A metering method and device for steel wire rope production

Abstract

The present application relates to a kind of wire rope production metering method and device, it is related to length measuring instrument technical field, metering measurement method, comprising: the angular velocity of the stranding equipment is acquired by the speed sensor acquisition, and the initial length of wire rope is calculated in combination with the lay length and diameter of wire rope;According to the temperature and humidity in the environment of wire rope production, environmental coupling effect equation is constructed, and the environmental compensation length of wire rope is calculated;According to the initial length of environmental compensation length revision, the final length of wire rope is obtained;According to the elastic modulus of environmental compensation length and structure compensation length, wire rope is measured, and compared with the preset elastic threshold interval, to obtain the judgment result;Through speed sensor and integral calculation, the influence of traction wheel groove contact depth on length measurement is avoided, and the measurement accuracy is improved;Through low cost, high reliability sensor and PLC controller, equipment cost and maintenance difficulty are reduced.

Description

Technical Field

[0001] This invention relates to the field of length measuring instruments, and in particular to a meter measuring method and apparatus for steel wire rope production. Background Technology

[0002] There are many varieties and specifications of wire rope products. They are used in various industries, from mines to ports, construction, bridges, aerospace, ships and engineering decoration. All kinds of wire rope products are used and the length of the wire rope needs to be measured and fixed.

[0003] Traditional length measurement methods primarily rely on the number of rotations of the traction wheel to calculate the length. Each rotation of the traction wheel transports the wire rope a corresponding circumference distance, i.e., wire rope length = number of rotations of the traction wheel × circumference of the traction wheel. However, to prevent wire rope slippage, grooves are designed on the surface of the traction wheel to accommodate the traction needs of wire ropes of different diameters. This results in the actual transported length of the wire rope being affected by the contact depth of the grooves.

[0004] Application number CN201310566677.7 discloses a wire rope length measuring device, mainly composed of an upper support, a lower support, a small transmission gear, a large transmission gear, a support roller, a clamping roller, a guide frame, and a digital reader. The measurement method involves pulling up the upper support, opening the upper and lower supports and the support roller, guiding the wire rope to be measured through the support roller, through the guide frame, and the center of the clamping roller, then lowering the upper support so that the clamping roller clamps the wire rope. The end of the wire rope is placed between the two clamping rollers, pulling the wire rope forward. The wire rope is released through the guide frame and the clamping roller, and friction drives the clamping roller to rotate. The rotation of the clamping roller further drives the small and large transmission gears, transmitting a signal to the digital reader, which displays the actual length of the wire rope, thus achieving the purpose of measuring the wire rope length. This invention is easy to operate and has high measurement accuracy.

[0005] Application number CN201310502820.6 discloses a meter-counting device for a strand twisting machine, comprising a pulse disk, two proximity sensors, and a winding roller that guides multiple monofilaments through the machine in a counter-clockwise, 360-degree manner. The pulse disk is fixedly mounted at the tail end of the winding roller, and the end of the winding roller is mounted on a mounting base of the strand twisting machine. The two proximity sensors are mounted on the mounting base. The pulse disk has two pulse sensing holes, the centers of which are equidistant from the center of the pulse disk, and the line connecting the centers of the two pulse sensing holes passes through the center of the pulse disk. 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 symmetrical along the central axis of the pulse disk. The meter-counting device for a strand twisting machine provided by the above invention has the advantage of high meter-counting accuracy.

[0006] The existing technical solutions mentioned above have the following drawbacks: 1. When the diameter of the wire rope is small, the wire rope is embedded in the groove deeply, which will make the actual conveying length less than the meter length. When the diameter of the wire rope is large, the wire rope is embedded in the groove shallowly, which will make the actual conveying length greater than the meter length. 2. Because the wire rope is subject to changes in the production environment, the expansion / moisture absorption deformation of the material is not fully compensated, which directly introduces drift error. Summary of the Invention

[0007] In order to improve the accuracy of metering measurement of steel wire ropes and address the shortcomings of existing technologies, this invention provides a metering method for steel wire rope production.

