Automatic loading steel wire rope spindle system

Abstract

The invention belongs to the technical field of automatic loading and unloading systems, and relates to an automatic loading steel wire rope spindle system which comprises a mechanism frame, a spindle seat, an initial tension device, an automatic loading and unloading trolley, an auxiliary inspection trolley and a control system. According to the mechanism frame, 16 square stand column steel pipes form four rows of supporting structures, and the four rows of supporting structures are divided into two groups to be symmetrically arranged. Five longitudinal square cross beams are connected between every two adjacent stand column steel pipes through flanges, and the 60 longitudinal square cross beams form a layered bearing structure. Four transverse square top beams are arranged at the top of the frame and are connected with vertical column steel pipes; rectangular guide rail beams with racks and sliding contact lines are arranged at two longitudinal ends of the frame in an extending manner; 16 groups of guide wheel groups are arranged on the front-row upright post steel pipe. The device has the advantages of efficient automation, accurate positioning, intelligent control and modular design, the production efficiency, the product quality and the operation safety are remarkably improved, and meanwhile the labor cost and the energy consumption are reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of automatic loading and unloading systems, and in particular relates to an automatic loading wire rope spindle system. Background Art

[0002] Conveyor belts are key components of material conveying machinery and are widely used in all walks of life, especially in mining, ports and other industries. There are many types of conveyor belts, which are divided into PVC, PU, ​​PVG, and rubber-based conveyor belts based on basic materials. Therefore, among all types of conveyor belts, rubber conveyor belts play an important role in conveying machinery. Among rubber conveyor belts, their skeleton types are divided into fabric core and wire rope core. Wire rope core conveyor belts are irreplaceable in the field of heavy-duty transportation. For this reason, the importance of wire rope conveyor belts is self-evident. We have conducted a lot of research and discussion on one of the important production links, and then developed an automatic control system to replace traditional manual operation.

[0003] The basic production process of steel wire rope core conveyor belt: raw material proportioning - mixing - extrusion, calendering - steel wire rope spindles are placed in the spindle rack - tension is applied to the steel wire rope - film and steel wire rope are combined into a sheet - vulcanization - inspection, measurement - stretching - cutting - winding - testing - storage.

[0004] In the production process of steel wire rope core conveyor belt, the steel wire rope spindles are placed in the spindle rack. Due to its product characteristics, a conveyor belt requires several steel wire ropes to be evenly arranged inside. The number of wire ropes is determined by the parameters of the conveyor. The steel wire rope has two structures with different rotation directions, left-handed and right-handed, which are cross-arranged to form a belt core structure. Before the production of a conveyor belt of a certain specification, the corresponding number of spindles wrapped with steel wire ropes need to be loaded into the spindle rack in a cross-arranged manner, i.e. left-handed and right-handed as required, and the steel wire ropes are pulled out to the tension station, which applies a certain tension for the forming machine to form.

[0005] At present, all wire rope conveyor belt manufacturers use manual operation in the loading and unloading of wire rope spindles, which is time-consuming, labor-intensive and inefficient. Summary of the invention

[0006] The object of the present invention is to provide an automatic loading wire rope spindle system, which solves the problems described in the above background technology.

[0007] In order to achieve the above-mentioned purpose, the technical solution adopted by the present invention is that the present invention provides an automatic loading wire rope spindle system, including a mechanism frame, a spindle seat and an initial tension device, an automatic loading and unloading vehicle, an auxiliary inspection vehicle and a control system; the mechanism frame is composed of a square column steel pipe to form a supporting structure, which is divided into two groups and arranged symmetrically; each two adjacent column steel pipes are connected to a longitudinal square beam by a flange, and the longitudinal square beam forms a layered bearing structure; a transverse square top beam is provided on the top to connect the column steel pipes, and rectangular guide beams with racks and busbars are extended at both longitudinal ends of the frame; the front row of column steel pipes are equipped with guide wheel groups.

[0008] Specifically, the spindle seats and the initial tension device are arranged in a matrix with equal spacing and distributed on two sets of mechanism frames, and the spindle seats and the initial tension device adopt a symmetrical installation layout.

