A hydraulic station pump group safety overhauling hanging card practical training examination system

Abstract

This application discloses a hydraulic station pump unit safety maintenance labeling training and assessment system, effectively solving the problem of the lack of an integrated intelligent training system for the "three-party confirmation" process in the safety maintenance labeling operation training and assessment of hydraulic station pump units. This application constructs a hydraulic station pump unit safety maintenance labeling training and assessment system by setting up related operating consoles, power distribution cabinets, and hydraulic station pump units, and provides corresponding training and assessment methods. It adopts a three-in-one mode of "physical operation + virtual feedback + intelligent control," achieving standardized processes that enforce operational sequences and reduce human error, dynamically simulating accident consequences, enhancing risk perception and safety awareness, and enabling automatic scoring and step judgment by the control system, thus saving assessment time and improving training efficiency.

Description

Technical Field

[0001] This application belongs to the field of industrial equipment safety maintenance training and assessment, specifically involving a hydraulic station pump group safety maintenance tagging training and assessment system. Background Technology

[0002] Hydraulic systems, as an important power transmission and control method in modern industry, are widely used in fields such as engineering machinery, metallurgical equipment, aerospace, and shipbuilding. The hydraulic pump unit is the core power unit of the hydraulic system, responsible for converting mechanical energy into hydraulic energy, providing stable pressure and flow to actuators (such as hydraulic cylinders and hydraulic motors).

[0003] Currently, there is a general lack of intelligent training systems integrating a "three-party confirmation" process for safety inspection and labeling training and assessment of personnel from the production, inspection, and maintenance parties involved in hydraulic power station pump units. Enterprises often rely on theoretical training, which struggles to replicate real-world operational procedures, interlocking controls, and operational signal confirmation. For example, failure to follow the labeling and removal procedures may lead to accidental start-up of the hydraulic power station pump unit, resulting in mechanical injury or electric shock. Furthermore, subjective factors such as complacency or carelessness among personnel can exacerbate risks, potentially triggering safety accidents. Therefore, it is necessary to design a safety inspection and labeling training and assessment system and method for hydraulic power station pump units to replicate real-world scenarios involving control panels, power distribution cabinets, and hydraulic power station pump units. This system should enable personnel from all three parties to sequentially complete operations such as shutdown, power disconnection, labeling and removal, power restoration, and resumption of production. The system should also provide warnings and reminders for operations not performed according to the procedures, and record the type of error, the number of errors, and the assessment score. Summary of the Invention

[0004] This application provides a training and assessment system and method for safety inspection and labeling of hydraulic station pump sets, which effectively solves the problem of the lack of an intelligent training system that integrates the "three-party confirmation" process for safety inspection and labeling operation training and assessment of hydraulic station pump sets.

[0005] According to one aspect of this application, a safety maintenance and labeling training and assessment system for hydraulic station pump units is provided. The system includes a power distribution cabinet, an operating console, and a hydraulic station pump unit, etc.

[0006] The power distribution cabinet includes a PLC and the following switches electrically connected to the PLC: A pump main power switch, A pump control power switch, B pump main power switch, B pump control power switch, filter pump main power switch, filter pump control power switch, A pump power failure tag sensor, B pump power failure tag sensor, filter pump power failure tag sensor, oil circuit simulation light strip drive relay, and training platform work permission relay.

[0007] The control panel includes a training platform working indicator light electrically connected to the training platform's working relay, and indicator lights for pump A main power, pump A control power, pump B main power, pump B control power, filter pump main power, filter pump control power, oil valve open, oil valve closed, accumulator online, accumulator pressure relief offline, pump A offline, pump B offline, filter pump offline, pump A running, pump B running, filter pump running, pump A stop / start switch, pump B stop / start switch, filter pump stop / start switch, emergency stop button, training assessment stop / start switch, operation error alarm buzzer, control panel tag position sensor, and touch screen. The training assessment stop / start switch is a three-position rotary switch, including a stop position, a training start position, and an assessment start position. The pump A stop / start switch, pump B stop / start switch, and filter pump stop / start switch are all two-position rotary switches, including a stop position and a start position.

[0008] The hydraulic station pump unit includes an A pump motor, a B pump motor, a filter pump motor, an accumulator, a return valve, an inlet valve, and a simulated oil circuit light strip located between the return valve and the inlet valve. At the A pump motor location, there are corresponding A pump motor position sensors, A pump motor simulation indicators, and A pump safety switches, all electrically connected to the PLC. At the B pump motor location, there are corresponding B pump motor position sensors, B pump motor simulation indicators, and B pump safety switches, all electrically connected to the PLC. At the filter pump motor location, there are corresponding filter pump motor position sensors, filter pump motor simulation indicators, and filter pump safety switches, all electrically connected to the PLC. At the accumulator location, there are corresponding accumulator position sensors and accumulator lights, all electrically connected to the PLC. The device includes a simulated indicator, with an accumulator ball valve connected to the accumulator. The accumulator ball valve has an open position sensor and a closed position sensor, both electrically connected to the PLC, at their respective open and closed positions. The return oil valve and inlet oil valve have corresponding position sensors, also electrically connected to the PLC. The oil circuit simulated light strip has an oil valve tag position sensor, also electrically connected to the PLC. The simulated indicator for pump A includes simulated red and green lights. The simulated indicator for pump B includes simulated red and green lights. The simulated indicator for filter pump motors includes simulated red and green lights. The simulated indicator for the accumulator includes simulated red and green lights.

[0009] Furthermore, the power distribution cabinet, control panel, and hydraulic station pump unit are respectively equipped with power distribution cabinet communication terminals, control panel communication junction box terminals, and hydraulic station communication junction box terminals.

[0010] The main power switch for pump A, the control power switch for pump A, the main power switch for pump B, the control power switch for pump B, the main power switch for the filter pump, the control power switch for the filter pump, the power failure tag sensor for pump A, the power failure tag sensor for pump B, and the power failure tag sensor for the filter pump in the power distribution cabinet are connected to the corresponding input ports of the PLC through the communication terminals of the power distribution cabinet.

[0011] The A pump stop / start switch, B pump stop / start switch, filter pump stop / start switch, emergency stop button, training assessment stop / start switch, and control panel tag position sensor on the control panel are connected to the corresponding input ports of the PLC through the control panel communication junction box terminals and the power distribution cabinet communication terminals, respectively.

[0012] The touchscreen on the control panel is connected to the PLC via a communication cable.

[0013] The main power indicator light for pump A, the control power indicator light for pump B, the main power indicator light for pump B, the control power indicator light for pump B, the main power indicator light for filter pump, the control power indicator light for filter pump, the oil valve open indicator light, the oil valve closed indicator light, the accumulator online indicator light, the accumulator pressure relief offline indicator light, the pump A offline indicator light, the pump B offline indicator light, the filter pump offline indicator light, the pump A running indicator light, the pump B running indicator light, and the filter pump running indicator light on the control panel are connected to the corresponding output ports of the PLC through the control panel communication junction box terminals and the power distribution cabinet communication terminals, respectively.

[0014] The A pump motor position sensor, A pump safety switch, B pump motor position sensor, B pump safety switch, filter pump motor position sensor, filter pump safety switch, accumulator position sensor, accumulator valve open position sensor, accumulator valve closed position sensor, return valve position sensor, inlet valve position sensor, and oil valve position sensor of the hydraulic station pump unit are connected to the corresponding input ports of the PLC through the hydraulic station connection junction box terminals and the power distribution cabinet connection terminals, respectively.

[0015] The A pump motor simulation indicator, B pump motor simulation indicator, filter pump motor simulation indicator, and accumulator simulation indicator of the hydraulic station pump unit are respectively connected to the corresponding output ports of the PLC through the hydraulic station connection junction box terminals and the power distribution cabinet connection terminals.

[0016] The coils of the oil circuit simulation light strip drive relay and the training platform enable relay are connected to the corresponding output ports of the PLC through the power distribution cabinet connection terminals. The normally open contact of the oil circuit simulation light strip drive relay is connected in series with the oil circuit simulation light strip, and the normally open contact of the training platform enable relay is connected in series with the training platform enable indicator light.

[0017] Furthermore, it also includes a power drive unit, which includes an AC220V power supply and an isolation transformer connected to the AC220V power supply via an automatic switch. The output of the isolation transformer is connected to a system drive power supply, which is connected to the touch screen, the PLC, and various components connected to the output ports of the PLC and provides power.

