CN109052207B - Protection control method for failure of hoisting mechanism brake of hoisting equipment - Google Patents
Protection control method for failure of hoisting mechanism brake of hoisting equipment Download PDFInfo
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- CN109052207B CN109052207B CN201810894737.0A CN201810894737A CN109052207B CN 109052207 B CN109052207 B CN 109052207B CN 201810894737 A CN201810894737 A CN 201810894737A CN 109052207 B CN109052207 B CN 109052207B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66D—CAPSTANS; WINCHES; TACKLES, e.g. PULLEY BLOCKS; HOISTS
- B66D5/00—Braking or detent devices characterised by application to lifting or hoisting gear, e.g. for controlling the lowering of loads
- B66D5/02—Crane, lift hoist, or winch brakes operating on drums, barrels, or ropes
- B66D5/24—Operating devices
- B66D5/30—Operating devices electrical
Abstract
The invention discloses a protection control method for failure of a hoisting mechanism brake of hoisting equipment, which comprises the following steps: step 1, detecting the rotating speed of a motor sent by an encoder in real time when a frequency converter is in a standby state; step 2, judging whether the rotating speed of the motor is greater than a set upper threshold, if so, sending a brake failure signal, and entering step 3, otherwise, directly entering step 5; step 3, starting a zero torque function and a rotating speed tracking function in sequence; step 4, after the frequency converter stops outputting zero torque, the speed control mode with the given speed being zero is switched to, and the heavy object is suspended in the air at the zero speed; and 5, receiving a handle given command by the frequency converter, and operating the frequency converter according to the handle given command. The invention can quickly brake the weight which is accelerated to slide downwards after the brake fails and suspend the weight in the air at zero speed stably and reliably, thereby avoiding the risk caused by the purely mechanical braking method of a hoisting mechanism only by the brake in the market.
Description
Technical Field
The invention belongs to the technical field of control of hoisting equipment, and particularly relates to a protection control method for failure of a hoisting mechanism brake of the hoisting equipment.
Background
On hoisting equipment, the brakes of various hoisting mechanisms have the possibility of mechanical failure, and the common failure protection is basically based on mechanical design, such as adding a safety brake and a fall-prevention brake, but the mechanical failure is usually gradual over a long time and is difficult to avoid if not enough maintenance is provided. Most hoisting mechanisms at present do not have an electrical brake failure protection function.
In recent years, some methods for solving the brake failure by an electrical method are proposed, but most methods have difficulty and instability in implementation and do not take full consideration of failure scenes. The patent CN 105110119 a starts from the perspective of brake failure detection, and only provides a method for conveniently judging the failure state of a brake when a hoisting device is unloaded, which is a method for preventing protection, but cannot protect the hoisting device when the hoisting device is in loaded operation and the brake fails; the method adopted by patents CN 105217403 a and CN 104444913 a in detecting the failure of the brake is to start zero servo, and patents CN 104150311B and CN 206088642U also obscure the control description of the motor when the weight slips down, and only torque is kept or kept to be shielded, so that zero servo and torque are simple to say, but many problems are encountered in the implementation process, after the brake fails, the speed of slipping down the weight will increase rapidly, and only outputting a zero speed given signal will cause the current given speed of the motor to differ too much from the actual speed, so that the inverter is easy to report the overcurrent fault when controlling the motor, and in this case, the weight will lose control, and the weight slips down all the way; the patent CN 103663225B also has the same problems as above, and it is also easy to cause the frequency converter to report an overcurrent fault by directly starting the hoisting motor to operate according to a set gear after detecting that the brake fails, and directly starting the frequency converter to control the motor in the process of driving the motor to rotate by slipping down a heavy object. In addition, residual magnetism exists on a rotor of a motor which just stops rotating under the action of an alternating current power supply, the residual magnetism can cause that the motor cannot stabilize output torque when being restarted under the condition of belt carrying speed, namely, a heavy object which is difficult to pull and stop and slides down quickly is difficult, and a frequency converter is easy to lose control. The problem of the above methods is that they can correctly find out that the brake is out of order, but there is a great risk in the details of the specific implementation method of protection, which easily causes the frequency converter to report failure, loses the ability of output torque, and as a result, the continuous sliding down of the heavy object cannot be prevented.
