A real-time dimension monitoring system for wire rope production

Abstract

The present invention discloses a real-time dimension monitoring system for steel wire rope production, which relates to the technical field of dimension monitoring. The present invention utilizes a force-sensitive resistor to monitor minute changes in the diameter of the steel wire, and reflects the change in diameter through voltage changes; by detecting the inductance of the second spring, it is possible to monitor whether the elastic force of the spring has changed, so that even after long-term use, the accuracy and reliability of the measurement system can still be guaranteed, avoiding measurement errors caused by spring aging. This design extends the service life of the equipment and reduces maintenance costs; it can not only monitor the diameter of the steel wire, but also measure the moving speed and distance of the steel wire through induced electromotive force. By integrating multi-dimensional data collection, the status of the steel wire in the production process is comprehensively monitored to ensure the consistency of product quality. This comprehensive measurement method can provide more production data support.

Description

Technical Field

[0001] The present invention relates to the technical field of dimension monitoring, and in particular to a real-time dimension monitoring system for steel wire rope production. Background Art

[0002] During the production process, steel wire ropes are formed by winding tiny steel wires together. Since the number of strands forming the steel wire rope is fixed, the diameter of the steel wire directly affects the strength of the wire rope. Currently, most steel wire production is not subject to dimensional monitoring and is directly used after production. The main reason is that due to the very long length of the steel wire, a large amount of manpower and material resources are required to monitor the size of the steel wire. In addition, manual measurement is very inefficient and has low accuracy. Therefore, it is necessary to develop a device that monitors the outer dimensions of the steel wire. During the steel wire production process, the diameter and length of the steel wire are monitored around the clock to ensure that the steel wire size is qualified. Summary of the Invention

[0003] In order to overcome the defects of the above-mentioned prior art, the present invention provides the following technical solutions: a real-time size monitoring system for wire rope production, comprising a base, on which two symmetrically arranged monitoring parts and two mutually perpendicularly arranged support parts are fixedly mounted; wherein the monitoring part comprises a monitoring support plate, on which a monitoring slide rod and a conductive slider support rod are slidably mounted via a spline, and one end of the conductive slider support rod is fixedly mounted with a contact conductive slider that slides in contact with the steel wire, and the contact conductive sliders in the two monitoring parts need to be symmetrically arranged on the circumferential surface of the steel wire, and permanent magnets are provided on the upper and lower sides of the symmetry plane of the two contact conductive sliders; wherein one end of the monitoring slide rod is fixedly mounted with an extrusion support plate, on which a contact roller bracket is slidably mounted, and a contact roller is rotatably mounted on the contact roller bracket, and the contact roller rolls in contact with the surface of the steel wire.

[0004] Preferably, two sliding pins are symmetrically fixed on the contact roller bracket, the sliding pins slide with the extrusion support plate, and each sliding pin is also fixed with a limiting ring for limiting the extrusion support plate, and a force-sensitive resistor is provided between the opposite surfaces of the contact roller bracket and the extrusion support plate.

[0005] Preferably, a second spring is arranged around the monitoring slide rod, one end of the second spring is fixed to the monitoring support plate, and the other end of the second spring is fixed to the extrusion support plate through the second spring top plate. A first spring is arranged around the conductive slider support rod, and both ends of the first spring are fixed to the conductive slider support rod and the monitoring support plate respectively.

[0006] Preferably, the support part includes two support rollers arranged in parallel, the support rollers are rotatably mounted on the support roller bracket, the two ends of the support roller bracket are slidably mounted on two support slide rods, the support slide rods are fixed on the base, a rack rack is fixedly mounted in the middle of the support slide rod, and a gear is rotatably mounted on the rack rack.

[0007] Preferably, two racks symmetrical about the center of the gear are slidably mounted on each rack frame, the racks are fixedly matched with the corresponding support roller brackets, and the racks are rotatably matched with the support rollers.

[0008] Preferably, the support part also includes a support motor, a planetary reducer is fixedly mounted on the outer casing of the support motor, the input shaft of the planetary reducer is fixed to the output shaft of the support motor, a transmission shaft that rotates with the monitoring support plate is fixed on the output shaft of the planetary reducer, and the transmission shaft and the gear are connected through a toothed belt transmission mechanism.

[0009] Preferably, the force-sensitive resistors, adjustable resistor R2 and fixed resistor R1 in the two monitoring parts are arranged in series between the two poles of the DC power supply, and a voltmeter is arranged in parallel at both ends of each force-sensitive resistor to monitor the displacement of the contact roller in the corresponding monitoring part.

[0010] Preferably, the two ends of the force-sensitive resistors in the two monitoring parts arranged in series are used to provide a positive bias voltage to the base and emitter of the NPN transistor, and the collector and emitter of the NPN transistor and the relay are arranged in series at the two ends of another DC power supply, wherein the relay is used to control the rotation of the motor of the traction wire mechanism.

