Kinetic energy recovery type miniature tensioner

Abstract

The invention relates to the field of power transmission line stringing equipment, and discloses a kinetic energy recovery type miniature tensioner. The kinetic energy recovery type miniature tensioner comprises a frame body (1) and a pair of tension wheels (2) which are rotatably arranged on the frame body (1), the pair of tension wheels (2) are connected with a speed reducer (4) through a gear set (3) and can drive the speed reducer (4) to rotate, the speed reducer (4) is connected with a motor (5), the motor (5) is connected with a controller (6) through a wire harness, and the controller (6) is connected with the frame body (1). The controller (6) is connected with the battery (7) and is set to be capable of controlling the battery (7) to consume power under the working condition of active traction or wire feeding and controlling the battery (7) to charge under the working condition of passive tension; the tension wheels (2) are high-strength forged aluminum alloy rollers, and the frame body (1) is made of high-strength aluminum alloy. The kinetic energy recovery type miniature tensioner is light in weight, simple in structure and capable of sensitively adjusting the tension, meanwhile, kinetic energy is recycled, and energy waste is effectively avoided.

Description

Technical Field

[0001] The invention relates to the technical field of power transmission line stringing equipment, and in particular to a kinetic energy recovery type micro tension machine. Background Art

[0002] As the main tool for construction operations such as power line stringing in power construction, the safety performance and quality of the tension machine will directly affect the safety and progress of power construction.

[0003] At present, although the existing tension machine can lay out φ13, φ16 anti-twist steel wire rope (primary and secondary guide rope) and φ13 strong wire (DuPont wire), it still has the following significant disadvantages:

[0004] 1. The tension machine is large in size, generally 3.5m long, 1.9m wide, 2m high, and weighs about 2.5 tons, so the transportation cost is high;

[0005] 2. The tension is too high. Under normal circumstances, the tension when laying out φ13, φ16 anti-twist wire ropes and φ13 strong wires is about 300kg, while the maximum continuous tension of the tension machine is 3 tons, which far exceeds the actual needs of the site, resulting in low economic efficiency;

[0006] 3. There is no active traction and rewinding function, which brings inconvenience to on-site construction and seriously affects construction efficiency;

[0007] 4. The energy utilization efficiency of the tension machine system is low during operation, and a large amount of energy is not effectively recycled, resulting in waste. Summary of the invention

[0008] The purpose of the present invention is to overcome the problem in the prior art that when a tension machine uses a fuel engine as the main power source, the thermal efficiency of the fuel engine is very low, resulting in energy waste, and to provide a kinetic energy recovery type micro tension machine. The kinetic energy recovery type micro tension machine is light in weight, simple in structure, can sensitively adjust the tension size, and at the same time realizes kinetic energy recovery and reuse, effectively avoiding energy waste.

[0009] In order to achieve the above-mentioned purpose, the present invention provides a kinetic energy recovery type micro tension machine, which includes a frame and a pair of tension wheels rotatably arranged on the frame, the pair of tension wheels are connected to the reducer through a gear set and are configured to drive the reducer to rotate, the reducer is connected to the motor, the motor is connected to the controller through a wiring harness, the controller is connected to the battery and is configured to control the battery power consumption in active traction or wire feeding conditions and control the battery charging in passive tension conditions; wherein the tension wheel is a high-strength forged aluminum alloy roller, and the frame is made of high-strength aluminum alloy.

[0010] Preferably, the diameter of the spreading wire d≤16mm, and the diameter of the bottom of the wheel groove of the tension wheel D≥40d-100mm.

[0011] Preferably, the number of grooves of the tension wheel is ≥5 and the groove bottom is arc-shaped.

[0012] Preferably, the reducer is a planetary reducer, and the motor is a permanent magnet synchronous motor.

[0013] Preferably, the kinetic energy recovery type micro tension machine also includes a human-machine interaction panel arranged on the frame, which is used for operators to operate the equipment and read equipment information.

[0014] Preferably, the battery includes a lithium battery pack and a battery management system BMS. The battery management system BMS can monitor and protect the battery status in real time by detecting the voltage, current and temperature of the lithium battery pack. In addition, the battery management system BMS controls the charging of the charger through the CAN bus and exchanges data and conducts real-time monitoring with the human-computer interaction panel through the RS232 interface.

