A power system for a cover device for a hybrid steel car

Abstract

This application provides a power system for a cover-applying device in a hybrid railway vehicle, including a cover-applying device and a battery connected to the cover-applying device. The cover-applying device includes several drive motors and multiple control components. The battery includes a 96V DC module and a 24V DC module. The 96V DC module is connected to a boost module, and the output of the boost module is connected to a frequency converter. Specifically, the boost module boosts the 96V DC output from the 96V DC module to 550V DC, and the frequency converter converts the 550V DC to 380V AC. The output of the frequency converter is connected to the drive motors. The 96V DC module is also connected to a buck module, which reduces the 96V DC output from the 96V DC module to 24V DC. The output of the buck module is connected to the various control components. This application replaces the traditional inverter with a combination of boost modules and frequency converters, effectively solving the problems of system instability and efficiency reduction caused by inverter failure. By adding an external buck module, the complex maintenance process when the low-voltage battery module is damaged is avoided.

Description

Technical Field

[0001] This application belongs to the field of mixed-rail vehicle technology and relates to a power system for a cover device for mixed-rail vehicles. Background Technology

[0002] The molten iron car cover device is used to cover the molten iron car during the transportation of molten iron. It can significantly reduce the heat loss of molten iron during transportation and waiting, and effectively reduce the emission of pollutants such as smoke and dust into the atmosphere. For example, the molten iron car cover device disclosed in Chinese patent application number CN202310034874.8, etc.

[0003] Figure 2 and 3 The diagrams show the power system of the existing mixed-steel car cover-applying device and the existing mixed-steel car and cover-applying device. The existing mixed-steel car includes two traveling mechanisms 53, each with an active end 52 and a driven end 54. The tank body 51 is located between the active end 52 and the driven end 54, and the tank body 51 can be tilted by the driving action of the active end 52 and the driven end 54. A cover-applying device 1 is installed at the top of the active end 52. A power electrical cabinet 2 and an operating cabinet 4 are also installed on the traveling mechanism 53 on one side of the active end 52 for operating the cover-applying device 1. The cover-applying device 1 includes a power unit for applying or removing the cover and a corresponding control unit. The power unit mainly includes various drive motors 7, etc., and the control unit mainly includes various control components and sensors. The power unit and the control unit are connected to the electrical control device via control cables and power cables, respectively. The power electrical cabinet 2 houses an electrical control device and a storage battery 3 connected by control cables and power cables. The electrical control device consists of various electrical components connected by control cables or power cables. It obtains control power and power power from the storage battery 3 and is connected to the control unit and power unit of the covering device 1, respectively, undertaking the control task of the entire covering device 1. The operation cabinet 4 houses an operation device connected to the electrical control device by control cables. The operation device consists of various buttons and indicator lights, etc., used to send control signals to the electrical control device in the electrical control cabinet and to provide feedback on the operation status of the covering device through indicator lights, etc. It also performs precise covering or uncovering operations on the covering device through the electrical control device to ensure the normal operation of the covering device.

[0004] In the existing hybrid vehicle cover system, the battery 3 includes a 96V DC module and a 24V DC module. In the original power system, the 96V DC power output from the battery 3 via the 96V DC module is converted to 380V AC power by the inverter 6 to drive the drive motor 7. However, in practical applications, this critical component, the inverter 6, experiences a high failure rate due to the complex and harsh working conditions. It frequently triggers the protection mechanism and struggles to automatically return to operating status after protection actions. This not only affects the reliability of the inverter itself but also indirectly increases the failure rate of the cover system, impacting the stability of the entire system. Furthermore, in the original power system, all components in the control section obtain 24V control power from the battery's 24V DC module via low-voltage control cables. This 24V control power is provided by a step-down module inside the battery. If the 24V DC module fails, numerous bolts on the battery casing need to be removed, the protective adhesive on the inner surface of the battery casing needs to be removed, the battery casing needs to be opened, the step-down module needs to be replaced, testing needs to be performed, the protective adhesive needs to be reapplied, and the battery casing and bolts need to be reinstalled. The replacement process is not only cumbersome and time-consuming, but also poses a potential risk of electric shock during the process of disassembling the battery to replace components.

[0005] In view of the above-mentioned technical deficiencies, the creators of this application have obtained the technical solution of this application after a long period of research and practice. Utility Model Content

[0006] To address the technical problems existing in the background art, this application provides a power system for a hybrid railway car cover device. By combining a boost module and a frequency converter to replace the traditional inverter, it effectively solves the problems of system instability and efficiency reduction caused by inverter failure. Furthermore, by using an external step-down module to convert the high-voltage DC of the battery into low-voltage DC to replace the low-voltage output of the battery itself, it avoids the complex and unsafe maintenance process when the low-voltage module of the battery is damaged.

