Thickener electric control box circuit

Abstract

This application relates to a thickener electromechanical control box circuit designed to improve operational accuracy. The circuit includes a programmable logic controller (PLC), a torque sensor, a mud layer height analyzer, a motor current feedback device, and a display and control unit. The PLC has an input / output terminal group and a display interface. The input terminal group is connected to the thickener's electrical load signal control switch, and the output terminal group is connected to the drive circuit, at least two rake motors, and a dilution motor. The torque sensor is located on the rake motor, and the mud layer height analyzer is installed inside the thickener tank. The signal outputs of both are connected to the controller's input terminal group. The number of motor current feedback devices is the same as the motor load, and they are located on the main circuit cable. Their signal outputs are also connected to the controller's input terminal group. The display and control unit is connected to the controller's display interface for information display and control. The power interfaces of all components are uniformly connected to the DC power grid to achieve stable power supply and precise control.

Description

Technical Field

[0001] This application relates to the field of thickener automation control, and more particularly to a thickener electrical control box circuit. Background Technology

[0002] In modern industrial production, thickeners, as key solid-liquid separation equipment, require increasingly higher precision and stability in their control. Traditional control methods are no longer sufficient to meet current production demands, revealing numerous drawbacks. Firstly, traditional control methods lack effective real-time monitoring mechanisms, failing to acquire key operating parameters of the thickener in real time, such as the torque of the rake motor, the sludge layer height in the thickening tank, and the motor's operating current. Without this crucial information, operators struggle to effectively coordinate the control of various components, including the rake motor and dilution motor, leading to unstable equipment operation and susceptibility to overloads and blockages. This not only severely impacts the reliable and safe operation of the equipment but also significantly reduces work efficiency and increases downtime and maintenance costs. Secondly, existing control devices suffer from design flaws. Their complex user interfaces lack intuitiveness and convenience, making it difficult for operators to quickly master the operating procedures. Furthermore, equipment maintenance is challenging, the repair process is cumbersome, and it consumes significant manpower and time, failing to meet the demands of efficient, intelligent, and convenient modern industrial production. Utility Model Content

[0003] In view of this, this application proposes a thickener electrical control box circuit to improve the operating accuracy of the thickener. Its structure includes a programmable logic controller, a torque sensor, a mud layer height analyzer, a motor current feedback device, and a display and control unit. The programmable logic controller (PLC) includes an input terminal group, an output terminal group, and a display interface. The input terminal group of the PLC is connected to the signal control switch signal receiving terminal of the thickener's electrical load. The output terminal group of the PLC is connected to a drive circuit. The output terminal group of the PLC is also connected to at least two rake motors and at least two dilution motors. The torque sensor signal output terminal is connected to the input terminal group of the programmable logic controller, and the torque sensor is installed on the rake frame motor; The signal output terminal of the mud layer height analyzer is connected to the input terminal group of the programmable logic controller, and the mud layer height analyzer is installed inside the thickening tank of the thickener; The signal output terminal of the motor current feedback device is connected to the input terminal group of the programmable logic controller. The number of motor current feedback devices is the same as the number of motor loads in the thickener. The motor current feedback devices are installed on the main circuit cable of the thickener motor load. The display control unit connects to the display interface of the programmable logic controller (PLC) and is used to display and control the information that the PLC needs to display; and The power interfaces of the programmable logic controller, torque sensor, mud layer height analyzer, motor current feedback device, and display and control unit are connected to the DC power grid.

[0004] In one possible implementation, the programmable logic controller consists of a main programmable logic controller and at least one redundant secondary programmable logic controller.

[0005] In one possible implementation, the programmable logic controller is connected to a switch, which enables the programmable logic controller to connect to an industrial network for collaborative operation.

[0006] In one possible implementation, the drive circuit includes a power grid input terminal and a power grid output terminal. The power grid input terminal is connected to the power grid of the thickener control box circuit, and the power grid output terminal is connected to the thickener electrical load.

[0007] In one possible implementation, the torque sensor is positioned around the output shaft of the rake motor.

[0008] In one possible implementation, the torque sensor is positioned between the stator and rotor of the rake motor.

[0009] In one possible implementation, the display control unit consists of an LCD screen and a set of control buttons.

[0010] In one possible implementation, the display control unit is a touch screen.

[0011] In one possible implementation, the control box circuit also includes a socket that connects to the dense electromechanical control box power grid.

[0012] In one possible implementation, the control box circuit includes a lighting circuit connected to the dense electromechanical control box power grid.