[0018] Furthermore, the PLC selected is the Mitsubishi FX2N-128MR.

[0019] The following pumps are listed: Pump A main power switch auxiliary normally open output side, Pump B main power switch auxiliary normally open output side, Filter pump main power switch auxiliary normally open output side, Pump A control power switch auxiliary normally open output side, Pump B control power switch auxiliary normally open output side, Filter pump control power switch auxiliary normally open output side, Pump A stop / start switch normally open output side, Pump B stop / start switch normally open output side, Filter pump stop / start switch normally open output side, Emergency stop button normally closed output side, Inlet valve position sensor normally open output side, Return valve position sensor normally open output side, Accumulator valve closed position sensor normally open output side, Accumulator valve open position sensor normally open output side, Pump A safety switch normally open output side, Pump B safety switch normally open output side, Filter pump safety switch normally open output side, Pump A power failure tag sensor normally open output side, Pump B power failure tag sensor normally open output side, Filter pump power failure tag sensor normally open output side. The normally open outputs of the accumulator position sensor, oil valve position sensor, A pump motor position sensor, B pump motor position sensor, filter pump motor position sensor, and control panel position sensor are respectively connected to PLC input ports X0, X1, X2, X6, X7, X10, X14, X15, X16, and X23. Points X24, X25, X26, X27, X30, X31, X32, X63, X64, X65, X66, X67, X70, X71, X72, and X73 are connected. The normally open output side of the stop / start switch in the practical training assessment is connected to the PLC input ports X50 and X51 respectively. The normally open or normally closed input sides of the above components are connected in parallel and connected to the PLC input port COM.

[0020] The system drive power supply is DC24V, with its 24+ terminal connected to the PLC output port COM. PLC output ports Y0, Y1, Y2, Y6, Y7, Y10, Y16, Y30, and Y22 are respectively connected to the input terminals of the main power indicator lights for pump A, pump B, filter pump, pump A, pump B, and filter pump, as well as the input terminal of the operation error alarm buzzer, oil valve close indicator light, and the input terminal of the training platform's work-allowing relay coil. PLC output port Y20 is connected to the input terminals of the pump A running indicator light and the pump A simulated red light. PLC output port Y21 is connected to the input terminals of the pump B running indicator light and the pump B simulated red light. PLC output port Y23 is connected to the input terminal of the filter pump running indicator light. The input terminals of the indicator lights and the simulated red light of the filter pump are connected; PLC output port Y27 is connected to the input terminal of the oil valve open indicator light and the input terminal of the oil circuit simulated light strip drive relay coil, respectively; PLC output port Y31 is connected to the input terminal of the accumulator online indicator light and the input terminal of the accumulator simulated red light, respectively; PLC output port Y32 is connected to the input terminal of the accumulator pressure relief offline indicator light and the input terminal of the accumulator simulated green light, respectively; PLC output port Y33 is connected to the input terminal of the A pump offline indicator light and the input terminal of the A pump simulated green light, respectively; PLC output port Y34 is connected to the input terminal of the B pump offline indicator light and the input terminal of the B pump simulated green light, respectively; PLC output port Y35 is connected to the input terminal of the filter pump offline indicator light and the input terminal of the filter pump simulated green light, respectively; the 24- terminal of the system drive power supply is connected in parallel with the output terminals of the above-mentioned indicator lights, buzzers, indicating devices and coils;

[0021] The 24+ terminal of the system drive power supply, the normally open contact of the oil circuit simulation light strip drive relay, the work-allowing indicator light of the training platform, and the 24- terminal of the system drive power supply are connected in sequence.

[0022] The 24+ terminal of the system drive power supply, the normally open contact of the training platform's working relay, the oil circuit simulation light strip, and the 24- terminal of the system drive power supply are connected in sequence.

[0023] Compared with existing technologies, this application constructs a hydraulic station pump group safety maintenance and labeling training and assessment system by setting up related operating consoles, power distribution cabinets, and hydraulic station pump groups, and matching them with corresponding training and assessment methods. It adopts a three-in-one mode of "physical operation + virtual feedback + intelligent control" to achieve a standardized process that enforces the operation sequence and reduces human error, realizes dynamic simulation of accident consequences, enhances risk perception and safety awareness, and realizes automatic scoring and step judgment of the control system, saving assessment time and improving training efficiency. Attached Figure Description

[0024] Figure 1This is an overall schematic diagram of a hydraulic station pump unit safety maintenance and labeling training and assessment system according to this application;

[0025] Figure 2 This is a schematic diagram of the power distribution cabinet in this application;

[0026] Figure 3 This is a schematic diagram of the hydraulic station pump unit in this application;

[0027] Figure 4 This is a schematic diagram of the operating console in this application;

[0028] Figure 5 This is a schematic diagram of the touchscreen screen in this application;

[0029] Figure 6 This is a connection diagram of the power drive unit, system drive power supply, PLC and other components in this application;

[0030] Figure 7 This is a schematic diagram showing the connection between the external input unit and the PLC in this application;

[0031] Figure 8 This is a schematic diagram showing the connection between the output unit and the PLC in this application;

[0032] Figure 9 This is a schematic diagram of the simulated lamp strip connection in the oil circuit of this application;

[0033] Figure 10 This is a schematic diagram of the emergency stop control in this application;

[0034] In the diagram: 1. Pump A main power indicator; 2. Pump A control power indicator; 3. Pump B main power indicator; 4. Pump B control power indicator; 5. Filter pump main power indicator; 6. Filter pump control power indicator; 7. Oil valve open indicator; 8. Oil valve closed indicator; 9. Accumulator online indicator; 10. Accumulator pressure relief offline indicator; 11. Pump A offline indicator; 12. Pump B offline indicator; 13. Filter pump offline indicator; 14. Pump A running indicator; 15. Pump B running indicator; 16. Filter pump running indicator; 17. Pump A stop / start switch; 18. Pump B stop / start switch; 19. Filter pump stop / start switch; 20. Emergency stop button; 21. Training assessment stop / start button. 1. Off; 22. Operation error alarm buzzer; 23. Test light button; 24. Training platform work permit indicator light; 25. Operating platform tag position sensor; 26. Operating platform communication junction box terminal; 27. Touch screen; 28. Power distribution cabinet operating area; 29. ​​A pump main power switch; 30. A pump control power switch; 31. B pump main power switch; 32. B pump control power switch; 33. Filter pump main power switch; 34. Filter pump control power switch; 35. A pump power failure tag sensor; 36. B pump power failure tag sensor; 37. Filter pump power failure tag sensor; 38. Power distribution cabinet communication terminal; 39. Power distribution cabinet control unit; 40. Hydraulic station pump set; 41. A pump motor; 42. 43. Pump A motor position sensor; 431. Pump A motor simulation indicator; 432. Pump A simulated red light; 433. Pump A simulated green light; 44. Pump B motor; 45. Pump B motor position sensor; 46. Pump B motor simulation indicator; 461. Pump B simulated red light; 462. Pump B simulated green light; 47. Filter pump motor; 48. Filter pump motor position sensor; 49. Filter pump motor simulation indicator; 491. Filter pump simulated red light; 492. Filter pump simulated green light; 50. Accumulator; 51. Accumulator position sensor; 52. Accumulator simulation indicator; 521. Accumulator simulated red light; 522. Accumulator simulated green light; 53. Accumulator ball valve; 54. 55. Accumulator valve open position sensor; 57. Accumulator valve closed position sensor; 58. Return oil valve; 59. Return oil valve position sensor; 60. Inlet oil valve; 61. Inlet oil valve position sensor; 62. Oil valve tag position sensor; 63. Pump A safety switch; 64. Pump B safety switch; 65. Filter pump safety switch; 66. Hydraulic station communication junction box terminal; 67. Control panel; 68. Power distribution cabinet; 69. Hydraulic station communication junction box; 70. Cable communication tray; 71. Keyboard area; 72. Oil circuit simulation light strip; 73. Power drive unit; 74. AC220V power supply; 75. System drive power supply; 86. PLC; 87. External input unit; 88. Output unit; 89. Oil circuit simulation light strip drive relay;84. Training platform working relay; 85. Automatic switch; 92. Isolation transformer; 1'. Pump A main power display block; 2'. Pump A control power display block; 3'. Pump B main power display block; 4'. Pump B control power display block; 5'. Filter pump main power display block; 6'. Filter pump control power display block; 22'. Operation error synchronous display block; 25'. Operating platform tag position sensor display block; 35'. Pump A power failure tag sensor display block; 36'. Pump B power failure tag sensor display block; 37'. Filter pump power failure tag sensor display block; 40'. Hydraulic station pump group 3D model display block; 42'. Pump A motor tag position sensor. Display block; 43', A pump motor simulation display block; 45', B pump motor tag position sensor display block; 46', B pump motor simulation display block; 48', filter pump motor tag position sensor display block; 49', filter pump motor simulation display block; 51', accumulator tag position sensor; 52', accumulator simulation display block; 61', oil valve tag position sensor display block; 66', control panel 3D model display block; 67', power distribution cabinet 3D model display block; 71', tag hanging operation sequence display block; 72', tag removal operation sequence display block; 73', timing and scoring display block; 74', error message box; 75', operation error count display block. Detailed Implementation

