A flying shear safety control circuit
By using a modular design and a unified grounding protection for the flying shear machine's safety control circuit, the problems of poor module linkage and untimely safety signal response in the existing flying shear machine control circuit have been solved, achieving rapid response and efficient operation.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SHANGHAI CANGCHU AUTOMATION TECHNOLOGY CO LTD
- Filing Date
- 2025-08-27
- Publication Date
- 2026-06-12
AI Technical Summary
Existing flying shear machine control circuits suffer from problems such as poor module linkage, untimely response to safety signals, incomplete grounding protection, chaotic wiring logic, and difficulty in wiring identification, resulting in low equipment safety and efficiency, making it difficult to meet the requirements of modern industrial production.
A safety control circuit for a flying shear machine was designed, adopting a modular architecture, including a power supply module, a PLC control module, a motor control module, a circuit breaker module, and a contactor module. Through clear signal input, logic processing, and execution output, it ensures the real-time transmission of critical alarm signals and sets up a unified grounding protection system to avoid the risk of high voltage intrusion and leakage. The inter-module linkage is enhanced.
It enables the flying shear machine to respond quickly when safety hazards occur, reduces the risk of electric shock to operators, improves equipment uptime and ease of maintenance, and ensures the safety and reliability of the shearing process.
Smart Images
Figure CN224354750U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of flying shear machine control systems, and in particular to a safety control circuit for flying shear machines. Background Technology
[0002] Flying shears, as core equipment in metal processing and sheet metal production, are mainly used for high-speed and precise shearing of continuously conveyed materials. During operation, they must simultaneously meet the dual requirements of "high power output" and "high safety protection." On the one hand, core components such as the flying shear cooling fan and shearing motor require a stable three-phase power supply to ensure shearing efficiency. On the other hand, key parameters such as the capacitor status, safety door closure status, and small motor operating conditions during equipment operation are directly related to the personal safety of operators and the stability of equipment operation. If any abnormality occurs and is not responded to in a timely manner, it can easily lead to deviations in shearing accuracy, equipment burnout, or even personal injury accidents.
[0003] Currently, most flying shear machines on the market use a "distributed relay control" or "simplified PLC control" architecture, which has many technical shortcomings. Safety signal monitoring and response are significantly weak. Traditional circuits often transmit signals such as capacitor detection, fault alarms, and safety door monitoring through a single loop. This is not only susceptible to interference from the power circuit, leading to signal distortion, but also lacks independent signal acquisition and logic judgment units. When a safety signal is abnormal, it cannot quickly pinpoint the fault and trigger protection actions. For example, if the safety door is not closed, the shear motor may still start erroneously due to signal delay. Poor module interoperability is also a prominent issue. The wiring logic of components such as the power module, motor control module, and circuit breaker module is chaotic. The three-phase power circuit and the 24V DC control circuit often share terminals, frequently resulting in high voltage entering the control circuit and burning out the PLC or relays. Furthermore, the corresponding control relationship between the contactor and the motor is unclear, easily leading to problems such as "the cooling fan not starting but the shear motor starting first," causing the cutter head to overheat and be damaged due to lack of cooling. The existing control circuit's grounding protection design does not meet industrial safety standards. Some equipment only grounds the motor casing, while metal components such as PLCs and contactors are not connected to a unified grounding system. This prevents the rapid dissipation of current in case of leakage, posing a high risk of electric shock to operators. Furthermore, the circuit layout lacks standardization; haphazardly arranged modules make wiring identification difficult, requiring line-by-line testing for troubleshooting, severely impacting equipment uptime. These problems render traditional flying shear machine control circuits inadequate for meeting the modern industrial production requirements of "safety, efficiency, and reliability." A new modular, highly interconnected, and robustly protected safety control circuit architecture is urgently needed to address the shortcomings of existing technologies. Utility Model Content
[0004] The purpose of this invention is to provide a safety control circuit for a flying shear machine to solve the problems existing in the prior art.
[0005] The above-mentioned technical objective of this utility model is achieved through the following technical solution:
[0006] A safety control circuit for a flying shear machine includes a power supply module, a PLC control module, a motor control module, a circuit breaker module, and a contactor module. These modules form a complete control loop via wiring. The PLC control module is DC-powered and has input interfaces I0.0, I0.1, I0.2, I0.3, I0.4, and I0.5. 0.5 and output interfaces Q0.0, Q0.1, Q0.2, Q0.3; the motor control module includes a flying shear cooling fan M2, a first motor M3, and a second motor M4. M2 has interfaces U1, V1, and W1, M3 has interfaces U2, V2, and W2, and M4 has interfaces U3, V3, and W3; the circuit breaker module includes three-phase branch circuit breakers QF4, QF5, and QF6, and 24V branch circuit breakers QF1, QF2, and QF3; the contactor module includes contactors KM1, KM2, and KM3. Each contactor has a coil interface and a main contact interface. The coil interface includes a first coil terminal and a second coil terminal. The main contact interface includes a first main contact input terminal, a second main contact input terminal, a third main contact input terminal, a first main contact output terminal, a second main contact output terminal, and a third main contact output terminal.
[0007] The power module outputs are connected to the circuit breaker module inputs; the PLC control module power interface is connected to the 24V branch circuit breaker output; input interface I0.0 is connected to the external capacitor detection alarm signal source output, I0.1 to the external fault alarm signal source output, I0.2 to the external small motor alarm signal source output, and I0.3 to the external safety door alarm signal source output; output interface Q0.0 is connected to the charging completion control circuit relay coil, Q0.1 to the drive alarm control circuit relay coil, and Q0.2 to the first terminal of the KM1 coil; the contactor main contact input is connected to the three-phase branch circuit breaker output, and the output is connected to the corresponding motor interface; the 24V branch circuit breaker output is connected to the positive terminal of the external alarm signal source, the positive terminal of the control circuit relay coil, and the positive terminal of the spare 24V electrical component.