[0015] Preferably, the gear set includes a large gear arranged at the root of the tension wheel and a small gear arranged and connected to the reducer, and a pair of large gears located on both sides are meshed with the small gear located in the middle at the same time.

[0016] Preferably, each tension wheel is rotatably mounted on the frame body via a rotating shaft, and a pair of rotating shafts are connected via a fixed arm.

[0017] Preferably, a pair of tension wheels are arranged horizontally symmetrically.

[0018] Preferably, the frame includes a frame and a cover body, a pair of tension wheels are arranged in front of the frame, the reducer, motor, controller and battery are arranged behind the frame, the cover body can be flipped to cover the reducer, motor, controller and battery, and the human-machine interaction panel is installed on the cover body.

[0019] According to the above technical scheme, a pair of tension wheels are used to drive the reducer to rotate through a gear set, and the reducer is connected to the motor, the motor is connected to the controller through a harness, and the controller is connected to the battery. In this way, when the tension machine is in a passive tension condition, the tension wheel rotates passively, which drives the gear to rotate, the gear drives the reducer to rotate, and the reducer finally drives the motor to rotate. A negative torque command is applied to the motor. Since the motor is passively rotating, the motor is used for power generation at this time, the motor generates electricity, and the collected electric energy is finally stored in the battery; when the tension machine is in an active traction or wire feeding condition, contrary to the passive tension condition, the motor is used as a power source, which drives the reducer and is finally transmitted to the tension wheel. In this process, the electric energy of the motor is provided by the battery. In actual use, the passive tension condition of the tension machine accounts for more than 90% of the entire tension machine use condition, so the tension machine can achieve self-sufficiency in energy utilization and achieve the effect of saving energy consumption. At the same time, the tension wheel is a high-strength forged aluminum alloy roller with light weight and simple structure, and the contact friction coefficient between aluminum and fiber rope and Dyneema rope is large. The frame is made of high-strength aluminum alloy, which has high strength and light overall weight. Compared with steel products, the weight is greatly reduced and it is not easy to oxidize, which extends the service life and saves production costs invisibly. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a principle diagram of the kinetic energy recovery type micro tension machine provided by the present invention under two working conditions;

[0021] Figure 2 The present invention provides a three-dimensional kinetic energy recovery type micro tension machine Figure 1 ;

[0022] Figure 3 The present invention provides a three-dimensional kinetic energy recovery type micro tension machine Figure 2 ;

[0023] Figure 4 It is a right side view of the kinetic energy recovery type micro tension machine provided according to the present invention;

[0024] Figure 5 It is a left view of the kinetic energy recovery type micro tension machine provided by the present invention;

[0025] Figure 6 is a rear view of a kinetic energy recovery type micro tension machine provided according to the present invention;

[0026] Figure 7 is a front view of a kinetic energy recovery type micro tension machine provided according to the present invention;

[0027] Figure 8 is a top view of a kinetic energy recovery type micro tension machine provided according to the present invention;

[0028] Fig. 9 is an internal perspective view of a kinetic energy recovery type micro tension machine provided according to the present invention;

[0029] Fig.10 is a schematic diagram of an internal intelligent control system of a battery in a kinetic energy recovery type micro tension machine provided by the present invention;

[0030] Fig.11 The figure is a schematic diagram of energy conversion of a kinetic energy recovery device in a kinetic energy recovery type micro tension machine provided according to the present invention.

[0031] Description of Reference Numerals

[0032] 1-frame 11-frame

[0033] 12-cover 2-tension wheel

[0034] 3-Gear set 31-Big gear

[0035] 32-pinion 4-reducer

[0036] 5- Motor 6- Controller

[0037] 7-Battery 8-Human-computer interaction panel DETAILED DESCRIPTION

[0038] The specific implementation of the present invention is described in detail below in conjunction with the accompanying drawings. It should be understood that the specific implementation described here is only used to illustrate and explain the present invention, and is not used to limit the present invention.

[0039] In the present invention, unless otherwise stated, directional words contained in terms such as "top, bottom, up, down, front, back, inside, outside" merely represent the orientation of the terms in normal usage, or are common names understood by those skilled in the art, and should not be regarded as limitations on the terms.

