Long-distance high-precision cable intelligent winding and unwinding method and device

Abstract

This invention discloses an intelligent cable laying device for long-distance, high-precision cable winding and unwinding. The device includes: a set of three-phase asynchronous motors connected to a power supply via frequency converters; each three-phase asynchronous motor is connected to the main shaft of a drum via a hysteresis coupler; the three-phase asynchronous motors are equipped with incremental encoders to provide smooth speed and torque control to the frequency converters. A set of servo motors drives a gear chain via a reducer, moving the cable guide wheel left and right. The cable is laid onto the drum via the cable guide wheel. The position signals from the absolute encoders of the servo motors and the absolute encoder of the drum can be input to a PLC controller, which then controls the working state of the drum and the cable laying device. This patent features good cable laying effect, reliable operation, good real-time performance, the ability to set the working state according to the cable width, and adaptability to large fluctuations in working speed and large changes in cable diameter.

Description

Technical Field

[0001] This invention relates to the field of cable laying technology, and in particular to a long-distance, high-precision intelligent cable winding and unwinding device. Background Technology

[0002] In recent years, with the rapid development of my country's social economy and urbanization, the demand and application of power cables have increased significantly. As technology advances, the length of cables used has increased, leading to the challenge of how to stably deploy and retrieve long-distance cables. Currently, cable-laying devices in mechanical equipment suffer from the problem of tangled and intertwined cables, ultimately affecting the efficiency of cable deployment and retrieval. Furthermore, most current cable-laying devices use screws for cable guidance, but screw guidance can lead to deflection, increasing the probability of problems with mechanical cable-laying equipment. This invention overcomes the deflection problem of screws by using sprockets for cable guidance and is more suitable for the deployment and retrieval of long-distance cables. This invention uses a PLC controller to control the working status of the drum and the drum cable-laying device, which is more intelligent than purely mechanical cable-laying devices. It features good cable-laying effect, reliable operation, good real-time performance, the ability to set the working status according to the cable width, and adaptability to large fluctuations in working speed and large changes in cable diameter. Summary of the Invention

[0003] To address the aforementioned problems in the prior art, this invention provides an intelligent cable laying device for long-distance cable laying and winding, ensuring the accuracy and efficiency of long-distance cable laying and winding.

[0004] To achieve the objectives of this invention, the technical solution adopted is as follows:

[0005] A method for intelligent cable winding and unwinding over long distances with high precision, comprising the following steps:

[0006] S1. The cable reel device resets, and the PLC controller collects pressure sensor data and tractor speed data. and cable running speed ;

[0007] S2 determines whether the guide wheel is aligned with the cable winding position of the drum based on the data collected from the pressure sensor. If it exceeds the error range, an alarm is issued and automatic or manual correction is performed. If it does not exceed the error range, it enters S2.

[0008] S3. Based on the collected tractor speed and cable running speed Calculated tension The data is compared with the starting tension of the cable winding device: if the collected data is less than the starting tension, the cable winding device locks and issues an alarm; if the collected data is greater than the starting tension, proceed to step S4.

[0009] S4. Determine the operating status of the tractor: If the tractor is moving forward, the drum releases the cable and proceeds to S5; if the tractor is moving backward, the drum retracts the cable and proceeds to S7.

[0010] S5. Determine whether the tension on the cable is caused by a sudden increase in vehicle speed or human factors. If so, the hysteresis coupler will work to stabilize the tension on the cable until the PLC determines that the cable has been fully released and the cable laying is completed. Otherwise, the drum will continue to release the cable until the PLC controller determines that the cable has been fully released and the cable laying is completed.

[0011] S6. Determine whether the tension on the cable is caused by a sudden decrease in vehicle speed or a sudden stop. If so, the cable reel device will lock and issue an alarm. Otherwise, the reel will continue to reel in the cable until the PLC controller determines that the cable has been reeled in and completes the cable routing.

[0012] Furthermore, the cable retraction method in S6 is as follows:

[0013] As the drum rotates one revolution, the chain moves a distance equal to one cable outer diameter in the winding direction.

[0014] The first layer of cable starts close to the reel coil;

[0015] After the first layer of cable is fully wound on the reel, the second layer of cable begins to be wound. The starting position of the second layer of cable should be placed in the recess where every two cables of the first layer are tightly connected. Therefore, the number of cables wound in the second layer is one less than the number of cables wound in the first layer.

