Methods and systems for overload protection of high-speed wire PF drive chains

Abstract

This invention provides a method and system for overload protection of high-speed wire PF (Power Factor) drive chains, relating to the field of detection and control technology. It aims to improve the difficulty in determining the cause of overload problems in high-speed wire P / F drive chains. The method for overload protection of high-speed wire PF drive chains includes: acquiring the pulse value output in real time by a first encoder; obtaining the chain tension F_chain, which characterizes the real-time tension of the drive chain, based on the pulse value; and determining whether the drive chain is overloaded and the cause of the overload based on the chain tension F_chain. The system for overload protection of high-speed wire PF drive chains includes a controller for executing the above method. By detecting the chain tension and establishing a trend graph through a PLC, the process control of the chain tension can be effectively performed. In case of overload, the cause of the overload can be determined, whether it is due to too many hooks simultaneously or jamming of the C-hook, greatly shortening the fault handling time and effectively preventing chain breakage accidents.

Description

Technical Field

[0001] This invention relates to the field of detection and control technology, and more specifically, to a method and system for overload protection of high-speed wire PF drive chain. Background Technology

[0002] The high-speed P / F line drive chain in a rolling mill mainly consists of C-hooks, a drive chain, and a transmission mechanism. Its main function is to drive the drive chain, which in turn drives the C-hooks, transporting the coils on the C-hooks sequentially from the coiling station to the packaging station, weighing station, and unloading station. The empty hooks then return to the coiling station. In actual production, equipment malfunctions such as transmission overload, hook jamming, and even chain breakage frequently occur, severely impacting production. However, the diagnosis and analysis of these problems rely solely on experience, lacking an effective detection and judgment device. Currently, overload detection devices in actual production have the following problems:

[0003] The P / F chain is driven by a 160M-4, 11 kW three-phase AC asynchronous motor, which, through a reducer, drives the drive wheel, which in turn drives the P / F chain, which in turn drives the C-hook. The drive mechanism includes the motor, reducer, and drive wheel. The entire drive mechanism is axially supported by bearing housings and radially movable, held in place by a spring, allowing it to swing radially. An overload proximity switch is installed in the radial position; when the driven chain is overloaded, the drive mechanism swings radially, triggering the proximity switch and stopping the motor due to overload. However, it's impossible to determine whether the overload is caused by excessive load or a stuck hook, and the troubleshooting process is generally lengthy. Summary of the Invention

[0004] The present invention includes, for example, providing a method for overload protection of high-speed wire PF drive chain, which can improve the problem of difficulty in determining the cause of overload problems in high-speed wire P / F drive chain.

[0005] The present invention also aims to provide a system for overload protection of high-speed wire PF drive chain, which can improve the problem of difficulty in determining the cause of overload problems in high-speed wire P / F drive chain.

[0006] The embodiments of the present invention can be implemented as follows:

[0007] Embodiments of the present invention provide a method for overload protection of high-speed wire PF drive chain, comprising:

[0008] Obtain the pulse value output in real time by the first encoder;

[0009] Based on the pulse value, the chain tension F, which characterizes the real-time tension of the transmission chain, is obtained. 链 ;

[0010] According to the chain tension F 链To determine whether the drive train is overloaded and the cause of the overload;

[0011] The first encoder is connected to the detection gear and is used to detect and output pulse values ​​that characterize the rotational state of the detection gear. The detection gear meshes with a detection rack, which is fixed on the drive platform along a preset direction. The detection rack is used to drive the detection gear to rotate as the drive platform moves. A drive mechanism and a transmission chain are installed on the drive platform. The drive mechanism is connected to the transmission chain and is used to drive the transmission chain to transmit data. A tension spring extending along the preset direction is connected to the bottom of the drive platform.

[0012] In addition, the method for overload protection of high-speed wire PF drive chain provided in the embodiments of the present invention may also have the following additional technical features:

[0013] Optionally, the chain tension F, which characterizes the real-time tension of the transmission chain, is obtained based on the pulse value. 链 The steps include:

[0014] Based on the circumference of the detection gear and the number of pulses Nt generated by the encoder rotating one revolution, the deformation U of the tension spring corresponding to one pulse is obtained;

[0015] According to the spring coefficient K of the tension spring 系 The spring force is obtained by taking the pulse value N and the spring deformation U corresponding to the pulse.

[0016] The chain tension is obtained based on the spring force.