[0035] The technical solutions in the embodiments will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0036] Example 1:

[0037] As shown in the attached figures, this application provides a safety maintenance and labeling training and assessment system for hydraulic station pump units, which includes a power distribution cabinet 67, an operating console 66, and a hydraulic station pump unit 40, etc., wherein:

[0038] The power distribution cabinet 67 adopts a split design, including a power distribution cabinet operation area 28 located at the upper front and a power distribution cabinet control unit 39 located at the lower rear. The power distribution cabinet control unit 39 includes a PLC 80 for controlling the entire system, as well as an oil circuit simulation light strip drive relay 83 and a training platform work-allowing relay 84, which are electrically connected to the PLC 80 respectively. The power distribution cabinet operation area 28 is arranged vertically with the following switches: A pump main power switch 29, A pump control power switch 30, B pump main power switch 31, B pump control power switch 32, filter pump main power switch 33, filter pump control power switch 34, A pump power failure tag sensor 35, B pump power failure tag sensor 36, and filter pump power failure tag sensor 37, all of which are electrically connected to the PLC 80.

[0039] The control panel 66 is used to simulate the actual production operation of the hydraulic station pump unit 40 and the display and feedback of various signals. It includes a training platform enable indicator light 24 electrically connected to the training platform enable relay 84, and indicator lights 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, and 13 of the filter pump, all electrically connected to the PLC 80. The following are listed: Pump A running indicator light 14, Pump B running indicator light 15, Filter pump running indicator light 16, Pump A stop / start switch 17, Pump B stop / start switch 18, Filter pump stop / start switch 19, Emergency stop button 20, Training assessment stop / start switch 21, Operation error alarm buzzer 22, Test light button 23, Operating panel tag position sensor 25, and Touch screen 27; Training assessment stop / start switch 21 is a three-position rotary switch, including stop, training start, and assessment start positions; Pump A stop / start switch 17, Pump B stop / start switch 18, and Filter pump stop / start switch 19 are all two-position rotary switches, including stop and start positions.

[0040] The hydraulic station pump unit 40 is used to simulate the hydraulic station pump unit equipment used in actual production. It includes an A pump motor 41, a B pump motor 44, a filter pump motor 47, an accumulator 50, a return valve 57, an inlet valve 59, and an oil circuit simulation light strip 76 located between the return valve 57 and the inlet valve 59. The oil circuit simulation light strip 76 is used to simulate the oil circuit status of the hydraulic station pump unit 40. A pump motor 41 is equipped with an A pump motor tag position sensor 42, an A pump motor simulation indicator 43, and an A pump motor 44, which are respectively electrically connected to the PLC 80. Safety switch 62; A B pump motor tag position sensor 45, a B pump motor analog indicator 46, and a B pump safety switch 63, all electrically connected to PLC 80, are respectively provided at the B pump motor 44; A filter pump motor tag position sensor 48, a filter pump motor analog indicator 49, and a filter pump safety switch 64, all electrically connected to PLC 80, are respectively provided at the filter pump motor 47; An accumulator tag position sensor 51 and an accumulator analog indicator 50, all electrically connected to PLC 80, are respectively provided at the accumulator 50. The device 52 includes an accumulator ball valve 53 connected to the accumulator 50. An accumulator valve open position sensor 54 and an accumulator valve closed position sensor 55, electrically connected to the PLC 80, are respectively installed at the open and closed positions of the accumulator ball valve 53. A return oil valve position sensor 58 and an inlet oil valve position sensor 60, electrically connected to the PLC 80, are respectively installed at the return oil valve 57 and inlet oil valve 59. An oil valve tag position sensor 61, electrically connected to the PLC 80, is installed at the oil circuit simulation light strip 76. An A pump motor simulation indicator is also included. Device 43 includes a simulated red light 431 and a simulated green light 432 for pump A; a simulated indicator device 46 for pump B motor includes a simulated red light 461 and a simulated green light 462 for pump B; a simulated indicator device 49 for filter pump motor includes a simulated red light 491 and a simulated green light 492 for filter pump; and a simulated indicator device 52 for accumulator includes a simulated red light 521 and a simulated green light 522 for accumulator. The simulated red light and simulated green light for each pump are used to simulate the operating status of each pump and the status of closing the corresponding safety switch during safety maintenance.

[0041] In this embodiment, to facilitate the wiring connection between the various components in the power distribution cabinet 67, the control panel 66, and the hydraulic station pump group 40, the power distribution cabinet 67, the control panel 66, and the hydraulic station pump group 40 are respectively equipped with a power distribution cabinet connection terminal 38, a control panel connection junction box terminal 26, and a hydraulic station connection junction box terminal 65.

[0042] The main power switch 29 for pump A, the control power switch 30 for pump A, the main power switch 31 for pump B, the control power switch 32 for pump B, the main power switch 33 for the filter pump, the control power switch 34 for the filter pump, the power failure tag sensor 35 for pump A, the power failure tag sensor 36 for pump B, and the power failure tag sensor 37 for the filter pump in the power distribution cabinet 67 are connected to the corresponding input ports of the PLC 80 via control cables and the power distribution cabinet connection terminal 38.

[0043] The A pump stop / start switch 17, B pump stop / start switch 18, filter pump stop / start switch 19, emergency stop button 20, practical training assessment stop / start switch 21, test light button 23, and the control panel tag position sensor 25 on the control panel 66 are connected to the corresponding input ports of PLC 80 via control cables and through the control panel communication junction box terminal 26 and the power distribution cabinet communication terminal 38.

[0044] The touch screen 27 on the control panel 66 is connected to the PLC 80 via a communication cable.

[0045] The following indicators on the control panel 66 are connected to the corresponding output ports of PLC 80 via control cables and through the control panel connection junction box terminal 26 and the power distribution cabinet connection terminal 38: Pump A main power indicator 1, Pump A control power indicator 2, Pump B main power indicator 3, Pump B control power indicator 4, Filter pump main power indicator 5, Filter pump control power indicator 6, Oil valve open indicator 7, Oil valve closed indicator 8, Accumulator online indicator 9, Accumulator pressure relief offline indicator 10, Pump A offline indicator 11, Pump B offline indicator 12, Filter pump offline indicator 13, Pump A running indicator 14, Pump B running indicator 15, and Filter pump running indicator 16.

[0046] The A pump motor position sensor 42, A pump safety switch 62, B ​​pump motor position sensor 45, B pump safety switch 63, filter pump motor position sensor 48, filter pump safety switch 64, accumulator position sensor 51, accumulator valve open position sensor 54, accumulator valve closed position sensor 55, return valve position sensor 58, inlet valve position sensor 60, and oil valve position sensor 61 of the hydraulic station pump unit 40 are connected to the corresponding input ports of PLC 80 via control cables and through the hydraulic station connection junction box terminal 65 and the power distribution cabinet connection terminal 38.

[0047] The simulated red and green lights of the A pump motor simulation indicator 43, B pump motor simulation indicator 46, filter pump motor simulation indicator 49, and accumulator simulation indicator 52 of the hydraulic station pump group 40 are connected to the corresponding output ports of PLC 80 via control cables and through the hydraulic station communication junction box terminal 65 and the power distribution cabinet communication terminal 38.

