Meter counting method and device for steel wire rope production

Abstract

The invention relates to a meter counting method and device for steel wire rope production, and relates to the technical field of length measuring instruments, and the meter counting method comprises the steps: obtaining the angular velocity of stranding equipment collected by a rotating speed sensor, and calculating the initial length of a steel wire rope in combination with the lay length and diameter of the steel wire rope; constructing an environment coupling effect equation according to the temperature and humidity in the steel wire rope production environment, and calculating the environment compensation length of the steel wire rope; correcting the initial length according to the environment compensation length to obtain the final length of the steel wire rope; according to the environment compensation length and the structure compensation length, the elastic modulus of the steel wire rope is measured and calculated and compared with a preset elastic threshold value interval for judgment, and a judgment result is obtained; through a rotating speed sensor and integral calculation, the influence of the contact depth of a traction wheel groove on length metering is avoided, and the metering precision is improved; and through a sensor and a PLC which are low in cost and high in reliability, the equipment cost and the maintenance difficulty are reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of length measuring instruments, in particular to a meter counting method and device for steel wire rope production. BACKGROUND

[0002] Steel wire rope products have various specifications, and are used in various industries, from mines to ports, construction, bridges, aerospace, ships and engineering decoration, etc. Steel wire rope products of various specifications are used, and the length of the steel wire rope needs to be measured and sized.

[0003] The traditional meter counting method mainly relies on the number of rotations of the traction wheel to calculate the length. Each rotation of the traction wheel will transport the corresponding circumference distance of the steel wire rope, i.e. the length of the steel wire rope = the number of rotations of the traction wheel x the circumference of the traction wheel. However, in order to prevent the steel wire rope from slipping, grooves are designed on the surface of the traction wheel to meet the traction requirements of steel wire ropes of different diameters, resulting in that the actual transportation length of the steel wire rope is affected by the contact depth of the grooves.

[0004] Application No. CN201310566677.7 discloses a steel wire rope meter counting device, mainly composed of an upper support, a lower support, a transmission pinion, a transmission gear, a supporting wheel, a clamping roller, a wire guide, a clamping roller and a digital reader. The measuring method is to pull up the upper support, open the upper support and the lower support and the supporting wheel, pass the steel wire rope to be measured through the supporting wheel, the wire guide and the central clamping roller, and then lower the upper support to clamp the steel wire rope with the clamping rollers. The end of the steel wire rope is placed between the two clamping rollers, and the steel wire rope is pulled forward. The steel wire rope is discharged through the wire guide and the clamping roller, and the friction drives the clamping roller to rotate. The rotation of the clamping roller further drives the transmission pinion and the transmission gear, and the signal is transmitted to the digital reader. The digital reader displays the actual length of the measured steel wire rope, achieving the purpose of measuring the length of the steel wire rope. The invention is easy to operate and has high measurement accuracy.

[0005] Application No. CN201310502820.6 discloses a meter counting device for a stranding machine, which comprises a pulse disc, two proximity sensors, and a winding roller for guiding a plurality of monofilament wires to pass through in a counterclockwise direction at 360 degrees. The pulse disc is fixedly installed at the tail of the winding roller, the tail end of the winding roller is installed on the mounting base of the stranding machine, and the two proximity sensors are installed on the mounting base. Two pulse sensing holes are formed in the pulse disc, the centers of the two pulse sensing holes are equidistant from the center of the pulse disc, and the line connecting the centers of the two pulse sensing holes passes through the center of the pulse disc. The distance between the centers of the two proximity sensors is equal to the distance between the centers of the two pulse sensing holes, and the two proximity sensors are symmetrically arranged along the axial center line of the pulse disc. The meter counting device for the stranding machine has the advantage of high meter counting accuracy.

[0006] The prior art in the above has the following defects: 1. When the diameter of the steel wire rope is small, the steel wire rope is embedded in the groove deep, which can make the actual conveying length less than the meter length, and when the diameter of the steel wire rope is large, the steel wire rope is embedded in the groove shallow, which can make the actual conveying length greater than the meter length; 2. Due to the expansion of the steel wire rope caused by the change of the production environment, the deformation caused by the moisture absorption is not fully compensated, which directly introduces the drift error. SUMMARY

[0007] In view of the defects of the prior art, in order to improve the metering accuracy of the steel wire rope, on the one hand, the application provides a metering method for steel wire rope production.

