A gear pitch pulsing based fast rope system and method

Abstract

This invention discloses a rapid rope adjustment system and method based on gear pitch pulsation, belonging to the field of hoist technology. The system includes a control box, a gear pitch detection device, and a hoist electrical drive. The method involves: after the rope adjustment clutch is engaged, the gear pitch detection device positions the initial position of the moving gear block; the control box calculates the pulsating speed curve based on the gear pitch of the internal gear ring, and uses a closed-loop position control mode to drive the hoist electrical drive to rotate the fixed drum in a pulsating manner according to the gear pitch. When the container reaches the target position, the system control device automatically and precisely stops at the current gear pitch position, then closes the clutch to engage the moving gear block with the internal gear ring, completing the rope adjustment. This invention automates the rope adjustment process, avoiding the manual observation and back-and-forth gear adjustment required in traditional methods, significantly improving the efficiency and accuracy of rope adjustment operations.

Description

Technical Field

[0001] This invention relates to the field of hoists, and more specifically to a rapid rope adjustment system and method based on gear pitch pulsation. Background Technology

[0002] Hoists are the vital link between the surface and underground of a mine, and are mainly used to transport personnel, crushed stone, and other materials.

[0003] The single-rope winding double-drum hoist is driven by an electric drive device to drive two drums. The two drums drive steel wire ropes wound in opposite directions, and the steel wire ropes connect to the container, which moves up and down relative to each other in the well.

[0004] As the well drilling hoist continues its drilling operations, the lower stop point is constantly being lowered. The containers connected by the wire ropes on the two drums of the twin-drum hoist also need to be frequently adjusted to keep the stopping positions of the two containers at the upper and lower stop points.

[0005] Currently, twin-drum hoists are generally used as permanent hoists in mines, with a relatively fixed working range. Rope adjustment is only required when the wire rope itself is stretched too far, resulting in infrequent rope adjustment operations and low efficiency requirements. During rope adjustment, the operator needs to manually drive the hoist, and someone must observe the position of the moving gears and direct the operator to stop when the rope is in place. This often involves repeated back-and-forth adjustments, leading to low efficiency. However, if the twin-drum hoist is used for shaft drilling, frequent rope adjustment operations are necessary. Traditional rope adjustment methods are inefficient and significantly impact work progress, necessitating a more efficient rope adjustment method. Summary of the Invention

[0006] The purpose of this invention is to provide a gear-pitch-based pulsed rapid rope adjusting system and method to address the aforementioned problems, thereby solving the issues of low automation and low efficiency in existing rope adjusting operations. The gear-pitch-based pulsed rapid rope adjusting method of this invention uses a detection device to locate the initial position of the moving gear block, detects the movement position of the moving gear block, and controls the electric drive device of the hoist to pulsately adjust the rope according to the gear pitch during the adjusting process. After reaching the desired adjustment position, it can automatically adjust the gears and stop automatically without manual observation or back-and-forth gear alignment. The detection and control are accurate and reliable, it is simple and convenient to use, requires virtually no maintenance, and has good practicality.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] A rapid rope adjustment system based on gear pitch pulsation includes: a control box, a gear pitch detection device, and a hoist electrical drive device; the gear pitch detection device is installed on the main shaft end of the drum, and the hoist electrical drive device drives the main shaft of the drum to rotate; the control box is electrically connected to the gear pitch detection device and the hoist electrical drive device; the drum includes a movable drum and a fixed drum, the movable drum is located outside the fixed drum and is movably connected to the main shaft, and the fixed drum is fixedly connected to the main shaft; an internal gear ring is concentrically installed on the outer wall of the movable drum, and a retractable movable gear block is installed on the main shaft; the movable gear block and the internal gear ring are located in the same plane and mesh; wherein, the control box adopts a position closed-loop control mode, and controls the hoist electrical drive device to drive the main shaft to drive the movable gear block to rotate pulsarily according to the gear pitch of the internal gear ring based on the feedback signal of the gear pitch detection device.

