Straightener transmission shaft monitoring system and method

Abstract

The embodiment of the invention provides a straightener transmission shaft monitoring system and method, and relates to straightener monitoring, the system comprises a torque sensor, a main control unit and a processing device, the torque sensor is arranged on a measured transmission shaft of a straightener and used for collecting torque data of the measured transmission shaft and sending the torque data to the main control unit, and the main control unit sends the torque data to the processing device; the main control unit converts torque data of the mechanical signal into a target torque signal of an electric signal and sends the target torque signal to the processing equipment, and the processing equipment is used for receiving the target torque signal and analyzing the target torque signal so as to monitor the state of the detected transmission shaft. The remote measuring system adopts a microstrain measuring method to measure the torque, adopts a wireless induction power supply mode for parts on the rotating shaft, wirelessly transmits measured signals to the receiving unit, and monitors the dynamic change of the torque of the transmission shaft of the straightening machine on line for a long time, so that the safe operation of the straightening machine is ensured, and the production efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the field of straightening machine monitoring, and in particular to a straightening machine transmission shaft monitoring system and method. Background Art

[0002] The two-roll straightening machine is a machine composed of one or more sets of working rolls. Generally, it includes two upper and lower working rolls and a transmission system. The upper and lower working rolls can realize forward and reverse rotation through the transmission system to achieve the purpose of straightening the bar.

[0003] At present, the overload identification and control unit of the straightening machine generally collects the actual current passing through the upper and lower straightening rollers, and compares it with the rated current of the straightening roller drive motor respectively. When the actual current of an active straightening roller is greater than or equal to the sum of its rated current and the current allowable deviation setting value, the straightening roller overload identification and control unit determines that the straightening roller is in an overload state; when the actual current of an active straightening roller is less than or equal to the difference between its rated current and the current allowable deviation setting value, the straightening roller overload identification and control unit determines that the straightening roller is not in an overload state or has exited the overload state; the straightening roller overload identification and control unit continuously reduces the speed of the active straightening roller by outputting the reference speed correction value until it exits the overload state or has reached the maximum allowable speed reduction.

[0004] However, there are many reasons that affect the overload of the straightening machine shaft transmission. In addition to the uneven mass distribution of the shaft itself, factors such as steel biting, steel throwing and irregular material defects during the straightening process will also cause impact loads such as transient increase or decrease in the torque load of the straightening machine transmission system. Especially when the straightening machine is straightening high-strength and large-sized bars, the straightening roller of the straightening machine will inevitably be overloaded or even severely overloaded, which will cause torsional vibration of the transmission system and cause certain fatigue damage to the transmission shaft. Especially in the production process of high-strength steel, the main transmission universal joint of the straightening machine has repeatedly broken at the cross-piece of the tiger's mouth, causing multiple universal joints to break continuously, resulting in the inability to produce high-strength steel varieties normally.

[0005] Therefore, relying solely on theory results in the existing monitoring of the straightening machine drive shaft being inaccurate. Summary of the invention

[0006] The object of the present invention is to provide a straightening machine transmission shaft monitoring system and method, which can improve the accuracy of monitoring the straightening machine transmission shaft.

[0007] In order to achieve the above purpose, the technical solution adopted in the embodiment of the present application is as follows:

[0008] In a first aspect, an embodiment of the present application provides a straightening machine transmission shaft monitoring system, the system comprising:

[0009] Torque sensor, main control unit and processing equipment;

[0010] The torque sensor is arranged on the measured transmission shaft of the straightening machine, and is used to collect torque data of the measured transmission shaft, and send the torque data to the main control unit;

[0011] The main control unit converts the torque data of the mechanical signal into a target torque signal of an electrical signal, and sends the target torque signal to the processing device;

[0012] The processing device is used to receive the target torque signal and analyze the target torque signal to monitor the state of the measured transmission shaft.

[0013] In an optional embodiment, the torque sensor includes a fixed outer ring, a rotating ring, and a strain gauge;

[0014] The rotating ring is fixedly connected to the transmission shaft to be measured, the fixed outer ring and the rotating ring are nested, and the strain gauge is used to determine the torque data of the transmission shaft to be measured.

