Unit cabling machine tension real-time monitoring equipment and monitoring method

Abstract

The invention provides unit cabling machine tension real-time monitoring equipment and a monitoring method, the unit cabling machine tension real-time monitoring equipment comprises a base, guide mechanisms respectively arranged at two ends of the base along a cable conveying direction, and a tension monitoring mechanism arranged between the two guide mechanisms, and the guide mechanisms are used for leading a cable in or out of the tension monitoring mechanism. The cable is wound on the tension monitoring mechanism, the tension monitoring mechanism comprises a tension sensing wheel and positioning wheels arranged on the two sides of the sensing wheel, and the sensing wheel is used for sensing the tension borne by the cable during conveying. The cable is wound on the tension sensing wheel, the tension sensing wheel can transmit the sensed tension value signal to the touch screen arranged on the base in the cable conveying process, the tension state of the cable in the cabling process is displayed in real time, the cable tension does not need to be estimated and adjusted depending on artificial experience, interference of artificial subjective factors is reduced, and the cable tension adjusting efficiency is improved. The cable tension control precision is obviously improved, and the tension fluctuation is reduced. The device has the advantages of reasonable structure, high stability and convenience in popularization and implementation.

Description

Technical Field

[0001] The present application belongs to the field of cable manufacturing technology, and specifically relates to a real-time monitoring device and method for the tension of a unit cabling machine. Background Art

[0002] In existing technologies, unit cabling machines play a key role in cable manufacturing, twisting multiple wire cores together to form a cable core, which is then transformed into the final cable product. During this process, precise control of tension has a crucial impact on cable quality, affecting aspects such as mechanical and electrical properties, and appearance. However, existing unit cabling machines often have shortcomings in tension monitoring and control.

[0003] Currently, some unit cabling machines rely primarily on manual experience to roughly estimate and adjust tension. This approach is not only inefficient but also susceptible to human interference, resulting in poor tension control accuracy. Even some cabling machines equipped with tension monitoring devices have many limitations. Existing tension monitoring equipment is relatively complex in structure, and the tension monitoring process is easily interfered with by various complex structures. The monitoring stability is poor, making it difficult to meet the needs of large-scale production. If the tension suddenly changes during the monitoring interval, it cannot be detected and handled in time, thus affecting cable quality and may even cause cable breakage, interrupting the production process. This not only reduces production efficiency, but also increases production costs and safety risks for enterprises.

[0004] In addition, the existing tension monitoring system has poor coordination with the control system of the cabling machine. Even if tension deviation is detected, it is impossible to quickly and accurately adjust the cabling machine's traction, wire-releasing and other devices, resulting in a lag in tension control, which further affects the manufacturing quality of the cable.

[0005] Therefore, in order to improve the accuracy, real-timeness and reliability of tension control of unit cabling machines, improve the quality and efficiency of cable manufacturing, and reduce production costs and safety hazards, it is urgently needed to improve and innovate the tension monitoring equipment of unit cabling machines, and develop a new type of equipment that can accurately monitor and effectively control tension in real time to meet the growing high-quality production needs of the wire and cable manufacturing industry. Summary of the Invention

[0006] This application aims to solve the technical problems in the prior art that, during the cabling process, the unit cabling machine mainly relies on manual experience to roughly estimate and adjust the cable tension, which is easily interfered with by human subjective factors, resulting in low cable tension control accuracy and large fluctuations. The existing cable tension monitoring equipment is relatively complex in structure and has poor monitoring stability, making it difficult to meet the needs of mass production. A real-time tension monitoring device for a unit cabling machine is proposed.

[0007] In order to solve the technical problem raised in this application, this application also provides a method for real-time monitoring of the tension of a unit cabling machine.

[0008] The present application adopts the following scheme: a real-time tension monitoring device for a unit cabling machine, comprising a base, guide mechanisms respectively arranged at both ends of the base along the cable conveying direction, and a tension monitoring mechanism arranged between the two guide mechanisms, wherein the guide mechanism is used to guide the cable into or out of the tension monitoring mechanism, the cable is wound on the tension monitoring mechanism, the tension monitoring mechanism comprises a tension sensing wheel, and positioning wheels arranged on both sides of the tension sensing wheel, and the tension sensing wheel is used to sense the tension exerted on the cable during conveyance.

