CN110723649A

CN110723649A - Braking torque detection system of potential energy load mechanism for port machinery

Info

Publication number: CN110723649A
Application number: CN201911109088.XA
Authority: CN
Inventors: 姜鑫; 徐鹏; 孟庆龙; 赵磊; 冀祥; 吴庆贺
Original assignee: Dalian Huarui Heavy Industry Group Co Ltd
Current assignee: Dalian Huarui Heavy Industry Group Co Ltd
Priority date: 2019-11-13
Filing date: 2019-11-13
Publication date: 2020-01-24
Anticipated expiration: 2039-11-13
Also published as: CN110723649B

Abstract

The invention provides a potential energy load mechanism braking torque detection system for port machinery, which comprises: testing an operation terminal and a host PLC control system; the test operation terminal includes: the system comprises a remote substation interface module, a DI/DO module and an operation panel; the operation panel includes: an HMI to specify parameters of brake settings and test results, a key switch to select a test mode, a mechanism selection switch to select a single mechanism for testing, a lighted run button to activate testing, a readiness indicator, a test pass indicator, and a test fail indicator. And the test operation terminal transmits the operation instruction and the parameter setting to the host PLC control system in an Ethernet mode. The brake torque detection operation platform is arranged near the tested brake, the devices such as a PLC, a frequency converter and a motor are arranged in the onboard control system, so that a maintainer can detect the brake torque of the brake by one key, and the system automatically judges a detection result and files and stores the detection result.

Description

Braking torque detection system of potential energy load mechanism for port machinery

Technical Field

The invention relates to the technical field of port machinery, in particular to a potential energy load mechanism braking torque detection system for port machinery.

Background

Whether the braking torque of potential energy load mechanisms such as lifting, pitching and the like of the port machinery reaches design requirements directly influences the production operation safety of equipment. At present, in the fields of elevators, automobiles and the like, a pressure detection sensor is additionally arranged on a brake disc, so that the braking torque can be monitored, but due to the difference of mechanical structures, use environments and load types of equipment, related detection devices are not practically applied to port machinery. The maintainer of harbour machinery generally detects braking torque through measuring the clearance size between brake disc and the braking piece, and whether braking torque satisfies the unable accurate judgement of safety in production demand, if harbour machinery braking inefficacy appears in the course of the work, major incident such as the load falls or equipment topples appears very probably, causes very big threat to personal and property safety.

Disclosure of Invention

According to the technical problem, the potential energy load mechanism braking torque detection system for the port machinery is provided. The invention mainly utilizes a potential energy load mechanism braking torque detection system for port machinery, which is characterized by comprising the following components: testing an operation terminal and a host PLC control system; the test operation terminal includes: the system comprises a remote substation interface module, a DI/DO module and an operation panel;

the operation panel includes: an HMI to specify parameters of brake settings and test results, a key switch to select a test mode, a mechanism selection switch to select a single mechanism for testing, a lighted run button to activate testing, a readiness indicator, a test pass indicator, and a test fail indicator.

Furthermore, the test operation terminal transmits the operation instruction and the parameter setting to the host PLC control system in the form of Ethernet.

Further, the host PLC control system includes: CMMS, PLC, Ethernet module, exchanger, frequency converter, motor and brake;

the switch sets the operation instruction and the parameters transmitted by the test operation terminal, and transmits the operation instruction and the parameters to the PLC through the Ethernet module; judging whether the interlocking condition meets the test condition or not through the PLC, and detecting whether the parameter setting meets the test range or not;

when the conditions meet the requirements, the torque amplitude limiting set value in the frequency converter is adjusted according to input parameters through the Ethernet module and the switch, the frequency converter is controlled to drive the motor to operate according to preset parameters, and meanwhile, the brake is tested and the irrelevant brake is forcibly opened;

the PLC receives parameters fed back to the motor by the frequency converter when the motor torque is tested, the test result is transmitted to the test operation terminal through the Ethernet, and a user can obtain the test result through the HMI and automatically archive and store the test result.

Furthermore, the detection parameter setting calculation formula of the lifting braking torque is as follows:

Tgz1≥Kgz1*Q1*Dj1*η1/(2*Zgz1*m1*i1)；

wherein Tgz1 represents the hoisting brake braking torque; kgz1 denotes a lifting safety factor; q1 denotes the lifting load; dj1 denotes the hoist drum diameter; eta 1 represents the total efficiency of the lifting transmission mechanism; zgz1 denotes the number of brakes; m1 represents the pulley magnification; i1 denotes the hoist gear ratio;

the detection parameter setting calculation formula of the braking torque of the pitching brake is as follows:

Tgz2≥Kgz2*Smax2*Dj2*η2/(Zgzl*i2)；

wherein Tgz2 represents the pitch brake braking torque; kgz2 represents a pitch brake safety factor; smax2 represents the maximum operating static tension of the pitch line; dj2 represents the pitch drum calculated diameter; η 2 represents the pitch motor to drum mechanical efficiency; zgz2 denotes the number of pitch brakes; i2 denotes the pitch reducer gear ratio.