[0017] Optionally, the calculation formula for the step of obtaining the deformation U of the tension spring corresponding to one pulse based on the circumference of the detection gear and the number of pulses Nt generated by the encoder rotating one revolution includes U=π*D / Nt, where D is the pitch circle diameter of the gear;

[0018] The spring coefficient K of the tension spring is used as a reference. 系 The calculation formula for obtaining the spring force from the pulse value N and the spring deformation U corresponding to the pulse includes F. 弹 =K 系 *N*U;

[0019] The calculation formula for obtaining the chain tension based on the spring force includes F 链 =F 弹 .

[0020] Optionally, the step of adjusting the chain tension F... 链The steps for determining whether the drive train is overloaded and the cause of the overload include:

[0021] If the chain tension F 链 If the value is less than the first preset value, a first signal indicating that the transmission chain is in a normal state is output.

[0022] If the chain tension F 链 The chain tension F is greater than the second preset value. 链 From the preset calibration value F 标 If the time interval T between the rise to the second preset value is less than the first preset time interval, then a second signal is output to indicate that the transmission chain is in a hook overload state.

[0023] If the chain tension F 链 The chain tension F is greater than the second preset value. 链 From the preset calibration value F 标 If the time interval T between the rise to the second preset value is greater than the first preset time interval, then a third signal is output to indicate that the transmission chain is in an overloaded state.

[0024] Wherein, the preset calibration value F 标 <First preset value<Second preset value.

[0025] Optionally, the method for overload protection of the high-speed wire PF drive chain further includes:

[0026] If the chain tension F 链 If the value exceeds the first preset value, a first alarm signal representing the first degree of overload will be output.

[0027] If the chain tension F 链 If the value exceeds the second preset value, a second alarm signal representing the second degree of overload will be output.

[0028] Optionally, the method for overload protection of the high-speed wire PF drive chain further includes:

[0029] The characteristic chain tension output from the second encoder is obtained from the preset calibration value F. 标 to overload tension value F G The count value for the time period;

[0030] Based on the count value N3, the number of pulses Nx of one revolution of the second encoder, the circumference of the driven gear, and the chain tension from the preset calibration value F... 标 to overload tension value F G The corresponding elongation per meter β is used to obtain the distance L1 from the overload position of the hook to the detection driven gear;

[0031] The second encoder is connected to the detection driven gear. The second encoder is used to detect and output a count value that characterizes the rotational state of the detection driven gear. The detection driven gear meshes with the transmission chain and is used to rotate under the drive of the transmission chain. β is measured experimentally.

[0032] Optionally, the step involves determining the count value N3, the number of pulses Nx from one revolution of the second encoder, the circumference of the driven gear, and the chain tension as it decreases from a preset calibration value F. 标 Value up to overload tension value F G The calculation formula for obtaining the distance L1 from the overload position of the hook to the detection driven gear, based on the elongation β per meter, includes:

[0033] L1=(N3 / Nx)*π*d / β, where d is the pitch circle diameter of the driven gear being tested.

[0034] Optionally, the step involves determining the count value N3, the number of pulses Nx from one revolution of the second encoder, the circumference of the driven gear, and the chain tension as it decreases from a preset calibration value F. 标 Value up to overload tension value F G The calculation formula for obtaining the distance L1 from the overload position of the hook to the driven gear, based on the elongation per meter β, also includes:

[0035] L2 = L1 ± 2m, where L1 is the distance from the overload position of the hook to the driven gear, and L2 is the range of the distance from the overload position of the hook to the driven gear.

[0036] Optionally, the preset calibration value F 标 The chain tension is calculated from the pulse value read by the first encoder when the hook is jammed by human operation.

[0037] Embodiments of the present invention also provide a system for overload protection of a high-speed PF wire drive chain. The system includes a detection gear, a detection rack, a first encoder, and a controller; the first encoder is connected to the detection gear and is used to detect and output pulse values ​​characterizing the rotational state of the detection gear; the detection gear meshes with the detection rack, the detection rack is fixed on a drive platform along a preset direction, and the detection rack is used to drive the detection gear to rotate as the drive platform moves; a drive mechanism and a drive chain are mounted on the drive platform, the drive mechanism is connected to the drive chain, and the drive mechanism is used to drive the drive chain to transmit power; a tension spring extending along the preset direction is connected to the bottom of the drive platform.

[0038] The first encoder is electrically connected to the controller, which is used to perform a method for overload protection of the high-speed wire PF drive chain.