[0015] In an optional embodiment, the strain gauge includes a first strain resistor, a second strain resistor, a third strain resistor and a fourth strain resistor;

[0016] The first strain resistor, the second strain resistor, the third strain resistor and the fourth strain resistor form a full bridge.

[0017] In an optional embodiment, the first strain resistor and the second strain resistor are arranged in a first direction of the end surface of the measured transmission shaft;

[0018] The third strain resistor and the fourth strain resistor are arranged in a second direction of the measured transmission shaft, wherein the first direction is perpendicular to the second direction.

[0019] In an optional embodiment, the processing device is specifically used for:

[0020] comparing the target torque signal with a preset torque signal;

[0021] When the target torque signal is greater than or equal to the preset torque signal, an alarm signal indicating that the tested transmission shaft is abnormal is output.

[0022] In an optional embodiment, the processing device is further used for:

[0023] When the target torque signal is greater than or equal to the preset torque signal, determining the angles of the upper and lower rollers of the measured transmission shaft;

[0024] Comparing the angles of the upper and lower rollers with a preset angle;

[0025] When the angles of the upper and lower rollers are greater than the preset angles, a prompt message is outputted indicating that the angles of the upper and lower rollers of the measured transmission shaft need to be adjusted;

[0026] Alternatively, when the target torque signal is greater than or equal to the preset torque signal, determining the roller gap value of the upper and lower rollers of the measured transmission shaft;

[0027] comparing the roll gap value with a preset roll gap value;

[0028] When the roll gap value is less than the preset roll gap value, a prompt message is outputted indicating that the upper and lower roll gap values ​​of the measured transmission shaft need to be adjusted.

[0029] In an optional embodiment, the processing device is specifically used for:

[0030] determining a torque peak value of the target torque signal;

[0031] comparing the peak torque value with a preset peak torque value;

[0032] When the torque peak value is greater than or equal to the preset torque peak value, obtaining a time period corresponding to the torque peak value;

[0033] Based on the time period corresponding to the torque peak, the fault cause of the tested transmission shaft is analyzed.

[0034] In an optional embodiment, the processing device is specifically used for:

[0035] determining torsional vibration and resonance of the target torque signal;

[0036] comparing the torsional vibration with a preset torsional vibration;

[0037] When the torsional vibration is greater than or equal to the preset torsional vibration, comparing the resonance with the preset resonance;

[0038] When the resonance is greater than or equal to the preset resonance, it is determined that the angles of the upper and lower rollers of the measured transmission shaft are larger, or the roller gap between the upper and lower rollers of the measured transmission shaft is smaller, or the guide plate spacing of the measured transmission shaft is smaller, or the speed of the straightening machine is larger.

[0039] In an optional embodiment, the processing device is further used for:

[0040] When the resonance is greater than or equal to a preset resonance, determining the angles of the upper and lower rollers of the measured transmission shaft;

[0041] Comparing the angles of the upper and lower rollers of the measured transmission shaft with a preset angle;

[0042] When the angles of the upper and lower rollers of the measured transmission shaft are greater than or equal to the preset angle, a prompt message for adjusting the angles of the upper and lower rollers of the measured transmission shaft is output.

[0043] In a second aspect, an embodiment of the present application provides a straightening machine transmission shaft monitoring method, which monitors the transmission shaft to be measured through a straightening machine transmission shaft monitoring system.

[0044] This application has the following beneficial effects:

[0045] The present application designs a monitoring system for the transmission shaft of a straightening machine. The system includes: a torque sensor, a main control unit, and a processing device. The torque sensor is arranged on the transmission shaft to be measured of the straightening machine, and is used to collect the torque data of the transmission shaft to be measured, and send the torque data to the main control unit. The main control unit converts the torque data of the mechanical signal into a target torque signal of an electrical signal, and sends the target torque signal to the processing device. The processing device is used to receive the target torque signal and analyze the target torque signal to monitor the state of the transmission shaft to be measured. The present application adopts a micro-strain measurement method to measure torque, and adopts a wireless induction power supply method for the components on the rotating shaft. The measured signal is wirelessly transmitted to the receiving unit, and a telemetry system is used to monitor the dynamic changes of the torque of the transmission shaft of the straightening machine online for a long time, so as to ensure the safe operation of the straightening machine and improve production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments are briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.