[0009] In some feasible embodiments, the tension monitoring mechanism also includes a connecting seat arranged on the top of the base, the tension sensing wheel is rotatably arranged on the connecting seat, the two positioning wheels are rotatably arranged on the connecting seat, and the two positioning wheels are respectively located on both sides of the tension sensing wheel.

[0010] In some feasible embodiments, the height from the center of the positioning wheel to the bottom of the connecting seat is defined as H, and the height from the center of the tension sensing wheel to the bottom of the connecting seat is defined as h, and H and h satisfy the following relationship: 1<H / h≤1.5, and the cable is wound in a "V" shape between the tension sensing wheel and the positioning wheel.

[0011] In some feasible embodiments, the tension monitoring mechanisms are provided in plurality along the length direction and width direction of the base, and adjacent tension monitoring mechanisms are arranged in an alternating manner.

[0012] In some feasible embodiments, the guide mechanism includes guide seats respectively arranged on both ends of the base, and a plurality of guide rollers spaced apart along the length direction of the guide seats, and a guide station is enclosed between two adjacent guide rollers, and the cable is matched and arranged in the guide station.

[0013] In some feasible embodiments, the tension sensing wheel includes a wheel body and a tension sensor provided on the wheel body, and the tension sensor is used to sense the tension value of the cable.

[0014] In some feasible embodiments, an alarm mechanism is further included that is connected to the tension sensing wheel signal. When the cable tension value sensed by the tension sensing wheel exceeds a preset interval value, the alarm mechanism is activated and emits an audible and visual signal.

[0015] In some feasible embodiments, the alarm mechanism includes a bracket provided on the top of the base, warning light poles provided at intervals along the length direction of the bracket, and a buzzer provided on the warning light poles.

[0016] In some feasible embodiments, a touch screen connected to the tension monitoring mechanism signal is further included, and the touch screen is used to display the tension value of the cable.

[0017] In order to solve the technical problem raised by the present application, the present application provides a method for real-time monitoring of the tension of a unit cabling machine, which uses the above-mentioned real-time monitoring device for the tension of a unit cabling machine for monitoring;

[0018] A method for real-time monitoring of tension of a unit cabling machine comprises the following steps:

[0019] S101. The real-time monitoring device for the tension of a cabling machine is connected to the cabling machine;

[0020] S102. Determine the tension sensing range of the induction wheel according to the cable size specifications;

[0021] S103. Along the cable conveying direction, the cable is input into the tension monitoring mechanism from the guide station at one end of the base, the cable is wound in a "V" shape between the induction wheel and the guide wheel, and then the cable is output from the guide station at the other end of the base to the cabling machine;

[0022] S104. The cabling machine is started, and the sensing wheel obtains the target cable tension value. The touch screen displays the target cable tension value obtained by the sensing wheel at preset time intervals.

[0023] Compared with the prior art, this application has the following beneficial effects:

[0024] The present application provides a real-time monitoring device and method for the tension of a unit cabling machine, which includes a base, a guide mechanism respectively provided at both ends of the base along the direction of cable transportation, and a tension monitoring mechanism provided between the two guide mechanisms, wherein the guide mechanism is used to guide the cable into or out of the tension monitoring mechanism, the cable is wound on the tension monitoring mechanism, and the tension monitoring mechanism includes a tension sensing wheel and positioning wheels provided on both sides of the sensing wheel, and the sensing wheel is used to sense the tension applied to the cable during transportation. By winding the cable on the tension sensing wheel, during the cable transportation process, the tension sensing wheel can transmit the sensed tension value signal to the touch screen provided on the base, and display the tension state of the cable during the cabling process in real time, without relying on manual experience to estimate and adjust the cable tension, reducing interference from human subjective factors, significantly improving the cable tension control accuracy, and reducing tension fluctuations. At the same time, its structure is relatively simple, the monitoring stability is strong, it can effectively meet the needs of mass production, improve production efficiency and product quality, and has the advantages of reasonable structure, accurate monitoring, good stability, and easy promotion and implementation. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is a structural diagram of a real-time monitoring device for tension of a unit cabling machine according to the present application;

