Device for self-balancing horizontal rotary manufacturing of cable loops

Abstract

The self-balancing horizontal rotary cable type ring cable manufacturing device comprises a strand rope winding system and a core rope tensioning transmission system; the strand rope winding system completes the ring motion of the strand rope wheel, and the core rope tensioning transmission system completes the ring motion of the core rope; the rotation centers of the strand rope winding system and the core rope tensioning transmission system are arranged in parallel to the ground, the strand rope winding system is arranged in a horizontal mode as a whole, the balance block of symmetrical rotation balancing solves the problem of rotation imbalance caused by the continuous consumption and weight reduction of the raw material strand rope wheel, the moment generated by the balance block is consistent with the moment generated by the weight of the spool at all times, the load of the power system is reduced, and the efficiency and stability of the operation of the device are improved. The portal necessary for the vertical rope winding machine is not needed, the height of the core replacement frame is not needed to be increased, the convenience of maintenance and repair is improved, the flexible core rope is used to wind the ring cable, and the problems, such as too large occupied space and complicated installation and disassembly caused by the use of the rigid core replacement, are avoided.

Description

Technical Field

[0001] This invention belongs to the field of wire rope rigging manufacturing technology, specifically relating to a device for self-balancing horizontal rotational manufacturing of cable-type ring ropes. Background Technology

[0002] A cable-type loop sling is a type of wire rope lifting sling, consisting of a continuous length of wire rope (referred to as "strand") wound around a specific loop core (referred to as "core rope") six times according to a specified lay length. Due to its good flexibility and high load-bearing capacity, it is widely used. Currently, the manufacturing process mainly relies on manual weaving, which suffers from problems such as high labor intensity, low production efficiency, unstable quality, and uneven stress relief. To improve the manufacturing method and enhance product quality, a self-balancing rotary device and method for manufacturing cable-type loop slings are designed. The method involves placing a full roll of strand rope in a rotating rope-laying device, allowing it to rotate continuously around a core rope. The strand rope is wound around the core rope (or other object) according to a certain pattern, with each turn forming a lay length. After completing one loop, a second loop is wound, continuing until the required number of loops are achieved. Finally, the core rope is replaced with strand rope, and the central rope end is tightly connected, forming an endless loop centered on the strand rope, i.e., a cable-type loop sling.

[0003] Cable-type ring cables have the advantages of good flexibility, high strength, long service life and small lifting space. They are widely used in marine engineering and large-tonnage lifting operations, and are especially suitable for lifting and installation operations with limited space.

[0004] Currently, most domestic manufacturers of cable ring cables use manual methods, resulting in low production efficiency, high costs, and unstable quality. Only a few manufacturers possess semi-automatic cable ring cable manufacturing equipment, but their output cannot keep up with market demand. As a result, my country still needs to import a large number of cable ring cables from abroad every year.

[0005] With the development of science and technology, several mechanical devices capable of semi-automatic winding and manufacturing of cable-like loops have emerged. These devices couple the two moving parts, the strand and the core rope. A circular track on a horizontal plane is used for the strand pulley's circular motion, with the pulley's axis of motion and rotation perpendicular to the ground. The core rope moves vertically through the center of the ring, and the pulley continuously releases rope, winding the strand onto the core rope at a specific lay length, thus manufacturing the cable-like loop. This type of loop manufacturing equipment is called a vertical loop manufacturing device. However, because the strand pulley generates centrifugal force during its circular motion on the track, operating at high speeds may cause it to detach. Therefore, high speeds are not permitted, limiting the overall production efficiency of the loop manufacturing process. Furthermore, the constantly changing center of gravity of the strand pulley during its circular motion on the track applies a periodically varying load to the support structure, which negatively impacts the stability and safety of the support. Due to the constraints of the strand pulley's movement track, the core rope's moving loops can only be arranged perpendicular to the ground. To support the flexible core rope's vertical arrangement and avoid the strand pulley and its auxiliary equipment, including the strand pulley and movement track, a gantry and guide wheels must be installed to support the core rope. This necessitates that at least one section of the core rope be installed on a high gantry and pass through multiple guide wheels, making the operation cumbersome. The core rope's inherent flexibility further complicates hoisting and poses certain safety risks; if the portion already wound on the core rope is suspended at a high position, it is inconvenient for easy inspection; equipment maintenance requires climbing to operate at heights, resulting in numerous inconveniences during use.