[0039] The beneficial effects of the method and system for overload protection of high-speed wire PF drive chain according to embodiments of the present invention include, for example:

[0040] A method for overload protection of high-speed wire PF drive chains includes: acquiring the pulse value output in real time from the first encoder; obtaining the chain tension F_chain, which characterizes the real-time tension of the drive chain, based on the pulse value; determining whether the drive chain is overloaded and the cause of the overload based on the chain tension F_chain; detecting the chain tension and establishing a trend chart through a PLC, which can effectively control the chain tension process and provide strong support for equipment maintenance and fault handling. The system is modified to include tension detection, minor overload alarm, and overload protection modes. Furthermore, in the event of an overload, the cause of the overload can be determined, whether it is due to too many hooks simultaneously or a jammed C-hook. This significantly shortens fault handling time and effectively prevents chain breakage accidents.

[0041] A system for overload protection of high-speed wire PF drive chain includes a controller for performing the methods described above. Attached Figure Description

[0042] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0043] Figure 1 A schematic diagram of the structure of a high-speed wire PF wire drive chain overload protection system provided in an embodiment of the present invention;

[0044] Figure 2 A flowchart illustrating the steps of a method for overload protection of a high-speed wire PF drive chain provided in an embodiment of the present invention;

[0045] Figure 3 A schematic diagram of the chain tension versus time during a slight overload in the high-speed PF wire drive chain overload protection method provided in this embodiment of the invention;

[0046] Figure 4 A schematic diagram of the chain tension and time during overload protection of the high-speed PF wire drive chain provided in this embodiment of the invention;

[0047] Figure 5This is a schematic diagram showing the chain tension and time during overload protection of the high-speed PF wire drive chain provided in this embodiment of the invention.

[0048] Icons: 100-Drive mechanism; 110-Motor; 120-Reducer; 200-Drive platform; 300-Transmission chain; 400-Drive gear; 500-Detection rack; 510-Detection gear; 520-First encoder; 600-Driven gear; 620-Second encoder; 700-Tension spring. Detailed Implementation

[0049] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0050] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0051] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0052] In the description of this invention, it should be noted that if terms such as "upper," "lower," "inner," or "outer" are used to indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of this invention is usually placed, they are only for the convenience of describing this invention and simplifying the description, and do not 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] Furthermore, the terms "first" and "second" are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.

[0054] It should be noted that, where there is no conflict, the features in the embodiments of the present invention can be combined with each other.

[0055] The following is combined with Figures 1 to 5 The method for overload protection of high-speed wire PF wire drive chain provided in this embodiment is described in detail.

[0056] Please refer to Figure 1 as well as Figure 2 The present invention provides a method for overload protection of high-speed wire PF drive chain, comprising:

[0057] Step Sa1: Obtain the pulse value output in real time by the first encoder 520;

[0058] Step Sa2: Based on the pulse value, obtain the chain tension F, which characterizes the real-time tension of the transmission chain 300. 链 ;

[0059] Step Sa3, based on the chain tension F 链 To determine whether the transmission chain 300 is overloaded and the cause of the overload;

[0060] The first encoder 520 is connected to the detection gear 510 and is used to detect and output pulse values ​​that characterize the rotational state of the detection gear 510. The detection gear 510 meshes with the detection rack 500, which is fixed on the drive platform 200 along a preset direction. The detection rack 500 is used to drive the detection gear 510 to rotate as the drive platform 200 moves. The drive platform 200 is equipped with a drive mechanism 100 and a transmission chain 300. The drive mechanism 100 is connected to the transmission chain 300 and is used to drive the transmission chain 300 to transmit data. A tension spring 700 extending along a preset direction is connected to the bottom of the drive platform 200.

[0061] The drive mechanism 100 includes a motor 110, a reducer 120 and a drive gear 400 connected in sequence, and the drive gear 400 meshes with the transmission chain 300.

[0062] A tension spring 700 is connected to the bottom of the drive platform 200. A detection rack 500, a detection gear 510, and a gear are arranged on the side of the drive platform 200. The detection rack 500 and the tension spring 700 are oriented in the same direction. The drive mechanism 100 and the transmission chain 300 are mounted on the drive platform 200. During transmission, the drive platform 200 oscillates as the drive mechanism 100 drives the transmission chain 300. When the transmission chain 300 is overloaded, the drive platform 200 and the drive mechanism 100 move downwards, compressing the tension spring 700. The detection rack 500 and the tension spring 700 are oriented in the same direction. During the compression of the tension spring 700, the detection rack 500 drives the detection gear 510 to rotate. The rotation state of the detection gear 510, detected by the first encoder 520, can determine the chain tension F. 链 Specifically, the first encoder 520 is an absolute encoder. The value from the absolute encoder is input into the PLC, and a chain tension trend graph is created via the network to monitor the chain tension online.

