Full-automatic variable frequency cable drum device and control method

Abstract

The invention discloses a full-automatic variable-frequency cable drum device and a control method. The full-automatic variable-frequency cable drum device comprises a mounting frame, a drum, a variable-frequency electric cabinet, a motor assembly, a cable arrangement assembly and a guide assembly. The motor assembly comprises a winding drum motor, a cable arrangement motor, a cable conveying motor and a guide motor, and the winding drum motor, the cable arrangement motor, the cable conveying motor and the guide motor are electrically connected with the first frequency converter, the second frequency converter, the third frequency converter and the fourth frequency converter respectively. The drum motor, the cable arranging motor and the cable conveying motor are controlled through the multiple frequency converters respectively to achieve torque adjustment and speed matching, the problem that the cable winding speed of an existing cable drum device is inconsistent with the advancing speed of electric equipment is solved, and the problems that cables are stacked, disengaged from grooves, disordered, moved and loosened, clamped and abraded and the like are solved. The frequency converter controls the guide motor to achieve angle adjustment of the guide rod and torque protection of the cable, so that tension borne by the cable is reduced to the maximum extent, the smoothness of the cable winding process is guaranteed, and the service life of the cable is prolonged.

Description

Technical Field

[0001] The present invention relates to the technical field of cable reel devices, and in particular to a full-automatic variable frequency cable reel device and a control method. Background Art

[0002] With the continuous mining of large open-pit mines, large-scale electric-driven mechanical equipment powered by electric motors has also been increasing, such as electric excavators, electric rotary drills, etc. This type of electric mechanical equipment is generally connected to an external power supply (generally 6kV or 10kV) through a power supply cable. During production, the cable is dragged at the rear of the equipment, and the power supply cable must move forward, backward, left, and right continuously with the operation of the equipment. If the cable is retracted and released manually throughout the entire process, there is a risk of electric shock, inconvenience in operation, and the labor intensity is extremely high and the efficiency is extremely low. In particular, in recent years, with the introduction of new concepts of intelligent and unmanned mines, it is urgent to use innovative technologies such as the Internet of Things, cloud computing, big data, and unmanned driving to achieve high efficiency and safety in mine production. Therefore, the demand for automatic retractable devices for the tail cables of large electric-driven mechanical equipment and unmanned automatic control is becoming increasingly strong.

[0003] As an indispensable part of electric-driven mechanical equipment, cables are mainly wound on drums for winding and unwinding operations. The existing cable drum winding mechanism is composed of a motor connected to a reducer, and then the reducer is connected to the drum shaft. The cable drum driving unit is mostly a combination drive of a three-phase asynchronous motor and a hysteresis coupler, a combination drive of a three-phase asynchronous motor and a hydraulic coupler, or a combination drive of a frequency conversion control and a frequency conversion motor. When the existing electric excavators, electric rotary drills and other mechanical equipment are in mobile operation, the cable drum has problems such as the cable winding speed being inconsistent with the equipment moving speed, the large impact during the winding start and stop process, and the unadjustable winding path and torque. The cable tension is often too tight, too loose, or the impact moves, resulting in excessive cable accumulation, the cable on the drum is out of the groove, the cable is loose, and the cable is stuck, pulled off or worn. Accidents often occur, and the cable needs to be replaced frequently, which not only affects production efficiency and increases costs, but also poses certain safety hazards.

[0004] For example, the utility model patent CN217458338U proposes an automatic cable retracting and releasing device for electric excavators in open-pit mines. The cable reel is driven by a variable frequency motor, and the automatic cable arrangement mechanism adopts a chain guide. The outer diameter of the cable can be set through the control panel. After the counting sensor and PLC calculate the command value, it is transmitted to the servo motor and then driven by the reducer to drive the chain guide. The guide roller frame moves according to the regulations to ensure that the cable is neatly coiled, which solves the problem that the traditional cable arrangement can only design a transmission ratio for one specification of cable. However, this solution uses a single variable frequency motor to drive the cable reel, and the chain guide structure of the cable arrangement mechanism can only achieve speed ratio follow-up, and cannot adjust the speed ratio independently to eliminate the cumulative error; and it lacks the torque adjustment and speed matching functions during the retraction and release process, and cannot effectively solve the problems of impact, wire running, loose ring, and jamming in the process of cable reel retraction and release. Moreover, the existing cable reel control technology cannot meet the new technical requirements of the current smart unmanned mines. Therefore, how to realize unmanned and fully automatic cable reeling and releasing, synchronous following, torque protection, cable fault diagnosis and anti-crushing protection during the operation and movement of the equipment, and provide a safe, efficient and intelligent variable frequency cable reel control method is of great significance. Summary of the invention

[0005] In view of this, the present invention provides a fully automatic variable frequency cable reel device, which can realize the functions of torque regulation and speed matching during the cable reeling and releasing process, and effectively solve the problems of impact, wire running, loose ring, jamming, etc. of the cable reel device during the cable reeling and releasing process.