[0016] The starting position of odd-numbered layer cables is the same as that of the first layer;

[0017] The starting position of the double-layer cable is the same as that of the second layer;

[0018] The cable is discharged in S5 as follows:

[0019] As the drum rotates one revolution, the chain moves a distance equal to the outer diameter of the cable in the direction of release.

[0020] The starting position of the odd-numbered layer cable is close to the drum;

[0021] The starting position of a double-layer cable is located at the recess where the two cables of the next layer of cable are tightly joined together.

[0022] Furthermore, in step S2, to qualitatively analyze the factors affecting cable tension, pressure sensors are installed on both sides of a pair of guide wheels on the cable guiding device. The measured pressure values ​​are sent to the Siemens PLC controller. When the measured pressure difference between the two sides exceeds the set pressure difference, the Siemens PLC controller will control the equipment accordingly. Based on the left or right tilt of the cable, a correction amount is provided for the chain's movement distance. Assume the current number of cable turns is The outer diameter of the cable is The distance traveled by the sprocket and chain It can be represented as:

[0023]

[0024] in: The pressure value is on the left side. The pressure value is on the right side. For the allowable pressure deviation value, This is the correction amount for the distance the chain travels. This represents the current number of cable turns. The outer diameter of the cable is, The distance traveled by the sprocket and chain. This indicates the current servo cable routing position.

[0025] Due to the specific type of cable, the settings are usually set manually;

[0026] And when or hour, ;when hour, ;when hour, .

[0027] Furthermore, the current number of cable turns The calculation formula is as follows:

[0028]

[0029] in: The resolution of the first absolute encoder, This represents the number of pulses detected per second by the first absolute encoder.

[0030] Current servo cable position The calculation formula is as follows:

[0031]

[0032] in: The resolution of the second absolute encoder, This represents the number of pulses detected per second by the second absolute encoder.

[0033] A long-distance, high-precision intelligent cable winding and unwinding device includes a three-phase asynchronous motor and a cable. The three-phase asynchronous motor is electrically connected to a frequency converter and a roller. An incremental encoder and a first absolute encoder are also electrically connected to the three-phase asynchronous motor. The incremental encoder is electrically connected to a PLC controller. The first absolute encoder is mounted on the roller's shaft. The roller is axially connected to the PLC control box via the shaft. A guide rod is mounted on the PLC control box, and a cable guide frame is slidably connected to the guide rod. The cable guide frame is perpendicular to the roller's shaft. Cable guide wheels are symmetrically arranged on both sides of the front end of the cable guide frame. Pressure sensing devices are installed on the inner sides of both cable guide wheels. The cable guide frame achieves horizontal displacement on the guide rod through a transmission chain. The transmission chain is fixed to the motor shaft of a servo motor through sprockets. The servo motor is electrically connected to a second absolute encoder and a servo driver. The servo driver is electrically connected to the PLC controller. The cable passes through the gap between the cable guide wheels on both sides of the front end of the cable guide frame and winds around the roller.

[0034] Furthermore, a hysteresis coupler and a speed reducer are sequentially connected between the three-phase asynchronous motor and the drum.

[0035] Furthermore, a servo reducer is connected between the servo motor and the sprocket.

[0036] Furthermore, it also includes a base, which is made of double-bar stainless steel and has positioning holes around its perimeter. The three-phase asynchronous motor is mounted on the base.

[0037] Compared with the prior art, the advantages of the present invention are as follows:

[0038] 1. Utilizing the structure of the sprocket guide cable, it is more suitable for long-distance cable laying than the lead screw, and there is no need to consider the issue of reversing.

[0039] 2. Utilizing a PLC controller for intelligent control of mechanical equipment allows for adaptation to large fluctuations in working speed, provides good real-time performance, and effectively reduces cable routing errors. Attached Figure Description

[0040] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0041] Figure 2 This is a schematic diagram of the cable guiding device of the present invention;

[0042] Figure 3 This is a top view of the overall device of the present invention;

[0043] Figure 4 This is a flowchart illustrating the implementation of the present invention. Detailed Implementation

[0044] To further illustrate the technical means and effects adopted by the present invention to achieve the intended purpose, the following detailed description, in conjunction with the accompanying drawings and preferred embodiments, describes an intelligent cable laying device for long-distance cable winding and unwinding according to the present invention:

[0045] like Figure 1 , 2 As shown in Figure 3, the intelligent cable laying system for long-distance cable winding and unwinding of the present invention includes a frequency converter 1, a motor incremental encoder 2, a three-phase asynchronous motor 3, a hysteresis coupler 4, a reducer 5, a drum 6, a drum absolute position encoder 7, a Siemens PLC controller 8, an AC servo driver 9, a servo motor absolute position encoder 10, a servo motor 11, a servo reducer 12, a pressure sensor 13, a cable guide frame 14, a drive chain 15, a cable 16, a base 20, a guide rod 21, a cable guide wheel 22, and a sprocket 23. A three-phase asynchronous motor 3 is connected to the power supply via the frequency converter 1, and is connected to the drum spindle chain via the hysteresis coupler and the reducer 5. The servo motor 11 drives the chain 15 on the cable laying device to rotate through the reducer 12. The chain 15 drives the cable guide frame 14 to move horizontally on the guide rod. The cable 16 is laid onto the drum 6 via the cable guide frame 14 and the pressure sensor 13. A three-phase asynchronous motor 3 has an incremental encoder 2 for motor speed detection installed at its tail. A drum 6 has an absolute encoder 7 for drum position installed on its main shaft drive chain. A servo motor 11 has a servo position absolute encoder 10 installed at its tail. The signals from the servo motor absolute encoder 10 and the drum position absolute encoder 7 are input to a Siemens PLC controller 8, which controls the operating status of the drum 6 and the cable guide. The signal from the pressure sensor 13 is also input to the Siemens PLC controller 8. The Siemens PLC controller 8 performs position correction compensation for the drum 6 and the cable guide.

[0046] like Figure 4 As shown, the control method is as follows:

[0047] S1. The cable reel device resets, and the PLC controller collects pressure sensor data and tractor speed data. and cable running speed ;

[0048] S2. Based on the data collected from the pressure sensor, determine whether the guide wheel is aligned with the cable laying position of the drum. If it exceeds the error range, issue an alarm and perform manual or automatic correction. During automatic correction, there will be a voice prompt. The PLC controller will confirm the current servo cable laying position and then control the sprocket to move to the servo cable laying position. If it does not exceed the error range, proceed to S2.

[0049] S3. Based on the collected tractor speed and cable running speed Calculated tension The data is compared with the starting tension of the cable winding device: if the collected data is less than the starting tension, the cable winding device locks and issues an alarm; if the collected data is greater than the starting tension, proceed to step S4.

[0050] S4. Determine the operating status of the tractor: If the tractor is moving forward, the drum releases the cable and proceeds to S5; if the tractor is moving backward, the drum retracts the cable and proceeds to S6.

[0051] S5. The tension sensor of the cable guide device determines whether the sudden increase in cable tension is caused by a sudden increase in vehicle speed or human factors. If so, the hysteresis coupler works to stabilize the cable tension until the PLC controller determines through the drum absolute encoder that the cable servo cable laying position is the end position. The cable laying is then completed. Otherwise, the drum continues to lay the cable until the PLC controller determines through the drum absolute encoder that the cable servo cable laying position is the end position. The cable laying is then completed.

[0052] S6. The tension sensor of the cable guide device determines whether the sudden decrease in the tension of the cable is caused by a sudden decrease in vehicle speed or a sudden stop. If so, the cable reeling device locks and issues an alarm. Otherwise, the drum continues to reel in the cable until the PLC controller determines the cable servo cable laying position as the cable laying end position through the absolute encoder of the drum. After the cable is reeled in, the cable laying is completed.

[0053] The three-phase asynchronous motor 3 is connected to the main shaft of the drum 6 via a hysteresis coupler 4. The hysteresis coupler 6 utilizes the interaction of magnetic fields to transmit torque. When the external rotor rotates through a transmission device (such as the aforementioned three-phase engine), it generates a rotating magnetic field. This magnetic field penetrates the internal rotor, causing it to rotate as well. Because the internal rotor is connected to the output end via bearings, it transmits rotational power to the output end device or mechanical equipment during rotation. The hysteresis coupler transmits rotational power through magnetic field coupling, avoiding frictional losses and wear of transmission components, thus extending the service life of the device. Simultaneously, the torque transmission of the hysteresis coupler 4 can be adjusted by changing the magnetic field strength at the input end. Since the rotor in the hysteresis coupler 4 has no mechanical connection, the output end can automatically disengage from the input end in case of overload or blockage, providing load protection and preventing damage and malfunctions caused by abnormal loads. This gives it good speed regulation performance. The hysteresis coupler 4 is used to stabilize the tension on the cable, preventing damage to the cable and potential safety hazards caused by excessive tension due to excessive speed of the tractor in unexpected situations.