[0009] Furthermore, the gear pitch detection device includes an absolute encoder and an image recognition camera.

[0010] Furthermore, the electric drive device of the hoist includes a hoisting motor and a speed regulating device.

[0011] Furthermore, the movable toothed block is mounted on the main shaft via a hub.

[0012] Furthermore, the hub is provided with a groove, and the moving toothed block performs a radial contraction movement along the groove.

[0013] Furthermore, when the moving toothed block extends, it engages with the inner toothed ring, causing the floating drum and the fixed drum to rotate synchronously with the main shaft; when the moving toothed block retracts, it separates from the inner toothed ring, and the main shaft only drives the fixed drum to rotate.

[0014] Furthermore, the control box is also equipped with a rope adjusting clutch control device, which is used to control the opening and closing of the rope adjusting clutch, thereby controlling the engagement and disengagement of the moving tooth block and the internal tooth ring.

[0015] Furthermore, a rapid rope adjustment method based on gear pitch pulsation, applied to the aforementioned system, includes the following steps: When the container's stop position needs adjustment, the rope adjustment clutch is opened, causing the moving toothed block to retract and separate from the internal gear ring; the control box collects signals from the gear pitch detection device in real time and defines the current position of the moving toothed block as the initial position; based on the number of internal teeth of the internal gear ring and the main shaft rotation angle and displacement corresponding to a single tooth pitch, a speed command curve for pulsating operation is set, and the speed command signal is transmitted to the hoist's electrical drive device; the control box controls the operation of the hoist's electrical drive device, driving the main shaft to rotate the fixed drum pulsatingly according to the set gear pitch based on the feedback signal from the gear pitch detection device; when the fixed drum rotates to the target stopping position, a stop command is issued, controlling the hoist's electrical drive device to precisely and automatically stop at the current gear pitch position; the rope adjustment clutch is closed, causing the moving toothed block to extend and mesh with the internal gear ring, completing the rope adjustment.

[0016] Furthermore, the specific method for setting the speed set curve for pulsating operation is as follows: based on the total number of internal teeth of the internal gear ring evenly distributed in 360 degrees, calculate the spindle rotation angle and displacement corresponding to a single tooth pitch, and set the periodic or intermittent speed set curve for pulsating operation accordingly.

[0017] Furthermore, before disengaging the rope adjusting clutch, the process includes the following steps: controlling the electric drive device of the hoist to drive the main shaft to rotate, and driving the floating drum to rotate through the meshing of the moving tooth block and the internal tooth ring, until the container on the floating drum side reaches the predetermined stopping position and then stops.

[0018] The beneficial effects are as follows: The gear pitch pulsating rapid rope adjustment method described in this invention uses a gear pitch detection device to detect the rotation angle and stroke of the moving gear block, and controls the low-speed pulsating rotation of the hoist's electrical transmission device through a position closed-loop control system. When the rope adjustment clutch is open, during the rope adjustment process, the fixed drum pulsates according to the pitch of the internal gear ring. It stops when the container reaches the required position for rope adjustment. At this point, there is no need for manual observation of whether the gear is in position, nor is it necessary to perform back-and-forth gear alignment; the rope adjustment clutch can be directly closed. This method provides immediate and accurate detection and control, improves rope adjustment efficiency, and has good practicality. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of the rapid rope adjustment system of the present invention;

[0020] Figure 2 This is a schematic diagram of the rope adjusting clutch of the present invention;

[0021] Figure 3 This is a flowchart of the rapid rope adjustment method of the present invention;

[0022] Figure 4 This is a schematic diagram of the internal structure of the control box 1 of the present invention;