[0008] The purpose of the application is realized by the following technical solutions: A metering method for steel wire rope production, comprising: acquiring the angular velocity of the stranding device collected by the rotational speed sensor, and combining the lay length and diameter of the steel wire rope to calculate the initial length of the steel wire rope; According to the temperature and humidity in the steel wire rope production environment, an environmental coupling effect equation is constructed to calculate the environmental compensation length of the steel wire rope; the initial length is corrected according to the environmental compensation length to obtain the final length of the steel wire rope; According to the environmental compensation length and the structural compensation length, the elastic modulus of the steel wire rope is calculated and compared with the preset elastic threshold interval; If the elastic modulus is within the elastic threshold interval, it is determined that the final length of the current steel wire rope is valid.

[0009] By adopting the above technical solutions, the rotational speed sensor deployed on the main shaft of the stranding device is used to collect the angular velocity in real time, the initial length is calculated by combining the lay length and diameter of the steel wire rope; the temperature and humidity environment coupling effect equation (such as the thermal expansion coefficient and the humidity deformation factor) is constructed to generate the environmental compensation length; then the structural compensation length is introduced to calculate the dynamic elastic modulus, when the dynamic elastic modulus is within the preset elastic threshold interval, it is determined that the final length after double compensation correction is valid, realizing the three-in-one closed-loop control of metering-compensation-quality inspection; through the rotational speed sensor and integral calculation, the influence of the contact depth of the traction wheel groove on the length measurement is avoided, and the measurement accuracy is improved.

[0010] The application is further provided as follows: the specific steps of acquiring the angular velocity of the stranding device collected by the rotational speed sensor, and combining the lay length and diameter of the steel wire rope to calculate the initial length of the steel wire rope include: According to the preset resolution, the controller controls the collection frequency of the rotational speed sensor to obtain the pulse count; According to the pulse count, the rotational speed sensor triggers a corresponding number of pulse signals to record the angular change amount of the stranding device to obtain the angular increment; measuring a time difference between rising edges of adjacent pulse signals to obtain a time interval; calculating an angular velocity of the stranding device according to the angle increment and the time interval; measuring a process parameter of the steel wire rope to obtain a lay pitch and a diameter; integrating the length of the steel wire rope according to the angular velocity and a running time of the stranding device to obtain an original length, and correcting the original length of the steel wire rope according to the lay pitch and the diameter to obtain a structure compensation length; calculating the original length and the structure compensation length to obtain an initial length of the steel wire rope.

[0011] By adopting the technical scheme, through high-precision pulse time sequence analysis (rising edge interval measurement accuracy 0.1 mu s) and multi-physical field coupling compensation technology, the angular velocity ω = 2πN / (PPR·Δt) is calculated based on the pulse count (N) and the rising edge time difference (Δt) of PPR, the correction coefficient k of phase noise δ (positively correlated with the lay pitch P) is introduced, the structure compensation length is constructed, and the microscopic deformation error caused by interlayer stress is eliminated; the original length adopts variable step Runge-Kutta integration (sampling frequency 1 kHz), the integration error is reduced under strong vibration working conditions, the pulse time sequence analysis, noise compensation and real-time integration are fused, the steel wire rope measurement accuracy is improved, and the maintenance cost is reduced.

[0012] The application is further provided as follows: the specific steps of constructing an environmental coupling effect equation to calculate the environmental compensation length of the steel wire rope according to the temperature and humidity in the steel wire rope production environment include: collecting the temperature and humidity in the steel wire rope production environment through a temperature and humidity composite sensor, and calculating a temperature change amount; extracting and aggregating all temperature data, all humidity data and all length data in the controller to construct a historical temperature data set, a historical humidity data set and a historical length data set; performing fitting operation on the historical temperature data set, the historical humidity data set and the historical length data set according to a time stamp to calculate a thermal expansion coefficient and a moisture expansion coefficient; performing fitting operation on the temperature change amount and the humidity by combining the thermal expansion coefficient and the moisture expansion coefficient of the steel wire rope with a material moisture absorption constant to obtain an environmental coupling effect equation; calculating the environmental compensation length by combining the original length of the steel wire rope with the environmental coupling effect equation.

