CN113346825A

CN113346825A - Integrated control system and control method for small and medium-sized hoisting equipment

Info

Publication number: CN113346825A
Application number: CN202110576289.1A
Authority: CN
Inventors: 孟晓丽
Original assignee: Nanjing Huayi Electronic Technology Co ltd
Current assignee: Nanjing Huayi Electronic Technology Co ltd
Priority date: 2021-05-26
Filing date: 2021-05-26
Publication date: 2021-09-03

Abstract

The invention discloses an integrated control system for small and medium-sized hoisting equipment, which comprises: a master control singlechip; each switch circuit is connected between a signal source and a functional pin of the master control singlechip and switches the conduction state of the switch circuit according to an alternating current operating signal sent by the signal source; the main control single chip microcomputer sends corresponding execution signals to a motor main loop according to the received signals so as to adjust the working state of the motor; the direct current power supply circuit is connected between the master control single chip microcomputer and the electric brake coil and is used for supplying power to the motor brake coil when the master control single chip microcomputer sends a motor starting signal to the motor driving loop; the singlechip controls the limit. The invention can directly access the alternating current signals required by the industry; the motor brake coil can be directly powered. Other accessories are greatly reduced, and the space occupation of the distribution box is greatly reduced; the limit control is reliable to realize accurate deceleration parking.

Description

Integrated control system and control method for small and medium-sized hoisting equipment

Technical Field

The invention relates to the technical field of industrial control of hoisting equipment, in particular to an integrated control system and a control method of small and medium-sized hoisting equipment.

Background

The motor controller in the professional field is a control system which integrates professional functions on the basis of a frequency conversion technology adapting to professional working condition requirements. Such as: the driving devices such as robot controllers and helicopter controllers are not called frequency converters or servo drivers, but called "drivers", "speed regulators" or "controllers". At present, medium and small-sized hoisting equipment does not have an integrated controller, main devices in a control distribution box for the medium and small-sized hoisting equipment are mostly frequency converters with stronger overload capacity, and a plurality of intermediate relays, terminal rows, contactors and the like are assembled for realizing the professional functions and occupy half space of the distribution box. Such as: the state stipulates that the crane must be under-voltage controlled. In practical application, the control of the alternating current 36v is adopted, and the control of the alternating current 24v or 48v is also adopted. At present, all frequency converters and servo driver control circuits and interfaces are not designed correspondingly in the special field. When the crane is actually used, a plurality of intermediate relays are adopted for secondary control. The control switch controls the coil of the intermediate relay through low-voltage alternating current, and controls different working conditions of the frequency converter through various short-circuit modes of the public end of the port of the frequency converter and other ports through opening and closing of the contact of the relay. Taking such a conventional circuit as an example: 3 converters need to use 10 intermediate relays and also need 40 wiring points and opposite wiring terminals, and occupy a large space of the distribution box. The control of the large and small cars and the lifting motor by the three frequency converters to high and low speed, positive and negative rotation is realized, the secondary control of the intermediate relay adopted in the prior art enables the operation reaction speed to be reduced and more fault points in the circuit are increased; the device cost is increased; the space and the cost of the distribution box are increased; the corresponding manufacturing cost and the later maintenance cost are increased; the control motor braking coil needs to be externally connected with a contactor and a rectifier, so that the cost is high, the occupied space is large, and the failure rate is high.

In addition, the large crane, the small crane (translation) and the lifting limit adopt a mechanical mode, a travel switch is pressed, a motor driving circuit is disconnected, and an emergency stop mode is adopted (the lifting motors are all braking motors, and the crane is immediately braked and stopped when the power is off), so that the crane has the advantages of poor effect, short service life and high failure rate;

the special controller for the medium and small-sized hoisting equipment is designed aiming at the special control requirement of the medium and small-sized hoisting equipment, and is a problem which needs to be solved urgently at present.

Disclosure of Invention

Aiming at the defects in the prior art, the invention provides an integrated control system and a control method for small and medium-sized hoisting equipment, which can directly access an alternating current signal required by the external industry and directly carry out synchronous control on a motor and a motor braking coil, the reaction speed reaches microsecond level, and the service life is greatly prolonged; in addition, the space occupation and the device cost of the distribution box are greatly reduced, and the problems that the space and the cost of the conventional distribution box are large, the multi-maintenance of fault points is difficult and the like are effectively solved; the emergency stop mode that the travel switch is pressed by a mechanical mode, and the motor driving circuit is disconnected is changed for large crane, small crane (translation) and lifting limit at present. The accurate and deceleration parking controlled by the single chip microcomputer is realized.