[0023] Reference numerals in the attached diagram: 1. Control box; 2. Drum; 3. Moving gear block; 4. Gear pitch detection device; 5. Internal gear ring; 6. Electric transmission device of the hoist; 7. Floating drum; 8. Fixed drum; 9. Hub; 10. Rope adjusting cylinder; 11. Moving hub; 12. Actuating ring. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below. Obviously, the described embodiments are merely a part of the embodiments of this invention, and not all of them. All other implementation methods obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0025] like Figure 1 As shown, the gear pitch pulsating rapid rope adjusting system provided by the present invention includes a control box 1, a gear pitch detection device 4, and a hoist electrical transmission device 6. The gear pitch detection device 4 can be an absolute encoder mounted on the main shaft end of the drum 2, used to measure the number of gear pitches rotated by the moving gear block, and used for feedback in the positioning closed-loop control; the gear pitch detection device 4 includes an absolute encoder and an image recognition camera. The hoist electrical transmission device 6 includes a hoisting motor and a speed regulating device, used to receive the speed control signal from the control box 1, and drive the main shaft of the drum 2 to rotate according to the gear pitch pulsating motion, thereby driving the drum 2 to rotate. The drum 2 includes a movable drum 7 and a fixed drum 8. The movable drum 7 is located outside the fixed drum 8 and is movably connected to the main shaft, while the fixed drum 8 is fixedly connected to the main shaft; an internal gear ring 5 is concentrically mounted on the outer wall of the movable drum 7. A hub is mounted on the main shaft, and a moving gear block 3 is mounted on the hub. The hub has a groove, and the moving gear block 3 can move radially along the groove. The movable toothed block 3 and the internal gear ring 5 are located in the same plane and mesh with each other. The electric drive device 6 of the hoist drives the main shaft to rotate, and through the meshing of the movable toothed block 3 and the internal gear ring 5, it drives the floating drum 7 to rotate, so that the floating drum 7 and the fixed drum 8 rotate synchronously with the main shaft. When the movable toothed block 3 retracts along the groove in the centripetal direction, the movable toothed block 3 separates from the internal gear ring 5, and the rotation of the main shaft can no longer drive the floating drum 7 to rotate, but only drives the fixed drum 8 to rotate.

[0026] Specifically: such as Figure 1 As shown, the drum 2 includes a movable drum 7 and a fixed drum 8. The movable drum 7 is located outside the fixed drum 8. The movable drum 7 is connected to the main shaft of the drum 2 through a rope adjusting clutch, which can realize the engagement and disengagement of the movable drum 7 and the main shaft of the drum 2. The fixed drum 8 is fixedly connected to the main shaft of the drum 2.

[0027] like Figure 2As shown, the rope adjusting clutch mainly includes an internal gear ring 5, a movable gear block 3, a hub 9, a rope adjusting cylinder 10, a movable hub 11, and a lever ring 12. The internal gear ring 5 is concentrically mounted on the outer wall of the movable drum 7. The hub 9 is fixedly mounted on the main shaft of the drum 2, and the movable gear block 3 is mounted on the hub 9. The hub 9 has a groove, and the movable gear block 3 can move radially along the groove. The movable hub 11 and the movable gear block 3 are connected by a connecting rod. The movable hub 11, the movable gear block 3, and the hub 9 form a slider linkage mechanism, which converts the axial translation of the movable hub 11 into the radial displacement of the movable gear block 3. The rope adjusting cylinder 10 is fixed on the bearing seat, and its piston rod is movably connected to the movable hub 11 through the lever ring 12, pulling the movable hub 11 to make axial translational movement. The lever ring 12 and the movable hub 11 always make circumferential relative movements.

[0028] When the piston rod of the rope adjusting cylinder 10 extends, the moving hub 11 is pushed forward by the actuating ring 12 in the axial direction. Through the slider linkage mechanism, it drives the moving tooth block 3 to extend centrifugally along the groove on the hub 9. The moving tooth block 3 meshes with the inner gear ring 5, completing the power connection between the floating drum 7 and the main shaft of the drum 2. The hoist's electrical transmission device 6 drives the main shaft of the drum 2 to rotate, which in turn drives the hub 9. Through the meshing of the moving tooth block 3 and the inner gear ring 5, the floating drum 7 rotates, realizing that the floating drum 7 and the fixed drum 8 rotate synchronously with the main shaft of the drum 2. When the piston rod of the rope adjusting cylinder 10 retracts, the moving hub 11 is pulled backward by the actuating ring 12 in the axial direction. Through the slider linkage mechanism, it drives the moving tooth block 3 to retract centripetally along the groove on the hub 9. The moving tooth block 3 separates from the inner gear ring 5, disengaging the power connection between the main shaft of the drum 2 and the floating drum 7. The floating drum 7 is fixed by a disc brake device, and the main shaft of the drum 2 only drives the fixed drum 8 to rotate, thereby changing the relative displacement difference between the floating drum 7 and the fixed drum 8.

