Energy conservation control device of cotton press
Affiliated technical field
The utility model belongs to the energy conservation control device of cotton press in the cotton manufacture field.
Technical background
Processing in last procedure in cotton, is that the loose gined cotton that processes is packed by constant weight.The main pressure limit of baling press that China uses at present is between 200 tons-400 tons, and the hydraulic pump drive motor per hour becomes 15-25 of bag between 22KW-75KW.That is to say that per hour calculating the main compression leg plug roof pressure of cotton press and return by maximum output also is 25 times, and plunger roof pressure and return about 40 seconds of time one time, so per hour the hydraulic pump drive motor on load operation time is about 17 minutes, all the other 40 fens clock times are all moved under unloaded state, equal no-load running.Because during the empty load of motor state, its copper coil winding produces excessive magnetic flux, this magnetic flux (being commonly referred to induced-current) is fixed, and causes motor to waste about 50% electric energy.So because the fixed loss of empty load of motor operation, not only power factor reduces the ratio that makes meritorious power consumption increases, and the motor operational efficiency descends.
The utility model content:
The purpose of this utility model is to provide a kind of simple to operate, Remarkable Energy Saving energy conservation control device of cotton press.
Energy conservation control device of cotton press provided by the utility model is made up of outside start and stop input circuit, hydraulic pump drive motor current detecting circuit, single chip circuit, control output circuit, display screen, button, power circuit, the input of power circuit, outside start and stop input circuit, hydraulic pump drive motor current detecting circuit, button order sheet machine circuit, the output of single chip circuit connects control output circuit and display screen, and the control output circuit connects the relay of hydraulic pump drive motor.
Described single chip circuit is made up of single-chip microcomputer IC2, crystal oscillator JZ, capacitor C 4, C5, described button S1-S4 meets four P1.3-P1.6 of P1 mouth among the single-chip microcomputer IC2 respectively, control pin RS, the R/W of display screen LCD, E, PSB, NC, RST meet six P3.0-P3.5 of P3 mouth among the single-chip microcomputer IC2 respectively, and its data input pin DB0-DB7 meets eight P2.0-P2.7 of P2 mouth among the single-chip microcomputer IC2 respectively.
Described outside start and stop input circuit is made up of binding post J, resistance R 1, R2, Zener diode DW, LED 1, capacitor C 1 and photoelectrical coupler V1, binding post J connecting resistance R1, Zener diode DW is the positive pole of sending and receiving optical diode LED1, photoelectrical coupler V1 luminous tube successively, capacitor C 1 is connected between the negative pole of the negative pole of Zener diode DW and photoelectrical coupler V1 luminous tube, and the colelctor electrode that photoelectrical coupler V1 receives light pipe meets a P1.7 of P1 mouth among the single-chip microcomputer IC2.
Described hydraulic pump drive motor current detecting circuit is made up of current transformer TA, power pack B1, adjustable resistance W1, amplifier IC1 and the peripheral resistance R 3-R10, diode D1, D2, capacitor C 2, the C3 that are contained on the hydraulic pump drive motor inlet wire, and the output of amplifier IC1 meets the P1.0 of P1 mouth among the single-chip microcomputer IC2 by resistance R 10.
Described control output circuit is by resistance R 11-R19, photoelectrical coupler V2-V4, triode U1-U3, diode D3-D5, LED 2-LED4, hydraulic pump drive motor relay JK1-JK3 forms, described photoelectrical coupler V2, the negative pole of V4 luminous tube is respectively by resistance R 11, R17 meets two P1.1 of P1 mouth among the single-chip microcomputer IC2, P1.2, the negative pole of photoelectrical coupler V3 luminous tube meets a P3.7 of P3 mouth among the single-chip microcomputer IC2 by resistance R 14, photoelectrical coupler V2-V4 receives the emitter stage of light pipe respectively by resistance R 12, R15, R18 connects the base stage of triode U1-U3, and hydraulic pump drive motor relay JK1-JK3 connects the colelctor electrode of triode U1-U3 respectively.