[0013] By adopting the technical scheme, the environment compensation length is finally output by collecting environment data (temperature change ΔT, humidity ΔH) in real time through the temperature and humidity composite sensor, and performing space-time fitting on the historical temperature and humidity and length data set to calculate the thermal expansion coefficient α (unit: ppm / ℃) and the wet expansion coefficient β (unit: ppm / %) of the steel wire rope, combining the material moisture absorption constant γ to construct an environment coupling effect equation; the length error after compensation is reduced by fusing the linear expansion of temperature, the moisture absorption expansion of humidity and the cross nonlinear effect of temperature and humidity; the α and β coefficients are fitted in real time based on the historical data set to adapt to the process fluctuation of different batches of steel wire ropes.

[0014] In the second aspect, the application further provides a metering device for steel wire rope production, which adopts the following technical scheme: A metering device for steel wire rope production is used to realize the automatic counting method, comprising a display, a rotating speed sensor, a stranding device and a controller; wherein, The signal input end of the display is connected to the communication interface of the controller; The rotating speed sensor is arranged on the main shaft of the stranding device, and the signal output end of the controller is connected to the signal input end of the rotating speed sensor and the signal input end of the stranding device; The controller is a PLC controller, and the twist pitch and resolution are set in the PLC controller; The rotating speed sensor is installed on the main shaft of the stranding device to ensure that the sensor rotates synchronously with the main shaft; the signal line of the rotating speed sensor is connected to the high-speed counting port of the controller; after the stranding device is started, the controller automatically calculates and displays the length of the steel wire rope; the installation state and signal transmission stability of the rotating speed sensor are checked regularly.

[0015] By adopting the technical scheme, the pulse signal is analyzed in real time based on the high-speed counting port (sampling frequency ≥ 10 kHz) of the PLC, the angular velocity is measured at the microsecond level (error < ± 0.001 rad / s) by combining the preset twist pitch and resolution (PPR ≥ 2000), the temperature and humidity sensor data are synchronously fused, and the environmental expansion effect is dynamically corrected; the sensor and the main shaft are rigidly and synchronously installed (radial runout tolerance ≤ 0.01 mm), so that the cumulative error caused by the slippage of the traditional metering wheel is greatly avoided; the PLC automatically diagnoses the sensor state (such as signal interruption triggering alarm within 0.1 s), and the annual production line failure rate is reduced by combining the regular self-checking mechanism (vibration / temperature drift compensation); by using the low-cost and high-reliability sensor and the PLC controller, the equipment cost and maintenance difficulty are reduced.

[0016] In the third aspect, the application further provides an electronic device, which adopts the following technical scheme: An electronic device comprises: One or more processors; a memory for storing one or more programs; When the one or more programs are executed by the one or more processors, the one or more processors implement the method as described above.

[0017] By adopting the technical scheme, the metering method for steel wire rope production is presented in the form of computer readable code and stored in the memory, and when the processor runs the computer readable code in the memory, the steps of the metering method for steel wire rope production are executed to obtain the effect of reducing labor intensity and improving the degree of automation.

[0018] In a fourth aspect, the present application further provides a computer storage medium, adopting the following technical scheme: A computer storage medium, having a computer program stored thereon, the program being executed by a processor to implement the method as described above.

[0019] To sum up, the beneficial technical effects of the present application are: 1. By means of the rotation speed sensor and integral calculation, the influence of the contact depth of the traction wheel groove on the length measurement is avoided, and the measurement accuracy is improved; 2. By means of the low-cost and high-reliability sensor and PLC controller, the equipment cost and maintenance difficulty are reduced; 3. By means of the display real-time display and historical data storage function, production management and quality control are facilitated. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 is a flowchart of the automatic counting method of one embodiment of the present application.

[0021] Figure 2 is a flowchart of the automatic counting method of one embodiment of the present application.

[0022] Figure 3 is a flowchart of the automatic counting method of one embodiment of the present application.

[0023] Figure 4 is a structural diagram of the automatic counting device of one embodiment of the present application. DETAILED DESCRIPTION

[0024] The present application will be further described in detail below with reference to the accompanying drawings.