[0006] To achieve the above object, the present invention provides the following technical solutions: A full-automatic variable frequency cable reel device comprises: a mounting frame, a reel, a variable frequency electric control box, a motor assembly, a cable arrangement assembly and a guide assembly.

[0007] Among them, the drum is rotatably mounted on the mounting frame, the frequency conversion electric control box is mounted on the mounting frame and is located on one side of the drum, and a data processing module, a first frequency converter, a second frequency converter, a third frequency converter and a fourth frequency converter are arranged in the frequency conversion electric control box, the first frequency converter, the second frequency converter, the third frequency converter and the fourth frequency converter are all electrically connected to the data processing module, and the data processing module is electrically connected to the equipment controller; the motor assembly includes a drum motor, a cable arrangement motor, a cable transmission motor and a guide motor, the drum motor, the cable arrangement motor, the cable transmission motor and the guide motor are electrically connected to the first frequency converter, the second frequency converter, the third frequency converter and the fourth frequency converter respectively, the drum motor is mounted at one end of the drum shaft to drive the drum shaft to rotate forward or reverse, thereby driving the drum to rotate forward or Reversal; the cable arrangement assembly includes a cable arrangement wire rod and a cable arrangement device, the cable arrangement wire rod is mounted at the rear of the drum, the cable arrangement device is threadedly assembled on the cable arrangement wire rod, and the cable arrangement motor is installed at one end of the cable arrangement wire rod to drive the cable arrangement wire rod to rotate, thereby driving the cable arrangement device to move left and right on the cable arrangement wire rod; the cable transmission motor is installed on the cable arrangement device to drive the cable arrangement device to work; the guide assembly includes a guide rod, a left torque sensor and a right torque sensor, one end of the guide rod is horizontally movably connected to the mounting frame through a guide motor, the guide motor is used to control the guide rod to swing left and right, and a wire feeder is arranged on the other end of the guide rod, the left torque sensor and the right torque sensor are respectively arranged on the left and right sides of the wire feeder, and the left torque sensor and the right torque sensor are both connected to the device controller signal.

[0008] Preferably, the cable arranger is provided with a square roller wire inlet, a pressure wheel, a front vertical roller, a rear vertical roller and a bottom transverse roller, and a plurality of the bottom transverse rollers are spaced apart along the front and rear directions of the cable arranger, and the square roller wire inlet, the front vertical roller, the pressure wheel and the rear vertical roller are sequentially arranged above the bottom transverse roller from front to back, and the square roller wire inlet, the pressure wheel, the front vertical roller, the rear vertical roller and the bottom transverse roller together constitute a cable conveying channel; the cable conveying motor is connected to the pressure wheel through a motor shaft to control the rotation of the pressure wheel.

[0009] Preferably, the cable arranger is also provided with a pressure wheel regulator, which is installed on the motor shaft of the cable transport motor and is used to adjust the position of the pressure wheel in the up and down directions, thereby adjusting the gap size between the pressure wheel and the bottom transverse roller.

[0010] Preferably, the guide assembly further comprises a support rod and a rotating shaft structure, wherein the rotating shaft structure is arranged under the upper cross beam of the mounting frame, one end of the support rod is fixedly connected to the rotating shaft structure, and the other end is fixedly connected to the wire feeder.

[0011] Preferably, with the guide motor as a 0° horizontal reference, the guide motor can control the guide rod to swing within a range of 45° to the left and 45° to the right.

[0012] The present invention also proposes a control method for a fully automatic variable frequency cable reel device, which is applied to the above-mentioned fully automatic variable frequency cable reel device, comprising: the equipment controller calculates and outputs a first control instruction to the variable frequency electric control box according to the operation instructions and travel speed instructions issued by the operating mechanism and in combination with the reel size, reel winding capacity, number of winding layers and cable outer diameter; the equipment controller calculates and outputs a second control instruction to the variable frequency electric control box according to the torque signals issued by the left torque sensor and the right torque sensor; the variable frequency electric control box controls the operation of the motor assembly according to the first control instruction and the second control instruction, so that the cable reel device and the electrical equipment are adapted to operate as a whole.

[0013] Preferably, the variable frequency electric control box controls the operation of the motor assembly according to the first control instruction, including the following contents: the first control instruction includes a drum control instruction, a cable arrangement control instruction and a cable transmission control instruction; the data processing module controls the operation of the drum motor through the first frequency converter according to the drum control instruction, so that the rotation speed of the drum is synchronized with the overall travel speed of the electrical equipment; the data processing module controls the operation of the cable arrangement motor through the second frequency converter according to the cable arrangement control instruction, so that the moving speed of the cable arrangement device is synchronized with the rotation speed of the drum; the data processing module controls the operation of the cable transmission motor through the third frequency converter according to the cable transmission control instruction, so that the cable transmission speed is synchronized with the overall travel speed of the electrical equipment.