[0048] The coils of the oil circuit simulation light strip drive relay 83 and the training platform enable relay 84 are connected to the corresponding output ports of PLC 80 via control cables and power distribution cabinet connection terminals 38, respectively. The normally open contact of the oil circuit simulation light strip drive relay 83 is connected in series with the oil circuit simulation light strip 76 via a control cable. The normally open contact of the training platform enable relay 84 is connected in series with the training platform enable indicator light 24 via a control cable.

[0049] In this embodiment, a cable tray can be installed between the power distribution cabinet 67, the control panel 66, and the hydraulic station pump group 40 to house various control cables, communication cables, etc.

[0050] In this embodiment, the components connected to each input port of PLC80 constitute an external input unit 81, which is used to input various signals to PLC80, and the components connected to each output port of PLC80 constitute an output unit 82, which is used to output corresponding signals according to various input signals.

[0051] In this example, to provide power to the system, a power drive unit 77 is also included. The power drive unit 77 includes an AC220V power supply 78 and an isolation transformer 92 connected to the AC220V power supply 78 via an automatic switch 85. The output terminal of the isolation transformer 92 is connected to a system drive power supply 79. The system drive power supply 79 is connected to the touch screen 27, the PLC 80, and various components connected to the output ports of the PLC 80, and provides power to them.

[0052] Taking the Mitsubishi FX2N-128MR PLC80 as an example, the following are the main power switches for pump A (29, auxiliary normally open output side), pump B (31, auxiliary normally open output side), filter pump (33, auxiliary normally open output side), pump A (30, auxiliary normally open output side), pump B (32, auxiliary normally open output side), filter pump (34, auxiliary normally open output side), pump A (17, normally open output side), pump B (18, normally open output side), and filter pump (19, normally open). Normally open output side of the following pumps: Test light button 23, Emergency stop button 20, Inlet valve position sensor 60, Return valve position sensor 58, Accumulator valve closed sensor 55, Accumulator valve open sensor 54, Pump A safety switch 62, Pump B safety switch 63, Filter pump safety switch 64, Pump A power failure tag sensor 35, Pump B power failure tag sensor 36, Filter pump... The normally open outputs of the pump power failure tag sensor 37, accumulator tag position sensor 51, oil valve tag position sensor 61, A pump motor tag position sensor 42, B pump motor tag position sensor 45, filter pump motor tag position sensor 48, and operator console tag position sensor 25 are respectively connected to the PLC80 input ports X0, X1, X2, X6, X7, X10, X14, X15, and X16. Points X22, X23, X24, X25, X26, X27, X30, X31, X32, X63, X64, X65, X66, X67, X70, X71, X72, and X73 are connected. The normally open output side of the training and assessment stop / start switch 21 is connected to the PLC80 input ports X50 and X51, respectively, corresponding to the training start position and the assessment start position. The normally open or normally closed input sides of the above components are connected in parallel and connected to the PLC80 input port COM.

[0053] The system drive power supply 79 is a DC 24V power supply, and its 24+ terminal is connected to the COM output port of PLC80; the output ports Y0, Y1, Y2, Y6, Y7, Y10, Y16, Y30, and Y22 of PLC80 are respectively connected to the input terminals of the following pumps: A pump main power indicator 1, B pump main power indicator 3, filter pump main power indicator 5, A pump control power indicator 2, B pump control power indicator 4, and filter pump control power indicator. The input terminals of lamp 6, operation error alarm buzzer 22, oil valve close indicator 8, and training platform enable relay 84 are connected; the output port Y20 of PLC80 is connected to the input terminal of pump A running indicator 14 and pump A simulated red light 431 respectively; the output port Y21 of PLC80 is connected to the input terminal of pump B running indicator 15 and pump B simulated red light 461 respectively; the output port Y23 of PLC80 is connected to the input terminal of filter pump running indicator 16. The input terminal is connected to the filter pump simulated red light input 491; the PLC80 output port Y27 is connected to the oil valve open indicator light input 7 and the oil circuit simulated light strip drive relay 83 coil input respectively; the PLC80 output port Y31 is connected to the accumulator online indicator light input 9 and the accumulator simulated red light input 521 respectively; the PLC80 output port Y32 is connected to the accumulator pressure relief offline indicator light input 10 and the accumulator simulated green light input 522 respectively; PLC80 Output port Y33 is connected to the input terminal of pump A offline indicator light 11 and the input terminal of pump A simulated green light 432, respectively; output port Y34 of PLC80 is connected to the input terminal of pump B offline indicator light 12 and the input terminal of pump B simulated green light 462, respectively; output port Y35 of PLC80 is connected to the input terminal of filter pump offline indicator light 13 and the input terminal of filter pump simulated green light 492, respectively; terminal 24 of the system drive power supply 79 is connected in parallel with the output terminals of the above-mentioned indicator lights, buzzers, indicating devices and coils;

[0054] The 24+ terminal of the system drive power supply 79, the normally open contact of the oil circuit simulation lamp strip drive relay 83, the work-enabling indicator light 24 of the training platform, and the 24- terminal of the system drive power supply 79 are connected in sequence.

[0055] The 24+ terminal of the system drive power supply 79, the normally open contact of the training platform enable relay 84, the oil circuit simulation light strip 76, and the 24- terminal of the system drive power supply 79 are connected in sequence.

[0056] In this embodiment, the system also includes a fingering area 70, which is used by the production party, the inspection party, and the maintenance party to complete the fingering action.

[0057] Example 2:

[0058] Based on Embodiment 1, a training and assessment method for a hydraulic station pump group safety maintenance tagging training and assessment system is provided. The training and assessment method includes a training mode and an assessment mode. Both modes involve the inspection party, maintenance party, and production party simulating and jointly completing the tagging and untagning operations during the safety maintenance of the hydraulic station pump group.

[0059] In training or assessment mode, the actual operating state of the hydraulic station pump unit is simulated before operation using the aforementioned hydraulic station pump unit safety inspection and labeling training and assessment system; that is:

[0060] The PLC80 inside the power distribution cabinet 67 is powered on and can receive various signals from external input units and output signals to achieve corresponding simulation effects. The A pump main power switch 29, A pump control power switch 30, B pump main power switch 31, B pump control power switch 32, filter pump main power switch 33, and filter pump control power switch 34 are all closed, inputting corresponding signals to the PLC80. The oil circuit simulation light strip drive relay 83 and the training platform enable relay 84 are respectively in working condition, i.e., the normally open contacts of the oil circuit simulation light strip drive relay 83 and the training platform enable relay 84 are closed or open. The coils of both relays are energized based on whether the PLC80's Y27 and Y22 output ports output.

[0061] The following indicators on the control panel 66 are illuminated: Pump A main power indicator 1, Pump A control power indicator 2, Pump B main power indicator 3, Pump B control power indicator 4, Filter pump main power indicator 5, Filter pump control power indicator 6, Oil valve open indicator 7, Accumulator online indicator 9, Pump A running indicator 14, Pump B running indicator 15, and Filter pump running indicator 16. The following indicators are off: Oil valve closed indicator 8, Accumulator pressure relief offline indicator 10, Pump A offline indicator 11, Pump B offline indicator 12, and Filter pump offline indicator 13. The operation error alarm buzzer 22 is inactive. Pump A stop / start switch 17, Pump B stop / start switch 18, and Filter pump stop / start switch 19 are in the start position. The emergency stop button 20 is closed. The training assessment stop / start switch 21 is in the stop position. The touchscreen 27 displays the real-time operating status of the entire system. The training platform work permit indicator 24 is off. The test light button 23 is open.

[0062] The simulated red lights 431 (A pump), 461 (B pump), 491 (filter pump), and 521 (accumulator) of the hydraulic station pump unit 40 are on; the simulated green lights 432 (A pump), 462 (B pump), 492 (filter pump), and 522 (accumulator) are off; the accumulator ball valve 53 is closed; and the simulated operating states of the A pump motor 41, B pump motor 44, filter pump motor 47, and accumulator 50 are on. The simulated oil circuit light strip 76 is on; the return valve 57 and inlet valve 59 are open; and the A pump safety switch 62, B ​​pump safety switch 63, and filter pump safety switch 64 are off.

[0063] When selecting the training mode, operate the training assessment stop / start switch 21 to the training start position. The output port Y22 of PLC80 outputs, which energizes the coil of the training platform enable relay 84. The normally open contact of the training platform enable relay 84 closes, controlling the training platform enable indicator light 24 to light up, thus entering the training mode.