[0025] Embodiment one: Reference Figure 1 A metering method for steel wire rope production disclosed by the present application comprises: S1: obtaining the angular velocity of the stranding device collected by the rotation speed sensor, and calculating the initial length of the steel wire rope in combination with the lay length and diameter of the steel wire rope; S2: Based on the temperature and humidity in the wire rope production environment, construct an environmental coupling effect equation and calculate the environmental compensation length of the wire rope; S3: Correct the initial length according to the environmental compensation length to obtain the final length of the wire rope; S4: Calculate the elastic modulus of the wire rope based on the environmental compensation length and structural compensation length, and compare it with the preset elastic threshold range to obtain the judgment result.

[0026] The implementation principle of this embodiment is as follows: high-precision measurement is achieved through spindle angular velocity-twist integral, dynamic compensation for temperature and humidity expansion, and elastic modulus mass interception. Based on the real-time acquisition of spindle angular velocity ω (sampling frequency ≥10kHz) by the rotation speed sensor, combined with the preset twist P and the measured diameter d, the original length is calculated through integral calculation; the temperature and humidity sensor synchronously acquires ΔT / ΔH data, which is substituted into the environmental coupling equation to eliminate the distortion caused by thermal and humidity synergistic expansion; the compensated length is superimposed on the initial length to generate the final length; the elastic modulus is inverted based on the compensation amount and compared with the preset threshold to intercept interlayer structural defects in real time.

[0027] Example 2: Reference Figure 2 The specific steps of step S1 include: S11: According to the preset resolution PPR, the controller controls the acquisition frequency of the speed sensor to obtain the pulse count N; S12: According to the pulse count, the speed sensor triggers a corresponding number of pulse signals to record the angle change of the twisting device, and obtains the angle increment Δθ: Δθ=2π / PPR; S13: Measure the time difference between the rising edges of adjacent pulse signals to obtain the time interval; S14: Calculate the angular velocity ω of the twisting device based on the angle increment Δθ and the time interval Δt: ω=(2π*N) / (PPR*Δt); S15: Measure the process parameters of the wire rope to obtain the lay length P and diameter d; S16: Integrate the length of the wire rope based on the angular velocity and the running time t of the twisting device to obtain the original length L0. τ is the sampling time; S17: Based on the lay length and diameter, the original length of the wire rope is corrected to obtain the structural compensation length ε. m , γ is the correction coefficient, and δ is the phase noise of the speed sensor, which is positively correlated with the twist pitch; S18: Calculate the original length and the structural compensation length to obtain the initial length L1 of the wire rope: L1 = L0 + ε m .

[0028] The implementation principle of the embodiment is: based on preset resolution PPR (≥2000) control pulse acquisition frequency, through measuring adjacent pulse rising edge time interval Δt (accuracy ±0.1 μs 12), combining angle increment Δθ = 2π / PPR, real-time calculating angular velocity ω = 2πN / (PPR·Δt), realizing 0.0018 rad / s level micro-dynamic measurement; introducing correction coefficient k of phase noise δ (positively correlated with twist pitch P), constructing structure compensation length Lstr = k*P*d*δ, eliminating microscopic deformation caused by interlayer stress of steel wire; using variable step Runge-Kutta method to integrate original length; synthesizing initial length by combining structure compensation length and original length, and synchronously transmitting to environmental compensation module, providing high-precision input reference for subsequent temperature and humidity coupling correction.

[0029] Embodiment three Referring to Figure 3 The specific steps in step S2 include: S21: collecting temperature and humidity in the steel wire rope production environment through the temperature and humidity composite sensor, and calculating temperature change ΔT; S22: extracting and aggregating all temperature data, all humidity data and all length data in the controller, and constructing historical temperature data set, historical humidity data set and historical length data set; S23: fitting and operating the historical temperature data set, the historical humidity data set and the historical length data set according to the time stamp, and calculating thermal expansion coefficient α T and humidity expansion coefficient α H ; S24: fitting and operating temperature change ΔT and humidity by combining thermal expansion coefficient and humidity expansion coefficient of the steel wire rope with material moisture absorption constant β, to obtain environmental coupling effect equation M, S25: calculating environmental compensation length ΔLenv by combining original length L0 of the steel wire rope with the environmental coupling effect equation M, ΔLenv = L0*M; The specific steps in step S3 include: Operating the environmental compensation length and the initial length to obtain the final length L f of the steel wire rope;

[0030] The specific steps in step S4 include: According to the environmental compensation length and the structure compensation length, the elastic modulus E of the steel wire rope is calculated and compared with the preset elastic threshold interval for judgment; Wherein, A is the cross-sectional area of the steel wire rope, F is the tension of the steel wire rope; If the elastic modulus is within the elastic threshold interval, it is determined that the final length of the current steel wire rope is valid.