[0014] Preferably, the variable frequency electric control box controls the operation of the motor assembly according to the second control instruction, including the following contents: the second control instruction includes a guide control instruction and an overload protection instruction; the data processing module controls the guide motor to drive the guide rod to swing left or right within the range of 45° to the left and 45° to the right through the fourth frequency converter according to the guide control instruction, so that the force directions of the guide rod and the cable are in the same direction, so that the cable torque acting on the guide rod is minimized; when the steering angle of the guide rod exceeds the range of 45° to the left and 45° to the right, the data processing module controls the guide motor to drive the guide rod to swing back to the swing range of 45° to the left and 45° to the right through the fourth frequency converter according to the overload protection instruction.

[0015] Preferably, a buffer protection program and a hovering control program are preset in the data processing module to realize the buffer protection function of cable reeling and releasing and the hovering function of the cable; the buffer protection program is: when the drum starts to reel in the cable, the cable transmission motor delays loading and starting compared to the drum motor; when the drum stops reeling in the cable, the cable transmission motor stops loading earlier than the drum motor; the hovering control program is: when the electrical equipment as a whole is in a static state, the pressure wheel connected to the cable transmission motor is controlled by the fourth inverter to output a preset cable reeling torque, so that the cable is in a hovering state when the equipment is static.

[0016] The beneficial effects of the present invention are as follows: compared with the prior art, the fully automatic variable frequency cable reel device disclosed in the present application controls the reel motor, the cable arrangement motor and the cable transmission motor respectively through multiple frequency converters to achieve torque adjustment and speed matching, solves the problem of the inconsistency between the cable winding speed and the travel speed of the electrical equipment in the existing cable reel device, and solves the problems of cable accumulation, cable derailment, loose ring movement, and jamming and wear. The guide motor is controlled by the frequency converter to achieve the angle adjustment of the guide rod and the torque protection of the cable. During the winding process, the winding path is automatically optimized based on the minimum torque condition, thereby minimizing the tension on the cable, thereby ensuring the smoothness of the cable winding process and extending the service life of the cable.

[0017] Additional aspects and advantages of the present invention will be given in part in the following description and in part will be obvious from the following description, or will be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a structural schematic diagram of the fully automatic variable frequency cable reel device of the present invention; Figure 2 It is a structural schematic diagram of the cable arrangement device of the fully automatic variable frequency cable reel device of the present invention; Figure 3 It is a control flow chart of the full-automatic variable frequency cable reel device of the present invention.

[0019] Reference numerals: 1. Mounting frame; 2. Reel; 3. Frequency conversion electric control box; 4. Motor assembly; 41. Drum motor; 42. Cable arrangement motor; 43. Cable transmission motor; 44. Guide motor; 5. Cable arrangement assembly; 51. Cable arrangement screw rod; 52. Cable arrangement device; 521. Square roller inlet; 522. Pressure roller; 523. Front vertical roller; 524. Rear vertical roller; 525. Bottom horizontal roller; 526. Pressure roller adjuster; 6. Guide assembly; 61. Guide rod; 62. Left torque sensor; 63. Right torque sensor; 64. Support rod; 65. Rotating shaft structure; 611. Wire feeder. DETAILED DESCRIPTION

[0020] The invention discloses a fully automatic variable frequency cable reel device, which can realize the functions of torque regulation and speed matching during cable reeling and releasing, and effectively solve the problems of impact, wire running, loose ring, jamming, etc. existing in the cable reel device during cable reeling and releasing.

[0021] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be construed as limiting the present invention.

[0022] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.

[0023] Reference below Figures 1 to 3 The fully automatic variable frequency cable reel device in the embodiment of the present invention is described.

[0024] The embodiment of the present application discloses a fully automatic variable frequency cable reel device, comprising: a mounting frame 1, a reel 2, a variable frequency electric control box 3, a motor assembly 4, a cable arrangement assembly 5 and a guide assembly 6.

[0025] Among them, the reel 2 is rotatably mounted on the mounting frame 1, the frequency conversion electric control box 3 is mounted on the mounting frame 1 and is located on one side of the reel 2, and the frequency conversion electric control box 3 is provided with a data processing module, a first frequency converter, a second frequency converter, a third frequency converter and a fourth frequency converter, the first frequency converter, the second frequency converter, the third frequency converter and the fourth frequency converter are all electrically connected to the data processing module, and the data processing module is electrically connected to the equipment controller; the equipment controller can issue control instructions to the data processing module so that the data processing module controls the first frequency converter, the second frequency converter, the third frequency converter and the fourth frequency converter to work respectively according to the control instructions.

[0026] The motor assembly 4 includes a drum motor 41, a cable arrangement motor 42, a cable transmission motor 43 and a guide motor 44. The drum motor 41, the cable arrangement motor 42, the cable transmission motor 43 and the guide motor 44 are electrically connected to the first frequency converter, the second frequency converter, the third frequency converter and the fourth frequency converter respectively. The first frequency converter, the second frequency converter, the third frequency converter and the fourth frequency converter can individually control the drum motor 41, the cable arrangement motor 42, the cable transmission motor 43 and the guide motor 44 according to the instructions of the data processing module, so that the multiple motors can cooperate with each other, thereby realizing the overall cable winding speed autonomous adjustment function of the device, so that the cable winding speed can match the current travel speed of the electrical equipment in real time. Compared with the simple speed ratio following design in tradition, it is no longer affected by the cumulative error.