[0008] By adopting the above technical solution, the problems of poor inter-module linkage and untimely response to safety signals in the control circuit of traditional flying shear machines are addressed. By clarifying the connection logic of core components such as the power supply module, PLC control module, and motor control module, a complete signal input, logic processing, execution output, and control link is constructed. This ensures that critical alarm signals such as external capacitor detection, faults, small motors, and safety doors can be transmitted to the PLC in real time. The PLC then precisely controls the contactors and relays through the output interface, avoiding equipment malfunctions caused by signal interruptions or module disconnections. From a circuit structure perspective, this guarantees the flying shear machine's rapid response capability in the event of safety hazards.
[0009] In a further embodiment, the power module includes a three-phase AC power interface and a 24V DC power interface. The three-phase AC power interface has four terminals: R, S, T, and PE. The R terminal connects to the R phase of an external three-phase power supply, the S terminal connects to the S phase of an external three-phase power supply, the T terminal connects to the T phase of an external three-phase power supply, and the PE terminal connects to an external grounding electrode. The PE terminal also connects to the metal casings of the PLC control module, the motors of the motor control module, the circuit breakers of the circuit breaker module, and the contactors of the contactor module. The 24V DC power interface has three terminals: 24V, 0V, and PE. The 24V terminal connects to an external 24V DC power supply. The positive terminal (0V) is connected to the negative terminal of an external 24V DC power supply, and the PE terminal is shared with the PE terminal of the three-phase AC power interface. The R, S, and T terminals of the three-phase AC power interface are connected to the input sides of the three-phase branch circuit breakers QF4, QF5, and QF6, respectively. The 24V terminal of the 24V DC power interface is connected to the input sides of the 24V branch circuit breakers QF1, QF2, and QF3, and the 0V terminal is connected to the negative terminal of the PLC control module power supply, the second terminal of the KM1 coil, the second terminal of the KM2 coil, the second terminal of the KM3 coil, and the negative terminal of the external alarm signal source.
[0010] By adopting the above technical solution, an independent three-phase AC power interface is set up to power power equipment such as motors and a 24V DC power interface to power control components such as PLCs and alarm signal sources, thus preventing three-phase high voltage from entering the control circuit and burning out precision components. At the same time, all module metal shells and PE terminals are connected to the same grounding electrode to form a unified grounding protection system, which solves the problem of leakage current not being effectively conducted away due to traditional decentralized grounding, greatly reducing the risk of electric shock to operators and meeting industrial safety electricity standards.
[0011] In a further embodiment, in the input interface of the PLC control module, I0.0 is connected to the output terminal of an external capacitance detection alarm signal source via a wire, with one end of the wire inserted into the I0.0 terminal hole and the other end inserted into the signal output terminal hole of the external capacitance detection alarm signal source; I0.1 is connected to the output terminal of an external fault alarm signal source via a wire, with one end of the wire inserted into the I0.1 terminal hole and the other end inserted into the signal output terminal hole of the external fault alarm signal source; I0.2 is connected to the output terminal of an external small motor alarm signal source via a wire, with one end of the wire inserted into the I0.2 terminal hole and the other end inserted into the signal output terminal hole of the external small motor alarm signal source; I0.3 is connected to the output terminal of an external safety door alarm signal source via a wire, with one end of the wire inserted into the I0.3 terminal hole and the other end inserted into the signal output terminal hole of the external safety door alarm signal source; I0.4 is a spare input interface, connected to a reserved terminal via a wire, which can be used to connect to a new external signal source; 0.5 is a spare input interface, which is connected to a reserved terminal block via a wire. The reserved terminal block can be connected to a new external signal source. Input interfaces I0.0, I0.1, I0.2, I0.3, I0.4, and I0.5 are all located in the upper area of the PLC control module. The corresponding interface number and connection signal name are marked next to the terminal block for easy wiring identification.
[0012] By adopting the above technical solutions, the signal names are labeled next to the interfaces, reducing the probability of signal source confusion during wiring and preventing safety signal failure; the reserved I 0.4 and I 0.5 interfaces and corresponding terminals solve the trouble of rewiring when adding external signals later; the input interfaces are concentrated in the upper area, which facilitates quick location of signal transmission fault points, solves the problem of low troubleshooting efficiency under the traditional decentralized layout, and improves the convenience of circuit maintenance.
[0013] In a further embodiment, in the output interface of the PLC control module, Q0.0 is connected to the input terminal of the relay coil of the charging completion control circuit via a wire, with a fuse connected in series in the middle of the wire to protect the relay coil from overcurrent damage; Q0.1 is connected to the input terminal of the relay coil of the drive alarm control circuit via a wire, with a fuse connected in series in the middle of the wire, and the fuse specifications are the same as those of the Q0.0 circuit; Q0.2 is connected to the first end of the contactor KM1 coil via a wire, with one end of the wire inserted into the terminal hole of Q0.2 and the other end inserted into the wiring terminal hole of the first end of the KM1 coil; Q0.3 is a spare output interface, connected to a reserved wiring terminal via a wire, which can be used to connect new actuators; the output interfaces Q0.0, Q0.1, Q0.2, and Q0.3 are all distributed in the lower area of the PLC control module, corresponding one-to-one with the input interfaces I0.0, I0.1, I0.2, I0.3, I0.4, and I0.5, with the interface number and the name of the controlled object labeled next to the terminals to avoid wiring confusion.
[0014] By adopting the above technical solution, fuses are connected in series in the Q0.0 and Q0.1 circuits, which can quickly blow when the relay coil is short-circuited, avoiding overcurrent damage to the relay and PLC output interface, and preventing failure of critical circuits such as alarm and charging control. The output interface is arranged at the bottom and corresponds to the input interface, and the controlled object is labeled, which solves the problem of confusion of the controlled object in traditional wiring, reduces motor misstart or alarm failure caused by wiring errors, and improves the reliability of the control circuit.
