A device and method for monitoring damage to folding cable trays

Abstract

This invention relates to a device and method for monitoring damage to folding cable trays. The device includes a tension sensor and a control module. The folding cable tray comprises multiple cable tray sections connected sequentially. The ends of adjacent cable tray sections are connected to each other by angle pins. The angle pins on both sides of the top cable tray section are connected to the cable tray fixing points via top steel wire ropes. The tension sensor is fixed to the top steel wire rope and connected to the control module. Each cable tray section has a fixing shackle and a connecting steel wire rope on both sides. The upper end of each connecting steel wire rope is fitted onto the previous connecting steel wire rope or the top steel wire rope via a fixing shackle, and the lower end of each connecting steel wire rope is fixed to the angle pin at the bottom of the corresponding cable tray section. The control module collects the tension value transmitted by the tension sensor in real time. If the tension value exceeds a preset alarm limit, an equipment alarm signal is generated. Compared with the prior art, this invention can achieve rapid alarm of the folding cable tray damage status, improving the safety of equipment operation.

Description

Technical Field

[0001] This invention relates to the field of folding cable tray monitoring technology, and in particular to a folding cable tray damage monitoring device and method. Background Technology

[0002] like Figure 1 As shown, the folding cable tray, as a key piece of equipment connecting the hoisting system, determines the safe and stable operation of the entire hoisting system during hoisting and lowering. Existing folding cable trays only use angle pins to fix the top wire rope as the stress point, with the entire weight of the folding cable tray acting on the wire rope. During operation, the angle pins are prone to detachment or the connecting angle pins of the folding cable tray may fall off. However, there are no clear indicators to show whether a malfunction has occurred in the use of existing folding cable trays.

[0003] If the fixing pins or connecting pins of the folding cable tray fall off, the weight of the entire or part of the folding cable tray will be applied to the cable connected to the hoisting system, causing the cable to be stressed and damaged. In severe cases, the entire folding cable tray may fall off, resulting in a major safety accident. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art, which lacks clear criteria for judging whether a fault has occurred during the use of folding cable trays, and to provide a folding cable tray damage monitoring device and method.

[0005] The objective of this invention can be achieved through the following technical solutions:

[0006] A folding cable tray damage monitoring device includes a tension sensor and a control module. The folding cable tray includes multiple cable tray sections connected in sequence. The two ends of two adjacent cable tray sections are connected to each other by corner pins. The corner pins on both sides of the cable tray section at the top of the folding cable tray are respectively connected to the cable tray fixing point by a top steel wire rope. The tension sensor is fixed on the top steel wire rope and connected to the control module.

[0007] Each cable tray section has a fixing shackle and a connecting wire rope on both sides. The upper end of each connecting wire rope is sleeved on the connecting wire rope above or the top wire rope through the fixing shackle, and the lower end of each connecting wire rope is fixed to the corner pin at the bottom of the corresponding cable tray section.

[0008] The control module collects the tension value transmitted by the tension sensor in real time. If the tension value is greater than the preset alarm limit, an alarm signal is generated.

[0009] Furthermore, the length of the top wire rope, and the total length of each connecting wire rope and the connecting fixing ring, are all within 1.05 to 1.5 times the length of the corresponding cable tray section, so that each fixing ring has a certain degree of freedom.

[0010] Furthermore, the control module is an electrical control circuit or a PLC control module, used to determine whether the folding cable tray is damaged based on changes in tension values.

[0011] Furthermore, the number of tension sensors is at least two, which are respectively fixed on the top steel wire ropes on both sides of the top bridge section of the folding bridge.

[0012] Furthermore, when one side of a cable tray section is damaged and disconnected from the main body of the folding cable tray, the cable tray sections below that section fall due to gravity. This causes the connecting wire rope on the damaged side of the cable tray section to be tightened, and through the fixing clasp, it causes the connecting wire rope above to be tightened. The tension is then transmitted from bottom to top through each connecting wire rope until the top wire rope on the corresponding side is tightened. This causes the gravity of the cable tray sections below that section to act on the tension sensor of the top wire rope, and the resulting tension value triggers the control module to generate an alarm signal.

[0013] Furthermore, the tension sensor is a pressure-side tension sensor.

[0014] The present invention also provides a method for monitoring damage to folded cable trays using a folded cable tray damage monitoring device as described above, comprising the following steps:

[0015] Install tension sensors, fixing rings, and connecting wire ropes on the folding cable tray, and connect the data output terminal of the tension sensor to the control module;

[0016] The folding cable tray is raised and lowered sequentially, and the range of changes in the tension sensor values ​​is recorded to determine the baseline value of the tension value.

[0017] Set the alarm limit of the tension sensor according to the reference value;

[0018] The system collects tension values ​​transmitted by the tension sensor in real time and compares these values ​​with alarm limits. If the tension value exceeds the alarm limit, an alarm signal is generated.

