Gear meshing type hydraulic cable bender

Abstract

The invention discloses a gear meshing type hydraulic cable bender, which belongs to the technical field of cable processing and comprises a bearing module, a bending module, a clamping module and a control module. The bearing module comprises a bearing base, the top of the bearing base is provided with a groove body with openings in the two sides, and a groove is formed in the groove body. The bending module comprises a hydraulic motor, a main bevel gear, an auxiliary bevel gear, a bending rod, a fixing rod and an abutting block. The clamping module comprises two arc-shaped grooves with downward openings, a clamping air cylinder and a clamping plate. The control module comprises a hydraulic system, an angle measuring system, a PLC and a lubricating system. A hydraulic system is matched with a rotary encoder to achieve closed-loop control, the opening degree of a proportional valve is dynamically adjusted through a PID algorithm, the bending angle precision is improved, and the strict requirement of distribution network operation for the bending shape is met. Parameter one-key calling is supported, and the operation threshold is lowered; the modular quick-release design facilitates maintenance and replacement, shortens the downtime, and adapts to bending of cables of different specifications.

Description

Technical Field

[0001] This invention belongs to the field of cable processing technology, specifically relating to a gear-engaging hydraulic cable bender. Background Technology

[0002] In the field of live-line power distribution, cable bending operations face numerous challenges. Traditional manual bending methods are not only inefficient and unsafe, but also easily damage the cable insulation layer, affecting the cable's lifespan and reliability. While existing electric bending devices are in use, they still fall short in terms of precisely controlling the bending angle, protecting the cable, and efficiently, accurately, and safely bending thicker cables. Therefore, there is an urgent need to develop a high-precision control, self-adaptive clamping, and automatically lubricated gear-engagement hydraulic cable bender to meet the growing operational demands. Summary of the Invention

[0003] The purpose of this invention is to provide a gear-engaging hydraulic cable bender to overcome the shortcomings of the above-mentioned technology.

[0004] To achieve the above objectives, the present invention provides a gear-engaging hydraulic cable bender, comprising a load-bearing module, a bending module, a clamping module, and a control module; The support module includes a support base, and the top of the support base has a groove with openings on both sides, and the groove has a recess. The bending module includes a hydraulic motor, a main bevel gear, a secondary bevel gear, a bending rod, a fixing rod, and a stop block. The hydraulic motor is fixedly installed in the groove, and its output shaft is fixedly connected to the main bevel gear. There are two secondary bevel gears, which are arranged opposite each other on both sides of the main bevel gear and are both meshed with it. The groove contains two bearing seats, each with a rotating shaft, which is fixedly connected to the two secondary bevel gears. The inner sides of the two secondary bevel gears are provided with bending rods. The fixing rod includes a horizontal rod, a vertical rod, and a support rod. The horizontal rod is located between the two bending rods, and its two ends are fixedly connected to the bearing base via the vertical rod. The support rod is fixedly connected to the horizontal rod, and the top of the support rod is detachably connected to the stop block via bolts. The top surface of the stop block has an arc-shaped slide rail. The clamping module includes two downward-opening arc-shaped grooves, a clamping cylinder, and a clamping plate. The two arc-shaped grooves are fixedly installed at the top of two curved rods, and are located on both sides of the abutment block. An arc-shaped plate is provided inside the arc-shaped groove, and the arc-shaped plate is detachably connected to the arc-shaped groove by bolt two. The clamping cylinder is fixedly installed on the curved rod, and a moving plate is provided on the output shaft of the clamping cylinder. The moving plate is detachably connected to the clamping plate by bolt three. Multiple evenly distributed ball bearings are provided on the inner surface of the clamping plate and the inner surface of the arc-shaped plate. The control module includes the following components: a hydraulic system, an angle measurement system, a PLC controller, and a lubrication system. The hydraulic system includes a hydraulic pump station, a pressure sensor, and a proportional valve. The proportional valve is connected to a hydraulic motor via an oil pipe, and the pressure sensor monitors the bending torque in real time. The angle measurement system includes a rotary encoder mounted on the shaft to detect the rotation angle of the bending rod. The PLC controller receives signals from the pressure sensor and the rotary encoder and dynamically adjusts the opening of the proportional valve using a PID algorithm. The PLC controller pre-stores bending parameters for different cable specifications and automatically matches the bending radius and speed according to input commands. The lubrication system includes automatic grease injectors located at the bearing housing, arc-shaped slide, and arc-shaped groove, which inject grease periodically via a micro pump.

[0005] Preferably, the surface of the arc-shaped slide is provided with a replaceable liner, the liner thickness is 5-8mm, and the surface has staggered oil storage pits.

