Intelligent cable pay-off reel braking device and braking method

Abstract

The invention provides an intelligent cable pay-off reel braking device and method, and belongs to the technical field of cable pay-off reel braking. Comprising a monitoring module, a remote control module, a control module and a motor braking module. Wherein the monitoring module, the remote control module and the motor braking module are all connected with the control module; the control module is used for dual-mode braking, and in the full-automatic mode, the control module dynamically adjusts the braking torque of the motor braking module according to data measured by the monitoring module, and the rotating speed of the cable pay-off reel is reduced; in the semi-automatic mode, the control module adjusts the braking torque of the motor braking module according to the target pay-off length set by the remote control module so as to brake the cable pay-off reel. On the basis that the cable pay-off reel can be safely and accurately braked, the braking efficiency and the automation degree of the cable pay-off reel can be improved.

Description

Technical Field

[0001] The invention belongs to the technical field of cable pay-off reel braking, and particularly relates to an intelligent cable pay-off reel braking device and a braking method. Background Art

[0002] The statements in this part only provide background technical information related to the present invention, and do not necessarily constitute prior art.

[0003] In high-voltage cable construction, traditional pay-off reels rely on manual observation and manual braking to adjust the pay-off speed, which poses significant safety hazards. According to statistics, cable off-line and reel collapse accidents caused by out-of-control pay-off speed in power grid construction account for 15%-20% of mechanical accidents. Especially in complex terrains or large-span erection scenarios, it is difficult for manual operation to accurately control the speed in real time, and accidents are prone to occur. In recent years, with the acceleration of the ultra-high voltage project, the diameter of the cable reel has exceeded 3.5 meters and the single-reel weight has reached 8 tons. The traditional control method has been difficult to meet the safety requirements of the new power system. Against the background of the accelerated construction of the new power system, the research and development of an automatic braking device for cable reels is urgent.

[0004] At present, traditional cable pay-off reels mostly adopt the method of manual braking by operators. This braking method has some technical problems in actual application, such as:

[0005] (1) Great safety hazards: The response speed of manual braking is slow, and it is easy to cause cable wear or breakage due to excessive speed; moreover, the mechanical braking accuracy is low, and the braking force cannot be dynamically adjusted according to the actual working conditions.

[0006] (2) Low construction efficiency: There is a lack of precise control over the pay-off length, which completely relies on manual experience and is inefficient.

[0007] (3) Low degree of automation: The entire braking process of the cable pay-off reel requires manual participation and cannot achieve full-automatic braking. Summary of the Invention

[0008] To overcome the deficiencies of the above-mentioned prior art, the present invention provides an intelligent cable pay-off reel braking device and a braking method, which can improve the braking efficiency and degree of automation of the cable pay-off reel on the basis of safe and precise braking of the cable pay-off reel.

[0009] To achieve the above object, one or more embodiments of the present invention provide the following technical solutions:

[0010] The first aspect of the present invention provides an intelligent cable pay-off reel braking device.

[0011] An intelligent cable pay-off reel braking device includes: a monitoring module, a remote control module, a control module, and an electric motor braking module;

[0012] The monitoring module, the remote control module, and the motor braking module are all connected to the control module;

[0013] The control module is used for dual-mode braking. Specifically: in the full-automatic mode, the control module dynamically adjusts the braking torque of the motor braking module according to the data measured by the monitoring module to reduce the rotation speed of the wire reel; in the semi-automatic mode, the control module adjusts the braking torque of the motor braking module according to the target wire-reeling length set by the remote control module to achieve braking of the cable wire reel.

[0014] Further, the monitoring module includes a first Hall sensor, a second Hall sensor, a third Hall sensor, and a signal processor.

[0015] Further, the remote control module uses a wireless remote controller, which is used to set the target wire-reeling length and send a remote control signal to the control module.

[0016] Further, the control module uses a PLC control module.

[0017] Further, the PLC control module integrates logic control and frequency modulation calibration functions, which are used to adjust the braking torque and braking speed of the motor braking module.

[0018] Further, an intelligent cable wire reel braking device further includes an alarm module, and the alarm module is connected to the control module.

[0019] Further, the motor braking module includes a braking disc, a braking motor, and a stepper motor driver.

[0020] Further, the braking disc is connected to the output end of the braking motor, and the input end of the braking motor is connected to the control module through the stepper motor driver.

[0021] The second aspect of the present invention provides an intelligent cable wire reel braking method.