[0019] Furthermore, during the setting of the alarm limit, the folding cable tray in normal condition is repeatedly used to observe the changes in the tension sensor value. If an alarm is triggered, the alarm limit is reset until the monitoring device for damage to the folding cable tray is operating normally.

[0020] Furthermore, the method also includes: if the tension value of the tension sensor collected in real time triggers an alarm, then the tension value is compared with the tension value range corresponding to the breakage of each cable tray section to determine the tension value range corresponding to the tension value, thereby predicting the damage location of the folding cable tray.

[0021] Furthermore, the method for obtaining the tension value range corresponding to the fracture of each cable tray section includes: generating a mathematical model by recording the tension alarm values ​​corresponding to the fracture of different cable tray sections, and determining the tension value range corresponding to the fracture of each cable tray section.

[0022] Compared with the prior art, the present invention has the following advantages:

[0023] (1) The present invention adds connecting steel wire ropes at each section of the folding bridge frame. The upper end of each connecting steel wire rope is sleeved on the previous section of steel wire rope by a fixing clasp, and the lower end is fixed on the corresponding angle pin. A side pressure tension sensor is installed on the top steel wire rope.

[0024] When the folding cable tray breaks, on the one hand, the connecting steel wire rope at the break point is tightened by force, and the fixed clasp drives the connecting steel wire rope above to be tightened by force, which is transmitted from bottom to top to the top steel wire rope. The tension sensor on the top steel wire rope monitors the tension of the steel wire rope in real time. When the folding cable tray breaks, the monitored tension of the steel wire rope will increase, thus triggering an alarm.

[0025] On the other hand, when the folding cable tray breaks, the added connecting steel wire rope can serve as a backup temporary protective cable to prevent the cable from being damaged by external forces, thus preventing the accident from spreading, threatening equipment operation, and buying time for maintenance personnel to carry out emergency repairs.

[0026] (2) The present invention can determine the different numerical ranges corresponding to the tension sensor when damage occurs at different cable tray connections. Thus, when a damage alarm value is actually measured, the alarm tension value is matched with the numerical range to roughly determine the location of the damage to the folding cable tray. From the perspective of installation and practicality, this invention greatly improves work efficiency and saves manpower. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of a folding cable tray provided in the background art of the present invention;

[0028] Figure 2 This is a schematic diagram of the structure of a folding cable tray damage monitoring device provided in an embodiment of the present invention;

[0029] Figure 3 This is a partial structural side view of a folding cable tray damage monitoring device provided in an embodiment of the present invention;

[0030] In the diagram, 1 is the tension sensor, 2 is the retaining ring, 3 is the connecting wire rope, 4 is the folding cable tray, 5 is the cable tray fixing point, and 6 is the angle pin. Detailed Implementation

[0031] 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.

[0032] 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.

[0033] 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.

[0034] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., 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 during use. 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. Therefore, they should not be construed as limitations on this invention.

[0035] It should be noted that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0036] Furthermore, terms such as "horizontal" and "vertical" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0037] Example 1

[0038] like Figure 2 and Figure 3 As shown, this embodiment provides a folding cable tray damage monitoring device, including a tension sensor 1 and a control module. The folding cable tray 4 includes multiple cable tray sections connected in sequence. The two ends of two adjacent cable tray sections are connected to each other by corner pins 6. The corner pins 6 on both sides of the cable tray section at the top of the folding cable tray 4 are respectively connected to the cable tray fixing point 5 by the top steel wire rope. The tension sensor 1 is fixed on the top steel wire rope and connected to the control module.

[0039] Each cable tray section is equipped with a fixing ring 2 and a connecting wire rope 3 on both sides. The upper end of each connecting wire rope 3 is sleeved on the previous connecting wire rope 3 or the top wire rope through the fixing ring 2, and the lower end of each connecting wire rope 3 is fixed on the corner pin 6 at the bottom of the corresponding cable tray section.

[0040] The control module collects the tension value transmitted by tension sensor 1 in real time. If the tension value is greater than the preset alarm limit, an alarm signal is generated.

[0041] In contrast, in the existing solution, the sections of the folding cable tray are connected by corner pins to allow for vertical movement. In this solution, a fixing ring is added at the connection point of each section of the folding cable tray. Adjacent sections of the folding cable tray are connected by steel wire ropes. The upper end of the next section of steel wire rope is fixed to the previous section of steel wire rope by a fixing ring. The fixing ring on the steel wire rope has a certain degree of freedom to prevent jamming during the lifting and lowering of the folding cable tray.