[0011] Compared with the existing technology, the present invention has the following advantages: (1) The present invention uses a force-sensitive resistor to monitor small changes in the diameter of the steel wire, and the change in diameter is reflected by the change in voltage; (2) The present invention can monitor whether the elastic force of the spring changes by detecting the inductance of the second spring. In this way, even after long-term use, the accuracy and reliability of the measurement system can still be guaranteed, avoiding measurement errors caused by spring aging. This design extends the service life of the equipment and reduces maintenance costs; (3) The present invention can not only monitor the diameter of the steel wire, but also measure the moving speed and distance of the steel wire through induced electromotive force. By integrating multi-dimensional data collection, the status of the steel wire in the production process is comprehensively monitored to ensure the consistency of product quality. This comprehensive measurement method can provide more production data support. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a schematic diagram of the overall structure of the present invention.

[0013] Figure 2 This is a layout diagram of the two support parts of the present invention.

[0014] Figure 3 Schematic diagram of the support structure of the present invention.

[0015] Figure 4 This is a schematic diagram of the support roller bracket structure of the present invention.

[0016] Figure 5 This is a schematic diagram of the structure of the contact conductive slider of the present invention.

[0017] Figure 6 This is a structural diagram of the second spring of the present invention.

[0018] Figure 7 This is a structural diagram of the force-sensitive resistor of the present invention.

[0019] Figure 8 This is a schematic diagram of the operating principle of the present invention.

[0020] In the figure: 101-monitoring support plate; 102-contact roller; 103-permanent magnet; 104-contact conductive slider; 105-conductive slider support rod; 106-first spring; 107-monitoring slide bar; 108-contact roller bracket; 109-extrusion support plate; 110-sliding pin; 111-second spring top plate; 112-second spring; 113-limiting ring; 114-force sensitive resistor; 201-support slide bar; 202-support roller; 203-support roller bracket; 204-rack; 205-gear; 206-rack rack; 207-toothed belt transmission mechanism; 208-planetary reduction box; 209-support motor; 210-drive shaft; 3-base. DETAILED DESCRIPTION

[0021] The following is combined with Figure 1-8 , and further illustrate the technical solution of the present invention through specific implementation methods.

[0022] The present invention provides a real-time size monitoring system for wire rope production, comprising a base 3, on which two symmetrically arranged monitoring parts and two mutually perpendicularly arranged support parts are fixedly mounted; wherein the monitoring part comprises a monitoring support plate 101, on which a monitoring slide bar 107 and a conductive slider support bar 105 are slidably mounted via a spline, and one end of the conductive slider support bar 105 is fixedly mounted with a contact conductive slider 104 that slides in contact with the steel wire, and the contact conductive sliders 104 in the two monitoring parts need to be symmetrically arranged on the circumferential surface of the steel wire, and permanent magnets 103 are provided on the upper and lower sides of the symmetry planes of the two contact conductive sliders 104; wherein one end of the monitoring slide bar 107 is fixedly mounted with an extrusion support plate 109, on which a contact roller bracket 108 is slidably mounted, and on which a contact roller 102 is rotatably mounted, and the contact roller 102 rolls in contact with the surface of the steel wire. Two sliding pins 110 are symmetrically fixed to the contact roller bracket 108. The sliding pins 110 slide in conjunction with the extrusion support plate 109. A limiting ring 113 is also fixed to each sliding pin 110 for limiting the extrusion support plate 109. A force-sensitive resistor 114 is provided between the opposing surfaces of the contact roller bracket 108 and the extrusion support plate 109. A second spring 112 is disposed around the monitoring slide bar 107. One end of the second spring 112 is fixed to the monitoring support plate 101, and the other end of the second spring 112 is fixed to the extrusion support plate 109 via a second spring top plate 111. A first spring 106 is disposed around the conductive slider support bar 105, with its ends fixed to the conductive slider support bar 105 and the monitoring support plate 101, respectively. The support portion includes two parallel support rollers 202, which are rotatably mounted on support roller brackets 203. The ends of support roller brackets 203 are slidably mounted on two support slides 201, which are fixed to the base 3. A rack rack 206 is fixedly mounted in the middle of the support slide 201, and a gear 205 is rotatably mounted on the rack rack 206. Each rack rack 206 is also slidably mounted with two racks 204 symmetrical about the center of the gear 205. The racks 204 are fixedly engaged with the corresponding support roller brackets 203, and the racks 204 are rotatably engaged with the support rollers 202. The support unit also includes a support motor 209, with a planetary reduction gearbox 208 fixedly mounted on its housing. The input shaft of the planetary reduction gearbox 208 is fixed to the output shaft of the support motor 209. A transmission shaft 210, which rotates with the monitoring support plate 101, is fixed to the output shaft of the planetary reduction gearbox 208. The transmission shaft 210 is connected to the gear 205 via a toothed belt transmission mechanism 207. The force-sensing resistors 114, adjustable resistors R2, and fixed resistors R1 in the two monitoring units are connected in series between the two poles of a DC power supply. A voltmeter is connected in parallel across each force-sensing resistor 114 to monitor the displacement of the contact roller 102 in the corresponding monitoring unit.The two ends of the force-sensitive resistor 114 in the two monitoring parts arranged in series are used to provide a positive bias voltage to the base and emitter of the NPN transistor. The collector and emitter of the NPN transistor and the relay are arranged in series at the two ends of another DC power supply, where the relay is used to control the rotation of the motor of the traction wire mechanism.