The invention content is as follows:
in order to overcome the defects of the background art, the invention provides a protection control method for the failure of a brake of a hoisting mechanism of hoisting equipment, which solves the technical problem that the safety of hoisting work cannot be guaranteed because a motor shaft cannot be clasped after the brake fails in the prior art.
In order to solve the technical problems, the invention adopts the technical scheme that:
a protection control method for failure of a hoisting mechanism brake of a hoisting device comprises the following steps:
step 1, detecting the rotating speed of a motor sent by an encoder in real time when a frequency converter is in a standby state;
step 2, judging whether the rotating speed of the motor is greater than a set upper threshold, if so, sending a brake failure signal, and entering step 3, otherwise, directly entering step 5;
step 3, starting a zero torque function and a rotating speed tracking function in sequence;
step 4, after the frequency converter stops outputting zero torque, the speed control mode with the given speed being zero is switched to, and the heavy object is suspended in the air at the zero speed;
and 5, receiving a handle given command by the frequency converter, and operating the frequency converter according to the handle given command.
Preferably, before step 1, a step of degaussing is also included, performed each time the motor is stalled, the method of degaussing comprising injecting a preset reverse current into the motor when the motor is stalled.
Preferably, the upper limit of the set threshold in step 2 is one tenth of the rated rotation speed of the motor.
Preferably, the method for sequentially starting the zero-torque function and the rotation speed tracking function in step 3 comprises the following steps:
step 31, the frequency converter only controls the exciting current of the lifting motor, and the torque current value is controlled to be 0;
and step 32, establishing a motor magnetic field, detecting the current speed of the downward sliding of the weight through a motor encoder, giving the speed to the current speed set value of the frequency converter in real time, tracking the rotating speed, and preparing for converting into a speed control mode.
Preferably, step 32 establishes a motor field, and the time period for the inverter to switch from outputting zero torque to the speed control mode is less than or equal to 0.2 seconds.
Preferably, the handle setting command comprises that a driver outputs a given speed, a lifting direction and a running command signal to the frequency converter through the handle in real time.
Preferably, the brake failure signal is sent in step 2, and simultaneously, an alarm signal is sent by an alarm device.
Preferably, the alarm device comprises a buzzer.
The invention has the beneficial effects that: the invention relates to a method for solving the failure of a brake by an electrical method, which does not need to increase any hardware cost, only needs to add a motor demagnetization function, a zero torque function and a rotating speed tracking function in the frequency converter software of the existing hoisting mechanism and combines the three functions in order, utilizes the motor demagnetization function of the frequency converter to carry out the treatment of eliminating residual magnetism when the motor stops rotating every time, then the frequency converter stops outputting and enters a standby state, detects and judges whether the brake fails in real time in the standby state, automatically and sequentially starts the zero torque function and the rotating speed tracking function if the brake fails, then switches to a speed control mode with the given speed being zero, controls the motor to output stable and reliable electromagnetic torque, stops a fast downward-sliding heavy object according to the preset deceleration time and hovers in the air at zero speed, and simultaneously outputs a brake failure alarm signal, and prompting a driver to take over the operating handle to control the frequency converter to lower the heavy object to a safe position on the ground. The invention can quickly brake the weight which is accelerated to slide downwards after the brake fails and suspend the weight in the air at zero speed stably and reliably, thereby avoiding the risk brought by the purely mechanical braking method of a hoisting mechanism which is only provided with a brake in the market, and simultaneously solving the problems of difficult realization and instability of electric methods for failure protection of some brakes.
Drawings
FIG. 1 is a flow chart of a method according to an embodiment of the present invention.
Detailed Description
The invention is further described below with reference to the accompanying drawings and examples.
