Active pay-off coil winding method

Abstract

This invention discloses an active wire rope winding method. First, the radius of the wire rope core and the radius of the winding wire rope are determined, and the length L of the winding wire rope within a single lead is calculated. Then, based on the length of the wire rope core, the number of leads is determined, and the total length of the winding wire rope required is calculated. Next, the wire rope core runs on the frame of the winding equipment, and the winding wire rope rotates around the wire rope core via a trolley. The winding wire rope is evenly wound around the outside of the wire rope core, forming a spiral line, and the length of the winding wire rope within all single leads is the same. After winding is completed, a core-replacing process completes the production. This invention, by releasing the wire rope according to the theoretical length, ensures that the wire rope wound on the core is uniform and does not generate interaction forces, thereby solving the problem of uneven winding and improving work efficiency.

Description

Technical Field

[0001] This invention relates to the field of wire rope winding technology, and in particular to an active wire rope loop winding method. Background Technology

[0002] Currently, there are two main methods for winding seamless wire rope loops in China. One method, represented by those in Europe and America, uses steel pipes as the core of the loop. This core is rigid and stationary, with the wire rope wound around it. This method is characterized by low production efficiency but high product quality. The other method uses my country's new winding machines to produce seamless wire rope loops. In this method, the core is the wire rope itself, with tensioning the wire rope instead of using a steel pipe. The core rotates on the machine frame via multiple drive wheels, thus winding the wire rope around it. This method is characterized by high production efficiency, but the product quality is inferior to that produced by foreign methods. This method is particularly suitable for manufacturing large seamless wire rope loops and is increasingly used in my country.

[0003] Both of these mainstream production methods employ a passive rope-laying method. During winding, the force exerted on the rope core during winding pulls the wire rope directly from the reel and onto the core; the length pulled out is the required length. The European and American method, which uses a steel pipe as the rope core, produces a stiff and rigid core, with the wire rope evenly wound around the pipe. However, when using wire rope as the winding core on a rope coiling machine, even if the core is tightened (considering equipment design, core operation, and other factors, the core cannot be infinitely tightened), the wound wire rope and the core wire rope will still exhibit a "twisted" state, such as... Figure 1 and Figure 2 As shown.

[0004] This results in the initial wire rope being "shorter" than intended, and issues like untwisting at the ends occur, leading to uneven twist. As the number of turns increases, the wire rope on the core is compressed, causing the core to straighten gradually. This results in the subsequent turns of wire rope becoming "longer," requiring greater tension and thus a longer actual length. Under the combined tension of multiple wire ropes, the final loop exhibits a wavy shape. This wavy loop, due to uneven wire rope length, severely impacts load-bearing capacity, necessitating manual repair and wasting significant manpower and resources. Summary of the Invention

[0005] The purpose of this invention is to provide an active method for releasing and winding rope loops to solve the problems existing in the prior art.

[0006] To achieve the above objectives, the present invention provides the following solution:

[0007] This invention provides an active method for winding a loop of yarn, comprising the following steps:

[0008] Step 1. Determine the core radius of the wire rope and the radius of the wound wire rope, and calculate the length L of the wound wire rope within a single lead.

[0009]

[0010] r = r1 + r2 (2)

[0011] Where: r1 is the radius of the wire rope core, r2 is the radius of the wound wire rope, and h is the lead length;

[0012] Step 2. Determine the number of leads based on the length of the wire rope core, and calculate the total length of wire rope required for winding.

[0013] Step 3. The wire rope core runs on the frame of the rope coiling device. The winding wire rope rotates around the wire rope core by a trolley. The winding wire rope is evenly wound around the outside of the wire rope core and forms a spiral line. The length of the winding wire rope in all individual leads is the same.

[0014] Step 4. After the winding is completed, the core replacement process is followed, and the production is finished.

[0015] Preferably, the inner diameter of the spiral formed by the wound steel wire rope is the same as the outer diameter of the steel wire rope core, and there is no interaction force between the wound steel wire rope and the steel wire rope core.

[0016] Preferably, the rope loop device is provided with a frame, and the frame is provided with an I-beam reel on which the wound steel wire rope is wound. A wire feeder is fixedly provided below the I-beam reel in the frame. The wound steel wire rope is fed out by the wire feeder to keep the wound steel wire rope at a constant speed.

[0017] Preferably, the wire feeder includes a frame with two sets of wire feed wheels rotatably connected to it. Each set of wire feed wheels is fixedly connected to a sprocket, and the two sprockets are connected by a chain and move synchronously. Several parallel annular receiving grooves are formed on the outer circumference of each wire feed wheel. The cross-section of each annular receiving groove is adapted to the winding wire rope, and the depth of each annular receiving groove is the same as the radius of the winding wire rope. The frame abuts against the outer edge of the two sets of wire feed wheels.