[0006] Preferably, the PLC controller is connected to an HMI touchscreen located on the support base, which can display real-time bending angle, torque curve and fault alarm information.

[0007] Preferably, the inner surface of the clamping plate is provided with a pressure distribution sensor, whose signal is fed back to the PLC controller to realize closed-loop control of the clamping force.

[0008] Preferably, the bottom of the support base is provided with adjustable anchor bolts, and the lower part of the adjustable anchor bolts is connected to a rubber suction cup.

[0009] The beneficial effects of this invention are: 1. Closed-loop control is achieved through a hydraulic system in conjunction with a rotary encoder, and the PID algorithm dynamically adjusts the opening of the proportional valve to improve the accuracy of the bending angle and meet the stringent requirements of power distribution network operations for bending shape; the PLC pre-stores parameters of multiple cable specifications and automatically matches the bending radius and speed to avoid errors caused by manual intervention.

[0010] 2. The clamping plate has a built-in pressure distribution sensor and ball bearing to achieve closed-loop control of clamping force, uniformly distribute pressure, and prevent damage to the cable insulation layer; the replaceable arc plate and pad design can adapt to cables of different diameters and reduce friction damage to the contact surface.

[0011] 3. The automatic lubrication system periodically sprays grease to key parts such as bearing housings and arc-shaped slides, reducing wear rate and extending equipment life; the oil storage pit design of the arc-shaped slides maintains continuous lubrication effect, and the gasket further reduces direct metal-to-metal friction.

[0012] 4. The hydraulic motor drive, combined with bevel gear transmission, can stably bend cables of different specifications through high output torque. The adjustable anchor bolts and rubber suction cups combine to ensure that the equipment does not shift during operation and improve its vibration resistance.

[0013] 5. The HMI touchscreen displays bending angle, torque curve and fault information in real time, supports one-click parameter recall, and lowers the operating threshold; the modular quick-release design facilitates maintenance and replacement, shortens downtime, and is compatible with bending of cables of different specifications. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0015] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the structure when the present invention is in use; Figure 3 This is a side view of the present invention; Figure 4 yes Figure 3 A magnified view of A in the middle.

[0016] In the diagram, 1. Support base, 2. Groove, 3. Recess, 4. Hydraulic motor, 5. Main bevel gear, 6. Secondary bevel gear, 7. Bending rod, 8. Bearing seat, 9. Shaft, 10. Horizontal bar, 11. Vertical bar, 12. Support rod, 13. Arc-shaped slide, 14. Bolt 1, 15. Arc-shaped groove, 16. Clamping cylinder, 17. Clamping plate, 18. Arc-shaped plate, 19. Bolt 2, 20. Moving plate, 21. Bolt 3, 22. Ball bearing, 23. Rotary encoder, 24. Automatic oil nozzle, 25. HMI touch screen, 26. Pressure distribution sensor, 27. Anchor bolt, 28. Rubber suction cup, 29. Gasket, 30. Abutment block. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0018] Reference Figure 1-4 This embodiment provides a gear-engaging hydraulic cable bender, including a load-bearing module, a bending module, a clamping module, and a control module; The support module includes a support base 1, and the support base 1 has a groove 2 with openings on both sides on the top, and the groove 2 has a recess 3 inside; The bending module includes a hydraulic motor 4, a main bevel gear 5, a secondary bevel gear 6, a bending rod 7, a fixing rod, and a stop block 30. The hydraulic motor 4 is fixedly installed in the groove 3, and the output shaft of the hydraulic motor 4 is fixedly connected to the main bevel gear 5. There are two secondary bevel gears 6, which are arranged opposite each other on both sides of the main bevel gear 5 and are both meshed with the main bevel gear 5. There are two bearing seats 8 inside the groove 2, and there are rotating shafts 9 on the bearing seats 8. The two rotating shafts 9 are fixedly connected to the two secondary bevel gears 6 respectively. There are bending rods 7 on the inner sides of the two secondary bevel gears 6. The fixing rod includes a horizontal rod 10, a vertical rod 11, and a support rod 12. The horizontal rod 10 is located between the two bending rods 7, and the two ends of the horizontal rod 10 are fixedly connected to the bearing base 1 through the vertical rod 11. The support rod 12 is fixedly connected to the horizontal rod 10, and the top of the support rod 12 is detachably connected to the stop block 30 through bolt 14. The top surface of the stop block 30 is provided with an arc-shaped slide rail 13. The clamping module includes two downward-opening arc-shaped grooves 15, a clamping cylinder 16, and a clamping plate 17. The two arc-shaped grooves 15 are respectively fixedly installed at the top of the two curved rods 7, and the two arc-shaped grooves 15 are respectively located on both sides of the abutment block 30. An arc-shaped plate 18 is provided inside the arc-shaped groove 15, and the arc-shaped plate 18 is detachably connected to the arc-shaped groove 15 by bolt 2 19. The clamping cylinder 16 is fixedly installed on the curved rod 7, and a moving plate 20 is provided on the output shaft of the clamping cylinder 16. The clamping plate 17 is detachably connected to the moving plate 20 by bolt 3 21. Multiple evenly distributed ball bearings 22 are provided on the inner surface of the clamping plate 17 and the inner surface of the arc-shaped plate. The control module includes the following components: a hydraulic system, an angle measurement system, a PLC controller, and a lubrication system. The hydraulic system comprises a hydraulic pump station, a pressure sensor, and a proportional valve. The proportional valve is connected to the hydraulic motor 4 via an oil pipe. The pressure sensor monitors the bending torque in real time. The angle measurement system includes a rotary encoder 23 mounted on the rotating shaft 9 to detect the rotation angle of the bending rod 7. The PLC controller receives signals from the pressure sensor and the rotary encoder 23 and dynamically adjusts the opening of the proportional valve using a PID algorithm. The PLC controller pre-stores bending parameters for different cable specifications and automatically matches the bending radius and speed according to input commands. The lubrication system includes automatic grease injectors 24 located at the bearing seat 8, the arc-shaped slide rail 13, and the arc-shaped groove 15. A micro-pump periodically sprays grease onto the bearing seat 8, slide rail, and other components to reduce wear and ensure long-term stable operation.