A protection control method for failure of a hoisting mechanism brake of a hoisting device comprises the following steps:
step 1, performing a demagnetization step each time when the motor stops rotating, wherein the demagnetization method comprises the step of injecting preset reverse current into the motor when the motor stops rotating. When the frequency converter is in a standby state, detecting the rotating speed of the motor sent by the encoder in real time;
when the frequency converter controls the motor to normally work every time, certain reverse current is injected into the motor when the motor is stopped, so that residual magnetism of a motor rotor is rapidly eliminated, and preparation is made for normally starting the motor next time and outputting large torque. If the residual magnetism is not eliminated, once the brake failure is detected, the motor is in a loaded speed state, the motor is started again, stable and reliable large torque is difficult to output to pull the heavy object to stop, and the fault that the frequency converter reports the loss speed and the overcurrent is easily caused.
When the frequency converter is in a standby state (power-on and non-operation state), the motor rotating speed transmitted back by the encoder is detected in real time, preparation is made for judging the failure of the brake, because the brake of the frequency converter is always in an open state in the process of driving the motor to operate, the brake does not need to be detected to be failed, and whether the brake fails or not needs to be judged only in the power-on and non-operation state of the frequency converter. When the fact that the rotating speed of the motor transmitted by the encoder exceeds a certain threshold value is detected, the brake can be judged to be in a failure state, the threshold value is preset in parameters of the frequency converter, the threshold value cannot be set too small, the frequency converter is prevented from being triggered to operate by mistake after the motor encoder is interfered, the threshold value cannot be set too large, the downward sliding distance of the brake after the brake fails is prevented from being too large, and the threshold value is generally set to be one tenth of the rated rotating speed of the motor according to field debugging experience.
Step 2, judging whether the rotating speed of the motor is less than or equal to a set threshold upper limit, if so, directly entering step 5, if not, sending a brake failure signal, and entering step 3, wherein the set threshold upper limit is one tenth of the rated rotating speed of the motor; and sending out a brake failure signal and simultaneously sending out an alarm signal through an alarm device. The alarm device comprises a buzzer.
When the failure of the brake is detected, the frequency converter outputs an alarm signal to inform a driver, and the alarm signal generally adopts a buzzer or a voice broadcast mode. When the motor speed does not exceed the threshold, it indicates that the brake is not disabled, and the brake is turned to respond to the normal operating handle command of the driver. The brake failure mentioned in the invention refers to the condition that the brake is not clamped or not clamped when the brake is clamped, and the condition that the brake is opened without opening the brake can not cause the safety accident that heavy objects slide downwards, so the brake failure is not considered in the embodiment of the invention.
Step 3, starting a zero torque function and a rotating speed tracking function in sequence;
step 31, the frequency converter only controls the exciting current of the lifting motor, and the torque current value is controlled to be 0;
and step 32, establishing a motor magnetic field, detecting the current speed of the downward sliding of the weight through a motor encoder, giving the speed to the current speed set value of the frequency converter in real time, and tracking the rotating speed. The time length of the frequency converter is less than or equal to 0.2 second when the frequency converter is switched to a speed control mode with the given speed being zero from outputting zero torque.
After the failure of the brake is detected, the frequency converter immediately and automatically starts a zero-torque function and a rotating speed tracking function in sequence, the zero-torque function is started firstly, and then the rotating speed tracking function is started. The zero-torque function means that the frequency converter controls the lifting motor to output zero torque, and at the moment, the motor does not have any load capacity, namely only the exciting current of the lifting motor is controlled, and the torque current value is controlled to be 0. In the process of outputting zero torque, the frequency converter starts the rotating speed tracking function while establishing a motor magnetic field. After the motor magnetic field is established, the frequency converter stops outputting zero torque, and the time for establishing the motor magnetic field is not more than 0.2 second. The rotating speed tracking function means that the frequency converter detects the current speed of slipping down of a heavy object through a motor encoder in the process of establishing a motor magnetic field, and gives the speed to the current speed set value of the frequency converter in real time.
Step 4, after the frequency converter stops outputting zero torque, switching to a speed control mode with the given speed being zero;
and after the frequency converter stops outputting zero torque, converting the frequency converter into a speed control mode with the given speed being zero, stopping the heavy object which slides downwards quickly according to the preset deceleration time, and hovering the heavy object in the air at the zero speed, wherein the deceleration time is also the deceleration time used by the normal work of the hoisting mechanism.