[0064] When selecting the assessment mode, operate the training assessment stop / start switch 21 to the assessment start position. The output port Y22 of PLC80 outputs, which energizes the coil of the training platform enable relay 84. The normally open contact of the training platform enable relay 84 is energized, and the training platform enable indicator light 24 is lit, thus entering the assessment mode.

[0065] The specific steps for the listing process are as follows:

[0066] S1. The maintenance team simulates accepting the maintenance task of the hydraulic station pump unit 40 from the inspection team.

[0067] S2. The inspection team, maintenance team, and production team conduct a simulated on-site safety briefing to confirm maintenance items;

[0068] S3. The production operator performs a sequential shutdown operation on each switch on the control panel 66, as follows:

[0069] S3.1. Operate the A pump stop / start switch 17 to the stop position, and control the A pump running indicator light 14 and the A pump simulated red light 431 to turn off through PLC80, simulating the A pump motor 41 to stop running, and synchronously control the touch screen 27 to display the above status.

[0070] S3.2. Operate the B pump stop / start switch 18 to the stop position, and control the B pump running indicator light 15 and the B pump simulated red light 461 to turn off through PLC80, simulating the B pump motor 44 to stop running, and synchronously control the touch screen 27 to display the above status.

[0071] S3.3. Operate the filter pump stop / start switch 19 to the stop position, and control the filter pump running indicator light 16 and the filter pump simulated red light 491 to turn off through PLC80, simulate the filter pump motor 47 to stop running, and synchronously control the touch screen 27 to display the above status.

[0072] S4. The manufacturer hangs a "stop" sign on the control panel 66 at the corresponding position of the control panel sign position sensor 25, triggering the control panel sign position sensor 25 to receive the signal and transmit it to the PLC 80. The PLC 80 controls the touch screen 27 to display the above status.

[0073] S5. The manufacturer completes the signaling action: "The control panel has stopped the machine and the sign has been hung up," informing the inspection and maintenance parties.

[0074] S6. The inspector confirms the labeling information and completes the power outage and labeling operations in sequence at power distribution cabinet 67. The specific steps are as follows:

[0075] S6.1 Disconnect the A pump control power switch 30, and control the A pump control power indicator 2 to turn off via PLC80, and simultaneously control the touch screen 27 to display the above status.

[0076] S6.2 Disconnect the main power switch 29 of pump A, and control the main power indicator light 1 of pump A to turn off through PLC80, and simultaneously control the touch screen 27 to display the above status.

[0077] S6.3 Hang a "Power Outage" sign at the corresponding position of the A pump power outage sign sensor 35 on the power distribution cabinet 67. After the sign is correctly hung, the A pump power outage sign sensor 35 is triggered to receive the signal and transmit it to the PLC80. The PLC80 controls the touch screen 27 to display the above status.

[0078] S6.4 Disconnect the power switch 32 for pump B, and control the power indicator light 4 for pump B to turn off via PLC80, and simultaneously control the touch screen 27 to display the above status.

[0079] S6.5 Disconnect the main power switch 31 of pump B, and control the main power indicator 3 of pump B to turn off through PLC80, and simultaneously control the touch screen 27 to display the above status.

[0080] S6.6 Hang a "Power Outage" sign at the corresponding position of the B pump power outage sign sensor 36 on the power distribution cabinet 67. After the sign is correctly hung, the B pump power outage sign sensor 36 is triggered to receive the signal and transmit it to the PLC80. The PLC80 controls the touch screen 27 to display the above status.

[0081] S6.7 Disconnect the filter pump control power switch 34, and control the filter pump control power indicator 6 to turn off via PLC80, and simultaneously control the touch screen 27 to display the above status.

[0082] S6.8 Disconnect the main power switch 33 of the filter pump, and control the main power indicator light 5 of the filter pump to turn off through PLC80, and simultaneously control the touch screen 27 to display the above status.

[0083] S6.9 Hang a "Power Outage" sign at the corresponding position of the filter pump power outage tag sensor 37 on the power distribution cabinet 67. After the sign is correctly hung, the filter pump power outage tag sensor 37 is triggered to receive the signal and transmit it to the PLC80. The PLC80 controls the touch screen 27 to display the above status.

[0084] S7. The inspector completes the pointing and chanting action: "Power distribution cabinet is de-energized and labeled", informing the manufacturer and maintenance personnel.

[0085] S8. The manufacturer performs pressure relief and tagging operations on the accumulator 50 of the hydraulic station pump unit 40, as detailed below:

[0086] S8.1. Operate the accumulator ball valve 53 to the open position to simulate pressure relief, trigger the accumulator valve open position sensor 54 to receive the signal and trigger the accumulator valve closed position sensor 55 to lose the signal and transmit it to PLC80. PLC80 controls the accumulator to simulate red light 521 and accumulator online indicator light 9 to turn off, and simultaneously controls the touch screen 27 to display the above status.

[0087] S8.2 After the preset simulated pressure relief time, the PLC80 controls the accumulator to simulate the green light 522 and the accumulator pressure relief offline indicator 10 to light up, and simultaneously controls the touch screen 27 to display the above status.

[0088] S8.3 Hang a "stop sign" at the corresponding position of the accumulator tag position sensor 51 of the hydraulic station pump group 40. After the sign is correctly hung, the accumulator tag position sensor 51 is triggered to receive the signal and transmit it to the PLC80. The PLC80 controls the touch screen 27 to display the above status.

[0089] S9. The manufacturer performs the tagging operation by sequentially closing the inlet valve 59 and the return valve 57 of the hydraulic station pump unit 40.

[0090] S9.1. Operate the oil inlet valve 59 to the closed position, trigger the oil inlet valve position sensor 60 to lose signal and transmit it to PLC80, and control the oil circuit analog light strip 76 to turn off through PLC80;

[0091] S9.2. Operate the return oil valve 57 to the closed position, triggering the return oil valve position sensor 58 to lose signal and transmit it to PLC 80. PLC 80 controls the oil valve closed indicator light 8 to light up.

[0092] S9.3 Hang a "stop" sign at the corresponding position of the oil valve tag position sensor 61 in the hydraulic station pump group 40. After the sign is correctly hung, the oil valve tag position sensor 61 is triggered to receive the signal and send it to the PLC80. The PLC80 controls the touch screen 27 to display the above status.

[0093] S10. The manufacturer completes the signaling action: "The hydraulic station has been stopped and a sign has been hung next to it," informing the inspection and maintenance parties.

[0094] S11. The maintenance team confirms the maintenance items for hydraulic station pump unit 40, completes the safety switch operation of the equipment in hydraulic station pump unit 40 in sequence, and affixes tags as follows:

[0095] S11.1. Close the safety switch 62 of pump A, and control the simulated green light 432 and the offline indicator light 11 of pump A to light up through PLC80, and simultaneously control the touch screen 27 to display the above status.

[0096] S11.2 Hang a "maintenance tag" at the corresponding position of the tag position sensor 42 of pump A motor in hydraulic station pump group 40. After the tag is correctly hung, the tag position sensor 42 of pump A motor is triggered to receive the signal and transmit it to PLC80. PLC80 controls the touch screen 27 to display the above status.

[0097] S11.3. Close the safety switch 63 of pump B, and control the simulated green light 462 and the offline indicator light 12 of pump B to light up through PLC80, and simultaneously control the touch screen 27 to display the above status.

[0098] S11.4 Hang a "maintenance tag" at the corresponding position of the tag position sensor 45 of the B pump motor in the hydraulic station pump group 40. After the tag is correctly hung, the B pump motor tag position sensor 45 is triggered to receive the signal and transmit it to the PLC80. The PLC80 controls the touch screen 27 to display the above status.

[0099] S11.5. Close the filter pump safety switch 64, and control the filter pump to simulate the green light 492 and the filter pump offline indicator light 13 to light up through PLC80, and simultaneously control the touch screen 27 to display the above status.

[0100] S11.6 Hang a "maintenance sign" at the corresponding position of the filter pump motor tag position sensor 48 in the hydraulic station pump group 40. After the sign is correctly hung, the filter pump motor tag position sensor 48 is triggered to receive the signal and transmit it to the PLC80. The PLC80 controls the touch screen 27 to display the above status.

[0101] S12. The maintenance team completes the signaling action: "The hydraulic station has been inspected and tagged," informing the inspection team and the production team. The tagging operation is now complete for all three parties.

[0102] S13. The maintenance team begins simulated maintenance operations.