[0013] The beneficial effects of this utility model are: By employing advanced sensor and PLC control technology, precise linkage control of various components of the thickener is achieved, ensuring that multiple motors provide the same torque and operate synchronously, thereby improving the stability and reliability of equipment operation.

[0014] It can monitor key parameters such as torque, mud layer height, and motor current in real time, promptly detect abnormalities in equipment operation, facilitate timely measures to deal with them, and avoid losses caused by equipment failure.

[0015] Equipped with a display and control module, operators can easily perform parameter settings, equipment start-up and shutdown, etc., reducing the difficulty of operation and labor intensity.

[0016] The overall structure is reasonably designed, and the connections between the components are clear, which makes it easy for maintenance personnel to maintain and repair the equipment, reducing maintenance time and costs.

[0017] Other features and aspects of this application will become clear from the following detailed description of exemplary embodiments with reference to the accompanying drawings. Attached Figure Description

[0018] The accompanying drawings, which are included in and form part of this specification, illustrate exemplary embodiments, features, and aspects of this application together with the specification and serve to explain the principles of this application.

[0019] Figure 1 A structural diagram of the dense electromechanical control box circuit according to an embodiment of this application is shown; Figure 2 This application shows a structural diagram of an internal electrical network of a thickener according to an embodiment of the present application; Figure 3 A structural diagram of the electrical network inside a thickener according to an embodiment of this application is shown; Figure 4 This paper shows a wiring diagram of a programmable logic controller according to an embodiment of the present application; Figure 5 The diagram shows a wiring structure of a redundant programmable logic controller 101 according to an embodiment of this application. Figure 6 The illustration shows a connection module for a redundant programmable logic controller 101 according to an embodiment of this application. Detailed Implementation

[0020] Various exemplary embodiments, features, and aspects of this application will now be described in detail with reference to the accompanying drawings. The same reference numerals in the drawings denote elements that have the same or similar functions. Although various aspects of the embodiments are shown in the drawings, they are not necessarily drawn to scale unless specifically indicated otherwise.

[0021] It should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model or 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.

[0022] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0023] The term “exemplary” as used herein means “serving as an example, embodiment, or illustration.” Any embodiment illustrated herein as “exemplary” is not necessarily to be construed as superior to or better than other embodiments.

[0024] Furthermore, to better illustrate this application, numerous specific details are provided in the following detailed embodiments. Those skilled in the art should understand that this application can be implemented without certain specific details. In some instances, methods, means, components, and circuits well-known to those skilled in the art have not been described in detail in order to highlight the main points of this application.

[0025] specifically refer to Figure 1 , Figure 1 A structural diagram of the dense electromechanical control box circuit according to an embodiment of this application is shown.

[0026] In one possible implementation, the dense electromechanical control box is connected to the power grid 100.

[0027] The utility model of this application is a thickener electrical control box circuit, which is used to improve the operating accuracy of the thickener. Its structure includes a programmable logic controller 101, a torque sensor 102, a mud layer height analyzer 103, a motor current feedback device 104, and a display and control unit 105. The programmable logic controller (PLC) 101 includes an input group, an output group, and a display interface. The input group of the PLC 101 is connected to the signal receiving terminal of the signal control switch for the thickener's electrical load. The output group of the PLC 101 is connected to a drive circuit 106. The output group of the PLC 101 is also connected to at least two rake motors 107 and at least two dilution motors 108. Through centralized control of multiple rake motors 107 and dilution motors 108 by the PLC 101, coordinated operation of the thickener's motor loads is achieved, improving motor control accuracy and response speed. Combined with the signal receiving terminal of the signal control switch, the motor status can be monitored and adjusted in real time, making the thickener's operation more stable and reliable, effectively reducing production fluctuations caused by improper motor control, and improving the overall operating accuracy and production efficiency of the thickener.

[0028] The torque sensor 102's signal output terminal is connected to the input terminal group of the programmable logic controller 101. The torque sensor 102 is mounted on the rake frame motor. The torque sensor 102 on the rake frame motor monitors the torque changes during rake frame operation in real time and transmits the signal to the programmable logic controller 101. When the rake frame encounters overload or abnormal resistance, the programmable logic controller 101 can react promptly, adjusting the motor output power or taking protective measures to prevent equipment damage, extend the service life of the rake frame motor, and ensure the stable operation of the thickener, avoiding production interruptions due to rake frame failure.