Further, the HMI is integrated in the CMMS.

Compared with the prior art, the invention has the following advantages:

the brake torque detection operation platform is arranged near the tested brake, the devices such as a PLC, a frequency converter and a motor are arranged in the onboard control system, so that a maintainer can detect the brake torque of the brake by one key, and the system automatically judges a detection result and files and stores the detection result. The method has the advantages of low investment cost, simple operation and clear test result, can inquire historical detection records, timely eliminate potential safety hazards caused by insufficient braking torque and ensure equipment, property and personal safety.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.

FIG. 1 is a network diagram of a control system according to the present invention.

FIG. 2 is a diagram of an operating panel of the present invention.

FIG. 3 is an internal view of the operation panel of the present invention.

Fig. 4 is a wiring diagram of the DI module of the present invention.

Fig. 5 is a wiring diagram of the DO module of the present invention.

FIG. 6 is a schematic diagram of the overall testing process of the present invention.

Detailed Description

In order to make the technical solutions of the present invention better understood, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

It should be noted that the terms "first," "second," and the like in the description and claims of the present invention and in the drawings described above are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used is interchangeable under appropriate circumstances such that the embodiments of the invention described herein are capable of operation in sequences other than those illustrated or described herein. Furthermore, the terms "comprises," "comprising," and "having," and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a list of steps or elements is not necessarily limited to those steps or elements expressly listed, but may include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus.

As shown in fig. 1, the present invention provides a system for detecting braking torque of a potential energy load mechanism for a harbor machine, comprising: a test operation terminal 11 and a host PLC control system 12.

In the present application, the test operation terminal 11 includes a remote substation interface module 1, a DI/DO module 2, and an operation panel 3 as a preferred embodiment. The operation panel 3, as shown in fig. 2, includes an HMI301, a key switch 302, a mechanism selection switch 303, and a lighted operation button 304, a preparatory condition indicator lamp 305, a test-passed indicator lamp 306, and a test-failed indicator lamp 307.

In the present embodiment, the HMI301 is used to specify parameters such as the motor rotation speed and the torque limit corresponding to the brake setting, and to display the test result; the key switch 302 is used for selecting a test mode, and the host cannot normally operate equipment to run after the test mode is selected, so that multiple operations are avoided, and the safety is ensured; the mechanism selection switch 303 is used for selecting a mechanism for testing, lifting or arm support, and the testing can be performed by only a single mechanism; the operation button 304 with the lamp is used for activating the test, the self-contained indicator lamp is normally on after the parameter setting of the HMI301 is successful, the parameter setting is prompted to be completed, the test can be operated, and at the moment, the operation command can be given only by pressing the operation button 304 with the lamp; the preparation condition indicator lamp 305 is used for displaying whether the test preparation condition is met, and the preparation condition indicator lamp is turned on only when the safety interlock condition is met, so that the test mode is allowed to enter; the test pass indicator light 306 is used for indicating test pass, and the indicator light is normally on after the test pass and is green; the test failed indicator lamp 307 is used for indicating that the test failed, and after the test failed, the indicator lamp is normally on and is a red lamp.

Preferably, in the present application, the remote substation interface module 1 and the DI/DO module 2 are arranged as shown in fig. 3, and the inside of the operation panel is arranged as a diagram. The operation panel 3 is connected to the DI/DO module 2 in a hard-wired, point-to-point manner as shown in fig. 4 and 5.

In a preferred embodiment, the test operation terminal 11 transmits the operation command and the parameter setting to the host PLC control system 12 via an ethernet format. The host PLC control system 12 is shown in fig. 1 and includes CMMS 4, PLC5, ethernet module 6, switch 7, frequency converter 8, motor, and brake 9. The switch 7 transmits the operation instruction and the parameter setting transmitted by the test operation terminal 11 to the PLC5 through the ethernet module 6. The PLC5 judges whether the interlocking condition meets the test condition or not, and detects whether the parameter setting meets the test range or not, wherein the calculation formula of the set value of the lifting braking torque parameter is as follows:

Tgz1≥Kgz1*Q1*Dj1*η1/(2*Zgz1*m1*i1)，

wherein Tgz1 represents the braking torque of a lifting brake, Kgz1 represents the lifting safety factor, Q1 represents the lifting load, Dj1 represents the diameter of a lifting winding drum, eta 1 represents the total efficiency of a lifting transmission mechanism, Zgz1 represents the number of brakes, m1 represents the multiplying power of a pulley, and i1 represents the transmission ratio of the lifting speed reducer.