[0026] Figure 2 This application Figure 1 A partial enlarged view of point A in the middle;

[0027] Figure 3 This is a front view of a real-time monitoring device for tension of a unit cabling machine according to the present application;

[0028] Figure 4 This application Figure 3 An enlarged view of the base at point B in the middle;

[0029] Figure 5 This is a graph showing the trend of the tension value sensed by the tension sensing wheel of the present application over time;

[0030] Figure 6 This is the logic control diagram of the tension sensor of this application. DETAILED DESCRIPTION

[0031] Combine Figure 1-6 The content shown further illustrates the technical solution proposed in this application. This application provides a real-time tension monitoring device for a unit cabling machine, comprising a base 1, guide mechanisms 2 respectively provided at both ends of the base 1 along the cable conveying direction, and a tension monitoring mechanism 3 provided between the two guide mechanisms 2, wherein the guide mechanism 2 is used to guide the cable into or out of the tension monitoring mechanism 3, the cable is wound around the tension monitoring mechanism 3, and the tension monitoring mechanism 3 includes a tension sensing wheel 30 and positioning wheels 31 provided on both sides of the tension sensing wheel 30, wherein the tension sensing wheel 30 is used to sense the tension of the cable during conveyance.

[0032] The present application provides a real-time monitoring device and method for the tension of a unit cabling machine, which includes a base, a guide mechanism respectively provided at both ends of the base along the direction of cable transportation, and a tension monitoring mechanism provided between the two guide mechanisms, wherein the guide mechanism is used to guide the cable into or out of the tension monitoring mechanism, the cable is wound on the tension monitoring mechanism, and the tension monitoring mechanism includes a tension sensing wheel and positioning wheels provided on both sides of the sensing wheel, and the sensing wheel is used to sense the tension applied to the cable during transportation. By winding the cable on the tension sensing wheel, during the cable transportation process, the tension sensing wheel can transmit the sensed tension value signal to the touch screen provided on the base, and display the tension state of the cable during the cabling process in real time, without relying on manual experience to estimate and adjust the cable tension, reducing interference from human subjective factors, significantly improving the cable tension control accuracy, and reducing tension fluctuations. At the same time, its structure is relatively simple, the monitoring stability is strong, it can effectively meet the needs of mass production, improve production efficiency and product quality, and has the advantages of reasonable structure, accurate monitoring, good stability, and easy promotion and implementation.

[0033] During the implementation of this embodiment, the tension monitoring mechanism 3 also includes a connecting seat 32 provided on the top of the base 1, the tension sensing wheel 30 is rotatably provided on the connecting seat 32, and the two positioning wheels 31 are rotatably provided on the connecting seat 32, and the two positioning wheels 31 are respectively located on both sides of the tension sensing wheel 30.

[0034] During the implementation of this embodiment, the height from the center of the positioning wheel 31 to the bottom of the connecting seat 32 is defined as H, and the height from the center of the tension sensing wheel 30 to the bottom of the connecting seat 32 is defined as h. H and h satisfy the following relationship: 1<H / h≤1.5. The cable is wound in a "V" shape between the tension sensing wheel 30 and the positioning wheel 31.

[0035] Exemplarily, the value of H / h is selected as 1.2, 1.3, 1.4, or 1.5.

[0036] During the implementation of this embodiment, a plurality of tension monitoring mechanisms 3 are provided along the length direction and the width direction of the base 1 , and adjacent tension monitoring mechanisms 3 are arranged in a staggered manner.

[0037] During the implementation of this embodiment, the guide mechanism 2 includes a guide seat 20 respectively arranged on both ends of the base 1, and a plurality of guide rollers 21 arranged at intervals along the length direction of the guide seat 20. A guide station 22 is enclosed between two adjacent guide rollers 21, and the cable is matched and arranged in the guide station 22.

[0038] In actual implementation, there are 2 to 15 guide stations, and the number of guide rollers can be set according to the actual needs of the guide stations;

[0039] Exemplarily, the number of guide stations is 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15.

[0040] During the implementation of this embodiment, the tension sensing wheel 30 includes a wheel body and a tension sensor provided on the wheel body, and the tension sensor is used to sense the tension value of the cable.