[0029] The mud layer height analyzer 103 has its signal output connected to the input group of the programmable logic controller 101. The mud layer height analyzer 103 is installed inside the thickening tank of the thickener. The mud layer height analyzer 103 monitors the mud layer height in the thickening tank in real time and feeds the data back to the programmable logic controller 101. The programmable logic controller 101 dynamically adjusts the operating parameters of the rake motor and the dilution motor 108 based on the mud layer height to ensure that the mud layer height is maintained within the optimal range, thus optimizing the thickening effect. This helps to improve the thickener's processing capacity and underflow concentration, reduce the solids content in the overflow, and improve product quality and resource utilization.

[0030] The signal output terminal of the motor current feedback device 104 is connected to the input terminal group of the programmable logic controller 101. The number of motor current feedback devices 104 is the same as the number of motor loads in the thickener. The motor current feedback devices 104 are installed on the main circuit cables of the thickener motor loads. By setting a current feedback device on the main circuit cable of each motor load, the changes in motor current are monitored in real time. The programmable logic controller 101 judges the motor operating status based on the current data, promptly detects abnormal conditions such as motor overload and short circuit, and takes corresponding protective measures, such as power cut-off and alarm. This not only ensures the safe operation of the motor, but also provides early warning of potential faults, reduces equipment maintenance costs and downtime, and improves the reliability and stability of the thickener.

[0031] The display and control unit 105 is connected to the display interface of the programmable logic controller 101 (PLC1) for displaying and controlling the information that the PLC1 needs to display. The power interfaces of the PLC1, torque sensor 102, mud layer height analyzer 103, motor current feedback device 104, and display and control unit 105 are connected to the DC power grid. The display and control unit 105 provides operators with an intuitive human-machine interface, capable of displaying the thickener's operating parameters, status information, and alarm signals in real time, facilitating timely understanding of equipment operation and remote control. DC power grid supply ensures the stability and reliability of the power supply for each device, reducing equipment failures caused by power fluctuations and improving the overall control system's anti-interference capability and operational stability.

[0032] In one possible implementation, the programmable logic controller 101 comprises a main programmable logic controller 101 and at least one redundant secondary programmable logic controller 101. This main-backup redundant programmable logic controller architecture allows the redundant controller to automatically and seamlessly switch over and take over control tasks when the main controller fails, ensuring the continuity and stability of the thickener control system. This redundancy design significantly improves the reliability of the control system, reduces the risk of production downtime due to controller failure, and is particularly suitable for industrial production environments with high continuity requirements, ensuring the long-term stable operation of the thickener.

[0033] In one possible implementation, the programmable logic controller 101 is connected to a switch, which enables the programmable logic controller 101 to connect to an industrial network for collaborative operation. Connecting the programmable logic controller 101 to the industrial network via the switch enables data interaction and collaborative operation between the thickener control system and other production equipment or management systems. Operators can obtain thickener operating data in real time through a remote monitoring system for centralized management and scheduling; simultaneously, the control system can receive instructions from other systems, achieving automation and intelligence of the entire production process, improving production efficiency and management level.

[0034] Optionally, the switch model can be selected as 6GK5008-0BA00-1AB2.

[0035] In one possible implementation, the drive circuit 106 includes a power grid input terminal and a power grid output terminal. The power grid input terminal is connected to the power grid of the thickener's electrical control box, and the power grid output terminal is connected to the thickener's electrical load. As an intermediate link connecting the power grid and the electrical load, the drive circuit 106 can convert and regulate the input electrical energy, providing a stable and matched power supply to the thickener's electrical load. This helps improve the motor's operating efficiency, reduce energy consumption, decrease motor heat generation and losses, and extend the motor's service life. Simultaneously, the drive circuit 106 can also isolate and filter power grid fluctuations and interference, protecting the electrical load from the effects of power grid anomalies and improving the reliability and stability of the equipment.

[0036] In one possible implementation, the torque sensor 102 is positioned around the output shaft of the rake motor 107. Positioning the torque sensor 102 around the output shaft of the rake motor 107 allows for more direct and accurate measurement of torque changes on the output shaft, reducing measurement errors and interference. This installation method reflects the actual load on the rake motor 107 in real time, enabling the programmable logic controller 101 to more precisely adjust the motor's output power, optimize the rake frame's operating status, and improve the thickener's operating efficiency and stability. Simultaneously, it facilitates the installation, maintenance, and replacement of the sensor, reducing equipment maintenance costs.

[0037] In one possible implementation, the torque sensor 102 is positioned between the stator and rotor of the rake motor 107. Positioning the torque sensor 102 between the stator and rotor allows for direct measurement of the electromagnetic torque within the motor, providing more accurate torque data. This helps the programmable logic controller 101 more accurately determine the motor's operating status and promptly detect internal motor faults and anomalies, such as rotor imbalance and bearing wear. Early fault detection prevents fault escalation, reduces equipment maintenance costs and downtime, improves the reliability and lifespan of the rake motor 107, and ensures stable operation of the thickener.