And 5, receiving a handle given command by the frequency converter, and operating the frequency converter according to the handle given command. The handle setting command comprises that a driver outputs a setting speed, a lifting direction and a running command signal to the frequency converter through the handle in real time.
When a driver receives a brake failure alarm signal, the driver immediately operates the handle to transmit a new given speed, a new lifting direction and a new operation command to the frequency converter, and the frequency converter receives the information and then suspends the heavy object in the air at no speed but operates according to the given command of the operating handle, so that the heavy object is safely and reliably placed at a safe position on the ground. If the frequency converter does not detect the failure of the brake in the standby state, the frequency converter waits for responding to a normal handle operation signal of a driver and enters a normal operation state at any time. According to the embodiment of the invention, a safe and reliable electric protection control method can be provided when a hoisting mechanism brake of the hoisting equipment fails without increasing any hardware cost.
The invention utilizes the frequency converter to demagnetize the remanence of the motor when controlling the motor to stop rotating each time. The frequency converter controls the lifting motor to output zero torque, namely only the exciting current of the lifting motor is controlled, the torque current value is controlled to be zero, and the motor does not have any load capacity. In the process that the frequency converter controls the motor to output zero torque, the speed of the current weight slipping down is detected through the motor encoder, and the speed is given to the current speed given value of the frequency converter in real time. The method comprises the steps that three software functions of a motor demagnetization function, a zero torque function and a rotating speed tracking function are combined in order, wherein the sequential combination means that the motor demagnetization function is started when a frequency converter controls a motor to stop rotating every time, the frequency converter enters a standby state after demagnetization is finished, and when a brake is detected to be invalid, the zero torque function is started first, and then the rotating speed tracking function is started.
The lifting mechanism of the embodiment comprises a frequency converter, a brake, a lifting motor, an encoder, a speed reducer, a winding drum, a pulley and a steel wire rope, wherein the frequency converter is used for driving the lifting motor in a closed-loop vector control mode, and the lifting motor rotates to drive the speed reducer, the winding drum, the pulley and the steel wire rope to act so as to drive a heavy object to do lifting motion; the brake is used for receiving an instruction sent by the frequency converter to control the motor rotating shaft to be tightly held or released; the encoder is installed on the rotating shaft of the lifting motor and used for measuring a rotating speed pulse signal of the lifting motor and then conveying the signal to the frequency converter, the frequency converter can detect the speed of the rotating shaft of the motor in real time, and when the frequency converter does not operate, if the speed of the rotating shaft of the motor is detected to exceed a certain threshold value, the brake can be judged to be in a failure state. It should be further noted that the frequency converter does not detect whether the brake fails during the operation of the control motor, and the detection is only performed when the frequency converter is in a standby state (power-on and non-operation state). When the brake is judged to be in a failure state, the frequency converter can automatically start a zero-torque function and a rotating speed tracking function in sequence, and the problem that the frequency converter reports overcurrent faults due to the fact that the difference between the current given speed and the actual speed of the motor is too large can be effectively solved after the two functions are used. The zero-torque function means that the frequency converter controls the lifting motor to output zero torque, and at the moment, the motor does not have any load capacity, namely only the exciting current of the lifting motor is controlled, and the torque current value is controlled to be zero. In the process of outputting zero torque, the frequency converter starts the rotating speed tracking function while establishing a motor magnetic field. After the magnetic field of the motor is built, the frequency converter stops outputting zero torque, the speed control mode that the given speed is zero is automatically switched to, at the moment, the motor can output stable and reliable electromagnetic torque to stop the fast-descending heavy object according to the preset deceleration time and hover in the air at the zero speed, and meanwhile, the frequency converter outputs a brake failure alarm signal to prompt a driver to take over an operating handle to control the frequency converter to lower the heavy object to a ground safety position. The rotating speed tracking function means that the frequency converter detects the current speed of slipping down of a heavy object through a motor encoder in the process of establishing a motor magnetic field, and gives the speed to the current speed set value of the frequency converter in real time to prepare for switching to a speed control mode with the set speed being zero subsequently. The duration of the zero torque output, i.e. the time for completion of the build-up of the motor field, does not exceed 0.2 seconds. The motor demagnetization function means that demagnetization treatment needs to be carried out on the remanence of the motor when the frequency converter controls the motor to stop rotating every time, and preparation is made for outputting stable and reliable large torque after the follow-up possible brake failure. The driver takes over the operating handle means that after receiving the brake failure alarm signal, the driver pushes the operating handle to transmit a new given speed, a new lifting direction and a new operation command to the frequency converter, and after receiving the information, the frequency converter no longer suspends the heavy object in the air at zero speed, but operates according to the given command of the operating handle, so that the heavy object is safely and reliably placed at a safe position on the ground.