[0009] Specifically, the spindle seat and initial tension device include a servo motor, a reducer, a small gear and a large gear for meshing transmission, a central shaft assembly, a driving pin with a spring and a latch; the spindle is sleeved on the central shaft assembly through the center hole and locked by the outer end latch, and the large gear is radially provided with a driving pin that cooperates with the positioning hole of the spindle disk.

[0010] Specifically, a spring sleeve is provided at the rear end of the driving pin shaft, and a compression spring is installed inside; the large gear and the central shaft assembly are connected by an eccentric transmission, and the distance between the driving pin shaft and the central shaft axis is equal to the distribution radius of the spindle disk positioning holes.

[0011] Specifically, the automatic loading and unloading vehicle includes an orthogonally arranged Y-axial drive mechanism, an X-axial drive mechanism and a Z-axial drive mechanism, and three-dimensional positioning is achieved by meshing gears with frame racks; the Y-axial drive mechanism includes a screw transmission assembly and a slider guide rail, the X-axial drive mechanism includes a gear drive assembly and a guide wheel, and the Z-axial drive mechanism includes a lifting guide rail and a push rod assembly.

[0012] Specifically, the auxiliary inspection vehicle includes a liftable platform, a screw lift mechanism, two guide wheels and an operating panel equipped with a button switch. It is driven by a motor to move along the rectangular guide beam of the frame and is provided with an interlocking control module with the automatic loading and unloading vehicle.

[0013] Specifically, the control system includes a PLC controller, an industrial computer, a photoelectric sensor array, an RFID identifier and a safety interlock module; the coded coordinate system accurately positions the spindle seat and the initial tension device, and each spindle seat and initial tension device is provided with a unique ID code bound to the spatial coordinates.

[0014] A control method for an automatic loading wire rope spindle system comprises the following steps:

[0015] S1. Input the wire rope specification parameters and rotation requirements, the system generates a spindle distribution matrix diagram and assigns coordinates;

[0016] S2. The automatic loading and unloading car loads the ingots synchronously in double stations, and verifies the rotation direction and ID code through sensors;

[0017] S3. The three-dimensional positioning system guides the loading and unloading vehicle to reach the target coordinates, and the push rod assembly of the Z-axis drive mechanism completes the precise docking of the spindle and the center shaft;

[0018] S4. The auxiliary inspection vehicle performs anti-drop pin insertion and rope threading and guidance operations, and establishes a safety interlock with the production line PLC;

[0019] S5. During the unloading operation, the steps S3-S4 are performed in reverse order, the empty ingots are recovered and fed back to the system to complete the production cycle.

[0020] Compared with the prior art, the advantages and positive effects of the present invention are:

[0021] The present invention has the advantages of efficient automation, precise positioning, intelligent control and modular design, which significantly improves production efficiency, product quality and operational safety, while reducing labor costs and energy consumption. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0023] Figure 1 This is an overall structural diagram of an automatic loading wire rope spindle system according to one embodiment;

[0024] Figure 2 It is an overall framework diagram of an automatic loading wire rope spindle system according to one embodiment;

[0025] Figure 3 It is a partial structural diagram of an automatic loading wire rope spindle system according to one embodiment;

[0026] Figure 4 It is a partial structural diagram of an automatic loading wire rope spindle system according to one embodiment;

[0027] Figure 5 It is a partial structural diagram of an automatic loading wire rope spindle system according to one embodiment;

[0028] Figure 6 It is a partial structural diagram of an automatic loading wire rope spindle system according to one embodiment;

[0029] Figure 7It is a partial structural diagram of an automatic loading wire rope spindle system according to one embodiment;