[0040] See also Figures 1 to 9 The present invention provides a kinetic energy recovery type micro tension machine, which includes a frame 1 and a pair of tension wheels 2 rotatably arranged on the frame 1, the pair of tension wheels 2 are connected to the reducer 4 through a gear set 3 and are configured to drive the reducer 4 to rotate, the reducer 4 is connected to the motor 5, the motor 5 is connected to the controller 6 through a wiring harness, the controller 6 is connected to the battery 7 and is configured to control the power consumption of the battery 7 in active traction or wire feeding conditions and control the charging of the battery 7 in passive tension conditions; wherein the tension wheel 2 is a high-strength forged aluminum alloy roller, and the frame 1 is made of high-strength aluminum alloy.

[0041] Through the above technical solution, a pair of tension wheels 2 are used to drive the reducer 4 to rotate through the gear set 3, and the reducer 4 is connected to the motor 5, the motor 5 is connected to the controller 6 through the wiring harness, and the controller 6 is connected to the battery 7. In this way, when the tension machine is in a passive tension condition, the tension wheel 2 rotates passively, which drives the gear to rotate, the gear drives the reducer 4 to rotate, and the reducer 4 finally drives the motor 5 to rotate. A negative torque command is applied to the motor 5. Since the motor 5 is passively rotated, the motor 5 is used as a power generation condition at this time, the motor 5 generates electricity, and the collected electric energy is finally stored in the battery 7; when the tension machine is in an active traction or wire feeding condition, contrary to the passive tension condition, the motor 5 is used as a power source, which drives the reducer 4 and finally transmits it to the tension wheel 2. In this process, the electric energy of the motor 5 is provided by the battery. In actual use, the passive tension condition of the tension machine accounts for more than 90% of the entire tension machine use condition, so the tension machine can achieve self-sufficiency in energy utilization and achieve the effect of saving energy consumption. At the same time, the tension wheel 2 is a high-strength forged aluminum alloy roller, which is light in weight, simple in structure, and has a large contact friction coefficient between aluminum and fiber rope and Dyneema rope. The frame 1 is made of high-strength aluminum alloy, which has high strength and overall light weight. Compared with steel products, the weight is greatly reduced and it is not easy to oxidize, which prolongs the service life and saves production costs invisibly.

[0042] In this embodiment, when designing the kinetic energy recovery type micro tension machine, taking into account the deployment line diameter d≤16mm and the curvature of the deployment piece, the wheel groove bottom diameter D of the tension wheel 2 is preferably ≥40d-100mm. This can also avoid damage to the deployment piece and ensure smooth deployment operation.

[0043] In actual operation, for safety reasons, the unfolding piece should be rolled in from the bottom of the tension wheel 2, perpendicular to the tension wheel 2 and arranged neatly, and the number of winding circles shall not be less than 5 circles. Therefore, in this embodiment, the number of grooves of the tension wheel 2 is preferably ≥ 5. The tension wheel 2 with such a structure can ensure that there is no slipping when the tension at the tail of the tension machine is not greater than 2kN. At the same time, in order to make the unfolding piece close to the surface of the tension wheel 2 during the winding process, and to avoid the occurrence of loose sliding between adjacent unfolding pieces, resulting in the unfolding pieces crossing each other or even randomly winding together, which seriously affects the subsequent winding operation or unfolding operation, it is preferred to design the groove bottom to be arc-shaped, so that when the unfolding piece is wound on the tension wheel 2, it can follow the guiding direction of the arc-shaped groove bottom and smoothly enter the arc-shaped groove bottom. Whether the tension wheel 2 is stationary or rotating, it will not easily slip out of the groove, so that the unfolding piece is always in the correct working state.

[0044] The above-mentioned spreading piece can be any long strip material commonly used in the art and suitable for the tension machine. Specifically, the spreading piece can be a steel wire rope, a nylon rope, an optical cable, or a conductor.

[0045] The traditional reducer is composed of a pair of gears, one large and one small. Its structural design is simple and easy to maintain. However, at the same speed ratio, the structural size is large and the weight is also large, which cannot meet the requirements of reducing the volume of the tension machine and reducing the overall weight of the tension machine in the present invention. Therefore, in this embodiment, the reducer 4 is preferably a planetary reducer, which is composed of a sun gear and multiple planetary gears. It has a compact structure, large torque transmission, and high efficiency. More importantly, at the same speed ratio, the structural size is small and the weight is also less than the traditional reducer, which can further reduce the volume of the tension machine and reduce the overall weight of the tension machine.