[0054] The device also includes a cable guide wheel and a slide bar. A servo motor drives a gear chain via a reducer, causing the cable guide wheel to move left and right. During cable winding or unwinding operations, the cable guide wheel aligns the cable with its position on the drum. To prevent cable movement on the drum, starting from the second layer, the cable is positioned in the recessed area where every two cables of the previous layer are tightly joined. The chain on the cable guide device rotates in a constant direction, either positive or negative. The servo motor uses a built-in incremental encoder to obtain cable position information for winding operations. The cable is routed onto the drum via the cable guide wheel. Pressure sensors are installed on both sides of the cable guide wheel to monitor the cable position. If there is a significant deviation between the cable and the guide wheel and the drum, an alarm is triggered to prevent errors from accumulating and causing accidents, requiring manual troubleshooting. The sprocket drive uses gear transmission, which has a high meshing efficiency, typically exceeding 95%. It is suitable for high-speed and high-frequency movements and can withstand large impact loads. In contrast, the commonly used screw drive structure has a lower transmission efficiency, typically around 50%, due to friction between the screw and nut. Therefore, the sprocket structure is more suitable for long-distance cable laying. Cable laying control, whether in automatic or manual mode, is generally at a fixed speed. The cable laying is accomplished by moving a slide bar left and right. The servo motor rotates in a fixed direction, thus fixing the direction of the chain and wheel movement. When a change of direction is needed on a certain side, it is controlled by the servo motor controlled by the PLC. The absolute position of the cable is obtained through the absolute encoder in the servo motor, determining whether the cable guide wheel should continue lateral cable laying or first turn and then lay the cable in the opposite direction. When the cable guide reaches the fixed transmission gears on both sides, relative displacement occurs, causing it to move up or down with the rotation of the gears, thus completing the reverse cable winding operation.

[0055] like Figure 1 As shown, the controller in this invention is a Siemens PLC controller. A hysteresis coupler 4 is installed next to the output terminal of the three-phase motor. Sometimes, during the cable laying process, sudden situations may occur that cause sudden changes in the speed and direction of the cable. The hysteresis coupler can keep the tension on the cable constant, avoiding accidents caused by excessive tension on the cable due to excessive speed of the traction vehicle. At the same time, the input terminal of the three-phase motor is equipped with an absolute encoder and a frequency converter controlled by the PLC to monitor the current angle position of the drum. The Siemens PLC controller is connected to a touch screen for convenient real-time monitoring of the operation status of the cable laying device and setting the initial position offset of each layer of cable laying. In case of emergency, it can brake or switch to manual operation.

[0056] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications, equivalent changes, and alterations made by those skilled in the art to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A method for intelligent cable reeling and unloading over long distances with high precision, characterized in that: The steps are as follows: S1. The cable reel device resets, and the PLC controller collects pressure sensor data and tractor speed data. and cable running speed ; S2. Based on the data collected from the pressure sensor, determine whether the guide wheel is aligned with the cable feeding position of the drum. If it exceeds the error range, issue an alarm and perform automatic or manual correction. If it does not exceed the error range, proceed to S2. S3. Based on the collected tractor speed and cable running speed Calculated tension The data is compared with the starting tension of the cable winding device: if the collected data is less than the starting tension, the cable winding device locks and issues an alarm; if the collected data is greater than the starting tension, proceed to step S4. S4. Determine the operating status of the tractor: If the tractor is moving forward, the drum releases the cable and proceeds to S5; if the tractor is moving backward, the drum retracts the cable and proceeds to S6. S5. Determine whether the tension on the cable is caused by a sudden increase in vehicle speed or human factors. If so, the hysteresis coupler will work to stabilize the tension on the cable until the PLC determines that the cable has been fully released and the cable laying is completed. Otherwise, the drum will continue to release the cable until the PLC controller determines that the cable has been fully released and the cable laying is completed. S6. Determine whether the tension on the cable is caused by a sudden decrease in vehicle speed or a sudden stop. If so, the cable reeling device will lock and an alarm will be issued. Otherwise, the reel will continue to reel in the cable until the PLC controller determines that the cable has been reeled in and completes the cable routing. The above steps are used to set up a three-phase asynchronous motor (3) and a cable (16). The three-phase asynchronous motor (3) is electrically connected to a frequency converter (1). The three-phase asynchronous motor (3) is connected to a drum (6). An incremental encoder (2) and a first absolute encoder (7) are also electrically connected to the three-phase asynchronous motor (3). The incremental encoder (2) is electrically connected to a PLC controller (8). The first absolute encoder (7) is installed on the shaft of the drum (6). The drum (6) is axially connected to the PLC control box (17) through the shaft. A guide rod (21) is installed on the PLC control box (17). A cable guide frame (14) is slidably connected to the guide rod (21). The cable guide frame (14) is perpendicular to the shaft of the drum (6). The cable guide frame (14) is symmetrically provided with cable guide wheels (22) on both sides of the front end. Pressure sensing devices (13) are installed on the inner side of the cable guide wheels (22) on both sides. The cable guide frame (14) achieves horizontal displacement on the guide rod (21) through the transmission chain (15). The transmission chain (15) is fixed on the motor shaft of the servo motor (11) through the sprocket (23). The servo motor (11) is electrically connected to the second absolute encoder (10). The servo motor (11) is electrically connected to the servo driver (9). The servo driver (9) is electrically connected to the PLC controller (8). The cable (16) passes through the gap between the cable guide wheels (22) on both sides of the front end of the cable guide frame (14) and is wound on the roller (6).