[0022] An intelligent cable wire reel braking method includes:

[0023] Based on the monitoring module, data of the cable wire reel is collected in real time, and the data includes the rotation speed and the wire-reeling length;

[0024] The control module is used to receive the data of the monitoring module and the remote control module, determine the working mode according to the received data, and perform braking and resetting of the cable wire reel according to the working mode. Specifically:

[0025] When the working mode is the full-automatic mode, a speed threshold is set. When the rotational speed monitored by the first Hall sensor in the monitoring module is greater than the set speed threshold, the signal processor converts the pulse signal into an electrical signal and controls the braking torque and direction of the motor through the control module. The motor rotates forward to drive the disc to the set position; the second Hall sensor acts as a proximity switch and returns an electrical signal to the PLC control module, and the motor stops rotating. At this time, the braking disc clamps to control the speed of the cable pay-off reel; when the speed is lower than the speed threshold, the control module controls the braking direction of the motor braking module again, the motor rotates in reverse to drive the disc to the initial position, and the third Hall sensor returns an electrical signal to the PLC control module, and the motor stops to realize the reset of the device.

[0026] When the working mode is the semi-automatic mode, the operator uses the remote control module to remotely control the start / stop, forward / reverse rotation of the braking motor in real time, which can meet the flexible control requirements of the cable reel pay-off speed at the construction site. At the same time, it is used to set the target pay-off length. When the pay-off length collected by the first Hall sensor of the monitoring module is greater than the set target pay-off length, the braking torque of the motor braking module is adjusted based on the control module to realize the braking of the cable pay-off reel.

[0027] Furthermore, the working mode is determined according to the received data, including: when the control module receives the remote control signal of the remote control module, it is the semi-automatic mode; when the control module does not receive the remote control signal of the remote control module, it is the full-automatic mode.

[0028] The above one or more technical solutions have the following beneficial effects:

[0029] (1) The present invention provides an intelligent cable pay-off reel braking device, including a monitoring module, a remote control module, a control module, and a motor braking module; wherein, the control module is used for dual-mode braking. In the full-automatic mode, through real-time speed monitoring and closed-loop control, it can respond to speed overrun in a very short time and ensure that the braking accuracy is controlled within the preset range, effectively avoiding accidents such as cable derailment and reel collapse caused by excessive cable speed. Compared with the prior art, the accident rate can be greatly reduced.

[0030] (2) The control module of the present invention is connected to the remote control module. In the semi-automatic mode, based on the high-precision length measurement and wireless remote control functions, it can flexibly control the cable reel pay-off speed, reduce the manual measurement and operation time, and greatly improve the operation efficiency. Therefore, the present invention has higher construction efficiency and is especially suitable for the laying of long-distance and large-diameter cables.

[0031] (3) The present invention provides an intelligent cable pay-off reel braking device, which includes a monitoring module, a remote control module, a control module and an electric motor braking module; the monitoring module, the remote control module and the electric motor braking module are all connected to the control module; wherein, the control module can be used for dual-mode braking. Through this dual-mode collaboration, modular design and integrated assembly, the present invention can not only adapt to the safety protection in complex working conditions (such as mountains and tunnels), but also realize manual intervention through a remote controller to meet diverse construction requirements. At the same time, the device can be "installed and used as needed", which is convenient and fast. Therefore, compared with the prior art, the present invention has a higher automation level.

[0032] Advantages of additional aspects of the present invention will be given in part in the following description, become apparent in part from the following description, or be learned through the practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The attached drawings forming a part of this specification are used to provide a further understanding of the present invention. The schematic embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation to the present invention.

[0034] Figure 1 It is a structural diagram of an intelligent cable pay-off reel braking device in Embodiment 1 of the present invention.

[0035] Figure 2 It is a schematic diagram of the connection relationship of an intelligent cable pay-off reel braking device in Embodiment 1 of the present invention.

[0036] Figure 3 It is a flowchart of an intelligent cable pay-off reel braking method in Embodiment 2 of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0037] It should be noted that the following detailed descriptions are all exemplary and are intended to provide further explanations of the present invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the technical field to which the present invention belongs.

[0038] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present invention.

[0039] Without conflict, the embodiments in the present invention and the features in the embodiments can be combined with each other.

[0040] Embodiment 1

[0041] This embodiment discloses an intelligent cable pay-off reel braking device.

[0042] As Figure 1As shown in the figure, an intelligent cable pay-off reel braking device includes a monitoring module, a remote control module, a control module, and an electric motor braking module;

[0043] The monitoring module, the remote control module, and the electric motor braking module are all connected to the control module;

[0044] The control module is used for dual-mode braking. Specifically, in the full-automatic mode, the control module dynamically adjusts the braking torque of the electric motor braking module according to the data measured by the monitoring module; in the semi-automatic mode, the control module adjusts the braking torque of the electric motor braking module according to the target pay-off length set by the remote control module; to achieve the braking of the cable pay-off reel.

