Contactor service life detection system

Abstract

The utility model provides a contactor service life detection system, and belongs to the technical field of contactor detection. The contactor service life detection system comprises a first voltage detection module, a second voltage detection module, a counting control module, a voltage comparison module, a counting module and a main control module. The first voltage detection module is configured to detect whether the crane is connected with a working power supply, a control end of the counting control module is connected with the first voltage detection module, a first end of the counting control module is connected with a counting power supply, and a second end of the counting control module is connected with a power supply end of the counting module; the second voltage detection module is configured to detect the output voltage of the contactor, the first input end of the voltage comparison module is connected with the second voltage detection module, the second input end of the voltage comparison module is connected with the reference voltage module, the output end of the voltage comparison module is connected with the input end of the counting module, and the output end of the counting module is connected with the main control module. The safety of port operation can be improved.

Description

Technical Field

[0001] This disclosure relates to the field of contactor testing technology, and in particular to a contactor life testing system. Background Technology

[0002] In port operations, gantry cranes are crucial equipment for loading and unloading ships. When their hoisting and luffing mechanisms operate, the brake mechanism correspondingly opens and closes, relying on the engagement and disengagement of the brake contactor. However, after prolonged use, contactors may age, and the contacts may stick together and fail to disconnect. If this occurs, the cargo on the crane risks slipping and falling, potentially causing cargo damage, ship damage, or even personal injury.

[0003] Currently, there is a lack of effective means to detect the usage status and lifespan of contactors. Usually, we can only rely on manual periodic inspections, which is not only inefficient but also makes it difficult to grasp the actual situation of the contactors in real time. Utility Model Content

[0004] This disclosure provides a contactor life detection system to improve the safety of port operations.

[0005] This disclosure provides a contactor life detection system, including: a first voltage detection module, a second voltage detection module, a counting control module, a voltage comparison module, a counting module, and a main control module;

[0006] The first voltage detection module is configured to detect whether the crane is connected to the working power supply. The control terminal of the counting control module is connected to the first voltage detection module, the first terminal of the counting control module is connected to the counting power supply, and the second terminal of the counting control module is connected to the power supply terminal of the counting module.

[0007] The second voltage detection module is configured to detect the output voltage of the contactor. The first input terminal of the voltage comparison module is connected to the second voltage detection module, the second input terminal of the voltage comparison module is connected to the reference voltage module, the output terminal of the voltage comparison module is connected to the input terminal of the counting module, and the output terminal of the counting module is connected to the main control module.

[0008] In one exemplary embodiment of this disclosure, the counting control module includes: a switching transistor Q1;

[0009] The control terminal of the switching transistor Q1 is connected to the first voltage detection module, the first terminal of the switching transistor Q1 is connected to the counting power supply, and the second terminal of the switching transistor Q1 is connected to the power supply terminal of the counting module.

[0010] In one exemplary embodiment of this disclosure, the voltage comparison module includes: operational amplifier U2;

[0011] The non-inverting input of the operational amplifier U2 is connected to the reference voltage module, the inverting input of the operational amplifier U2 is connected to the second voltage detection module, and the output of the operational amplifier U2 is connected to the input of the counting module.

[0012] In one exemplary embodiment of this disclosure, the voltage comparison module further includes: NOT gate U3 and NOT gate U4;

[0013] The input terminal of the NOT gate U3 is connected to the output terminal of the operational amplifier U2, the output terminal of the NOT gate U3 is connected to the input terminal of the NOT gate U4, and the output terminal of the NOT gate U4 is connected to the input terminal of the counting module.

[0014] In one exemplary embodiment of this disclosure, the reference voltage module includes: a resistor R4 and a Zener diode D2;

[0015] The first end of the resistor R4 is connected to the counting power supply, the second end of the resistor R4 is connected to the non-inverting input of the operational amplifier U2, the cathode of the Zener diode D2 is connected to the second end of the resistor R4, and the anode of the Zener diode D2 is grounded.

[0016] In one exemplary embodiment of this disclosure, the counting module includes: a timer U1, a resistor R1, and a capacitor C1;

[0017] The power supply terminal of the timer U1 is connected to the second terminal of the counting control module. The first terminal of the resistor R1 is connected to the power supply terminal of the timer U1. The second terminal of the resistor R1 is connected to the discharge terminal of the timer U1, the high trigger terminal of the timer U1, and the first terminal of the capacitor C1. The second terminal of the capacitor C1 is grounded. The low trigger terminal of the timer U1 is connected to the output terminal of the voltage comparison module. The output terminal of the timer U1 is connected to the main control module.

