Anti-overwinding sensor based on magnetic induction

Abstract

The invention provides an anti-overwinding sensor based on magnetic induction, and relates to the field of cranes, the anti-overwinding sensor based on magnetic induction comprises a body and a transmission shaft, and the transmission shaft is installed on the body; the counting device comprises a magnet piece, a magnetic induction piece and a multi-dimensional sensor used for counting, the magnet piece is installed on the transmission shaft, and the magnetic induction piece is installed on the body so that the number of rotation turns of the transmission shaft can be accurately determined; and after the multi-dimensional sensor collects the rotation data, anomaly detection is carried out on the rotation data, and under the condition that it is determined that the rotation data is abnormal, a locking signal is generated and sent to an external interlocking controller so as to indicate the interlocking controller to control an external motor to stop driving the winding drum. Through the steel wire rope monitoring and protecting device, the problems of high cost, complex installation and insufficient reliability are solved, and then the effects of the steel wire rope monitoring and protecting device which is simple in structure, powerful in function and high in reliability are achieved.

Description

Technical Field

[0001] The embodiments of the present invention relate to the field of cranes, and in particular, to an anti-overwinding sensor based on magnetic induction. Background Art

[0002] In the construction machinery industry, wire rope monitoring and protection devices for equipment such as cranes and hoists are of great significance for ensuring the safety of equipment operation and extending the service life of equipment. At present, most of the existing overwinding protection devices use a transmission shaft with multiple gear reductions. By setting the number of safety turns, when the preset number of turns is reached, the internal mechanical switch is triggered to output a signal, thereby playing the role of overwinding protection.

[0003] However, this traditional mechanical overwinding protection device has many shortcomings. First, once the number of turns protection range of the mechanical switch is set, it cannot be changed, which is extremely inconvenient in actual use, because different operating scenarios may require different number of turns protection range. Secondly, when multiple gears are used together, they are prone to wear after long-term operation, resulting in reduced equipment accuracy and shortened service life. In addition, the function of this mechanical protection device is relatively single, and it can only send a signal when the number of turns reaches a certain value, and it is impossible to monitor other conditions of the wire rope in real time, such as abnormal rotation speed.

[0004] To solve the above problems, a Chinese invention patent application with application number CN201010620047.X discloses a winch wire rope over-release protection device, which is used to measure the number of turns of the wire rope, including a detection switch for detecting the rotation angle of the drum, the detection switch is arranged on the drum, and also includes a display device connected to the signal output end of the detection switch. The detection switch is a potentiometer counter, which is connected to the drum through a rotatable connecting shaft at the end. However, this solution still relies on a complex mechanical structure or external electronic equipment, and once the counter fails or the mechanical structure fails, it is easy to cause counting errors. Summary of the invention

[0005] The embodiment of the present invention provides an anti-overwinding sensor based on magnetic induction, so as to at least solve the problem of counting errors caused by counting device failure in the related art.

[0006] According to one embodiment of the present invention, there is provided an anti-overwinding sensor based on magnetic induction, comprising: a body, a transmission shaft, the transmission shaft being mounted on the body; and a counting device, the counting device comprising a magnet, a magnetic induction member and a multi-dimensional sensor for counting, the magnet being mounted on the transmission shaft, the magnetic induction member being mounted on the body, so as to accurately determine the number of rotations of the transmission shaft; after the multi-dimensional sensor collects rotation data, an abnormality detection is performed on the rotation data, and when it is determined that the rotation data is abnormal, a locking signal is generated, and the locking signal is sent to an external interlocking controller, so as to instruct the interlocking controller to control the external motor to stop driving the reel; wherein the rotation data comprises the number of rotations of the transmission shaft, the rotation speed, the magnetic field change data, and the rotation time of the transmission shaft; A waterproof cover is installed on the main body and covers the magnet. A spiral air groove is arranged inside the waterproof cover.

[0007] Through the above technical solution, the number of rotations of the transmission shaft can be accurately measured by the cooperation of the magnet and the magnetic induction component, thereby realizing accurate monitoring of the number of windings of the crane or crane wire rope. Through the cooperation of the magnet and the magnetic induction component, the number of rotations of the transmission shaft can be accurately measured, thereby realizing accurate monitoring of the number of windings of the crane or crane wire rope; the waterproof cover can effectively prevent the entry of moisture and dust, protect the magnet and the magnetic induction component from the influence of the external environment, and extend the service life of the device. In harsh environments such as humidity and dust, the waterproof cover can ensure the normal operation of the device and improve the environmental adaptability of the device.