[0030] In the above figures, 100, mechanism frame, 200, spindle seat and initial tension device, 300, automatic loading and unloading vehicle, 400, auxiliary inspection vehicle, 500, control system; 101, column steel pipe, 102, square beam, 103, square top beam, 104, rack, 105, busbar, 106, guide rail beam, 107, guide wheel group; 201, servo motor, 202, reducer, 203, small gear, 204, large gear, 205, central shaft assembly, 206, Driving pin; 301, Y-axis driving mechanism, 302, X-axis driving mechanism, 303, Z-axis driving mechanism, 304, gear, 305, screw transmission assembly, 306, slider guide, 307, gear driving assembly, 308, guide wheel one, 309, lifting guide, 310, push rod assembly; 401, liftable platform, 402, screw lifting mechanism, 403, guide wheel two, 404, operation panel; 501, industrial computer, 502, photoelectric sensor. DETAILED DESCRIPTION

[0031] In order to more clearly understand the above-mentioned purpose, features and advantages of the present invention, the present invention is further described below in conjunction with the accompanying drawings and embodiments. It should be noted that the embodiments of the present application and the features in the embodiments can be combined with each other without conflict.

[0032] In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention may also be implemented in other ways than those described herein. Therefore, the present invention is not limited to the specific embodiments of the following disclosure.

[0033] Embodiment 1, as Figure 1-7 As shown, an automatic loading wire rope spindle system includes a mechanism frame 100, a spindle seat and an initial tension device 200, an automatic loading and unloading vehicle 300, an auxiliary inspection vehicle 400 and a control system 500; the mechanism frame 100 is an integral supporting structure, carrying the spindle seat and the initial tension device 200, the automatic loading and unloading vehicle 300 and the auxiliary inspection vehicle 400, and the mechanism frame 100 adopts a modular design, and the structure is stable and easy to assemble.

[0034] The mechanism frame 100 is composed of 16 square column steel pipes 101 forming 4 rows of support structures, which are divided into two groups and arranged symmetrically; 5 longitudinal square beams 102 are connected between every two adjacent column steel pipes 101 through flanges, and a total of 60 longitudinal square beams 102 form a layered bearing structure; 4 transverse square top beams 103 are arranged on the top to connect the column steel pipes 101, and rectangular guide beams 106 with racks 104 and busbars 105 are extended at both longitudinal ends of the frame; the front row of column steel pipes 101 are equipped with 16 groups of guide wheel groups 107, and the guide wheel groups 107 enable the wire rope to be orderly turned into the tension station.

[0035] The following is a detailed description of the design of the above key components:

[0036] There are 224 spindle seats and initial tension devices 200 in total, which are arranged in a matrix with equal spacing on two sets of mechanism frames 100. In each set of mechanism frames 100, 112 spindle seats are arranged in 14 rows in the longitudinal direction and 4 layers in the vertical direction. The spindle seats and initial tension devices 200 in the same set are installed in a symmetrical layout. If used for different spindle frames, the number is not limited to 224.

[0037] The spindle seat and initial tension device 200 include a servo motor 201, a reducer 202, a small gear 203 and a large gear 204 for meshing transmission, a central shaft assembly 205, a spring-loaded driving pin 206 and a latch; the spindle is sleeved on the central shaft assembly 205 through the central hole and locked by the outer end latch, and the large gear 204 is radially provided with a driving pin 206 that matches the spindle plate positioning hole. The servo motor 201, the reducer 202, the small gear 203, and the large gear 204 form a driving initial tension device, which is applied to the tension station after the steel wire rope is pulled out. The tension station applies a certain tension to each steel wire rope. Since the tension application stroke is limited, the steel wire rope is in a relaxed state after being pulled out. The tension applied by the tension station at this time will not achieve the expected effect. It is necessary to drive the initial tension device to pull back the stroke to a certain degree of tension. The servo motor 201 rotates accurately according to the current signal transmitted by the steel wire rope during the stretching process to achieve the set initial tension value.

[0038] The rear end of the driving pin 206 is provided with a spring sleeve, which is equipped with a compression spring; the large gear 204 and the central shaft assembly 205 are connected by an eccentric transmission, and the distance between the driving pin 206 and the central shaft axis is equal to the distribution radius of the spindle plate positioning holes. The spindle pull-back rotation is driven by the driving pin 206, which is installed at a certain distance between the large gear 204 and the central shaft. There is a sleeve behind the driving pin 206, and there is a spring inside the sleeve, so that the driving pin 206 has a telescopic function. There is a small hole in the spindle plate at a certain distance from the central hole to match the driving pin 206.