[0063] This method can be used to measure chain tension F. 链 By performing detection and establishing trend charts through a controller (PLC), the tension F of the chain can be effectively monitored. 链 By conducting process analysis, under overload conditions, the cause of the overload can be determined, whether it is due to too many hooks being hooked at the same time or a jammed C-hook. This greatly shortens the troubleshooting time and effectively prevents accidents caused by chain breakage, providing strong support for equipment maintenance and troubleshooting.

[0064] In this embodiment, step Sa2 involves obtaining the chain tension F, which characterizes the real-time tension of the transmission chain 300, based on the pulse value. 链 ,include:

[0065] Step Sa21: Based on the circumference of the detection gear 510 and the number of pulses Nt generated by the encoder rotating one revolution, obtain the deformation U of the tension spring 700 corresponding to one pulse.

[0066] Step Sa22, based on the spring coefficient K of the tension spring 700 系 The spring force is obtained by taking the pulse value N and the spring deformation U corresponding to one pulse.

[0067] Step Sa23: Obtain the chain tension based on the spring force.

[0068] The detection rack 500 and the tension spring 700 are set in the same direction. During the compression of the tension spring 700, the detection rack 500 drives the detection gear 510 to rotate. By observing the rotation of the gear, the elastic restoring force of the tension spring 700 can be determined, thereby determining the overload condition of the transmission chain 300, i.e., the chain tension.

[0069] The tension spring 700 is compressed from its initial position and will not stretch beyond that position because its elastic force only moves in one direction, increasing or decreasing. In the initial position, the elastic force is zero. The elastic coefficient of the tension spring 700 can be chosen to be large, providing sufficient elastic force even with a short stroke. The detection gear 510 can be selected with a smaller diameter, allowing the tension spring 700 to rotate more times when its stroke is short, increasing the magnification. The tension spring 700 should be installed close enough to the detection rack 500, and the movement of the rack 500 should be synchronized with the spring's movement.

[0070] In this embodiment, step Sa21, based on the circumference of the detection gear 510 and the number of pulses Nt generated by the encoder rotating one revolution, the formula for calculating the deformation U of the tension spring 700 corresponding to one pulse includes: U=π*D / Nt, where D is the pitch circle diameter of the gear.

[0071] Step Sa22, based on the spring coefficient K of the tension spring 700 系The formula for calculating the spring force, F, is derived from the pulse value N and the spring deformation U corresponding to one pulse. 弹 =K 系 *N*U;

[0072] Step Sa23, based on the spring force, obtain the formula for calculating the chain tension, including F. 链 =F 弹 .

[0073] F 链 =F 弹 =K 系 *L=K 系 *(N1-N2)*U; where F 链 For chain tension, F 弹 For the spring force, K 系 L is the spring constant, N1 is the first count value of the encoder, N2 is the second count value of the encoder, and U is the spring deformation corresponding to one pulse.

[0074] When N2 is set to zero, F 链 =K 系 *N1*U. The initial count value N1 has a linear relationship with the chain tension, meaning that the reading of the absolute encoder can linearly reflect the chain tension.

[0075] For example: F 链 =K 系 *L=K 系 *(N / 1000)*3.1415*D; where F 链 For chain tension, K 系 L is the spring constant, N is the spring deformation, N is the encoder count value, Nt is the number of pulses generated by the encoder in one revolution (assuming Nt is 1000), and D is the gear pitch circle diameter.

[0076] When K 系 =200 N / mm, N=1, D=100 mm, the spring deformation U=π*D / Nt=(3.14*100) / 1000 corresponding to one pulse; the chain tension F corresponding to one pulse 链 =K 系 *N*U=(200*3.14*100) / 1000=62.8N.

[0077] In this embodiment, step Sa3, based on the chain tension F 链 The steps for determining whether the drive train 300 is overloaded and the cause of the overload include:

[0078] Step Sa31, if the chain tension F 链If the value is less than the first preset value, a first signal indicating that the transmission chain 300 is in a normal state will be output.

[0079] Step Sa32, if the chain tension F 链 The chain tension F is greater than the second preset value. 链 From the preset calibration value F 标 If the time interval T between the rise to the second preset value is less than the first preset time interval, then a second signal is output to indicate that the transmission chain 300 is in a hook overload state.

