CN110723649B - Potential energy load mechanism braking moment detection system for harbour machinery - Google Patents

Abstract

The application provides a potential energy load mechanism braking moment detection system for port machinery, which comprises: testing an operation terminal and a host PLC control system; the test operation terminal comprises: a remote substation interface module, a DI/DO module and an operation panel; the operation panel includes: an HMI specifying 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 for activating a test, a readiness indicator light, a test pass indicator light, and a test fail indicator light. And the test operation terminal transmits the operation instruction and the parameter setting to the host PLC control system in the form of Ethernet. According to the technology, a brake moment detection operation table is arranged near a tested brake, a maintainer can detect the brake moment of the brake by one key by utilizing devices such as a PLC, a frequency converter and a motor on an on-board control system, and the system automatically judges and files and stores detection results.

Description

Potential energy load mechanism braking moment detection system for harbour machinery

Technical Field

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

Background

Whether the braking moment of the potential energy load mechanisms such as lifting and pitching of the harbour machinery meets the design requirement directly influences the production operation safety of the equipment. At present, the fields of elevators, automobiles and the like can monitor braking torque by additionally arranging a pressure detection sensor on a brake disc, but related detection devices are not practically applied to port machinery due to different mechanical structures, use environments and load types of equipment. Maintenance personnel of the harbour machinery commonly detect the braking moment through measuring the clearance between the brake disc and the brake pad, whether the braking moment meets the safety production requirement can not be accurately judged, if the harbour machinery has braking failure in the working process, serious safety accidents such as load falling or equipment overturning are likely to occur, and great threat is caused to personal and property safety.

Disclosure of Invention

According to the technical problem, a potential energy load mechanism braking moment detection system for port machinery is provided. The application mainly utilizes a potential energy load mechanism braking moment 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 comprises: a remote substation interface module, a DI/DO module and an operation panel;

the operation panel includes: an HMI specifying 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 for activating a test, a readiness indicator light, a test pass indicator light, and a test fail indicator light.

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 transmits the operation instruction and parameter setting transmitted by the test operation terminal 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, adjusting a torque limiting set value in the frequency converter according to input parameters through the Ethernet module and the switch, controlling the frequency converter to drive the motor to operate according to preset parameters, and meanwhile, enabling the band-type brake to be tested and enabling the brake to be opened forcedly;

the PLC receives parameters fed back to the motor by the frequency converter during motor torque test, and transmits test results to the test operation terminal through the Ethernet, so that a user can obtain the test results through the HMI and automatically archive and store the test results.

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

Tgz1≥Kgz1*Q1*Dj1*η1/(2*Zgz1*m1*i1)；

wherein Tgz represents the brake torque of the lifting brake; kgz1 the lifting safety coefficient; q1 represents a lifting load; dj1 represents the diameter of the lifting reel; η1 represents the total efficiency of the lifting transmission mechanism; zgz1 the number of brakes; m1 represents the pulley magnification; i1 represents the transmission ratio of the lifting speed reducer;

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

Tgz2≥Kgz2*Smax2*Dj2*η2/(Zgzl*i2)；

wherein Tgz represents pitch brake braking torque; kgz2 represents pitch brake safety factor; smax2 represents the maximum working static tension of the pitching wire rope; dj2 represents the pitch drum calculated diameter; η2 represents pitch motor to roll mechanical efficiency; zgz2 represents the number of pitch brakes; i2 represents pitch retarder gear ratio.

Further, the HMI is integrated in the CMMS.

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

according to the technology, a brake moment detection operation table is arranged near a tested brake, a maintainer can detect the brake moment of the brake by one key by utilizing devices such as a PLC, a frequency converter and a motor on an on-board control system, and the system automatically judges and files and stores detection results. The method has the advantages of low investment cost, simple operation and clear test result, can query the history detection record, eliminates the potential safety hazard of insufficient braking torque in time, and ensures the safety of equipment, property and personnel.

Drawings

In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, and it is obvious that the drawings in the following description are some embodiments of the present application, and other drawings may be obtained according to the drawings without inventive effort to a person skilled in the art.

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

Fig. 2 is a view of an operation panel according to the present application.

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

Fig. 4 is a diagram of DI module wiring according to the present application.

FIG. 5 is a wiring diagram of a DO module of the present application.

FIG. 6 is a schematic diagram of the overall test flow of the present application.

Detailed Description

In order that those skilled in the art will better understand the present application, a technical solution in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings in which it is apparent that the described embodiments are only some embodiments of the present application, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the present application without making any inventive effort, shall fall within the scope of the present application.