[0039] The automatic loading and unloading vehicle 300 includes an orthogonally arranged Y-axis drive mechanism 301, an X-axis drive mechanism 302 and a Z-axis drive mechanism 303, and realizes three-dimensional positioning through the meshing of the gear 304 with the frame rack 104; the Y-axis drive mechanism 301 includes a screw transmission assembly 305 and a slider guide rail 306, the X-axis drive mechanism 302 includes a gear 304 drive assembly 307 and a guide wheel 308, and the Z-axis drive mechanism 303 includes a lifting guide rail 309 and a push rod assembly 310. The automatic loading and unloading vehicle 300 starts from 0 and accurately puts the wire rope spindle into the set position through the Y-axis, X-axis and Z-axis operations. It includes three parts, the Y-axis drive mechanism 301, the X-axis drive mechanism 302, and the Z-axis drive mechanism 303, which constitute the core mechanism of automatic loading and unloading, and are located on the upper part of the frame rack 104. The three mechanisms are combined together and can run simultaneously to greatly improve production efficiency, and no interference will occur between them during operation.

[0040] The auxiliary inspection vehicle 400 includes a liftable platform 401, a screw lift mechanism 402, a guide wheel 403 and an operation panel 404 equipped with a button switch. It is driven by a motor to move along the frame guide beam 106 and is provided with an interlocking control module with the automatic loading and unloading vehicle 300. After the ingot is installed in place, the safety pin is installed, the wire rope is pulled out and inserted into the guide device, and the platform is equipped with a button switch and can be randomly operated in the Y-axis and X-axis directions.

[0041] The control system 500 includes a PLC controller, an industrial computer 501, an array of photoelectric sensors 502, an RFID identifier and a safety interlock module; the coded coordinate system accurately locates the 224 spindle seats and the initial tension device 200, and each spindle seat and initial tension device 200 is provided with a unique ID code and bound to the spatial coordinates. The control system 500 is divided into two parts: hardware and software. The hardware includes an electric control box, a power switch, a button switch, a contactor, a sensor, a scanner, an industrial computer, a PLC and other components. The software includes an ICS instruction software with logical operations developed based on the WINDOWS platform, and an execution program PLC with an operating program. The two are combined to form a complete automatic operating system.

[0042] Embodiment 2, a control method for an automatic loading wire rope spindle system as shown in Embodiment 1, comprises the following steps:

[0043] S1. Input the wire rope specification parameters and rotation requirements, the system generates a spindle distribution matrix diagram and assigns coordinates;

[0044] S2. The automatic loading and unloading car 300 double-stations load the ingots synchronously, and the rotation direction and ID code are verified by sensors;

[0045] S3. The three-dimensional positioning system guides the automatic unloading vehicle to reach the target coordinates, and the push rod assembly 310 of the Z-axis drive mechanism 303 completes the precise docking of the spindle and the center axis;

[0046] S4. The auxiliary inspection vehicle 400 performs the anti-drop pin insertion and rope threading guidance operations, and establishes a safety interlock with the production line PLC;

[0047] S5. During the unloading operation, the steps S3-S4 are performed in reverse order, the empty ingots are recovered and fed back to the system to complete the production cycle.

[0048] Embodiment 3, a control method for an automatic loading wire rope spindle system as shown in Embodiment 2, the specific application implementation steps are as follows:

[0049] 1. When a task is issued, according to the requirements of the task, the computer inputs the specifications, quantity, and number of left and right rotations of the wire rope. After calculation, the system program gives the location where each spindle needs to be installed and displays it on the screen. After confirmation, the task is issued to the PLC program. After receiving the instruction, the PLC program performs a detection to detect whether there is a spindle on the spindle support shaft. Each spindle support shaft is equipped with a sensor to sense the presence of materials and a coding identifier to identify the rotation direction of the wire rope spindle. After sensing and identification, it is fed back to the PLC. After confirming that the material exists and the rotation direction is consistent, the running indicator light turns on and the task begins. If the material is not detected, wait for a certain period of time. If the waiting time is exceeded, the system will issue a warning reminder. If the detection and identification spindle placement rotation direction is wrong, the task will not be executed and a warning reminder will be issued.