[0080] Step Sa33, if the chain tension F 链 The chain tension F is greater than the second preset value. 链 From the preset calibration value F 标 If the time interval T between rising to the second preset value is greater than the first preset time interval, then a third signal is output indicating that the transmission chain 300 is in an overloaded state.

[0081] Among them, the preset calibration value F 标 <First preset value<Second preset value.

[0082] Reference Figures 3 to 5 The time interval T is equal to the time from t1 to t2. This can be determined by the chain tension F. 链 The time taken from a rated value to an overload value in the curve is used to determine this. If the chain tension F... 链 If the curve rises slowly to the overload value, it indicates that the normal load is too heavy, caused by excessive chain hooking at once. If the chain tension F... 链 The curve takes a very short time to rise from a rated value to the overload value; the tension quickly reaches the overload value, indicating an overload caused by a stuck hook. The ultimate tensile load of the high-strength chain is 386 kN. The slight overload alarm value is 386 * 60% = 231 kN, and the overload alarm value is 386 * 70% = 270 kN. The first preset value = ultimate tensile load of the chain * 60%, and the second preset value = ultimate tensile load of the chain * 70%.

[0083] The tension of the P / F chain is used to drive the chain and C-hooks, which can be loaded or unloaded. At various workstations such as packing and unloading, the C-hooks are actually stationary, and the P / F chain tension does not actually increase. That is, the same C-hook exists in two states: a running tension of F (maximum) increasing to the overload value of 270KN within a 5-second interval, and a stationary state, as well as a loaded and unloaded state. The P / F chain only drives the running C-hooks. Under normal automatic conditions, the C-hooks transition between running and stationary states, causing variations in the P / F chain tension. Normal chain overload is caused by manually releasing too many C-hooks or manually altering the C-hook layout. The PLC samples the chain tension every 20 milliseconds, generating a real-time tension value F. 链(Real-time). Under normal automatic mode, the real-time tension value F is compared. 链 (Real-time) The generated F (standard) is 160KN. With the chain end jammed, the experimental test recorded that the time interval between the tension increasing from the standard F to the overload value of 270KN was 5 seconds. Due to poor lubrication or excessive hooks causing overload, the tension increases slowly, and the time interval will be much longer than 5 seconds.

[0084] Normal state: F 链 (Real-time) <231KN;

[0085] Overload: F 链 (Real-time) >270KN, when the tension changes from F 标 If the time interval between reaching the overload value of 270KN is less than 5 seconds, the hook is considered overloaded.

[0086] F 链 (Real-time) >270KN, when the tension changes from F 标 A normal overload occurs when the time interval between the current value of 270 kN and the overload value is greater than 5 seconds.

[0087] In this embodiment, the method for overload protection of high-speed wire PF drive chain further includes:

[0088] Step Sb1, if the chain tension F 链 If the value exceeds the first preset value, a first alarm signal representing the first degree of overload will be output.

[0089] Step Sb2, if the chain tension F 链 If the value exceeds the second preset value, a second alarm signal representing the second degree of overload will be output.

[0090] By adjusting the chain tension F 链 The system performs a test. A minor overload alarm, also known as the first level of overload, is triggered by outputting a first alarm signal. The overload protection mode, or the second level of overload, triggers a second alarm signal. The second level of overload is greater than the first level. Minor overload and overload thresholds are set. Minor overload only triggers an alarm, while overload will cause a shutdown and sound an alarm bell.

[0091] In this embodiment, the method for overload protection of high-speed wire PF drive chain further includes:

[0092] Step Sc1: Obtain the chain tension output from the second encoder 620 from the preset calibration value F. 标 to overload tension value F G The count value for the time period;

[0093] Step Sc2 involves calculating the count value N3, the number of pulses Nx from one revolution of the second encoder 620, the circumference of the driven gear 600, and the chain tension as it decreases from the preset calibration value F.标 to overload tension value F G The corresponding elongation per meter β is used to obtain the distance L1 from the overload position of the hook to the detection driven gear 600;

[0094] The second encoder 620 is connected to the driven gear 600. The second encoder 620 is used to detect and output a count value that characterizes the rotation state of the driven gear 600. The driven gear 600 meshes with the transmission chain 300 and is used to rotate under the drive of the transmission chain 300. β is measured experimentally.