[0007] The technical solution to the technical problem solved in this application is as follows:

[0008] According to one aspect of this application, a power system for a cover-applying device for a mixed-rail vehicle is provided, including a cover-applying device and a battery connected to the cover-applying device. The cover-applying device includes a plurality of drive motors and multiple control components for controlling the operation of the cover-applying device. The battery includes a 96V DC module and a 24V DC module. The 96V DC module is connected to a boost module, and the output terminal of the boost module is connected to a frequency converter. The boost module is used to boost the 96V DC output from the 96V DC module to 550V DC, and the frequency converter is used to convert the input 550V DC into 380V AC. The output terminal of the frequency converter is connected to the drive motors.

[0009] As a further improvement to the technical solution, the 96V DC module is connected to a step-down module, which is used to reduce the 96V DC output of the 96V DC module to 24V DC. The output terminal of the step-down module is connected to each of the control components.

[0010] As a further improvement to the technical solution, the battery is a lithium iron phosphate battery.

[0011] Compared to existing technologies, the power system for a hybrid train cover device described in this application has a simple and reasonable structural design. By replacing the traditional inverter in the power system with a combination of a boost module and a frequency converter, it effectively solves the problems of power system instability and efficiency reduction caused by inverter failure, providing more stable and efficient power conversion, ensuring the continuous operation and performance of the hybrid train cover device. Compared with traditional inverters, the boost module has a lower failure rate, effectively reducing maintenance frequency and cost, and improving system reliability. The frequency converter in the power system can convert DC to AC and reduce starting current, reducing the impact on motors and other equipment. Furthermore, by connecting a step-down module externally to the battery, this application simplifies the replacement steps of the 24V DC power supply, effectively ensuring battery integrity, extending battery life, reducing maintenance difficulty and time, improving maintenance efficiency, and effectively reducing the risk of electric shock and other safety hazards to maintenance personnel, ensuring their safety. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of a power system for a cover device for a mixed-rail vehicle according to this application;

[0013] Figure 2 A schematic diagram of the power system for adding a cover to an existing mixed-rail vehicle;

[0014] Figure 3 A schematic diagram of an existing mixed-rail vehicle and its cover assembly;

[0015] In the diagram: 1. Covering device; 2. Power electrical cabinet; 3. Storage battery; 31. 96V DC module; 32. 24V DC module; 4. Control cabinet; 51. Tank body; 52. Active end; 53. Traveling mechanism; 54. Slave end; 6. Inverter; 7. Drive motor; 8. Control components; 9. Boost module; 10. Frequency converter; 11. Buck module. Detailed Implementation

[0016] The technical solutions of the embodiments of this application 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 of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application. Unless otherwise defined, the technical or scientific terms used herein should have the ordinary meaning understood by those skilled in the art to which this disclosure pertains. The terms "upper," "lower," "left," "right," "front," and "back" used in the specification and claims of this patent application are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship also changes accordingly. Words such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Anything not detailed in this application is common knowledge to those skilled in the art.

[0017] As attached Figure 1 and Figure 3 As shown, this application provides a power system for a cover-applying device for a mixed-rail vehicle, including a cover-applying device 1 and a battery 3 connected to the cover-applying device 1. The battery 3 includes a 96V DC module 31 and a 24V DC module 32. The cover-applying device 1 includes several drive motors 7 for driving the cover-applying device 1 to complete the cover-applying or cover-removing operation, and multiple control components 8 for controlling the operation of the cover-applying device 1 and providing feedback on its operating status. The drive motors 7 are driven by 380V AC power. The control components 8 include a PLC module, a touch screen, a power distribution isolator, sensors, a wireless communication device, a switch, a fan, a fan temperature controller, a card reader, and a motor encoder, etc., and are driven by 24V DC power. The PLC module is responsible for logic control, the touch screen is used to display the status of the cover-applying device in real time, the power distribution isolator is connected to analog sensors such as pressure and displacement, the wireless communication device enables remote control communication, the switch is responsible for network data exchange, the fan and fan temperature controller are responsible for heat dissipation, the card reader enables remote control, and the motor encoder is used to precisely control the cover-applying position. These devices together form an efficient and reliable control power system, providing strong support for the stable operation of the iron-mixed car cover device.