[0041] In the actual implementation process, the tension sensor selected is the HBMU9C strain type tension sensor.

[0042] In actual implementation, the tension sensor is common knowledge in the art and can be implemented by those skilled in the art without any creative effort. Detailed description is omitted here. For details, please refer to the following website A;

[0043] Website A:

[0044] https: / / zhuanlan.zhihu.com / p / 1896508970597851447.

[0045] During the implementation of this embodiment, an alarm mechanism 4 is further included which is signal-connected to the tension sensing wheel 30 . When the cable tension value sensed by the tension sensing wheel 30 exceeds a preset interval, the alarm mechanism 4 is activated and emits an audible and visual signal.

[0046] During the implementation of this embodiment, the alarm mechanism 4 includes a bracket 40 provided on the top of the base 1 , warning light poles 41 spaced apart along the length direction of the bracket 40 , and a buzzer provided on the warning light poles 41 .

[0047] During actual implementation, the buzzer can be replaced by a speaker, and the corresponding voice alarm can be broadcast according to actual production needs.

[0048] During the implementation of this embodiment, a touch screen 5 connected to the tension monitoring mechanism 3 is further included, and the touch screen 5 is used to display the tension value of the cable.

[0049] In actual implementation, the tension monitoring mechanism is connected to a signal with a storage module, and the storage module is used to store the tension values sensed by the tension sensor in chronological order.

[0050] In order to solve the technical problem raised by the present application, the present application also provides a method for real-time monitoring of the tension of a unit cabling machine, which uses a real-time monitoring device for the tension of a unit cabling machine as described above for monitoring;

[0051] The method for real-time monitoring of tension of a unit cabling machine comprises the following steps:

[0052] S101. The real-time monitoring device for the tension of a cabling machine is connected to the cabling machine;

[0053] S102. Determine the tension sensing range of the induction wheel according to the cable size specifications;

[0054] S103. Along the cable conveying direction, the cable is input into the tension monitoring mechanism from the guide station at one end of the base, the cable is wound in a "V" shape between the induction wheel and the guide wheel, and then the cable is output from the guide station at the other end of the base to the cabling machine;

[0055] S104. The cabling machine is started, and the sensing wheel obtains the target cable tension value. The touch screen displays the target cable tension value obtained by the sensing wheel at preset time intervals.

[0056] like Figure 6As shown, after the tension sensor in the induction wheel obtains the tension value of the cable, it compares the tension value with the preset interval value. When the obtained cable tension value exceeds the preset interval, the alarm mechanism sends out an audible and visual signal. When the obtained cable tension value continues to exceed the preset interval value, the alarm mechanism sends out an audible and visual signal, and the cabling machine stops urgently to avoid damage to the cable during the cabling process.

[0057] The present application provides a real-time monitoring device and method for the tension of a unit cabling machine, which includes a base, a guide mechanism respectively provided at both ends of the base along the direction of cable transportation, and a tension monitoring mechanism provided between the two guide mechanisms, wherein the guide mechanism is used to guide the cable into or out of the tension monitoring mechanism, the cable is wound on the tension monitoring mechanism, and the tension monitoring mechanism includes a tension sensing wheel and positioning wheels provided on both sides of the sensing wheel, and the sensing wheel is used to sense the tension applied to the cable during transportation. By winding the cable on the tension sensing wheel, during the cable transportation process, the tension sensing wheel can transmit the sensed tension value signal to the touch screen provided on the base, and display the tension state of the cable during the cabling process in real time, without relying on manual experience to estimate and adjust the cable tension, reducing interference from human subjective factors, significantly improving the cable tension control accuracy, and reducing tension fluctuations. At the same time, its structure is relatively simple, the monitoring stability is strong, it can effectively meet the needs of mass production, improve production efficiency and product quality, and has the advantages of reasonable structure, accurate monitoring, good stability, and easy promotion and implementation.