[0047] Figure 1 A block diagram of a processing device provided by an embodiment of the present invention;

[0048] Figure 2 One of the schematic diagrams of a straightening machine transmission shaft monitoring system provided by an embodiment of the present invention;

[0049] Figure 3 A second schematic diagram of a straightening machine transmission shaft monitoring system provided by an embodiment of the present invention;

[0050] Figure 4 A schematic diagram of a strain gauge provided in an embodiment of the present invention;

[0051] Figure 5 One of the flow charts of the straightening machine transmission shaft monitoring method provided by the embodiment of the present invention;

[0052] Figure 6A second flow chart of a method for monitoring a transmission shaft of a straightening machine provided in an embodiment of the present invention;

[0053] Figure 7 The third flowchart of the method for monitoring the transmission shaft of a straightening machine provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0054] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0055] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0056] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, further definition and explanation thereof is not required in subsequent drawings.

[0057] In the description of the present invention, it should be noted that if the terms "upper", "lower", "inside", "outside", etc. appear to indicate an orientation or position relationship, they are based on the orientation or position relationship shown in the accompanying drawings, or are the orientation or position relationship in which the product of the invention is usually placed when used. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0058] In addition, the terms “first”, “second”, etc., if used, are merely used to distinguish between the descriptions and should not be understood as indicating or implying relative importance.

[0059] In the description of this application, it should also be noted that, unless otherwise clearly specified and limited, the terms "set", "install", "connect", and "connect" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two elements. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0060] After extensive research by the inventors, it was found that the overload identification and control unit of the current straightening machine generally collects the actual current passing through the upper and lower straightening rollers, and compares it with the rated current of the straightening roller drive motor respectively. When the actual current of an active straightening roller is greater than or equal to the sum of its rated current and the current allowable deviation setting value, the straightening roller overload identification and control unit determines that the straightening roller is in an overload state; when the actual current of an active straightening roller is less than or equal to the difference between its rated current and the current allowable deviation setting value, the straightening roller overload identification and control unit determines that the straightening roller is not in an overload state or has exited the overload state; the straightening roller overload identification and control unit continuously reduces the speed of the active straightening roller by outputting a reference speed correction value until it exits the overload state or has reached the maximum allowable speed reduction.

[0061] However, there are many reasons that affect the overload of the straightening machine shaft transmission. In addition to the uneven mass distribution of the shaft itself, factors such as steel biting, steel throwing and irregular material defects during the straightening process will also cause impact loads such as transient increase or decrease in the torque load of the straightening machine transmission system. Especially when the straightening machine is straightening high-strength and large-sized bars, the straightening roller of the straightening machine will inevitably be overloaded or even severely overloaded, which will cause torsional vibration of the transmission system and cause certain fatigue damage to the transmission shaft. Especially in the production process of high-strength steel, the main transmission universal joint of the straightening machine has repeatedly broken at the cross-piece of the tiger's mouth, causing multiple universal joints to break continuously, resulting in the inability to produce high-strength steel varieties normally.

[0062] Therefore, relying solely on theory results in the existing monitoring of the straightening machine drive shaft being inaccurate.

[0063] In view of the discovery of the above problems, the present embodiment provides a straightening machine transmission shaft monitoring system and method. By designing a straightening machine transmission shaft monitoring system, the system includes: a torque sensor, a main control unit and a server. The torque sensor is arranged on the measured transmission shaft of the straightening machine, and is used to collect the torque data of the measured transmission shaft, and send the torque data to the main control unit. The main control unit converts the torque data of the mechanical signal into a target torque signal of an electrical signal, and sends the target torque signal to the server. The server is used to receive the target torque signal and analyze the target torque signal to monitor the state of the measured transmission shaft. The present application adopts a micro-strain measurement method to measure torque, and adopts a wireless induction power supply method for the components on the rotating shaft. The measured signal is wirelessly transmitted to the receiving unit. The telemetry system for long-term online monitoring of the dynamic changes of the torque of the straightening machine transmission shaft ensures the safe operation of the straightening machine and improves production efficiency. The scheme provided in the present embodiment is described in detail below.

[0064] This embodiment provides a processing device that can monitor the transmission shaft of a straightening machine. In a possible implementation, the processing device can be a user terminal, for example, the processing device can be, but is not limited to, a server, a smart phone, a personal computer (PC), a tablet computer, a personal digital assistant (PDA), a mobile Internet device (MID), etc.