In order to achieve the purpose, the invention adopts the following technical scheme:

in a first aspect, an embodiment of the present application provides an integrated control system for small and medium-sized hoisting equipment, where the integrated control system includes:

a master control singlechip;

each switching circuit is connected between a signal source and a functional pin of the master control single chip microcomputer, switches the conduction state of the switching circuit according to an alternating current operating signal sent by the signal source, and sends the operating signal to the master control single chip microcomputer; the main control single chip microcomputer sends a corresponding execution signal to a main circuit of the motor according to the received operation signal so as to adjust the working state of the motor;

the direct current power supply circuit is used for conducting a direct current power supply loop between a power supply and a motor brake coil when the master control single chip microcomputer sends a motor starting signal to the motor driving loop, and synchronously and directly supplying power to the motor brake coil;

the limiting device comprises a Hall sensor which is arranged on the object and generates a limiting signal when the object approaches a limiting point, and the Hall sensor is connected with the main control singlechip, the main control singlechip receives the limiting signal, embedded software arranged in the main control singlechip is adopted to sequentially cut off corresponding functional pins, and the motor is controlled step by step, so that the object is gradually decelerated until the object stops at the limiting point under the control of a limited operation signal; the object at least comprises a vehicle body or a lifting hoist.

Optionally, the switching circuit includes a current-limiting resistor, a first optocoupler, a second optocoupler, a filter capacitor, and a diode;

the light emitter of the first optical coupler is connected with the light emitter of the second optical coupler in series, and the signal input end of the first optical coupler light emitter is connected with a signal source through a current-limiting resistor; the light receptor of first opto-coupler and the light receptor of second opto-coupler are parallelly connected form, and the light receptor is connected with two branches: the light receiver is grounded through a filter capacitor, and the light receiver is connected to one of the functional pins of the main control singlechip through a reversely connected diode.

Optionally, the switch circuit comprises a third optocoupler, a filtering unit and a field effect transistor which are connected in sequence;

the third optical coupler switches the conduction state of the light receiver according to an input operation signal;

the filtering unit is used for filtering the conducting pulse signal output by the third optocoupler into a square wave signal which is used as a switching signal of the field effect transistor;

the field effect tube adopts an N-channel field effect tube, the source electrode of the N-channel field effect tube is grounded and is connected with the drain electrode through a diode, and the drain electrode is connected with a functional pin of the master control singlechip.

Optionally, the dc power supply circuit includes a triode, a thyristor-dedicated optocoupler, a voltage dividing unit, a thyristor, a first rectifying diode, and a second rectifying diode;

the triode, the special optocoupler for the controlled silicon, the voltage division unit and the controlled silicon are sequentially connected, when a high-level signal is input to the base electrode of the triode, the special optocoupler for the controlled silicon is conducted, and a voltage signal is applied between the control electrode and the cathode of the controlled silicon through the voltage division circuit;

the negative pole of the controllable silicon is connected with the positive pole of the motor brake coil, the control pole is connected with the negative pole of the motor brake coil through a first rectifier diode which is connected in the reverse direction, and the positive pole is connected with the power supply through a second rectifier diode which is connected in the reverse direction.

Optionally, the integrated control system further comprises a limiting device, wherein the limiting device comprises a vehicle body limiting unit and a lifting hoist limiting unit;

the vehicle body limiting unit comprises a magnet arranged close to the stop position of the track and a Hall sensor arranged on the vehicle body, and the Hall sensor is connected with the main control single chip microcomputer and used for detecting whether the distance between the Hall sensor and the magnet is smaller than a set distance threshold value or not; when the vehicle body travels forwards by taking the rail stop position as a target and the distance between the Hall sensor and the magnet is smaller than a set distance threshold, the main control single chip microcomputer cuts off a high-speed running signal of the motor, and cuts off a motor same-direction running signal after a preset time length, and the motor low-speed forward running signal is recovered and received after the vehicle body reverse running signal is received and the vehicle body is caused to travel backwards, and the motor high-speed forward running signal is recovered and received after the magnet is installed;

the lifting hoist limiting unit comprises N magnets which are arranged on a shaft or an extension device and rotate by taking the shaft central line of the shaft as a rotating shaft, and a Hall sensor arranged nearby, wherein the Hall sensor is connected with the main control single chip microcomputer and used for collecting the number of revolutions of the shaft; the main control single chip microcomputer calculates lifting position information of the hoist lifting hook and distance information between the hoist lifting hook and a limited stopping point according to the acquisition result of the Hall sensor, and the limited stopping point represents at least one stopping position of the hoist lifting hook in the lifting direction; when the hoist lifting hook reaches a limited stopping point, the motor is forcibly closed to run in the same direction until a hoist reverse running signal is received, the hoist lifting hook is enabled to run in the reverse direction and then to recover to receive a motor forward running signal, and the motor forward high-speed running signal is recovered after the rotation number of the shaft exceeds a preset rotation number; when the hoist lifting hook moves to the limited stopping point and approaches the limited stopping point, the main control single chip microcomputer automatically selects whether to set a high-speed running signal for cutting off the motor according to the condition of goods or the requirement of a user so as to decelerate and approach the limited stopping point.

