An overwinding prevention sensor based on magnetic induction

Abstract

The present application provides an overwind prevention sensor based on magnetic induction, which relates to the field of cranes. The overwind prevention sensor based on magnetic induction includes a body and a transmission shaft, and the transmission shaft is installed on the body; and a counting device, which includes a magnet piece, a magnetic induction piece and a multi-dimensional sensor for counting. The magnet piece is installed on the transmission shaft, and the magnetic induction piece is installed on the body to accurately determine the number of rotations of the transmission shaft. After the multi-dimensional sensor collects rotation data, abnormal detection is performed on the rotation data. When it is determined that the rotation data is abnormal, a locking signal is generated and sent to an external interlock controller to instruct the interlock controller to control the external motor to stop driving the drum. Through the present invention, the problems of high cost, complex installation and insufficient reliability are solved, and the effect of a wire rope monitoring and protection device with a simple structure, powerful functions and high reliability is achieved.

Description

Technical Field

[0001] The embodiments of the present invention relate to the field of cranes, and more particularly, 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 safe operation of the equipment and extending its service life. Currently, most of the existing anti-overwinding protectors adopt the method of a transmission shaft cooperating with multiple gears for speed reduction. By setting the safety number of turns, when the preset number of turns is reached, an internal mechanical switch is triggered to output a signal, thereby playing a role in anti-overwinding protection.

[0003] However, this traditional mechanical anti-overwinding protection device has many deficiencies. First, once the protection range of the number of turns of the mechanical switch is set, it cannot be changed, which is extremely inconvenient in actual use because different working scenarios may require different protection ranges of the number of turns. Second, when multiple gears are used in combination, wear is likely to occur after long-term operation, resulting in a decrease in equipment accuracy and a shortening of the 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 cannot monitor other states of the wire rope in real time, such as abnormal rotation speed, etc.

[0004] To solve the above problems, a Chinese invention patent application with the application number CN201010620047.X discloses a wire rope anti-overrelease protection device for measuring the number of turns of a wire rope, including a detection switch for detecting the rotation angle of a drum. The detection switch is arranged on the drum, and further includes a display device connected to the signal output end of the detection switch. The detection switch is a potentiometer type counter, and the potentiometer type counter 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 embodiments of the present invention provide an anti-overwinding sensor based on magnetic induction to at least solve the problem of counting errors caused by the failure of counting equipment in related technologies.

[0006] According to an embodiment of the present invention, a magnetic induction-based overwinding sensor is provided, including: a body, a transmission shaft, the transmission shaft being installed on the body; and a counting device, the counting device including a magnet member, a magnetic induction member, and a multi-dimensional sensor for counting, the magnet member being installed on the transmission shaft, the magnetic induction member being installed on the body to accurately determine the number of rotations of the transmission shaft; after the multi-dimensional sensor collects rotation data, abnormal detection is performed on the rotation data, and when it is determined that the rotation data is abnormal, a locking signal is generated and sent to an external interlock controller to instruct the interlock controller to control an external motor to stop driving the drum; wherein the rotation data includes the number of rotations of the transmission shaft, the rotation speed, the magnetic field change data, and the rotation duration of the transmission shaft.

[0007] A waterproof cover, the waterproof cover being installed on the body, and the waterproof cover covering the magnet member, and a spiral air groove being provided inside the waterproof cover.

[0008] Through the above technical solution, through the cooperation of the magnet member and the magnetic induction member, the number of rotations of the transmission shaft can be accurately measured, so as to realize accurate monitoring of the number of winding turns of the steel wire rope of a crane or a hoist. Through the cooperation of the magnet member and the magnetic induction member, the number of rotations of the transmission shaft can be accurately measured, so as to realize accurate monitoring of the number of winding turns of the steel wire rope of a crane or a hoist; the waterproof cover can effectively prevent moisture and dust from entering, protect the magnet member and the magnetic induction member from the influence of the external environment, and extend the service life of the device. In harsh environments such as humidity and dustiness, the waterproof cover can ensure the normal operation of the device and improve the environmental adaptability of the device.

[0009] According to an embodiment of the present invention, a plurality of connecting columns are provided on the body, and the magnetic induction member is connected to the connecting columns.