[0065] Please refer to Figure 1 , Figure 1 1 is a schematic diagram of the structure of the processing device 100 provided in the embodiment of the present application. The processing device 100 may also include Figure 1 More or fewer components as shown, or with Figure 1 Different configurations are shown. Figure 1 Each component shown in the figure can be implemented by hardware, software or a combination thereof.

[0066] The processing device 100 includes a straightening machine transmission shaft monitoring device 110 , a memory 120 and a processor 130 .

[0067] The components of the memory 120 and the processor 130 are electrically connected to each other directly or indirectly to realize data transmission or interaction. For example, these components can be electrically connected to each other through one or more communication buses or signal lines. The straightening machine transmission shaft monitoring device 110 includes at least one software function module that can be stored in the memory 120 in the form of software or firmware or solidified in the operating system (OS) of the processing device 100. The processor 130 is used to execute the executable modules stored in the memory 120, such as the software function modules and computer programs included in the straightening machine transmission shaft monitoring device 110.

[0068] The memory 120 may be, but is not limited to, a random access memory (RAM), a read only memory (ROM), a programmable read-only memory (PROM), an erasable programmable read-only memory (EPROM), an electrically erasable read-only memory (EEPROM), etc. The memory 120 is used to store a program, and the processor 130 executes the program after receiving an execution instruction.

[0069] Please refer to Figure 2 , Figure 2 For application Figure 1 A structural schematic diagram of a straightening machine transmission shaft monitoring system of a processing device 100 is shown, and the system including each device is described in detail below.

[0070] The straightening machine transmission shaft monitoring system includes: a torque sensor 1, a main control unit 2 and a processing device 3; the torque sensor 1 is arranged on the measured transmission shaft 4 of the straightening machine, and is used to collect the torque data of the measured transmission shaft 4, and send the torque data to the main control unit 2; the main control unit 2 converts the torque data of the mechanical signal into a target torque signal of an electrical signal, and sends the target torque signal to the processing device 3; the processing device 3 is used to receive the target torque signal and analyze the target torque signal to monitor the state of the measured transmission shaft.

[0071] The torque sensor 1 is actually a sensor for measuring torque, which can measure the torsional moment on the transmission shaft of the straightening machine. It is usually composed of an elastic element and an induction circuit. When subjected to torque, the elastic element deforms, causing the induction circuit to output a signal. By collecting and processing these signals, an electrical signal corresponding to the torque value can be obtained.

[0072] The torque sensor is set on the measured transmission shaft of the straightening machine to obtain the torque data of the measured transmission shaft in real time.

[0073] Factors that affect torque include material properties, workpiece size, straightener type, straightening speed, straightening angle, and the yield strength and plasticity of different materials will affect the required torque. The larger the diameter, thickness, and other dimensions of the workpiece, the greater the torque required. Different straightener designs and structures will directly affect the torque requirements. The faster the straightening speed, the greater the torque may be required to overcome inertia. The larger the straightening angle, the greater the torque required.

[0074] In addition to obtaining the torque data of the measured transmission shaft of the straightening machine based on the torque sensor, the torque data of the measured transmission shaft of the straightening machine can also be calculated according to the material mechanics formula and the design parameters of the straightening machine.

[0075] The main control unit 2 is responsible for tasks such as power supply processing, signal reception processing, signal output, calibration and adjustment, etc. The main control unit 2 converts the torque data of the mechanical signal into a target torque signal of an electrical signal, and sends the target torque signal to the processing device 3 .

[0076] The processing device 3 receives the target torque signal and analyzes the target torque signal to monitor the state of the measured transmission shaft.

[0077] The processing equipment processes and analyzes the target torque signal, monitors the torque data of the tested drive shaft in real time, strengthens the early warning function, and can play a positive role in ensuring the safe operation of the drive shaft and production efficiency.

[0078] The processing equipment analyzes the target torque data of the transmission shaft and monitors the changes in the operating status of the straightening machine. When the transmission shaft torque is detected to be abnormal, the monitoring and early warning management system will immediately issue an alarm to remind the operator to handle it comprehensively and promptly. If a value exceeds the limit value, an alarm message can be issued in time to notify the rolling mill operator. At the same time, the monitored target torque data can also provide data support for technicians to modify the straightening procedures remotely.