[0015] In a further embodiment, in the motor control module, the U1 terminal of the flying shear cooling fan M2 is connected to the first output terminal of the main contact of contactor KM1 via a wire; the V1 terminal of M2 is connected to the second output terminal of the main contact of KM1 via a wire; and the W1 terminal of M2 is connected to the third output terminal of the main contact of KM1 via a wire. When the main contact of KM1 is closed, three-phase AC power is transmitted to the U1, V1, and W1 terminals through the main contacts, driving M2 to operate; the U2 terminal of the first motor M3 is connected to the first output terminal of the main contact of contactor KM2 via a wire; the V2 terminal of M3 is connected to the second output terminal of the main contact of KM2 via a wire; and the W1 terminal of M2 is connected to the third output terminal of the main contact of KM1 via a wire. Terminal 2 is connected to the third output terminal of the KM2 main contact via a wire, and the start and stop of M3 are controlled by the opening and closing of the KM2 main contact; the U3 terminal of the second motor M4 is connected to the first output terminal of the KM3 main contact via a wire, the V3 terminal of M4 is connected to the second output terminal of the KM3 main contact via a wire, and the W3 terminal of M4 is connected to the third output terminal of the KM3 main contact via a wire, and the start and stop of M4 are controlled by the opening and closing of the KM3 main contact; the metal casings of M2, M3, and M4 are all connected to grounding wires via dedicated grounding bolts, and the other end of the grounding wire is connected to the grounding busbar together with the output wire of the PE terminal of the three-phase AC power interface to form grounding protection.
[0016] By adopting the above technical solution, the main contacts of the contactor are connected to the motor interface, and KM1 is connected one-to-one with U1, V1, and W1 of M2, ensuring that the motor can start and stop accurately according to the PLC instructions. This avoids problems such as delayed start of the cooling fan and runaway shear motor caused by loose wiring in traditional methods. The metal casing of the motor is connected to the grounding busbar through a special grounding bolt, which solves the risk of leakage caused by poor grounding and ensures the personal safety of operators when working near the motor. This is especially suitable for equipment such as flying shears that require close-range operation.
[0017] In a further embodiment, in the circuit breaker module, the first input terminal of the three-phase branch circuit breaker QF4 is connected to the output terminal of the three-phase AC power interface R terminal via a wire; the second input terminal of QF4 is connected to the output terminal of the S terminal via a wire; and the third input terminal of QF4 is connected to the output terminal of the T terminal via a wire. The first output terminal of QF4 is connected to the first input terminal of the main contact of KM1 via a wire; the second output terminal of QF4 is connected to the second input terminal of the main contact of KM1 via a wire; and the third output terminal of QF4 is connected to the third input terminal of the main contact of KM1 via a wire. QF4 is used for overload and short-circuit protection of the M2 branch, and automatically disconnects when the branch current is abnormal. The first input terminal of the three-phase branch circuit breaker QF5 is connected to the output terminal of the R terminal via a wire; the second input terminal of QF5 is connected to the output terminal of the S terminal via a wire; and the third input terminal of QF5 is connected to the output terminal of the T terminal via a wire. The output terminal of QF5 is connected to the main contact of KM2. The input terminal is used to protect the M3 branch circuit; the input side connection of the three-phase branch circuit breaker QF6 is the same as that of QF5, and the output side is connected to the main contact input terminal of KM3 to protect the M4 branch circuit; the input side of the 24V branch circuit breaker QF1 is connected to the 24V DC power interface 24V terminal output terminal, and the output side is connected to the positive power interface of the PLC control module and the positive terminal of the external alarm signal source, with terminal blocks installed at the wire branch; the input side of QF2 is connected to the 24V terminal output terminal, and the output side is connected to the positive power interface of the PLC control module and the positive terminal of the control circuit relay coil; the input side of QF3 is connected to the 24V terminal output terminal, and the output side is connected to the positive terminal of the spare 24V electrical component; QF4, QF5, and QF6 are installed side by side in the distribution box below the three-phase power input side, and QF1, QF2, and QF3 are installed side by side in the distribution box below the 24V DC power output side, and each circuit breaker surface is marked with the corresponding branch name and protected object.
[0018] By adopting the above technical solution, the three-phase branch circuit breakers QF4-QF6 and the 24V branch circuit breakers QF1-Q3 protect their respective circuits. When a motor or control component fails, only the corresponding circuit breaker operates, avoiding the whole machine shutdown caused by the tripping of the traditional main circuit breaker. The circuit breakers are installed in zones according to voltage type and labeled with the protected objects, which solves the problem of difficulty in quickly identifying faulty branches in the traditional case without labeling, greatly shortening the fault diagnosis time and improving equipment uptime.
[0019] In a further embodiment, in the contactor module, the first end of the contactor KM1 coil is connected to the output terminal of the PLC control module Q0.2 via a wire, and the second end of the KM1 coil is connected to the output terminal of the 0V terminal of the 24V DC power interface via a wire. A normally closed contact of a manual control button is connected in series in the KM1 coil circuit. The input terminal of the manual control button is connected to the output side of the 24V branch circuit breaker QF2, and the output terminal is connected to the first end of the KM1 coil. The manual control button is used to cut off the coil power supply in an emergency. The first end of the contactor KM2 coil is connected to the reserved output terminal of the PLC control module via a wire. The second end of the KM2 coil is connected to the 0V terminal output terminal via a wire. The normally closed contact of the manual control button is connected in series in the KM2 coil circuit. The first end of the KM3 coil is connected to the reserved output terminal of the PLC control module via a wire. The second end of the KM3 coil is connected to the 0V terminal output terminal via a wire. The normally closed contact of the manual control button is connected in series in the KM3 coil circuit. The coil interfaces of KM1, KM2, and KM3 are all located in the control area on the left side of the distribution box, and the main contact interface is located in the power area on the right side of the distribution box. The coils and main contacts are isolated by the internal insulation plate of the contactor to avoid mutual interference between the coil control circuit and the main contact power circuit.
[0020] By adopting the above technical solution, a manually operated normally closed button is connected in series in the coil circuit, providing an emergency control method when the PLC fails to control it. This can forcibly cut off the power supply to the contactor, making up for the limitations of single automatic control. The coil and the main contacts are isolated by an insulating plate and installed in separate areas, which solves the problem of the main contact arc interfering with the coil signal in the traditional layout. This ensures that the PLC instructions can accurately control the contactor's on and off states, avoids motor malfunctions caused by interference, and ensures the safety of the flying shear machine's cutting process.