[0006] Existing vertical cable ring cable manufacturing equipment has disadvantages such as low production efficiency, cumbersome core rope disassembly and assembly, inability to check product quality at any time, and inconvenient maintenance. Therefore, how to overcome a series of disadvantages in the production process of vertical cable ring cables has become a problem that needs to be solved. Summary of the Invention

[0007] The purpose of this invention is to provide a self-balancing horizontal rotary manufacturing device for cable ring cables, which can efficiently produce cable ring cables, thereby solving the problems of cumbersome core rope disassembly and assembly and inconvenient maintenance in the process of manufacturing cable ring cables using vertical ring cable manufacturing equipment.

[0008] The technical solution adopted in this invention is a self-balancing horizontal rotary cable-like loop manufacturing device, comprising two main parts: a strand winding system and a core rope tensioning transmission system. The strand winding system completes the circular motion of the strand wheel, and the core rope tensioning transmission system completes the circular motion of the core rope. The rotation centers of the strand winding system and the core rope tensioning transmission system are arranged parallel to the ground. A variable-pitch counterweight device is configured at the opposite position of the strand wheel, and rotating blocks are symmetrically arranged. This solves the imbalance caused by the continuous release and weight reduction of the strand wheel, ensuring that the torque generated by the balancing device and the torque generated by the weight of the strand wheel remain consistent throughout the cable-like loop winding process, achieving high efficiency, stability, and safety in the cable-like loop manufacturing process.

[0009] The invention is further characterized in that,

[0010] The strand winding system mainly consists of three parts: a main drum, a turning frame, and a variable-pitch counterweight device. It is equipped with a power system that allows it to rotate independently (hereinafter referred to as "self-rotation"). After the strands of wire rope are fully wound onto the strand wheel, it is mounted on the turning frame. The turning frame is mounted on the main drum via bearing seats. The main drum is supported by a roller frame and driven by a motor and a reduction gearbox via a large gear ring, causing the turning frame on the main drum to rotate in a circular motion around the core rope (hereinafter referred to as "revolution"). The drive of the main drum and the drive of the turning frame are independent and can be controlled independently to meet the twisting / untwisting process requirements in the loop winding. The variable-pitch counterweight device consists of two symmetrically arranged sets of balance blocks. A pair of meshing synchronous gears are mounted on their rotating shafts, allowing the balance blocks to rotate symmetrically. At this time, the center of gravity of the counterweight device will move radially along the main drum. Changing the lever arm length of the counterweight device's center of gravity achieves real-time balance with the torque of the strand wheel, avoiding the need to stop the machine to add or remove balance blocks as required by conventional balancing methods, thus achieving uninterrupted operation during the winding process. A mechanical brake device is also installed on the connecting shaft between the rope sheave frame and the rope sheave to provide a certain tension for the winding loop cable and ensure the tightness of the strand winding. The turning frame and the variable pitch counterweight device are driven by power supply through slip rings.

[0011] Two parallel and symmetrical rotating shafts are connected between the two main rollers, with the rotating shafts arranged away from the turning frame. The main body of the variable pitch counterweight device includes two sets of hook-shaped balance blocks arranged symmetrically from left to right. Each set of balance blocks is fixedly connected to the rotating shaft in an up-and-down manner. A pair of meshing synchronous gears are installed at the end of the rotating shaft near one of the main rollers. The synchronous gears drive the rotating shaft to rotate, enabling the balance blocks to rotate symmetrically.

[0012] The strand pulley is also equipped with a mechanical brake device, which provides a certain damping for the release of the strand, generates tension on the strand, and controls the tightness of the strand winding on the core rope.

[0013] The centers of the two main rollers are connected by a hollow sleeve. An axial slit is provided at the upward position of the hollow sleeve. There is a through slot on the main roller for disassembling and assembling the core rope and the finished ring rope. The slot is connected to the slit. Each slot is provided with a detachable patch block. The patch block is equipped with a segmented large gear ring and a slip ring. The main roller, the large gear ring and the slip ring form a complete ring shape, ensuring that the continuous rotation of the main roller, the transmission of the large gear ring and the power supply of the slip ring are not affected by the through slot.

[0014] The core rope tensioning transmission system is responsible for supporting the core rope and the semi-finished cable loop as a whole, maintaining the shape and size of the finished cable loop, and realizing the overall transmission of the core rope and the semi-finished loop. The rotation speed and direction of all roller frames are consistent with the movement state of the core rope. It mainly includes a tensioning trolley, which can move on the track when winding the rope; the core rope passes through the hollow sleeve and wraps around the drive wheel and the tensioning wheel; the tensioning wheel is fixedly connected to the tensioning trolley by a bracket; the drive wheels are distributed on the outer side of the main drum; the tensioning wheel and the drive wheel are located on the same plane and at the same height as the hollow sleeve; the tensioning wheel maintains the tension of the core rope and the loop, and the drive wheel provides power to move the core rope and the loop.