[0018] In one exemplary embodiment of this disclosure, it further includes: an alarm module;

[0019] The alarm module is connected to the main control module.

[0020] In one exemplary embodiment of this disclosure, it further includes: a communication module;

[0021] The main control module communicates with the monitoring platform through the communication module.

[0022] The beneficial effects of the contactor life detection system provided in this disclosure are as follows: In terms of safety, this disclosure can accurately count the number of contactor engagements and promptly remind the user to perform maintenance when the contactor reaches its electrical lifespan. This prevents contactor aging and adhesion from causing the contacts to fail to disconnect, thus preventing cargo from slipping and falling from the crane, reducing the risk of cargo damage, ship damage, and personal injury accidents, and ensuring port operation safety. In terms of efficiency, the first voltage detection module automatically detects the crane's operating power supply and controls the power supply of the counting module, eliminating the need for frequent manual intervention. The second voltage detection module, voltage comparison module, and counting module work together to automatically detect and convert signals, transforming the contactor engagement state into pulse signals for the main control module to accumulate, greatly improving detection efficiency and providing strong support for the stable operation of the crane. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this disclosure, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this disclosure. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the contactor life detection system provided in an embodiment of this disclosure;

[0025] Figure 2 This is a circuit diagram of a contactor life detection system provided in an embodiment of this disclosure. Detailed Implementation

[0026] To enable those skilled in the art to better understand this solution, the technical solutions in the embodiments of this solution will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this solution, not all of them. Based on the embodiments of this solution, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this solution.

[0027] The term "comprising" and any other variations thereof in the specification, claims, and accompanying drawings of this invention mean "including but not limited to," and are intended to cover a non-exclusive inclusion, not limited to the examples listed herein. Furthermore, the terms "first" and "second," etc., are used to distinguish different objects, not to describe a specific order.

[0028] The implementation of this disclosure will be described in detail below with reference to the specific accompanying drawings:

[0029] Figure 1 This is a schematic diagram of a contactor life detection system provided in an embodiment of this disclosure. (Refer to...) Figure 1The contactor life detection system includes: a first voltage detection module, a second voltage detection module, a counting control module, a voltage comparison module, a counting module, and a main control module. The first voltage detection module is configured to detect whether the crane is connected to the working power supply. The control terminal of the counting control module is connected to the first voltage detection module, the first terminal of the counting control module is connected to the counting power supply, and the second terminal of the counting control module is connected to the power supply terminal of the counting module. The second voltage detection module is configured to detect the output voltage of the contactor. The first input terminal of the voltage comparison module is connected to the second voltage detection module, the second input terminal of the voltage comparison module is connected to the reference voltage module, the output terminal of the voltage comparison module is connected to the input terminal of the counting module, and the output terminal of the counting module is connected to the main control module.

[0030] In this embodiment, the contactor life detection system can be applied to gantry cranes, which are the main equipment for loading and unloading ships in ports. When the hoisting and luffing mechanisms operate, the brake mechanism releases and locks. Each time the crane's hoisting and luffing mechanisms operate, the corresponding brake contactor engages and disengages. After prolonged use and aging, the contacts of the brake contactor may stick together and fail to disconnect; this poses a risk of cargo slipping and falling, potentially causing cargo damage, ship damage, or even personal injury. Therefore, when the contactor reaches the end of its electrical lifespan, maintenance personnel should be reminded to replace the contactor to avoid safety hazards such as equipment slippage caused by contactor aging, sticking, or other malfunctions.

[0031] Before operating a gantry crane, the operator needs to connect the crane's power supply. The first voltage detection module is used to detect whether the gantry crane is connected to the power supply and converts the detected power supply into a suitable voltage signal, which is then applied to the control terminal of the counting control module. If the gantry crane is connected to the power supply, the counting control module can receive the voltage signal output by the first voltage detection module. The counting control module responds and connects the counting power supply to the counting module, and the counting module enters the working state.

[0032] The second voltage detection module detects the contactor's output voltage. When the contactor is engaged, a voltage signal is generated at its output. The second voltage detection module converts this output voltage into a suitable voltage signal, which is then applied to the first input of the voltage comparison module. The voltage comparison module compares this voltage signal with the reference voltage provided by the reference voltage module. When the contactor is engaged, the voltage signal output by the second voltage detection module is greater than the reference voltage. When the contactor is not engaged, the voltage signal output by the second voltage detection module is less than the reference voltage. The voltage comparison module compares these two voltages and outputs a high-level or low-level signal, which is then applied to the input of the counting module. Based on the result from the voltage comparison module, the counting module converts each engagement state of the contactor into a suitable pulse signal and outputs it to the main control module. The main control module accumulates the number of pulses output by the counting module to obtain the number of times the contactor has engaged.