[0079] The straightening machine drive shaft monitoring system can select sensitivity thresholds and alarm strategies. The sensitivity threshold is set based on the operation of the drive shaft and the requirements of the technical infrastructure, and can be used to determine whether the drive shaft torque changes abnormally. The system will conduct real-time and dynamic data monitoring of the collected torque data according to the sensitivity threshold. If an abnormality exceeding the threshold is detected, the alarm mechanism will be triggered immediately. At the same time, the system can also classify and process abnormal information and scenarios according to different alarm contents, such as distinguishing temporary fluctuations from persistent abnormalities, and dividing alarm levels according to severity.

[0080] The present invention adopts a non-contact telemetry torque sensor to transmit the obtained torque signal to the processing equipment through the network, thereby realizing real-time display, storage and analysis and processing of data. Its advantage is that the on-site operator adjusts the operating state of the straightening machine according to the collected real-time torque data; the remote diagnosis engineer uses the internal network / Internet to access the database of the processing equipment, analyzes the data in detail, takes reasonable countermeasures, and then adjusts the correction procedures through the on-site operator, effectively avoiding the occurrence of transmission shaft fracture.

[0081] Still refer to Figure 3 The torque sensor 1 includes a fixed outer ring 11, a rotating ring 12 and a strain gauge 13; the rotating ring 12 is fixedly connected to the measured transmission shaft 4, the fixed outer ring 11 and the rotating ring 12 are nested, and the strain gauge 13 is used to determine the torque data of the measured transmission shaft 4.

[0082] The torque sensor 1 consists of a fixed outer ring 11 and a rotating ring 12. It is used to collect torque data of the transmission shaft under test in real time and convert mechanical torque into electrical signal output. The fixed outer ring 11 is provided with a main control unit 2, which is mainly used to wirelessly transmit power to the rotating ring 12.

[0083] The rotating ring 12 is fixed on the measured transmission shaft 4 and rotates together with the measured transmission shaft 4. The rotating ring 12 has a built-in wireless signal processing and sending device and a power induction receiving device to provide power for the strain gauge 13. The torque data is processed and transmitted to the receiving device of the main control unit 2 through the wireless sending device.

[0084] like Figure 4 As shown, the strain gauge 13 includes a first strain resistor 131 , a second strain resistor 132 , a third strain resistor 133 and a fourth strain resistor 134 ; the first strain resistor 131 , the second strain resistor 132 , the third strain resistor 133 and the fourth strain resistor 134 form a full bridge.

[0085] The first strain resistor 121 and the second strain resistor 132 are arranged in a first direction of the end surface of the measured transmission shaft 4;

[0086] The third strain resistor 133 and the fourth strain resistor 134 are arranged in a second direction of the measured transmission shaft 4 , wherein the first direction is perpendicular to the second direction.

[0087] The strain gauge 13 is a full bridge composed of four strain resistors. The connecting wires of the strain gauge 13 are glued to the measured transmission shaft 4. The first strain resistor and the second strain resistor are used to detect the horizontal direction of the measured transmission shaft, and the third strain resistor and the fourth strain resistor are used to detect the vertical direction of the measured transmission shaft.

[0088] When the measured transmission shaft is subjected to torque, the bridge composed of four strain resistors loses balance and generates a measurement signal proportional to the torque, which is the torque signal. After amplification and modulation by the transmitter of the main control unit, the signal is transmitted to the outside by the transmitting antenna. The electromagnetic wave signal is sent to the preamplifier through the receiving antenna for pre-amplification, and then demodulated and amplified by the telemeter receiver to restore the electrical signal proportional to the torque, which is the target torque signal. The target torque signal is sent to the processing equipment, which processes and displays the target torque signal. The restoration result is used for computer acquisition, display and data processing.

[0089] In an implementation in which a processing device is used to receive the target torque signal and analyze the target torque signal to monitor the state of the measured transmission shaft, Figure 5 As shown, the following steps are included:

[0090] S201: Compare the target torque signal with the preset torque signal.

[0091] S202: When the target torque signal is greater than or equal to the preset torque signal, an alarm signal indicating that the tested transmission shaft is abnormal is output.

