Method and system for detecting and controlling tidy winding of grabbing beam cable drum

Abstract

A method and system for detecting and controlling tidy winding of a grabbing beam cable drum comprises the following steps that S1, the lowering length S of a cable is obtained in real time through a height encoder, and data information of the lowering length S is transmitted to a controller; s2, the controller correspondingly obtains the layer number N1 of the remaining cable on the winding drum according to the lowering length S, a linear corresponding relation between the layer number and the rotating speed of the winding drum is preset in the controller, and the corresponding first rotating speed V1 of the winding drum is obtained according to the layer number N1; s3, whether the cable exists in each layer of area or not is sensed in real time through a sensor, the layer number N2 of the remaining cable on the winding drum is obtained, data of the layer number N2 is transmitted to a controller, and the controller obtains the corresponding second rotating speed V2 of the winding drum according to the layer number N2; s4, the controller judges whether the first rotating speed V1 is equal to the second rotating speed V2 or not; if yes, the controller receives the real-time lifting linear speed V0 of the grabbing beam, the V0 is converted into a third rotating speed V3 corresponding to the winding drum, and the final rotating speed V = V1 + V3 of the winding drum is obtained through data processing; if not, the controller outputs an abnormal instruction, and the equipment stops running. According to the invention, the lowering speed of the cable is matched with the operation speed of the grabbing beam in real time.

Description

Technical Field

[0001] The invention belongs to the technical field of cable winding equipment, and in particular relates to a method and system for detecting and controlling the neat winding of a grab beam cable drum. Background Art

[0002] In the hydropower industry, the mechanical grab beams used on gantry cranes have been gradually replaced by hydraulic grab beams because their reliability is not as good as that of hydraulic grab beams. In the hydraulic grab beam control system, one of the most critical links is the cable retraction and release. How to control the retraction and release of the cable reel is directly related to the realization of the entire grab beam function.

[0003] The cable drum for grabbing beam is usually driven by a frequency converter, which requires the cable drum to have not only a suitable torque, but also a speed that is synchronized with the lifting grabbing beam mechanism. However, if the torque is too large, it is easy to break the cable, and if the torque is too small, the cable drum is prone to slipping; if the speed is too large, it will lead to poor synchronization, and if the speed is too small, it will damage the cable.

[0004] In addition, the cable is wound on the cable drum in multiple layers. If the cable drum always runs at the same speed, the reeling and releasing speeds of the cables in different layers will be different. How to adjust the speed of the cable drum in real time so that the reeling and releasing speed of the cable is synchronized and matched with the lifting and lowering of the grab beam, and at the same time make the cable not easy to be damaged by tension or too loose during the reeling and releasing process is an urgent problem to be solved. Summary of the invention

[0005] The present invention provides a method and system for detecting and controlling the neat winding of a grab beam cable reel, so as to solve the problem that the retracting and releasing speed of the grab beam cable reel is difficult to regulate.

[0006] In order to solve the above technical problems, the technical solution adopted by the present invention is: On the one hand, the present application provides a method for detecting and controlling the neat winding of a grab beam cable drum, comprising the following steps: S1: The lowering length S of the cable is obtained in real time through the height encoder, and the data information of the lowering length S is transmitted to the controller; S2: The controller obtains the number of layers N1 of the remaining cable on the drum according to the lowering length S. The controller is preset with a linear correspondence between the number of layers and the drum rotation speed. The corresponding first drum rotation speed V1 is obtained according to the number of layers N1. S3: Using a sensor to sense in real time whether there is cable in each layer area, the number of layers N2 of the remaining cables on the drum is obtained, and the data of the number of layers N2 is transmitted to the controller, and the controller obtains the corresponding second reel rotation speed V2 according to the number of layers N2; S4: The controller determines whether the first speed V1 is equal to the second speed V2; If yes, the controller receives the real-time lifting and lowering linear speed V0 of the grab beam, converts V0 into the third rotation speed V3 corresponding to the drum, and performs data processing to obtain the final rotation speed V=V1+V3 of the drum; if no, the controller outputs an abnormal instruction and the equipment stops running.