[0033] As can be concluded from the above, in terms of safety, this embodiment can accurately count the number of contactor engagements and promptly remind maintenance when the electrical life is reached, avoiding the inability to disconnect contacts due to aging or adhesion of the contactor, preventing cargo from slipping and falling from the crane, reducing the risk of cargo damage, ship damage, and personal injury accidents, and ensuring port operation safety. In terms of efficiency, the first voltage detection module automatically detects the crane's operating power supply and controls the power supply of the counting module, eliminating the need for frequent manual intervention; the second voltage detection module, voltage comparison module, and counting module work together to automatically detect and convert signals, transforming the contactor engagement state into pulse signals for the main control module to accumulate, greatly improving detection efficiency and providing strong support for the stable operation of the crane.

[0034] like Figure 2 As shown, in one embodiment of this disclosure, the counting control module includes: a switching transistor Q1; the control terminal of the switching transistor Q1 is connected to a first voltage detection module, the first terminal of the switching transistor Q1 is connected to a counting power supply, and the second terminal of the switching transistor Q1 is connected to the power supply terminal of the counting module.

[0035] In this embodiment, the first voltage detection module detects whether the crane is powered on. When the crane is powered on, the first voltage detection module converts the detected power supply into a suitable voltage signal. The control terminal of the switch Q1 receives the voltage signal output from the first voltage detection module. If the crane is powered on, the control terminal of the switch Q1 receives a valid control signal. After receiving the valid control signal, the switch Q1 enters the conducting state. At this time, the first terminal of the switch Q1 is connected to the counting power supply, and the second terminal is connected to the power supply terminal of the counting module. After conduction, the counting power supply can power the counting module. After receiving power from the counting power supply, the counting module enters the working state and begins to count the number of contactor engagements.

[0036] In this embodiment, by turning the switch Q1 on and off, the counting control module can flexibly control the power supply of the counting module according to the connection status of the crane's working power supply, ensuring that the counting module only starts working when the crane is working.

[0037] like Figure 2 As shown, in one embodiment of this disclosure, the voltage comparison module includes: operational amplifier U2; the non-inverting input terminal of operational amplifier U2 is connected to a reference voltage module, the inverting input terminal of operational amplifier U2 is connected to a second voltage detection module, and the output terminal of operational amplifier U2 is connected to the input terminal of a counting module.

[0038] In this embodiment, the reference voltage module supplies a pre-set reference voltage to the non-inverting input of operational amplifier U2. The second voltage detection module detects the output voltage of the contactor, converts it into a suitable voltage signal, and then sends it to the inverting input of operational amplifier U2.

[0039] When the contactor is engaged, a voltage signal is generated at the contactor output. The voltage signal output by the second voltage detection module is greater than the reference voltage provided by the reference voltage module, meaning the voltage at the inverting input of operational amplifier U2 is greater than the voltage at the non-inverting input. When the contactor is not engaged, the voltage signal output by the second voltage detection module is less than the reference voltage provided by the reference voltage module, meaning the voltage at the inverting input of operational amplifier U2 is less than the voltage at the non-inverting input.

[0040] Operational amplifier U2 outputs a corresponding level signal based on the comparison result of the voltages at its two input terminals. When the voltage at the inverting input terminal is greater than the voltage at the non-inverting input terminal, operational amplifier U2 outputs a low-level signal; when the voltage at the inverting input terminal is less than the voltage at the non-inverting input terminal, operational amplifier U2 outputs a high-level signal.

[0041] The high or low level signal output by operational amplifier U2 is sent to the input terminal of the counting module. Based on these high and low level signals, the counting module converts each contactor engagement state into a suitable pulse signal, and then outputs it to the main control module so that the main control module can count the number of contactor engagements.

[0042] As can be seen from the above, the voltage comparison module can use operational amplifier U2 to compare the reference voltage and the contactor output voltage, output high and low level signals, provide a basis for judgment for the counting module, and finally realize the statistics of the number of times the contactor is engaged.