[0029] The image recognition camera is used to acquire images of the tooth surface of the internal gear ring. Its image processor is used to extract the center positions of adjacent tooth tips or roots from the images and calculate the angular deviation between the current tooth position and the standard pitch. Additionally, the image recognition camera in this embodiment also includes a supplementary light source and a protective cover, the protective cover having a transparent viewing window and a compressed air inlet.

[0030] Control box 1 is installed near the rope adjusting device in the hoist room and is electrically connected to gear pitch detection device 4 and hoist electrical drive device 6. Control box 1 adopts a position closed-loop control mode, controlling hoist electrical drive device 6 to drive the moving gear block 3 to rotate pulsatingly according to the pitch of the internal gear ring through the main shaft. The control box 1 of this rope adjusting system is designed with a rope adjusting clutch control device, which can operate to start forward or reverse rope adjusting, rotate the traveling drum 7 and the fixed drum 8 to wind up and unwind the wire rope, realize the lifting and lowering of the container. When the container reaches the predetermined position, the operation stops, and control box 1 controls hoist electrical drive device 6 to stop according to the stop signal.

[0031] Specifically: The control box integrates the following electrical components: programmable logic controller (PLC), switching power supply, relays, terminal block, and Ethernet communication module. The input of the PLC is connected to the output of the vision inspection unit via signal lines to receive angle deviation signals; the output of the PLC is connected to the electric drive device of the hoist (6) via a bus; the switching power supply provides DC 24V control power to the PLC, vision inspection unit, and servo driver;

[0032] The control box adopts a position closed-loop control mode with a dual-loop cascade structure of outer loop position and inner loop speed: the outer loop uses the angular deviation output by the visual detection unit as the position setpoint, and the inner loop uses the actual rotation angle fed back by the absolute encoder as the position feedback. In each control cycle, the control box calculates the outer loop position error, generates a speed command through proportional-integral control, and then generates a drive signal from the inner loop speed control, which is output to the hoist's electrical drive unit 6.

[0033] The control process is as follows: When the spindle of drum 2 is stationary, the control box 1 triggers visual detection to obtain the angular deviation between the current tooth position and the standard pitch; if the deviation exceeds the preset dead zone, a pulsed drive command is output to make the spindle rotate. During the rotation, the encoder feedback is read in real time and the drive output is dynamically adjusted; when the spindle of drum 2 rotates close to the command step angle, it automatically decelerates and stops; after the spindle of drum 2 stops completely, a delay is triggered to trigger visual detection again, update the deviation, and repeat the above operation until the deviation falls into the dead zone, completing a precise pulse of one gear pitch.

[0034] The gear pitch detection device 4 includes an absolute encoder and an image recognition camera. The absolute encoder provides feedback on the actual rotation angle of the spindle 2; the image recognition camera acquires images of the internal gear ring's tooth surface, and its image processor extracts the center positions of adjacent tooth tips or roots from the images and calculates the angular deviation between the current tooth position and the standard pitch. Additionally, the image recognition camera in this embodiment includes a supplementary light source and a protective cover. The protective cover has a transparent window and a compressed air nozzle. The supplementary light source provides additional light to the image recognition camera, and the protective cover protects the camera from dust or other foreign objects. The transparent window of the protective cover allows observation of the camera's operating status, and the compressed air nozzle sprays jets of gas to clean the camera lens and prevent camera contamination.

