A cable traction steel wire rope intelligent synchronous storage control method

Abstract

The application discloses a kind of cable traction steel wire rope intelligent synchronous storage control methods, it is related to cable traction steel wire rope winding technical field, comprising the following steps: S1, by closed-loop torque motor control, realize the intelligent control of motor;S2, utilize cable reel to carry out synchronous storage cable traction steel wire rope, cable reel transmission connection cable reel from shallow dish to full dish constant speed is greater than cable traction speed, by controlling torque and speed, ensure that the speed is always greater than cable traction speed in whole cable reel process;S3, utilize pre-tightening force sensor real-time monitoring and adjusting pre-tightening force;S4, by the combination of PLC and alternating current servo motor realizes one-key sequence control function;By real-time monitoring motor state, control torque and speed, and the intelligent adjustment of pre-tightening force, the synchronous, uniform, efficient storage of cable traction steel wire rope is realized.Meanwhile, by motor control strategy of least square method, sample data are fitted, relationship function is calculated, and control precision and robustness are improved.

Description

Technical Field

[0001] This invention relates to the field of cable traction wire rope winding technology, specifically to an intelligent synchronous winding control method for cable traction wire rope. Background Technology

[0002] The winding technology of cable traction wire ropes is a crucial step in cable laying, and its efficiency and accuracy directly impact the quality and safety of the laying process. Traditional cable traction methods often rely on manual coordination, which suffers from low efficiency, susceptibility to errors, and poor safety. With the continuous development of automation technology, the demand for intelligent synchronous winding control methods for cable traction wire ropes is becoming increasingly prominent.

[0003] In the prior art, CN116902684A discloses a fireproof cable processing and traction device and method. In use, one end of the cable is passed through a guide device and then wound around a winding device. A drive motor drives a rotating shaft to rotate, which in turn drives an annular hydraulic pipe to rotate. The annular hydraulic pipe drives an annular extrusion plate to rotate through an extrusion sleeve and an extrusion piston. The annular extrusion plate drives an extrusion ball head to rotate through an arc spring. At the same time, the extrusion ball head rotates in conjunction with a ball groove to drive a control disc to rotate. The control disc drives a winding shaft to rotate, thus winding and traction the cable through the winding shaft. The guide device controls the position of the cable wound on the winding device, so that the winding position on the winding device can be used in a reasonable way.

[0004] However, existing cable traction and winding devices like these still have many problems during the winding process:

[0005] Open-loop control problem: Most motors and motor control systems used in existing technologies employ open-loop control, lacking the ability to accurately monitor and adjust the motor's real-time status. This results in the inability to effectively synchronize the relationship between the motor's output torque and the cable traction speed during cable traction, easily leading to problems such as uneven cable winding and unstable traction speed.

[0006] Insufficient preload adjustment: Existing technologies lack real-time monitoring and adjustment methods for preload adjustment, making it difficult to maintain the preload within a reasonable range during cable winding. This can cause instability and unevenness in the cable during winding.

[0007] Lack of intelligent synchronous storage control: The existing cable traction operation method relies on manual coordination, which has problems such as low efficiency, easy error and poor safety.

[0008] Lack of high-precision motor control strategies: Existing motor control strategies are relatively simple and lack high-precision control methods. During cable traction, the lack of real-time monitoring and accurate adjustment of the motor status can easily lead to system instability and unsatisfactory traction performance.

[0009] Cumbersome operating procedures: Some existing technologies involve cumbersome operating procedures, requiring a large number of personnel to work together. This not only increases labor costs but also affects operational efficiency and safety. Summary of the Invention

[0010] The problem this invention aims to solve is to achieve synchronous, uniform, and efficient cable traction wire rope retraction by employing closed-loop torque motor control technology. This is achieved through real-time monitoring of motor status, control of torque and speed, and intelligent adjustment of preload. Simultaneously, by using a least-squares motor control strategy to fit sample data and calculate the relationship function, the intelligent synchronous retraction control method for cable traction wire ropes improves control accuracy and robustness.

[0011] To address the above problems, this invention provides an intelligent synchronous retraction control method for cable traction wire ropes, comprising the following steps:

[0012] S1. Intelligent control of the motor is achieved through closed-loop torque motor control, wherein the motor speed range is 0 to 100% of the rated speed;

[0013] S2. Use a take-up reel to synchronously take in the cable traction wire rope. The take-up reel connected to the take-up reel rotates at a speed that is always greater than the cable traction speed from shallow reel to full reel. The torque value is infinitely adjustable and the preload is kept within a reasonable range. By controlling the torque and speed, it is ensured that the speed is always greater than the cable traction speed throughout the entire take-up process.