[0046] In this embodiment, in order to ensure that the tension wheel 2 on the kinetic energy recovery type micro-tension machine can rotate synchronously and avoid the loosening of the unfolding parts wrapped on the tension wheel 2 due to the asynchronous rotation of the tension wheel 2, and the inability to fit tightly in the wheel groove on the tension wheel 2, resulting in the subsequent operations cannot be carried out smoothly, and repeated corrections will waste a lot of production and processing time, seriously affecting the efficiency, the motor 5 is preferably a permanent magnet synchronous motor, which has high efficiency, high energy density, accurate execution of actions, and ensures smooth operation.

[0047] In this embodiment, in order to facilitate the operator to operate the device and read the information of the device more simply and efficiently, the kinetic energy recovery type micro tension machine preferably also includes a human-machine interaction panel 8 arranged on the frame 1. Specifically, the human-machine interaction panel 8 may include a 7-inch liquid crystal touch screen for engineering machinery, which is used to record the operating status and display various types of information, such as tension value, preset value, speed, cumulative length and device status. The human-machine interaction panel 8 may also include control parts such as a direction speed selection knob, a tension setting knob, an emergency stop button and a power switch, so that the operator can operate the device simply and efficiently.

[0048] In this embodiment, the kinetic energy recovery type micro tension machine uses kinetic energy recovery to supplement energy, converts kinetic energy into electrical energy and stores it in the battery, and then uses the energy in the battery during active operation. The whole process has zero emissions, low noise, self-sufficiency in energy utilization, high conversion efficiency, and is not limited by altitude. In order to achieve the above technical effects, such as Fig.10As shown, the preferred battery 7 includes a lithium battery pack and a battery management system BMS. The battery management system BMS can monitor and protect the battery status in real time by detecting the voltage, current and temperature of the lithium battery pack. In addition, the battery management system BMS controls the charging of the charger through the CAN bus, and exchanges data and performs real-time monitoring with the human-machine interaction panel 8 through the RS232 interface. In this way, the tension energy generated by the tension machine can be converted into electrical energy through the power generation condition of the permanent magnet synchronous motor, and then stored in the battery 7, that is, the unfolding member drives the tension wheel 2 to rotate, and then the motor rotates to start generating electricity, so that the electrical energy enters the controller and is converted into direct current, and finally the electrical energy is stored in the battery 7, and the excess electricity is consumed by the resistor box (see Fig.11 ). This process utilizes the characteristics of the motor and adopts the principle of kinetic energy recovery to generate tension. The tension can be changed by adjusting the size of the kinetic energy recovery. The adjustment is sensitive and the dynamic response is fast, thus realizing stepless adjustment and kinetic energy recovery and reuse. In addition, the battery 7 also includes a PTC heating module, which can discharge when the lithium battery pack is full during power generation to protect the lithium battery pack.

[0049] In this embodiment, the gear set 3 is used to assist the pair of tension wheels 2 in driving the reducer 4 to rotate, and the reducer 4 drives the motor 5 to rotate and generate electricity. In order to ensure the balance and stability of the kinetic energy transmission of the gear set 3, the gear set 3 preferably includes a large gear 31 arranged at the root of the tension wheel 2 and a small gear 32 arranged and connected to the reducer 4, and the pair of large gears 31 on both sides are meshed with the small gear 32 in the middle at the same time. In this way, the pair of tension wheels 2 rotate synchronously, and the pair of large gears 31 on both sides also rotate synchronously, thereby driving the small gear 32 meshing with them to rotate stably.

[0050] In the process of the rotation of the tension wheel 2, in order to avoid the rotation axis of a single tension wheel 2 being offset due to external force after a long time, thereby causing the pair of tension wheels 2 to be unable to rotate synchronously, preferably, each tension wheel 2 is rotatably mounted on the frame 1 through a rotating shaft, and the pair of rotating shafts are connected by a fixed arm. This connection structure can ensure that each tension wheel 2 can always be located on its own rotating shaft and rotate stably and efficiently, and the mutual restriction and limitation between the rotating shafts are achieved through the connection of the fixed arm.

[0051] In this embodiment, in order to ensure the overall balance of the kinetic energy recovery type micro-tension machine, it is preferred that a pair of tension wheels 2 are horizontally symmetrically arranged.