As a preferred embodiment, the calculation formula of the braking torque parameter set value of the pitch brake is as follows:

Tgz2≥Kgz2*Smax2*Dj2*η2/(Zgzl*i2)，

where Tgz2 represents the pitch brake braking torque, Kgz2 represents the pitch brake safety factor, Smax2 represents the pitch wire maximum operating static pull, Dj2 represents the pitch drum calculated diameter, η 2 represents the pitch motor to drum mechanical efficiency, Zgz2 represents the number of pitch brakes, i2 represents the pitch retarder gear ratio.

When the conditions meet the requirements, the set value of torque amplitude limiting in the frequency converter 8 is adjusted according to input parameters through the Ethernet module 6 and the switch 7, the frequency converter 8 is controlled to drive the motor 9 to operate according to the set parameters such as torque, direction, speed and the like, and meanwhile, the brake is tested and is forcibly opened irrespectively. The PLC5 receives the parameters of the motor 9 fed back by the frequency converter 8 during the motor torque test, the test result is transmitted to the test operation terminal 11 through the Ethernet, a maintainer can observe the test result through the HMI301, and the test result and the curve are automatically filed and stored.

As a preferred embodiment of the present application, HMI301 related functions can be integrated into the CMMS 4, and the requirement for one-touch test brake torque can be achieved by the same method.

Therefore, maintenance personnel can judge the brake capacity of the brake through the potential energy load mechanism braking torque detection system for the port machinery and verify whether the braking torque can meet the safety requirement, so that the safety and reliability of equipment are improved, the operation is simple and convenient, the labor intensity of the maintenance personnel is reduced, and the labor cost is reduced to a certain degree.

Example 1

The hydraulic brake of the shore bridge hoisting mechanism is tested by using the potential energy load mechanism braking torque detection system for the port machinery as an example for explanation. The test flow is shown in fig. 6: when the system confirms that the current equipment trolley is anchored and a lifting steel wire rope is in a rope loosening state, a preparation condition indicator lamp 305 of an operation panel 3 in an operation terminal 11 is normally on, otherwise, the equipment needs to be checked and adjusted to enter a maintenance position; maintenance personnel select to enter a test mode through the key switch 302, point the mechanism selection switch 303 to the hoisting mechanism, then select a hoisting safety brake on the HMI301, and set parameters such as motor torque limit and motor rotating speed. The parameter data is transmitted to the host PLC control system 12 through the Ethernet, namely, the PLC5 receives the parameter data from the operation terminal 11 through the switch 7 and the Ethernet module 6, and modifies the torque amplitude limiting set value in the frequency converter corresponding to the lifting hydraulic brake according to the parameter data. After parameter setting is completed, the right lower end confirmation key of the HMI301 is pressed, and after the PLC5 verifies that parameter setting is successful, the indicator lamp of the operation button 304 with the lamp is controlled to be normally on through the Ethernet, so that maintenance personnel is prompted to perform operation tests when parameter setting is successful, and at the moment, the lifting high-speed brake can be automatically opened, and the lifting hydraulic brake can keep an internal contracting brake. The maintenance personnel press the operation button 304 with the lamp, the PLC5 receives an operation command from the operation terminal 11 through the Ethernet, and controls the frequency converter 8 through the Ethernet to drive the lifting motor 9 to operate for 3 seconds according to the set parameters of torque, direction, speed and the like. If the hydraulic brake can hold the motor 9 within 3 seconds of the test, the test is passed, the PLC5 controls the test passing indicator lamp 306 on the operation panel 3 to be normally on through the Ethernet, and the indicator lamp is green, so that maintenance personnel is prompted to pass the test; if the brake can not hold the motor within 3 seconds of the test, the motor rotates to indicate that the test is failed, the PLC5 controls the failed test indicator lamp 307 on the operation panel 3 through the Ethernet to be normally on, the indicator lamp is red to prompt maintenance personnel that the test is failed and the lifting hydraulic brake needs to be adjusted. In the testing process, parameters such as motor current, torque and rotating speed can be transmitted to the PLC5 through the frequency converter 8 through the Ethernet in real time, after the PLC5 is processed, the parameters are transmitted to the HMI301 in the testing terminal 11 through the Ethernet for displaying, and a maintainer can observe a testing result through the HMI 301. After the test is finished, the exit key at the right lower end of the HMI301 is pressed, the PLC5 receives a command through the Ethernet and automatically modifies the parameters of the lifting hydraulic brake into default set values and controls the brake of the lifting high-speed brake. The maintenance personnel observes through HMI301 that the parameter has returned to the set value and then selects key switch 302 to the normal mode and the entire test process is finished.