[0021] In a further embodiment, a control system is also included, comprising a power circuit, a control circuit, and a signal circuit. The power circuit consists of a three-phase AC power interface, a three-phase branch circuit breaker, contactor main contacts, and a motor, used to transmit the electrical energy required for motor operation. The control circuit consists of a 24V DC power interface, a 24V branch circuit breaker, a PLC control module output interface, contactor coils, and relay coils, used to realize the on / off control of contactors and relays. The signal circuit consists of a 24V DC power interface, a 24V branch circuit breaker, an external alarm signal source, and a PLC control module input interface, used to transmit external device status signals to the PLC. The modules are arranged vertically in an orderly manner, with the power module at the top, the circuit breaker module below the power module, the contactor module below the circuit breaker module, the PLC control module in the center below the contactor module, and the motor control module at the bottom. Operating space is reserved between each module to facilitate later wiring, maintenance, and troubleshooting.
[0022] By adopting the above technical solutions, independent power circuits, control circuits, and signal circuits are divided, avoiding the impact of a fault in one circuit on other circuits and reducing the risk of downtime due to non-fatal faults. The modules are arranged vertically according to power supply, circuit breaker, contactor, PLC, and motor, with reserved operating space. This solves the problem of difficult contactor maintenance and motor wiring maintenance caused by the crowded layout of traditional systems, making daily inspection and fault handling more efficient and meeting the design requirements of easy maintenance of industrial equipment.
[0023] In summary, this utility model has the following beneficial effects:
[0024] 1. By connecting a manually closed button in series in the coil circuit, an emergency control method is provided in case of PLC failure, which can forcibly cut off the power supply to the contactor, making up for the limitations of single automatic control; the coil and main contacts are isolated by an insulating plate and installed in separate areas, which solves the problem of main contact arc interference with coil signals in the traditional layout, ensuring that PLC instructions can accurately control the contactor's on and off, avoiding motor malfunction due to interference, and ensuring the safety of the flying shear machine's cutting process. Attached Figure Description
[0025] Figure 1 This is the circuit diagram of this utility model;
[0026] Figure 2 This is the electrical schematic diagram of this utility model. Detailed Implementation
[0027] The present invention will be further described in detail below with reference to the accompanying drawings.
[0028] Identical parts are indicated by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "upper," and "lower" used in the following description refer to the attached figures. Figure 1 In this specification, the terms "bottom surface" and "top surface," "inner" and "outer" refer to the direction toward or away from the geometry of a specific component. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this specification, "a plurality of" means two or more, unless otherwise explicitly and specifically defined by the direction of the center.
[0029] Example 1:
[0030] like Figures 1-2As shown, a safety control circuit for a flying shear machine includes a power supply module, a PLC control module, a motor control module, a circuit breaker module, and a contactor module. These modules form a complete control loop via wires. The PLC control module is DC-powered and has input interfaces I0.0, I0.1, I0.2, I0.3, I0.4, and I0.5. 0.5 and output interfaces Q0.0, Q0.1, Q0.2, Q0.3; the motor control module includes a flying shear cooling fan M2, a first motor M3, and a second motor M4. M2 has interfaces U1, V1, and W1, M3 has interfaces U2, V2, and W2, and M4 has interfaces U3, V3, and W3; the circuit breaker module includes three-phase branch circuit breakers QF4, QF5, and QF6, and 24V branch circuit breakers QF1, QF2, and QF3; the contactor module includes contactors KM1, KM2, and KM3. Each contactor has a coil interface and a main contact interface. The coil interface includes a first coil terminal and a second coil terminal. The main contact interface includes a first main contact input terminal, a second main contact input terminal, a third main contact input terminal, a first main contact output terminal, a second main contact output terminal, and a third main contact output terminal.
[0031] The power module outputs are connected to the circuit breaker module inputs. The PLC control module power interface is connected to the 24V branch circuit breaker output. Input interface I0.0 is connected to the external capacitor detection alarm signal source output, I0.1 to the external fault alarm signal source output, I0.2 to the external small motor alarm signal source output, and I0.3 to the external safety door alarm signal source output. Output interface Q0.0 is connected to the charging completion control circuit relay coil, Q0.1 to the drive alarm control circuit relay coil, and Q0.2 to the first terminal of the KM1 coil. The contactor main contact input is connected to the three-phase branch circuit breaker output, and the output is connected to the corresponding motor interface. The 24V branch circuit breaker output is connected to the positive terminal of the external alarm signal source, the positive terminal of the control circuit relay coil, and the positive terminal of the spare 24V electrical component.
[0032] The power module includes a three-phase AC power interface and a 24V DC power interface. The three-phase AC power interface has four terminals: R, S, T, and PE. The R terminal connects to the R phase of an external three-phase power supply, the S terminal connects to the S phase, the T terminal connects to the T phase, and the PE terminal connects to the external grounding electrode. The PE terminal also connects to the metal casings of the PLC control module, the motors in the motor control module, the circuit breakers in the circuit breaker module, and the contactors in the contactor module. The 24V DC power interface has three terminals: 24V, 0V, and PE. The 24V terminal connects to the positive terminal of an external 24V DC power supply, and the 0V terminal connects to the positive terminal. The external 24V DC power supply negative terminal is connected, and the PE terminal is shared with the PE terminal of the three-phase AC power interface; the R, S, and T terminals of the three-phase AC power interface are respectively connected to the input side of the three-phase branch circuit breaker QF4, QF5, and QF6; the 24V terminal output of the 24V DC power interface is connected to the input side of the 24V branch circuit breaker QF1, QF2, and QF3; the 0V terminal output is connected to the PLC control module power supply negative interface, the second terminal of the contactor KM1 coil, the second terminal of the contactor KM2 coil, the second terminal of the contactor KM3 coil, and the negative terminal of the external alarm signal source.