[0018] The present invention discloses the following technical effects: By releasing the steel wire rope according to the theoretical length, the steel wire rope wound on the rope core is uniform and does not generate interaction forces, thereby solving the problem of uneven rope winding and improving work efficiency. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 An ideal diagram of existing technology for winding steel wire rope;

[0021] Figure 2 Diagram showing the intertwined state of a wire rope and its core in existing winding technology;

[0022] Figure 3 This is a schematic diagram of an existing rope loop device.

[0023] Figure 4 Top view of an existing rope loop device;

[0024] Figure 5 The existing technology presents the rope loop in a spiral wave shape;

[0025] Figure 6 This is a schematic diagram of the wire feeder structure of the present invention. Detailed Implementation

[0026] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0027] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0028] Figure 3 and Figure 4 This is a schematic diagram of an existing rope loop device. Typically, the H-beam reel passively releases the wire; the amount of wire rope wound around the core depends on the amount pulled out during winding. The length of the pulled-out wire rope depends on the radius of rotation of the wire rope wound around the core. As analyzed in the background section, initially, during the winding of a jointless rope loop, the wire ropes intertwine ("twisting"), causing the actual rotation diameter to decrease (smaller than the diameter of the core wire rope). As the number of turns increases, the position of the wound wire rope on the core progresses, causing the core to gradually become "straighter," and the rotation diameter to gradually increase. Figure 5When the rope loop is wound 5 times, the state of the rope core causes the rope loop to present a spiral wave shape.

[0029] Theoretically, the best solution to prevent wavy wire rope loops is to prevent "twisting" between the wound wire rope and the core. This involves actively releasing the rope, winding the wire rope according to the theoretical winding values ​​for the core, thus eliminating any interaction force between the wire rope and the core. There are two methods for actively releasing the rope. One is using a variable tension method, which involves gradually changing the tension from zero at the beginning of the winding loop to the maximum tension on the sixth loop, ensuring uniform winding. The second method is fixed-length release. This involves calculating the required wire rope length based on the loop diameter, ensuring it is neither too long nor too short. Initially, the core is not stressed (no bending occurs). Even if tension is applied to the wire rope during the last three loops due to wire rope arrangement, the release speed remains constant, ensuring that each loop has a consistent wire rope length and thus a smooth winding.

[0030] The following are the specific methods for the second type of rope loop wrapping:

[0031] This invention discloses an active method for releasing and winding rope loops, comprising the following steps:

[0032] Step 1. Determine the core radius of the wire rope and the radius of the wound wire rope, and calculate the length L of the wound wire rope within a single lead.

[0033]

[0034] r = r1 + r2 (2)

[0035] Where: r1 is the radius of the wire rope core, r2 is the radius of the wound wire rope, and h is the lead length;

[0036] Step 2. Determine the number of leads based on the length of the wire rope core, and calculate the total length of wire rope required for winding.

[0037] Step 3. The wire rope core runs on the frame of the rope coiling equipment. The winding wire rope rotates around the wire rope core by a trolley. The winding wire rope is evenly wound around the outside of the wire rope core and forms a spiral line. The length of the winding wire rope in all individual leads is the same.

[0038] Step 4. After the winding is completed, the core replacement process is followed, and the production is finished.

[0039] The rope loop device in step three can be adopted Figure 3 and Figure 4 The equipment shown can also be the same as that in the existing patent "200510123957.6, Manufacturing equipment for jointless steel wire rope loops".

[0040] The seamless wire rope coiling equipment mainly includes a frame, straight rails, circular rails, a running trolley, and wire winding and unwinding mechanisms. The wire rope core rotates on the frame, and the trolley rotates around the wire rope core, winding the wire rope from the I-beam reel, through the middle hole of the unwinding frame, and through the middle hole of the trolley to connect with the wire rope core and wind it onto the wire rope core, forming a spiral. After six turns, the wire rope core is wrapped around it. Then, after a core replacement process, the production is completed.

[0041] The scheme was further optimized so that the inner diameter of the spiral formed by the winding steel wire rope is the same as the outer diameter of the steel wire rope core, and there is no interaction force between the winding steel wire rope and the steel wire rope core.