[0014] S3. Use a preload sensor to monitor and adjust the preload in real time to keep the preload within a reasonable range;

[0015] S4. One-button sequential control is achieved through a combination of PLC and AC servo motor. The motor control strategy based on the least squares method is as follows:

[0016] s41. Set the preload value F0, the initial value of the take-up reel radius x0, and start the intelligent wire rope take-up device;

[0017] s42. Based on the least squares method, fit the output tension F and calculate the torque T in real time;

[0018] s43. Real-time calculation of parameters such as the radius x of the take-up reel and the motor speed, and control of the servo motor through the encoder and PLC;

[0019] s44. Determine if the coil is full. If it is, end the process; otherwise, return to step two.

[0020] Preferably, the motor control strategy based on the least squares method obtains the relationship function by fitting sample data, wherein the sample data consists of n pairs of linearly correlated sample data, and the sample data are (x1, y2), (x1, y2)..., (x... i ,y i ), …(x n ,y n ).

[0021] Preferably, the calculation formula for the motor control strategy based on the least squares method is as follows:

[0022]

[0023] Where x is the radius of the take-up reel, and y is the winding force of the take-up device. The average value of the radius. This represents the average tension value.

[0024] Preferably, the calculation formula for the motor control strategy based on the least squares method is further as follows:

[0025] T = F * x

[0026] F = y + F0

[0027] Where T is the torque, F is the tension value, and F0 is the preload value. Given the radius x of the take-up reel and the preload value F0, the torque T and the tension value F can be calculated.

[0028] Preferably, when satisfying In the minimum case, the fitted function is y = ax + b.

[0029] Preferably, the take-up device has the function of real-time calculation of the diameter of the take-up reel. The pulse is output to the PLC through the servo driver, and the PLC performs high-speed pulse counting to calculate the diameter of the take-up reel in real time.

[0030] Preferably, the servo driver provides the output torque as a percentage, ensuring that the ratio of the motor output torque to the rated torque remains within the set range throughout the entire winding process.

[0031] Compared with the prior art, the present invention achieves the following beneficial technical effects:

[0032] 1. Closed-loop torque motor control: This invention employs a closed-loop torque motor control method, which monitors the motor status in real time. By controlling torque and speed, it effectively solves the problem that existing motor control technologies often use open-loop methods, lacking the ability to accurately monitor and adjust the motor's real-time status. This helps ensure effective synchronous control of the motor output torque and cable traction speed, reducing the risks of uneven cable winding and unstable traction speed.

[0033] 2. Intelligent Preload Adjustment: This invention uses a preload sensor to monitor and adjust the preload in real time, ensuring that the preload remains within a reasonable range during cable winding. Compared to existing technologies that lack real-time monitoring and adjustment methods for preload regulation, this invention improves the control precision of the preload, helping to maintain the stability and uniformity of the cable during winding.

[0034] 3. Least Squares-Based Motor Control Strategy: This invention employs a least squares-based motor control strategy. By fitting sample data to obtain the relationship function, the control accuracy and robustness are improved. This strategy helps adapt to the motor control requirements under different operating conditions, enhancing the system's reliability and stability.

[0035] 4. One-button sequential control function: This invention achieves one-button sequential control through the combination of PLC and AC servo motor, simplifying operation steps, improving the accuracy of device control, reducing the number of components and overall weight, while increasing human-machine interaction. This is beneficial to improving the safety and economic efficiency of cable laying operations.

[0036] 5. Automation replaces manual operation: This invention replaces traditional manual coordination operation with automation technology, realizes intelligent synchronous storage control of cable traction wire rope, reduces operational risks, improves safety, and can replace multiple operators, thereby improving the efficiency of cable laying. Attached Figure Description

[0037] Figure 1 This is a schematic diagram illustrating the steps of the intelligent synchronous storage control method for cable traction wire rope of the present invention.

[0038] Figure 2 This is a flowchart illustrating the intelligent synchronous storage control method for cable traction steel wire rope of the present invention.

[0039] Figure 3 This is a control principle diagram for data exchange between a PLC and a servo driver.

[0040] Figure 4 This is a control principle diagram that uses a counter to record the number of revolutions of the take-up reel in real time.

[0041] Figure 5 This is a schematic diagram illustrating the method for real-time calculation of the diameter of the take-up reel.

[0042] Figure 6 This is a schematic diagram illustrating the principle of closed-loop torque motor control technology.

[0043] Figure 7 This is a schematic diagram illustrating the principle of inching control mode. Detailed Implementation

[0044] The present invention will be further explained and described below with reference to the accompanying drawings and embodiments.