[0008] According to an embodiment of the present invention, a plurality of connecting pillars are disposed on the main body, and the magnetic induction member is connected to the connecting pillars.

[0009] Through the above technical solution, the magnetic induction component is firmly fixed to the body through the cooperation of the connecting column and the connecting piece, ensuring that the magnetic induction component will not loosen during operation, thereby improving the structural stability of the device. This connection method makes the installation and removal of the magnetic induction component more convenient, and is easy to maintain and replace.

[0010] According to an embodiment of the present invention, at least one bearing is disposed between the body and the transmission shaft.

[0011] Through the above technical solution, the use of bearings significantly reduces the friction between the transmission shaft and the body, reduces mechanical wear, and prolongs the service life of the device. The bearings can ensure the high-precision rotation of the transmission shaft, reduce vibration and shaking, and thus improve the accuracy of magnetic induction component signal acquisition. The use of bearings makes the rotation of the transmission shaft more stable and improves the overall operating stability of the device.

[0012] According to one embodiment of the present invention, it further comprises a monitoring device, wherein the monitoring device is installed on the transmission shaft.

[0013] Through the above technical solution, the monitoring device can monitor the operating status of the transmission shaft in real time, such as speed, vibration, etc., to provide more comprehensive protection for the safe operation of the equipment. Through the monitoring device, potential fault hazards can be discovered in advance, and timely measures can be taken to avoid accidents.

[0014] According to an embodiment of the present invention, the monitoring device includes an annular bracket and a magnet, wherein the annular bracket is mounted on the transmission shaft, and the magnet is mounted on the annular bracket in a lifting manner.

[0015] Through the above technical solution, the liftable design of the magnet enables the monitoring device to dynamically monitor the axial displacement of the transmission shaft, further enriching the monitoring function. The structural design of the annular bracket ensures the stability and measurement accuracy of the magnet and improves the reliability of the device.

[0016] According to an embodiment of the present invention, the monitoring device further comprises a plurality of tension springs, one end of each tension spring is mounted on the magnet, and the other end of each tension spring is mounted on the body.

[0017] Through the above technical solution, the tension spring can buffer the movement of the magnet, reduce the measurement error caused by vibration or impact, and improve the stability of the measurement. The design of the tension spring enables the magnet to automatically reset after being subjected to external force, ensuring the normal operation of the device.

[0018] According to one embodiment of the present invention, it further includes an upper cover, wherein the upper cover is mounted on the body.

[0019] Through the above technical solution, the upper cover can provide additional protection for the entire device, preventing external objects from interfering with and damaging the internal structure of the device. The cooperation between the upper cover and the body further enhances the sealing of the device and improves the waterproof and dustproof effect.

[0020] Through the above technical solution, various operating data of the transmission shaft are collected through multi-dimensional sensors, so that the transmission shaft can be monitored from multiple dimensions. At the same time, the coordinated work of the magnetic induction detection module, interlocking controller and multi-dimensional sensor realizes intelligent control of the rotation state of the transmission shaft, avoids counting errors caused by malfunctions of equipment such as counters, and effectively improves the counting accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 is an overall schematic diagram of an anti-overwinding sensor based on magnetic induction according to an embodiment of the present invention; Figure 2 is an exploded schematic diagram of an anti-overwinding sensor based on magnetic induction according to an embodiment of the present invention; Figure 3 is a cross-sectional view of an exploded schematic diagram of an anti-overwinding sensor based on magnetic induction according to an embodiment of the present invention; Figure 4 is an exploded schematic diagram of an anti-overwinding sensor based on magnetic induction according to another embodiment of the present invention; Figure 5 is a partial structural schematic diagram of a monitoring device for showing an anti-overwinding sensor based on magnetic induction according to another embodiment of the present invention; Figure 6 It is a schematic structural diagram of an anti-overwinding sensor based on magnetic induction with added spiral air grooves according to another embodiment of the present invention.

[0022] Reference numerals: 10. Main body; 11. Connecting column; 20. Counting device; 21. Magnet; 22. Magnetic induction element; 2201. Give way groove; 30. Transmission shaft; 40. Waterproof cover; 401. Spiral air groove; 50. Upper cover; 60. Bearing; 70. Monitoring device; 71. Ring bracket; 72. Magnet; 73. Tension spring. DETAILED DESCRIPTION

[0023] The technical solutions in the embodiments of the present application will be described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all of the embodiments.

[0024] In the following, the terms "first", "second", etc. are used for descriptive purposes only and are not to be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Thus, a feature defined as "first", "second", etc. may explicitly or implicitly include one or more of the features. In the description of this application, unless otherwise specified, "plurality" means two or more.