[0007] Furthermore, in step S4, if the controller outputs an abnormal instruction, the reel stops rotating, and the controller sends a start instruction to the visual camera, the visual camera takes a picture of the reel, and transmits the real-time image taken to the image processing unit; The image processing unit uses tools to annotate images according to the format requirements of a typical YOLO model, and sets the cable winding conditions to multiple categories such as normal, chaotic winding, and jump out; The image processing unit transmits the image and information such as the winding condition of the cable to the display device for display via the display device; At the same time, the controller sends a command to the alarm device, controlling the alarm device to send out an alarm of abnormal operation of the reel.

[0008] Furthermore, in the step of controlling the rotation of the reel by the controller, a dual control mode of a network control mode and an IO control mode is provided. When a failure occurs in the network control mode, the IO control mode is used to realize the controller's control over the operation of the reel.

[0009] Further, in step S2, the controller obtains the number of remaining cable layers N1 on the drum according to the lowering length S, which further includes: calculating the corresponding relationship between the theoretical lowering length S and the number of remaining cable layers on the drum according to the theoretical value of the cable length wound on each layer of the drum, and setting the corresponding relationship between the lowering length S and the number of remaining cable layers N1 on the drum in the controller; After the setting is completed, start the grab beam lifting mechanism, and conduct multiple tests to adjust whether the corresponding relationship between the lowering length S and the remaining number of layers N1 of the drum in the actual operation process is consistent with the theoretical calculation, and adaptively adjust the settings in the controller.

[0010] Furthermore, in the process of setting the remaining number of layers of the drum and the corresponding rotational speed of the drum, without considering the operation of the grab beam, the length of the cable lowered by one circle of any layer of cable is set to S0, and the rotational speed of the drum corresponding to this layer is V0. Then, the value of S0×V0 of any layer needs to be kept constant and the same, and then the rotational speed V0 of the drum corresponding to each layer can be calculated, and the linear relationship between the remaining number of layers of the drum and the rotational speed of the drum can be obtained.

[0011] Furthermore, in step S3, the step of sensing in real time whether there is a cable in each layer area by using a sensor also includes: starting the sensors one by one from the sensor closest to the drum surface toward the direction away from the drum surface; If the induction receiving device does not receive the signal sent by the induction sending device, it means that there is a cable on this layer. It runs one by one until the induction receiving device receives the signal sent by the induction sending device, identifies the layer number of the sensor, and subtracts 1 from the layer number as the remaining layer number N2 of the cable.

[0012] On the other hand, the present application also provides a system for detecting and controlling the neat winding of the grab beam cable drum, comprising: Height encoder, used to obtain the lowering length S of the cable in real time; The controller is responsible for the management and control of all equipment, and the controller has the corresponding relationship between the number of remaining cable layers and the reel speed input; The frequency converter is used to receive the instructions transmitted by the controller and control the speed of the reel motor according to the instructions; The sensors are evenly arranged in multiple layers along the height direction of the drum, and each layer of sensors is set corresponding to the height of one layer of cables.

[0013] Furthermore, each layer of the sensors includes an induction sending device and an induction receiving device, and the induction sending device and the induction receiving device are respectively arranged at two ends of the reel.

[0014] Furthermore, when the frequency converter controls the reel to rotate, it uses speed control and torque limiting to control the operation of the motor.

[0015] Furthermore, it also includes: Visual camera, used to collect images of the real-time situation of the cable at the reel; An image processing unit is used to perform image preprocessing and feature extraction on the data collected by the visual camera, and to implement annotation; A display device is used to display the image processed by the image processing unit.