[0018] In the traditional power system of the battery cover device, the drive motor 7 transmits 380V AC power to the inverter 6 via the 96V DC module 31 of the battery 3. The inverter 6 then converts the 96V DC power to 380V AC power, while the various control components 8 are directly connected to the 24V DC module 32 of the battery 3. Due to the complex operating conditions of the mixed-rail vehicle, the inverter has a high failure rate during operation, frequently triggering the equipment protection mechanism, and cannot automatically restart after the protection action. Furthermore, the 24V DC module 32 built into the battery 3 is connected to numerous control components 8. Once the 24V DC module 32 malfunctions, a series of complex replacement steps are required: removing numerous bolts on the battery casing, removing the protective adhesive on the inner surface of the battery casing, opening the battery casing, replacing the step-down module, testing, reapplying the protective adhesive, and reinstalling the battery casing and bolts. This process is not only time-consuming and labor-intensive, but each time the battery casing is opened, it damages its high protection level. In addition, disassembling the battery to replace components may pose a risk of electric shock.

[0019] To address the aforementioned issues, this application offers the following innovations:

[0020] Firstly, an external boost module 9 is connected to the 96V DC module 31, and then a frequency converter 10 is connected to the output of the boost module 9; wherein: the boost module 9 is used to boost the 96V DC power output from the 96V DC module 31 to 550V DC power, the frequency converter 10 is used to convert the input 550V DC power into 380V AC power, and the output of the frequency converter 10 is connected to the drive motor 7.

[0021] When selecting the boost module 9, all protection parameters are met based on load calculations and measured current and voltage values. Equipment protection functions include undervoltage protection, overvoltage protection, overload protection, temperature protection, peak current protection, and reverse polarity protection. Peak current protection is particularly important, as it is the most frequently triggered protection based on field experience. Peak currents of all covered devices were measured, and the boost module selection was determined based on the test results. The boost module has an automatic start-up function when equipment protection is activated. The input voltage is 100V±18%, with a soft-start time of 2-3 seconds, allowing the equipment to operate within a wide voltage range. The chassis-type, metal design is suitable for harsh industrial environments. The equipment has a low no-load power consumption of approximately 5W, allowing for long-term uninterrupted operation. The boost module has a low failure rate and a long service life.

[0022] The working principle of a frequency converter includes AC-DC-AC conversion, which involves rectifying the non-adjustable three-phase / single-phase AC power from the power grid into DC power via a rectifier bridge, and then inverting the DC power into three-phase AC power with adjustable voltage and frequency. The frequency converter used in this embodiment has both AC 380V input and DC 550V input interfaces. The function of the frequency converter in the system is to convert DC to AC and reduce starting current, thereby minimizing the impact on the motor and hydraulic system.

[0023] Secondly, a step-down module 11 is connected to the 96V DC module 31. The step-down module 11 reduces the 96V DC output from the 96V DC module 31 to 24V DC. The output of the step-down module 11 is connected to the various control components 8. This design not only simplifies the voltage conversion process but also improves voltage stability, ensuring the stability and reliability of the various control components in various operating environments. When the 24V DC power supply needs to be replaced, only the step-down module needs to be replaced and tested. This improvement greatly reduces maintenance difficulty and time, and improves work efficiency.

[0024] As a preferred embodiment, the battery is preferably a lithium iron phosphate battery, which has good thermal stability and safety. Compared with lithium-ion batteries, lithium iron phosphate batteries are less prone to overheating; and compared with lead-acid batteries, they are lighter, have a longer service life, and can typically be charged more than 2,000 times. They also have lower maintenance requirements and a longer service life, while lead-acid batteries can only be charged about 500 times.

Claims

1. A power system for a mixer car capping device, comprising a capping device (1), a battery (3) connected with the capping device (1), the capping device (1) comprising a plurality of drive motors (7) and a plurality of control components (8) for controlling the operation of the capping device (1), the battery (3) comprising 96V DC modules (31) and 24V DC modules (32), characterized in that, The 96V DC module (31) is connected to a boost module (9), and the output terminal of the boost module (9) is connected to a frequency converter (10); wherein: the boost module (9) is used to boost the 96V DC output of the 96V DC module (31) to 550V DC, the frequency converter (10) is used to convert the input 550V DC into 380V AC, and the output terminal of the frequency converter (10) is connected to the drive motor (7).

2. A power system for a charging car capping device according to claim 1, wherein, The 96V DC module (31) is connected to a step-down module (11), which is used to reduce the 96V DC output of the 96V DC module (31) to 24V DC. The output terminal of the step-down module (11) is connected to each of the control components (8).

3. A power system for a charging device of a mixing car according to claim 1, characterized in that, The battery is a lithium iron phosphate battery.

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