[0008] The objective of this invention is achieved through the following technical solution:

[0009] A method for measuring the length of steel wire rope in production, comprising:

[0010] The angular velocity of the twisting device, collected by the rotation speed sensor, is obtained, and the initial length of the wire rope is calculated by combining the lay length and diameter of the wire rope.

[0011] Based on the temperature and humidity in the wire rope production environment, an environmental coupling effect equation is constructed to calculate the environmental compensation length of the wire rope.

[0012] The initial length is corrected based on the environmental compensation length to obtain the final length of the wire rope;

[0013] The elastic modulus of the wire rope is calculated based on the environmental compensation length and the structural compensation length, and then compared with the preset elastic threshold range.

[0014] If the elastic modulus is within the elastic threshold range, then the final length of the current wire rope is determined to be a valid value.

[0015] By adopting the above technical solution, the angular velocity is collected in real time by a speed sensor deployed on the main shaft of the twisting equipment, and the initial length is calculated by combining the wire rope lay length and diameter. At the same time, an environmental coupling effect equation (such as thermal expansion coefficient and humidity deformation factor) is constructed to generate an environmental compensation length. Then, the dynamic elastic modulus is calculated by introducing structural compensation length. When the dynamic elastic modulus is within the preset elastic threshold range, the final length after double compensation correction is determined to be valid, realizing a three-in-one closed-loop control of measurement, compensation and quality inspection. By using speed sensors and integral calculations, the influence of the contact depth of the traction wheel groove on the length measurement is avoided, thus improving the measurement accuracy.

[0016] The present invention is further configured such that: the specific steps of obtaining the angular velocity of the stranding device collected by the rotation speed sensor, and calculating the initial length of the wire rope in combination with the lay pitch and diameter of the wire rope include:

[0017] Based on the preset resolution, the controller controls the acquisition frequency of the speed sensor to obtain pulse counts;

[0018] Based on the pulse count, the speed sensor triggers a corresponding number of pulse signals to record the angle change of the twisting device, thus obtaining the angle increment;

[0019] The time difference between the rising edges of adjacent pulse signals is measured to obtain the time interval;

[0020] The angular velocity of the twisting device is calculated based on the angle increment and the time interval.

[0021] The process parameters of the wire rope are measured to obtain the lay pitch and diameter;

[0022] The length of the wire rope is obtained by integrating the angular velocity and the running time of the twisting device;

[0023] Based on the lay length and the diameter, the original length of the wire rope is corrected to obtain the structural compensation length;

[0024] The initial length of the wire rope is obtained by calculating the original length and the structural compensation length.

[0025] By adopting the above technical solution, high-precision pulse timing analysis (rising edge interval measurement accuracy of 0.1μs) and multi-physics field coupling compensation technology are used to calculate the angular velocity ω=2πN / (PPR·Δt) based on the pulse count (N) and rising edge time difference (Δt) of PPR. A correction coefficient k for phase noise δ (positively correlated with the twist pitch P) is introduced to construct the structural compensation length and eliminate the micro-deformation error caused by interlayer stress. The original length adopts variable step size Runge-Kutta integration (sampling frequency 1kHz), which reduces the integration error under strong vibration conditions. By integrating pulse timing analysis, noise compensation and real-time integration, the accuracy of wire rope measurement is improved and the maintenance cost is reduced.

[0026] The present invention is further configured such that the specific steps for constructing an environmental coupling effect equation based on the temperature and humidity in the wire rope production environment and calculating the environmental compensation length of the wire rope include:

[0027] The temperature and humidity in the wire rope production environment are collected by a temperature and humidity composite sensor, and the temperature change is calculated.

[0028] Extract and aggregate all temperature data, all humidity data, and all length data from the controller to construct historical temperature datasets, historical humidity datasets, and historical length datasets;

[0029] Based on the timestamp, the historical temperature dataset, the historical humidity dataset, and the historical length dataset are fitted to calculate the thermal expansion coefficient and the moisture expansion coefficient.

