Special intelligent holding hopper for brewing wine
Through intelligent control system and multi-level protection mechanism, the problems of response delay, contact error and steel rope failure in traditional buckets have been solved, realizing high reliability and energy efficiency optimization of equipment and supporting production data traceability.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SICHUAN LANGJIU CO LTD
- Filing Date
- 2025-07-18
- Publication Date
- 2026-07-24
AI Technical Summary
Traditional manual bucket hoisting suffers from problems such as delayed response of mechanical limit switches, large contact gap errors, motor stalling, and high steel rope failure rates, leading to equipment damage and unstable operation.
An intelligent control system is adopted, including a rope encoder device, a frequency conversion drive unit, a position loop and a torque loop. Combined with an edge computing architecture and an adaptive PID algorithm, it realizes dual closed-loop control, monitors and compensates for the opening and torque of the bucket in real time, and sets up a multi-level protection mechanism to eliminate installation eccentricity error and preload monitoring.
It improves the reliability and safety of the equipment, extends the life of the gearbox, reduces the failure rate and energy consumption, and supports production data traceability and compatibility expansion.
Smart Images
Figure CN224547898U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of intelligent bucket technology, and more specifically to the field of intelligent bucket technology for brewing. Background Technology
[0002] Traditional manual bucket clamping relies on mechanical limit switches for opening and closing position detection, which has systemic technical shortcomings: ① The contactor control has a millisecond-level response delay, which causes the reducer gear to be subjected to an excessive instantaneous impact torque (actual data: peak torque can reach 1.8 times the rated value), accelerating gear fatigue failure; ② The contact gap error of the mechanical limit switch is ≥3mm, and the cumulative deviation reaches ±15mm after long-term use (refer to JB / T8863-2015 standard), which causes the bucket to not close properly; ③ When the steel rope touches the bottom or encounters an obstacle, the motor stall current surges (measured to 3.2 times the rated current), exceeding the thermal relay protection threshold (normal setting value 1.15In), causing the coil to overheat and burn out; ④ The high rates of steel rope derailment and strand breakage (statistics from a winery show an average monthly failure rate of 8.7%) are mainly due to the lack of real-time tension monitoring and dynamic correction mechanisms. Utility Model Content
[0003] The purpose of this utility model is to provide a special intelligent hopper for brewing in order to solve the above-mentioned technical problems.
[0004] To achieve the above objectives, this utility model specifically adopts the following technical solution: This utility model provides a smart brewing bucket for brewing, including a bucket body, a control system and connecting cables; the control system includes a rope encoder device, a frequency conversion drive unit, a position loop and a torque loop. The bucket body includes a connecting rod, a hinge at the bottom of the connecting rod, bucket units symmetrically arranged on both sides of the hinge, traction steel ropes for controlling the opening and closing of the two buckets, and a tension sensor at the connection between the traction steel ropes and the bucket units. A frequency converter drive unit is located at the top of the connecting rod. One end of each traction steel rope is connected to the rotating disk of the frequency converter drive unit, and the other end of each traction steel rope is fixed to the outer edge of the top of the corresponding bucket unit.
[0005] In one embodiment, the pull-rope encoder device is mounted on the top of the connecting rod using a universal bearing floating bracket, which can eliminate installation eccentricity errors.
[0006] In one embodiment, the preload of the traction steel rope is set to 25N ± 2N (monitored by a tension sensor).
[0007] In one embodiment, the connecting cable includes a power line and a signal line. The power line is a 7-core power line of type JTRVV22-4×2.5+1×1.5, and the signal line is a shielded cable of type RVSP-2×1.0.
[0008] Specifically, power lines are indispensable power transmission components in industrial electrical equipment, mainly used to provide power output to high and low voltage distribution cabinets, power control boxes, power control cabinets, building lighting, electric motors, welding machines, machine tools, industrial fans, and other equipment. The grounding resistance of each device is <1Ω.
[0009] In one embodiment, the connector at the connection point of the connecting cable is equipped with an IP67 protection rating (refer to IEC 60529 standard), and the connection point of the connecting cable is provided with an anti-loosening snap-fit structure. In one embodiment, the cable encoder device (model: Cable transducer GCI / GCA4) adopts absolute value encoding technology with a resolution of 1024 PPR, a mechanical limit compensation range of ±15°, real-time feedback of bucket opening θ∈[0°,180°], synchronous monitoring of steel rope displacement ΔL (accuracy ±0.5mm), and linkage with PLC to execute preload compensation algorithm. In one implementation, the variable frequency drive unit (Siemens G120X) is equipped with a SINAMICS V200 control core, supports vector control mode, and monitors motor current (sampling period 1ms), torque (accuracy ±1%FS), and speed (±1r / min) in real time. The variable frequency drive unit has a built-in overload protection model (I²t algorithm).