It should be noted that the terms "first," "second," and the like in the description and the claims of the present application and the above figures are used for distinguishing between similar objects and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used may be interchanged where appropriate such that the embodiments of the application described herein may be implemented in sequences other than those illustrated or otherwise 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 application provides a potential energy load mechanism braking moment detection system for a harbor machine, comprising: a test operation terminal 11 and a host PLC control system 12.

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

In this embodiment, HMI301 is configured to designate parameters such as a motor rotation speed and a torque limit corresponding to a brake setting, and display a test result; the key switch 302 is used for selecting a test mode, and after the test mode is selected, the host cannot normally operate the equipment, so that multiple operations are avoided, and the safety is ensured; the mechanism selection switch 303 is used for selecting a mechanism to be tested, lifting or arm support, and the test can be performed by a single mechanism; the running 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 completion of the parameter setting is prompted, the test can be run, and at the moment, the running command is given only by pressing the running button 304 with the lamp; the preparation condition indicator 305 is used to display whether the test preparation condition is met, and the preparation condition indicator is turned on only if the safety interlock condition is met, so that the test mode is allowed to be entered; the test passing indicator lamp 306 is used for indicating the passing of the test, and the indicator lamp is normally on after the passing of the test, and is green; the test failed indicator 307 is used for indicating that the test failed, and the indicator is always on after the test failed, and the indicator is red.

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 operation panel is arranged internally. The operation panel 3 is connected to the DI/DO module 2 in a point-to-point manner by hard wires as shown in fig. 4 and 5.

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

Tgz1≥Kgz1*Q1*Dj1*η1/(2*Zgz1*m1*i1)，

wherein Tgz represents a brake moment of a lifting brake, kgz1 represents a lifting safety coefficient, Q1 represents a lifting load, dj1 represents a lifting reel diameter, eta 1 represents a total efficiency of a lifting transmission mechanism, zgz1 represents the number of brakes, m1 represents a pulley multiplying power, and i1 represents a transmission ratio of a lifting speed reducer.

As a preferred embodiment, the pitch brake braking torque parameter set point calculation formula is:

Tgz2≥Kgz2*Smax2*Dj2*η2/(Zgzl*i2)，

wherein Tgz represents pitch brake braking moment, kgz represents pitch brake safety factor, smax2 represents pitch wire rope maximum working static tension, dj2 represents pitch drum calculated diameter, η2 represents pitch motor to drum mechanical efficiency, zgz2 represents pitch brake number, and i2 represents pitch reducer transmission ratio.

When the conditions are satisfied, the torque limiting set value in the frequency converter 8 is adjusted through the Ethernet module 6 and the switch 7 according to the input parameters, 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 band-type brake is tested to be opened forcedly without the brake. The PLC5 receives parameters of the motor 9 fed back by the frequency converter 8 during motor torque test, and transmits a test result to the test operation terminal 11 through the Ethernet, so that maintenance personnel can observe the test result through the HMI301, and the test result and the curve are automatically archived and saved.

As a preferred embodiment of the present application, HMI301 related functions may be integrated into CMMS 4, and the same approach may be used to achieve the brake torque on demand for one-touch testing.

Therefore, maintenance personnel can judge the band-type brake capacity of the brake through the potential energy load mechanism braking moment detection system for the harbour machinery, and verify whether the braking moment can meet the safety requirement, so that the safety and reliability of the 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 extent.