[0023] The working principle of a real-time size monitoring system for wire rope production disclosed in the present invention is as follows: the steel wire is passed through the contact roller 102 and the support roller 202 in the two support parts and the monitoring part, and then the support motor 209 in the two support parts is started. The output shaft of the support motor 209 drives the transmission shaft 210 to rotate through the planetary reduction box 208 (a self-locking mechanism, such as a worm gear mechanism, is provided in the planetary reduction box 208). The transmission shaft 210 drives the gear 205 to rotate through the toothed belt transmission mechanism 207. The gear 205 drives the two racks 204 to move relative to each other, thereby driving the support rollers 202 to move relative to each other. The two support rollers 202 clamp the steel wire and clamp the steel wire in position through two mutually perpendicular support parts.

[0024] The monitoring support plate 101 in the monitoring part can be fixed on the base 3 or slidably installed on the base 3. However, if it is slidably installed on the base 3, a positioning device is required. For example, a screw drives the monitoring support plate 101 to slide on the base 3 to adjust the distance between the two monitoring parts. Therefore, the positional relationship between the monitoring support plate 101 and the base 3 needs to be fixed, and the screw transmission is also a fixed relationship when the screw does not rotate.

[0025] The steel wire moves between the two contact rollers 102, and the contact roller 102 is always in contact with the surface of the steel wire under the action of the second spring 112. Therefore, when the diameter of the steel wire changes, the distance between the contact roller 102 and the axis of the steel wire will also change. At the same time, the compression of the second spring 112 will also change. The change in the compression of the second spring 112 will cause the pressure on the force-sensitive resistor 114 to change (decrease). At this time, the voltage divided at both ends of the force-sensitive resistor 114 will also increase accordingly (the resistance value becomes larger). The change in size can be known through the corresponding voltmeter reading. Since the axis of the steel wire is not necessarily in the ideal position, there will definitely be deviations. Therefore, the two contact rollers 102 are set independently, and then the displacements of the two contact rollers 102 are superimposed to obtain the diameter of the steel wire. Therefore, it is necessary to set the two force-sensitive resistors 114 in series so that their resistance values ​​are superimposed. When the sum of their resistance values ​​is greater than the set value (this needs to be set according to the theoretical diameter of the monitored steel wire, and adjusted by the adjustable resistor R2 (or changing the spacing between the two monitoring support plates 101), and changing the voltage threshold across the two series-set force-sensitive resistors 114), the two second springs 112 are compressed at the beginning, and the force-sensitive resistor 114 is subjected to the pressure of the second springs 112. When the diameter of the steel wire decreases, the compression of the second spring 112 decreases. The pressure on the force-sensitive resistor 114 decreases, the resistance increases, and the potential difference across the two force-sensitive resistors 114 increases, making it greater than 0.7V, which can provide a trigger voltage to the base and emitter of the NPN transistor, so that the collector and emitter of the NPN transistor are turned on. At this time, the relay is energized, and the normally open contact of the relay can be connected to the alarm. The normally closed contact of the relay is connected to the traction motor that controls the movement of the steel wire. When the relay is energized, the normally closed contact opens, and the traction motor no longer works. At this time, it can be known that the diameter of the steel wire at this point is unqualified.

[0026] When the steel wire moves, it will continuously slide with the contact conductive slider 104. At the same time, the steel wire will also vertically pass through the magnetic field formed by the two permanent magnets 103 (the two permanent magnets 103 have fixed positions. For the convenience of display, the supporting plate frame is hidden in the figure). The steel wire, as a conductor, will cut the magnetic flux lines of the permanent magnets 103, thereby generating an induced electromotive force. The induced current is drawn out through the two contact conductive sliders 104. The magnitude of the induced electromotive force is related to the moving speed of the steel wire. Therefore, the moving speed of the steel wire can be judged. Combined with the time, the moving distance of the steel wire can be known, and the length of the steel wire monitored can be determined.