[0016] The present invention can achieve the following beneficial effects: 1. By utilizing the method provided in the present application, the speed at which the cable reel reels and releases the cable can be adjusted in real time, so that the cable reeling and releasing speed is roughly synchronized with the lifting speed of the grab beam. Furthermore, during the lifting and lowering process of the grab beam, the cable is not easily affected by the tension from the grab beam, nor is it easy to get entangled due to the low tension. Compared with conventional reel speed control schemes, this control method can greatly improve the safety and reliability of the use of the cable reel, reduce hidden dangers, and reduce the frequency of cable replacement.

[0017] 2. The number of remaining cable layers on the drum can be double-identified by the sensor and the length of the cable lowered. On the one hand, it can reduce the occurrence of errors, and on the other hand, it can identify the cable winding. Then, when the cable is entangled or other situations occur, it can send a signal in real time and stop the drum operation to reduce the occurrence of cable damage.

[0018] 3. Setting up a visual camera can quickly transmit the situation at the cable to the staff, making it convenient for the staff to identify and judge the problem and provide maintenance plans in time, thereby improving maintenance efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The present invention will be further described below in conjunction with the accompanying drawings and embodiments: Figure 1 A flow chart of a method for detecting and controlling the neat winding of a grab beam cable drum according to the present invention; Figure 2 A schematic diagram of a system for detecting and controlling the neat winding of a grab beam cable drum according to the present invention; Figure 3 The schematic diagram of the front cross section of the reel for demonstrating the arrangement of the sensors on the reel according to the present invention; Figure 4 This is a control principle diagram of the frequency converter of the present invention; Figure 5 The figure is a connection diagram of the visual camera, the image processing center and the display device of the present invention.

[0020] In the accompanying drawings, the components represented by the reference numerals are listed as follows: 1. Induction sending device; 2. Induction receiving device; 3. Reel; 4. Cable. DETAILED DESCRIPTION

[0021] In order to facilitate understanding of the present application, the present application will be described more fully below with reference to the relevant drawings. Embodiments of the present application are provided in the drawings. However, the present application can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present application more thorough and comprehensive.

[0022] like Figures 1 to 5 As shown, the present application provides a method and system for detecting and controlling the neat winding of a grab beam cable drum.

[0023] A system for detecting and controlling the neat winding of the cable drum of the grab beam, referring to Figure 2, including controller, frequency converter, height encoder, visual camera, image processing center and display device, etc. In this application, the controller is PLC, which is the core of the whole system and is responsible for the management and control of all equipment. The controller inputs the correspondence between the number of remaining cable layers and the reel speed. The number of remaining cable layers is input into the controller, and the controller can output the reel speed accordingly; the frequency converter is used to receive the instructions issued by the controller, and drive the cable reel motor to operate and control the reel speed; the height encoder is used to obtain the lowering length of the cable in real time, and transmit the lowering length data to the controller; the visual camera is set on the side of the reel to shoot the real-time situation of the cable at the reel; the image processing center is used to receive the image taken by the visual camera, and perform image preprocessing and feature extraction on the received image, and realize the annotation of the cable status; the display device is used to display the picture processed by the image processing center.

[0024] Reference Figure 3 The system of the present application further includes sensors arranged on the drum 3, and the sensors are arranged in multiple layers along the direction of the number of layers of the cable 4, and the distance between two adjacent layers of sensors is the diameter of the cable 4. Each layer of sensors includes an inductive transmitting device 1 and an inductive receiving device 2, and the inductive transmitting device 1 and the inductive receiving device 2 are respectively arranged at the two ends of the drum 3. When there are cables 4 corresponding to the number of layers of the sensors, the signal sent by the inductive transmitting device 1 is difficult to pass through the cables 4 and be received by the inductive receiving device 2. Only when there are no cables 4 corresponding to the number of layers of the sensors, the signal sent by the inductive transmitting device 1 can be received by the inductive receiving device 2.

[0025] In addition, the frequency converter uses speed control and torque limiting to control the operation of the motor. Speed ​​control can adjust the rotation speed of the cable drum motor so that the cable reeling and releasing speed is well matched with the lifting mechanism; torque limiting can limit the torque of the cable drum motor to ensure that the cable is not broken in extreme cases.