[0031] The implementation principle of the embodiment is that: real-time collection of ΔT / ΔH data by the temperature and humidity composite sensor, dynamic fitting of the thermal expansion coefficient α, the wet expansion coefficient β and the cross term γ (such as γΔTΔH) combined with the historical data set (temperature / humidity / length), construction of the environmental coupling equation Lenv=Lraw(αΔT+βΔH+γΔTΔH), accurate compensation of the nonlinear expansion caused by the thermal and wet synergistic effect; superposition of the environmental compensation length Lenv to the initial length Lraw (based on angular velocity integration), output of the final length; comparison of the elastic modulus based on the compensation amount with the preset threshold, real-time identification of the interlayer structure defect. Embodiment five: Referring to Figure 4 A metering device for steel wire rope production is applied to the automatic counting method, comprising: a display, a rotational speed sensor, a stranding device and a controller; wherein, The signal input end of the display is connected to the communication interface of the controller; The rotational speed sensor is arranged on the main shaft of the stranding device, and the signal output end of the controller is connected to the signal input end of the rotational speed sensor and the signal input end of the stranding device: The controller is a PLC controller, and the PLC controller is provided with a lay length and a resolution; The rotational speed sensor is installed on the main shaft of the stranding device to ensure that the sensor rotates synchronously with the main shaft; the signal line of the rotational speed sensor is connected to the high-speed counting port of the controller; after the stranding device is started, the controller automatically calculates and displays the length of the steel wire rope; the installation state and signal transmission stability of the rotational speed sensor are checked regularly.

[0032] The implementation principle of the embodiment is that: the rotational speed sensor (radial run-out ≤0.01mm) directly connected to the main shaft collects the angular velocity signal in real time, the pulse sequence (PPR≥2000) is analyzed through the PLC high-speed counting port (≥10kHz sampling rate), the preset lay length P and the diameter d are integrated and operated to generate the raw length (φ(d) suppresses the interlayer stress error); the temperature and humidity sensor data are synchronously integrated, the thermal and wet expansion is dynamically compensated through the environmental coupling equation; the final output length value is displayed on the monitoring interface after the elastic modulus inversion verification, and the PLC self-diagnosis system monitors the signal stability (fault response time <0.1s) in real time, and the precision (length fluctuation ≤±0.03mm) 25 times that of the traditional wheel type metering and the maintenance cost reduction are realized under the extreme working conditions of -40℃ to 85℃.

[0033] Embodiment six: An electronic device, comprising: one or more processors; memory storing one or more programs; when the one or more programs are executed by the one or more processors, cause the one or more processors to implement the above method.

[0034] Embodiment seven: A computer storage medium having stored thereon a computer program, the program being executed by a processor to implement the above method.

[0035] The embodiments of the present disclosure are all the preferred embodiments of the present disclosure, and are not intended to limit the protection scope of the present disclosure, so that: any equivalent changes made according to the structure, shape, principle of the present disclosure should be covered within the protection scope of the present disclosure.

Claims

1. A metering method for steel wire rope production, the method being applied to a metering device, the device comprising a rotational speed sensor, a stranding apparatus and a controller, the rotational speed sensor being arranged on a spindle of the stranding apparatus, a signal output of the controller being connected to a signal input of the rotational speed sensor and to a signal input of the stranding apparatus, characterized in that The metering method comprises: acquiring the angular velocity of the stranding device collected by the rotation speed sensor, and combining the lay length and diameter of the steel wire rope to calculate the initial length of the steel wire rope; According to the temperature and humidity in the steel wire rope production environment, the environmental coupling effect equation is constructed, and the environmental compensation length of the steel wire rope is calculated; the initial length is corrected according to the environmental compensation length to obtain the final length of the steel wire rope.