[0010] In one implementation, the intelligent control system is based on the edge computing architecture of S7-1200, runs an adaptive PID algorithm, and integrates the displacement data of the pull-rope encoder device and the torque data of the frequency converter drive unit to construct a dual closed-loop control model.
[0011] In one embodiment, the position ring sets the opening error band of the two buckets to ε≤0.5°, and the position ring dynamically adjusts the frequency f of the variable frequency drive unit, with the frequency f ranging from 20Hz to 50Hz.
[0012] In one implementation, the torque loop sets a torque threshold T_max = 18 N·m (corresponding to stall protection), compares the deviation ΔT between the actual torque T_real and T_max in real time, and triggers a graded speed reduction strategy.
[0013] The beneficial effects of this utility model are as follows: 1. This utility model has a reasonable design, extending the gearbox MTBF from 3200h to 5800h (according to GB / T 307.1 standard), thus improving reliability.
[0014] 2. By adopting a potential energy recovery strategy, the braking energy feedback efficiency reaches 75%, saving 1.2 kWh of electricity per shift and optimizing energy consumption.
[0015] 3. The failure rate of steel ropes has decreased to 0.3 times / month, and the annual maintenance cost has been reduced by 42%, resulting in lower maintenance costs.
[0016] 4. The control system supports the OPC UA protocol and can be connected to the MES system to achieve production data traceability and expand compatibility. Attached Figure Description
[0017] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.
[0018] Figure 1 This is a schematic diagram of the structure of this utility model; Reference numerals: 1. Rope encoder device; 2. Traction steel rope; 3. Bucket unit. Detailed Implementation
[0019] To make the technical problems, technical solutions, and technical effects of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of this utility model. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.
[0020] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.
[0021] It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. Furthermore, the terms "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.
[0022] In the description of the embodiments of this utility model, it should be noted that the terms "inner", "outer", "upper", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship in which the utility model product is usually placed when in use. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.
[0023] like Figure 1 As shown, this embodiment provides an intelligent hopper for brewing, including a hopper body, a control system, and connecting cables; the control system includes a rope encoder device 1, a frequency converter drive unit, a position loop, and a torque loop; The bucket body includes a connecting rod, a hinge at the bottom of the connecting rod, bucket units 3 symmetrically arranged on both sides of the hinge, traction steel ropes 2 for controlling the opening and closing of the two buckets, and a tension sensor at the connection between the traction steel ropes 2 and the bucket units 3. A frequency conversion drive unit is located at the top of the connecting rod. One end of each traction steel rope 2 is connected to the rotating disk of the frequency conversion drive unit, and the other end of each traction steel rope 2 is fixed to the outer edge of the top of the corresponding bucket unit 3.
[0024] In one embodiment, the pull-rope encoder device 1 is mounted on the top of the connecting rod using a universal bearing floating bracket, which can eliminate installation eccentricity error.
[0025] In one embodiment, the preload of the traction steel rope 2 is set to 25N±2N (monitored by a tension sensor).
[0026] In one embodiment, the connecting cable includes a power line and a signal line. The power line is a 7-core power line of model JTRVV22-4×2.5+1×1.5, and the signal line is a shielded cable of model RVSP-2×1.0.
[0027] Specifically, power lines are indispensable power transmission components in industrial electrical equipment, mainly used to provide power output to high and low voltage distribution cabinets, power control boxes, power control cabinets, building lighting, electric motors, welding machines, machine tools, industrial fans, and other equipment. The grounding resistance of each device is <1Ω.
[0028] In one embodiment, the connector at the connection point is equipped with an IP67 protection rating (refer to IEC 60529 standard), and the connection point is provided with an anti-loosening snap-fit structure. In one embodiment, the cable encoder device 1 (model: Cable transducer GCI / GCA4) adopts absolute value encoding technology with a resolution of 1024 PPR, a mechanical limit compensation range of ±15°, real-time feedback of the bucket opening θ∈[0°,180°], synchronous monitoring of the steel rope displacement ΔL (accuracy ±0.5mm), and linkage with the PLC to execute the preload compensation algorithm.
[0029] In one embodiment, the variable frequency drive unit (Siemens G120X) is equipped with a SINAMICS V200 control core, supports vector control mode, and monitors motor current (sampling period 1ms), torque (accuracy ±1%FS), and speed (±1r / min) in real time. The variable frequency drive unit has a built-in overload protection model (I²t algorithm).
[0030] In one embodiment, the intelligent control system is based on the edge computing architecture of S7-1200, runs an adaptive PID algorithm, and integrates the displacement data of the rope encoder device 1 and the torque data of the frequency converter drive unit to construct a dual closed-loop control model.
[0031] In one embodiment, the position ring sets the opening error band of the two buckets to ε≤0.5°, and the position ring dynamically adjusts the frequency f of the variable frequency drive unit, with the frequency f ranging from 20Hz to 50Hz.