[0033] In the input interfaces of the PLC control module, I0.0 is connected to the output terminal of an external capacitance detection alarm signal source via a wire. One end of the wire is inserted into the I0.0 terminal hole, and the other end is inserted into the signal output terminal hole of the external capacitance detection alarm signal source. I0.1 is connected to the output terminal of an external fault alarm signal source via a wire. One end of the wire is inserted into the I0.1 terminal hole, and the other end is inserted into the signal output terminal hole of the external fault alarm signal source. I0.2 is connected to the output terminal of an external small motor alarm signal source via a wire. One end of the wire is inserted into the I0.2 terminal hole, and the other end is inserted into the signal output terminal hole of the external small motor alarm signal source. I0.3 is connected to the output terminal of an external safety door alarm signal source via a wire. One end of the wire is inserted into the I0.3 terminal hole, and the other end is inserted into the signal output terminal hole of the external safety door alarm signal source. I0.4 is a spare input interface, connected to a reserved terminal via a wire. The reserved terminal can be connected to a new external signal source. I0.5 is a spare input interface, connected to a reserved terminal via a wire. The reserved terminal can be connected to a new external signal source. I0.0, I0.1, I0.2, I0.3, I0.4, and I0.5 are all located in the upper area of the PLC control module. The corresponding interface number and connection signal name are labeled next to the terminals for easy wiring identification.
[0034] In the output interfaces of the PLC control module, Q0.0 is connected to the input terminal of the relay coil in the charging completion control circuit via a wire, with a fuse connected in series in the middle of the wire to protect the relay coil from overcurrent damage; Q0.1 is connected to the input terminal of the relay coil in the drive alarm control circuit via a wire, with a fuse connected in series in the middle of the wire, and the fuse specifications are the same as those in the Q0.0 circuit; Q0.2 is connected to the first terminal of the contactor KM1 coil via a wire, with one end of the wire inserted into the terminal hole of Q0.2 and the other end inserted into the terminal hole of the first terminal of the KM1 coil; Q0.3 is a spare output interface, connected to a reserved terminal via a wire, which can be used to connect new actuators; the output interfaces Q0.0, Q0.1, Q0.2, and Q0.3 are all located in the lower area of the PLC control module, corresponding one-to-one with the input interfaces I0.0, I0.1, I0.2, I0.3, I0.4, and I0.5, with the interface number and the name of the controlled object labeled next to the terminal to avoid wiring confusion.
[0035] In the motor control module, the U1 terminal of the flying shear cooling fan M2 is connected to the first output terminal of the main contact of contactor KM1 via a wire; the V1 terminal of M2 is connected to the second output terminal of the main contact of KM1 via a wire; and the W1 terminal of M2 is connected to the third output terminal of the main contact of KM1 via a wire. When the main contact of KM1 is closed, three-phase AC power is transmitted to the U1, V1, and W1 terminals through the main contacts, driving M2 to operate. Similarly, the U2 terminal of the first motor M3 is connected to the first output terminal of the main contact of contactor KM2 via a wire; the V2 terminal of M3 is connected to the second output terminal of the main contact of KM2 via a wire; and the W2 terminal of M3 is connected to the third output terminal of the main contact of KM1 via a wire. The third output terminal of the main contact 2 is connected by a wire, and the start and stop of M3 are controlled by the opening and closing of the main contact of KM2; the U3 terminal of the second motor M4 is connected to the first output terminal of the main contact of contactor KM3 by a wire, the V3 terminal of M4 is connected to the second output terminal of the main contact of KM3 by a wire, and the W3 terminal of M4 is connected to the third output terminal of the main contact of KM3 by a wire, and the start and stop of M4 are controlled by the opening and closing of the main contact of KM3; the metal shells of M2, M3 and M4 are all connected to the grounding wire by a dedicated grounding bolt, and the other end of the grounding wire is connected to the output wire of the PE terminal of the three-phase AC power interface to the grounding busbar to form grounding protection.
[0036] In the circuit breaker module, the first input terminal of the three-phase branch circuit breaker QF4 is connected to the output terminal R of the three-phase AC power interface via a wire; the second input terminal of QF4 is connected to the output terminal S via a wire; and the third input terminal of QF4 is connected to the output terminal T via a wire. The first output terminal of QF4 is connected to the first input terminal of the main contact of KM1 via a wire; the second output terminal of QF4 is connected to the second input terminal of the main contact of KM1 via a wire; and the third output terminal of QF4 is connected to the third input terminal of the main contact of KM1 via a wire. QF4 is used for overload and short-circuit protection of the M2 branch, and automatically disconnects when the branch current is abnormal. The first input terminal of the three-phase branch circuit breaker QF5 is connected to the output terminal R via a wire; the second input terminal of QF5 is connected to the output terminal S via a wire; and the third input terminal of QF5 is connected to the output terminal T via a wire. The output terminal of QF5 is connected to the input terminal of the main contact of KM2. For protecting branch M3; the input side connection of the three-phase branch circuit breaker QF6 is the same as that of QF5, and the output side is connected to the main contact input terminal of KM3, used to protect branch M4; the input side of the 24V branch circuit breaker QF1 is connected to the 24V DC power interface 24V terminal output terminal, and the output side is connected to the positive power interface of the PLC control module and the positive terminal of the external alarm signal source, with terminal blocks installed at the wire branch; the input side of QF2 is connected to the 24V terminal output terminal, and the output side is connected to the positive power interface of the PLC control module and the positive terminal of the control circuit relay coil; the input side of QF3 is connected to the 24V terminal output terminal, and the output side is connected to the positive terminal of the spare 24V electrical component; QF4, QF5, and QF6 are installed side by side in the distribution box below the three-phase power input side, and QF1, QF2, and QF3 are installed side by side in the distribution box below the 24V DC power output side, and each circuit breaker surface is marked with the corresponding branch name and protected object.
[0037] In the contactor module, the first terminal of contactor KM1 coil is connected to the output terminal of PLC control module Q0.2 via a wire, and the second terminal of KM1 coil is connected to the 0V terminal output terminal of 24V DC power interface via a wire. A normally closed contact of a manual control button is connected in series in the KM1 coil circuit. The input terminal of the manual control button is connected to the output side of 24V branch circuit breaker QF2, and the output terminal is connected to the first terminal of KM1 coil. The manual control button is used to cut off the coil power supply in an emergency. The first terminal of contactor KM2 coil is connected to the reserved output terminal of PLC control module via a wire, and the second terminal of KM2 coil is connected to the 0V terminal output terminal of 24V DC power interface. The V terminal output is connected via a wire, and the normally closed contact of the manual control button is connected in series in the KM2 coil circuit; the first end of the KM3 coil is connected to the reserved output terminal of the PLC control module via a wire, and the second end of the KM3 coil is connected to the 0V terminal output via a wire, and the normally closed contact of the manual control button is connected in series in the KM3 coil circuit; the coil interfaces of KM1, KM2, and KM3 are all located in the control area on the left side of the distribution box, and the main contact interface is located in the power area on the right side of the distribution box. The coil and the main contact are isolated by the internal insulation plate of the contactor to avoid mutual interference between the coil control circuit and the main contact power circuit.