[0095] Because the chain has a guide pulley every meter, and is suspended from the track by these pulleys, there is a slight sag in the chain between the guide pulleys. Furthermore, there are gaps between chain links during operation. Therefore, the chain exhibits stretching from its running state to its overloaded state. Since the entire chain is replaced, this stretching is evenly distributed. Testing can determine how much a section of the chain can stretch from its running state to its overloaded state, thus calculating the increase per meter. When a snag occurs, the chain tension is calculated from F... 标 During the time it takes for the overload value to be reached, the counting value of the second encoder 620 on the driven gear 600 of the transmission mechanism, combined with the pitch circle diameter of the driven gear 600, can be used to calculate the increase in chain length when the hook is overloaded. This allows for the deduction of the distance between the hook point and the driven wheel, thus determining the hook position. The second encoder 620 is an incremental encoder.

[0096] In this embodiment, step Sc2 involves detecting the count value N3, the number of pulses Nx from one revolution of the second encoder 620, the circumference of the driven gear 600, and the chain tension from the preset calibration value F. 标 Value up to overload tension value F G The formula for calculating the distance L1 from the overload position of the hook to the detection driven gear 600, based on the elongation rate β per meter, includes:

[0097] L1=(N3 / Nx)*π*d / β, where d is the pitch circle diameter of the driven gear 600.

[0098] L1 = (N3 / 1000) * 3.1415 * d / β; L1 is the distance from the overload position of the hook to the detection driven gear 600, and N3 is the chain tension from the preset calibration value F. 标 Value up to overload tension value F G The time period is the count value of the second encoder 620, Nx is the number of pulses for one revolution of the second encoder 620, assuming Nx is 1000, d is the pitch circle diameter of the driven gear 600, and β is the chain tension when the chain tension drops from the preset calibration value F. 标 Value up to overload tension value F G Elongation per meter, this data was measured by actual experiments.

[0099] During chain operation, the engagement and disengagement of the hooks constantly change, meaning the chain tension fluctuates. However, it has a distinct characteristic: when the chain is driving the hook normally, the hook's speed is 15 meters per minute. When the hook gets stuck, causing the chain to slow down, the hook's speed will exceed the chain's speed, causing the hook to disengage. At this point, the chain tension changes the same whether the hook is loaded or unloaded. Specifically, the tension will show a significant increase, which we define as F. 标 With this F 标 The standard is used to measure the elongation of the chain.

[0100] In this embodiment, the preset calibration value F is the chain tension calculated from the pulse value read by the first encoder 520 when the hook is manually engaged and jammed.

[0101] Elongation measurement: When unloaded, the hook is manually jammed 50 or 100 meters away from the drive wheel. When the tension reaches the overload value of 270KN, the elongation can be measured to be 25mm / m. 标 It is set at 160KN.

[0102] In this embodiment, step Sc2 involves detecting the count value N3, the number of pulses Nx from one revolution of the second encoder 620, the circumference of the driven gear 600, and the chain tension from the preset calibration value F. 标 Value up to overload tension value F G The formula for calculating the distance L1 from the overload position of the hook to the detection driven gear 600, based on the elongation per meter β, also includes:

[0103] L2 = L1 ± 2m, where L1 is the distance from the overload position of the hook to the detection driven gear 600, and L2 is the range of the distance from the overload position of the hook to the detection driven gear 600.

[0104] Due to errors in the data, the actual position of the hook is 2 meters before and after the calculation point, which is a range value.

[0105] Example 1: Mild overload

[0106] When F 链 When (real-time) = 231KN, it is a light overload.

[0107] Example 2: Normal Overload

[0108] F 链 (Real-time) >270KN, and tension from F 标 A normal overload occurs when the time interval between 160KN and the overload value of 270KN is greater than 5 seconds.

[0109] Example 3: Hook overload

[0110] 1. Overload detection of the hook: F 链 (Real-time) >270KN, and tension from F 标 The hook is considered overloaded when the time interval between 160KN and the overload value of 270KN is less than 5 seconds.

[0111] 2. Determining the position of the hook

[0112] The driven wheel has a diameter of 400mm and a circumference of 1256mm. The second encoder 620 outputs 1000 pulses per revolution. Therefore, the number of pulses corresponding to the hook at a 1-meter position is (1000 * 0.025) / 1.25 = 20. When a hook jamming accident occurs, the tension changes from F... 标 If the encoder pulse count is 5000 within the time interval from 160KN to the overload value of 270KN, then the hook position can be determined to be 250 meters away (5000 / 20=250).

[0113] According to the overload protection method for high-speed wire PF drive chain provided in this embodiment, the working principle of the high-speed wire PF drive chain overload protection method is as follows:

[0114] When an overload alarm occurs, an audible and visual alarm will sound. At the same time, the screen will display whether the overload is normal or caused by the latch. If it is a latch overload, the screen will highlight the latch position in red, prompting equipment maintenance personnel to confirm and handle the situation on-site.