Energy conservation control device of cotton press operation principle provided by the utility model is as follows: the working power that energy-saving control device is provided by power circuit, outside start and stop input circuit is to be provided with for the signal of carrying external key start and stop hydraulic pump drive motor, display screen can show the operational factor of cotton press in real time, parameter and running status are set, cooperate button to use setting and the modification that to finish all parameters, operate very simple, before the operation, as long as with hydraulic pump drive motor mutual inductor ratio, the scope of motor rated working current value and motor operating current value deposits single chip circuit in, and the work of energy-saving control device will be finished under the control of single chip circuit automatically.By the hydraulic pump drive motor current detecting circuit hydraulic pump drive motor operating current value is detected in real time, and the hydraulic pump drive motor operating current value that detects flowed to single chip circuit, single chip circuit is under the control of program, this current value is carried out calculation process, analysis, send control signal and be connected on the relay of the hydraulic pump drive motor of its output, adopt the star or the leg-of-mutton method of operation thereby control the hydraulic pump drive motor automatically by the control of control output circuit.When detecting current value greater than hydraulic pump drive motor rated current 50%, control device makes the hydraulic pump drive motor enter the triangle operation, when hydraulic pump drive motor during at Light Condition, when the detection current value is lower than motor rated current 50%, control device makes the hydraulic pump drive motor enter the star operation, and the motor coil winding voltage is reduced, and reduces the flux of magnetic induction electric current, improve power factor and motor operational efficiency, reduce meritorious power consumption and reach energy-conservation purpose.Concrete control procedure is: the hydraulic pump drive motor of cotton press starts under unloading condition, directly enters star energy-saving run state after the startup.When the cotton amount of baling press precompressed case reaches pressure bag weight, the main pressure-controlled valve of baling press hydraulic pump is opened, the hydraulic pump drive motor moves having under the lotus state, along with main compression leg plug is pressed the shortening of bag stroke, pressure rises gradually, and the hydraulic pump drive current of electric also rises thereupon, when electric current is increased to specified 50% the time, single chip circuit makes the hydraulic pump drive motor be automatically converted to the triangle method of operation by control output circuit output control signal, enters the operation of total head state.After pressing bag to put in place, the main pressure-controlled valve of baling press hydraulic pump cuts out, hydraulic pump enters the unloading condition operation again, the hydraulic pump drive current of electric can descend again, when less than rated value 50%, single chip circuit makes the hydraulic pump drive motor enter the operation of star power save mode again by control output circuit output control signal, carries out so repeatedly, adopt the triangle method of operation when hydraulic pump drive motor is moved under the lotus state is arranged, unloading condition adopts the star power save mode method of operation when moving down.This energy-saving control device also has defencive functions such as overcurrent, phase shortage, stall; principle be single chip circuit by the real-time detected value of hydraulic pump drive current of electric is carried out calculation process and with the scope of running current value relatively; detect running current whether in normal range of operation; when the detection electric current was not in normal range (NR), single chip circuit quit work to reach the protection purpose hydraulic pump drive motor by the relay of control output circuit automatic disconnection hydraulic pump drive motor.
Energy conservation control device of cotton press that the utility model provides is by detecting in real time hydraulic pump drive current of electric in the cotton press, and the employing triangle method of operation when adopting singlechip technology to control the hydraulic pump drive motor automatically under the lotus state is arranged, move, unloading condition adopts the star power save mode method of operation when moving down, the power factor and the operational efficiency of motor have been improved, reduced meritorious power consumption, energy-saving effect is remarkable.By contrasting using the forward and backward power consumption of energy conservation control device of cotton press that the utility model provides to measure, this energy conservation control device of cotton press can economize on electricity more than 20%.
Description of drawings
The functional-block diagram of the real energy conservation control device of cotton press that provides of utility model is provided Fig. 1;
Fig. 2 is the electrical schematic diagram of the utility model embodiment;
Fig. 3 is the workflow diagram of the utility model embodiment.