[0045] Example 1: Refer to Figure 1 , 2 As shown, a method for intelligent synchronous retraction control of cable traction wire rope includes the following steps:

[0046] S1. Intelligent control of the motor is achieved through closed-loop torque motor control, wherein the motor speed range is 0 to 100% of the rated speed;

[0047] S2. Use a take-up reel to synchronously take in the cable traction wire rope. The take-up reel connected to the take-up reel rotates at a speed that is always greater than the cable traction speed from shallow reel to full reel. The torque value is infinitely adjustable and the preload is kept within a reasonable range. By controlling the torque and speed, it is ensured that the speed is always greater than the cable traction speed throughout the entire take-up process.

[0048] S3. Use a preload sensor to monitor and adjust the preload in real time to keep the preload within a reasonable range;

[0049] S4. One-button sequential control is achieved through a combination of PLC and AC servo motor. The motor control strategy based on the least squares method is as follows:

[0050] s41. Set the preload value F0, the initial value of the take-up reel radius x0, and start the intelligent wire rope take-up device;

[0051] s42. Based on the least squares method, fit the output tension F and calculate the torque T in real time;

[0052] s43. Real-time calculation of parameters such as the radius x of the take-up reel and the motor speed, and control of the servo motor through the encoder and PLC;

[0053] s44. Determine if the coil is full. If it is, end the process; otherwise, return to step two.

[0054] The motor control strategy based on the least squares method obtains the relationship function by fitting sample data. The sample data consists of n pairs of linearly correlated sample data, namely (x1, y2), (x1, y2)...

[0055] (x i ,y i ), …(x n ,yn ).

[0056] The calculation formula for the motor control strategy based on the least squares method is as follows:

[0057]

[0058] Where x is the radius of the take-up reel, and y is the winding force of the take-up device. The average value of the radius. This represents the average tension value.

[0059] The calculation formula for the motor control strategy based on the least squares method is also as follows:

[0060] T = F * x

[0061] F = y + F0

[0062] Where T is the torque, F is the tension value, and F0 is the preload value. Given the radius x of the take-up reel and the preload value F0, the torque T and the tension value F can be calculated.

[0063] In satisfying In the minimum case, the fitted function is y = ax + b.

[0064] In this embodiment, the control box is equipped with a servo driver, a PLC control unit, a human-machine interface, a master switch, and a DC power supply module. The remote control has buttons for emergency stop, start, forward jog, reverse jog, tension increase, and tension decrease. The effective remote control distance reaches 100 meters. The power supply is a 220V single-phase AC power supply, including an energy storage battery, a single-phase AC generator, and single-phase mains power.

[0065] This embodiment uses a PLC and a servo driver for data exchange, refer to... Figure 3 As shown, the communication mainly involves the exchange of two types of data:

[0066] The system reads the actual operating torque and displays the data on the HMI (Human Machine Interface). It also writes the percentage of the real-time given torque and displays the data on the HMI. Communication is via RS485 serial port using the MODBUS-RTU protocol. Communication begins as soon as the device is powered on.

[0067] Reference Figure 4 As shown, this embodiment uses a counting method to record the number of revolutions of the take-up reel in real time, providing parameters for torque calculation, including the following steps:

[0068] (1) Start counting when the device starts running and perform increment counting operation.

[0069] (2) Counting stops when the equipment stops.

[0070] (3) When the equipment stops and the take-up reel is removed (when the unloading sensor detects a signal), the current count is reset to zero. (4) When the take-up reel is reinstalled and the equipment is started, the count restarts.

[0071] Reference Figure 5 As shown, the calculation method in this embodiment includes the following steps:

[0072] (1) Count the actual required tension based on the set tension value (kg) and the actual diameter on the take-up reel (i.e., the I-beam reel); calculate the real-time torque given percentage (%) based on the rated torque of the motor and the reduction ratio of the reducer.

[0073] (2) Equipment nominal values: servo motor power: 1.3KW, servo motor rated torque: 8.2766NM, servo motor rated speed: 1500R / min, reducer reduction ratio: 55, torque conversion efficiency: 0.7.

[0074] (3) No-load torque: Calculate the rated output torque of the equipment when it is unloaded (i.e., without the take-up reel) = 9550 * power / (output speed) * torque conversion efficiency. That is, the no-load rated torque = 9550 * 1.3 / (1500 / 55) * 0.7 ≈ 318 N.M. Or, the no-load rated torque = motor rated torque * reducer reduction ratio * torque conversion efficiency. That is, the no-load rated torque = 8.2766 * 55 * 0.7 ≈ 318 N.M.