In a second aspect, an embodiment of the present application provides an integrated control method for small and medium-sized hoisting equipment, where the integrated control method is based on the integrated control system described above, and includes:

initializing a master control single chip microcomputer;

receiving an alternating current operating signal, switching the conduction state of a switching circuit connected with the alternating current operating signal according to the alternating current operating signal, and enabling the main control single chip microcomputer to send a corresponding execution signal to the motor driving loop according to the received operating signal combination;

the master control singlechip instructs the motor driving circuit to start the motor and instructs the direct current power supply circuit to work to directly supply power to the motor braking coil;

collecting alternating current operating signals of a signal source in real time, forming level signals required by the identification of the single chip microcomputer through the combination of a switch circuit group, and then controlling the motor by the single chip microcomputer according to the signals;

and in the running process of the motor, if a limit signal is received, the corresponding functional pins are sequentially cut off, and the motor is controlled step by step, so that the object is gradually decelerated until the object stops at a limit point under the control of the limited operation signal.

Optionally, the integrated control method further includes:

a magnet is arranged in front of the rail stop position, a Hall sensor is arranged on the vehicle body, and the Hall sensor is connected with the main control single chip microcomputer and used for detecting whether the distance between the Hall sensor and a set terminal is smaller than a set distance threshold value;

when the vehicle body travels forwards by taking the rail stop position as a target, the distance between the Hall sensor and the magnet is collected in real time, when the distance between the Hall sensor and the magnet is gradually reduced and the distance between the Hall sensor and the magnet is smaller than a set distance threshold value, the main control single chip microcomputer cuts off a high-speed operation signal of the motor, and cuts off a motor same-direction operation signal after a preset time length, and the motor low-speed operation signal is recovered and received after the vehicle body travels backwards, and the motor forward high-speed operation signal is recovered and received after the magnet is installed.

Optionally, the integrated control method further includes:

the method comprises the following steps that N magnets are arranged on a shaft or an extension device of a lifting hoist, the magnets rotate along with the shaft by taking the shaft center line of the shaft as a rotating shaft, and a Hall sensor is arranged in the vicinity and connected with a master control single chip microcomputer and used for collecting the rotation number of the shaft;

defining at least one stop position of the hoist hook in the lifting direction as a defined stop point;

in the lifting process of the hoist lifting hook, according to the acquisition result of the Hall sensor, calculating in real time to obtain the lifting position information of the hoist lifting hook and the distance information between the hoist lifting hook and a limited stop point;

when the hoist lifting hook reaches a limited stopping point, the motor is forcibly closed to run in the same direction until a hoist reverse running signal is received, the hoist lifting hook is enabled to run in the reverse direction and then to recover to receive a motor forward running signal, and the motor forward high-speed running signal is recovered after the rotation number of the shaft exceeds a preset rotation number; when the hoist lifting hook moves to the limited stopping point and approaches the limited stopping point, the main control single chip microcomputer automatically selects whether to set a high-speed running signal for cutting off the motor according to the condition of goods or the requirement of a user so as to decelerate and approach the limited stopping point.

Further, the integrated control method further includes:

when the single-speed hoist is controlled, if a limit signal is received, the real-time position change condition of the lifting hook is identified, and the alternating current contactor in the operation direction is disconnected when the lifting hook is controlled to reach the upper limit point and the lower limit point step by step according to the identification result; and meanwhile, starting a voltage monitoring circuit, identifying the voltage at the output end of the alternating current contactor after the coil of the alternating current contactor in the running direction is disconnected, judging that the contacts of the alternating current contactor are adhered if the output end of the alternating current contactor still outputs working current for the motor, and immediately disconnecting the main power supply.

The invention has the beneficial effects that:

(1) according to the embodiment of the application, alternating current signals required by the external industry can be directly accessed, and compared with other frequency converters or servo drivers, the two-stage control mode is adopted, a plurality of intermediate relays and corresponding terminal rows are omitted, and the response speed in performance is improved by thousands of times (microsecond and millisecond); more fault points in the secondary control circuit are reduced, and the reliability is greatly improved; the space and the cost of the distribution box are greatly reduced; the device cost is reduced; the corresponding labor cost is reduced.