[0103] The steps for removing a sign are as follows:

[0104] S1. The maintenance team simulates the completion of the maintenance work and accepts the inspection and confirmation from the inspection team and the production team in accordance with the maintenance task of the hydraulic station pump unit 40.

[0105] S2. Before the inspection team, maintenance team, and production team simulate on-site safe resumption of production, confirm that the maintenance items have been completed.

[0106] S3. The maintenance team shall, in sequence, remove the tags from the motors of each pump in the hydraulic station pump unit 40 and turn off all safety switches, as follows:

[0107] S3.1 Remove the "Maintenance tag" from the position corresponding to the filter pump motor tag position sensor 48, triggering the loss of signal from the filter pump motor tag position sensor 48, and control the touch screen 27 to display the above status through PLC80;

[0108] S3.2 Turn off the filter pump safety switch 64, and control the filter pump to turn off the simulated green light 492 and the filter pump offline indicator light 13 through PLC80, and simultaneously control the touch screen 27 to display the above status.

[0109] S3.3 Remove the "Maintenance tag" from the position corresponding to the B pump motor tag position sensor 45, triggering the B pump motor tag position sensor 45 to lose signal, and control the touch screen 27 to display the above status through PLC80;

[0110] S3.4 Turn off the safety switch 63 of pump B, and control the PLC80 to turn off the simulated green light 462 and the offline indicator light 12 of pump B, and simultaneously control the touch screen 27 to display the above status.

[0111] S3.5 Remove the "Maintenance tag" from the position corresponding to the A pump motor tag position sensor 42, triggering the A pump motor tag position sensor 42 to lose signal, and control the touch screen 27 to display the above status through PLC80;

[0112] S3.6 Turn off the safety switch 62 of pump A, and control the PLC80 to turn off the simulated green light 432 and the offline indicator light 11 of pump A, and simultaneously control the touch screen 27 to display the above status.

[0113] S4. The maintenance team completes the signaling action: "Hydraulic station maintenance completed, tag removed," and informs the inspection team and the production team.

[0114] S5. The manufacturer completes the unpinning operation at the ball valve position in hydraulic station pump unit 40 and sequentially opens the return valve 57 and the inlet valve 59, as follows:

[0115] S5.1 Remove the "Stop" tag corresponding to the position of the oil valve tag position sensor 61, triggering the oil valve tag position sensor 61 to lose signal, and control the touch screen 27 to display the above status through PLC80;

[0116] S5.2. Operate the return oil valve 57 to the open position, trigger the return oil valve position sensor 58 to receive the signal and transmit it to PLC 80, and control the oil valve to close and turn off the indicator light 8 through PLC 80;

[0117] S5.3. Operate the oil inlet valve 59 to the open position, trigger the oil inlet valve position sensor 60 to receive the signal and transmit it to PLC80, and control the oil circuit simulation light strip 76 and the oil valve open indicator light 7 to light up through PLC80;

[0118] S6. The manufacturer completes the tag removal operation at the accumulator 50 position of the hydraulic station pump unit 40 and operates to close the accumulator ball valve 53, simulating that the accumulator 50 is in an online state, as detailed below:

[0119] S6.1 Remove the "Stop" sign corresponding to the position of the accumulator tag position sensor 51, triggering the loss of signal of the accumulator tag position sensor 51, and control the touch screen 27 to display the above status through PLC80;

[0120] S6.2. Operate the accumulator ball valve 53 to the closed position, trigger the accumulator valve closed position sensor 55 to receive the signal and the accumulator valve open position sensor 54 to lose the signal. Control the accumulator simulated green light 522 and the accumulator pressure relief offline indicator 10 to turn off and the accumulator online indicator 9 to turn on through PLC80, and simultaneously control the touch screen 27 to display the above status.

[0121] S7. The manufacturer completes the signaling action: "The sign next to the hydraulic station has been removed," and informs the inspection and maintenance parties.

[0122] S8. The inspector confirms the details of the tag removal and completes the tag removal and power supply operations in sequence at power distribution cabinet 67, as follows:

[0123] S8.1 Remove the "power outage sign" from the corresponding position of the filter pump power outage sign sensor 37, triggering the loss of signal of the filter pump power outage sign sensor 37, and control the touch screen 27 to display the above status through PLC80;

[0124] S8.2. Turn on the main power switch 33 of the filter pump, and control the main power indicator 5 of the filter pump to light up through PLC80, and simultaneously control the touch screen 27 to display the above status.

[0125] S8.3. Turn on the filter pump control power switch 34, and control the filter pump control power indicator 6 to light up through PLC80, and simultaneously control the touch screen 27 to display the above status.

[0126] S8.4 Remove the "Power Outage" sign at the corresponding position of the B pump power outage sign sensor 36, triggering the B pump power outage sign sensor 36 to lose signal, and control the touch screen 27 to display the above status through PLC80;

[0127] S8.5. Turn on the main power switch 31 of pump B, and control the main power indicator 3 of pump B to light up through PLC80, and simultaneously control the touch screen 27 to display the above status.

[0128] S8.6. Close the B pump control power switch 32, and control the B pump control power indicator 4 to light up through PLC80, and simultaneously control the touch screen 27 to display the above status.

[0129] S8.7 Remove the "Power Outage" sign at the corresponding position of the A Pump Power Outage Sign Sensor 35, triggering the A Pump Power Outage Sign Sensor 35 to lose signal, and control the touch screen 27 to display the above status through PLC80;

[0130] S8.8. Turn on the main power switch 29 of pump A, and control the main power indicator light 1 of pump A to light up through PLC80, and simultaneously control the touch screen 27 to display the above status.

[0131] S8.9. Close the A pump control power switch 30, and control the A pump control power indicator 2 to light up through PLC80, and simultaneously control the touch screen 27 to display the above status.

[0132] S9. The inspector completes the pointing and chanting action: "The power distribution cabinet has been de-tagged and powered on," informing the manufacturer and maintenance personnel.

[0133] S10. The production operator removes the "Stop" sign at position 66 on the control panel and simulates the resumption of production in sequence, as follows:

[0134] S10.1 Remove the "Stop" sign corresponding to the position of the sign hanging position sensor 25 on the control panel, triggering the loss of signal of the sign hanging position sensor 25 on the control panel, and control the touch screen 27 to display the above status through PLC80;

[0135] S10.2. Operate the filter pump stop / start switch 19 to the start position, and control the filter pump operation indicator 16 and the filter pump simulated red light 491 to light up through PLC80, and simultaneously control the touch screen 27 to display the above status.

[0136] S10.3. Operate the B pump stop / start switch 18 to the start position, and control the B pump running indicator light 15 and the B pump simulated red light 461 to light up through PLC80, and simultaneously control the touch screen 27 to display the above status.

[0137] S10.4. Operate the A pump stop / start switch 17 to the start position, and control the A pump running indicator light 14 and the A pump simulated red light 431 to light up through PLC80, and simultaneously control the touch screen 27 to display the above status.

[0138] S11. The production party completes the signaling action: "The control panel has been removed from the sign, and the hydraulic station has resumed production." The inspection party and the maintenance party are informed, and the removal of the sign by all three parties is completed.

[0139] S12. After the three parties confirm that the equipment is operating normally, the inspector counts and retrieves the safety sign, operates the simulation test stop / start switch 28 to the stop position, initializes the operation program and touch screen 27 through PLC80 control, and controls the work-allowed indicator light 24 of the training platform to turn off, and the process is completed.

[0140] If any step in the tag hanging or tag removal operation is not performed correctly, the PLC80 controls the operation error alarm buzzer 22 to issue a warning. Once the error is corrected, the PLC80 controls the operation error alarm buzzer 22 to stop sounding. If the erroneous step is not corrected, subsequent operations are invalid, ensuring that all operations are strictly executed in the set sequence.

[0141] In a preferred embodiment, the touch screen 27 includes: a 3D model display block 67' of the power distribution cabinet, a 3D model display block 66' of the control console, a 3D model display block 40' of the hydraulic station pump group, a main power display block 1' of pump A, a control power display block 2' of pump A, a main power display block 3' of pump B, a control power display block 4' of pump B, a main power display block 5' of the filter pump, and a control power display block 6' of the filter pump; the 3D model display block 67' of the power distribution cabinet is equipped with a power failure tag display block 35' of pump A, a power failure tag display block 36' of pump B, and a power failure tag display block 35' of the filter pump. The device display block 37'; the control panel 3D model display block 66' is equipped with a control panel tag position sensor display block 25'; the hydraulic station pump group 3D model display block 40' is equipped with an A pump motor tag position sensor display block 42', an A pump motor simulation display block 43', a B pump motor tag position sensor display block 45', a B pump motor simulation display block 46', a filter pump motor tag position sensor display block 48', a filter pump motor simulation display block 49', an accumulator tag position sensor 51', an accumulator simulation display block 52', and an oil valve tag position sensor display block 61'.