[0038] It also includes a control system, which comprises a power circuit, a control circuit, and a signal circuit. The power circuit consists of a three-phase AC power interface, a three-phase branch circuit breaker, contactor main contacts, and a motor, used to transmit the electrical energy required for motor operation. The control circuit consists of a 24V DC power interface, a 24V branch circuit breaker, a PLC control module output interface, contactor coils, and relay coils, used to realize the on / off control of contactors and relays. The signal circuit consists of a 24V DC power interface, a 24V branch circuit breaker, an external alarm signal source, and a PLC control module input interface, used to transmit external device status signals to the PLC. The modules are arranged vertically in an orderly manner, with the power module at the top, the circuit breaker module below the power module, the contactor module below the circuit breaker module, the PLC control module in the center below the contactor module, and the motor control module at the bottom. Operating space is reserved between each module to facilitate later wiring, maintenance, and troubleshooting.
[0039] Specific implementation process: First, power is supplied. An external three-phase AC power supply is connected to the three-phase AC interface of the power module, and grounding protection is formed by connecting the PE terminal to the grounding bus. At the same time, an external 24V DC power supply is connected to the 24V DC interface, and the PE terminal of the external power supply is connected to the PE terminal of the three-phase AC interface to ensure reliable grounding of the entire system. Then, the operator manually closes all circuit breakers of the circuit breaker module, including the three-phase branch circuit breakers QF4, QF5, and QF6 that supply power to the motor circuit, and the 24V branch circuit breakers QF1, QF2, and QF3 that supply power to the PLC, alarm signal source, and control relay. At this time, the electrical energy output by the power module is transmitted to the downstream module through the circuit breaker, and the circuit enters the standby state.
[0040] Next, the signal acquisition and PLC initialization phase begins. A 24V DC power supply powers the external alarm signal sources via QF1. Each signal source monitors the status of its corresponding equipment in real time. If the safety door is closed, the capacitors are normal, the small motors are functioning correctly, and the equipment is functioning correctly overall, each signal source outputs a "normal signal" and transmits it to the PLC input interfaces I0.0, I0.1, I0.2, and I0.3 via wires. If a monitoring point is abnormal, the corresponding signal source outputs an "alarm signal," which the PLC input interface immediately captures. Simultaneously, the PLC control module starts after obtaining 24V DC power through QF1 and QF2, automatically reading the signal status of input interfaces I0.0-I0.3. If all input signals are normal, the PLC determines that "the equipment meets the startup conditions" and enters standby control mode. If any alarm signal is present, the PLC immediately locks the output interface, prohibits contactors and relays from operating, and triggers the subsequent alarm process.
[0041] When the equipment meets the startup conditions and the operator issues a "start command," the circuit enters the normal operation phase. The PLC controls the output interface actions sequentially according to preset logic. First, a control signal is output through Q0.2. The 24V DC power supply is transmitted to the contactor KM1 coil via QF2 and Q0.2. After the KM1 coil is energized, the main contacts close, and the three-phase power supply is transmitted to the terminals of the flying shear cooling fan M2 via QF4 and the KM1 main contacts. M2 starts to provide cooling for the flying shear head. After M2 has been running for 3-5 seconds, the PLC outputs a signal through the reserved output terminals, energizing the KM2 and KM3 coils. When the contacts close, the three-phase power supply is supplied to the first motor M3 via the main contacts QF5 and KM2, and to the second motor M4 via the main contacts QF6 and KM3. M3 and M4 start and drive the flying shear to perform the shearing action. During this process, the auxiliary functions operate synchronously. The PLC outputs a signal through Q0.0 to energize the relay coil of the charging completion control circuit. After the relay is activated, it connects the charging circuit to charge the energy storage element of the equipment to ensure stable shearing power. Meanwhile, Q0.1 remains at a "low level", driving the relay coil of the alarm control circuit to de-energize. The alarm device does not activate, indicating that the equipment is operating normally.
[0042] During operation, the circuit is always in an abnormal protection monitoring state. The PLC continuously scans the signals of input interfaces I0.0-I0.3. For example, when the capacitor detection device detects capacitor leakage, the PLC immediately determines "power component abnormality"; when the small motor is overloaded, the PLC determines "auxiliary equipment failure". After capturing an abnormal signal, the PLC will execute the protection action within 0.1 seconds, cutting off the signals of the reserved output terminals corresponding to output interface Q0.2 and KM2 and KM3. The coils of KM1, KM2, and KM3 are de-energized, the main contacts open, and the motors M2, M3, and M4 immediately stop to avoid... Continuous operation under fault-free conditions may cause equipment damage or deviation in shearing accuracy. Simultaneously, the output interface Q0.1 signal is activated, driving the relay coil of the alarm control circuit to be energized. The alarm device is activated to alert the operator of the fault, and the Q0.0 signal state is maintained to prevent abnormal charging of the energy storage element. If the abnormality escalates to overload or short circuit, the corresponding three-phase branch circuit breaker will automatically trip due to the current exceeding the rated value, cutting off the power supply of the corresponding branch and preventing the fault from spreading to the three-phase main power supply. If a short circuit occurs in the 24V circuit, the corresponding 24V branch circuit breaker will trip immediately to protect the PLC output interface from being burned out.
[0043] In the event of a PLC malfunction or a sudden safety incident, the operator can press the "manual normally closed button" on the contactor module. After the button contacts open, the KM1, KM2, and KM3 coil circuits are cut off, the main contacts are forcibly opened, and the motor stops. At the same time, the button signal can trigger the PLC emergency input to further lock the circuit. After a fault occurs, the operator can locate the fault point according to the alarm prompts and the circuit breaker tripping status. After troubleshooting, the operator can manually close the tripped circuit breaker, repair the external alarm signal source, restore the "safety signal" of the PLC input interfaces I0.0-I0.3, and then press the PLC reset button. The PLC will clear the fault memory and re-enter the initialization stage. After all signals are normal, the start command can be issued again, and the circuit will resume normal operation.