[0045] Through the integration of intelligent control technology, based on the above device, the present invention can improve the braking efficiency and automation degree of the cable pay-off reel on the basis of safe and precise braking of the cable pay-off reel, realizing the integration of real-time monitoring, alarm and control of the speed of the cable pay-off reel. The flexible full-automatic and semi-automatic modes effectively solve the defects of large safety hazards in manual operation of mechanical brakes, low automation degree, and low construction efficiency. For the convenience of understanding the technical solution of the present invention, the following further explains and illustrates the specific implementation method of the technical solution of the present invention.

[0046] The present invention provides an intelligent cable pay-off reel braking device, including a monitoring module, a remote control module, a control module, and an electric motor braking module.

[0047] As Figure 2 shown, the control module adopts a PLC integrated circuit controller. Specifically, the PLC control module integrates logic control and frequency modulation calibration functions, and is used to adjust the braking torque and braking speed of the electric motor braking module; at the same time, when the intelligent cable pay-off reel braking device is working, the PLC control module supports the switching between the full-automatic mode and the semi-automatic mode.

[0048] As Figure 1 shown, the monitoring module is connected to the control module; among them, the monitoring module includes a first Hall sensor, a second Hall sensor, a third Hall sensor, and a signal processor. Among them, the first Hall sensor is used as a monitoring probe (for speed monitoring and counting the length of the cable), and the second Hall sensor and the third Hall sensor are used as proximity switches. Specifically, the first Hall sensor is connected to the signal processor to monitor the rotation speed and pay-off length of the cable pay-off reel; the second Hall sensor and the third Hall sensor are used as proximity switches. When the motor rotates forward to drive the disc to the set position or the initial position, an electrical signal is returned to the PLC control module, and the motor stops rotating.

[0049] As an alternative embodiment, the first Hall sensor is connected to the signal input pin of the signal processor, that is, the sensor probe of the first Hall sensor transmits data such as the rotation speed and the pay-off length of the cable pay-off reel collected through the signal processor to the PLC control module in the form of an electrical signal through the pin ins. The second Hall sensor and the third Hall sensor are connected to the limit 1 and limit 2 pins of the PLC control module to realize the control of the forward and reverse limits of the motor.

[0050] As Figure 1 , Figure 2 shown, the remote control module is connected to the control module; among them, the remote control module is dedicated to the semi-automatic mode, and a wireless remote control is used to set the target pay-off length and send a remote control signal to the control module for the operator to remotely start and stop the device and set the target pay-off length.

[0051] As an alternative embodiment, the wireless remote control can be used for remote control in the form of wireless Bluetooth, that is, a connection is established with the PLC control module by setting a frequency band (433 MHz) matching the PLC radio frequency receiving module. Among them, the wireless remote control includes FWD (motor forward), REV (motor reverse), and STOP (stop) buttons.

[0052] As Figure 1 shown, the intelligent cable pay-off reel braking device further includes an alarm module, and the alarm module is connected to the control module; among them, the alarm module uses an audible and visual alarm.

[0053] As an alternative embodiment, the audible and visual alarm is connected to the NO pin of the PLC control module. When the PLC control module determines that the pay-off speed of the cable pay-off reel exceeds the limit, it can trigger and control the audible and visual alarm to work.

[0054] As Figure 1 , Figure 2 shown, the motor braking module is connected to the control module; among them, the motor braking module includes a braking disc, a braking motor, and a motor driver. The motor braking module outputs torque through the braking motor to make the braking disc move forward or backward, thereby realizing the braking and restoration of the pay-off reel.

[0055] As an alternative embodiment, the braking disc is connected to the output end of the braking motor, and the input end of the braking motor is connected to the "direction signal", "pulse signal", and "enable signal" pins of the PLC control module through the motor driver.

[0056] Embodiment 2

[0057] This embodiment discloses an intelligent cable pay-off reel braking method.

[0058] As Figure 3 shown, an intelligent cable pay-off reel braking method includes:

[0059] Step S1: Based on the data collected by the monitoring module in real time for the cable pay-off reel, the data includes the rotation speed and the pay-off length;

[0060] Step S2: Use the control module to receive the data from the monitoring module and the remote control module, determine the working mode according to the received data, and brake the cable pay-off reel according to the working mode. Specifically:

[0061] When the working mode is the full-automatic mode, set a speed threshold. When the rotation speed collected by the monitoring module is greater than the set speed threshold, adjust the braking torque of the motor braking module based on the control module;

[0062] When the working mode is the semi-automatic mode, use the remote control module to set the target pay-off length. When the pay-off length collected by the monitoring module is greater than the set target pay-off length, adjust the braking torque of the motor braking module based on the control module; to achieve braking of the cable pay-off reel.