[0043] like Figure 2 As shown, in one embodiment of this disclosure, the voltage comparison module further includes: NOT gate U3 and NOT gate U4; the input terminal of NOT gate U3 is connected to the output terminal of operational amplifier U2, the output terminal of NOT gate U3 is connected to the input terminal of NOT gate U4, and the output terminal of NOT gate U4 is connected to the input terminal of the counting module.

[0044] In this embodiment, NOT gate U3 and NOT gate U4 constitute a shaping circuit to ensure that the counting module can receive a stable level signal. Since signals may be subject to interference during transmission, problems such as non-sharp signal edges and jitter may occur, leading to signal instability. After continuous inversion by two NOT gates, the signal waveform can be shaped, converting the irregular signal into a standard high / low level signal with steep edges and no jitter. For example, a high-level signal that is originally affected by interference and has glitches will become a clean and stable high-level signal after passing through two NOT gates.

[0045] The NOT gate U4 outputs a stable level signal to the input of the counting module. Based on these stable level signals, the counting module can reliably convert the contactor's engagement state into a pulse signal, ensuring the accuracy of the main control module's counting of contactor engagements.

[0046] like Figure 2 As shown, in one embodiment of this disclosure, the reference voltage module includes: a resistor R4 and a Zener diode D2; the first end of the resistor R4 is connected to the counting power supply, the second end of the resistor R4 is connected to the non-inverting input of the operational amplifier U2, the cathode of the Zener diode D2 is connected to the second end of the resistor R4, and the anode of the Zener diode D2 is grounded.

[0047] In this embodiment, resistor R4 is connected between the counting power supply and the non-inverting input of operational amplifier U2, serving as a current limiter. This prevents excessive current from flowing into operational amplifier U2 and Zener diode D2, protecting the circuit components from damage. Zener diode D2 has the characteristic of maintaining a stable voltage even in the reverse breakdown state. When the Zener diode operates in the reverse breakdown region, the voltage across its terminals remains essentially constant; this stable voltage value is the reference voltage.

[0048] like Figure 2 As shown, in one embodiment of this disclosure, the counting module includes: a timer U1, a resistor R1, and a capacitor C1; the power supply terminal of the timer U1 is connected to the second terminal of the counting control module, the first terminal of the resistor R1 is connected to the power supply terminal of the timer U1, the second terminal of the resistor R1 is connected to the discharge terminal of the timer U1, the high trigger terminal of the timer U1, and the first terminal of the capacitor C1, respectively, the second terminal of the capacitor C1 is grounded, the low trigger terminal of the timer U1 is connected to the output terminal of the voltage comparison module, and the output terminal of the timer U1 is connected to the main control module.

[0049] In this embodiment, timer U1, resistor R1 and capacitor C1 constitute a metastable circuit, and a 555 timer can be used as timer U1.

[0050] Based on the signal from the first voltage detection module, if the crane is powered on, the counting control module will connect the counting power supply to the counting module, supplying power to timer U1 and initiating its operation. After timer U1 is powered on, the power supply charges capacitor C1 through resistor R1. The voltage across capacitor C1 gradually increases. The low-level trigger terminal of timer U1 is connected to the output of the voltage comparator module. When the contactor engages, the voltage comparator module outputs a low-level signal to the low-level trigger terminal of timer U1. When the voltage comparator module outputs a low-level signal to trigger timer U1, the state of timer U1 changes, entering a quasi-stable state. During this quasi-stable state, timer U1 outputs a specific pulse signal (e.g., a high level). The pulse width is determined by the parameters of resistor R1 and capacitor C1, and this pulse signal is sent to the main control module. After the quasi-stable state ends, the discharge tube inside timer U1 conducts, and capacitor C1 discharges rapidly through the discharge terminal of timer U1, preparing for the next trigger. When the contactor engages again, timer U1 will output another specific pulse signal (e.g., a high level).

[0051] After receiving the pulse signal output by timer U1, the main control module accumulates the number of pulses to obtain the number of times the contactor engages.

[0052] As can be seen from the above, the counting module uses a quasi-stable circuit composed of timer U1, resistor R1 and capacitor C1 to convert the level signal output by the voltage comparison module into a pulse signal, thereby counting the number of times the contactor is engaged.

[0053] like Figure 1 As shown, in one embodiment of this disclosure, it further includes: an alarm module; the alarm module is connected to the main control module.

[0054] In this embodiment, when the cumulative number of engagements reaches or exceeds a preset threshold, the main control module determines that the contactor may have reached the end of its service life and is at risk of aging, sticking, or other malfunctions. At this time, the main control module sends a trigger signal to the connected alarm module.