The specific embodiment
Below in conjunction with description of drawings enforcement of the present utility model.Fig. 1 is the functional-block diagram of energy conservation control device of cotton press that utility model provides.Referring to Fig. 1: energy conservation control device of cotton press provided by the utility model is made up of outside start and stop input circuit, hydraulic pump drive motor current detecting circuit, single chip circuit, control output circuit, display screen, button, power circuit, the input of power circuit, outside start and stop input circuit, hydraulic pump drive motor current detecting circuit, button order sheet machine circuit, the output of single chip circuit connects control output circuit and display screen, and the control output circuit connects the relay of hydraulic pump drive motor.Fig. 2 is the electrical schematic diagram of the utility model embodiment.Referring to Fig. 2, the outside start and stop input circuit of this energy conservation control device of cotton press is by binding post J, resistance R 1, R2, and voltage stabilizing DW, LED 1, capacitor C 1 and optocoupler V1 form.The hydraulic pump drive motor current detecting circuit is made up of current transformer TA, the power pack B1, adjustable resistance W1, resistance R 3-R10, amplifier IC1, diode D1, D2, capacitor C 2, the C3 that are contained on the hydraulic pump drive motor inlet wire.Single chip circuit is by single-chip microcomputer IC2, crystal oscillator JZ, and capacitor C 4, C5 form.Control output circuit by resistance R 11-19, optocoupler V2-V4, triode U1-U3, diode D3-D5, LED 2-LED4, hydraulic pump drive motor relay JK1-JK3 form.The display part is made up of adjustable resistance W2, resistance R 20 and LCDs LCD, and the button part is made up of button S1-S4.Power circuit is by transformer B2, diode D5-D13, and three terminal regulator IC4-IC6, capacitor C 6-C17, voltage changer IC3 form.
Power circuit becomes 12V, 15V two-way with 220V voltage through transformer B2,12V voltage is by after the filtering of commutation diode D6-D9 bridge rectifier, again after three terminal regulator IC4, IC5 voltage stabilizing output+9V ,+the 5V DC voltage, + 5V voltage uses for single-chip microcomputer and liquid crystal display, + 9V voltage goes out-9V voltage by voltage changer IC3 conversion again, the amplifier rectification is used in the power supply current detection circuit, and 15V voltage uses for the control output circuit through three terminal regulator IC6 voltage stabilizing output 12V DC voltage after commutation diode D10-D13 bridge rectifier, filtering.After the start and stop control signal of external button is imported by binding post, the 12V DC voltage passes through resistance R 1 step-down, voltage-stabiliser tube DW clamper interfering signal, and luminous indicating diode LED1 makes optocoupler V1 conducting, enter single-chip microcomputer IC2 after the isolation, a P1.7 voltage that makes single-chip microcomputer P1 mouth is by+5V, and drop-down is 0V, and single-chip microcomputer is judged according to the work at present state, if the hydraulic pump drive motor is in running status, stop signal will be judged to, in halted state, enabling signal will be judged to as motor.The hydraulic pump drive motor current detecting circuit enters power pack B1 output 0-5V voltage by the current transformer TA output 0-5A electric current that is connected on the hydraulic pump drive motor inlet wire, pass through amplifier IC2, diode D1, D2 then, the amplifier rectification is after resistance R 10, and output 0-5V DC voltage enters that inner A/D converter input port P1.0 carries out the A/D conversion among the single-chip microcomputer IC2 after capacitor C 3 filtering.Single-chip microcomputer IC2 internal clocking produces clock pulse sequence by external crystal JZ and capacitor C 4, C5, is used to coordinate the work with control single chip computer.The single-chip microcomputer that uses has inner electrify restoration circuit, and institute adopts the processing of direct ground connection through resetting pin RST.The control output circuit enters optocoupler V2, V3, V4 through resistance R 11, R14, R17 respectively by output port P1.1, P3.7, the P1.2 of single-chip microcomputer IC2, after isolating output, drive hydraulic pump drive motor relay JK1, JK2, JK3 break-make by triode U1, U2, U3, to reach control motor star, triangle conversion operation and to stop.Each control pin of LCDs LCD of display part meets the port P3.0-P3.5 of single-chip microcomputer IC2 respectively, its data input pin connects the P2.0-P2.7 port of single-chip microcomputer IC2 respectively, by the internal processes operation, can show operational factor in real time, parameter, running status are set all adopt Chinese prompt.Display screen and button S1, S2, S 3 are used and can finish all parameters setting and modifications.Button S4 can control electric motor starting and stop.