[0075] (4) Rated traction force of empty take-up reel: N = rated torque under no load * (2 / diameter of empty reel 0.32m) i.e. 318 * (2 / 0.32) = 1987.5N, traction force N converted to KG = 1987.5 / 9.8 ≈ 200KG.

[0076] (5) Calculate the full diameter of the take-up reel: The width of the take-up reel is 400mm, and the diameter of the wire rope is 14mm. The total length of the wire rope is 100m. 400mm / 14mm≈28 turns, that is, every 28 turns of the take-up reel constitute one layer, and the diameter of the take-up reel increases by 28mm. The average length of each turn is 1m, so the length of the wire rope for each layer is 28m, 100 / 28≈4 layers. Therefore, the diameter of the take-up reel when full is 320mm + 28mm * 4 = 432mm. Due to the cable arrangement problem, the estimated full diameter is 500mm, which is 0.5m.

[0077] (6) Rated traction force of fully loaded reel: traction force of empty reel N = rated torque under no load * (2 / diameter of empty reel 0.5m) i.e. 318 * (2 / 0.5) = 1272N, traction force N converted to KG = 1272 / 9.8 ≈ 130KG.

[0078] (7) If the constant tension is required to be 20KG, then the servo motor output torque % when the reel is empty = 20KG / 200KG = 10%, and the servo motor output torque % when the reel is full = 20KG / 130KG = 15%. Considering the weight of the wire rope, a coefficient of 1.3 is needed when the reel is full, i.e., 15% * 1.3 ≈ 20%. Conclusion: When the constant tension is required to be 20KG, the servo motor output torque ratio is 10%-20%.

[0079] (8) Finally, based on the increase in the number of rotations of the I-beam wheel during actual operation, the output torque ratio of the servo motor increases proportionally from 10% to 20%.

[0080] This embodiment employs closed-loop torque motor control technology, referring to... Figure 6 As shown, under fault-free conditions and when the equipment is not in a jogging process, the operation control can be activated. During operation, it operates in torque mode, with the torque setpoint calculated by the subsequent program. Operation is unidirectional; stopping requires pressing the stop button. In emergencies, pressing the emergency stop button will immediately halt operation. The speed control range is 0-100% of the rated speed, and the preload range is determined by actual measurement. During operation, the intelligent control system maintains the torque and speed of the take-up reel. From shallow to full reel, the speed is consistently greater than the cable traction speed. The torque is infinitely adjustable, and the preload is kept within the set range.

[0081] In this embodiment, the diameter of the take-up reel is calculated in real time. The servo driver outputs pulses to the PLC, which performs high-speed pulse counting to calculate the diameter of the take-up reel in real time. Assuming the diameter of the empty bottom of the take-up reel is 320mm, the width of the reel is 390mm, and the diameter of the wire rope is 13mm, then 390 / 13=30. For every 30 rotations of the take-up reel, the diameter of the take-up reel increases by 26mm for each layer. Therefore, the real-time diameter of the take-up reel = current rotations / 30 * 26 + 320mm.

[0082] This embodiment uses a servo driver to control the output torque, which is given as a percentage of the rated torque. If the servo motor has a rated power of 1.3kW, a rated output torque of 8.34NM, and a rated speed of 1500R / min, and assuming the wire rope preload can be set to 200N, when the take-up reel is shallow, the servo motor's output torque is 20 / 147*8.3 = 1.13NM, which is 13.7% of the motor's rated torque. When the take-up reel is full, the servo motor's output torque is 20 / 78*8.3 = 2.13NM, which is 25.7% of the motor's rated torque. Similarly, assuming the wire rope preload can be set to 400N, the percentage range of the motor's output torque to the rated torque from shallow to full is 27.4%-51.4%.

[0083] The test results for this embodiment are as follows:

[0084] Serial Number Number of workers at cable pulling station (persons) Wire rope uniformity (thickest layer - thinnest layer) Remark Before applying this invention 3 5 After applying this invention 1 1

[0085] Under the precise control of PLC and AC servo motor, the pretension of the wire rope between the cable traction winch and the present invention is maintained within a set range, realizing the synchronous winding of the cable traction wire rope, replacing one operator who previously operated the tail rope of the traction winch; the wire guide and the take-up device work together, with the wire guide pushing the wire rope to move back and forth, realizing the uniform distribution of the wire rope on the take-up reel, replacing one operator who previously operated the rolling take-up reel, and adding the function of uniformly winding the wire rope.