[0058] The embodiments provided by the present invention are described in detail above. Specific examples are used herein to illustrate the principles and implementation methods of the present invention. The description of the above embodiments is only intended to help understand the method and core concept of the present invention. It should be noted that for those skilled in the art, without departing from the principles of the present invention, several improvements and modifications can be made to the present invention, and these improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. A real-time monitoring device for the tension of a unit cabling machine, characterized in that: The invention comprises a base (1), guide mechanisms (2) respectively arranged at both ends of the base (1) along the cable conveying direction, and a tension monitoring mechanism (3) arranged between the two guide mechanisms (2), wherein the guide mechanism (2) is used to guide the cable into or out of the tension monitoring mechanism (3), the cable is wound around the tension monitoring mechanism (3), and the tension monitoring mechanism (3) comprises a tension sensing wheel (30) and positioning wheels (31) arranged on both sides of the tension sensing wheel (30), and the tension sensing wheel (30) is used to sense the tension applied to the cable during conveyance.

2. The real-time monitoring device for tension of a unit cabling machine according to claim 1 is characterized in that: The tension monitoring mechanism (3) further includes a connecting seat (32) disposed on the top of the base (1), the tension sensing wheel (30) is rotatably disposed on the connecting seat (32), the two positioning wheels (31) are rotatably disposed on the connecting seat (32), and the two positioning wheels (31) are respectively located on both sides of the tension sensing wheel (30).

3. The real-time monitoring device for tension of a unit cabling machine according to claim 2, characterized in that: The height of the center of the positioning wheel (31) from the bottom of the connecting seat (32) is defined as H, and the height of the center of the tension sensing wheel (30) from the bottom of the connecting seat (32) is defined as h. H and h satisfy the following relationship: 1<H / h≤1.

5. The cable is wound in a "V" shape between the tension sensing wheel (30) and the positioning wheel (31).

4. The real-time monitoring device for tension of a unit cabling machine according to claim 1 is characterized in that: A plurality of the tension monitoring mechanisms (3) are respectively provided along the length direction and the width direction of the base (1), and adjacent tension monitoring mechanisms (3) are arranged in a staggered manner.

5. The real-time monitoring device for tension of a unit cabling machine according to claim 1 is characterized in that: The guide mechanism (2) comprises guide seats (20) respectively arranged on both ends of the base (1), and a plurality of guide rollers (21) spaced apart along the length direction of the guide seats (20), wherein a guide station (22) is enclosed between two adjacent guide rollers (21), and the cable is matched and arranged in the guide station (22).

6. The real-time monitoring device for tension of a unit cabling machine according to claim 2, characterized in that: The tension sensing wheel (30) comprises a wheel body and a tension sensor arranged on the wheel body, and the tension sensor is used to sense the tension value of the cable.

7. The real-time monitoring device for tension of a unit cabling machine according to claim 2, characterized in that: It also includes an alarm mechanism (4) connected to the tension sensing wheel (30) signal, and when the cable tension value sensed by the tension sensing wheel (30) exceeds a preset interval value, the alarm mechanism (4) is activated and emits an audible and visual signal.

8. The real-time monitoring device for tension of a unit cabling machine according to claim 7, characterized in that: The alarm mechanism (4) comprises a bracket (40) arranged on the top of the base (1), warning light poles (41) arranged at intervals along the length direction of the bracket (40), and a buzzer arranged on the warning light poles (41).

9. The real-time monitoring device for tension of a unit cabling machine according to claim 1, characterized in that: It also includes a touch screen (5) connected to the tension monitoring mechanism (3) for signal transmission, and the touch screen (5) is used to display the tension value of the cable.

10. A method for real-time monitoring of tension of a unit cabling machine, characterized in that: Monitoring is performed using a real-time monitoring device for tension of a unit cabling machine according to any one of claims 1 to 9; The method for real-time monitoring of tension of a unit cabling machine comprises the following steps: S101. The real-time monitoring device for the tension of a cabling machine is connected to the cabling machine; S102. Determine the tension sensing range of the induction wheel according to the cable size specifications; S103. Along the cable conveying direction, the cable is input from the guide station at one end of the base into the tension monitoring mechanism, the cable is wound in a "V" shape between the induction wheel and the guide wheel, and then the cable is output from the guide station at the other end of the base to the cabling machine; S104. The cabling machine is started, and the sensing wheel obtains the target cable tension value. The touch screen displays the target cable tension value obtained by the sensing wheel at preset time intervals.

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