[0032] In one embodiment, the torque loop sets a torque threshold T_max = 18 N·m (corresponding to stall protection), compares the deviation ΔT between the actual torque T_real and T_max in real time, and triggers a graded speed reduction strategy.
[0033] The effect of this embodiment is as follows: Mechatronics coordinated control: Establish the dynamic model of the bucket Mθ̈+Cθ̇+Kθ=F(t), solve the angular displacement θ(t) through the rope coding device, and combine the torque feedback F(t) of the variable frequency drive unit to achieve mechanical vibration suppression (damping ratio ζ≥0.7). Predictive maintenance system: Historical fault diagnosis model, predicts gearbox remaining life (RUL) based on historical operating data (sampling rate 1Hz), with an accuracy of ≥92%; Safety redundancy design: Three-level protection mechanism is set up: Level 1 protection mechanism, zero-position verification of the pull rope coding device (cycle 10ms). Two-level protection mechanism, variable frequency drive unit OC (overcurrent) threshold graded response (5-level speed reduction); Three-level protection mechanism, mechanical limit switch mechanical interlocking (response time <50ms); Software Algorithm: Open-loop start-up phase: S-shaped acceleration / deceleration curve (jerk value = 5000 rpm / s³) is used to suppress start-up shock; Closed-loop control phase: Implement an improved Smith predictor (compensating for time constant τ=2s) to eliminate pure time delay effects; Abnormal operating condition handling: When ΔT > 15%T_max is detected, the brake linkage program is executed (braking time < 0.5s).
[0034] Calibration process: Zero point calibration: The preset value of the pull rope encoder device 1 is zeroed; Full-scale calibration: Apply rated load (1m³ of mash, approximately 1t) and verify the consistency of the position at θ=180°; Torque calibration: Apply stepped loads (10%, 50%, 100% of rated torque) to correct the slope of the torque-current curve.
Claims
1. A smart hopper specifically for brewing, characterized in that, It includes the bucket body, the control system, and the connecting cables; the control system includes a rope encoder device (1), a frequency conversion drive unit, a position loop, and a torque loop. The bucket body includes a connecting rod, a hinge at the bottom of the connecting rod, bucket units (3) symmetrically arranged on both sides of the hinge, traction steel ropes (2) for controlling the opening and closing of the two buckets, a tension sensor at the connection between the traction steel ropes (2) and the bucket units (3), a frequency conversion drive unit at the top of the connecting rod, one end of each traction steel rope (2) connected to the rotating disk of the frequency conversion drive unit, and the other end of each traction steel rope (2) fixed at the outer edge of the top of the corresponding bucket unit (3).
2. The intelligent brewing bucket according to claim 1, characterized in that, The pull-rope encoder device (1) is mounted on the top of the connecting rod using a universal bearing floating bracket.
3. The intelligent brewing bucket according to claim 1, characterized in that, The preload of the traction steel rope (2) is set to 25N±2N.
4. The intelligent brewing bucket according to claim 1, characterized in that, The connecting cable includes a power line and a signal line. The power line is a 7-core power line of model JTRVV22-4×2.5+1×1.5, and the signal line is a shielded cable of model RVSP-2×1.
0.
5. The intelligent brewing bucket according to claim 1, characterized in that, The connector at the connection point of the connecting cable is equipped with an IP67 protection rating, and the connection point of the connecting cable is provided with an anti-loosening snap-fit structure.
6. The intelligent brewing bucket according to claim 1, characterized in that, The rope encoder device (1) has a resolution of 1024 PPR, a mechanical limit compensation range of ±15°, real-time feedback of bucket opening θ∈[0°,180°], synchronous monitoring of steel rope displacement ΔL, and linkage with PLC to execute pre-tension compensation algorithm.
7. The intelligent brewing bucket according to claim 1, characterized in that, The variable frequency drive unit is equipped with the SINAMICS V200 control kernel, supports vector control mode, and monitors motor current, torque and speed in real time. The variable frequency drive unit has a built-in overload protection model.
8. The intelligent brewing bucket according to claim 1, characterized in that, The intelligent control system is based on the edge computing architecture of S7-1200, runs an adaptive PID algorithm, and integrates the displacement data of the pull rope encoder device (1) and the torque data of the frequency conversion drive unit to construct a dual closed-loop control model.
9. The intelligent brewing bucket according to claim 1, characterized in that, The position ring sets the opening error band of the two buckets to ε≤0.5°, and the position ring dynamically adjusts the frequency f of the variable frequency drive unit, with the frequency f ranging from 20Hz to 50Hz.
10. The intelligent brewing bucket according to claim 1, characterized in that, The torque loop is set with a torque threshold T_max = 18 N·m, and the deviation ΔT between the actual torque T_real and T_max is compared in real time.