[0027] The installation and transmission of each motor in the motor assembly 4 are as follows Figure 1As shown, the drum motor 41 is installed at one end of the drum 2 shaft to drive the drum 2 shaft to rotate forward or reverse, thereby driving the drum 2 to rotate forward or reverse to complete the work of cable winding and cable releasing.

[0028] The cable arrangement assembly 5 includes a cable arrangement screw rod 51 and a cable arrangement device 52. The cable arrangement screw rod 51 is mounted behind the drum 2, and the cable arrangement device 52 is threadedly assembled on the cable arrangement screw rod 51. The cable arrangement motor 42 is installed at one end of the cable arrangement screw rod 51 to drive the cable arrangement screw rod 51 to rotate, thereby driving the cable arrangement device 52 to move left and right on the cable arrangement screw rod 51; specifically, the data processing module coordinates and matches the drum motor 41 and the cable arrangement motor 42 through the first frequency converter and the second frequency converter according to the control instruction, that is, by controlling the speed ratio of the rotation speed of the drum 2 to the rotation speed of the cable arrangement screw rod 51, to ensure that the cable arrangement device 52 arranges the cables neatly and sequentially on the outside of the drum 2.

[0029] The cable transmission motor 43 is installed on the cable reel 52 to drive the cable reel 52 to work; specifically, the cable transmission motor 43 is installed on the side of the cable reel 52, and the data processing module drives the cable transmission motor 43 on the cable reel 52 to rotate forward or reverse through the third frequency converter, thereby realizing the cable reeling or cable unwinding. At the same time, the data processing module coordinates and matches the drum motor 41 and the cable transmission motor 43 through the first frequency converter and the third frequency converter according to the control instructions, so that the rotation speed of the drum 2 and the cable transmission speed are synchronized with the overall travel speed of the electrical equipment, thereby ensuring that there will be no cable impact, wire skewing, loose loops, jamming and other problems during the cable transmission or cable unwinding process, so that the overall cable transmission and unwinding process of the device is more stable and smooth.

[0030] The guide assembly 6 includes a guide rod 61, a left torque sensor 62 and a right torque sensor 63. One end of the guide rod 61 is horizontally movably connected to the mounting frame 1 through a guide motor 44. The guide motor 44 is used to control the left and right swings of the guide rod 61. A wire feeder 611 is provided on the other end of the guide rod 61. The left torque sensor 62 and the right torque sensor 63 are respectively provided on the left and right sides of the wire feeder 611. The left torque sensor 62 and the right torque sensor 63 are both connected to the device controller signal. Specifically, the guide assembly 6 can support and guide the cable so that the cable retraction process will be smoother and avoid the cable from getting stuck during the retraction process. The device controller can transmit an adjustment instruction of the guide motor 44 to the data processing module according to the torque signal transmitted by the left torque sensor 62 or the right torque sensor 63. The data processing module controls the guide motor 44 to rotate forward or reverse through the fourth frequency converter according to the adjustment instruction, so that the guide rod 61 swings within the range of 45° to 45° to the left with the guide motor 44 as the 0° horizontal reference. During the swinging of the guide rod 61, the left torque sensor 62 or the right torque sensor 63 will still transmit the torque signal to the device controller in real time until the torque data transmitted by the torque signal is minimum. Then the guide motor 44 stops rotating, and the guide rod 61 supports and guides the cable at the current angle. At this time, the cable torque applied to the cable during the retraction and release process is minimum, which can minimize the influence of the torque on the retraction and release of the cable, thereby ensuring smooth retraction and release of the cable.

[0031] In this embodiment, multiple frequency converters are used to control the drum motor 41, the cable arrangement motor 42 and the cable transmission motor 43 to achieve torque adjustment and speed matching, thereby solving the problem of the inconsistency between the cable winding speed and the travel speed of the electrical equipment in the existing cable drum device, and solving the problems of cable accumulation, cable derailment, loose ring movement, and jamming and wear. The guide motor 44 is controlled by the frequency converter to achieve angle adjustment of the guide rod 61 and torque protection of the cable. During the winding process, the winding path is automatically optimized based on the minimum torque condition, thereby minimizing the tension on the cable, thereby ensuring the smoothness of the cable winding process and extending the service life of the cable.

[0032] In some embodiments, for example Figure 2As shown, the cable arranger 52 is provided with a square roller wire inlet 521, a pressure wheel 522, a front vertical roller 523, a rear vertical roller 524 and a bottom transverse roller 525. The multiple bottom transverse rollers 525 are spaced apart along the front and rear directions of the cable arranger 52. The square roller wire inlet 521, the front vertical roller 523, the pressure wheel 522 and the rear vertical roller 524 are sequentially arranged above the bottom transverse roller 525 from front to back. The square roller wire inlet 521, the pressure wheel 522, the front vertical roller 523, the rear vertical roller 524 and the bottom transverse roller 525 together constitute a cable transmission channel. The cable transmission motor 43 is connected to the pressure wheel 522 through a motor shaft to control the rotation of the pressure wheel 522. The cable arranger 52 is also provided with a pressure wheel regulator 526 which is mounted on the motor shaft of the cable transport motor 43 and is used to adjust the position of the pressure wheel 522 in the up and down directions, thereby adjusting the gap between the pressure wheel 522 and the bottom transverse roller 525 .