(2) Compared with the limiting mode of breaking the motor driving circuit to emergently stop by pressing the travel switch at present, the embodiment of the application adopts a non-contact signal, changes the emergency stop mode of directly breaking the motor driving circuit by pressing the travel switch into the mode of slowly and accurately decelerating and stopping by the program control of the single chip after sending a signal to the single chip, and integrates and manages the mode in the control system, thereby effectively eliminating the defects of unstable danger and high failure rate caused by the emergency stop mode to the lifting working condition.

(3) The embodiment of the application can directly output the half-wave direct current required by braking to the braking coil when the motor works, and the half-wave direct current required by braking is not required to be provided through an external contactor and a rectifier like a frequency converter and a servo driver at present.

Drawings

Fig. 1 is a schematic structural diagram of an integrated control system for small and medium-sized hoisting equipment according to an embodiment of the present application.

Fig. 2 is a schematic structural diagram of one of the switch circuits according to the embodiment of the present application.

Fig. 3 is a schematic structural diagram of another switching circuit according to an embodiment of the present application.

Fig. 4 is a schematic structural diagram of a dc power supply circuit according to an embodiment of the present application.

Fig. 5 is a schematic diagram of an operating principle of a hall sensor according to an embodiment of the present application.

Detailed Description

The present invention will now be described in further detail with reference to the accompanying drawings.

It should be noted that the terms "upper", "lower", "left", "right", "front", "back", etc. used in the present invention are for clarity of description only, and are not intended to limit the scope of the present invention, and the relative relationship between the terms and the terms is not limited by the technical contents of the essential changes.

Example one

Fig. 1 is a schematic structural diagram of an integrated control system for small and medium-sized hoisting equipment according to an embodiment of the present application. The application is suitable for hoisting control equipment, especially small and medium-sized hoisting equipment, and can achieve the technical effect of completely replacing the secondary control mode of the intermediate relay adopted by the traditional mode. The integrated control system is characterized in that the control part is integrated on the control panel except for necessary limiting devices such as a magnet and a Hall sensor, and the control part is centered on the main control single chip microcomputer and can be directly connected with a control device and a driving motor on the basis of meeting the low-voltage control specified by the industry. The integrated control system can be designed on a circuit board in a special controller for all or part of different hoisting equipment; the product can also be designed independently to be used as a matched extension control product for making up the shortage of the lifting professional function of the existing frequency converter.

Referring to fig. 1, the integrated control system at least comprises a master control single chip microcomputer, a plurality of switch circuits, a direct current supply circuit and a main circuit board, wherein the main circuit board provides power for a hall sensor, and the hall sensor signals are connected with a circuit interface of the single chip microcomputer.

Switch circuit

In this embodiment, the input end of each ac operating signal is connected to a switch circuit, that is, each switch circuit is connected between a signal source and a functional pin of the main control single chip, and switches its on state according to the operating signal sent by the signal source, and sends the operating signal to the main control single chip. One of the following two modes can be selected according to the type of the operation signal source (the mainstream alternating current 36V is applicable to the first type; the 24V to 48V signal source is applicable to the second type).

First switching circuit

Referring to fig. 2, the switching circuit includes a current limiting resistor, a first optocoupler, a second optocoupler, a filter capacitor, and a first diode. The light emitter of the first optical coupler is connected with the light emitter of the second optical coupler in series, and the signal input end of the first optical coupler light emitter is connected with a signal source through a current-limiting resistor; the light receptor of first opto-coupler and the light receptor of second opto-coupler are parallelly connected form, and the light receptor is connected with two branches: the light receiver is grounded through the filter capacitor, and the light receiver is connected to one of the functional pins of the main control singlechip through the reversely connected first diode.

When a low-voltage alternating current signal is connected to the optocoupler through a current-limiting resistor R1 (different in voltage and different in resistance), the first optocoupler OP1 is lightened when the half shaft is positive. The internal resistance between its

output terminals

3,4 becomes immediately smaller, thus forming a conducting state. This on state simulates the function of a key. The second optical coupler OP2 utilizes the reverse process of low voltage ac. The two processes combine to make the simulated button a continuous on, rather than a jittered on.

In fig. 2, a single set of operating principles, several sets of opto-couplers simulate several switches. Directly connecting the signal source and the corresponding functional pin of the singlechip. The scheme is suitable for most working conditions with smaller voltage ranges.

Second switching circuit configuration

The switch circuit comprises a third optocoupler, a filtering unit and a field effect transistor which are connected in sequence; the third optical coupler switches the conduction state of the light receiver according to the input operation signal; the filtering unit is used for filtering the conducting pulse signal output by the third optocoupler into a square wave signal which is used as a switching signal of the field effect transistor; the field effect tube adopts an N-channel field effect tube, the source electrode of the N-channel field effect tube is grounded and is connected with the drain electrode through a second diode, and the drain electrode is connected with a functional pin of the main control singlechip.