[0027] Over time, the elasticity of the second spring 112 decreases. Since the pressure of the force-sensitive resistor 114 depends on the elastic force of the second spring 112, it is very important to maintain the elastic performance of the second spring 112. The elastic force of the second spring 112 will decrease, but the deformation will not change. Therefore, the deformation of the second spring 112 can also be calculated by detecting the inductance of the second spring 112. This is because when the spring is stretched or compressed, the effective length of the coil will change. According to the formula, the inductance is inversely proportional to the coil length, so the change in length will directly affect the inductance (the change in the number of turns density will affect the magnetic flux density, which in turn affects the inductance). Therefore, when the displacement of the contact roller 102 obtained by measuring the inductance of the second spring 112 is different from the displacement obtained by measuring the resistance of the force-sensitive resistor 114, the second spring 112 needs to be inspected and replaced. This can effectively ensure that there are no loopholes in the detection process of the steel wire diameter.

Claims

1. A real-time dimensional monitoring system for wire rope production, comprising a base (3), characterized in that: Two symmetrically arranged monitoring parts and two mutually perpendicularly arranged supporting parts are fixedly mounted on the base (3); The monitoring part includes a monitoring support plate (101), a monitoring slide rod (107) and a conductive slider support rod (105) are slidably mounted on the monitoring support plate (101) via a spline, and a contact conductive slider (104) that is in sliding contact with the steel wire is fixedly mounted on one end of the conductive slider support rod (105), and the contact conductive sliders (104) in the two monitoring parts need to be symmetrically arranged on the circumferential surface of the steel wire, and permanent magnets (103) are provided on both upper and lower sides of the symmetry plane of the two contact conductive sliders (104); One end of the monitoring slide bar (107) is fixedly mounted with an extrusion support plate (109), a contact roller bracket (108) is slidably mounted on the extrusion support plate (109), a contact roller (102) is rotatably mounted on the contact roller bracket (108), and the contact roller (102) is in rolling engagement with the surface of the steel wire; two sliding pins (110) are symmetrically fixed on the contact roller bracket (108), the sliding pins (110) are in sliding engagement with the extrusion support plate (109), and each sliding pin (110) is also fixed with a limiting ring (113) for limiting the extrusion support plate (109), and the contact roller A force-sensitive resistor (114) is provided between the bracket (108) and the opposite surfaces of the extrusion support plate (109); a second spring (112) is provided around the monitoring slide bar (107), one end of the second spring (112) is fixed to the monitoring support plate (101), and the other end of the second spring (112) is fixed to the extrusion support plate (109) through the second spring top plate (111); a first spring (106) is provided around the conductive slider support bar (105), and the two ends of the first spring (106) are fixed to the conductive slider support bar (105) and the monitoring support plate (101), respectively.

2. A real-time dimension monitoring system for steel wire rope production according to claim 1, characterized in that: The support portion comprises two support rollers (202) arranged in parallel, the support rollers (202) being rotatably mounted on a support roller bracket (203), the two ends of the support roller bracket (203) being slidably mounted on two support slide bars (201), the support slide bars (201) being fixed on a base (3), a rack rack (206) being fixedly mounted in the middle of the support slide bars (201), and a gear (205) being rotatably mounted on the rack rack (206).

3. A real-time dimension monitoring system for steel wire rope production according to claim 2, characterized in that: Two racks (204) symmetrical about the center of the gear (205) are also slidably mounted on each rack frame (206). The racks (204) are fixedly matched with the corresponding support roller brackets (203), and the racks (204) are rotationally matched with the support rollers (202).

4. A real-time dimension monitoring system for steel wire rope production according to claim 3, characterized in that: The support portion further comprises a support motor (209), a planetary reduction gearbox (208) being fixedly mounted on a housing of the support motor (209), an input shaft of the planetary reduction gearbox (208) being fixed to an output shaft of the support motor (209), a transmission shaft (210) being fixed on the output shaft of the planetary reduction gearbox (208) and being in rotation with the monitoring support plate (101), and a transmission connection being connected between the transmission shaft (210) and the gear (205) via a toothed belt transmission mechanism (207).

5. A real-time dimension monitoring system for steel wire rope production according to claim 4, characterized in that: The force-sensitive resistors (114), the adjustable resistor R2, and the fixed resistor R1 in the two monitoring parts are connected in series between the two poles of the DC power supply, and a voltmeter is connected in parallel at both ends of each force-sensitive resistor (114) to monitor the displacement of the contact roller (102) in the corresponding monitoring part.

6. A real-time dimension monitoring system for steel wire rope production according to claim 5, characterized in that: The two ends of the force-sensitive resistor (114) in the two monitoring parts arranged in series are used to provide a positive bias voltage to the base and emitter of the NPN transistor, and the collector and emitter of the NPN transistor and the relay are arranged in series at the two ends of another DC power supply, wherein the relay is used to control the rotation of the motor of the traction wire mechanism.

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