Improvement Of Electric Control System For Container Yard Bridge

First, the shortcomings of the system
US General Electric Company's programmable controller series 6 and 90, and thyristor rectifier DC300, DC2000 and IGBT inverter AC2000 are early products, this system has the following shortcomings Motor
1. Higher operating costs Motor The container yard is powered by a diesel generator set, and the fuel cost becomes the evaluation standard for the electronic control system. In the same configuration, the fuel consumption of the GE system is 14.7L/h, while the fuel consumption of the Yaskawa system is 12.5L/h. The heat dissipation of the inverter is large. The large amount of heat dissipation is unfavorable to the operation of the inverter, which may cause damage to the inverter. Especially in summer, it is necessary to ensure that the ambient temperature meets the requirements of the inverter operation. Spare parts are expensive and the procurement cycle is long. A communication module costs more than 30,000 yuan, and a circuit board sells for more than 50,000 yuan. With only these two components, the annual loss is more than 600,000 yuan, and the procurement cycle is up to six months. Some parts of GE have stopped production of encoders. The mechanical environment of the port is humid, the GE system is not suitable, and the encoder occurs when the fault occurs. For the above problems, the following improved encoder is implemented

Second, change some units in GE electronic control system
Replace GEAC2000 inverter with Yaskawa 61665 and 686CR5 inverter; CP316H programmable controller replaces series 9030 programmable controller; do not replace motor; replace speed encoder And supplemented by the corresponding line; update the control relay.

Three, for the original system failure counterpart improvement
1. When the programmable logic controller (PLC) series 6 intelligent bus fault system works, the communication line connection of each module on the intelligent bus is loose and the operation is unstable, and the control power is disconnected.
Measures: First, add the intelligent module communication line interface to the terminal; secondly, regularly check the connection between the module interface and the bus, and detect the resistance at both ends of the intelligent bus.
2. AC2000 Inverter 129# Fault
Inverter often appears 129# fault during initial power-on, its fault is initial power-on check fault, when the inverter central processor checks its working voltage (3.3~3.8V) normally The inverter enters the normal working state. When the power plug is loose or the pin is oxidized, the CPU can not detect the correct voltage value:
Remedy: Regularly clean and fasten the power plug and pin, and at the same time Anti-oxidation treatment.
3. AC2000 inverter IGBT burnout failure
Inverter power module IGBT damage: The reason is that IG-BT works quickly when the heat is dissipated, the ambient temperature rises; the plug components of the inverter appear loose, causing IGBT control disorder and damage.
Corrective measures: (1) install air conditioning and refrigeration in the electrical room; (2) add a first-level control delay in the peripheral control circuit of the inverter to reduce the malfunction caused by the looseness of the connector, and perform the connector Fastening treatment.

Fourth, equipment maintenance
1. Strengthen engine maintenance and inspection of the speed control system.
2. Make sure the electrical component wiring is securely fastened.
3. Strengthen the maintenance of inverter motors. Due to the influence of higher harmonics, the temperature rise of the variable frequency motor, the damage of the winding insulation and the bearing loss are higher than those of the conventional asynchronous motor. Therefore, it is necessary to do a good job of maintenance: (1) to ensure that the motor casing is clean and the cooling air duct is unobstructed; (2) noise and insulation inspection; (3) lubrication according to the instructions and technical documents.
4. Maintenance of motor accessories, including overspeed switches, encoder cleaning, etc.
After partial rectification and preventive maintenance, the equipment utilization rate has been increased from the original 20% to 50%; the equipment failure time has been reduced from about 15h/month to about 3h/month.