[0015] The position and number of the drive wheel and tension wheel are adjusted according to the circumference of the ring cable.

[0016] A rope guide frame is installed at the rope hole of the turning frame.

[0017] The beneficial effects of this invention are:

[0018] 1. This invention employs a horizontal manufacturing device for cable-type ring cables. The rotation centers of the strand winding system and the core rope tensioning transmission system are arranged parallel to the ground, and the main drum can achieve a high working speed, thereby improving the production efficiency of cable-type ring cables.

[0019] 2. The variable pitch counterweight device used in this invention is positioned opposite the strand pulleys, and the balance blocks rotate symmetrically. This solves the imbalance problem caused by the continuous release of rope from the strand pulleys to reduce weight, ensuring that the torque generated by the counterweight is always consistent with the torque generated by the weight of the strand pulleys. This reduces the load on the power system and improves the efficiency and stability of the equipment operation.

[0020] 3. In the manufacture of the cable-type ring cable in this invention, a flexible core rope is used, which avoids the problems of excessive space occupation and complicated installation and disassembly caused by using a rigid core rope.

[0021] 4. This invention avoids the use of a vertical gantry structure, eliminates the need to elevate the core rope, avoids working at heights, and improves the convenience of maintenance and repair. At the same time, the semi-finished ring cable is close to the ground, which facilitates quality inspection of the ring cable during the production process. Attached Figure Description

[0022] Figure 1This is a schematic diagram of the structure of the self-balancing horizontal rotary manufacturing device for cable rings according to the present invention.

[0023] Figure 2 This is a schematic diagram of a strand winding system;

[0024] Figure 3 This is a schematic diagram of a variable pitch counterweight device;

[0025] Figure 4 This is a schematic diagram of the core tensioning transmission system;

[0026] Figure 5 This is a schematic diagram of the main roller.

[0027] In the diagram: 1. Strand winding system; 2. Core rope tensioning transmission system; 3. Main drum; 4. Strand pulley; 5. Turning frame; 6. Motor and reducer; 7. Variable pitch counterweight device; 8. Roller frame; 9. Large gear ring; 10. Balance block; 11. Synchronous gear; 12. Balance block drive device; 13. Slip ring; 14. Core rope; 15. Drive wheel; 16. Tensioning wheel; 17. Tensioning trolley; 18. Track; 19. Supplementing block; 20. Rope guide frame. Detailed Implementation

[0028] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. All other embodiments obtained by those skilled in the art based on the described embodiments are within the scope of protection of the present invention.

[0029] The structure of the self-balancing horizontal rotary manufacturing cable ring device of the present invention is as follows: Figure 1-2 As shown, it mainly consists of two parts: a strand winding system 1 and a core rope tensioning transmission system 2. The strand winding system 1 completes the circular motion of the strand wheel, while the core rope tensioning transmission system 2 completes the circular motion of the core rope. The rotation centers of the strand winding system and the core rope tensioning transmission system are arranged parallel to the ground. A variable-pitch counterweight device is placed opposite the strand wheel and rotates symmetrically. The variable-pitch counterweight device solves the torque imbalance caused by the continuous consumption and weight reduction of the strand, enabling the manufacturing device to operate at a higher speed and improving production efficiency.

[0030] The strand winding system 1 consists of three main parts: main drum 3, turning frame 5, and variable pitch counterweight device 7. The strand winding system 1 includes a pair of main drums 3 arranged opposite each other. After the strands of steel wire rope are fully wound on the strands of the strand wheel 4, it is installed on the turning frame 5. The turning frame 5 is installed on the main drum 3 through bearing seats. The main drum 3 is supported by roller frame 8. The main drum 3 is driven to rotate by a motor and a gearbox through a large gear ring 9, which drives the turning frame 5 on the main drum 3 to make a circular motion around the core rope.

[0031] like Figure 3 As shown, two parallel and symmetrical rotating shafts are connected between the two main rollers 3, and the rotating shafts are arranged on the side away from the turning frame 5. The main body of the variable pitch counterweight device 7 includes two sets of hook-shaped balance blocks 10 arranged symmetrically on the left and right. Each set of balance blocks 10 is fixedly connected to the rotating shaft in an up-and-down manner. A pair of meshing synchronous gears 11 are installed at the end of the rotating shaft near one of the main rollers 3. The synchronous gears 11 drive the rotating shaft to rotate so that the balance blocks can rotate symmetrically.