[0010] Through the above technical solution, through the cooperation of the connecting columns and the connecting members, the magnetic induction member is firmly fixed on the body, ensuring that the magnetic induction member will not loosen during operation, and improving the structural stability of the device. This connection method makes the installation and disassembly of the magnetic induction member more convenient, facilitating maintenance and replacement.

[0011] According to an embodiment of the present invention, at least one bearing is provided between the body and the transmission shaft.

[0012] Through the above technical solution, the use of the bearing significantly reduces the friction between the transmission shaft and the body, reduces mechanical wear, and extends the service life of the device. The bearing can ensure the high-precision rotation of the transmission shaft, reduce vibration and shaking, thereby improving the accuracy of signal acquisition of the magnetic induction member. The use of the bearing makes the rotation of the transmission shaft more stable and improves the overall operation stability of the device.

[0013] According to an embodiment of the present invention, it further includes a monitoring device, and the monitoring device is installed on the transmission shaft.

[0014] Through the above technical solution, the monitoring device can monitor the operating state of the transmission shaft in real time, such as rotational speed, vibration, etc., providing more comprehensive guarantee for the safe operation of the equipment. Through the monitoring device, potential fault hazards can be detected in advance, and measures can be taken in time to avoid accidents.

[0015] According to an embodiment of the present invention, the monitoring device includes an annular bracket and a magnet. The annular bracket is installed on the transmission shaft, and the magnet is installed on the annular bracket in a liftable manner.

[0016] 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, improving the reliability of the device.

[0017] According to an embodiment of the present invention, the monitoring device further includes a plurality of tension springs. One end of each tension spring is installed on the magnet, and the other end is installed on the body.

[0018] Through the above technical solution, the tension springs 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 springs enables the magnet to automatically reset after being subjected to external forces, ensuring the normal operation of the device.

[0019] According to an embodiment of the present invention, it further includes an upper cover, and the upper cover is installed on the body.

[0020] 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 performance of the device, improving the waterproof and dustproof effects.

[0021] Through the above technical solution, a variety of operating data of the transmission shaft are collected by multi-dimensional sensors, realizing the monitoring of the transmission shaft from multiple dimensions. At the same time, the coordinated work of the magnetic induction detection module, the interlock controller and the multi-dimensional sensors realizes the intelligent control of the rotational state of the transmission shaft, avoiding problems such as counting errors caused by malfunctions of devices such as counters, and effectively improving the counting accuracy. Description of the Drawings

[0022] Figure 1 is an overall schematic diagram of a magnetic induction-based anti-overwinding sensor according to an embodiment of the present invention;

[0023] Figure 2Explosion schematic diagram of an overwind prevention sensor based on magnetic induction according to an embodiment of the present invention;

[0024] Figure 3 Cross-sectional view of the explosion schematic diagram of an overwind prevention sensor based on magnetic induction according to an embodiment of the present invention;

[0025] Figure 4 Explosion schematic diagram of an overwind prevention sensor based on magnetic induction according to another embodiment of the present invention;

[0026] Figure 5 Partial structural schematic diagram of an overwind prevention sensor based on magnetic induction according to another embodiment of the present invention for showing the monitoring device;

[0027] Figure 6 Structural schematic diagram of an overwind prevention sensor based on magnetic induction according to another embodiment of the present invention with an added spiral air groove.

[0028] Reference numerals:

[0029] 10, body; 11, connecting column; 20, counting device; 21, magnet member; 22, magnetic induction member; 2201, relief groove; 30, transmission shaft; 40, waterproof cover; 401, spiral air groove; 50, upper cover; 60, bearing; 70, monitoring device; 71, annular bracket; 72, magnet; 73, tension spring. Detailed implementation manners

[0030] Next, the technical solutions in the embodiments of the present application will be described with reference to the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments.

[0031] Hereinafter, terms such as "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, features defined with "first", "second", etc. may explicitly or implicitly include one or more of such features. In the description of the present application, unless otherwise stated, the meaning of "a plurality" is two or more.

[0032] In addition, in the present application, orientation terms such as "upper", "lower", "left", "right", etc. may include but are not limited to being defined relative to the schematic placement orientation 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 they may change accordingly with the change of the orientation of the components placed in the drawings.