[0038] In one possible implementation, the display and control unit 105 comprises an LCD screen and a control button group. The LCD screen offers advantages such as clear display, wide viewing angle, and low power consumption, and can intuitively display various operating parameters and status information of the thickener. The control button group provides a simple and reliable operating method, allowing operators to quickly input commands and adjust equipment operating parameters via the buttons. This combination ensures both intuitive information display and a convenient operating experience, reducing the learning cost for operators and improving operational efficiency and accuracy.

[0039] In one possible implementation, the display control unit 105 is a touchscreen. The touchscreen display control unit 105 integrates display and operation functions, featuring intuitiveness, convenience, and intelligence. Operators can directly operate the device via the touchscreen, such as clicking, swiping, and inputting, making the operation more natural and efficient. The touchscreen can also implement a graphical interface design, providing a rich interactive experience, such as real-time curve display and parameter setting wizards, enabling operators to more easily grasp the equipment's operating status and perform precise control, thus improving the convenience and intelligence level of production management.

[0040] In one possible implementation, the control box circuit also includes a socket connected to the dense electromechanical control box's electrical grid. The socket in the control box circuit provides a convenient power interface for temporary electrical equipment, such as maintenance tools and testing equipment. This eliminates the need for additional power cables during equipment maintenance and repair, improving work efficiency. Simultaneously, the socket's connection to the dense electromechanical control box's electrical grid ensures the stability and safety of the power supply, preventing safety accidents caused by improper temporary power use and providing convenient conditions for equipment maintenance and production operations.

[0041] In one possible implementation, the control box circuit includes a lighting circuit connected to the dense electromechanical control box's electrical grid. The lighting circuit provides ample light inside the control box, facilitating equipment inspection, maintenance, and operation by operators in low-light conditions. This helps improve work efficiency and reduce operational errors caused by visual impairment. Simultaneously, the connection of the lighting circuit to the dense electromechanical control box's electrical grid ensures the reliability of the lighting power supply, eliminating the need for an additional power supply, simplifying circuit design, and reducing equipment costs and maintenance complexity.

[0042] specifically refer to Figure 2 , Figure 2 A structural diagram of the internal electrical network of a thickener according to an embodiment of this application is shown. As shown, the thickener electrical network includes a three-phase power grid, and its loads include, but are not limited to, a rotary main drive motor 200, a lifting drive motor 201, an air cooler motor 202, a heater 203, and a main drive motor fan 204. The thickener internal electrical network also includes, but is not limited to, a rotary main drive motor safety switch 210, a lifting drive motor safety switch 211, an air cooler motor safety switch 212, a heater safety switch 213, and a main drive motor fan safety switch 214. The lifting drive motor safety switch 211, the air cooler motor safety switch 212, and the main drive motor fan safety switch 214 are controlled by signals from a programmable logic controller (PLC). The thickener internal electrical network also includes, but is not limited to, a lifting drive motor signal control switch 221, an air cooler motor signal control switch 222, and a main drive motor fan signal control switch 224. These signal control switches are controlled by signals from a PLC. A frequency converter 230 is connected between the main rotary drive motor 200 and the main rotary drive motor fuse switch 210. The frequency converter 230 is controlled by a programmable logic controller. The dense motor electrical network also includes a main fuse 240.

[0043] Optionally, the inverter 230 is model ACS580-01-018A-4. It can precisely control motor speed and torque, adapting to the complex operating conditions of thickeners. Its efficient frequency conversion regulation capability reduces motor energy consumption, minimizes equipment heat generation, and extends lifespan. It supports multiple communication protocols, facilitating integration with programmable logic controllers (PLCs) to achieve intelligent control, improve system stability and automation levels, and reduce maintenance costs.

[0044] Further, specifically refer to Figure 3 , Figure 3A structural diagram of the electrical network inside a thickener according to an embodiment of this application is shown. As shown, the thickener electrical network includes a single-phase power grid, which includes, but is not limited to, a programmable logic controller (PLC) power supply 300, a five-way socket 301, an internal lighting circuit 302, an AC-to-DC module 303, a PLC power supply fuse switch 310, a five-way socket fuse switch 311, an internal lighting circuit fuse switch 312, and an AC-to-DC module fuse switch 313. The output terminals of the AC-to-DC module 303 include a touchscreen power cable 320, an intermediate relay power cable 321, a switch power cable 322, and a module input signal power cable 323. The single-phase power grid also includes a set of redundant connection ports 330.