[0142] When the main power switch 29 of pump A, the control power switch 30 of pump A, the main power switch 31 of pump B, the control power switch 32 of pump B, the main power switch 33 of filter pump, and the control power switch 34 of filter pump are respectively in the closed or open state, the main power display block 1' of pump A, the control power display block 2' of pump A, the main power display block 3' of pump B, the control power display block 4' of pump B, the main power display block 5' of filter pump, and the control power display block 6' of filter pump are respectively displayed in red or green.

[0143] When the control panel position sensor 25, the A pump power failure position sensor 35, the B pump power failure position sensor 36, the filter pump power failure position sensor 37, the A pump motor position sensor 42, the B pump motor position sensor 45, the filter pump motor position sensor 48, the accumulator position sensor 51, and the oil valve position sensor 61 are in the triggered or non-triggered state respectively, the corresponding display blocks 25', 35', 36', 37', 42', 45', 48', 51', and 61' will be displayed in green or red respectively.

[0144] When the simulated red lights 431 for pump A, 461 for pump B, 491 for filter pump, and 521 for accumulator are lit, the simulated display blocks 43' for pump A motor, 46' for pump B motor, and 49' for filter pump motor will be displayed in red respectively; when the simulated green lights 432 for pump A, 462 for pump B, 492 for filter pump, and 522 for accumulator are lit, the simulated display blocks 43' for pump A motor, 46' for pump B motor, 49' for filter pump motor, and 52' for accumulator motor will be displayed in green respectively.

[0145] In a preferred embodiment, the touchscreen 27 screen further includes nine tag-hanging operation sequence display blocks 71' arranged in the same direction and corresponding to tag-hanging operations, and nine tag-removal operation sequence display blocks 72' arranged in the same direction and corresponding to tag-removal operations. Adjacent tag-hanging operation sequence indicator blocks 71' and adjacent tag-removal operation sequence indicator blocks 72' are connected by arrows pointing in the same direction. Before a tag-hanging operation, all nine tag-hanging operation sequence indicator blocks 71' are displayed in red; before a tag-removal operation, the nine tag-removal operation sequence indicator blocks 72' are displayed in green. Each of the nine tag-removal operation sequence indicator blocks 71' corresponds to a tag-hanging operation. In the operation steps S4, S6.3, S6.6, S6.9, S8.3, S9.3, S11.2, S11.4, and S11.6, after each of these steps is completed, the corresponding listing operation sequence indicator block 71' changes from red to green; the nine delisting operation sequence indicator blocks 72' correspond to steps S3.1, S3.3, S3.5, S5.1, S6.1, S8.1, S8.4, S8.7, and S10.1 in the delisting operation, respectively. After each of these steps is completed, the corresponding delisting operation sequence indicator block 69 changes from green to red.

[0146] In a preferred embodiment, the touch screen 27 screen also includes an operation error synchronization display block 22', a timing and scoring display block 73', an error prompt box 74', and an operation error count display block 75'. The operation error synchronization display block 22' is green by default.

[0147] When the tag hanging and tag removal operations are not performed correctly according to the steps of the two operations, the PLC80 controls the operation error alarm buzzer 22 to warn, and at the same time controls the operation error synchronization display block 22' to change from green to flashing red. Simultaneously, the operation error count display block 75' displays the number of times, and the operation error synchronization display block 22' displays the error information. After the step is corrected, the PLC80 controls the operation error alarm buzzer 22 to stop warning, and at the same time controls the operation error synchronization display block 22' to change from flashing red to green.

[0148] When in training mode, the operation time is recorded by PLC80, and the tag hanging and tag taking operations are scored according to the pre-set scoring rules and displayed by the timing and scoring display block 73'.

[0149] When in assessment mode, the operation duration is recorded by PLC80, and the tag hanging and tag taking operations are scored according to the preset scoring rules and displayed through the timing and scoring display block 73'. When the preset assessment time is reached, the timing and scoring stop and are displayed through the timing and scoring display block 73'.

Claims

1. A safety maintenance and labeling training and assessment system for hydraulic station pump sets, characterized in that, Includes power distribution cabinet (67), control panel (66) and hydraulic station pump unit (40); The power distribution cabinet (67) includes a PLC (80) and the following switches electrically connected to the PLC (80): A pump main power switch (29), A pump control power switch (30), B pump main power switch (31), B pump control power switch (32), filter pump main power switch (33), filter pump control power switch (34), A pump power failure tag sensor (35), B pump power failure tag sensor (36), filter pump power failure tag sensor (37), oil circuit simulation light strip drive relay (83), and training platform work permit relay (84). The control panel (66) includes a training platform working indicator light (24) electrically connected to the training platform working relay (84), and the following indicators electrically connected to the PLC (80): Pump A main power indicator light (1), Pump A control power indicator light (2), Pump B main power indicator light (3), Pump B control power indicator light (4), Filter pump main power indicator light (5), Filter pump control power indicator light (6), Oil valve open indicator light (7), Oil valve closed indicator light (8), Accumulator online indicator light (9), Accumulator pressure relief offline indicator light (10), Pump A offline indicator light (11), Pump B offline indicator light (12), Filter pump offline indicator light (13), and Pump A running indicator light (14). 4) Pump B running indicator (15), filter pump running indicator (16), pump A stop / start switch (17), pump B stop / start switch (18), filter pump stop / start switch (19), emergency stop button (20), training assessment stop / start switch (21), operation error alarm buzzer (22), operating table tag position sensor (25) and touch screen (27); the training assessment stop / start switch (21) is a three-position rotary switch, including a stop position, a training start position and an assessment start position; the pump A stop / start switch (17), pump B stop / start switch (18) and filter pump stop / start switch (19) are all two-position rotary switches, including a stop position and a start position; The hydraulic station pump unit (40) includes an A pump motor (41), a B pump motor (44), a filter pump motor (47), an accumulator (50), a return valve (57), an inlet valve (59), and an oil circuit simulation light strip (76) located between the return valve (57) and the inlet valve (59); the A pump motor (41) is equipped with an A pump motor tag position sensor (42), an A pump motor simulation indicator (43), and an A pump safety switch (62), which are electrically connected to the PLC (80) respectively; the B pump motor (44) is equipped with a corresponding... The PLC (80) is equipped with a B pump motor position sensor (45), a B pump motor simulation indicator (46), and a B pump safety switch (63), all electrically connected to the PLC (80). The filter pump motor (47) is equipped with a filter pump motor position sensor (48), a filter pump motor simulation indicator (49), and a filter pump safety switch (64), all electrically connected to the PLC (80). The accumulator (50) is equipped with an accumulator position sensor (51) and an accumulator simulation indicator (64), all electrically connected to the PLC (80). The indicator device (52) is equipped with an accumulator ball valve (53) connected to the accumulator (50). The accumulator ball valve (53) has an accumulator valve open position sensor (54) and an accumulator valve closed position sensor (55) electrically connected to the PLC (80) at its open and closed positions, respectively. The return oil valve (57) and inlet oil valve (59) are respectively equipped with a return oil valve position sensor (58) and an inlet oil valve position sensor (60) electrically connected to the PLC (80). The oil circuit simulation light strip (76) is equipped with a sensor connected to the PLC (80). The oil valve tag position sensor (61) is electrically connected; the A pump motor simulation indicator (43) includes an A pump simulation red light (431) and an A pump simulation green light (432); the B pump motor simulation indicator (46) includes a B pump simulation red light (461) and a B pump simulation green light (462); the filter pump motor simulation indicator (49) includes a filter pump simulation red light (491) and a filter pump simulation green light (492); the accumulator simulation indicator (52) includes an accumulator simulation red light (521) and an accumulator simulation green light (522).