[0030] By combining the thermal expansion coefficient and hygroscopic expansion coefficient of the steel wire rope with the material's moisture absorption constant, the temperature change and humidity are fitted and calculated to obtain the environmental coupling effect equation.

[0031] The original length of the wire rope is calculated by combining it with the environmental coupling effect equation to obtain the environmental compensation length.

[0032] By adopting the above technical solution, environmental data (temperature change ΔT, humidity ΔH) is collected in real time by a temperature and humidity composite sensor. Historical temperature, humidity and length datasets are aggregated for spatiotemporal fitting to calculate the thermal expansion coefficient α (unit: ppm / ℃) and moisture expansion coefficient β (unit: ppm / %RH) of the wire rope. Combined with the material's hygroscopic constant γ, an environmental coupling effect equation is constructed, and the environmental compensation length is finally output. The linear expansion due to temperature, the hygroscopic expansion due to humidity and the nonlinear effect of temperature and humidity cross-nonlinearity are integrated to reduce the length error after compensation. The α and β coefficients are fitted in real time based on historical datasets to adapt to the process fluctuations of different batches of wire rope.

[0033] Secondly, the present invention also provides a meter-counting device for steel wire rope production, which adopts the following technical solution:

[0034] A meter-counting device for steel wire rope production, used to implement the aforementioned automated counting method, includes a display, a speed sensor, a stranding device, and a controller; wherein,

[0035] The signal input terminal of the display is connected to the communication interface of the controller;

[0036] The speed sensor is mounted on the main shaft of the twisting device, and the signal output terminal of the controller is connected to the signal input terminal of the speed sensor and the signal input terminal of the twisting device.

[0037] The controller is a PLC controller; the PLC controller is configured with twist pitch and resolution.

[0038] The speed sensor is installed on the main shaft of the twisting equipment to ensure that the sensor rotates synchronously with the main shaft; the signal line of the speed sensor is connected to the high-speed counting port of the controller; after the twisting equipment is started, the controller automatically calculates and displays the wire rope length; the installation status and signal transmission stability of the speed sensor are checked periodically.

[0039] By adopting the above technical solution, the pulse signal is analyzed in real time based on the PLC high-speed counting port (sampling frequency ≥10kHz), and the angular velocity is measured at the microsecond level (error <±0.001rad / s) by combining the preset twist pitch and resolution (PPR≥2000). The temperature and humidity sensor data are simultaneously fused to dynamically correct the environmental expansion effect. The sensor and the main shaft are rigidly and synchronously installed (radial runout tolerance ≤0.01mm), which greatly avoids the cumulative error caused by the slippage of the traditional meter counting wheel. The PLC automatically diagnoses the sensor status (such as triggering an alarm within 0.1s if the signal is interrupted), and the annual production line failure rate is reduced by combining the periodic self-check mechanism (vibration / temperature drift compensation). The low-cost and high-reliability sensor and PLC controller reduce the equipment cost and maintenance difficulty.

[0040] Thirdly, the present invention also provides an electronic device, which adopts the following technical solution:

[0041] An electronic device, comprising:

[0042] One or more processors;

[0043] Memory, used to store one or more programs;

[0044] When the one or more programs are executed by the one or more processors, the one or more processors implement the method described above.

[0045] By adopting the above technical solution, the meter counting method for steel wire rope production is presented in the form of computer-readable code and stored in the memory. When the processor runs the computer-readable code in the memory, the steps of the meter counting method for steel wire rope production are executed, thereby reducing the intensity of manual labor and improving the degree of automation.

[0046] Fourthly, the present invention also provides a computer storage medium, which adopts the following technical solution:

[0047] A computer storage medium having a computer program stored thereon, which, when executed by a processor, implements the method described above.

[0048] In summary, the beneficial technical effects of the present invention are as follows:

[0049] By using a speed sensor and integral calculation, the influence of the contact depth of the traction wheel groove on the length measurement is avoided, thus improving the measurement accuracy.