[0045] Optionally, the AC to DC module is a 220V AC to 24V DC module.

[0046] In one possible implementation, the programmable logic controller 101 is model CPU-SR60. See specifically... Figure 4 , Figure 4 A wiring diagram of a programmable logic controller according to an embodiment of this application is shown. As shown, the module input signal 400 of the CPU-SR60 is connected to the control button group 410 of the rake frame motor and the control button group 411 of the hydraulic station. Control button groups 412 for the rotary main drive motor 200, 413 for the lifting drive motor 201, 414 for the air cooler motor 202, 415 for the main drive motor fan 204, and 416 for overload control. The CPU-SR60 also includes an intermediate relay power supply 401.

[0047] specifically refer to Figure 5 , Figure 5 A wiring diagram of a redundant dual-programmable logic controller 101 according to an embodiment of this application is shown. As shown, the modules connected to the redundant dual-programmable logic controller 101 include, but are not limited to, a main motor frequency feedback module 501, a hydraulic pressure signal sensor 502, a hydraulic oil temperature signal sensor 503, and a lifting cylinder pressure module 504. The redundant dual-programmable logic controller 101 also includes a frequency setpoint line group 510 and a redundant line group 511 for connecting to a frequency converter 230.

[0048] For further specific reference Figure 6 , Figure 6 The illustration shows a redundant programmable logic controller 101 connection module according to an embodiment of this application. This includes, but is not limited to, a main drive motor frequency feedback 601, a main drive motor current feedback 602, a hydraulic system pressure signal module 603, an oil tank temperature signal module 604, and a lifting pressure module 605.

[0049] The various embodiments of this application have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical application, or improvement of the technology in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A thickener control box circuit for improving the operating accuracy of a thickener, characterized in that, Includes a programmable logic controller, torque sensor, mud layer height analyzer, motor current feedback device, and display and control unit; The programmable logic controller includes an input terminal group, an output terminal group, and a display interface. The input terminal group of the programmable logic controller is connected to the signal control switch signal receiving terminal of the thickener electrical load. The output terminal group of the programmable logic controller is connected to a drive circuit. The output terminal group of the programmable logic controller is also connected to at least two rake table motors and at least two dilution motors. The torque sensor signal output terminal is connected to the input terminal group of the programmable logic controller, and the torque sensor is mounted on the rake motor; The signal output terminal of the mud layer height analyzer is connected to the input terminal group of the programmable logic controller, and the mud layer height analyzer is installed inside the thickening tank of the thickener. The signal output terminal of the motor current feedback device is connected to the input terminal group of the programmable logic controller. The number of motor current feedback devices is the same as the number of motor loads in the thickener. The motor current feedback devices are installed on the main circuit cable of the thickener motor load. The display control unit is connected to the display interface of the programmable logic controller (PLC) and is used to display and control the information that the PLC needs to display; and The power interfaces of the programmable logic controller, the torque sensor, the mud layer height analyzer, the motor current feedback device, and the display and control unit are connected to the DC power grid.

2. The dense electromechanical control box circuit according to claim 1, characterized in that, The programmable logic controller consists of a main programmable logic controller and at least one redundant secondary programmable logic controller.

3. The dense electromechanical control box circuit according to claim 1, characterized in that, The programmable logic controller is connected to a switch, which enables the programmable logic controller to connect to an industrial network for collaborative operation.

4. The dense electromechanical control box circuit according to claim 1, characterized in that, The drive circuit includes a power grid input terminal and a power grid output terminal. The power grid input terminal is connected to the power grid of the thickener control box circuit, and the power grid output terminal is connected to the thickener electrical load.

5. The dense electromechanical control box circuit according to claim 1, characterized in that, The torque sensor is positioned around the output shaft of the rake motor.

6. The dense electromechanical control box circuit according to claim 1, characterized in that, The torque sensor is located between the stator and rotor of the rake motor.

7. The dense electromechanical control box circuit according to claim 1, characterized in that, The display and control unit consists of an LCD screen and a set of control buttons.

8. The dense electromechanical control box circuit according to claim 1, characterized in that, The display control unit is a touch screen.

9. A dense electromechanical control box circuit according to claim 1, characterized in that, The electrical control box circuit also includes a socket, which is connected to the power grid of the dense generator electrical control box.

10. A dense electromechanical control box circuit according to claim 1, characterized in that, The electrical control box circuit includes a lighting circuit, which is connected to the power grid of the dense generator electrical control box.

Images