Constant Torque Hydraulic Station

This hydraulic station adopts a multi-redundancy integrated modular structure. Building on traditional core components, it achieves technological breakthroughs through high-performance component selection and system redundancy design, ensuring the reliability and response speed of the braking system under extreme working conditions. Fits mining port construction heavy industry braking scenarios widely. This hydraulic station series targets various mine hoists mining winches. Performs disc brake drive control, undertakes service braking safety braking constant torque constant deceleration functions.

High-performance Hydraulic Pump Unit: Variable-frequency servo motor drives high-pressure internal gear pump or variable displacement piston pump. Dynamic flow pressure adjustment follows real-time load. Energy consumption cuts over 15%. Main auxiliary pumps adopt hot standby design. Bumpless automatic switching activates upon single pump failure.

Low-flow Resistance Integrated Manifold: 3D conformal flow channel design plus CFD simulation optimization. High-precision polished and DLC coated oil passage inner walls. System pressure loss reduced ~30%, response speed ≤0.15s. Lower oil contamination risk.

Redundant Safety Valve System:

○Proportional Control Module: High-response closed-loop proportional valve + displacement sensor. Continuous precise braking pressure control (accuracy ±0.5%).

○Safety Redundancy Module: "Parallel conduction + series blocking" dual redundancy. Parallel backup units for key valves (secondary braking safety valve, pressure regulating valve). System function unaffected by single valve failure. Series independent solenoid valves for fault isolation and emergency manual pressure relief.

Intelligent Temperature Control & Purification System: Oil tank with thermoelectric temperature control module + plate heat exchanger. Oil temperature maintained at 40±5°C optimal range. Integrated online oil particle size and water content sensors. Real-time oil quality warning + on-demand filtration.

Distributed Intelligent Control Unit: Multi-core safety PLC (SIL2/SIL3) main control + independent safety relay hard-wired circuit as final safeguard. Pressure/flow composite sensors at pump outlet and brake cylinder inlet, plus vibration and temperature sensors. Full-system condition awareness network.

Working Principle & Modes:

This system adopts multi-mode intelligent coordinated control strategies to achieve precise and reliable management of the braking process.

Intelligent Constant-Torque Service Braking Mode: PLC calculates target braking torque dynamically based on real-time hoist load (weighing/current signal) and speed. Proportional valve performs closed-loop regulation via pressure feedback. Braking torque fluctuation ≤ ±2%.

Full-Redundancy Safety & Constant-Deceleration Braking Mode:

○1st-stage (Constant-Deceleration Braking): Switches to safety loop on emergency stop signal. Targets preset optimal deceleration (0.5–1.0 m/s²). Regulates safety valve group rapidly. Smooth, controlled deceleration, minimal mechanical shock.

○2nd-stage (Full-Pressure Parking): Applies maximum safety braking force automatically when hoisting container speed drops below safety threshold. Two independent valve/controller sets perform parallel switching, eliminating single-point failure risk.

Adaptive Fault Tolerance & Predictive Maintenance: System analyzes sensor data continuously. Provides early warning for potential faults (oil contamination, slight response lag). Switches seamlessly to backup control channel/valve group within 50ms on main controller/valve failure. Ensures uninterrupted braking.