This device can use external key start and stop motor, also available button S4 start and stop motor own by outside start and stop input circuit.Single-chip microcomputer IC2 is by two P1.6, P1.7 of its P1 mouth, when detection has the enabling signal input, two P1.1, the P1.2 output that makes its P1 mouth is 0V voltage by 5V voltage is drop-down, photoelectrical coupler V2, V4 conducting, triode U1, U3 conducting, make hydraulic pump drive motor relay JK1, JK3 adhesive, hydraulic pump drive motor A.C. contactor KB1, KB3 adhesive, the hydraulic pump drive motor of baling press starts operation under the star state.After certain startup time-delay, the hydraulic pump drive motor operating current is imported power pack B1 into and is carried out the AD conversion by the P1.0 that the amplifier rectification enters single-chip microcomputer P1 mouth through current transformer TA, single-chip microcomputer is according to the transformer ratio and the motor load current value of input, convert, compare, control hydraulic pump drive motor star, the triangle conversion of baling press.When the detection electric current is lower than motor rated current 50%, single-chip microcomputer makes hydraulic pump drive motor relay JK1, JK3 adhesive by the control output circuit, hydraulic pump drive motor relay JK2 disconnects, the hydraulic pump drive motor enters the star running status, when detect electric current greater than hydraulic pump drive motor rated current 50% the time, single-chip microcomputer makes hydraulic pump drive motor relay JK1, JK2 adhesive by the control output circuit, and relay J K3 disconnects, and the hydraulic pump drive motor enters the triangle running status.Because hydraulic pump all is to start under unloading condition, so after starting time-delay, will directly enter star energy-saving run state.When the cotton amount of baling press precompressed case reaches pressure bag weight, main pressure-controlled valve is opened, the hydraulic pump drive motor moves having under the lotus state, along with main compression leg plug is pressed the shortening of bag stroke, pressure rises gradually, and the hydraulic pump drive current of electric also rises thereupon, when electric current is increased to specified 50% the time, the hydraulic pump drive motor will be automatically converted to triangle, enter the operation of total head state.After pressing bag to put in place, main pressure-controlled valve cuts out, and hydraulic pump enters the unloading condition operation again.The hydraulic pump drive current of electric can descend again, and when less than rated value 50%, the hydraulic pump drive motor enters the operation of star power save mode again.Carry out so repeatedly.This device has overcurrent, phase shortage rotation-clogging protection function; principle is to compare by real-time current detection computing and motor load current value; detect running current whether in normal range of operation; when detecting electric current not in normal range (NR); handle by internal delay time; with automatic disconnection hydraulic pump drive motor relay JK1, JK2, JK3, motor is quit work to reach the protection purpose.Because this device current detecting adopts the General Current transformer; motor for different capacity; as long as select the current transformer of suitable no-load voltage ratio; then mutual inductor ratio and motor rated working current value are passed through button S1; S2; S3 cooperates input single-chip microcomputer IC2 with display screen after; single-chip microcomputer IC2 is storage automatically; and power down can not lost yet; when moving, adopts by Single-chip Controlling hydraulic pump drive motor the triangle method of operation under the lotus state is arranged; unloading condition adopts the star power save mode method of operation when moving down; the power factor and the operational efficiency of motor have been improved; reduced meritorious power consumption, single-chip microcomputer can be controlled shutdown when judgement has fault, avoid accident.This device is simple to operate, adapt to any model baling press, and energy-saving effect is very remarkable.
Fig. 3 is an energy conservation control device of cotton press workflow diagram provided by the utility model.Bring into operation; program detects at first whether the startup stop signal is arranged; if enabling signal; motor enters star and starts running status; behind the electric motor starting; because starting current is greater than rated operational current, thus when starting, certain time-delay value shield detection current value is set, after certain time-delay; after motor reaches rated speed; program enters motor operating current and motor load current value 50% relatively, less than the time enter the star operation, greater than the time enter the triangle operation; running current also compares with normal setting range value simultaneously; if in normal range (NR),,, will enter shutdown automatically as not in normal range (NR) with operate as normal.As the normal stop signal input that has in service, program meeting hard stop enters wait state.