[0019] The surface of the arc-shaped slide 13 is provided with a replaceable liner 29, which is 5-8mm thick and has staggered oil storage pits on its surface to reduce friction with the cable.

[0020] The PLC controller is connected to the HMI touch screen 25 located on the support base 1, which can display real-time bending angle, torque curve and fault alarm information.

[0021] The inner surface of the clamping plate 17 is provided with a pressure distribution sensor 26, whose signal is fed back to the PLC controller to realize closed-loop control of the clamping force.

[0022] The bottom of the support base 1 is provided with an adjustable anchor bolt 27, and the lower part of the adjustable anchor bolt 27 is connected to a rubber suction cup 28. The support base 1 can be used by hand or placed on the ground.

[0023] The working principle of this invention is as follows: the cable is placed on the arc-shaped slide 13 of the abutment block 30, the clamping cylinder 16 pushes the clamping plate 17 to rise, and the cable is fixed in conjunction with the arc plate 18 in the arc groove 15; the ball bearing 22 reduces the friction when the cable moves and bends, the pressure detection sensor provides real-time feedback of the clamping force, and the PLC dynamically adjusts to the preset value to avoid overpressure damage.

[0024] The hydraulic system's hydraulic pump station and proportional valve provide power. After receiving the PLC control signal, the hydraulic motor 4 outputs rotational torque. The main bevel gear 5 rotates with the output shaft of the hydraulic motor 4, driving the meshing secondary bevel gears 6 on both sides to rotate in the opposite direction, causing the two bending rods 7 to swing inward or outward synchronously, thereby achieving the bending or repositioning of the cable.

[0025] Hydraulic motor 4 drives bending rod 7 to rotate around shaft 9, causing the cable to bend along the arc-shaped slide rail 13 of abutment block 30. Rotary encoder 23 monitors the bending angle, and PLC compares the angle with a preset value and adjusts the proportional valve opening to ensure bending accuracy. The signal from rotary encoder 23 is fed back to PLC, which dynamically corrects the speed of hydraulic motor 4 through a PID algorithm to achieve precise stopping. Pressure detection sensor monitors bending resistance; if the resistance exceeds the limit, it automatically reduces the load or triggers an alarm to prevent overload damage to the cable or equipment.

[0026] After bending is completed, the hydraulic motor 4 reverses, the gear transmission causes the bending rod 7 to return to its original position, the clamping cylinder 16 is released, and the cable can be removed or its position adjusted; different cable specifications can be switched via the HMI touch screen 25, and the bending radius and speed are automatically matched.

[0027] The device provides stable power through a hydraulic gear transmission system, and achieves high-precision bending by combining sensor feedback and PLC intelligent control. At the same time, it uses adaptive clamping and automatic lubrication to ensure cable protection and equipment durability, greatly improving the efficiency and safety of power distribution network operations.

