rope switch and other safety elements are transmitted to the safety controller SC through two independent circuits; the safety controller SC cross-compares the double-circuit signals to ensure signal consistency. In the material passing area, the shielding sensor of the safety light curtain R detects the material characteristics (such as volume and speed), and generates a shielding signal; the safety controller SC temporarily releases the shutdown function of the safety light curtain, allowing the material to pass without interruption.

[0052] Step 3: Abnormality detection and logical judgment. When any safety element (such as emergency stop button trigger, safety light curtain blocked) sends an abnormal signal: the safety controller SC performs redundant verification on the dual-loop signal to exclude the possibility of false triggering; if both loops detect abnormalities, it is determined to be a real failure; if only a single loop is abnormal, start the self-diagnosis program to locate the fault point.

[0053] Step 4: Trigger safety control logic. Safety shutdown instruction generation: the safety controller SC sends a shutdown instruction to the actuator module; the shutdown instruction is transmitted through two independent output loops to ensure instruction reliability. Actuator response: contactor control scheme: two contactors (KM1, KM2) are connected in series, and any contactor disconnection can cut off the power; frequency converter control scheme: through the safety torque shutdown STO function, the frequency converter output torque is forced to zero.

[0054] Step 5: System state feedback and alarm. The safety controller SC feeds back the shutdown reason (such as emergency stop trigger, light curtain obstruction) to the general PLC; the PLC is linked to the sound and light alarm (for example, the alarm module is not designed separately), prompting the operator to handle the fault.

[0055] Step 6: Dynamic recovery and reset. After the abnormality is resolved: the operator starts the reset process through the reset button of the safety controller SC or the HMI interface; the safety controller SC re-verifies the status of all safety elements and confirms that there are no abnormalities, and then restores the dual-loop signal transmission. System restart: the safety controller SC sends a restart instruction to the actuator module (for example, close the contactor, release the frequency converter STO state); the conveying line resumes normal operation.

[0056] As Figures 3-8 shown, it is a circuit diagram of a heavy-load conveying line safety control system of the utility model, and the circuit comprises a safety controller SC, an actuator module, a safety element group, and a redundant power supply module.

[0057] Among them, the safety controller SC model: BANNER SC2-BAN.85073, configured with 4 pairs of safety outputs (OSSD1 / OSSD2), input channels: 18 safety signals (IN1-IN18), supporting dual-loop redundant verification, output channels: 4 pairs of safety outputs (SO1a / SO1b to SO4a / SO4b).

[0058] The actuator module includes double contactors KM1 / KM2, a frequency converter INV, the double contactors KM1 / KM2 are modelled as SE.LC1N0601M5N, rated current 6A, mechanical interlocking is designed for auxiliary contact interlocking, main contact is in series in three-phase main circuit (L1-L3 to U1-W1);The frequency converter INV is modelled as SIE.6SL3210-1KE13-2UB2, integrated safety torque off (STO) function, safety input terminals: DI0+ / DI0- and DI1+ / DI1-, two-channel control is carried out.

[0059] The safety component group includes an emergency stop button EMS, a 4-level safety light curtain R and a pull cord switch, the emergency stop button EMS is modelled as APT.PB3N-ZR41S02 / r23, double normally closed contact;The 4-level safety light curtain R is modelled as a BANNER input module with a shielded sensor (logic signal input IN5);The pull cord switch is double contact design, connected to SC input channel IN6 / IN7.

[0060] The redundant power module includes two independent 24VDC power supplies (PSENopII4H-s-30-165) in parallel through isolation diodes;Power input: terminal 1 (+24VDC), terminal 5 (+24VDC), terminal 3 (0VDC).

[0061] The above is only the preferred embodiment of the utility model, and does not limit the patent range of the utility model, and equivalent structure or equivalent process transformation using the utility model specification and drawing contents, or direct or indirect application in other related technical fields, are all included in the patent protection range of the utility model.

Claims

1. A heavy load conveyor line safety control system, characterized by, The application relates to a safety control system for material handling equipment, comprising: a safety controller SC configured to receive redundant input signals from a safety element group and control an actuator module through a redundant output circuit; a safety element group comprising an emergency stop button EMS, a safety light curtain R, and a pull cord switch, each safety element in the safety element group being connected to the safety controller SC through two independent circuits; an actuator module comprising a double contactor KM1, a double contactor KM2 connected in series, and a frequency converter INV with a safety torque off STO function, the double contactor KM1 and the double contactor KM2 connected in series are respectively driven by two independent output terminals of the safety controller SC; the safety input terminal of the frequency converter INV with the safety torque off STO function is controlled by two independent output terminals of the safety controller SC; a redundant power module providing double independent power supply for the safety controller SC and the safety element group.

2. The heavy haul conveyor line safety control system of claim 1, wherein: The safety light curtain R is configured as a four-stage safety light curtain in a material passing area.

3. The heavy load conveyor line safety control system of claim 2, wherein: The safety light curtain R is further integrated with a shielding sensor which distinguishes personnel from materials through a logic signal and temporarily shields the shutdown function of the safety light curtain when the materials pass.

4. The heavy haul conveyor line safety control system of claim 1, wherein: The redundant power module comprises two independent 24V DC power supplies, each power supply is connected to the system in parallel through an isolation diode, and the system automatically switches to a standby power supply when any power supply fails.

5. The heavy haul conveyor line safety control system of claim 1, wherein: The safety controller SC communicates with a common PLC through an industrial Ethernet or a field bus to form a layered control architecture, wherein the safety controller SC independently processes safety logic, and the common PLC is responsible for non-safety logic control.

6. The heavy load conveyor line safety control system of claim 4, wherein: The electrical design of the redundant input circuit and the redundant output circuit meets the safety certification requirements of the PLd or PLe level in ISO13849-1, and the safety controller SC is provided with a fault self-diagnosis function to monitor the integrity of the circuit in real time.

7. The heavy load conveyor line safety control system of claim 1, wherein: The safety element group further comprises a limit switch connected to the safety controller SC through a double circuit.

8. The heavy load conveyor line safety control system of claim 1, wherein: The double contactors KM1 and KM2 in the actuator module adopt a mechanical interlocking design to ensure that the power output is forcibly cut off when any one of the contactors KM1 and KM2 fails.

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