[0086] Example 2: Refer to Figure 7 As shown, this embodiment is basically the same as Embodiment 1, except that: this embodiment adopts a jog control mode for manual control of the release and rewinding of the cable traction wire rope. Through the human-machine interface of the control box, the speed control mode of the servo driver can be switched and the drive motor parameters can be set. The operator can use the jog button to control the forward and reverse rotation of the take-up coil. In this mode, jogging can be operated via remote control buttons or via the master switch of the control box. Under fault-free conditions and when the equipment is not running, jog control is possible at a fixed speed, allowing for jogging in both directions, with the two directions interlocked.

[0087] Example 3: This example is basically the same as Example 2, except that: in this example, the cable traction wire rope is released in conjunction with the remote control or the master switch of the control box. The drive motor works in reverse mode, and the cable traction wire rope is released directly from the take-up device without passing through the cable guide, thus achieving efficient release of the cable traction wire rope.

[0088] To facilitate understanding of the above technical solutions of the present invention, the following detailed description of the above technical solutions of the present invention will be provided through specific usage methods.

[0089] The specific work process is as follows:

[0090] Step 1, Pre-work preparation: The operator pushes the device to a suitable position, unfolds the folding support legs to support the ground, and installs the empty take-up reel.

[0091] Step 2, Pre-operation preparation: The operator passes the wire rope through the cable guide and connects it to the take-up reel.

[0092] Step 3: Start the intelligent synchronous take-up device for cable traction wire rope: The operator sets the preload value F0, the initial value of the take-up reel radius x0, and presses the one-button sequential start button on the master switch of the control box.

[0093] Step four, cable pulling: The operator operates the cable pulling winch, paying attention to the wire rope segmentation point. If the wire rope passes the segmentation point through the winch and reaches the take-up reel, stop the machine immediately and proceed to the next step.

[0094] Step 5, Replace the take-up reel: The operator folds up the support legs to ensure the wire rope reel supports the ground, unlocks the pin device, removes the original take-up reel, installs the new take-up reel, and then proceeds to step 2 to continue the operation.

[0095] In the description of this invention, it should be noted that the terms "upper," "lower," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the 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 the invention. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two elements. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.

[0096] It should be noted that in this invention, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0097] The above description is merely a specific embodiment of the present invention, enabling those skilled in the art to understand or implement the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features of the invention described herein.

Claims

1. A method for intelligent synchronous storage and control of cable traction wire rope, characterized in that, Includes the following steps: S1. Intelligent control of the motor is achieved through closed-loop torque motor control, wherein the motor speed range is 0~100% of the rated speed; S2. Use a take-up reel to synchronously take in the cable traction wire rope. The take-up reel connected to the take-up reel rotates at a speed that is always greater than the cable traction speed from shallow reel to full reel. The torque value is infinitely adjustable and the preload is kept within a reasonable range. By controlling the torque and speed, it is ensured that the speed is always greater than the cable traction speed throughout the entire take-up process. S3. Use a preload sensor to monitor and adjust the preload in real time to keep the preload within a reasonable range; S4. One-button sequential control is achieved through a combination of PLC and AC servo motor. The motor control strategy based on the least squares method is as follows: s41. Set the preload value F0, the initial value of the take-up reel radius x0, and start the intelligent wire rope take-up device; s42. Based on the least squares method, fit the output tension F and calculate the torque T in real time; s43. Real-time calculation of parameters such as the radius x of the take-up reel and the motor speed, and control of the servo motor through the encoder and PLC; s44. Determine the closing position of the coil. If it is full, end the process; otherwise, return to step two. The motor control strategy based on the least squares method obtains the relationship function by fitting sample data. The sample data consists of n pairs of linearly correlated sample data, namely (x1, y1), (x2, y2), ..., (x...). i ,y i ), ...(x n ,y n ); The calculation formula for the motor control strategy based on the least squares method is as follows: ; Where x is the radius of the take-up reel, and y is the winding force of the take-up device. The average value of the radius. This represents the average tension. The calculation formula for the motor control strategy based on the least squares method is also as follows: T=F*x F=y+F0 Where T is the torque, F is the tension value, and F0 is the preload value. Given the radius x of the take-up reel and the preload value F0, the torque T and the tension value F can be calculated. In satisfying In the minimum case, the fitted function is y = ax + b.

2. The intelligent synchronous storage control method for cable traction wire rope according to claim 1, characterized in that, The take-up device has the function of calculating the diameter of the take-up reel in real time. It outputs pulses to the PLC through a servo driver, and the PLC performs high-speed pulse counting to calculate the diameter of the take-up reel in real time.

3. The intelligent synchronous storage control method for cable traction wire rope according to claim 2, characterized in that, The servo driver provides the output torque as a percentage, ensuring that the ratio of the motor output torque to the rated torque remains within the set range throughout the entire winding process.

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