[0042] The pressure-side tension sensor is fixed to the top steel wire rope. By adding this sensor, the fault detection of the folding cable tray is achieved: During normal operation, all sections of the steel wire rope are not under stress, and the tension sensor reading is normal. When the folding cable tray malfunctions, the steel wire rope becomes tensile due to gravity, the tension sensor reading increases, the equipment alarms, and operation stops.

[0043] Specifically, the length of the top wire rope, and the total length of each connecting wire rope 3 and the connecting fixing ring 2, are all within 1.05 to 1.5 times the length of the corresponding cable tray section, so that each fixing ring 2 has a certain degree of freedom.

[0044] There are at least two tension sensors 1, which are fixed on the top steel wire ropes on both sides of the top section of the folding cable tray 4.

[0045] The tension sensor 1 can be a strain gauge sensor, capacitive sensor, inductive sensor, resistive sensor, or pressure-side tension sensor, etc., which can measure the tension of the wire rope. In this embodiment, a pressure-side tension sensor is used.

[0046] Optionally, the control module is an electrical control circuit or a PLC control module, used to determine whether the folding cable tray 4 is damaged based on changes in tension values.

[0047] Working principle: When one side of a cable tray section is damaged and disconnected from the main body of the folding cable tray 4, the cable tray sections below that section fall due to gravity, causing the connecting steel wire rope 3 on the damaged side of the cable tray section to be tightened. This tightens the connecting steel wire rope 3 above the damaged section through the fixing ring 2, and the tension is transmitted from bottom to top through each connecting steel wire rope 3 until the top steel wire rope on the corresponding side is tightened. This causes the gravity of the cable tray sections below that section to act on the tension sensor 1 of the top steel wire rope, and the resulting tension value triggers the control module to generate an alarm signal.

[0048] Example:

[0049] When the left-side connection between the 1st and 2nd folding cable trays is damaged and detached, all the cable trays starting from the 2nd section fall downwards due to gravity. The second section of the steel wire rope on the left (from top to bottom) is tightened, simultaneously tightening the first section of the steel wire rope on the left. The corresponding tension sensor reading changes. At this point, the weight of all the cable trays starting from the 2nd section will act on the tension sensor on the left through the tension of the steel wire ropes. The tension sensor reading at this time reflects the force exerted on all the cable trays starting from the 2nd section, thus allowing the determination of whether the folding cable tray is damaged based on the change in the tension sensor reading. Similarly, when the connection between the 2nd and 3rd folding cable trays is damaged, the third section of the steel wire rope on the left (from top to bottom) is tightened, simultaneously tightening the second and first sections of the steel wire rope on the left. The corresponding tension sensor reading changes, reflecting the force exerted on all the cable trays starting from the 3rd section. This pattern continues, and the folding cable tray has a total of 16 sections.

[0050] The same applies to the right side.

[0051] Example 2

[0052] This embodiment provides a method for monitoring damage to folded cable trays using a folded cable tray damage monitoring device as described in Embodiment 1, including the following steps:

[0053] Install tension sensor 1, fixing ring 2 and connecting wire rope 3 on folding cable tray 4, and connect the data output terminal of tension sensor 1 to control module;

[0054] The folding cable tray 4 is raised and lowered sequentially, and the range of changes in the tension sensor 1 is recorded to determine the reference value of the tension value.

[0055] Set the alarm limit for tension sensor 1 according to the reference value;

[0056] The tension value transmitted by tension sensor 1 is collected in real time. The collected tension value is compared with the alarm limit. If the tension value is greater than the alarm limit, an alarm signal is generated.

[0057] Optionally, during the alarm limit setting process, the folding cable tray 4 in normal state is repeatedly used to observe the value change of the tension sensor 1. If an alarm is triggered, the alarm limit is reset until the monitoring device is operating normally after the folding cable tray is damaged.

[0058] This embodiment provides a process example of the above method, as follows:

[0059] S1: Install wire rope, fixing shackle, and side-pressure tension sensor;

[0060] S2: Signal access to the coal conveying control system;

[0061] S3: According to the actual situation on site, raise and lower the folding cable tray in sequence, and record the range of change of tension sensor values ​​(baseline value);

[0062] S4: Set the alarm limit for the tension sensor based on the reference value;

[0063] S5: Start the equipment and observe the change in tension sensor readings to check for alarms. If the equipment is operating normally, put it into use. If an alarm sounds, return to S4.

[0064] S6: Repeat S4 to S5 until the equipment is operating normally.

[0065] Preferably, the method further includes: if the tension value of the tension sensor 1 collected in real time triggers an alarm, then the tension value is compared with the tension value range corresponding to the breakage of each cable tray section to determine the tension value range corresponding to the tension value, thereby predicting the damage location of the folding cable tray 4.

[0066] The method for obtaining the tension value range corresponding to the fracture of each cable tray section includes: generating a mathematical model by recording the tension alarm values ​​corresponding to the fracture of different cable tray sections, and determining the tension value range corresponding to the fracture of each cable tray section.