It will be understood that modifications and variations can be made by persons skilled in the art in light of the above teachings and all such modifications and variations are intended to be included within the scope of the invention as defined in the appended claims.
Claims (7)
1. A protection control method for failure of a hoisting mechanism brake of a hoisting device is characterized by comprising the following steps:
step 1, detecting the rotating speed of a motor sent by an encoder in real time when a frequency converter is in a standby state;
step 2, judging whether the rotating speed of the motor is greater than a set upper threshold, if so, sending a brake failure signal, and entering step 3, otherwise, directly entering step 5;
step 3, starting a zero torque function and a rotating speed tracking function in sequence; the method for sequentially starting the zero-torque function and the rotating speed tracking function in the step 3 comprises the following steps: step 31, controlling the exciting current of a lifting motor by a frequency converter, and controlling the torque current value to be 0; step 32, establishing a motor magnetic field, detecting the current speed of the downward sliding of the weight through a motor encoder, giving the speed to the current speed set value of the frequency converter in real time, and tracking the rotating speed; the time length of the frequency converter from outputting zero torque to converting to a speed control mode with the given speed being zero is less than or equal to 0.2 second;
after the failure of the brake is detected, the frequency converter immediately and automatically starts a zero-torque function and a rotating speed tracking function in sequence, the zero-torque function is started firstly, and then the rotating speed tracking function is started; the zero-torque function means that the frequency converter controls the lifting motor to output zero torque, and at the moment, the motor does not have any load capacity, namely only the exciting current of the lifting motor is controlled, and the torque current value is controlled to be 0; in the process of outputting zero torque, the frequency converter establishes a motor magnetic field and starts a rotating speed tracking function at the same time; after the motor magnetic field is established, the frequency converter stops outputting zero torque, and the time for establishing the motor magnetic field is not more than 0.2 second; the rotating speed tracking function is that the frequency converter detects the current speed of slipping down of a heavy object through a motor encoder in the process of establishing a motor magnetic field, and gives the speed to the current speed set value of the frequency converter in real time;
step 4, after the frequency converter stops outputting zero torque, converting the frequency converter into a speed control mode with the given speed being zero, stopping the heavy object which slides downwards quickly according to the preset deceleration time, and hovering the heavy object in the air at the zero speed;
and 5, receiving a handle given command by the frequency converter, and operating the frequency converter according to the handle given command.
2. A protection control method for failure of a hoisting mechanism brake of a hoisting device according to claim 1, characterized in that:
before the step 1, a demagnetization step is further included, wherein the demagnetization step is performed each time the motor stops rotating, and the demagnetization method comprises the step of injecting a preset reverse current into the motor when the motor stops rotating.
3. A protection control method for failure of a hoisting mechanism brake of a hoisting device according to claim 1, characterized in that: and the upper limit of the set threshold in the step 2 is one tenth of the rated rotating speed of the motor.
4. A protection control method for failure of a hoisting mechanism brake of a hoisting device according to claim 1, characterized in that: said step 32 establishes the motor field and the time length for the frequency converter to switch from outputting zero torque to the speed control mode with the given speed being zero is less than or equal to 0.2 seconds.
5. A protection control method for failure of a hoisting mechanism brake of a hoisting device according to claim 1, characterized in that: the handle given command comprises a given speed, lifting direction and running command signal received by the frequency converter from the handle.