[0035] The image recognition camera consists of an industrial camera, a fixed-focus lens, a ring LED supplementary light source, an image processor, and a protective housing. The industrial camera and lens are coaxially mounted on a bracket at the end of the roll spindle, with the lens optical axis perpendicular to the tooth surface of the internal gear ring. The ring LED supplementary light source is fixed around the camera lens. The image processing module is integrated into the control box or used in an embedded smart camera. The protective housing is made of aluminum alloy, with a transparent window at the front and a compressed air connector on the side.

[0036] like Figure 3 and Figure 4 As shown, this invention also provides a rapid rope adjustment method based on gear pitch pulsation. When the container's stopping position needs to be adjusted, this system performs rapid rope adjustment. The hoist's electrical drive device 6 drives the main shaft to rotate, and through the meshing of the moving tooth block 3 and the internal gear ring 5, it drives the floating drum 7 to rotate. When the floating drum 7 rotates to the required stopping position (upper or lower position) of the container on that side, the control box 1 controls the hoist's electrical drive device 6 to stop. At this time, the rope adjustment clutch opens, the piston rod of the rope adjustment cylinder 10 retracts, and the moving hub 11 is pulled backward in the axial direction by the actuating ring 12. Through the slider linkage mechanism, the moving tooth block 3 is driven to retract in the centripetal direction along the groove on the hub 9. The moving tooth block 3 separates from the internal gear ring 5, disengaging the power connection between the main shaft of the drum 2 and the floating drum 7. The floating drum 7 is fixed by a disc brake device, and the main shaft of the drum 2 only drives the fixed drum 8 to rotate, changing the relative displacement difference between the floating drum 7 and the fixed drum 8. Control box 1 acquires the absolute encoder values ​​in real time and defines the position of the moving tooth block 3 detected by gear pitch detection device 4 as the initial position. Based on the number of internal teeth of the internal gear ring 5 evenly distributed in 360 degrees, it calculates the main shaft rotation angle and displacement corresponding to a single tooth pitch, sets the periodic or intermittent speed command curve for pulsating operation, and transmits the speed command signal to the hoist electrical drive device 6. Control box 1 controls the operation of the hoist electrical drive device 6. According to the feedback signal from gear pitch detection device 4, it operates in a pulsating manner according to the pre-calculated gear pitch. The hoist electrical drive device 6 drives the main shaft to rotate, thereby driving the fixed drum. 8. When the fixed drum 8 rotates to the required stopping position of the container on that side (another position corresponding to the container on the side of the moving drum 7, either the lower or upper position), the operator issues a stop command through the control box 1, controlling the electric drive device 6 of the hoist to precisely and automatically stop at the current gear pitch position; the rope adjusting clutch is closed, and when the piston rod of the rope adjusting cylinder 10 is pushed out, the moving hub 11 is pushed forward in the axial direction by the actuating ring 12, driving the moving tooth block 3 to be pushed out in the centrifugal direction along the groove on the hub 9 through the slider linkage mechanism. The moving tooth block 3 extends into the tooth gap of the inner gear ring 5, and the power connection between the moving drum 7 and the main shaft of the drum 2 is completed, thus completing the rope adjusting. After the rope adjusting is completed, the moving tooth block 3 meshes with the inner gear ring 5, and the moving drum 7 and the fixed drum 8 rotate synchronously with the main shaft, realizing the movement of the containers on the moving drum side and the fixed drum side between the new positions.