Referring to fig. 3, when a current flows through the input terminal of the optical coupler OP3, the output terminal is turned on. Because the input end has different conditions from 24V to 48V, the conduction condition of the optical coupler OP3 is far away, and the singlechip is controlled by directly driving the resistor, so that the singlechip is unreliable.

After the N-channel field effect transistor Q1 is adopted, the output of the optocoupler OP3 is used as a voltage signal of the field effect transistor, and the difference is reduced. The fet Q1 is turned on regardless of the degree of conduction of the optocoupler OP 3. Because the input end of the optical coupler OP3 is an alternating current signal, the output end of the optical coupler OP3 is a conducting pulse signal of 50HZ, and the pulse signal is filtered into a square wave signal by adding a capacitor C2. In fig. 3, a single group of working principle simulates that several switches are directly connected with the signal source and the corresponding functional pins of the master control singlechip.

(II) master control single chip microcomputer

The main control single chip microcomputer is used as a control center of the application, related control programs of the crane are installed in the main control single chip microcomputer, the main control single chip microcomputer can be matched with related structures of the existing crane to operate, and the control programs can adopt control methods provided by the existing programs aiming at the walking or lifting control process of the crane, such as a speed regulation control method of a special frequency converter for a heavy load motor and the like provided by the invention with the patent number ZL 201810426050.4. However, the processing of the input signal and the output signal has the characteristics of the present application, such as the introduction and processing of the completely new limit signal mentioned later.

The main control single chip microcomputer sends corresponding execution signals to the motor controller according to the received operation signal combination so as to adjust the working state of the motor. In the embodiment, the operation control mode of a common handle does not need to be changed, the operation signals can still be input by the original equipment such as an operation switch or a remote controller, the change is that the secondary control of an intermediate relay is not needed when the alternating current direct control is carried out, the corresponding relation between the operation signal combination and the motor execution signals can also follow the original scheme, the development process of related software is reduced, and meanwhile, the adaptability of the integrated control system of the embodiment is improved. For example, the working condition when the common terminal (ground) in the variable frequency speed control circuit is connected with different functional pins of the main control singlechip can be set as follows: suppose that the master control singlechip is connected with five signal sources respectively used for receiving operation signals XC, X1, X2, X3 and X4:

(1) when the operation signals XC, X1 and X4 are received simultaneously, the motor rotates forwards at a high speed.

(2) When the operation signals XC, X2, and X4 are received at the same time, the motor is rotated in reverse at a high speed.

(3) When the operation signals XC and X1 are received simultaneously, the motor rotates forward at a low speed.

(4) When the operation signals XC and X2 are received at the same time, the motor is reversed at a low speed.

(5) When the controller reports a fault and stops working, the controller resets after receiving the operation signals XC and X3 at the same time.

In the embodiment, four or five parallel switch circuits are designed on the control circuit board, so that the alternating current signal direct control ground end required by the industry and applied in practice can be connected or disconnected with the corresponding functional pin of the singlechip, and the functional low-voltage alternating current direct control is realized.

Compared with other frequency converters or servo drivers which adopt a two-stage control mode, the embodiment omits a plurality of intermediate relays and corresponding terminal rows, and the response speed is improved by thousands of times in performance (compared with the millisecond level of the intermediate relays); because more fault points in the secondary control circuit are subtracted, the reliability is greatly improved; meanwhile, the space and cost of the distribution box, the device cost and the labor cost are greatly reduced.

(III) DC power supply circuit

The direct current supply circuit is connected between the main control single chip microcomputer and the motor brake coil, when the main control single chip microcomputer sends a motor starting signal to the motor controller, a one-way current loop between the direct current supply circuit and the motor brake coil is conducted, and the direct current supply circuit on the main circuit board is adopted to directly supply power for the motor brake coil.

Referring to fig. 4, the dc power supply circuit includes a triode, a thyristor-dedicated optocoupler, a voltage dividing unit, a thyristor, a third diode, and a fourth diode; the triode, the special optocoupler for the controlled silicon, the voltage division unit and the controlled silicon are sequentially connected, when a high-level signal is input to the base electrode of the triode, the special optocoupler for the controlled silicon is conducted, and a voltage signal is applied between the control electrode and the cathode of the controlled silicon through the voltage division circuit; the negative pole of the controlled silicon is connected with the positive pole of the motor brake coil, the control pole is connected with the negative pole of the motor brake coil through a first rectifier diode which is connected in the reverse direction, and the positive pole is connected with the power supply through a second rectifier diode which is connected in the reverse direction.