[0050] By using low-cost, high-reliability sensors and PLC controllers, equipment costs and maintenance difficulties have been reduced.

[0051] The real-time display and historical data storage functions facilitate production management and quality control. Attached Figure Description

[0052] Figure 1 This is a flowchart illustrating an automated counting method according to one embodiment of the present invention.

[0053] Figure 2 This is a flowchart illustrating an automated counting method according to one embodiment of the present invention.

[0054] Figure 3 This is a flowchart illustrating an automated counting method according to one embodiment of the present invention.

[0055] Figure 4 This is a schematic diagram of the structure of an automated counting device according to one embodiment of the present invention. Detailed Implementation

[0056] The present invention will be further described in detail below with reference to the accompanying drawings. Example

[0057] Reference Figure 1 The present invention discloses a method for measuring the length of steel wire rope in production, comprising:

[0058] S1: Obtain the angular velocity of the twisting device collected by the rotation speed sensor, and calculate the initial length of the wire rope by combining the lay length and diameter of the wire rope;

[0059] 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;

[0060] S3: Correct the initial length according to the environmental compensation length to obtain the final length of the wire rope;

[0061] 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.

[0062] 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. Example

[0063] Reference Figure 2 The specific steps of step S1 include:

[0064] S11: Based on the preset resolution PPR, the controller controls the acquisition frequency of the speed sensor to obtain the pulse count N;

[0065] S12: Based on 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;

[0066] S13: Measure the time difference between the rising edges of adjacent pulse signals to obtain the time interval;

[0067] 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);

[0068] S15: Measure the process parameters of the wire rope to obtain the lay length P and diameter d;

[0069] S16: Based on the angular velocity and the running time of the twisting device The original length is obtained by integrating the length of the wire rope. , Sampling time;

[0070] S17: Based on the lay length and diameter, the original length of the wire rope is corrected to obtain the structural compensation length. , For correction factor, This is the phase noise of the speed sensor, and it is positively correlated with the twist pitch;

[0071] S18: Calculate the original length and the structural compensation length to obtain the initial length of the wire rope. .

[0072] The implementation principle of this embodiment is as follows: Based on the preset resolution PPR (≥2000), the pulse acquisition frequency is controlled. By measuring the time interval Δt between the rising edges of adjacent pulses (accuracy ±0.1μs 12), combined with the angle increment Δθ=2π / PPR, the angular velocity ω=2πN / (PPR·Δt) is calculated in real time to achieve micro-dynamic measurement at the level of 0.0018rad / s. A correction coefficient k for the phase noise δ (positively correlated with the twist P) is introduced to construct the structural compensation length Lstr=k*P*d*δ, eliminating the micro-deformation caused by the interlayer stress of the steel wire. The original length is integrated using the variable step size Runge-Kutta method. The structural compensation length and the original length are combined to form the initial length, which is synchronously transmitted to the environmental compensation module to provide a high-precision input reference for subsequent temperature and humidity coupling correction.

[0073] Example 3:

[0074] Reference Figure 3 The specific steps in step S2 include:

[0075] S21: The temperature and humidity in the wire rope production environment are collected by a temperature and humidity composite sensor, and the temperature change is calculated.

[0076] S22: Extract and aggregate all temperature data, all humidity data, and all length data in the controller to construct historical temperature dataset, historical humidity dataset, and historical length dataset;

[0077] S23: Fit the historical temperature dataset, the historical humidity dataset, and the historical length dataset according to the timestamp, and calculate the coefficient of thermal expansion. and coefficient of moisture expansion ;

[0078] S24: Combining the thermal expansion coefficient and hygroscopic expansion coefficient of steel wire rope with the material's moisture absorption constant. By fitting the temperature change and humidity, the environmental coupling effect equation is obtained. ;

[0079] S25: Calculate the environmental compensation length by combining the original length of the wire rope with the aforementioned environmental coupling effect equation. ;

[0080] The specific steps in step S3 include:

[0081] The final length of the wire rope is obtained by calculating the environmental compensation length and the initial length. ;

[0082] .