[0092] It should be noted that the preset torque signal can be set according to actual conditions, and the embodiment of the present application does not impose any specific limitation on this.

[0093] The target torque signal is compared with the preset torque signal. When the target torque signal is greater than or equal to the preset torque signal, an alarm signal indicating that the tested transmission shaft is abnormal is output so that the operator can adjust the straightening machine.

[0094] When the target torque signal is less than the preset torque signal, it indicates that there is no abnormality in the measured transmission shaft, and the current working parameter information of the straightening machine can be output for the operator to monitor the straightening machine in real time.

[0095] In another implementation, the processing device is used to receive the target torque signal and analyze the target torque signal to monitor the state of the measured transmission shaft. Figure 6 As shown, the following steps are included:

[0096] S301: When the target torque signal is greater than or equal to the preset torque signal, determining the angles of the upper and lower rollers of the measured transmission shaft.

[0097] S302: Compare the angles of the upper and lower rollers with preset angles.

[0098] S303: When the angles of the upper and lower rollers are greater than the preset angles, a prompt message is outputted indicating that the angles of the upper and lower rollers of the measured transmission shaft need to be adjusted.

[0099] In a straightening machine, the angle of the upper and lower rollers has a significant effect on the amount of torque applied to the material. The straightening machine achieves the purpose of straightening by adjusting the angle of the upper and lower rollers to change the bending and straightening effect on the material.

[0100] Increasing the angle of the upper and lower rollers will cause an increase in torque: When the angle of the upper and lower rollers increases, the pressure of the upper and lower rollers on the material will increase, causing the material to be subjected to greater bending force. This will cause greater stress inside the material, which in turn increases the torque. Larger angles of the upper and lower rollers can correct the bending of the material more effectively, but at the same time it also increases the internal stress of the material, which may cause material damage. When the angle of the upper and lower rollers decreases, the pressure of the upper and lower rollers on the material will decrease, and the bending force on the material will also decrease, thereby reducing the torque. Smaller angles of the upper and lower rollers may not be able to effectively correct the bending of the material, especially for more severe bending situations. The selection of the angle of the upper and lower rollers requires a comprehensive consideration of the straightening accuracy and the integrity of the material. Too large a straightening angle may cause scratches on the surface of the material or internal cracks.

[0101] Therefore, the processing device can output the adjustment angle of the angle of the upper and lower rollers of the straightener based on the material acted on by the straightener, and the operator can adjust the straightener based on the adjustment angle output by the processing device.

[0102] In another example, when the upper and lower roller gap angles are less than or equal to a preset angle, the roller gap value of the upper and lower rollers of the measured transmission shaft can be determined; the roller gap value is compared with the preset roller gap value; when the roller gap value is less than the preset roller gap value, a prompt message is output indicating that the upper and lower roller gap values ​​of the measured transmission shaft need to be adjusted.

[0103] The gap between the upper and lower rollers of the straightening machine (i.e. the gap between the upper and lower rollers) also has an important influence on the torque applied to the material.

[0104] Straightening machines are mainly used to correct the bending or twisting deformation of metal plates, bars and other materials. By adjusting the gap between the upper and lower rollers, the material is subjected to different pressures and bending forces when passing through the straightening machine, thus achieving straightening.

[0105] When the gap between the upper and lower rollers is small, that is, the roll gap value is small, the material will be subjected to greater pressure when passing through the straightener. This greater pressure will cause greater stress inside the material, which will increase the torque. A smaller roll gap value can correct the material's bend more effectively, but it also increases the material's internal stress, which may cause material damage or surface scratches. When the gap between the upper and lower rollers is larger, the material is subjected to less pressure and the stress generated inside the material will also be reduced, thereby reducing the torque. A larger roll gap value may not be able to effectively correct the material's bend, especially for more severe bends.

[0106] The mechanical properties of different materials (e.g. elastic modulus, yield strength) will affect their sensitivity to the roll gap value. For example, harder materials may require a smaller roll gap value for effective straightening.

[0107] The selection of the roll gap value needs to comprehensively consider the straightening accuracy and the integrity of the material. Too small a roll gap value may cause scratches on the surface of the material or internal cracks.