2. The hydraulic station pump unit safety maintenance tagging training and assessment system according to claim 1, characterized in that, The power distribution cabinet (67), the control panel (66) and the hydraulic station pump group (40) are respectively equipped with a power distribution cabinet communication terminal (38), a control panel communication junction box terminal (26) and a hydraulic station communication junction box terminal (65). The A pump main power switch (29), A pump control power switch (30), B pump main power switch (31), B pump control power switch (32), filter pump main power switch (33), filter pump control power switch (34), A pump power failure tag sensor (35), B pump power failure tag sensor (36) and filter pump power failure tag sensor (37) in the power distribution cabinet (67) are respectively connected to the corresponding input ports of the PLC (80) through the power distribution cabinet communication terminal (38); The A pump stop / start switch (17), B pump stop / start switch (18), filter pump stop / start switch (19), emergency stop button (20), training assessment stop / start switch (21), and operating console tag position sensor (25) on the operating console (66) are respectively connected to the corresponding input ports of the PLC (80) through the operating console communication junction box terminal (26) and the power distribution cabinet communication terminal (38); The touch screen (27) on the control panel (66) is connected to the PLC (80) via a communication cable; The A pump main power indicator (1), A pump control power indicator (2), B pump main power indicator (3), B pump control power indicator (4), filter pump main power indicator (5), filter pump control power indicator (6), oil valve open indicator (7), oil valve closed indicator (8), accumulator online indicator (9), accumulator pressure relief offline indicator (10), A pump offline indicator (11), B pump offline indicator (12), filter pump offline indicator (13), A pump running indicator (14), B pump running indicator (15), and filter pump running indicator (16) on the control panel (66) are respectively connected to the corresponding output ports of the PLC (80) through the control panel communication junction box terminal (26) and the power distribution cabinet communication terminal (38); The A pump motor position sensor (42), A pump safety switch (62), B pump motor position sensor (45), B pump safety switch (63), filter pump motor position sensor (48), filter pump safety switch (64), accumulator position sensor (51), accumulator valve open position sensor (54), accumulator valve closed position sensor (55), return valve position sensor (58), inlet valve position sensor (60) and oil valve position sensor (61) of the hydraulic station pump group (40) are respectively connected to the corresponding input ports of the PLC (80) through the hydraulic station connection junction box terminal (65) and the power distribution cabinet connection terminal (38); The A pump motor simulation indicator (43), B pump motor simulation indicator (46), filter pump motor simulation indicator (49) and accumulator simulation indicator (52) of the hydraulic station pump group (40) are respectively connected to the corresponding output ports of the PLC (80) through the hydraulic station connection junction box terminal (65) and the power distribution cabinet connection terminal (38). The coils of the oil circuit simulation light strip drive relay (83) and the training platform enable relay (84) are respectively connected to the corresponding output ports of the PLC (80) through the power distribution cabinet connection terminal (38). The normally open contact of the oil circuit simulation light strip drive relay (83) is connected in series with the oil circuit simulation light strip (76), and the normally open contact of the training platform enable relay (84) is connected in series with the training platform enable indicator light (24).

3. The hydraulic station pump unit safety maintenance tagging training and assessment system according to claim 2, characterized in that, A cable connection bridge (69) is provided between the power distribution cabinet (67), the operating console (66), and the hydraulic station pump group (40). The power distribution cabinet connection terminal (38) of the power distribution cabinet (67) is connected to the operating console connection junction box terminal (26) of the operating console (66) and the hydraulic station connection junction box terminal (65) of the hydraulic station pump group (40) through control cables or communication cables. Each control cable or communication cable is set in the corresponding cable connection bridge (69).

4. The hydraulic station pump unit safety maintenance tagging training and assessment system according to claim 1, characterized in that, It also includes a power drive unit (77), which includes an AC220V power supply (78) and an isolation transformer (92) connected to the AC220V power supply (78) via an automatic switch (85). The output terminal of the isolation transformer (92) is connected to a system drive power supply (79), which is connected to the touch screen (27), the PLC (80), and each component connected to each output port of the PLC (80) and provides power.

5. The hydraulic station pump unit safety maintenance tagging training and assessment system according to claim 4, characterized in that, The PLC (80) is a Mitsubishi FX2N-128MR; The following circuits are connected: the auxiliary normally open output side of the main power switch (29) for pump A, the auxiliary normally open output side of the main power switch (31) for pump B, the auxiliary normally open output side of the main power switch (33) for the filter pump, the auxiliary normally open output side of the control power switch (30) for pump A, the auxiliary normally open output side of the control power switch (32) for pump B, the auxiliary normally open output side of the control power switch (34) for the filter pump, the normally open output side of the stop / start switch (17) for pump A, the normally open output side of the stop / start switch (18) for pump B, the normally open output side of the stop / start switch (19) for the filter pump, and the emergency stop button. (20) Normally closed output side, oil inlet valve position sensor (60) Normally open output side, oil return valve position sensor (58) Normally open output side, accumulator valve closed sensor (55) Normally open output side, accumulator valve open sensor (54) Normally open output side, A pump safety switch (62) Normally open output side, B pump safety switch (63) Normally open output side and filter pump safety switch (64) Normally open output side, A pump power failure tag sensor (35) Normally open output side, B pump power failure tag sensor (36) Normally open output side, filter pump power failure The normally open output side of the electric tag sensor (37), the normally open output side of the accumulator tag position sensor (51), the normally open output side of the oil valve tag position sensor (61), the normally open output side of the A pump motor tag position sensor (42), the normally open output side of the B pump motor tag position sensor (45), the normally open output side of the filter pump motor tag position sensor (48), and the normally open output side of the control panel tag position sensor (25) are respectively connected to the input ports X0, X1, X2, X6, X7, X10, and X14 of the PLC (80). Points X15, X16, X23, X24, X25, X26, X27, X30, X31, X32, X63, X64, X65, X66, X67, X70, X71, X72, and X73 are connected. The normally open output side of the training assessment stop / start switch (21) is connected to the input ports X50 and X51 of the PLC (80) respectively. The normally open or normally closed input sides of the above components are connected in parallel and connected to the input port COM of the PLC (80). The system drive power supply (79) is a DC24V power supply, and its 24+ terminal is connected to the COM point of the output port of the PLC (80); the output ports Y0, Y1, Y2, Y6, Y7, Y10, Y16, Y30 and Y22 of the PLC (80) are respectively connected to the input terminals of the main power indicator (1) of pump A, the main power indicator (3) of pump B, the main power indicator (5) of the filter pump, the control power indicator (2) of pump A, the control power indicator (4) of pump B, and the control power indicator (6) of the filter pump. The PLC (80) output port Y20 is connected to the input terminals of the operation error alarm buzzer (22), the oil valve closing indicator (8), and the training platform enable relay (84). The output port Y21 of the PLC (80) is connected to the input terminals of the A pump running indicator (14) and the A pump simulated red light (431). The output port Y23 of the PLC (80) is connected to the filter pump running indicator (16). The input terminal is connected to the input terminal of the filter pump simulated red light (491); the output port Y27 of the PLC (80) is connected to the input terminal of the oil valve open indicator (7) and the coil input terminal of the oil circuit simulated light strip drive relay (83) respectively; the output port Y31 of the PLC (80) is connected to the input terminal of the accumulator online indicator (9) and the input terminal of the accumulator simulated red light (521) respectively; the output port Y32 of the PLC (80) is connected to the input terminal of the accumulator pressure relief offline indicator (10) and the input terminal of the accumulator simulated green light (522) respectively; the PLC ( 80) Output port Y33 is connected to the input terminal of pump A offline indicator (11) and pump A simulated green light (432) respectively; output port Y34 of PLC (80) is connected to the input terminal of pump B offline indicator (12) and pump B simulated green light (462) respectively; output port Y35 of PLC (80) is connected to the input terminal of filter pump offline indicator (13) and filter pump simulated green light (492) respectively; the 24- terminal of the system drive power supply (79) is connected in parallel with the output terminals of the above-mentioned indicator lights, buzzers, indicating devices and coils; The 24+ terminal of the system drive power supply (79), the normally open contact of the oil circuit simulation lamp strip drive relay (83), the work-allowing indicator light (24) of the training platform, and the 24- terminal of the system drive power supply (79) are connected in sequence; The 24+ terminal of the system drive power supply (79), the normally open contact of the training platform enable relay (84), the oil circuit simulation light strip (76), and the 24- terminal of the system drive power supply (79) are connected in sequence.

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