[0033] Specifically, the cable transmission motor 43 is installed on the side of the cable arrangement 52, and the pressure wheel 522 connected to the motor shaft of the cable transmission motor 43 is located between the front and rear vertical rollers 524, and is vertically located above the transverse rollers of the cable arrangement 52, and a gap is reserved with the bottom transverse roller 525 for the cable to pass through, so that the cable can pass through the square roller inlet 521 at the front of the cable arrangement 52, the bottom transverse roller 525, the front vertical roller 523, the gap between the pressure wheel 522 and the bottom transverse roller 525, and the rear vertical roller 524. The pressure wheel regulator 526 connected to the motor shaft of the cable transmission motor 43 can realize the upward and downward adjustment of the position of the pressure wheel 522. According to the outer diameter of the cable passing through the gap, the gap between the pressure wheel 522 and the bottom transverse roller 525 is adjusted by the pressure wheel regulator 526, so as to provide an adjustable compression friction force for the cable, so that the pressure wheel 522 can use the compression friction force to transport the cable.

[0034] In this embodiment, the data processing module controls the action of the cable transmission motor 43 through the third frequency converter, and can also realize the buffer protection function and the suspension control function of the cable, specifically: in the buffer protection process, in order to reduce the rotation impact of the instantaneous start when the reel 2 is cabled, the cable transmission motor 43 is delayed in loading and starting compared with the reel motor 41, and the friction resistance between the pressure wheel 522 and the bottom transverse roller 525 during the delayed stop period is used to provide a buffer to prevent the cable from being suddenly forced to move and loosening the coil and messing the line at the moment of starting; at the same time, in order to reduce the rotation impact of the instantaneous stop when the reel 2 is cabled, the cable transmission motor 43 stops loading in advance compared with the reel motor 41, and the friction resistance between the pressure wheel 522 and the bottom transverse roller 525 during the early stop period is used to provide a buffer to prevent the cable from being loosened and messing the line at the moment of stopping due to inertial impact. Especially in the process of reeling the cable, the pressure wheel 522 connected to the cable transmission motor 43 is controlled to always provide a cable release tension to overcome the friction resistance at the cable arranger 52, so as to prevent the cable from being blocked and loosening the coil and messing the line when there is no tension.

[0035] During the hovering control process, the hovering torque is preset in the data processing module according to the suspended length of the cable from the cable arranger 52 to the ground and the total weight of the cable, combined with factors such as friction resistance. The hovering torque is the cable-retracting torque output by the pressure wheel 522 connected to the cable transmission motor 43 when the device is in a stationary state. The torque is too small to achieve the cable-retracting operation, and can only overcome the tension generated by the deadweight of the suspended cable, thereby ensuring that the cable is in a suspended state when the device is stationary, and preventing the drum 2 from rotating out of control due to the influence of the deadweight of the cable.

[0036] In some embodiments, for example Figure 1 As shown, the guide assembly 6 also includes a support rod 64 and a pivot structure 65. The pivot structure 65 is arranged under the upper cross beam of the mounting frame 1. One end of the support rod 64 is fixedly connected to the pivot structure 65, and the other end is fixedly connected to the wire feeder 611. The support frame is connected to the pivot structure 65, which can provide support for the left and right swing of the guide rod 61 to prevent the guide rod 61 from sagging and deforming due to its own weight.

[0037] The present invention also proposes a fully automatic variable frequency cable reel device control method, which is applied to the above-mentioned fully automatic variable frequency cable reel device, specifically comprising: the equipment controller calculates and outputs a first control instruction to the variable frequency electric control box 3 according to the operation instruction and travel speed instruction issued by the operating mechanism and in combination with the reel size, reel winding capacity, number of winding layers and cable outer diameter; the equipment controller calculates and outputs a second control instruction to the variable frequency electric control box 3 according to the torque signal issued by the left torque sensor 62 and the right torque sensor 63; the variable frequency electric control box 3 controls the operation of the motor assembly 4 according to the first control instruction and the second control instruction, so that the cable reel device and the electrical equipment are adapted to operate as a whole.

[0038] Specifically, during the movement of the electrical equipment, the driver operates the handle or the remote control center to issue operating instructions for the electrical equipment to move forward, backward, turn left, or turn right, and the speed measuring device issues a speed value for the electrical equipment, which is then received and processed by the equipment controller.

[0039] The equipment controller calculates the speed command value (i.e., the first control command) for cable winding or releasing that matches the travel speed of the electrical equipment according to the parameters such as the drum winding capacity, the number of winding layers, and the outer diameter of the cable, and synchronously controls the first frequency converter to drive the drum motor 41, the second frequency converter to drive the cable arrangement motor 42, and the third frequency converter to drive the cable transmission motor 43, so as to realize the synchronization of torque regulation and speed command value. Specifically, the data processing module controls the torque of the drum motor 41, the cable arrangement motor 42, and the cable transmission motor 43 to be continuously adjustable according to the speed command value, that is, the longer the paid-out cable, the greater the force of the variable frequency cable reel 2 to reel in the cable, and vice versa, so as to ensure that the increased or decreased distance of the equipment movement is completely matched with the length of the cable release or winding, and at the same time ensure that the cable is subjected to minimal force when the cable is wound or released at any length.