[0042] Further optimization involves a frame within the rope loop device, containing a reel with a wound steel wire rope. A wire feeder is fixed below the reel. The wound steel wire rope is fed out via the wire feeder, maintaining a constant speed. Formulas (1) and (2) are used to calculate the length of the wire rope fed per revolution for different diameters and lay ratios. Based on the winding speed, the wire rope is proportionally pulled from the reel and wound onto the core. This method reduces or eliminates the force between the wire rope and the core, ensuring consistent wire rope length in each loop. This invention, by adding a constant-speed output wire feeder, achieves consistent winding dimensions for each loop of wound steel wire rope, thereby reducing or eliminating loop waviness, improving product quality, and increasing production efficiency.

[0043] Further optimization of the design: The rope-feeding device includes a frame with two sets of rope-feeding pulleys rotatably connected to it. Each set of pulleys is fixedly connected to a sprocket, which is connected by a chain and moves synchronously. Several parallel annular grooves are arranged on the outer circumference of each pulley. The cross-section of these grooves matches the winding wire rope, and the depth of the grooves is the same as the radius of the winding wire rope. The frame abuts against the outer edges of the two sets of rope-feeding pulleys. The two sets of rope-feeding pulleys are synchronized via sprockets. One set of pulleys is directly connected to an electromagnetic clutch and driven by a variable frequency motor. The variable frequency motor is controlled by a frequency converter with closed-loop control and speed sensor vector control function to ensure a constant speed during rope feeding under varying tensions. The electromagnetic clutch is synchronized with the motor to disengage from the reducer during wire rope retraction, without affecting the original function of the equipment.

[0044] Passive rope release. Typically, passive winding occurs when the wound wire rope interacts with the wire rope core, resulting in entanglement. This causes a shift of Δr between the wire rope core and its theoretical centerline. The actual winding radius is:

[0045] r 实际 =r1-Δr+r2 (3)

[0046] The actual length of the wire rope within one lead:

[0047]

[0048] Obviously, L 实际 It varies with the offset Δr of the centerline.

[0049] Because the wire rope is a single piece when it is wound onto the core, and the wire ropes are arranged side by side within one lay pitch, Δr changes continuously, resulting in unevenness in the rope loops.

[0050] This invention uses a wire feeder to ensure that the actual length L of the wire rope within one lead is... 实际 = Theoretically, the length L of the wire rope is such that the interaction force between the wound wire rope and the wire rope core is 0, or so small as to be negligible, i.e., Δr≡0. At this point, the actual length L of the wire rope within one lead is measured at any point inside the rope loop. 实际 ≡L. The wire feeder automatically calculates the required wire rope length L based on the input rope diameter r value. Moreover, the lead h is different for different rope diameter loops. The ratio of h to L is constant in different rope loops, which is achieved by controlling the frequency of the walking motor and the frequency of the rope feeder motor.

[0051] This method reduces or eliminates the force between the wire and the core, ensuring that each loop of wire rope is of consistent length. By adding a constant-speed feeder, this invention achieves consistent winding dimensions for each loop of wire rope, thereby reducing or eliminating loop waviness, improving product quality, and increasing production efficiency.

[0052] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0053] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. An active pay-off coil winding method, characterized by: It comprises the following steps: Step one. Determine the steel cord core radius, winding steel cord radius, calculate the length of the winding steel cord L in a single lead, r＝r1+r2 (2) Wherein: r1 is the steel cord core radius, r2 is the winding steel cord radius, h is the lead length; Step two. According to the length of the steel cord core, determine the number of lead, calculate the total length of the winding steel cord required; Step three. Steel cord core runs on the frame of the rope loop equipment, winding steel cord rotates around the steel cord core through the trolley, winding steel cord is evenly wound outside the steel cord core and forms a spiral line, and the length of winding steel cord in all single leads is the same; Step four. After completing the winding, after the core replacement process, the production is completed; The spiral line formed by the winding steel cord has the same inner diameter as the outer diameter of the steel cord core, and there is no interaction force between the winding steel cord and the steel cord core; The frame is provided in the rope loop equipment, the spool wound with winding steel cord is provided in the frame, and the pay-off device is fixedly provided below the spool; The winding steel cord is payed off by the pay-off device to keep the winding steel cord at a constant speed; The pay-off device comprises a work type frame, two groups of pay-off wheels are rotatably connected to the work type frame, two groups of the pay-off wheels are fixedly connected with sprockets, and the two sprockets are connected by chains and move synchronously; A plurality of annular accommodating grooves are arranged in parallel on the outer side of the pay-off wheel, the cross section of the annular accommodating groove is matched with the winding steel cord, and the depth of the annular accommodating groove is the same as the radius of the winding steel cord, and the work type frame abuts against the outer edges of the two groups of pay-off wheels.

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