2. The intelligent cable reeling and unwinding method for long-distance, high-precision cables as described in claim 1, characterized in that: The cable retraction method in S6 is as follows: As the drum rotates one revolution, the chain moves a distance equal to one cable outer diameter in the winding direction. The first layer of cable starts close to the reel coil; After the first layer of cable is fully wound on the reel, the second layer of cable begins to be wound. The starting position of the second layer of cable should be placed in the recess where every two cables of the first layer are tightly connected. Therefore, the number of cables wound in the second layer is one less than the number of cables wound in the first layer. The starting position of odd-numbered layer cables is the same as that of the first layer; The starting position of the double-layer cable is the same as that of the second layer; The cable is discharged in S5 as follows: As the drum rotates one revolution, the chain moves a distance equal to the outer diameter of the cable in the direction of release. The starting position of the odd-numbered layer cable is close to the drum; The starting position of a double-layer cable is located at the recess where the two cables of the next layer are tightly joined together.

3. The intelligent cable winding and unwinding method for long-distance, high-precision cables as described in claim 1, characterized in that: In step S2, to qualitatively analyze the factors affecting cable tension, pressure sensors are installed on both sides of a pair of guide wheels on the cable guiding device. The measured pressure values ​​are sent to the PLC controller. When the measured pressure difference between the two sides exceeds the set pressure difference, the PLC controller will control the equipment accordingly. Based on the left or right tilt of the cable, a correction amount is provided for the chain's movement distance. Assume the current number of cable turns is The outer diameter of the cable is The distance traveled by the sprocket and chain It can be represented as: in: The pressure value is on the left side. The pressure value is on the right side. For the allowable pressure deviation value, This is the correction amount for the distance the chain moves. This represents the current number of cable turns. The outer diameter of the cable is, The distance traveled by the sprocket and chain. This indicates the current servo cable routing position. Due to the specific type of cable, the settings are usually determined manually; And when or hour, ;when hour, ;when hour, .

4. The intelligent cable reeling and unwinding method for long-distance, high-precision cables as described in claim 3, characterized in that: The current number of cable turns The calculation formula is as follows: in: The resolution of the first absolute encoder, This represents the number of pulses detected per second by the first absolute encoder. Current servo cable position The calculation formula is as follows: in: The resolution of the second absolute encoder, This represents the number of pulses detected per second by the second absolute encoder.

5. The intelligent cable reeling and unwinding method for long-distance, high-precision cables as described in claim 1, characterized in that: A hysteresis coupler (4) and a speed reducer (5) are connected sequentially between the three-phase asynchronous motor (3) and the drum (6).

6. The intelligent cable reeling and unwinding method for long-distance, high-precision cables as described in claim 1, characterized in that: A servo reducer (12) is connected between the servo motor (11) and the sprocket (23).

7. The intelligent cable winding and unwinding method for long-distance, high-precision cables as described in claim 1, characterized in that: It also includes a base (20), which is made of double-bar type stainless steel. The base (20) is equipped with positioning holes around its perimeter. The three-phase asynchronous motor (3) is installed on the base (20).

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