[0055] After receiving a trigger signal from the main control module, the alarm module can activate the corresponding alarm mechanism. There are various alarm methods, such as audible alarm (emitting a buzzer), visual alarm (flashing warning lights), or a combination of both, to attract the attention of maintenance personnel and remind them to replace the contactor in a timely manner.

[0056] like Figure 1 As shown, in one embodiment of this disclosure, it further includes: a communication module; the main control module is connected to the monitoring platform through the communication module.

[0057] In this embodiment, the main control module collects and accumulates the pulse signals output by the counting module to obtain the number of contactor engagements. The main control module then transmits the collected and processed data to the monitoring platform according to the communication protocol supported by the communication module. After receiving the encapsulated data from the main control module, the communication module can send the data out via a specific communication method (such as wireless communication or wired network communication). The monitoring platform can display the contactor's usage status and remaining lifespan. If the contactor's engagement count approaches or reaches its electrical lifespan, the monitoring platform can issue a timely warning, notifying relevant personnel to perform maintenance or replacement.

[0058] As can be seen from the above, the communication module enables data interaction between the main control module and the monitoring platform, allowing the monitoring platform to remotely monitor the contactor's usage, promptly identify potential problems, and improve the efficiency and safety of equipment management.

[0059] The above embodiments are only used to illustrate the technical solutions of this disclosure, and are not intended to limit it. Although this disclosure 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 of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this disclosure.

Claims

1. A contactor life detection system, characterized in that, include: The system comprises a first voltage detection module, a second voltage detection module, a counting control module, a voltage comparison module, a counting module, and a main control module. The first voltage detection module is configured to detect whether the crane is connected to the working power supply. The control terminal of the counting control module is connected to the first voltage detection module, the first terminal of the counting control module is connected to the counting power supply, and the second terminal of the counting control module is connected to the power supply terminal of the counting module. The second voltage detection module is configured to detect the output voltage of the contactor. The first input terminal of the voltage comparison module is connected to the second voltage detection module, the second input terminal of the voltage comparison module is connected to the reference voltage module, the output terminal of the voltage comparison module is connected to the input terminal of the counting module, and the output terminal of the counting module is connected to the main control module.

2. The contactor life detection system as described in claim 1, characterized in that, The counting control module includes: a switching transistor Q1; The control terminal of the switching transistor Q1 is connected to the first voltage detection module, the first terminal of the switching transistor Q1 is connected to the counting power supply, and the second terminal of the switching transistor Q1 is connected to the power supply terminal of the counting module.

3. The contactor life detection system as described in claim 1, characterized in that, The voltage comparison module includes: operational amplifier U2; The non-inverting input of the operational amplifier U2 is connected to the reference voltage module, the inverting input of the operational amplifier U2 is connected to the second voltage detection module, and the output of the operational amplifier U2 is connected to the input of the counting module.

4. The contactor life detection system as described in claim 3, characterized in that, The voltage comparison module further includes: NOT gate U3 and NOT gate U4; The input terminal of the NOT gate U3 is connected to the output terminal of the operational amplifier U2, the output terminal of the NOT gate U3 is connected to the input terminal of the NOT gate U4, and the output terminal of the NOT gate U4 is connected to the input terminal of the counting module.

5. The contactor life detection system as described in claim 3, characterized in that, The reference voltage module includes: resistor R4 and Zener diode D2; The first end of the resistor R4 is connected to the counting power supply, the second end of the resistor R4 is connected to the non-inverting input of the operational amplifier U2, the cathode of the Zener diode D2 is connected to the second end of the resistor R4, and the anode of the Zener diode D2 is grounded.

6. The contactor life detection system as described in claim 1, characterized in that, The counting module includes: timer U1, resistor R1, and capacitor C1; The power supply terminal of the timer U1 is connected to the second terminal of the counting control module. The first terminal of the resistor R1 is connected to the power supply terminal of the timer U1. The second terminal of the resistor R1 is connected to the discharge terminal of the timer U1, the high trigger terminal of the timer U1, and the first terminal of the capacitor C1. The second terminal of the capacitor C1 is grounded. The low trigger terminal of the timer U1 is connected to the output terminal of the voltage comparison module. The output terminal of the timer U1 is connected to the main control module.

7. The contactor life detection system as described in claim 1, characterized in that, Also includes: Alarm module; The alarm module is connected to the main control module.

8. The contactor life detection system as described in claim 1, characterized in that, Also includes: Communication module; The main control module communicates with the monitoring platform through the communication module.

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