[0067] That is, when damage occurs at different cable tray connections, the location of the damage to the folding cable tray can be roughly determined by the different value ranges of the tension sensor. Different fault points can be identified by a single sensor, which greatly improves work efficiency and saves manpower in terms of installation and practicality.

[0068] The numerical range can be obtained by long-term monitoring and recording the tension alarm values ​​of different cable tray detachments. This can generate a mathematical model to help maintenance personnel accurately determine which specific section of equipment has malfunctioned and detached.

[0069] The preferred embodiments of the present invention have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of the present invention without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of the present invention through logical analysis, reasoning, or limited experimentation on the basis of existing technology should be within the scope of protection defined by the claims.

Claims

1. A folding cable tray damage monitoring device, characterized in that, The folding cable tray (4) includes a tension sensor (1) and a control module. The folding cable tray (4) includes multiple cable tray sections connected in sequence. The two ends of two adjacent cable tray sections are connected to each other by corner pins (6). The corner pins (6) on both sides of the cable tray section at the top of the folding cable tray (4) are respectively connected to the cable tray fixing point (5) by the top steel wire rope. The tension sensor (1) is fixed on the top steel wire rope and connected to the control module. Each cable tray section is provided with a fixing ring (2) and a connecting wire rope (3) on both sides. The upper end of each connecting wire rope (3) is sleeved on the upper connecting wire rope (3) or the top wire rope through the fixing ring (2). The lower end of each connecting wire rope (3) is fixed on the corner pin (6) at the bottom of the corresponding cable tray section. The control module collects the tension value transmitted by the tension sensor (1) in real time. If the tension value is greater than the preset alarm limit, an alarm signal is generated. When one side of a cable tray section is damaged and disconnected from the main body of the folding cable tray (4), the cable tray sections below that section fall due to gravity, causing the connecting steel wire rope (3) on the damaged side of the cable tray section to be tightened. It also drives the connecting steel wire rope (3) above to be tightened through the fixing ring (2), and the tension is transmitted from bottom to top through each connecting steel wire rope (3) until the top steel wire rope on the corresponding side is tightened. This causes the gravity of the cable tray section below that section to act on the tension sensor (1) of the top steel wire rope, and the resulting tension value triggers the control module to generate an alarm signal.

2. The folding cable tray damage monitoring device according to claim 1, characterized in that, The length of the top wire rope, and the total length of each connecting wire rope (3) and the connecting fixing ring (2), are all within 1.05 to 1.5 times the length of the corresponding bridge section, so that each fixing ring (2) has a certain degree of freedom.

3. The folding cable tray damage monitoring device according to claim 1, characterized in that, The control module is an electrical control circuit or a PLC control module, used to determine whether the folding cable tray (4) is damaged based on the change in tension value.

4. The folding cable tray damage monitoring device according to claim 1, characterized in that, The number of tension sensors (1) is at least two, which are fixed on the top wire ropes on both sides of the top bridge section of the folding bridge (4).

5. The folding cable tray damage monitoring device according to claim 1, characterized in that, The tension sensor (1) is a side-pressure type tension sensor.

6. A method for monitoring damage to folding cable trays using a folding cable tray damage monitoring device as described in any one of claims 1-5, characterized in that, Includes the following steps: Install a tension sensor (1), a fixing ring (2), and a connecting wire rope (3) on the folding cable tray (4), and connect the data output terminal of the tension sensor (1) to the control module; The folding bridge frame (4) is raised and lowered sequentially, and the range of changes in the values ​​of the tension sensor (1) is recorded to determine the reference value of the tension value. The alarm limit of the tension sensor (1) is set according to the reference value; The tension value transmitted by the tension sensor (1) is collected in real time. The collected tension value is compared with the alarm limit. If the tension value is greater than the alarm limit, an alarm signal is generated.

7. The method according to claim 6, characterized in that, During the setting of the alarm limit, the folding cable tray (4) in normal state is repeatedly used to observe the change in the value of the tension sensor (1). If an alarm is triggered, the alarm limit is reset until the monitoring device for damage to the folding cable tray is operating normally.

8. The method according to claim 6, characterized in that, The method further includes: if the tension value of the tension sensor (1) collected in real time triggers an alarm, the tension value is compared with the tension value range corresponding to the breakage of each cable tray section to determine the tension value range corresponding to the tension value, thereby predicting the damage location of the folding cable tray (4).

9. The method according to claim 8, characterized in that, The method for obtaining the tension value range corresponding to the fracture of each cable tray section includes: generating a mathematical model by recording the tension alarm values ​​corresponding to the fracture of different cable tray sections, and determining the tension value range corresponding to the fracture of each cable tray section.

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