6. A protection control method for failure of a hoisting mechanism brake of a hoisting device according to claim 1, characterized in that: and (3) sending out a brake failure signal in the step (2) and sending out an alarm signal through an alarm device.
7. A protection control method for failure of a hoisting mechanism brake of a hoisting device according to claim 6, characterized in that: the alarm device comprises a buzzer.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201810894737.0A CN109052207B (en) | 2018-08-08 | 2018-08-08 | Protection control method for failure of hoisting mechanism brake of hoisting equipment |
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| CN201810894737.0A CN109052207B (en) | 2018-08-08 | 2018-08-08 | Protection control method for failure of hoisting mechanism brake of hoisting equipment |
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| CN109052207B true CN109052207B (en) | 2020-11-10 |
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Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN112570467A (en) * | 2019-09-27 | 2021-03-30 | 上海宝信软件股份有限公司 | Anti-slip control method and system suitable for vertical loop |
| CN111039132A (en) * | 2019-12-25 | 2020-04-21 | 徐州中矿大传动与自动化有限公司 | Method and device for safe parking control of lifting system |
| CN111245301A (en) * | 2020-03-25 | 2020-06-05 | 中冶建工集团有限公司 | Control system of anti-falling climbing aid |
| WO2023272573A1 (en) * | 2021-06-30 | 2023-01-05 | 深圳市英威腾电气股份有限公司 | Contracting-brake failure protection method and apparatus |
| CN113666265B (en) * | 2021-08-11 | 2024-02-06 | 西门子（中国）有限公司 | Crane control method, crane control device, electronic equipment and storage medium |
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| CN106571762A (en) * | 2016-11-02 | 2017-04-19 | 武汉智明力强光电系统有限公司 | Frequency converter used for controlling running state of asynchronous motor |
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| US6831432B2 (en) * | 2001-12-05 | 2004-12-14 | Matsushita Electric Industrial Co., Ltd. | Motor driving device and motor driving method |
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| JPH05124793A (en) * | 1991-11-01 | 1993-05-21 | Mitsubishi Electric Corp | Variable speed winding machine |
| CN104444913A (en) * | 2014-09-24 | 2015-03-25 | 深圳市正弦电气股份有限公司 | Braking method and device of crane |
| CN105720864A (en) * | 2014-12-01 | 2016-06-29 | 中车大连电力牵引研发中心有限公司 | Motor deceleration frequency giving method, frequency converter and motor deceleration frequency giving system |
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Effective date of registration: 20201019 Address after: 430223 No. 6, science and engineering Park, science and engineering Park, East Lake New Technology Development Zone, Wuhan, Hubei Applicant after: WUHAN GUIDE ELECTRIC DRIVE TECHNOLOGY Co.,Ltd. Applicant after: SHAANXI CONSTRUCTION MACHINERY Co.,Ltd. Address before: 430223 No. 6, science and engineering Park, science and engineering Park, East Lake New Technology Development Zone, Wuhan, Hubei Applicant before: WUHAN GUIDE ELECTRIC DRIVE TECHNOLOGY Co.,Ltd. Applicant before: WUHAN GUIDE ELECTRIC Co.,Ltd. Applicant before: SHAANXI CONSTRUCTION MACHINERY Co.,Ltd. |
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| CP03 | Change of name, title or address | ||
| CP03 | Change of name, title or address |
Address after: 430223 workshop D, No. 6, ligongyuan Road, Science Park, Wuhan University of technology, East Lake Development Zone, Wuhan, Hubei Province Patentee after: Wuhan Gangdi Technology Co.,Ltd. Patentee after: SHAANXI CONSTRUCTION MACHINERY Co.,Ltd. Address before: No.6, ligongyuan Road, science and Technology Park, University of science and technology, Donghu New Technology Development Zone, Wuhan, Hubei 430223 Patentee before: WUHAN GUIDE ELECTRIC DRIVE TECHNOLOGY Co.,Ltd. Patentee before: SHAANXI CONSTRUCTION MACHINERY Co.,Ltd. |