Specifically, the master control singlechip controls the B set of the triode, the N3 high level (3.3V) enables the triode to be conducted, the voltage of more than 1.1V is provided at the input end of the special optocoupler U2 for the controlled silicon, and pins 6 and 4 of the optocoupler U2 are conducted. Thus, a voltage of 3V or more obtained by dividing the voltage by the resistor R5 and the resistor R6 is applied between the G pin and the K pin of the thyristor Q5. Thus, the 380V external power flows from the S terminal D1Q 5M terminal (coil +) - > T terminal (coil-). The reverse direction is not.

At present, a brake coil for controlling a hoisting motor is externally connected with a contactor and a rectifier by a signal end of a frequency converter, and has the defects of high cost, large occupied space and the like. In the embodiment, the control of the motor brake coil is also handed to the main control singlechip by the direct current power supply circuit on the premise of not needing an external intermediate device. Through the direct current power supply circuit, the main control single chip microcomputer can directly output half-wave direct current required by braking to the braking coil when the motor works, synchronous control of the motor and the braking coil is achieved, and the half-wave direct current required by braking is not required to be provided through an external contactor and a rectifier in the prior art like a frequency converter and a servo driver.

(IV) limiting device

At present, a collision travel switch is generally adopted, and a motor driving circuit is disconnected in an emergency stop mode. Taking a common hoisting device as an example, a cart is mounted on a first translation rail and horizontally and transversely moves along the first translation rail, a second translation rail is arranged on the cart, and a trolley is mounted on the cart and horizontally and longitudinally moves along the second translation rail. The hoist is arranged below the trolley and can be a steel wire rope or a ring chain with a lifting hook, and the hoist is responsible for lifting the heavy object to move up and down, so that the heavy object can move freely on a three-axis coordinate system. The cart, trolley and hook are sometimes headed or topped for various reasons, and in order to avoid hitting the end, a bump travel switch is usually provided at the end position. But frequent bumping and bumping travel switches: firstly, the collision travel switch needs frequent maintenance and even replacement, and the high-altitude operation is quite dangerous, and secondly, as the operation objects of the hoisting equipment are all heavy objects, the sudden stop when the heavy objects are hung has great risks of unhooking the heavy objects and the like.

In order to eliminate unstable danger, high failure rate and other defects caused by the emergency stop mode to the lifting working condition, the embodiment provides that a non-contact signal is adopted, the emergency stop mode that a travel switch is directly disconnected with a motor driving circuit is changed into the emergency stop mode that a single chip microcomputer sends a signal and then is controlled by a program of the single chip microcomputer to slowly and accurately decelerate and stop, and the control circuits are also integrated and managed in the system.

Fig. 5 is a schematic diagram of an operating principle of a hall sensor according to an embodiment of the present application. The signal source uses a hall sensor. The proximity sensor outputs a high level when the magnet is set and switches to a low level when the magnet is removed. The hall sensor in fig. 5 needs a resistor to be pulled up because of the open circuit output, so as to ensure the high level required by the subsequent circuit, and the capacitor functions as filtering.

Specifically, the integrated control system further comprises a limiting device, and the limiting device comprises a vehicle body limiting unit and a lifting hoist limiting unit.

First, the car body limit unit

The vehicle body limiting unit comprises a magnet arranged close to a rail stop position and a Hall sensor arranged on a vehicle body, wherein the Hall sensor is connected with a main control single chip microcomputer and is used for detecting whether the distance between the Hall sensor and the magnet is smaller than a set distance threshold value or not; when the vehicle body travels forwards by taking the rail stop position as a target and the distance between the Hall sensor and the magnet is smaller than a set distance threshold, the main control single chip microcomputer cuts off a high-speed operation signal of the motor, and cuts off the forward operation signal of the motor after a preset time length until the vehicle body resumes to receive a forward low-speed operation signal of the motor after traveling backwards and resumes to receive the forward high-speed operation signal of the motor after passing through the magnet installation position.

For example, magnets are respectively arranged at the proper positions of the two ends of the track; hall sensors are respectively arranged at proper positions of the cart and the cart. When the cart (or the trolley) is operated to reach the end position, the magnet arranged at the fixed position beside the track and the Hall sensor arranged on the cart (or the trolley) are close to a set distance, and then the Hall sensor sends out signals. The single chip microcomputer receives the signal to cut off the high speed, if the operator continues to operate the operation, the single chip microcomputer can only operate for 3 seconds (adjustable and program set) at the low speed, and cuts off the signal after the operation is performed for 3 seconds at the low speed, and the vehicle is forcibly stopped. And slow and accurate deceleration parking is achieved. After the magnet is reversely arranged, the main control single chip microcomputer can only receive a forward low-speed running signal, and the forward high-speed running signal is recovered to be received after the magnet is reversely arranged. The limiting device can also effectively prevent various risks caused by misoperation of a user.