[0025] In addition, in the present application, directional terms such as "up", "down", "left" and "right" may be defined including but not limited to the orientation relative to the schematic placement of the components in the drawings. It should be understood that these directional terms may be relative concepts, which are used for relative description and clarification, and may change accordingly according to the change in the orientation of the components in the drawings.

[0026] In this application, unless otherwise specified or limited, the term "connection" should be understood in a broad sense. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection or an indirect connection through an intermediate medium. In addition, the term "coupling" can be a way of achieving electrical connection for signal transmission.

[0027] As used herein, "about," "substantially," or "approximately" includes the stated value and an average value that is within an acceptable range of variation from the particular value as determined by one of ordinary skill in the art taking into account the measurements in question and the errors associated with the measurement of the particular quantity (i.e., the limitations of the measurement system).

[0028] In this embodiment, a magnetic induction-based anti-overwinding sensor is provided, which will be described in detail below.

[0029] Reference Figures 1 to 6 The magnetic induction-based anti-overwinding sensor includes a main body 10, a counting device 20 and a transmission shaft 30, wherein the counting device 20 is installed on the main body 10, the transmission shaft 30 is rotatably installed on the main body 10, and one end of the transmission shaft 30 is connected to the counting device 20, and the other end of the transmission shaft 30 is connected to the external structure.

[0030] That is to say, when the external structure rotates, it drives the transmission shaft 30 to rotate. After the transmission shaft 30 rotates, the counting device 20 can measure the number of rotations of the transmission shaft 30, thereby accurately determining the number of rotations of the external structure.

[0031] In this embodiment, the external structure is implemented as a reel, on which a steel wire rope is wound according to a prescribed winding method. When the steel wire rope needs to be released or reeled in, the external motor drives the reel to rotate under the control of an external interlocking controller. When the reel rotates, it drives the transmission shaft 30 to rotate. At this time, the counting device 20 records and detects the number of rotations of the transmission shaft 30.

[0032] Specifically, the counting device 20 includes a magnet 21 and a magnetic induction member 22 and a multi-dimensional sensor for counting, wherein the sensor includes a timing module, an alarm module, a counting module, a communication module and a control module, wherein the counting module counts by converting the number of collected voltage pulses into the number of rotations of the transmission shaft 30 and records real-time data; the timing module is used to time the rotation process, the alarm module is used to alarm when an abnormality occurs, the control module is used to generate control instructions and judge the data of the counting module and the magnetic induction condition of the magnetic induction member 22; the communication module is used to transmit control instructions; The magnet part 21 is rotatably mounted on the body 10, and the magnet part 21 is connected to the transmission shaft 30, and the magnetic induction part 22 is fixedly mounted on the body 10. It is worth mentioning that in this embodiment, a plurality of connecting columns 11 are mounted on the body 10, and the height of the connecting column 11 is higher than the height of the magnet part 21, that is, a magnetic induction area is formed between the body 10 and the magnetic induction part 22, and the magnetic induction part 22 is provided with a plurality of connecting parts, and the connecting parts are adapted to the connecting columns 11. When the connecting parts are mounted on the connecting columns 11, the magnetic induction part 22 is fixed. In this way, it is easy to maintain and replace.

[0033] In this way, when the external structure drives the transmission shaft 30 to rotate, the transmission shaft 30 drives the magnet part 21 to rotate. When the magnet part 21 rotates, the position of the magnetic induction part 22 corresponds to the magnet part 21, and is used to detect the changes in the magnetic field generated during the rotation of the magnet part 21. The magnetic induction part 22 generates a corresponding induction signal by detecting these magnetic field changes. According to Faraday's law of electromagnetic induction, when the magnet part 21 rotates, the magnetic flux passing through the magnetic induction part 22 changes, thereby generating an induced electromotive force in the magnetic induction part 22.

[0034] In addition, each time the magnet 21 completes a complete rotation cycle, the magnetic induction element 22 detects a specific magnetic field change signal. By converting these signals into pulse signals, the counting device 20 can count the pulses, thereby achieving accurate measurement of the number of rotations of the transmission shaft 30.

[0035] During operation, rotation data is collected through a multi-dimensional sensor, and then the rotation data is detected for abnormalities. When it is determined that there is an abnormality in the rotation data, a locking signal is generated, and the locking signal is sent to an external preset interlocking controller to instruct the interlocking controller to control the motor to stop driving the reel, thereby stopping the rotation of the transmission shaft 30. The rotation data includes the number of rotations of the transmission shaft 30, the rotation speed, the changes in the magnetic field during the rotation process (such as the difference between the extreme values ​​of the magnetic field and different time periods), the rotation duration of the transmission shaft 30, etc.