[0044] In the embodiments disclosed in this utility model, the terms "installation," "connection," "linking," and "fixing" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; "linking" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments disclosed in this utility model according to the specific circumstances.
[0045] This specific embodiment is merely an explanation of the present utility model and is not intended to limit the present utility model. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but as long as they are within the scope of the claims of the present utility model, they are protected by patent law.
Claims
1. A safety control circuit for a flying shear machine, characterized in that: It includes a power supply module, a PLC control module, a motor control module, a circuit breaker module, and a contactor module. These modules form a complete control loop via wiring. The PLC control module has input interfaces I0.0, I0.1, I0.2, I0.3, I0.4, and I0.
5. The system includes 0.5 and output interfaces Q0.0, Q0.1, Q0.2, and Q0.3; the motor control module includes a flying shear cooling fan M2, a first motor M3, and a second motor M4. M2 has interfaces U1, V1, and W1; M3 has interfaces U2, V2, and W2; and M4 has interfaces U3, V3, and W3. The circuit breaker module includes three-phase branch circuit breakers QF4, QF5, and QF6, and 24V branch circuit breakers QF1, QF2, and QF3. The contactor module includes contactors KM1, KM2, and KM3. Each contactor has a coil interface and a main contact interface. The coil interface includes a first coil end and a second coil end. The main contact interface includes a first main contact input end, a second main contact input end, a third main contact input end, a first main contact output end, a second main contact output end, and a third main contact output end. The power module output terminals are connected to the circuit breaker module input side; the PLC control module power interface is connected to the 24V branch circuit breaker output side, input interface I0.0 is connected to the external capacitor detection alarm signal source output terminal, I0.1 is connected to the external fault alarm signal source output terminal, I0.2 is connected to the external small motor alarm signal source output terminal, and I0.3 is connected to the external safety door alarm signal source output terminal; output interface Q0.0 is connected to the charging completion control circuit relay coil, Q0.1 is connected to the drive alarm control circuit relay coil, and Q0.2 is connected to the first terminal of KM1 coil; the contactor main contact input side is connected to the three-phase branch circuit breaker output side, and the output side is connected to the corresponding motor interface; the 24V branch circuit breaker output side is connected to the positive terminal of the external alarm signal source, the positive terminal of the control circuit relay coil, and the positive terminal of the spare 24V electrical component.
2. The safety control circuit for a flying shear machine according to claim 1, characterized in that: The power module includes a three-phase AC power interface and a 24V DC power interface. The three-phase AC power interface has four terminals: R, S, T, and PE. The R terminal connects to the R phase of an external three-phase power supply, the S terminal connects to the S phase, the T terminal connects to the T phase, and the PE terminal connects to the external grounding electrode. The PE terminal also connects to the metal casings of the PLC control module, the motors in the motor control module, the circuit breakers in the circuit breaker module, and the contactors in the contactor module. The 24V DC power interface has three terminals: 24V, 0V, and PE. The 24V terminal connects to the positive terminal of an external 24V DC power supply. The 0V terminal is connected to the negative terminal of an external 24V DC power supply, and the PE terminal is connected to the same terminal as the PE terminal of the three-phase AC power supply interface. The R, S, and T terminals of the three-phase AC power supply interface are connected to the input sides of the three-phase branch circuit breakers QF4, QF5, and QF6, respectively. The 24V terminal of the 24V DC power supply interface is connected to the input sides of the 24V branch circuit breakers QF1, QF2, and QF3. The 0V terminal is connected to the negative terminal of the PLC control module power supply interface, the second terminal of the KM1 coil, the second terminal of the KM2 coil, the second terminal of the KM3 coil, and the negative terminal of the external alarm signal source.
3. The safety control circuit for a flying shear machine according to claim 1, characterized in that: In the input interface of the PLC control module, I0.0 is connected to the output terminal of the external capacitance detection alarm signal source via a wire. One end of the wire is inserted into the I0.0 terminal hole, and the other end is inserted into the signal output terminal hole of the external capacitance detection alarm signal source. Input I0.1 is connected to the output of an external fault alarm signal source via a wire. One end of the wire is inserted into the terminal hole of I0.1, and the other end is inserted into the signal output terminal hole of the external fault alarm signal source. Input I0.2 is connected to the output of an external small motor alarm signal source via a wire. One end of the wire is inserted into the terminal hole of I0.2, and the other end is inserted into the signal output terminal hole of the external small motor alarm signal source. Input I0.3 is connected to the output of an external safety door alarm signal source via a wire. One end of the wire is inserted into the terminal hole of I0.3, and the other end is inserted into the signal output terminal hole of the external safety door alarm signal source. Input I0.4 is a spare input interface, connected to a reserved terminal via a wire. This reserved terminal can be used to connect to a new external signal source. Input I0.5 is a spare input interface, connected to a reserved terminal via a wire. This reserved terminal can be used to connect to a new external signal source. Input interfaces I0.0, I0.1, I0.2, I0.3, I0.4, I... The 0.5 terminals are distributed in the upper area of the PLC control module, with the corresponding interface number and connection signal name labeled next to the terminals for easy wiring identification.
4. The safety control circuit for a flying shear machine according to claim 1, characterized in that: In the output interfaces of the PLC control module, Q0.0 is connected to the input terminal of the relay coil of the charging completion control circuit via a wire, with a fuse connected in series in the middle of the wire to protect the relay coil from overcurrent damage; Q0.1 is connected to the input terminal of the relay coil of the drive alarm control circuit via a wire, with a fuse connected in series in the middle of the wire, and the fuse specifications are the same as those in the Q0.0 circuit; Q0.2 is connected to the first terminal of the contactor KM1 coil via a wire, with one end of the wire inserted into the terminal hole of Q0.2 and the other end inserted into the terminal hole of the first terminal of the KM1 coil; Q0.3 is a spare output interface, connected to a reserved terminal via a wire, which can be used to connect new actuators; the output interfaces Q0.0, Q0.1, Q0.2, and Q0.3 are all located in the lower area of the PLC control module, corresponding one-to-one with the input interfaces I0.0, I0.1, I0.2, I0.3, I0.4, and I0.5, with the interface number and the name of the controlled object labeled next to the terminal to avoid wiring confusion.