[0040] The equipment controller determines the stress condition of the cable on the left or right side of the support rod 64 according to the torque signals transmitted by the left torque sensor 62 and the right torque sensor 63, thereby transmitting a second control instruction to the data processing module, and driving the guide motor 44 forward or reverse through the fourth inverter, thereby controlling the guide rod 61 to swing left and right, so as to measure the minimum cable torque exerted on the guide rod 61, and perform winding and releasing operations in this position, which can minimize the tension on the cable, thereby ensuring the smoothness of the cable winding process and extending the service life of the cable.

[0041] The frequency conversion electric control box 3 controls the operation of the motor assembly 4 according to the first control instruction, including the following contents: the first control instruction includes a drum control instruction, a cable arrangement control instruction and a cable transmission control instruction; the data processing module controls the operation of the drum motor 41 through the first frequency converter according to the drum control instruction, so that the rotation speed of the drum 2 is synchronized with the overall travel speed of the electrical equipment; the data processing module controls the operation of the cable arrangement motor 42 through the second frequency converter according to the cable arrangement control instruction, so that the moving speed of the cable arrangement device 52 is synchronized with the rotation speed of the drum 2; the data processing module controls the operation of the cable transmission motor 43 through the third frequency converter according to the cable transmission control instruction, so that the cable transmission speed is synchronized with the overall travel speed of the electrical equipment.

[0042] Specifically, for example Figure 1 As shown, when the cable drum 2 is automatically retracted and released, the data processing module outputs a drum speed instruction of the drum motor 41 according to the drum control instruction, and further controls the first frequency converter to drive the drum motor 41 to rotate forward, thereby realizing the cable reeling speed control by driving the cable drum 2 to rotate forward, and conversely controls the first frequency converter to drive the drum motor 41 to rotate reversely, thereby realizing the cable releasing speed control by driving the drum 2 to rotate reversely.

[0043] The data processing module outputs the cable arrangement speed instruction of the cable arrangement motor 42 according to the cable arrangement control instruction, further controls the forward rotation speed of the cable arrangement motor 42 driven by the second frequency converter, and drives the cable arrangement screw rod 51 to rotate forward through the cable arrangement motor 42, so as to drive the cable arrangement device 52 on the cable arrangement screw rod 51 to move from the initial left end position to the right, and guides the cable to complete the speed matching of the cable drum 2 when the cable is collected in the forward rotation by controlling the right movement speed of the cable arrangement device 52, so that the cable is wound around the outside of the cable drum 2 in turn, so as to achieve the precision control of cable arrangement without gap between two adjacent turns, and the first frequency converter and the second frequency converter respectively obtain the rotation speed, torque and other parameters of the drum motor 41 and the cable arrangement motor 42, and then the equipment controller calculates the number of winding turns, for example, controlling to achieve 30 turns of winding per layer, one turn is about 6 meters, and one layer is about 180 meters. When the number of turns of one layer reaches the calculated number of turns, the second frequency converter is controlled to drive the cable arrangement motor 42 to reverse the direction, so as to drive the cable arrangement screw rod 51 to reverse through the cable arrangement motor 42, thereby driving the cable arrangement device 52 on the cable arrangement screw rod 51 to move leftward to perform the second layer cable arrangement operation. When the number of turns of the second layer reaches the calculated number of turns again, the cable arrangement motor 42 is controlled to rotate forward again, and the winding operation of one layer is repeated, and finally the cable winding operation is completed.

[0044] During the cable winding process of the reel 2, the data processing module controls the third frequency converter according to the cable transmission control instruction to drive the cable transmission motor 43 on the cable arranger 52 to operate, thereby controlling the torque and speed of the pressure wheel 522 connected to the motor shaft driving the cable transmission motor 43, so that the speed of the cable conveying by the pressure wheel 522 is synchronized with the travel speed of the electrical equipment.

[0045] The variable frequency electric control box 3 controls the operation of the motor assembly 4 according to the second control instruction, including the following contents: the second control instruction includes a guide control instruction and an overload protection instruction; the data processing module controls the guide motor 44 through the fourth frequency converter according to the guide control instruction to drive the guide rod 61 to swing left or right within the range of 45° to the left and 45° to the right, so that the force direction of the guide rod 61 and the cable are in the same direction, so that the cable torque on the guide rod 61 is minimized; when the steering angle of the guide rod 61 exceeds the range of 45° to the left and 45° to the right, the data processing module controls the guide motor 44 through the fourth frequency converter according to the overload protection instruction to drive the guide rod 61 to swing back to the swing range of 45° to the left and 45° to the right.