[0036] In the prior art, the number of rotations of the reel is simply determined by detecting the number of rotations of the transmission shaft 30. Once the magnetic induction component 22 fails, the induced electromotive force will change, thereby affecting the detection accuracy. Compared with the prior art, the present application performs a comprehensive detection and judgment of the transmission condition of the transmission shaft 30 from multiple dimensions such as rotation duration, rotation speed, and magnetic field change on the basis of detecting the number of rotations of the transmission shaft 30, so as to accurately determine whether the rotation of the transmission shaft 30 is abnormal, and avoid abnormal counting caused by the failure of the magnetic induction component 22.

[0037] Furthermore, the magnetic induction component 22 is provided with a plurality of clearance grooves 2201, and the clearance grooves 2201 can provide sufficient space for other components during the installation process, so that the magnetic induction component 22 can be smoothly installed on the body 10. In this embodiment, the shape and size of the clearance grooves 2201 can be linear, arc-shaped or other suitable shapes to meet different installation and operation requirements.

[0038] Specifically, the magnetic induction-based anti-overwinding sensor further includes a waterproof cover 40, which is installed on the body 10 and covers the magnet 21, that is, the waterproof cover 40 is installed in the magnetic induction area. The waterproof cover 40 can effectively prevent moisture and dust from entering, protect the magnet 21 and the magnetic induction component 22 from the influence of the external environment, and extend the service life of the device. In harsh environments such as humidity and dust, the waterproof cover 40 can ensure the normal operation of the device and improve the environmental adaptability of the device.

[0039] In addition, the magnetic induction-based anti-overwinding sensor also includes an upper cover 50, which is installed on the main body 10. The upper cover 50 has an installation space, wherein the magnet 21, the magnetic induction component 22 and the waterproof cover 40 are all installed in the installation space.

[0040] It is worth mentioning that the upper cover 50 also has a plurality of first mounting holes, and the operator installs the upper cover 50 on the body 10 by using a locking member to pass through the first mounting holes. The cooperation between the upper cover 50 and the body 10 further enhances the sealing of the device and improves the waterproof and dustproof effect.

[0041] In addition, at least one bearing 60 is installed between the transmission shaft 30 and the body 10. In this embodiment, two bearings 60 are provided, which improves the service life and operation accuracy of the device, so that it can better meet the high requirements of crane and hoist wire rope monitoring and protection in the engineering machinery industry. The use of the bearing 60 makes the rotation of the transmission shaft 30 more stable, improving the overall operation stability of the device.

[0042] In another embodiment, high-viscosity silicone oil is added between the transmission shaft 30 and the bearing 60 to form rotation damping to suppress the interference of high-frequency vibration on magnetic signal collection.

[0043] Furthermore, the magnetic induction-based anti-overwinding sensor further includes a monitoring device 70 , and the monitoring device 70 is installed on a side of the transmission shaft 30 close to the magnet member 21 .

[0044] Specifically, the monitoring device 70 includes an annular bracket 71 and a plurality of magnets 72. The annular bracket 71 is mounted on the transmission shaft 30. The annular bracket 71 is provided with a plurality of second mounting holes. The plurality of magnets 72 are mounted in the second mounting holes. In this embodiment, the annular bracket 71 is provided with 6 second mounting holes and 6 magnets 72 are provided.

[0045] Furthermore, the monitoring device 70 also includes a plurality of tension springs 73, the number of which is the same as the number of the magnets 72. The tension springs 73 are installed between the magnet member 21 and the main body 10 to limit the position of the magnet 72 so that the head of the magnet 72 can be 2 mm-3 mm higher than the annular bracket 71.

[0046] When the external structure stops running, the tension of the tension spring 73 makes all the magnets 21 centered, and the induction ring of the magnetic induction member 22 detects a uniformly distributed magnetic field and outputs a reference signal; when the transmission shaft 30 vibrates abnormally, the magnet deviates from the center due to the inertial force, resulting in a sudden change in the local magnetic field strength. The design of the tension spring 73 enables the magnet 72 to automatically reset after being subjected to external force, ensuring the normal operation of the device.

[0047] That is to say, according to the difference in displacement directions of the six magnets 72 (such as the displacement of three adjacent magnets in the same direction), it is determined that the source of the vibration is axial eccentricity or radial impact.

[0048] In addition, a polyurethane damping sleeve is arranged in the mounting hole to provide friction buffering.