[0083] The specific steps in step S4 include:

[0084] Based on the environmental compensation length and structural compensation length, the elastic modulus of the wire rope is... Calculations are performed and compared with the preset elastic threshold range for judgment;

[0085] ;

[0086] in, The cross-sectional area of ​​the wire rope is... The tension force on the wire rope;

[0087] If the elastic modulus is within the elastic threshold range, then the final length of the current wire rope is determined to be a valid value.

[0088] The implementation principle of this embodiment is as follows: real-time acquisition of ΔT / ΔH data through a temperature and humidity composite sensor, dynamic fitting of thermal expansion coefficient α, moisture expansion coefficient β and cross term γ (such as γΔTΔH) based on historical dataset (temperature / humidity / length), construction of environmental coupling equation Lenv=Lraw(αΔT+βΔH+γΔTΔH) to accurately compensate for nonlinear expansion caused by the combined effect of heat and humidity; superimposition of environmental compensation length Lenv onto initial length Lraw (generated based on angular velocity integral) to output final length; comparison of elastic modulus inverted based on compensation amount with preset threshold to identify interlayer structural defects in real time.

[0089] Example 5:

[0090] Reference Figure 4 A meter counting device for steel wire rope production, applied to the aforementioned automated counting method, comprising:

[0091] Display, speed sensor, twisting device, and controller; among which,

[0092] The signal input terminal of the display is connected to the communication interface of the controller;

[0093] The speed sensor is mounted on the main shaft of the twisting device, and the signal output terminal of the controller is connected to the signal input terminal of the speed sensor and the signal input terminal of the twisting device.

[0094] The controller is a PLC controller; the PLC controller is configured with twist pitch and resolution.

[0095] The speed sensor is installed on the main shaft of the twisting equipment to ensure that the sensor rotates synchronously with the main shaft; the signal line of the speed sensor is connected to the high-speed counting port of the controller; after the twisting equipment is started, the controller automatically calculates and displays the wire rope length; the installation status and signal transmission stability of the speed sensor are checked periodically.

[0096] The implementation principle of this embodiment is as follows: Angular velocity signals are collected in real time by a speed sensor (radial runout ≤ 0.01 mm) directly connected to the main shaft. The pulse sequence (PPR ≥ 2000) is analyzed by the high-speed counting port of the PLC (≥ 10 kHz sampling rate). Combined with the preset twist pitch P and diameter d, the original length is generated by integral calculation (φ(d) suppresses interlayer stress error). Temperature and humidity sensor data are integrated simultaneously, and thermal and humid expansion is dynamically compensated through environmental coupling equations. The final output length value is displayed on the monitoring interface after being verified by elastic modulus inversion. At the same time, the PLC self-diagnostic system monitors the signal stability in real time (fault response time < 0.1 s). Under extreme working conditions of -40℃ to 85℃, it achieves 25 times the accuracy of traditional wheel meter counting (length fluctuation ≤ ± 0.03 mm) and a reduction in maintenance costs.

[0097] Example 6:

[0098] An electronic device, comprising:

[0099] One or more processors;

[0100] Memory, used to store one or more programs;

[0101] When the one or more programs are executed by the one or more processors, the one or more processors implement the method described above.

[0102] Example 7:

[0103] A computer storage medium having a computer program stored thereon, which, when executed by a processor, implements the method described above.