[0063] Further, determining the working mode according to the received data includes: when the control module receives the remote control signal from the remote control module, it is the semi-automatic mode; when the control module does not receive the remote control signal from the remote control module, it is the full-automatic mode.

[0064] In step S2, brake the cable pay-off reel according to the working mode, that is, in the full-automatic mode, realize speed closed-loop control by dynamically adjusting the braking torque, and in the semi-automatic mode, the pay-off length can be set by the wireless remote control and the start and stop can be triggered.

[0065] Further, the control module is built-in with logic control and frequency modulation calibration functions. The logic control can comprehensively realize the forward and reverse rotation and instantaneous start and stop of the motor according to the input of various signals, and adjust the working state of the braking device in real time.

[0066] Further, the control module is built-in with a frequency modulation calibration function. By adjusting the working frequency of the stepper motor, the smooth acceleration and deceleration of the motor can be realized, avoiding out-of-step or mechanical shock caused by sudden start and stop.

[0067] Even further, in step S2, brake the cable pay-off reel according to the working mode. Specifically:

[0068] A. The working process in the full-automatic mode is as follows:

[0069] The monitoring module collects the rotation speed of the cable pay-off reel in real time and transmits the obtained rotation speed to the control module;

[0070] Set a speed threshold for the control module in advance; based on the comparison of the set speed threshold and the collected rotational speed by the control module, if it exceeds the limit (i.e., the measured rotational speed is greater than the speed threshold), then trigger the alarm module and output a braking instruction to the motor braking module;

[0071] The motor braking module dynamically adjusts the braking torque of the brake disc according to the braking instruction until the rotational speed returns to the safe range.

[0072] B. The working process in semi-automatic mode is as follows:

[0073] The operator sets the target wire laying length through the remote control module;

[0074] The control module can remotely trigger braking when the set target wire laying length is reached according to the real-time length data fed back by the encoder or the length measuring wheel. It should be noted that the device in semi-automatic mode supports manual intervention. For example, when the operator faces other emergencies, the wire laying speed can be emergently braked or adjusted at any time through the remote controller.

[0075] Based on the above design of the present invention, the following breakthroughs have been achieved:

[0076] ① Dual-mode collaboration: The full-automatic mode ensures personnel safety; further, in the full-automatic mode, through real-time speed monitoring and closed-loop control, it can respond to speed overlimit within 0.2 seconds, and the braking accuracy reaches ±0.05 m / s, effectively avoiding accidents such as cable derailment and reel collapse caused by excessive cable speed. The semi-automatic mode improves flexibility; further, in the semi-automatic mode, based on high-precision length measurement and wireless remote control functions, the manual measurement and operation time are reduced, and the operation efficiency is increased by 30% - 50%. It is especially suitable for the laying of long-distance and large-diameter cables, greatly optimizing the construction efficiency.

[0077] To further prove the actual effect of the present invention, taking a cable reel with a diameter of 1.2 m and a weight of 3000 kg as an example, the upper limit speed of the cable reel rotation is set at 50 m / min. The following is the theoretical analysis of the response time and braking accuracy of the braking device in the full-automatic mode of this application:

[0078] A. Response time of the braking device of the present invention:

[0079] The device of the present invention is based on a control board made of FR4 material and adopts circuit signal response. Therefore, the response time calculation formula can be expressed as follows:

[0080]

[0081] Where T delay is the response time (s), L is the circuit line length (m), v is the signal propagation speed (m / s), c is the speed of light, and ε r is the relative dielectric constant of the medium, and the FR4 material is 4.5.

[0082] Furthermore, the response time of the braking device in the present invention can be obtained as follows:

[0083]

[0084] B. Braking accuracy of the braking device of the present invention:

[0085] The braking accuracy of the present invention is mainly determined by the sensor error and the actuator response error, that is:

[0086]

[0087] Δv actuator = a × T delay ;

[0088] where Δv is the total braking accuracy, Δv sensor is the measurement error of the speed sensor, and Δv actuator is the response error of the braking motor; R is the sensor resolution, T is the sampling period, 0.01 s; a is the braking acceleration, which is related to the braking torque and the mass of the cable reel.

[0089] Furthermore, the braking accuracy of the braking device in the embodiment of the present invention is:

[0090]

[0091] It can be seen that the braking accuracy of the present invention meets the requirement of ±0.05 m / s.