[0049] To sum up, the working process is: first, the operator installs the main body on the reel of the external structure, so that the transmission shaft 30 is connected to the reel. When the reel rotates, it drives the transmission shaft 30 to rotate, and drives the magnet part 21 to rotate. After the magnet part 21 rotates, it corresponds to the magnetic induction part 22 and generates an induction signal. At this time, the multidimensional sensor in the counting device starts to count according to the induction signal, thereby realizing accurate measurement of the number of rotations of the transmission shaft 30 to prevent overwinding.

[0050] Specifically, a spiral air groove 401 is provided inside the waterproof cover 40 , and the airflow is driven by the rotation of the transmission shaft 30 to form a vortex, thereby preventing water mist from entering the magnetic induction area.

[0051] The following is an example to illustrate: Step S1, the magnetic induction detection module self-calibrates to eliminate the error of installation eccentricity; Step S2, the magnetic induction detection module loads safety parameters; Step S3, the multi-dimensional sensor collects rotation data, and then the controller performs anomaly detection on the collected data; Step S4: the interlocking controller receives the locking signal and brakes the reel according to the locking signal to stop the reel from rotating.

[0052] To sum up, the working principle is that in the initial stage, the magnetic induction detection module self-calibrates to eliminate the error of installation eccentricity, and then loads the safety parameters. When the transmission shaft 30 rotates, the multi-dimensional sensor collects rotation data according to the preset time, and when an abnormality is detected, the locking signal is transmitted to the interlocking controller of the peripheral device to brake the reel so that the transmission shaft 30 stops rotating. It should be noted that when performing abnormality detection, the rotation data can be compared with the data under normal conditions. When the difference with the normal rotation data is greater than the preset range, it is determined that the data is abnormal. It can also be based on the rotation data and the rotation process of the magnet 21. The magnetic field changes generated in the rotation data change matrix are used to construct the rotation data change matrix, and then the correlation value of the matrix is ​​calculated. When the correlation value is within the preset range, the data is judged to be normal, otherwise it is judged to be abnormal. It can also be based on the data change matrix, and the elements in the matrix are normalized and converted into grayscale values. At this time, the elements in the matrix are grayscale pixels, thereby forming a grayscale pixel map, and then the confidence is calculated by the softmax function (only applicable to the case where a neural network is used for abnormal judgment). When the confidence is within the preset range, it is judged to be normal, otherwise it is judged to be abnormal. Other schemes can also be used for detection, which are not limited here.

[0053] The above contents are only specific implementation methods of the present application, but the protection scope of the present application is not limited thereto. Any changes or substitutions within the technical scope disclosed in the present application shall be included in the protection scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims.

Claims

1. A magnetic induction based anti-overwinding sensor, applied to a reel, on which a steel wire rope is wound, characterized in that: include: ontology; A transmission shaft, the transmission shaft being mounted on the body; as well as A counting device, the counting device comprising a magnet and a magnetic induction member and a multi-dimensional sensor for counting, the magnet being mounted on the transmission shaft, the magnetic induction member being mounted on the body, so as to determine the number of rotations of the transmission shaft; after the multi-dimensional sensor collects the rotation data, an abnormality detection is performed on the rotation data, and when it is determined that the rotation data is abnormal, a locking signal is generated, and the locking signal is sent to an interlocking controller of an external device, so as to instruct the interlocking controller to control the external motor to stop driving the reel; wherein the rotation data comprises the number of rotations of the transmission shaft, the rotation speed, the magnetic field change data, and the rotation time of the transmission shaft; A waterproof cover is installed on the main body and covers the magnet. A spiral air groove is arranged inside the waterproof cover.

2. The magnetic induction-based anti-overwinding sensor according to claim 1, characterized in that: The main body is provided with a plurality of connection pillars, and the magnetic induction component is connected to the connection pillars.

3. The magnetic induction-based anti-overwinding sensor according to claim 1, characterized in that: At least one bearing is arranged between the body and the transmission shaft.

4. The magnetic induction-based anti-overwinding sensor according to claim 1, characterized in that: Also included is a monitoring device, which is mounted on the transmission shaft.

5. The magnetic induction-based anti-overwinding sensor according to claim 4, characterized in that: The monitoring device comprises an annular support and a magnet. The annular support is mounted on the transmission shaft, and the magnet is mounted on the annular support in a lifting manner.

6. The magnetic induction-based anti-overwinding sensor according to claim 5, characterized in that: The monitoring device further comprises a plurality of tension springs, one end of each of the tension springs being mounted on the magnet and the other end of each of the tension springs being mounted on the body.

7. The magnetic induction-based anti-overwinding sensor according to claim 1, characterized in that: It also includes an upper cover, which is installed on the body.

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