[0028] Of course, the above description is not limited to the examples above. Technical features not described in this invention can be implemented by or using existing technology, and will not be repeated here. The above embodiments and drawings are only used to illustrate the technical solutions of this invention and are not intended to limit this invention. This invention has been described in detail with reference to preferred embodiments. Those skilled in the art should understand that any changes, modifications, additions or substitutions made by those skilled in the art within the scope of this invention do not depart from the spirit of this invention and should also fall within the scope of protection of the claims of this invention.

Claims

1. A gear-operated hydraulic cable bender, characterized in that, Includes a load-bearing module, a bending module, a clamping module, and a control module; The support module includes a support base (1), the support base (1) has a groove (2) with openings on both sides on the top, and a groove (3) is provided inside the groove (2); The bending module includes a hydraulic motor (4), a main bevel gear (5), a secondary bevel gear (6), a bending rod (7), a fixing rod, and a stop block (30); the hydraulic motor (4) is fixedly installed in the groove (3), and the output shaft of the hydraulic motor (4) is fixedly connected to the main bevel gear (5); there are two secondary bevel gears (6), which are arranged opposite to each other on both sides of the main bevel gear (5) and both mesh with the main bevel gear (5); the groove (2) is provided with two bearing seats (8), and the bearing seats (8) are provided with rotating shafts (9), and the two rotating shafts (9) are connected to each other. Two secondary bevel gears (6) are fixedly connected to each other; the inner sides of the two secondary bevel gears (6) are provided with bending rods (7); the fixing rod includes a horizontal rod (10), a vertical rod (11), and a support rod (12). The horizontal rod (10) is located between the two bending rods (7), and the two ends of the horizontal rod (10) are fixedly connected to the bearing base (1) through the vertical rod (11); the support rod (12) is fixedly connected to the horizontal rod (10), and the top of the support rod (12) is detachably connected to the abutment (30) through bolt one (14). The top surface of the abutment (30) is provided with an arc-shaped slide (13). The clamping module includes two downward-facing arc-shaped grooves (15), a clamping cylinder (16), and a clamping plate (17). The two arc-shaped grooves (15) are fixedly installed on the tops of the two curved rods (7), and the two arc-shaped grooves (15) are located on both sides of the abutment block (30). An arc-shaped plate (18) is provided inside the arc-shaped groove (15), and the arc-shaped plate (18) is detachably connected to the arc-shaped groove (15) by bolt two (19). The clamping cylinder (16) is fixedly installed on the curved rod (7), and a moving plate (20) is provided on the output shaft of the clamping cylinder (16). The clamping plate (17) is detachably connected to the moving plate (20) by bolt three (21). Multiple evenly distributed ball bearings (22) are provided on the inner surface of the clamping plate (17) and the inner surface of the arc-shaped plate. The control module includes the control system, which includes a hydraulic system, an angle measurement system, a PLC controller, and a lubrication system. The hydraulic system includes a hydraulic pump station, a pressure detection sensor, and a proportional valve. The proportional valve is connected to a hydraulic motor (4) via an oil pipe. The pressure detection sensor monitors the bending torque in real time. The angle measurement system includes a rotary encoder (23) mounted on a rotating shaft (9) to detect the rotation angle of the bending rod (7). The PLC controller receives signals from the pressure detection sensor and the rotary encoder (23) and dynamically adjusts the opening of the proportional valve through a PID algorithm. The PLC controller pre-stores bending parameters for different cable specifications and automatically matches the bending radius and speed according to the input command. The lubrication system includes an automatic grease injector (24) located at the bearing seat (8), the arc-shaped slide (13), and the arc-shaped groove (15) to inject grease at regular intervals through a micro pump.

2. The gear-engaging hydraulic cable bender according to claim 1, characterized in that: The surface of the arc-shaped slide (13) is provided with a replaceable liner (29), the liner (29) is 5-8mm thick, and the surface is provided with staggered oil storage pits.

3. The gear-engaging hydraulic cable bender according to claim 1, characterized in that: The PLC controller is connected to the HMI touch screen (25) located on the support base (1), which can display real-time bending angle, torque curve and fault alarm information.

4. The gear-engaging hydraulic cable bender according to claim 1, characterized in that: The inner surface of the clamping plate (17) is provided with a pressure distribution sensor (26), whose signal is fed back to the PLC controller to realize closed-loop control of clamping force.

5. The gear-engaging hydraulic cable bender according to claim 1, characterized in that: The bottom of the support base (1) is provided with an adjustable anchor bolt (27), and the lower part of the adjustable anchor bolt (27) is connected to a rubber suction cup (28).

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