[0026] Furthermore, as the basis for the reel speed control, the encoder is required to transmit a stable and reliable signal. This solution filters and verifies the signal input from the encoder to the controller in a programming manner.

[0027] Specifically, an electronic filtering program is written in the loop program block of the PLC, with 500 as the threshold value. When the fluctuation is greater than 500, the addition and subtraction method and the coefficient method are used for filtering according to the period of the fluctuation. This makes the electronic filtering program have an obvious filtering effect on small fluctuations in the code value, but almost no filtering effect on large fluctuations, thereby achieving the purpose of filtering out the clutter caused by interference, while retaining the abnormal fluctuations in the code value caused by faults.

[0028] Program the encoder code values ​​of two adjacent sampling cycles in the PLC's cyclic interruption organization block. Their difference is the rate of change of the code value in one sampling cycle (denoted as b). The difference in the rate of change of two adjacent cycles should be less than the rate of change of the fastest acceleration and deceleration, denoted as m. When |b1-b2|>>m, and the grab beam reel works normally (whether the grab beam reel works normally is determined by other detection elements, such as speed encoder, overspeed switch, etc.), it indicates that the encoder is faulty. In actual applications, the best effect is achieved when the interruption time is set to 200ms and m=1.0.

[0029] At the same time, considering the reliability of system operation, network control mode and IO control mode are set. IO control mode is a backup plan for network control, that is, the relay coil is used as the PLC output end and the contact is used as the inverter input end, so that the PLC can directly control the inverter operation without going through the network. Even in the event of a communication failure, the PLC can still control the inverter operation through IO. The specific control principle of the inverter is as follows Figure 4 As shown, 1 is the grab beam drum inverter, 2 is the relay used in the IO control mode, 3 is the inverter fault signal output relay, 4 is the inverter brake signal output relay, 5 is the inverter closing output relay, and 6 is the PROFINET communication bus.

[0030] When designing a visual camera, refer to Figure 5 Considering the all-weather application environment, light sources are configured around the visual camera. The light source is required to be able to work at night, and the lens can be used normally in rainy and foggy days. The camera uses an Ethernet communication interface to enhance data transmission speed and anti-interference ability. The pixel of the industrial camera is not less than 2 million.

[0031] A visual camera is arranged on the front of the grab beam drum to collect real-time images of the cable winding on the drum. The collected data is preprocessed and feature extracted by the image processing center, and the image is annotated according to the format requirements of the typical YOLO model using tools. The winding conditions of the grab beam cable are set to multiple categories such as normal, chaotic, and jump out.

[0032] Based on the above system, this application proposes a method for detecting and controlling the neat winding of the grab beam cable drum, referring to Figure 1 , including the following steps: Step 1: Obtain the lowering length S of the cable in real time through the height encoder, and transmit the data information of the lowering length S to the controller; Step 2: The controller obtains the number of layers N1 of the remaining cable on the drum according to the lowering length S. A linear correspondence between the number of layers and the drum rotation speed is preset in the controller, and the corresponding first drum rotation speed V1 is obtained according to the number of layers N1.

[0033] Among them, when setting the linear correspondence between the number of cable layers and the drum rotation speed, the correspondence between the theoretical lowering length S and the number of remaining layers of the drum cable is calculated according to the theoretical value of the cable length wound on each layer of the drum, and the correspondence between the lowering length S and the number of remaining layers of the drum N1 is set inside the controller; After the setting is completed, the grab beam lifting mechanism is started, and multiple tests are conducted to adjust whether the corresponding relationship between the lowering length S and the remaining number of layers N1 of the roll in the actual operation process is consistent with the theoretical calculation, and the settings in the controller are adaptively adjusted. When testing the corresponding relationship between the lowering length S and the remaining number of layers N1 of the roll, ensure that the grab beam lifting mechanism runs at a uniform speed, and at this time the grab beam lifting mechanism does not grab other materials.