[0046] Specifically, the left torque sensor 62 is installed at the left roller of the square roller inlet 521, and is used to measure the torque of the left roller during the cable retraction process. The right torque sensor 63 is installed at the right roller of the square roller inlet 521, and is used to measure the torque of the right roller during the cable retraction process. The device controller determines the force condition of the left or right cable of the guide rod 61 according to the torque signal transmitted by the left torque sensor 62 and the right torque sensor 63, and then sends a guide control instruction to the data processing module, and drives the guide motor 44 to rotate forward or reverse through the fourth inverter to control the guide rod 61 to swing between 45° to the left and 45° to the right, so as to measure the minimum cable torque within the angle range, and perform the winding and retraction operation at this position angle state.

[0047] The data processing module is preset with a buffer protection program and a hovering control program to realize the buffer protection function of cable reeling and releasing and the cable hovering function; the buffer protection program is: when the drum 2 starts to reel in the cable, the cable transmission motor 43 delays loading and starting compared to the drum motor 41; when the drum 2 stops reeling in the cable, the cable transmission motor 43 stops loading earlier than the drum motor 41; the hovering control program is: when the electrical equipment as a whole is in a static state, the pressure wheel 522 connected to the cable transmission motor 43 is controlled by the fourth inverter to output a preset cable reeling torque, so that the cable is in a hovering state when the equipment is static.

[0048] Specifically, during the buffer protection process, in order to reduce the rotational impact of the instantaneous start of the drum 2 when it is reeling in the cable, the cable transmission motor 43 is delayed in loading and starting compared to the drum motor 41, and the friction resistance between the pressure wheel 522 and the bottom transverse roller 525 during the delayed stop period is used to provide a buffer to prevent the cable from being loosened and disordered due to sudden force when starting; in order to reduce the rotational impact of the instantaneous stop of the drum 2 when it is reeling in the cable, the cable transmission motor 43 stops loading earlier than the drum motor 41, and the friction resistance between the pressure wheel 522 and the bottom transverse roller 525 during the early stop period is used to provide a buffer to prevent the cable from being loosened and disordered due to inertial impact when it stops. The delayed loading start time and the early stop loading time can be adjusted according to actual conditions, and are not specifically limited here.

[0049] During the hovering control process, the hovering torque value required for the cable to hover is calculated based on the suspended length of the cable from the cable arranger 52 to the ground, the total weight of the cable, the friction resistance and other factors, and the hovering torque value is preset in the data processing module. The hovering torque is the cable-winding torque output by the pressure wheel 522 connected to the cable transmission motor 43 when the device is stationary. This torque is too small to achieve the cable-winding operation, and can only overcome the tension generated by the deadweight of the suspended cable, thereby ensuring that the cable is in a suspended state when the device is stationary, and preventing the drum 2 from rotating out of control due to the deadweight of the cable.

[0050] In addition, during the cable release process of the drum 2, the pressure wheel 522 connected to the cable transport motor 43 is controlled to always provide a certain cable release tension to overcome the friction resistance at the cable arranger 52. This can prevent the cable from being loosened and tangled due to obstruction when there is no tension.

[0051] The equipment controller can adjust the operating system parameters of the fully automatic variable frequency cable reel device through the monitor, and the monitor can monitor and display the current status of the device in real time and issue early warning alarms to the device. The equipment controller can also obtain the operating information of the fully automatic variable frequency cable reel device in real time through the communication device and receive the control instructions issued by the remote control platform.

[0052] Other structures and operations of the full-automatic variable frequency cable reel device and the control method of the full-automatic variable frequency cable reel device according to the embodiments of the present invention are well known to those skilled in the art and will not be described in detail here.

[0053] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, without contradiction.

[0054] Although the embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the claims and their equivalents.

Claims

1. A fully automatic variable frequency cable reel device, characterized in that: include: Mounting frame, reel, variable frequency electric control box, motor assembly, cable assembly and guide assembly; The reel is rotatably mounted on the mounting frame, the variable frequency electric control box is mounted on the mounting frame and is located on one side of the reel, a data processing module, a first frequency converter, a second frequency converter, a third frequency converter and a fourth frequency converter are arranged in the variable frequency electric control box, the first frequency converter, the second frequency converter, the third frequency converter and the fourth frequency converter are all electrically connected to the data processing module, and the data processing module is electrically connected to the equipment controller; The motor assembly includes a drum motor, a cable arrangement motor, a cable transmission motor and a guide motor, wherein the drum motor, the cable arrangement motor, the cable transmission motor and the guide motor are electrically connected to the first frequency converter, the second frequency converter, the third frequency converter and the fourth frequency converter respectively, and the drum motor is installed at one end of the drum shaft to drive the drum shaft to rotate forward or reverse, thereby driving the drum to rotate forward or reverse; The cable arrangement assembly includes a cable arrangement screw rod and a cable arrangement device, wherein the cable arrangement screw rod is mounted behind the drum, the cable arrangement device is threadedly mounted on the cable arrangement screw rod, the cable arrangement motor is mounted at one end of the cable arrangement screw rod to drive the cable arrangement screw rod to rotate, thereby driving the cable arrangement device to move left and right on the cable arrangement screw rod; the cable transmission motor is mounted on the cable arrangement device to drive the cable arrangement device to work; The guide assembly includes a guide rod, a left torque sensor and a right torque sensor. One end of the guide rod is horizontally movably connected to the mounting frame through the guide motor. The guide motor is used to control the left and right swing of the guide rod. A wire feeder is arranged on the other end of the guide rod. The left torque sensor and the right torque sensor are respectively arranged on the left and right sides of the wire feeder. The left torque sensor and the right torque sensor are both connected to the device controller signal.