[0115] The overload protection method for high-speed wire PF wire drive chain provided in this embodiment has at least the following advantages:

[0116] By detecting the chain tension and establishing a trend chart through PLC, the process of controlling the chain tension can be effectively implemented. At the same time, the position of the latch can be determined, providing strong support for equipment maintenance and troubleshooting.

[0117] Set a light overload and an overload threshold. Light overload will only trigger an alarm, while overload will cause the machine to shut down and the alarm to sound.

[0118] By analyzing the chain tension trend chart, it can be determined whether the overload is caused by excessive chain load or by a stuck C-hook, and the specific location of the stuck hook can be detected, which can greatly shorten the troubleshooting time.

[0119] Embodiments of the present invention also provide a system for overload protection of a high-speed PF wire drive chain. The system includes a detection gear 510, a detection rack 500, a first encoder 520, and a controller. The first encoder 520 is connected to the detection gear 510 and is used to detect and output pulse values ​​characterizing the rotational state of the detection gear 510. The detection gear 510 meshes with the detection rack 500, which is fixed to a drive platform 200 along a preset direction. The detection rack 500 is used to drive the detection gear 510 to rotate as the drive platform 200 moves. A drive mechanism 100 and a drive chain 300 are mounted on the drive platform 200. The drive mechanism 100 is connected to the drive chain 300 and is used to drive the drive chain 300 for transmission. A tension spring 700 extending along a preset direction is connected to the bottom of the drive platform 200. The first encoder 520 is electrically connected to the controller, which is used to execute a method for overload protection of the high-speed PF wire drive chain.

[0120] This device is extremely convenient to install on-site and offers high detection accuracy. It also provides valuable guidance for equipment maintenance. Specifically, it addresses issues such as whether the C-hook guide wheel is jammed, causing rolling friction to become sliding friction, whether the C-hook bracket is sagging, and whether the chain lubrication is adequate.

[0121] The implementation method of the overload protection system for high-speed wire PF drive chain includes: First, installing a rack at the end of the transmission mechanism. With the P / F chain stopped, loosening the drive chain 300, adjusting the tension spring 700 to its free state, and zeroing the absolute encoder. Installing the detection gear 510 at the bottom of the detection rack 500, fixing the gear shaft, and installing the connecting plate and incremental encoder. The value from the absolute encoder is acquired by the counting template and sent to the PLC. The incremental encoder is installed on the shaft of the driven gear 600 of the transmission mechanism.

[0122] 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 method for overload protection of a high-speed wire PF drive chain, characterized in that, include: Obtain the pulse value output in real time by the first encoder (520); Based on the pulse value, the chain tension F_chain, which characterizes the real-time tension of the transmission chain (300), is obtained; Obtain the count value of the time period from the preset calibration value F to the overload tension value FG, which is represented by the output of the second encoder (620); based on the count value N3, the number of pulses Nx of the second encoder (620) rotating one revolution, the circumference of the driven gear (600) and the elongation per meter β of the chain from the preset calibration value F to the overload tension value FG, obtain the distance L1 from the hook overload position to the driven gear (600), and calculate the formula: L1=(N3 / Nx)*π*d / β, where d is the pitch circle diameter of the driven gear (600); Based on the chain tension F, it is determined whether the transmission chain (300) is overloaded and the cause of the overload, and the position of the hook is determined based on the distance L1 from the overload position of the hook to the detection driven gear (600). The first encoder (520) is connected to the detection gear (510), and the first encoder (520) is used to detect and output pulse values ​​that characterize the rotation state of the detection gear (510); the detection gear (510) meshes with the detection rack (500), and the detection rack (500) is fixed on the drive platform (200) along a preset direction. The detection rack (500) is used to drive the detection gear (510) to rotate as the drive platform (200) moves; a drive mechanism (100) and a transmission chain (300) are installed on the drive platform (200), and the drive mechanism (100) and the transmission chain (300) are connected to the detection gear (510) and the detection rack (500) are connected to the detection gear (510) and the detection rack (500) are connected to the detection gear (510) and the detection rack (500) are connected to the detection gear (510) and the detection rack (51 ... The transmission chain (300) is connected, and the drive mechanism (100) is used to drive the transmission chain (300) to transmit; the bottom of the drive platform (200) is connected to a tension spring (700) extending along the preset direction; the second encoder (620) is connected to the detection driven gear (600), and the second encoder (620) is used to detect and output a count value characterizing the rotation state of the detection driven gear (600). The detection driven gear (600) meshes with the transmission chain (300), and the detection driven gear (600) is used to rotate under the drive of the transmission chain (300). β is measured experimentally.