[0034] In the process of setting the remaining number of layers of the drum and the corresponding rotational speed of the drum, without considering the operation of the grab beam, the length of the cable lowered by one rotation of any layer of cable is set to S0, and the rotational speed of the drum corresponding to this layer is V0. It is necessary to keep the value of S0×V0 of any layer constant and the same, and then the rotational speed V0 of the drum corresponding to each layer can be calculated, and the linear relationship between the remaining number of layers of the drum and the rotational speed of the drum can be obtained.

[0035] Step 3: Use the sensor to sense in real time whether there is cable in each layer area, and obtain the number of layers N2 of the remaining cables on the reel. Transmit the data of the number of layers N2 to the controller, and the controller obtains the corresponding second reel rotation speed V2 according to the number of layers N2.

[0036] Specifically, the sensors closest to the drum surface are started one by one in the direction away from the drum surface. If the induction receiving device does not receive the signal sent by the induction sending device, it means that there is a cable in this layer. The induction receiving device is operated one by one until the induction receiving device receives the signal sent by the induction sending device, identifies the layer number of the sensor, and subtracts 1 from the layer number as the remaining layer number N2 of the cable.

[0037] Step 4: The controller determines whether the first speed V1 is equal to the second speed V2; If yes, the controller receives the real-time lifting and lowering linear speed V0 of the grab beam, converts V0 into the third rotation speed V3 corresponding to the drum, and performs data processing to obtain the final rotation speed V=V1+V3 of the drum; if no, the controller outputs an abnormal instruction and the equipment stops running.

[0038] Specifically, if the controller outputs an abnormal command, the reel stops rotating, and the controller sends a start command to the visual camera, which takes a picture of the reel and transmits the real-time image to the image processing unit. The image processing unit annotates the image and sets the cable winding status to normal, disorderly winding, jump out, etc. After the processing is completed, the image processing unit transmits the image and the cable winding status and other information to the display device for display; at the same time, the controller sends a command to the alarm device to control the alarm device to issue an alarm of abnormal operation of the reel.

[0039] In summary, the present application provides a method and system for detecting and controlling the neat winding of the cable reel of the grab beam, which reduces the possibility of the cable being subjected to tension during the retraction and release process, greatly reduces the damage to the cable caused by the tension, and on the one hand, improves the service life of the cable, and on the other hand, reduces the situation where the construction work is suspended due to the cable breaking during the operation of the grab beam. In addition, through the system of dual identification of the remaining layers of the cable, it is possible to detect abnormal cable winding, and combined with the visual camera, it can effectively prompt abnormal phenomena such as cable winding and jumping out; compared with the traditional control scheme, this scheme has the advantages of low technical cost, good economy, and high detection accuracy.

[0040] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for detecting and controlling the neat winding of a grab beam cable drum, characterized in that: The following steps are involved: S1: The lowering length S of the cable is obtained in real time through the height encoder, and the data information of the lowering length S is transmitted to the controller; S2: The controller obtains the number of layers N1 of the remaining cable on the drum according to the lowering length S. The controller is preset with a linear correspondence between the number of layers and the drum rotation speed. The corresponding first drum rotation speed V1 is obtained according to the number of layers N1. S3: Using a sensor to sense in real time whether there is cable in each layer area, the number of layers N2 of the remaining cables on the drum is obtained, and the data of the number of layers N2 is transmitted to the controller, and the controller obtains the corresponding second reel rotation speed V2 according to the number of layers N2; S4: The controller determines whether the first speed V1 is equal to the second speed V2; If yes, the controller receives the real-time lifting and lowering linear speed V0 of the grab beam, converts V0 into the third rotation speed V3 corresponding to the drum, and performs data processing to obtain the final rotation speed V=V1+V3 of the drum; if no, the controller outputs an abnormal instruction and the equipment stops running.