Example 1

The hydraulic brake of the crane lifting mechanism is tested by using the potential energy load mechanism braking moment detection system for the harbour machinery as an example. The test flow is shown in fig. 6: when the system confirms that the current equipment trolley is anchored and the lifting steel wire rope is in a rope loosening state, the preparation condition indicator lamp 305 of the operation panel 3 in the operation terminal 11 is always on, otherwise, the equipment needs to be checked and adjusted to enter a maintenance position; the maintainer selects to enter a test mode through the key switch 302, directs the mechanism selection switch 303 to the lifting mechanism, then selects to lift the safety brake on the HMI301, and sets parameters such as motor torque limit, motor rotation speed and the like. The parameter data is transmitted to a 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 the torque limiting set value in the frequency converter corresponding to the lifting hydraulic brake is modified according to the parameter data. After parameter setting is completed, an HMI301 right lower end confirmation button is pressed down, after the PLC5 verifies that parameter setting is successful, an indicator lamp of an operation button 304 with a lamp is normally on through Ethernet control, maintenance personnel is prompted that parameter setting is successful, a test can be operated, a lifting speed brake can be automatically opened at the moment, and a lifting hydraulic brake can keep a band-type brake. The maintainer presses the operation button 304 with the lamp, the PLC5 receives the operation command from the operation terminal 11 through the Ethernet, and drives the lifting motor 9 to operate for 3 seconds according to the set parameters such as torque, direction, speed and the like through the Ethernet control frequency converter 8. If the hydraulic brake can hold the motor 9 within 3 seconds of testing, 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, the indicator lamp is green, and maintenance personnel is prompted to pass the test; if the motor cannot be held by the brake within 3 seconds of the test, the motor rotates to indicate that the test fails, the PLC5 is normally on through the test fail indicator lamp 307 on the Ethernet control operation panel 3, the indicator lamp is red, and maintenance personnel is prompted that the test fails, and the lifting hydraulic brake needs to be adjusted. In the test process, parameters such as motor current, torque, rotating speed and the like are transmitted to the PLC5 in real time through the frequency converter 8 by the Ethernet, after the PLC5 is processed, the parameters are transmitted to the HMI301 in the test terminal 11 by the Ethernet for display, and maintenance personnel can observe the test result through the HMI 301. After the test is completed, the lower right end exit button of the HMI301 is pressed, and the PLC5 automatically modifies the parameters of the lifting hydraulic brake to default set values and controls the lifting high-speed brake band-type brake after receiving a command through the Ethernet. The maintenance personnel observe through the HMI301 that the parameters have recovered to the set values, and then select the normal mode with the key switch 302, and the entire test procedure ends.

The foregoing embodiment numbers of the present application are merely for the purpose of description, and do not represent the advantages or disadvantages of the embodiments.

In the foregoing embodiments of the present application, the descriptions of the embodiments are emphasized, and for a portion of this disclosure that is not described in detail in this embodiment, reference is made to the related descriptions of other embodiments.

In the several embodiments provided in the present application, it should be understood that the disclosed technology may be implemented in other manners. The above-described embodiments of the apparatus are merely exemplary, and the division of the units, for example, may be a logic function division, and may be implemented in another manner, for example, a plurality of units or components may be combined or may be integrated into another system, or some features may be omitted, or not performed. Alternatively, the coupling or direct coupling or communication connection shown or discussed with each other may be through some interfaces, units or modules, or may be in electrical or other forms.

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 may be selected according to actual needs to achieve the purpose of the solution of this embodiment.

In addition, each functional unit in the embodiments of the present application may be integrated in one processing unit, or each unit may exist alone physically, or two or more units may be integrated in one unit. The integrated units may be implemented in hardware or in software functional units.

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

Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present application, and not for limiting the same; although the application has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the application.

Claims (2)

1. The potential energy load mechanism braking moment detecting system for the harbor machinery is characterized by comprising:

a test operation terminal (11) and a host PLC control system (12); the test operation terminal (11) includes: the remote substation 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 a test, a lighted run button (304) for activating a test, a ready light (305), a test pass light (306), and a test fail light (307);

the test operation terminal (11) transmits operation instructions and parameter settings to the host PLC control system (12) in the form of Ethernet;

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

the switch (7) transmits the operation instruction and 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, adjusting a torque limiting set value in the frequency converter (8) according to input parameters through the Ethernet module (6) and the switch (7), controlling the frequency converter (8) to drive the motor to operate according to preset parameters, and meanwhile, enabling the band-type brake to be tested by a brake, and enabling the brake to be opened forcedly independently;

the PLC (5) receives parameters fed back to the motor by the frequency converter (8) during motor torque test, and transmits a test result to the test operation terminal (11) through the Ethernet, so that a user can acquire the test result through the HMI (301) and automatically archive and store the test result;

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

Tgz1≥Kgz1*Q1*Dj1*η1/(2*Zgz1*m1*i1)；

wherein Tgz represents the brake torque of the lifting brake; kgz1 the lifting safety coefficient; q1 represents a lifting load; dj1 represents the diameter of the lifting reel; η1 represents the total efficiency of the lifting transmission mechanism; zgz1 the number of brakes; m1 represents the pulley magnification; i1 represents the transmission ratio of the lifting speed reducer;

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

Tgz2≥Kgz2*Smax2*Dj2*η2/(Zgzl*i2)；

wherein Tgz represents pitch brake braking torque; kgz2 represents pitch brake safety factor; smax2 represents the maximum working static tension of the pitching wire rope; dj2 represents the pitch drum calculated diameter; η2 represents pitch motor to roll mechanical efficiency; zgz2 represents the number of pitch brakes; i2 represents pitch retarder gear ratio.

2. The harbour machinery potential energy load mechanism braking torque detection system of claim 1, further characterized by: the HMI (301) is integrated in the CMMS (4).