[0108] Therefore, the processing device can output an adjustment value for the upper and lower roll gap values ​​of the straightener based on the material acted on by the straightener, and the operator can adjust the straightener based on the adjustment value output by the processing device.

[0109] In another implementation, the processing device is used to receive the target torque signal and analyze the target torque signal to monitor the state of the measured transmission shaft. Figure 7 As shown, the following steps are included:

[0110] S401: Determine the torque peak value of the target torque signal.

[0111] S402: Compare the torque peak value with the preset torque peak value.

[0112] S403: When the torque peak value is greater than or equal to the preset torque peak value, obtaining a time period corresponding to the torque peak value.

[0113] S404: Analyze the cause of the failure of the tested transmission shaft based on the time period corresponding to the torque peak.

[0114] In another implementation method of analyzing the target torque signal to monitor the state of the measured transmission shaft, it can also be: determining the torsional vibration and resonance of the target torque signal; comparing the torsional vibration with the preset torsional vibration; when the torsional vibration is greater than or equal to the preset torsional vibration, comparing the resonance with the preset resonance; when the resonance is greater than or equal to the preset resonance, determining that the angle of the upper and lower rollers of the measured transmission shaft is larger, or the roller gap between the upper and lower rollers of the measured transmission shaft is smaller, or the guide plate spacing of the measured transmission shaft is smaller, or the speed of the straightening machine is larger.

[0115] The processing device determines the abnormal data in the target torque signal according to the following rules: for a target torque signal, time domain analysis, frequency domain analysis or amplitude domain analysis can generally be used. This embodiment mainly uses time domain analysis.

[0116] Perform synchronous comparison of the upper and lower couplings. By comparing the torque values ​​of the upper and lower couplings, the operation of the coupling can be better judged, and the hidden equipment risks and torsional vibration and resonance of the coupling can be compared. Record the abnormal torque peaks that are randomly generated. When an abnormal situation occurs during the correction process or there are hidden dangers in the equipment, the torque will be transmitted to the coupling. By analyzing the torque value of the coupling offline, find out the time period when the abnormality occurs, analyze the cause, and do preventive maintenance. If there are equipment hidden dangers in the transmission system, such as serious wear of the key plate at the connection position between the coupling sleeve and the working roll, resulting in excessive clearance, large or damaged bearing clearance in the cross-pack coupling, large or damaged bearing clearance in the coupling balance bearing seat, etc., the causes can be found through vibration analysis, thereby providing strong support for equipment maintenance.

[0117] The processing equipment analyzes and processes the received target torque data, displays and stores it in real time, and issues sound and light alarms for abnormal data; on-site operating staff adjust the equipment operating status based on the real-time target torque data; remote diagnosis engineers access the server database through the intranet or the Internet, analyze the data in detail, and then adjust the correction procedures.

[0118] In the embodiments provided in the present application, it should be understood that the disclosed devices and methods can also be implemented in other ways. The device embodiments described above are merely schematic. For example, the flowcharts and block diagrams in the accompanying drawings show the possible architecture, functions and operations of the devices, methods and computer program products according to the multiple embodiments of the present application. In this regard, each box in the flowchart or block diagram can represent a module, a program segment or a part of a code, and the module, a program segment or a part of a code contains one or more executable instructions for implementing the specified logical function. It should also be noted that in some alternative implementations, the functions marked in the box can also occur in a different order from the order marked in the accompanying drawings. For example, two consecutive boxes can actually be executed substantially in parallel, and they can sometimes be executed in the opposite order, depending on the functions involved. It should also be noted that each box in the block diagram and / or the flowchart, and the combination of boxes in the block diagram and / or the flowchart can be implemented with a dedicated hardware-based system that performs a specified function or action, or can be implemented with a combination of dedicated hardware and computer instructions.

[0119] In addition, each functional module in each embodiment of the present application can be integrated together to form an independent part, or each module can exist separately, or two or more modules can be integrated to form an independent part. If the function is implemented in the form of a software functional module and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on such an understanding, the technical solution of the present application is essentially or the part that contributes to the prior art or the part of the technical solution can be embodied in the form of a software product, and the computer software product is stored in a storage medium, including several instructions to enable a computer device (which can be a personal computer, a server, or a network device, etc.) to perform all or part of the steps of the method described in each embodiment of the present application. The aforementioned storage medium includes: various media that can store program codes, such as a USB flash drive, a mobile hard disk, a read-only memory (ROM, Read-Only Memory), a random access memory (RAM, Random Access Memory), a disk or an optical disk.