[0032] As the strands continuously wind around the core rope 14, the weight changes due to the decreasing number of strands on the strand pulley 4, causing an imbalance in the force on the main drum 3 during rotation. At this point, the balance block drive device 12 on the variable-pitch counterweight device 7 activates, driving the two symmetrically arranged balance blocks 10 on the device to rotate. Because a pair of meshing synchronous gears 11 are mounted on their fixed shafts, the two balance blocks 10 can rotate symmetrically. This causes the center of gravity of the entire variable-pitch counterweight device 7 to shift towards the center along the radius of the main drum, changing the position of the center of gravity and achieving a change in the balancing torque, thus eliminating the force imbalance that occurs during the rotation of the drum 3. The strand pulley 4 is also equipped with a mechanical brake device, providing damping for the release of the strands and generating tension on the strands to control the tightness of the strands wound around the core rope 14. The turning frame 5 and the variable-pitch counterweight device 7 are powered and driven by the slip ring 13.

[0033] The strand pulley 4 is also equipped with a mechanical brake device, which provides a certain damping for the release of the strand by the strand pulley, so as to generate tension on the strand and control the tightness of the strand winding on the core rope 14.

[0034] like Figure 5 As shown, the centers of the two main rollers 3 are connected by a hollow sleeve. An axial slit is provided at the upward-facing position of the hollow sleeve. A through slot is located on the main roller 3 for assembling and disassembling the core rope 14 and the finished ring rope; the slot connects to the slit. Two detachable patch blocks 19 are provided at the slot. Each patch block 19 is equipped with a segmented large gear ring 9 and a slip ring 13. After the patch blocks 19 are installed, the main roller 3, the large gear ring 9, and the slip ring 13 form a complete circular shape, ensuring that the continuous rotation of the main roller 3, the transmission of the large gear ring 9, and the power supply of the slip ring 13 are not affected by the through slot. A rope guide frame 20 is installed at the rope outlet of the turning frame 5 to prevent the strands from rubbing against each other.

[0035] The core rope tensioning transmission system 2 mainly consists of multiple sets of drive wheels 15 and tensioning wheels 16, a tensioning carriage 17, and a track 18. During rope winding, the tensioning carriage 17 moves on the track 18, driving the tensioning wheels 16 to maintain the tension of the core rope 14 and the ring cable. The drive wheels 15 provide power to allow the core rope 14 and the ring cable to move according to the installation process requirements. The positions of the drive wheels 15 and tensioning wheels 16 determine the circumference of the ring cable, which can be adjusted according to product specifications. The maximum length of the ring cable is determined by the length of the track 18. Adding more drive wheels 15 or idler wheels and extending the length of the track 18 can further expand the equipment's production capacity.

[0036] The position and number of the drive wheel 15 and tension wheel 16 are adjusted according to the circumference of the ring cable.

[0037] A rope guide frame 20 is installed at the rope outlet of the turning frame 5.

[0038] The manufacturing method of the self-balancing horizontal rotational manufacturing cable ring of the present invention is as follows:

[0039] like Figure 4 As shown, during the manufacturing of the ring cable, the strands for production are first wound onto the strand pulley 4, then installed on the turning frame 5, and the strands are led out from the opening on the main roller 3 and fixed to the core rope 14. The main roller 3 is supported by the roller frame 8, and the motor and reducer 6 drive the large gear ring 9, causing the main roller 3 and the turning frame 5 to revolve around the core rope 14. At the same time, the core rope 14 is pulled by the core rope tensioning transmission system 2, causing the strands to continuously spirally wind around the core rope 14. During this process, a power system equipped with the turning frame 5 can drive the turning frame 5 to rotate, realizing the twisting / untwisting process requirements in the ring cable winding.

[0040] The three power systems—the motor and reducer 6 driving the main roller 3, the motor and reducer driving the turning frame 5, and the motor and reducer driving the drive wheel 15—operate proportionally according to the speed requirements of the ring cable winding process. All three power systems use variable frequency motors with encoders, and their speed and torque are precisely controlled by a PLC and variable frequency controller to ensure the twist pitch and tightness of the ring cable.

[0041] During operation, the balance of the counterweight and the strand pulley + strands is monitored in real time. The output torque of the motor is detected and adjusted by the frequency converter of the main drum drive device to avoid excessive unbalanced torque that could pose safety risks to the equipment and operators. The main drum 3 rotates at a constant speed. When the variable pitch counterweight device is well balanced, the output torque of the main drum drive motor will not change abruptly during one rotation, and the output torque curve of the drive motor is approximately a straight line, indicating stable motor operation. When the variable pitch counterweight device is poorly balanced, the rotation of the main drum can be considered as consisting of two stages: climbing and releasing. The drive motor will continuously switch between driving and braking conditions. At this time, the output torque curve of the drive motor will appear as a sine wave, and the larger the unbalanced torque, the larger the difference between the "peak" and "trough" of the sine wave. By monitoring the output torque of the drive motor through the frequency converter, the magnitude of the unbalanced torque can be monitored in real time, and the variable pitch counterweight device 7 can be controlled to make corresponding adjustments to reduce the difference between the "peak" and "trough" and keep the balance close to the ideal state.