[0033] In this application, unless otherwise clearly defined and limited, the term "connection" shall be understood in a broad sense. For example, "connection" can be a fixed connection, a detachable connection, or an integral one; it can be directly connected or indirectly connected through an intermediate medium. In addition, the term "coupling" can be a way of realizing electrical connection for signal transmission.

[0034] As used herein, "about", "substantially" or "approximate" includes the stated value and the average value within an acceptable deviation range of the specific value, where the acceptable deviation range is determined by a person of ordinary skill in the art considering the measurement being discussed and the errors associated with the measurement of a particular quantity (i.e., the limitations of the measurement system).

[0035] In this embodiment, a magnetic induction-based over-winding prevention sensor is provided, which will be elaborated in detail below.

[0036] Refer to Figures 1 to 6 , the magnetic induction-based over-winding prevention sensor includes a main body 10, a counting device 20, and a transmission shaft 30. The counting device 20 is installed on the main body 10, the transmission shaft 30 is rotatably installed on the main body 10, 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 an external structure.

[0037] 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 turns of the transmission shaft 30, so as to accurately determine the number of turns of the external structure.

[0038] In this embodiment, the external structure is implemented as a drum, and a steel wire rope is wound on the drum in a specified winding manner. When it is necessary to pay out or wind up the steel wire rope, an external motor drives the drum to rotate under the control of a peripheral interlock controller. When the drum rotates, it drives the transmission shaft 30 to rotate, and at this time, the counting device 20 records and detects the number of turns of the transmission shaft 30.

[0039] Specifically, the counting device 20 includes a magnet member 21, a magnetic induction member 22, and a multi-dimensional sensor for counting. The sensor includes a timing module, an alarm module, a counting module, a communication module, a control module, etc. Among them, the counting module realizes counting by converting the number of collected voltage pulses into the number of rotation circles 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 give an alarm when an abnormality occurs, and the control module is used to generate control instructions and judge the data of the counting module and the magnetic induction situation of the magnetic induction member 22; the communication module is used to transmit control instructions; the magnet member 21 is rotatably installed on the body 10, and the magnet member 21 is connected to the transmission shaft 30. It is worth mentioning that in this embodiment, a plurality of connecting columns 11 are installed on the body 10, and the height of the connecting columns 11 is higher than the height of the magnet member 21. That is to say, a magnetic induction area is formed between the body 10 and the magnetic induction member 22. The magnetic induction member 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 installed on the connecting columns 11, the magnetic induction member 22 is fixed. In this way, it is convenient for maintenance and replacement.

[0040] In this way, when the external structure drives the transmission shaft 30 to rotate, the transmission shaft 30 drives the magnet member 21 to rotate. When the magnet member 21 rotates, the position of the magnetic induction member 22 corresponds to that of the magnet member 21, which is used to detect the magnetic field change generated during the rotation of the magnet member 21. The magnetic induction member 22 generates corresponding induction signals by detecting these magnetic field changes. According to Faraday's law of electromagnetic induction, when the magnet member 21 rotates, the magnetic flux passing through the magnetic induction member 22 changes, thereby generating an induced electromotive force in the magnetic induction member 22.

[0041] In addition, every time the magnet member 21 completes a complete rotation cycle, the magnetic induction member 22 will detect a specific magnetic field change signal. By converting these signals into pulse signals, the counting device 20 can count the pulses, thereby realizing the accurate measurement of the number of rotation circles of the transmission shaft 30.

[0042] During the working process, rotation data is collected through a multi-dimensional sensor, and then the rotation data is subjected to abnormality detection; in the case of determining that the rotation data is abnormal, a locking signal is generated and sent to a preset interlock controller outside to instruct the interlock controller to control the motor to stop driving the drum, so that the transmission shaft 30 stops rotating; the rotation data includes the number of rotation circles of the transmission shaft 30, the rotation speed, the magnetic field change situation during the rotation process (such as magnetic field extreme values and differences in different time periods), the rotation duration of the transmission shaft 30, etc.