Second, a hoisting block limiting unit

The lifting hoist lifting hook limiting unit comprises N magnets and a Hall sensor, wherein the N magnets are installed on a shaft or an extension device and rotate by taking the shaft center line of the shaft as a rotating shaft, and the Hall sensor is installed nearby and connected with a main control single chip microcomputer and used for collecting the rotation number of the shaft; the main control single chip microcomputer calculates lifting position information of the hoist lifting hook and distance information between the hoist lifting hook and a limited stopping point according to the acquisition result of the Hall sensor, and the limited stopping point represents two stopping positions of the hoist lifting hook in the lifting direction; when the hoist lifting hook reaches a limited stopping point, the motor is forcibly closed to run in the same direction until a hoist reverse running signal is received, the forward low-speed running signal of the motor is recovered to be received after the hoist lifting hook runs in the reverse direction, and the forward high-speed running signal of the motor is recovered to be received after the rotation number of the shaft exceeds the preset rotation number. When the hoist lifting hook moves to the limited stopping point and approaches the limited stopping point, the main control single chip microcomputer automatically selects whether to set a high-speed running signal for cutting off the motor to slow down to approach the limited stopping point according to the goods condition or the user requirement (the user can select a stopping mode for directly setting the hoist lifting hook and also can independently select whether to slow down when approaching the limited stopping point).

For example, N magnets are mounted at appropriate positions on the shaft or extension device to rotate with the shaft, and a fixed Hall sensor is mounted beside the shaft or extension device. After the hoist lifting hook is operated to a set starting point (end point) after power-on and then is shut down, a set key is pressed, a display lamp is turned on, a set state is entered, and a starting position is recorded. And (4) lifting (or descending) is operated, and the direction is recorded. After the operation is stopped when the operation is operated to another set starting point (end point), the display lamp is turned off and enters a set state by pressing a set key. These two positions are defined stopping points before the next setting. When the manual operation is carried out for 3 circles (adjustable and programmed), the vehicle can only run at low speed and is forcibly stopped at the limit point. The reverse operation can be realized after the shutdown. The slow and accurate deceleration stop is realized.

In this embodiment, different from the automatic deceleration control process in other technical fields such as current automobiles, because the operation object of crane is quite special, the process of lifting by crane of crane can't leave artificial monitoring or even artificial operation process, consequently, the main control singlechip of this embodiment provides the limiting function except, more importantly provides the function restriction effect, through the restriction motor function, under the prerequisite of guaranteeing operation safety, makes the user still can realize the autonomous operation control to the crane.

Example two

The embodiment of the present application provides an integrated control method for small and medium-sized hoisting equipment, where the integrated control method is based on the integrated control system, and the integrated control method includes:

and initializing the master control single chip microcomputer.

And receiving the alternating current operating signal, switching the conduction state of a switching circuit connected with the alternating current operating signal according to the alternating current operating signal, and enabling the main control single chip microcomputer to send a corresponding execution signal to the motor driving loop according to the received operating signal combination.

The master control singlechip instructs the motor driving circuit to start the motor and instructs the direct current power supply circuit to work to directly supply power for the motor braking coil.

The alternating current operating signal of the signal source is collected in real time, the level signal required by the single chip microcomputer for identification is formed through the combination of the switch circuit group, and then the single chip microcomputer controls the motor according to the signal.

As a preferred example, the integrated control method further includes:

when the vehicle body travels forwards by taking the rail stop position as a target, the distance between the Hall sensor and the magnet is collected in real time, when the distance between the Hall sensor and the magnet is gradually reduced and the distance between the Hall sensor and the magnet is smaller than a set distance threshold value, the main control single chip microcomputer cuts off a high-speed running signal of the motor, and cuts off a same-direction running signal of the motor after a preset time length, and the forward low-speed running signal of the motor is recovered to be received after the vehicle body travels backwards, and the forward high-speed running signal of the motor is recovered to be received after the vehicle body passes through the magnet installation position.

As another preferred example, the integrated control method further includes:

when the hoist lifting hook moves to the limited stop point and approaches the limited stop point, the main control single chip microcomputer cuts off a high-speed running signal of the motor, and when the limited stop point is reached, the motor is forcibly turned off until a hoist reverse running signal is received and runs, then the motor forward low-speed running signal is recovered, and the motor high-speed forward running signal is recovered after the number of revolutions of the shaft exceeds the preset number of revolutions.