[0050] 2. There are 224 spindle seats installed on the spindle rack, arranged in a row vertically, with 14 spindles in each row, 4 layers in a column vertically, 56 spindles in a group, and 4 groups horizontally. Each group has a number, and each spindle seat has its own code and fixed coordinates.

[0051] 3. Two spindles can be placed on each loading car at the same time. The placement of the spindles is based on the rotation direction given by the system program calculation. For example, if a left-handed spindle or a right-handed spindle should be placed on a certain support shaft, it will be displayed on the display screen to prevent incorrect placement and form a double insurance with coding recognition.

[0052] 4. The loading car starts to run, and according to the coordinate position of the spindle given by the system, it runs in the Y-axis and X-axis directions to find the coordinate position. After reaching the coordinate position, the center hole of the spindle is accurately aligned with the center axis of the spindle seat. The servo motor 201 has a brake to fix the coordinate. After the coordinate is fixed, the Z-axis car moves to accurately push the spindle into the center axis, then exits and returns to the loading 0 point. A loading task is completed. If two spindles are loaded at the same time, the system defaults to symmetrical installation of the two spindles. First find the first coordinate to complete the loading and exit, and then find the symmetrical coordinate to load.

[0053] The system issues instructions to the two loading vehicles, and the two loading vehicles can work at the same time to execute their respective task instructions. When the loading task is completed, the system display screen will show "Complete loading task, waiting for unloading instructions".

[0054] 5. The loading task and unloading task are a complete task cycle. After the loading task is completed, the system will send a signal to the PLC program of the production line. The automatic control loading and unloading program is an independent system, which is used interchangeably with the production line program and controls each other. They cannot work at the same time. When the automatic control loading and unloading program is working, the production line program related to the program receives the signal to lock the program. After the loading task and auxiliary work are completed, a signal is sent to the production line program, and the production line program can work. After the wire rope on the spindle is used up, the production line stops working and feedback signals are given to the automatic control loading and unloading program. The program reconfirms the start and confirms that the unloading task is performed after the auxiliary work is completed. The unloading task originates from the loading task and performs the reverse operation. The loading car is started without load, runs to a specified spindle position, unloads the spindle and returns to the task starting point, repeats the action to complete the command task, and feedback is given to the command system to end a task cycle.

[0055] 6. After the loading task is completed, the feedback signal is sent to the PLC. At this time, the auxiliary inspection vehicle 400 can be started to check the ingot position, install the anti-drop pin shaft, and thread the rope into the guide device. After completing the task, it returns to its original position and sends a signal to transfer to the production line program. Before the reverse unloading program is started, the auxiliary inspection vehicle 400 starts to recover the anti-drop pin shaft, check the ingot status, return to its original position, and send a signal to the system to confirm the reverse operation. The reverse operation can work. The auxiliary inspection vehicle 400 and the automatic loading and unloading vehicle 300 control each other and cannot act at the same time. The lock can be released by manual operation in the maintenance state.

[0056] 7. The host computer has the functions of task input, task editing, storage, query, modification, printing and connecting with the company's management terminal to remotely monitor the operating status of equipment. The PLC displays operating instructions and operating dynamics in real time through the human-machine interface, and the touch operation is accurate and efficient.

[0057] The standard parts used in the present invention can all be purchased from the market, and special-shaped parts can be customized according to the description in the specification and the drawings. The specific connection methods of each part adopt conventional means such as mature bolts, rivets, welding, etc. in the prior art. Machinery, parts and equipment all adopt conventional models in the prior art, and the circuit connection adopts the conventional connection method in the prior art. It will not be described in detail here. The content not described in detail in this specification belongs to the prior art known to professional and technical personnel in this field.