The above-mentioned serial numbers of the embodiments of the present invention are merely for description and do not represent the merits of the embodiments.

In the above embodiments of the present invention, the descriptions of the respective embodiments have respective emphasis, and for parts that are not described in detail in a certain embodiment, reference may be made to related descriptions of other embodiments.

In the embodiments provided in the present application, it should be understood that the disclosed technology can be implemented in other ways. The above-described embodiments of the apparatus are merely illustrative, and for example, the division of the units may be a logical division, and in actual implementation, there may be another division, for example, multiple units or components may be combined or integrated into another system, or some features may be omitted, or not executed. In addition, the shown or discussed mutual coupling or direct coupling or communication connection may be an indirect coupling or communication connection through some interfaces, units or modules, and may be in an electrical or other form.

The units described as separate parts may or may not be physically separate, and parts displayed as units may or may not be physical units, may be located in one place, or may be distributed on a plurality of units. Some or all of the units can be selected according to actual needs to achieve the purpose of the solution of the embodiment.

In addition, functional units in the embodiments of the present invention may be integrated into one processing unit, or each unit may exist alone physically, or two or more units are integrated into one unit. The integrated unit can be realized in a form of hardware, and can also be realized in a form of a software functional unit.

The integrated unit, if implemented in the form of a software functional unit and sold or used as a stand-alone product, may be stored in a computer readable storage medium. Based on such understanding, the technical solution of the present invention may be embodied in the form of a software product, which is stored in a storage medium and includes instructions for causing a computer device (which may be a personal computer, a server, or a network device) to execute all or part of the steps of the method according to the embodiments of the present invention. And the aforementioned storage medium includes: a U-disk, a Read-Only Memory (ROM), a Random Access Memory (RAM), a removable hard disk, a magnetic or optical disk, and other various media capable of storing program codes.

Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. Harbor machinery is with potential energy load mechanism braking torque detecting system, its characterized in that includes:

a test operation terminal (11) and a host PLC control system (12); the test operation terminal (11) includes: the system comprises a remote substation interface module (1), a DI/DO module (2) and an operation panel (3);

the operation panel (3) includes: an HMI (301) specifying parameters of brake settings and test results, a key switch (302) selecting a test mode, a mechanism selection switch (303) selecting a single mechanism for testing, a lighted run button (304) for activating a test, a readiness indicator light (305), a test pass indicator light (306), and a test fail indicator light (307);

and the test operation terminal (11) transmits the operation instruction and the parameter setting to the host PLC control system (12) in an Ethernet mode.

2. The system for detecting the braking torque of the potential energy load mechanism for the port machinery as claimed in claim 1, further characterized in that:

the host PLC control system (12) comprises: CMMS (4), PLC (5), Ethernet module (6), exchanger (7), frequency converter (8), motor and brake (9);

the switch (7) transmits the operation instruction and the parameter setting transmitted by the test operation terminal (11) to the PLC (5) through the Ethernet module (6); judging whether the interlocking condition meets the test condition or not through the PLC (5), and detecting whether the parameter setting meets the test range or not;

when the conditions meet the requirements, the torque amplitude limiting set value in the frequency converter (8) is adjusted according to input parameters through the Ethernet module (6) and the switch (7), the frequency converter (8) is controlled to drive the motor to operate according to preset parameters, and meanwhile, a brake is tested and an irrelevant brake is forcibly opened;

when the PLC (5) receives a motor torque test, the frequency converter (8) feeds back parameters of the motor, test results are transmitted to the test operation terminal (11) through the Ethernet, and a user can obtain the test results through the HMI (301) and automatically archive and store the test results.

3. The system for detecting the braking torque of the potential energy load mechanism for the port machinery as claimed in claim 1, further characterized in that:

the detection parameter setting calculation formula of the lifting braking torque is as follows:

Tgz1≥Kgz1*Q1*Dj1*η1/(2*Zgz1*m1*i1)；

Tgz2≥Kgz2*Smax2*Dj2*η2/(Zgzl*i2)；

4. The system for detecting the braking torque of the potential energy load mechanism for the port machinery as claimed in claim 1, further characterized in that: the HMI (301) is integrated in the CMMS (4).