The integrated control method further includes:

when the single-speed hoist is controlled, if a limit signal is received, the real-time position change condition of the lifting hook is identified, the lifting hook is controlled step by step according to the identification result, the AC contactor in the operation direction is disconnected when the lifting hook reaches the upper limit point and the lower limit point, and the single-speed hoist can still run reversely at the moment. Meanwhile, a voltage monitoring circuit is started, the voltage of the output end of the alternating current contactor is identified after the coil of the alternating current contactor in the running direction is disconnected, if the output end of the alternating current contactor still outputs working current for the motor, the contact adhesion of the alternating current contactor is judged, the main power supply is disconnected immediately, double-limit step-by-step control is realized, and a plurality of defects caused by direct disconnection of the main power supply in the traditional control method are overcome, for example, the damage to the alternating current contactor or the motor per se is caused, so that the service life of the motor is shortened, and the like.

The above is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above-mentioned embodiments, and all technical solutions belonging to the idea of the present invention belong to the protection scope of the present invention. It should be noted that modifications and embellishments within the scope of the invention may be made by those skilled in the art without departing from the principle of the invention.

Claims

1. An integrated control system for small and medium-sized hoisting equipment is characterized by comprising:

a master control singlechip;

the direct current power supply circuit is used for conducting a one-way current loop between a power supply and a motor brake coil and synchronously and directly supplying power to the motor brake coil when the master control singlechip sends a motor starting signal to the motor driving loop;

the limiting device comprises a Hall sensor which is arranged on the object and generates a limiting signal when the object approaches a limiting point, and the Hall sensor is connected with the main control singlechip, the main control singlechip receives the limiting signal, embedded software arranged in the main control singlechip is adopted to sequentially cut off corresponding functional pins, and the motor is controlled step by step, so that the object is gradually decelerated until the object stops at the limiting point under the control of a limited operation signal; the object at least comprises a vehicle body and a lifting hoist.

2. The integrated control system for small and medium-sized hoisting equipment according to claim 1, wherein the switch circuit comprises a current-limiting resistor, a first optical coupler, a second optical coupler, a filter capacitor and a diode;

3. The integrated control system for the small and medium-sized hoisting equipment according to claim 1, wherein the switch circuit comprises a third optocoupler, a filtering unit and a field-effect tube which are connected in sequence;

4. The integrated control system for small and medium-sized hoisting equipment according to claim 1, wherein the direct current power supply circuit comprises a triode, a silicon controlled special optocoupler, a voltage division unit, a silicon controlled rectifier, a first rectifier diode and a second rectifier diode;

5. The integrated control system for small and medium-sized hoisting equipment according to claim 1, further comprising a limiting device, wherein the limiting device comprises a vehicle body limiting unit and a hoisting hoist limiting unit;

the vehicle body limiting unit comprises a magnet arranged close to the stop position of the track and a Hall sensor arranged on the vehicle body, and the Hall sensor is connected with the main control single chip microcomputer and used for detecting whether the distance between the Hall sensor and the magnet is smaller than a set distance threshold value or not; when the vehicle body travels forwards by taking the rail stop position as a target and the distance between the Hall sensor and the magnet is smaller than a set distance threshold, the main control single chip microcomputer cuts off a high-speed running signal of the motor, and cuts off a motor same-direction running signal after a preset time length, and the main control single chip microcomputer recovers to receive a motor forward low-speed running signal after receiving a vehicle body reverse running signal to enable the vehicle body to travel backwards and recovers to receive a motor forward high-speed running signal after passing through the magnet installation position;

6. An integrated control method for small and medium-sized hoisting equipment, characterized in that the integrated control method is based on the integrated control system as claimed in any one of claims 1 to 5, and comprises the following steps:

initializing a master control single chip microcomputer;

7. The integrated control method of small and medium-sized hoisting equipment according to claim 6, characterized in that the integrated control method further comprises:

8. The integrated control method of small and medium-sized hoisting equipment according to claim 7, characterized in that the integrated control method further comprises:

9. The integrated control method of small and medium-sized hoisting equipment according to claim 6, characterized in that the integrated control method further comprises:

when the single-speed hoist is controlled, if a limit signal is received, the real-time position change condition of the lifting hook is identified, and the alternating current contactor in the operation direction is disconnected when the lifting hook is controlled to reach the upper limit point and the lower limit point step by step according to the identification result; and meanwhile, starting a monitoring circuit, identifying the voltage at the output end of the alternating current contactor after the coil of the alternating current contactor is disconnected in the running direction, judging that the contacts of the alternating current contactor are adhered if the output end of the alternating current contactor still outputs working current for the motor, and immediately disconnecting the main power supply.