[0058] The above description is only a preferred embodiment of the present invention and does not limit the present invention in other forms. Any technician familiar with the profession may use the technical content disclosed above to change or modify it into an equivalent embodiment with equivalent changes and apply it to other fields. However, any simple modification, equivalent change and modification made to the above embodiment based on the technical essence of the present invention without departing from the content of the technical solution of the present invention still falls within the protection scope of the technical solution of the present invention.

Claims

1. An automatic loading wire rope spindle system, characterized in that: It includes a mechanism frame, a spindle seat and an initial tension device, an automatic loading and unloading vehicle, an auxiliary inspection vehicle and a control system; the mechanism frame is composed of a supporting structure of column steel pipes, which are divided into two groups and arranged symmetrically; each two adjacent column steel pipes are connected to a longitudinal square beam through a flange, and the longitudinal square beam forms a layered bearing structure; a transverse square top beam is provided on the top to connect the column steel pipes, and rectangular guide beams with racks and busbars are extended at both longitudinal ends of the frame; the front column steel pipes are equipped with guide wheel groups.

2. The automatic loading wire rope spindle system according to claim 1, characterized in that: The spindle seats and the initial tension device are arranged in a matrix with equal spacing and distributed on two sets of mechanism frames, and the spindle seats and the initial tension device adopt a symmetrical installation layout.

3. The automatic loading wire rope spindle system according to claim 1, characterized in that: The spindle seat and initial tension device include a servo motor, a reducer, a small gear and a large gear for meshing transmission, a central shaft assembly, a driving pin shaft with a spring and a latch; the spindle is sleeved on the central shaft assembly through the central hole and locked by the outer end latch, and the large gear is radially provided with a driving pin shaft that cooperates with the spindle disk positioning hole.

4. The automatic loading wire rope spindle system according to claim 3, characterized in that: The rear end of the driving pin shaft is provided with a spring sleeve, in which a compression spring is installed; the large gear and the central shaft assembly are connected by an eccentric transmission, and the distance between the driving pin shaft and the central shaft axis is equal to the distribution radius of the spindle disk positioning holes.

5. The automatic loading wire rope spindle system according to claim 1, characterized in that: The automatic loading and unloading vehicle comprises an orthogonally arranged Y-axial drive mechanism, an X-axial drive mechanism and a Z-axial drive mechanism, and realizes three-dimensional positioning by meshing gears with frame racks; the Y-axial drive mechanism comprises a lead screw transmission assembly and a slider guide rail, the X-axial drive mechanism comprises a gear drive assembly and a guide wheel, and the Z-axial drive mechanism comprises a lifting guide rail and a push rod assembly.

6. The automatic loading wire rope spindle system according to claim 1, characterized in that: The auxiliary inspection vehicle comprises a liftable platform, a screw lift mechanism, two guide wheels and an operation panel equipped with a button switch. It is driven by a motor to move along the frame guide beam and is provided with an interlocking control module with the automatic loading and unloading vehicle.

7. The automatic loading wire rope spindle system according to claim 1, characterized in that: The control system includes a PLC controller, an industrial computer, a photoelectric sensor array, an RFID identifier and a safety interlock module; the spindle seat and the initial tension device are positioned by encoding coordinates in the control system, and each spindle seat and initial tension device is provided with a unique ID code bound to the spatial coordinates.

8. A control method for an automatic loading wire rope spindle system according to any one of claims 1 to 7, characterized in that: The following steps are involved: S1. Input the wire rope specification parameters and rotation requirements, the system generates a spindle distribution matrix diagram and assigns coordinates; S2. The automatic loading and unloading car loads the ingots synchronously in double stations, and verifies the rotation direction and ID code through sensors; S3. The three-dimensional positioning system guides the loading and unloading vehicle to reach the target coordinates, and the push rod assembly of the Z-axis drive mechanism completes the precise docking of the spindle and the center shaft; S4. The auxiliary inspection vehicle performs anti-drop pin insertion and rope threading and guidance operations, and establishes a safety interlock with the production line PLC; S5. During the unloading operation, the steps S3-S4 are performed in reverse order, the empty ingots are recovered and fed back to the system to complete the production cycle.

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