[0092] Furthermore, through multiple embodiments, when the speed of the cable reel is greater than 50 m / min, the present invention can respond to braking reliably. In the semi-automatic mode, for every 100 meters of cable, it saves nearly 20 minutes compared with the mechanical braking device, and the actual working efficiency is increased by 30% - 50%.

[0093] ② Intelligent automatic braking: The present invention integrates modules of unmanned monitoring, control, and alarm, replacing the manual mechanical brake.

[0094] ③ Flexible operation: The dual-mode collaboration, modular design, and integral assembly can not only adapt to the safety protection in complex working conditions (such as mountains and tunnels), but also realize manual intervention through the remote control to meet diverse construction requirements. At the same time, the device can be "installed and used as needed", which is convenient and fast.

[0095] ④ Wide application range: It is compatible with cable reels of different specifications (diameter 0.5 - 3 m), supports dual power supply modes of mains electricity and lithium battery, and can be widely applied in fields such as electric power, communication, and rail transit.

[0096] Each step involved in the device of the first embodiment above corresponds to the second method embodiment, and for the specific implementation, reference may be made to the relevant description part of the second embodiment.

[0097] Those skilled in the art should understand that the above-mentioned modules or steps of the present invention can be implemented by a general-purpose computer device. Optionally, they can be implemented by program codes executable by the computing device, so that they can be stored in the storage device and executed by the computing device, or they can be separately fabricated into individual integrated circuit modules, or multiple modules or steps among them can be fabricated into a single integrated circuit module for implementation. The present invention is not limited to any specific combination of hardware and software.

[0098] Although the specific implementation of the present invention has been described above in conjunction with the accompanying drawings, it is not a limitation on the protection scope of the present invention. Those skilled in the art should understand that based on the technical solution of the present invention, various modifications or deformations that can be made by those skilled in the art without creative efforts are still within the protection scope of the present invention.

Claims

1. An intelligent cable pay-off drum brake device, characterized in that: include: Monitoring module, remote control module, control module and motor brake module; The monitoring module, remote control module and motor brake module are all connected to the control module; The control module is used for dual-mode braking. Specifically: in the fully automatic mode, the control module dynamically adjusts the braking torque of the motor brake module according to the data measured by the monitoring module; in the semi-automatic mode, the control module adjusts the braking torque of the motor brake module according to the target pay-off length set by the remote control module to achieve cable pay-off drum braking.

2. The intelligent cable pay-off drum brake device according to claim 1, characterized in that: The monitoring module is a Hall sensor, which includes a sensor probe and a monitoring signal processor.

3. The intelligent cable pay-off drum brake device according to claim 1, characterized in that: The remote control module adopts a wireless remote controller, which is used to set the target line length and send a remote control signal to the control module.

4. The intelligent cable pay-off drum brake device according to claim 1, characterized in that: The control module is controlled by PLC.

5. The intelligent cable pay-off drum brake device according to claim 4, characterized in that: The PLC control module is integrated with logic control and frequency modulation calibration functions for adjusting the braking torque and braking speed of the motor brake module; at the same time, when the intelligent cable pay-off drum brake device is working, the PLC control module supports switching between full-automatic mode and semi-automatic mode.

6. The intelligent cable pay-off drum brake device according to claim 1, characterized in that: It also includes an audible and visual alarm module, which is connected to the control module.

7. The intelligent cable pay-off drum brake device according to claim 1, characterized in that: The motor brake module includes a brake disc, a brake motor and a motor driver.

8. The intelligent cable pay-off drum brake device according to claim 7, characterized in that: The brake disc is connected to the output end of the brake motor, and the input end of the brake motor is connected to the control module through a motor driver.

9. An intelligent cable pay-off drum braking method, characterized in that: include: Based on the monitoring module, real-time data of the cable pay-off drum is collected, and the data includes rotation speed and pay-off length; The control module receives data from the monitoring module and the remote control module, determines the working mode according to the received data, and brakes the cable pay-off drum according to the working mode. Specifically: When the working mode is fully automatic, a speed threshold is set. When the speed collected by the monitoring module is greater than the set speed threshold, the braking torque of the motor brake module is adjusted based on the control module to reduce the speed of the pay-off reel. When the working mode is semi-automatic mode, the target pay-off length is set by using the remote control module. When the pay-off length collected by the monitoring module reaches the set target pay-off length, the cable pay-off drum is braked.

10. The intelligent cable pay-off drum braking method according to claim 9, characterized in that: The working mode is determined according to the received data, including: when the control module receives the remote control signal from the remote control module, it is a semi-automatic mode; when the control module does not receive the remote control signal from the remote control module, it is a fully automatic mode.

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