2. A method for detecting and controlling the neat winding of a grab beam cable drum according to claim 1, characterized in that: In step S4, if the controller outputs an abnormal instruction, the reel stops rotating, and the controller sends a start instruction to the visual camera, the visual camera takes a picture of the reel, and transmits the real-time image taken to the image processing unit; The image processing unit uses tools to annotate images according to the format requirements of a typical YOLO model, and sets the cable winding conditions to multiple categories such as normal, chaotic winding, and jump out; The image processing unit transmits the image and information such as the winding condition of the cable to the display device for display via the display device; At the same time, the controller sends a command to the alarm device, controlling the alarm device to send out an alarm of abnormal operation of the reel.

3. A method for detecting and controlling the neat winding of a grab beam cable reel according to claim 1, characterized in that: In the step of the controller controlling the rotation of the reel, a dual control mode of a network control mode and an IO control mode is provided. When a failure occurs in the network control mode, the IO control mode is used to realize the controller's control over the operation of the reel.

4. A method for detecting and controlling the neat winding of a grab beam cable drum according to claim 1, characterized in that: In step S2, the controller obtains the number of remaining cable layers N1 on the drum according to the lowering length S, which also includes: calculating the corresponding relationship between the theoretical lowering length S and the number of remaining cable layers on the drum according to the theoretical value of the cable length wound on each layer of the drum, and setting the corresponding relationship between the lowering length S and the number of remaining cable layers N1 on the drum in the controller; After the setting is completed, start the grab beam lifting mechanism, and conduct multiple tests to adjust whether the corresponding relationship between the lowering length S and the remaining number of layers N1 of the drum in the actual operation process is consistent with the theoretical calculation, and adaptively adjust the settings in the controller.

5. A method for detecting and controlling the neat winding of the grab beam cable reel according to claim 4, characterized in that: In the process of setting the remaining number of layers of the drum and the corresponding rotational speed of the drum, without considering the operation of the grab beam, the length of the cable lowered by one rotation of any layer of cable is set to S0, and the rotational speed of the drum corresponding to this layer is V0. It is necessary to keep the value of S0×V0 of any layer constant and the same, and then the rotational speed V0 of the drum corresponding to each layer can be calculated, and the linear relationship between the remaining number of layers of the drum and the rotational speed of the drum can be obtained.

6. A method for detecting and controlling the neat winding of a grab beam cable drum according to claim 1, characterized in that: In step S3, the step of sensing in real time whether there is a cable in each layer area by using a sensor also includes: starting the sensors one by one from the direction closest to the drum surface toward the direction away from the drum surface; If the induction receiving device does not receive the signal sent by the induction sending device, it means that there is a cable on this layer. It runs one by one until the induction receiving device receives the signal sent by the induction sending device, identifies the layer number of the sensor, and subtracts 1 from the layer number as the remaining layer number N2 of the cable.

7. A system for detecting and controlling the neat winding of the cable drum of the grab beam, characterized in that: include: Height encoder, used to obtain the lowering length S of the cable in real time; The controller is responsible for the management and control of all equipment, and the controller has the corresponding relationship between the number of remaining cable layers and the reel speed input; The frequency converter is used to receive the instructions transmitted by the controller and control the speed of the reel motor according to the instructions; The sensors are evenly arranged in multiple layers along the height direction of the drum, and each layer of sensors is set corresponding to the height of one layer of cables.

8. A system for detecting and controlling the neat winding of the grab beam cable drum according to claim 7, characterized in that: Each layer of the sensors comprises an induction sending device and an induction receiving device, and the induction sending device and the induction receiving device are respectively arranged at two ends of the reel.

9. A system for detecting and controlling the neat winding of the grab beam cable drum according to claim 7, characterized in that: When the frequency converter controls the reel to rotate, it uses two methods, speed control and torque limiting, to control the operation of the motor.

10. A system for detecting and controlling the neat winding of the grab beam cable drum according to claim 7, characterized in that: Also includes: Visual camera, used to collect images of the real-time situation of the cable at the reel; An image processing unit is used to perform image preprocessing and feature extraction on the data collected by the visual camera, and to implement annotation; A display device is used to display the image processed by the image processing unit.

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