[0104] The embodiments described herein are preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Therefore, all equivalent changes made in accordance with the structure, shape, and principle of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A method for measuring the length of steel wire rope during production, the method being applied to a measuring device, the device comprising a speed sensor, a stranding device, and a controller; the speed sensor being mounted on the main shaft of the stranding device, and the signal output terminal of the controller being connected to the signal input terminal of the speed sensor and the signal input terminal of the stranding device, respectively: characterized in that, The metering measurement method includes: The angular velocity of the stranding device, acquired by the speed sensor, is obtained, and the initial length of the wire rope is calculated by combining the lay length and diameter of the wire rope, including: Based on the preset resolution PPR, the controller controls the acquisition frequency of the speed sensor to obtain the pulse count N; Based on the pulse count, the speed sensor triggers a corresponding number of pulse signals to record the angle change of the twisting device, obtaining the angle increment Δθ: Δθ = 2π / PPR; The time difference between the rising edges of adjacent pulse signals is measured to obtain the time interval; Based on the angle increment Δθ and the time interval Δt, calculate the angular velocity ω of the twisting device: ω = (2π * N) / (PPR * Δt); The process parameters of the wire rope are measured to obtain the lay length P and diameter d; Based on the angular velocity and the running time of the twisting device The original length is obtained by integrating the length of the wire rope. , Sampling time; Based on the lay length and diameter, the original length of the wire rope is corrected to obtain the structural compensation length. , For correction factor, This is the phase noise of the speed sensor, and it is positively correlated with the twist pitch; The initial length of the wire rope is obtained by calculating the original length and the structural compensation length. ; Based on the temperature and humidity in the wire rope production environment, an environmental coupling effect equation is constructed to calculate the environmental compensation length of the wire rope. The initial length is corrected based on the environmental compensation length to obtain the final length of the wire rope.

2. The metering method for steel wire rope production according to claim 1, characterized in that: The specific steps for constructing an environmental coupling effect equation based on the temperature and humidity in the wire rope production environment and calculating the environmental compensation length of the wire rope include: The temperature and humidity in the wire rope production environment are collected by a temperature and humidity composite sensor, and the temperature change is calculated. Extract and aggregate all temperature data, all humidity data, and all length data from the controller to construct historical temperature datasets, historical humidity datasets, and historical length datasets; The historical temperature dataset, the historical humidity dataset, and the historical length dataset are fitted together based on the timestamps to calculate the coefficient of thermal expansion. and coefficient of moisture expansion ; Combining the thermal expansion coefficient and hygroscopic expansion coefficient of steel wire rope with the material's hygroscopic constant For temperature change By fitting the equation with humidity, the environmental coupling effect equation is obtained. ; The environmental compensation length is obtained by calculating the original length of the wire rope in conjunction with the aforementioned environmental coupling effect equation. .

3. The method for measuring lengths in steel wire rope production according to claim 2, characterized in that, The specific steps for correcting the initial length based on the environmental compensation length to obtain the final length of the wire rope include: The final length of the wire rope is obtained by calculating the environmental compensation length and the initial length. ; .

4. The method for measuring lengths in steel wire rope production according to claim 2, characterized in that, The metering method also includes: Based on the environmental compensation length and structural compensation length, the elastic modulus of the wire rope is... Calculations are performed and compared with the preset elastic threshold range for judgment; ; in, The cross-sectional area of ​​the wire rope is... The tension force on the wire rope; If the elastic modulus is within the elastic threshold range, then the final length of the current wire rope is determined to be a valid value.

5. A meter-counting device for steel wire rope production, used to implement the meter-counting measurement method as described in any one of claims 1-4, characterized in that: Includes a display, speed sensor, twisting device, and controller; among which, The signal input terminal of the display is connected to the communication interface of the controller.

6. The meter-counting device for steel wire rope production according to claim 5, characterized in that: The speed sensor is installed on the main shaft of the twisting equipment to ensure that the sensor rotates synchronously with the main shaft; the signal line of the speed sensor is connected to the high-speed counting port of the controller; after the twisting equipment is started, the controller automatically calculates and displays the wire rope length; the installation status and signal transmission stability of the speed sensor are checked periodically.

7. The meter-counting device for steel wire rope production according to claim 5, characterized in that: The controller is a PLC controller; the PLC controller is configured with twist pitch and resolution.

8. An electronic device, characterized in that, include: One or more processors; Memory, used to store 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 in any one of claims 1-4.

9. A computer storage medium having a computer program stored thereon, characterized in that, When the program is executed by the processor, it implements the method as described in any one of claims 1-4.

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