[0120] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.

[0121] The above are only various implementations of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art who is familiar with the present technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

Claims

1. A straightening machine transmission shaft monitoring system, characterized in that: The system comprises: Torque sensor, main control unit and processing equipment; The torque sensor is arranged on the measured transmission shaft of the straightening machine, and is used to collect torque data of the measured transmission shaft, and send the torque data to the main control unit; The main control unit converts the torque data of the mechanical signal into a target torque signal of an electrical signal, and sends the target torque signal to the processing device; The processing device is used to receive the target torque signal and analyze the target torque signal to monitor the state of the measured transmission shaft.

2. The system according to claim 1, characterized in that The torque sensor comprises a fixed outer ring, a rotating ring and a strain gauge; The rotating ring is fixedly connected to the transmission shaft to be measured, the fixed outer ring and the rotating ring are nested, and the strain gauge is used to determine the torque data of the transmission shaft to be measured.

3. The system according to claim 2, characterized in that The strain gauge includes a first strain resistor, a second strain resistor, a third strain resistor and a fourth strain resistor; The first strain resistor, the second strain resistor, the third strain resistor and the fourth strain resistor form a full bridge.

4. The system according to claim 3, characterized in that The first strain resistor and the second strain resistor are arranged in a first direction of the end surface of the measured transmission shaft; The third strain resistor and the fourth strain resistor are arranged in a second direction of the measured transmission shaft, wherein the first direction is perpendicular to the second direction.

5. The system according to claim 1, characterized in that The processing equipment is specifically used for: comparing the target torque signal with a preset torque signal; When the target torque signal is greater than or equal to the preset torque signal, an alarm signal indicating that the tested transmission shaft is abnormal is output.

6. The system according to claim 5, characterized in that The processing device is also used for: When the target torque signal is greater than or equal to the preset torque signal, determining the angles of the upper and lower rollers of the measured transmission shaft; Comparing the angles of the upper and lower rollers with preset angles; When the angles of the upper and lower rollers are greater than the preset angles, a prompt message is outputted indicating that the angles of the upper and lower rollers of the measured transmission shaft need to be adjusted; Alternatively, when the target torque signal is greater than or equal to the preset torque signal, determining the roller gap value of the upper and lower rollers of the measured transmission shaft; comparing the roll gap value with a preset roll gap value; When the roll gap value is less than the preset roll gap value, a prompt message is outputted indicating that the upper and lower roll gap values ​​of the measured transmission shaft need to be adjusted.

7. The system according to claim 5, characterized in that The processing equipment is specifically used for: determining a torque peak value of the target torque signal; comparing the peak torque value with a preset peak torque value; When the torque peak value is greater than or equal to the preset torque peak value, obtaining a time period corresponding to the torque peak value; Based on the time period corresponding to the torque peak, the fault cause of the tested transmission shaft is analyzed.

8. The system according to claim 5, characterized in that The processing equipment is specifically used for: determining torsional vibration and resonance of the target torque signal; comparing the torsional vibration with a preset torsional vibration; When the torsional vibration is greater than or equal to the preset torsional vibration, comparing the resonance with the preset resonance; When the resonance is greater than or equal to the preset resonance, it is determined that the angles of the upper and lower rollers of the measured transmission shaft are larger, or the roller gap between the upper and lower rollers of the measured transmission shaft is smaller, or the guide plate spacing of the measured transmission shaft is smaller, or the speed of the straightening machine is larger.

9. The system according to claim 8, characterized in that The processing device is also used for: When the resonance is greater than or equal to a preset resonance, determining the angles of the upper and lower rollers of the measured transmission shaft; Comparing the angles of the upper and lower rollers of the measured transmission shaft with a preset angle; When the angles of the upper and lower rollers of the measured transmission shaft are greater than or equal to the preset angle, a prompt message for adjusting the angles of the upper and lower rollers of the measured transmission shaft is output.

10. A method for monitoring a transmission shaft of a straightening machine, characterized in that: The transmission shaft to be tested is monitored by the straightening machine transmission shaft monitoring system according to any one of claims 1 to 9.

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