5. The safety control circuit for a flying shear machine according to claim 1, characterized in that: In the motor control module, the U1 terminal of the flying shear cooling fan M2 is connected to the first output terminal of the main contact of contactor KM1 via a wire; the V1 terminal of M2 is connected to the second output terminal of the main contact of KM1 via a wire; and the W1 terminal of M2 is connected to the third output terminal of the main contact of KM1 via a wire. When the main contact of KM1 is closed, three-phase AC power is transmitted to the U1, V1, and W1 terminals through the main contacts, driving M2 to operate. The U2 terminal of the first motor M3 is connected to the first output terminal of the main contact of contactor KM2 via a wire; the V2 terminal of M3 is connected to the second output terminal of the main contact of KM2 via a wire; and the W2 terminal of M3 is connected to the third output terminal of the main contact of KM1 via a wire. The third output terminal of the main contact of M2 is connected by a wire, and the start and stop of M3 are controlled by the opening and closing of the main contact of KM2; the U3 terminal of the second motor M4 is connected to the first output terminal of the main contact of contactor KM3 by a wire, the V3 terminal of M4 is connected to the second output terminal of the main contact of KM3 by a wire, and the W3 terminal of M4 is connected to the third output terminal of the main contact of KM3 by a wire, and the start and stop of M4 are controlled by the opening and closing of the main contact of KM3; the metal shells of M2, M3 and M4 are all connected to the grounding wire by a dedicated grounding bolt, and the other end of the grounding wire is connected to the output wire of the PE terminal of the three-phase AC power interface to the grounding busbar to form grounding protection.
6. The safety control circuit for a flying shear machine according to claim 1, characterized in that: In the circuit breaker module, the first input terminal of the three-phase branch circuit breaker QF4 is connected to the output terminal R of the three-phase AC power interface via a wire; the second input terminal of QF4 is connected to the output terminal S via a wire; and the third input terminal of QF4 is connected to the output terminal T via a wire. The first output terminal of QF4 is connected to the first input terminal of the main contact of KM1 via a wire; the second output terminal of QF4 is connected to the second input terminal of the main contact of KM1 via a wire; and the third output terminal of QF4 is connected to the third input terminal of the main contact of KM1 via a wire. QF4 is used for overload and short-circuit protection of the M2 branch, and automatically disconnects when the branch current is abnormal. The first input terminal of the three-phase branch circuit breaker QF5 is connected to the output terminal R via a wire; the second input terminal of QF5 is connected to the output terminal S via a wire; and the third input terminal of QF5 is connected to the output terminal T via a wire. The output terminal of QF5 is connected to the main contact input terminal of KM2. Used to protect branch M3; the input side connection of the three-phase branch circuit breaker QF6 is the same as that of QF5, and the output side is connected to the main contact input terminal of KM3, used to protect branch M4; the input side of the 24V branch circuit breaker QF1 is connected to the 24V DC power interface 24V terminal output terminal, and the output side is connected to the positive power interface of the PLC control module and the positive terminal of the external alarm signal source, with terminal blocks installed at the wire branch; the input side of QF2 is connected to the 24V terminal output terminal, and the output side is connected to the positive power interface of the PLC control module and the positive terminal of the control circuit relay coil; the input side of QF3 is connected to the 24V terminal output terminal, and the output side is connected to the positive terminal of the spare 24V electrical component; QF4, QF5, and QF6 are installed side by side in the distribution box below the three-phase power input side, and QF1, QF2, and QF3 are installed side by side in the distribution box below the 24V DC power output side, and each circuit breaker surface is marked with the corresponding branch name and protected object.
7. The safety control circuit for a flying shear machine according to claim 1, characterized in that: In the contactor module, the first end of the KM1 coil is connected to the output terminal of the PLC control module Q0.2 via a wire, and the second end of the KM1 coil is connected to the 0V terminal output terminal of the 24V DC power interface via a wire. A normally closed contact of a manual control button is connected in series in the KM1 coil circuit. The input terminal of the manual control button is connected to the output side of the 24V branch circuit breaker QF2, and the output terminal is connected to the first end of the KM1 coil. The manual control button is used to cut off the coil power supply in an emergency. The first end of the KM2 coil is connected to the reserved output terminal of the PLC control module via a wire, and the second end of the KM2 coil is connected to... The 0V terminal output is connected via a wire, and the normally closed contact of the manual control button is connected in series in the KM2 coil circuit; the first end of the KM3 coil is connected to the reserved output terminal of the PLC control module via a wire, and the second end of the KM3 coil is connected to the 0V terminal output via a wire, and the normally closed contact of the manual control button is connected in series in the KM3 coil circuit; the coil interfaces of KM1, KM2, and KM3 are all located in the control area on the left side of the distribution box, and the main contact interface is located in the power area on the right side of the distribution box. The coil and the main contact are isolated by the internal insulation plate of the contactor to avoid mutual interference between the coil control circuit and the main contact power circuit.
8. The safety control circuit for a flying shear machine according to claim 1, characterized in that: It also includes a control system, which comprises a power circuit, a control circuit, and a signal circuit. The power circuit consists of a three-phase AC power interface, a three-phase branch circuit breaker, contactor main contacts, and a motor, used to transmit the electrical energy required for motor operation. The control circuit consists of a 24V DC power interface, a 24V branch circuit breaker, a PLC control module output interface, contactor coils, and relay coils, used to realize the on / off control of contactors and relays. The signal circuit consists of a 24V DC power interface, a 24V branch circuit breaker, an external alarm signal source, and a PLC control module input interface, used to transmit external device status signals to the PLC. The modules are arranged vertically in an orderly manner, with the power module at the top, the circuit breaker module below the power module, the contactor module below the circuit breaker module, the PLC control module in the center below the contactor module, and the motor control module at the bottom. Operating space is reserved between each module to facilitate later wiring, maintenance, and troubleshooting.