[0043] In the prior art, the rotation speed of the drum is simply determined by detecting the number of rotations of the transmission shaft 30. Once the magnetic induction component 22 fails, it will cause a change in the induced electromotive force, thereby affecting the detection accuracy. Compared with the prior art, based on detecting the number of rotations of the transmission shaft 30, the present application comprehensively detects and judges the transmission condition of the transmission shaft 30 from multiple dimensions such as rotation duration, rotation speed, and magnetic field change, so as to accurately judge whether the rotation of the transmission shaft 30 is abnormal and avoid abnormal counting caused by the failure of the magnetic induction component 22.

[0044] Further, the magnetic induction component 22 is provided with a plurality of relief grooves 2201. The relief 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 relief grooves 2201 can be linear, arc-shaped or other suitable shapes to meet different installation and operation requirements.

[0045] Specifically, the magnetic induction-based over-winding prevention sensor further includes a waterproof cover 40. The waterproof cover 40 is installed on the body 10, and the waterproof cover 40 covers the magnet component 21. That is to say, 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 component 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 humid and dusty environments, the waterproof cover 40 can ensure the normal operation of the device and improve the environmental adaptability of the device.

[0046] In addition, the magnetic induction-based over-winding prevention sensor further includes an upper cover 50. The upper cover 50 is installed on the body 10. The upper cover 50 has an installation space, and the magnet component 21, the magnetic induction component 22, and the waterproof cover 40 are all installed in the installation space.

[0047] It is worth mentioning that the upper cover 50 also has a plurality of first installation holes. The operator passes a locking member through the first installation holes to install the upper cover 50 on the body 10. The cooperation between the upper cover 50 and the body 10 further enhances the sealing performance of the device and improves the waterproof and dustproof effects.

[0048] 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. In this way, the service life and operation accuracy of the device are improved, so that it can better meet the high requirements of wire rope monitoring and protection for cranes and hoists in the construction machinery industry. The use of the bearings 60 makes the rotation of the transmission shaft 30 more stable and improves the overall operation stability of the device.

[0049] In another embodiment, high-viscosity silicone oil is added between the transmission shaft 30 and the bearing 60 to form a rotational damping, which suppresses the interference of high-frequency vibration on magnetic signal acquisition.

[0050] Furthermore, the magnetic induction-based overwinding prevention sensor further includes a monitoring device 70, and the monitoring device 70 is installed on one side of the transmission shaft 30 close to the magnet member 21.

[0051] Specifically, the monitoring device 70 includes an annular bracket 71 and a plurality of magnets 72. The annular bracket 71 is installed on the transmission shaft 30. A plurality of second mounting holes are formed in the annular bracket 71, and the plurality of magnets 72 are installed in the second mounting holes. In this embodiment, 6 second mounting holes are formed in the annular bracket 71, and 6 magnets 72 are provided.

[0052] Furthermore, the monitoring device 70 further includes a plurality of tension springs 73. The number of the tension springs 73 is the same as that of the magnets 72. The tension springs 73 are installed between the magnet member 21 and the body 10 to limit the position of the magnets 72, so that the heads of the magnets 72 can protrude 2 mm - 3 mm above the annular bracket 71.

[0053] When the external structure stops operating, the tension of the tension springs 73 centers all the magnet members 21, and the magnetic induction ring of the magnetic induction member 22 detects a uniformly distributed magnetic field and outputs a reference signal; when the transmission shaft 30 has abnormal vibration, the magnets deviate from the center under the action of inertial force, resulting in a sudden change in the local magnetic field intensity. The design of the tension springs 73 enables the magnets 72 to automatically reset after being subjected to an external force, ensuring the normal operation of the device.

[0054] That is to say, according to the displacement direction differences of the 6 magnets 72 (such as 3 adjacent magnets shifting in the same direction), it is judged whether the vibration source is axial eccentricity or radial impact.

[0055] In addition, a polyurethane damping sleeve is arranged in the mounting hole, which can provide frictional buffering.