2. The fully automatic variable frequency cable reel device according to claim 1, characterized in that: The cable arranger is provided with a square roller wire inlet, a pressure wheel, a front vertical roller, a rear vertical roller and a bottom transverse roller, a plurality of the bottom transverse rollers are spaced apart along the front and rear directions of the cable arranger, the square roller wire inlet, the front vertical roller, the pressure wheel and the rear vertical roller are sequentially arranged above the bottom transverse roller from front to back, the square roller wire inlet, the pressure wheel, the front vertical roller, the rear vertical roller and the bottom transverse roller together constitute a cable conveying channel; the cable conveying motor is connected to the pressure wheel through a motor shaft to control the rotation of the pressure wheel.

3. The fully automatic variable frequency cable reel device according to claim 2, characterized in that: The cable arranger is also provided with a pressure wheel regulator, which is installed on the motor shaft of the cable transport motor. The pressure wheel regulator is used to adjust the position of the pressure wheel in the up and down directions, thereby adjusting the gap size between the pressure wheel and the bottom transverse roller.

4. The fully automatic variable frequency cable reel device according to claim 1, characterized in that: The guide assembly also includes a support rod and a rotating shaft structure. The rotating shaft structure is arranged under the upper cross beam of the mounting frame. One end of the support rod is fixedly connected to the rotating shaft structure, and the other end is fixedly connected to the wire feeder.

5. The fully automatic variable frequency cable reel device according to claim 1, characterized in that: With the guide motor as a 0° horizontal reference, the guide motor can control the guide rod to swing within a range of 45° to the left and 45° to the right.

6. A control method for a fully automatic variable frequency cable reel device, applied to the fully automatic variable frequency cable reel device as claimed in any one of claims 1 to 5, characterized in that: include: The equipment controller calculates and outputs a first control instruction to the variable frequency electric control box according to the operation instruction and the travel speed instruction issued by the operating mechanism and in combination with the drum size, the drum winding capacity, the number of winding layers and the outer diameter of the cable; The equipment controller calculates and outputs a second control instruction to the frequency conversion electric control box according to the torque signals sent by the left torque sensor and the right torque sensor; The variable frequency electric control box controls the operation of the motor assembly according to the first control instruction and the second control instruction, so that the cable reel device and the electrical equipment can be adapted to operate as a whole.

7. The control method of the fully automatic variable frequency cable reel device according to claim 6, characterized in that: The variable frequency electric control box controls the operation of the motor assembly according to the first control instruction, including the following contents: The first control instruction includes a reel control instruction, a cable arrangement control instruction and a cable transmission control instruction; The data processing module controls the operation of the drum motor through the first frequency converter according to the drum control instruction, so that the rotation speed of the drum is synchronized with the overall travel speed of the electrical equipment; The data processing module controls the operation of the cable arrangement motor through the second frequency converter according to the cable arrangement control instruction, so that the moving speed of the cable arrangement device is synchronized with the rotation speed of the drum; The data processing module controls the operation of the cable transmission motor through the third frequency converter according to the cable transmission control instruction, so that the cable transmission speed is synchronized with the overall travel speed of the electrical equipment.

8. The control method of the fully automatic variable frequency cable reel device according to claim 6, characterized in that: The variable frequency electric control box controls the operation of the motor assembly according to the second control instruction, including the following contents: The second control instruction includes a guidance control instruction and an overload protection instruction; The data processing module controls the guide motor through the fourth frequency converter according to the guide control instruction to drive the guide rod to swing left or right within the range of 45° to the left and 45° to the right, so that the force direction of the guide rod and the cable is in the same direction, so that the cable torque on the guide rod is minimized; When the steering angle of the guide rod exceeds the range of 45° to 45° on the left, the data processing module controls the guide motor through the fourth inverter according to the overload protection instruction to drive the guide rod to swing back to the swing range of 45° to 45° on the left.

9. The control method of the fully automatic variable frequency cable reel device according to claim 7, characterized in that: The data processing module is preset with a buffer protection program and a hovering control program to realize the buffer protection function of the cable retracting and the cable hovering function; The buffer protection procedure is: when the drum starts to reel in the cable, the cable transmission motor starts loading later than the drum motor; when the drum stops reeling in the cable, the cable transmission motor stops loading earlier than the drum motor; The hovering control procedure is: when the electrical equipment as a whole is in a stationary state, the pressure wheel connected to the cable transmission motor is controlled by the fourth inverter to output a preset cable retracting torque so that the cable is in a hovering state when the equipment is stationary.

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