2. The method for overload protection of high-speed wire PF drive chain according to claim 1, characterized in that, The step of obtaining the chain tension F chain, which characterizes the real-time tension of the transmission chain (300), based on the pulse value includes: Based on the circumference of the detection gear (510) and the number of pulses Nt generated by the encoder rotating one revolution, the deformation U of the tension spring (700) corresponding to one pulse is obtained; The spring force is obtained based on the spring coefficient K of the tension spring (700), the pulse value N, and the spring deformation U corresponding to the pulse. The chain tension is obtained based on the spring force.

3. The method for overload protection of high-speed wire PF drive chain according to claim 2, characterized in that, The calculation formula for the step of obtaining the deformation U of the tension spring (700) corresponding to one pulse based on the circumference of the detection gear (510) and the number of pulses Nt generated by the encoder rotating one revolution includes U=π*D / Nt, where D is the pitch circle diameter of the gear; The calculation formula for obtaining the spring force based on the spring coefficient K of the tension spring (700), the pulse value N, and the spring deformation U corresponding to the pulse includes: F_spring = K_coefficient * N * U; The calculation formula for obtaining the chain tension based on the spring force includes F_chain = F_spring.

4. The method for overload protection of high-speed wire PF drive chain according to any one of claims 1-3, characterized in that, The step of determining whether the transmission chain (300) is overloaded and the cause of the overload based on the chain tension F includes: If the chain tension F is less than a first preset value, a first signal indicating that the transmission chain (300) is in a normal state is output. If the chain tension F is greater than the second preset value, and the time interval T between the chain tension F rising from the preset calibration value F to the second preset value is less than the first preset time interval, then a second signal is output indicating that the transmission chain (300) is in a hook overload state. If the chain tension F is greater than the second preset value, and the time interval T between the chain tension F rising from the preset calibration value F to the second preset value is greater than the first preset time interval, then a third signal indicating that the transmission chain (300) is in an overloaded state is output. Wherein, the preset calibration value Fcalibrated < the first preset value < the second preset value.

5. The method for overload protection of high-speed wire PF drive chain according to claim 4, characterized in that, The method for overload protection of the high-speed wire PF wire drive chain also includes: If the chain tension F_chain is greater than a first preset value, a first alarm signal representing a first degree of overload is output. If the chain tension F_chain is greater than the second preset value, a second alarm signal representing the second degree of overload will be output and the machine will stop.

6. The method for overload protection of high-speed wire PF drive chain according to claim 1, characterized in that, The calculation formula for obtaining the distance L1 from the hook overload position to the driven gear (600) based on the count value N3, the number of pulses Nx of one revolution of the second encoder (620), the circumference of the driven gear (600), and the chain elongation per meter β when the chain tension changes from the preset calibration value F to the overload tension value FG, further includes: L2 = L1 ± 2m, where L1 is the distance from the overload position of the hook to the detection driven gear (600), and L2 is the range of the distance from the overload position of the hook to the detection driven gear (600).

7. The method for overload protection of high-speed wire PF drive chain according to claim 1, characterized in that: The preset calibration value F is the chain tension calculated from the pulse value read by the first encoder (520) when the hook is jammed by human operation.

8. A system for overload protection of a high-speed wire PF drive chain, characterized in that: The overload protection system for the high-speed wire PF wire drive chain includes a detection gear (510), a detection rack (500), a first encoder (520), and a controller; The first encoder (520) is connected to the detection gear (510), and the first encoder (520) is used to detect and output pulse values ​​that characterize the rotation state of the detection gear (510); the detection gear (510) meshes with the detection rack (500), and the detection rack (500) is fixed on the drive platform (200) along a preset direction. The detection rack (500) is used to drive the detection gear (510) to rotate as the drive platform (200) moves; a drive mechanism (100) and a transmission chain (300) are installed on the drive platform (200). The drive mechanism (100) is connected to the transmission chain (300), and the drive mechanism (100) is used to drive the transmission chain (300) to transmit; a tension spring (700) extending along the preset direction is connected to the bottom of the drive platform (200). The first encoder (520) is electrically connected to the controller, which is used to perform the method for overload protection of high-speed wire PF wire drive chain as described in any one of claims 1-7.

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