[0042] The self-balancing horizontal rotary cable ring manufacturing device of the present invention does not require the gantry necessary for a vertical rope winding machine, nor does it require raising the core, thus avoiding high-altitude operations and improving the convenience of maintenance. At the same time, the ring cable semi-finished product is close to the ground, which facilitates quality inspection of the ring cable during the production process.

[0043] The self-balancing horizontal rotational manufacturing device for cable rings of the present invention uses a flexible core rope, which avoids the problems of excessive space occupation and complicated installation and disassembly caused by using a rigid core rope.

Claims

1. A self-balancing horizontal rotary device for manufacturing cable-type ring cables, characterized in that, It includes two main parts: a strand winding system (1) and a core rope tensioning transmission system (2); the strand winding system (1) completes the circular motion of the strand wheel, and the core rope tensioning transmission system (2) completes the circular motion of the core rope; the rotation centers of the strand winding system (1) and the core rope tensioning transmission system (2) are arranged parallel to the ground, and a variable pitch counterweight device is arranged at the opposite position of the strand wheel, and rotating blocks are symmetrically arranged; The strand winding system (1) includes a pair of main rollers (3) arranged opposite to each other. The strand wheel (4) is fully wound with steel wire rope strands and then installed on the turning frame (5). The turning frame (5) is installed on the main roller (3) through a bearing seat. The main roller (3) is supported by a roller frame (8). The main roller (3) is driven to rotate by a motor and a gearbox through a large gear ring (9), which drives the turning frame (5) on the main roller (3) to make a circular motion around the core rope. Two parallel and symmetrical rotating shafts are connected between the two main rollers (3), and the rotating shafts are arranged on the side away from the turning frame (5). The main body of the variable pitch counterweight device (7) includes two sets of hook-shaped balance blocks (10) arranged symmetrically on the left and right. Each set of balance blocks (10) is fixedly connected to the rotating shaft in an up-and-down manner. A pair of meshing synchronous gears (11) are installed at the end of the rotating shaft near one of the main rollers (3). The synchronous gears (11) drive the rotating shaft to rotate so that the balance blocks can rotate symmetrically.

2. The apparatus for manufacturing cable loops by self-balancing horizontal rotation according to claim 1, characterized in that, The strand wheel (4) is also equipped with a mechanical brake device to provide a certain damping for the strand wheel to release the strand, so as to generate tension on the strand and control the tightness of the strand wrapped around the core rope (14).

3. The apparatus for manufacturing cable loops by self-balancing horizontal rotation according to claim 1, characterized in that, The centers of the two main rollers (3) are connected by a hollow sleeve. The hollow sleeve has an axial slit at the upward position. The main roller (3) has a through slot for assembling and disassembling the core rope (14) and the finished ring rope. The slot is connected to the slit. Each slot has a detachable patch (19). The patch (19) is equipped with a segmented large gear ring and a collector ring (13). The main roller (3), the large gear ring (9) and the collector ring (13) form a complete ring shape, ensuring that the continuous rotation of the main roller (3), the transmission of the large gear ring (9) and the power supply of the collector ring (13) are not affected by the through slot.

4. The apparatus for manufacturing cable loops by self-balancing horizontal rotation according to claim 1, characterized in that, The core rope tensioning transmission system (2) mainly includes a tensioning trolley (17), which can move on the track (18) when winding the rope; the core rope (14) passes through the hollow sleeve and wraps around the drive wheel (15) and the tensioning wheel (16); the tensioning wheel (16) is fixedly connected to the tensioning trolley (17) by a bracket; the drive wheel (15) is distributed on the outer side of the main drum; the tensioning wheel (16) and the drive wheel (15) are located on the same plane and at the same height as the hollow sleeve; the tensioning wheel (16) maintains the tension of the core rope (14) and the ring cable, and the drive wheel (15) provides power to make the core rope (14) and the ring cable move.

5. The apparatus for manufacturing cable loops by self-balancing horizontal rotation according to claim 4, characterized in that, The position and number of the drive wheel (15) and tension wheel (16) are adjusted according to the circumference of the ring cable.

6. The apparatus for manufacturing cable loops by self-balancing horizontal rotation according to claim 1, characterized in that, A rope guide frame (20) is provided at the rope outlet of the turning frame (5).

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