[0052] Similarly, in order to further optimize the overall structure of the kinetic energy recovery type micro tension machine, make the structure of the tension machine more compact, and reduce the operating space it occupies, preferably, the frame 1 includes a frame 11 and a cover 12, a pair of tension wheels 2 are arranged in front of the frame 11, the reducer 4, the motor 5, the controller 6 and the battery 7 are arranged behind the frame 11, the cover 12 is reversibly covered above the reducer 4, the motor 5, the controller 6 and the battery 7, and the human-machine interaction panel 8 is installed on the cover 12. Among them, the use of a reversible cover 12 facilitates the quick and convenient opening of the tension machine when an internal device fails and needs maintenance or adjustment, and provides sufficient maintenance operation space for maintenance workers.

[0053] The preferred embodiments of the present invention are described in detail above in conjunction with the accompanying drawings, but the present invention is not limited thereto. Within the technical concept of the present invention, the technical solution of the present invention can be subjected to a variety of simple modifications, including the combination of various specific technical features in any suitable manner. In order to avoid unnecessary repetition, the present invention will not further describe various possible combinations. However, these simple modifications and combinations should also be regarded as the contents disclosed by the present invention and belong to the protection scope of the present invention.

Claims

1. A kinetic energy recovery type micro tension machine, characterized in that: The kinetic energy recovery type micro tension machine comprises a frame (1) and a pair of tension wheels (2) rotatably arranged on the frame (1); the pair of tension wheels (2) are connected to a reducer (4) via a gear set (3) and are configured to drive the reducer (4) to rotate; the reducer (4) is connected to a motor (5); the motor (5) is connected to a controller (6) via a wiring harness; the controller (6) is connected to a battery (7) and is configured to control the power consumption of the battery (7) in an active traction or wire feeding condition and to control the charging of the battery (7) in a passive tension condition; wherein the tension wheel (2) is a high-strength forged aluminum alloy roller, and the frame (1) is made of a high-strength aluminum alloy.

2. The kinetic energy recovery type micro tension machine according to claim 1, characterized in that: The diameter of the unwinding wire d≤16mm, and the diameter of the bottom of the wheel groove of the tension wheel (2) D≥40d-100mm.

3. The kinetic energy recovery type micro tension machine according to claim 2, characterized in that: The number of grooves of the tension wheel (2) is ≥5 and the bottom of the groove is arc-shaped.

4. The kinetic energy recovery type micro tension machine according to claim 1, characterized in that: The reducer (4) is a planetary reducer, and the motor (5) is a permanent magnet synchronous motor.

5. The kinetic energy recovery type micro tension machine according to claim 1, characterized in that: The kinetic energy recovery type micro tension machine also includes a human-machine interaction panel (8) arranged on the frame (1) and used for an operator to operate the device and read device information.

6. The kinetic energy recovery type micro tension machine according to claim 5, characterized in that: The battery (7) comprises a lithium battery pack and a battery management system (BMS). The battery management system (BMS) can monitor and protect the battery status in real time by detecting the voltage, current and temperature of the lithium battery pack. In addition, the battery management system (BMS) controls the charging of the charger via a CAN bus and exchanges data and performs real-time monitoring with the human-machine interaction panel (8) via an RS232 interface.

7. The kinetic energy recovery type micro tension machine according to claim 1, characterized in that: The gear set (3) comprises a large gear (31) arranged at the root of the tension wheel (2) and a small gear (32) arranged and connected to the reducer (4), and a pair of large gears (31) located on both sides are simultaneously meshed with the small gear (32) located in the middle.

8. The kinetic energy recovery type micro tension machine according to claim 1, characterized in that: Each tension wheel (2) is rotatably mounted on the frame (1) via a rotating shaft, and a pair of the rotating shafts are connected via a fixed arm.

9. The kinetic energy recovery type micro tension machine according to claim 8, characterized in that: A pair of tension wheels (2) are arranged horizontally and symmetrically.

10. The kinetic energy recovery type micro tension machine according to any one of claims 5 to 9, characterized in that: The frame (1) comprises a frame (11) and a cover (12); a pair of tension wheels (2) are arranged in front of the frame (11); the reducer (4), the motor (5), the controller (6) and the battery (7) are arranged behind the frame (11); the cover (12) is flippably arranged above the reducer (4), the motor (5), the controller (6) and the battery (7); and the human-machine interaction panel (8) is mounted on the cover (12).

Images