2. The metering method for steel wire rope production according to claim 1, characterized in that, The specific steps of acquiring the angular velocity of the stranding device collected by the rotation speed sensor, and combining the lay length and diameter of the steel wire rope to calculate the initial length of the steel wire rope include: According to the preset resolution PPR, the controller controls the collection frequency of the rotation speed sensor to obtain the pulse count N; According to the pulse count, the rotation speed sensor triggers a corresponding number of pulse signals to record the angular change amount of the stranding device to obtain the angular increment Δθ: Δθ = 2π / PPR; The time difference between the rising edges of adjacent pulse signals is measured to obtain the time interval; According to the angular increment Δθ and the time interval Δt, the angular velocity ω of the stranding device is calculated: ω = (2π*N) / (PPR*Δt); The process parameters of the steel wire rope are measured to obtain the lay length P and the diameter d; The length of the steel wire rope is integrated according to the angular velocity and the running time t of the stranding device to obtain an original length L0, τ is a sampling time; According to the lay length and the diameter, an original length of the steel wire rope is corrected to obtain a structure compensation length ε m , γ is a correction factor, δ is a phase noise of a speed sensor, and is positively correlated with the lay length; The original length and the structure compensation length are calculated to obtain the initial length L1 of the steel wire rope: L1=L0+ε m .

3. The metering method for steel wire rope production according to claim 1, characterized in that: The specific steps of constructing the environmental coupling effect equation according to the temperature and humidity in the steel wire rope production environment to calculate the environmental compensation length of the steel wire rope include: collecting the temperature and humidity in the steel wire rope production environment through the temperature and humidity composite sensor, and calculating the temperature change ΔT; All temperature data, all humidity data and all length data in the controller are extracted and aggregated to construct historical temperature data set, historical humidity data set and historical length data set; fitting the historical temperature dataset, the historical humidity dataset, and the historical length dataset according to timestamps, calculating a thermal expansion coefficient a T and a humidity expansion coefficient a H ; The thermal expansion coefficient and the wet expansion coefficient of the steel wire are combined with the material moisture absorption constant β to perform fitting operation on the temperature variation ΔT and the humidity, to obtain an environment coupling effect equation M, The original length L0 of the steel wire is combined with the environment coupling effect equation M to perform calculation, to obtain an environment compensation length ΔLenv, ΔLenv=L0*M.

4. The metering method for steel wire rope production according to claim 1, characterized in that, The specific steps of correcting the initial length according to the environmental compensation length to obtain the final length of the steel wire rope include: The environmental compensation length and the initial length are operated to obtain the final length L of the steel wire rope f ; 5. The metering method for steel wire rope production according to claim 1, characterized in that, The metering method further comprises: According to the environmental compensation length and the structural compensation length, the elastic modulus E of the steel wire rope is calculated and compared with the preset elastic threshold interval; Wherein, A is the cross-sectional area of the steel wire rope, and F is the tension of the steel wire rope; If the elastic modulus is within the elastic threshold interval, it is determined that the final length of the current steel wire rope is valid.

6. A metering device for steel wire rope production for implementing the metering method according to any one of claims 1 to 5, characterized in that: It comprises a display, a rotation speed sensor, a stranding device and a controller; wherein, The signal input end of the display is connected to the communication interface of the controller.

7. The metering device for steel wire rope production according to claim 6, characterized in that: The rotation speed sensor is installed on the main shaft of the stranding device to ensure that the sensor rotates synchronously with the main shaft; the signal line of the rotation speed sensor is connected to the high-speed counting port of the controller; after the stranding device is started, the controller automatically calculates and displays the length of the steel wire rope; the installation state and signal transmission stability of the rotation speed sensor are checked regularly.

8. The metering device for steel wire rope production according to claim 6, characterized in that: The controller is a PLC controller; the PLC controller is provided with a lay length and a resolution.

9. An electronic device, comprising: It comprises: One or more processors; Memory for storing one or more programs; When the one or more programs are executed by the one or more processors, the one or more processors implement the method of any one of claims 1-5.

10. A computer storage medium having stored thereon a computer program, characterized in that The program, when executed by the processor, implements the method of any one of claims 1-5.

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