[0056] To sum up, the working process is as follows: First, the operator installs the body on the drum of the external structure, so that the transmission shaft 30 is connected to the drum. When the drum rotates, it drives the transmission shaft 30 to rotate, and then drives the magnet member 21 to rotate. After the magnet member 21 rotates, it corresponds to the magnetic induction member 22, generating an induction signal. At this time, the multi-dimensional sensor in the counting device starts to count according to the induction signal, so as to accurately measure the number of rotations of the transmission shaft 30 and prevent the phenomenon of overwinding.

[0057] Specifically, a spiral air groove 401 is provided inside the waterproof cover 40. The rotation of the transmission shaft 30 drives the air flow to form a vortex, preventing water mist from entering the magnetic induction area.

[0058] The following is illustrated by specific examples:

[0059] Step S1, the magnetic induction detection module performs self-calibration to eliminate the error of installation eccentricity;

[0060] Step S2, the magnetic induction detection module loads safety parameters;

[0061] Step S3, the multi-dimensional sensor collects rotation data, and then the controller performs anomaly detection on the collected data;

[0062] Step S4, the interlock controller receives the locking signal and brakes the drum according to the locking signal to stop the drum from rotating.

[0063] In summary, the working principle is as follows: in the initial stage, the magnetic induction detection module performs self-calibration to eliminate the error of installation eccentricity, and then loads safety parameters. When the transmission shaft 30 rotates, the multi-dimensional sensor collects rotation data at preset times. And when an anomaly is detected, a locking signal is transmitted to the external interlock controller to brake the drum, so that the transmission shaft 30 stops rotating; it should be noted that when performing anomaly detection, the rotation data can be compared with the data under normal conditions, and when the difference from the normal rotation data is greater than the preset range, the data is determined to be abnormal; it can also be based on the rotation data and the magnetic field change generated during the rotation of the magnet 21 to construct a rotation data change matrix, and then calculate the correlation value of the matrix. 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, normalize the elements in the matrix and convert them into gray values. At this time, the elements in the matrix are gray pixel points, thus forming a gray pixel map, and then calculate its confidence through the softmax function (only applicable to the case of using a neural network for anomaly judgment). When the confidence is within the preset range, it is judged to be normal, otherwise it is judged to be abnormal; other solutions can also be used for detection, which are not limited here.

[0064] The above content is only the specific implementation manner of the present application, but the protection scope of the present application is not limited thereto. Any change or replacement within the technical scope disclosed in the present application should be covered by the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. An overwind prevention sensor based on magnetic induction, which is applied to a winding drum around which a steel wire rope is wound, is characterized in that, Comprising: A body; A drive shaft, which is installed on the body; And A counting device, which includes a magnet part, a magnetic induction part and a multi-dimensional sensor for counting. The magnet part is installed on the drive shaft, and the magnetic induction part is installed on the body to determine the number of turns of the drive shaft. After the multi-dimensional sensor collects the rotation data, abnormal detection is performed on the rotation data. When it is determined that the rotation data is abnormal, a locking signal is generated and sent to an external interlock controller to instruct the interlock controller to control the external motor to stop driving the drum. Among them, the rotation data includes the number of turns of the drive shaft, the rotation speed, the magnetic field change data, and the rotation duration of the drive shaft; A waterproof cover, which is installed on the body, and the waterproof cover covers the magnet part, and a spiral air groove is provided on the inner side of the waterproof cover.

2. The overwind prevention sensor based on magnetic induction according to claim 1, characterized in that A plurality of connecting columns are provided on the body, and the magnetic induction part is connected to the connecting columns.

3. The over-winding prevention sensor based on magnetic induction according to claim 1, wherein At least one bearing is provided between the body and the drive shaft.

4. The overwind prevention sensor based on magnetic induction according to claim 1, characterized in that, It further includes a monitoring device, which is installed on the drive shaft.

5. The overwind prevention sensor based on magnetic induction according to claim 4, characterized in that, The monitoring device includes an annular bracket and a magnet. The annular bracket is installed on the drive shaft, and the magnet is installed on the annular bracket in a lifting manner.

6. The overwind prevention sensor based on magnetic induction according to claim 5, characterized in that, The monitoring device further includes a plurality of tension springs. One end of the tension spring is installed on the magnet, and the other end is installed on the body.

7. The overwind prevention sensor based on magnetic induction according to claim 1, characterized in that, It further includes an upper cover, which is installed on the body.

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