[0037] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A rapid rope adjustment system based on gear pitch pulsation, characterized in that, include: The control box (1), the gear pitch detection device (4), and the hoist electrical drive device (6) are all included. The gear pitch detection device (4) is installed on the main shaft end of the drum (2), and the hoist electrical drive device (6) drives the main shaft of the drum (2) to rotate. The control box (1) is electrically connected to the gear pitch detection device (4) and the hoist electrical drive device (6). The drum (2) includes a movable drum (7) and a fixed drum (8). The movable drum (7) is located outside the fixed drum (8) and is movably connected to the main shaft. The fixed drum (8) is fixedly connected to the main shaft. An internal gear ring (5) is concentrically installed on the outer wall of the movable drum (7). A retractable movable gear block (3) is installed on the main shaft. The movable gear block (3) and the internal gear ring (5) are located in the same plane and mesh with each other. The control box (1) adopts a position closed-loop control mode. Based on the feedback signal of the gear pitch detection device (4), it controls the electric transmission device (6) of the hoist to drive the main shaft to drive the moving gear block (3) to rotate pulsatingly according to the gear pitch of the internal gear ring (5).

2. The gear pitch pulsating rapid rope adjustment system according to claim 1, characterized in that, The gear pitch detection device (4) includes an absolute encoder and an image recognition camera.

3. The gear pitch pulsating rapid rope adjustment system according to claim 1, characterized in that, The electric drive device (6) of the hoist includes a hoisting motor and a speed regulating device.

4. The gear pitch pulsating rapid rope adjustment system according to claim 1, characterized in that, The movable tooth block (3) is mounted on the main shaft via a hub.

5. The gear pitch pulsating rapid rope adjustment system according to claim 4, characterized in that, The hub is provided with a groove, and the moving tooth block (3) performs radial contraction motion along the groove.

6. The gear pitch pulsating rapid rope adjustment system according to claim 1, characterized in that, When the moving tooth block (3) extends, it engages with the inner tooth ring (5), causing the floating drum (7) and the fixed drum (8) to rotate synchronously with the main shaft; when the moving tooth block (3) retracts, it separates from the inner tooth ring (5), and the main shaft only drives the fixed drum (8) to rotate.

7. The gear pitch pulsating rapid rope adjustment system according to claim 1, characterized in that, The control box (1) is also equipped with a rope adjusting clutch control device, which is used to control the opening and closing of the rope adjusting clutch, and thus control the engagement and disengagement of the moving tooth block (3) and the internal tooth ring (5).

8. A rapid rope adjustment method based on gear pitch pulsation, characterized in that, The system applied to any one of claims 1-7 comprises the following steps: When it is necessary to adjust the container stop position, open the adjusting rope clutch to retract the moving tooth block (3) and separate it from the inner tooth ring (5); The control box (1) collects the signal from the gear pitch detection device (4) in real time and defines the current position of the moving tooth block (3) as the initial position; Based on the number of internal teeth of the internal gear ring (5) and the rotation angle and displacement of the main shaft corresponding to the pitch of a single tooth, the speed command curve for pulsating operation is set, and the speed command signal is transmitted to the electric drive device (6) of the hoist. The control box (1) controls the operation of the electric drive device (6) of the hoist. Based on the feedback signal of the gear pitch detection device (4), it drives the main shaft to drive the fixed drum (8) to rotate pulsatingly according to the set gear pitch. When the fixed drum (8) rotates to the target stopping position, a stop command is issued to control the electric drive device (6) of the hoist to stop precisely and automatically at the current gear pitch position; Close the rope adjusting clutch to allow the moving tooth block (3) to extend and engage with the inner tooth ring (5) to complete the rope adjusting.

9. The rapid rope adjustment method based on gear pitch pulsation according to claim 8, characterized in that, The specific speed setting curve for the pulsating operation is as follows: based on the total number of internal teeth of the internal gear ring (5) with a uniform distribution of 360 degrees, calculate the spindle rotation angle and displacement corresponding to a single tooth pitch, and set the periodic or intermittent speed setting curve for the pulsating operation accordingly.

10. The rapid rope adjustment method based on gear pitch pulsation according to claim 8, characterized in that, Before opening the rope adjustment clutch, the following steps are also included: controlling the electric drive device (6) of the hoist to drive the main shaft to rotate, and driving the floating drum (7) to rotate through the meshing of the moving tooth block (3) and the internal tooth ring (5) until the container on the side of the floating drum (7) reaches the predetermined stopping position and then stops.

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