Automatic take-up tension control system

Abstract

The invention discloses an automatic take-up tension control system, belongs to the field of take-up and pay-off devices, solves the problem of lack of self-adaptive control of rope tension in the prior art, and adopts the technical scheme that two fixed guide wheels and a movable pulley located between the two fixed guide wheels are arranged between a take-up reel and a turntable; the rope between the take-up reel and the rotating disc is sequentially wound on the fixed pulley and the movable pulley, the detection end of the tension detection mechanism is connected with the movable pulley, and the included angle between the rope on the two sides of the movable pulley and the vertical direction is equal to 0. The tension detection mechanism comprises a gradienter used for detecting the included angle and a tension sensor used for detecting the tension of the movable pulley and transmitting the tension to the control assembly, the control assembly calculates and compares the current tension with the target tension, and if a difference exists between the current tension and the target tension, the control assembly adjusts the output torque of the driving motor to be the same as the target tension. According to the invention, self-adaptive control of rope tension is realized.

Description

Technical Field

[0001] This invention relates to the field of wire take-up and take-up devices, and in particular to an automatic take-up tension control system. Background Technology

[0002] In power transmission and distribution engineering construction sites, due to the large number of construction objects with varying types, weights, and shapes, wire rope winding and unwinding angle grinders are needed to control the winding and unwinding of wire ropes. However, haphazardly stacking wire ropes poses significant safety risks; therefore, all wound wire ropes must be coiled into a cylindrical shape. Existing technologies, such as the invention patent CN101685946A, disclose a field winding and unwinding device. While the tension is adjusted to the target value before pulling, the tension of the wire rope changes during winding due to dynamic torque caused by acceleration, deceleration, and friction. This is particularly noticeable in long-length, high-load winding and unwinding operations. This device lacks real-time tension monitoring and feedback adjustment capabilities, and cannot dynamically adjust tension control parameters according to actual working conditions. This makes it difficult for operators to accurately control the winding and unwinding state of the wire rope, easily leading to safety hazards such as knots, twisting, or even breakage. Summary of the Invention

[0003] The objective of this invention is to provide an automatic rope tension control system that solves the problem of lack of adaptive control of rope tension in existing technologies and achieves adaptive control of rope tension.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: an automatic take-up tension control system, comprising a rope, a turntable, a take-up reel, and a drive motor for driving the take-up reel to rotate. The fixed end of the rope is wound around the take-up reel, and the free end of the rope is wound around the turntable and used to connect a weight. The automatic take-up tension control system further includes a control component and a tension detection mechanism. Two fixed pulleys and a movable pulley located between the two fixed pulleys are provided between the take-up reel and the turntable. The rope between the take-up reel and the turntable is sequentially wound around the fixed pulleys and the movable pulley. The detection end of the tension detection mechanism is connected to the movable pulley. When the drive motor drives the take-up reel to rotate for take-up, the rope exerts tension on the movable pulley. The angle between the ropes on both sides of the movable pulley and the vertical direction is... and The tensile testing mechanism includes a component for detecting the included angle. and A level and a device for detecting the tension of the movable pulley. And transmits the data to the tension sensor of the control component, which calculates... And compare the current tension With target tension ,like and If there is a difference, the control component adjusts the output torque of the drive motor to make... and same.

[0005] By adopting the above technical solution, the present invention has the following advantages: through the connection between the detection end of the tension detection mechanism and the movable pulley, the system can monitor the tension of the rope on the movable pulley in real time. When the tension of the ropes on both sides of the movable pulley is unbalanced, the angle between the ropes on both sides of the movable pulley and the vertical direction is measured using a level. and It can accurately obtain angle parameters, providing accurate basic data for subsequent tension calculations. By combining the detected angle with the tension F measured by the tension sensor, the actual tension of the rope can be calculated more accurately, allowing the control components to make more precise comparisons. and At the same time, it makes more precise adjustments to the drive motor torque. If there is a difference between the two, the control component will automatically adjust the output torque of the drive motor to achieve the desired result. and This dynamic adjustment capability ensures that the rope tension remains within the set range under the influence of dynamic torques such as acceleration, deceleration, and friction, thus improving the system's adaptability and stability.

[0006] Furthermore, the electromagnetic torque of the drive motor is The armature current of the drive motor is The torque sensitivity of the drive motor is , The control component changes the armature current of the drive motor to adjust the output torque of the drive motor.

[0007] Using the aforementioned technical solution, the control component can change the armature current. Directly adjust electromagnetic torque This enables more precise and rapid control of the output torque of the drive motor without the need for complex conversion. It can respond to tension adjustment needs more promptly, improve the real-time performance and accuracy of tension control, and make tension adapt to working conditions more quickly during the winding and unwinding process.

[0008] Furthermore, the tension of the take-up reel is The tension of the turntable is ,when and At the same time, the and same.

[0009] By adopting the aforementioned technical solution, and This indicates that the wire rope is in force balance between the take-up reel and the turntable, corresponding to... and Once the relationship is established, operators only need to ensure that the tension of both is consistent during system debugging or calibration to confirm that the tension setting is in place. There is no need to measure complex parameters, which greatly simplifies the initial setup and maintenance process of the equipment.

[0010] Furthermore, the real-time radius of the rope on the take-up reel is... The moment of inertia of the fixed pulley is The linear density of the rope is The acceleration of the rope is The length of the rope is .

[0011] The above technical solution introduces the real-time winding radius of the rope on the take-up reel. Moment of inertia of a fixed pulley Linear density of rope Length of rope and the acceleration of the rope A high-precision tension expression was constructed that comprehensively considers the dynamic characteristics and structural parameters of the system. This expression can reflect in real time the effects of changes in the winding radius, rope mass, and the rotational inertia of the fixed pulley on the tension, enabling the control system to more accurately match actual working conditions. This improves the stability and response speed of tension adjustment, making it particularly suitable for complex operating scenarios such as high-speed, variable acceleration, or multi-layer winding. For example, when the take-up reel winds the rope, the radius... The value increases with the number of winding layers, directly affecting the electromagnetic torque of the drive motor. With tension The transformation relationship.

[0012] Furthermore, the real-time radius of the rope on the take-up reel is... The acceleration of the rope is The length of the rope is The viscous friction torque of the rope is The dry friction torque of the rope is The moment of inertia of the take-up reel and the rope is The linear velocity of the rope is , .

[0013] The above technical solution further incorporates the viscous friction torque of the rope on the original basis. Dry friction torque Time-varying moment of inertia of the take-up reel and rope system and linear velocity A more comprehensive and realistic tension target expression was constructed, taking into account various friction effects and dynamic inertia changes in the system. This allows tension control to not only reflect the current tension state, but also more accurately predict and compensate for the effects caused by changes in motion state, differences in material properties, and mechanical structure response.

[0014] Furthermore, the control component includes a PWM pulse width modulation power amplifier, an AD conversion circuit, a controller, and a motor driver. The tension data collected by the tension sensor is transmitted to the control component, amplified by the PWM pulse width modulation power amplifier, and the AD conversion circuit converts the analog signal into a digital signal. After calculation by the controller, the signal is output to the motor driver, which controls the drive motor.

[0015] Through the above technical solution, the weak analog signal collected by the tension sensor is amplified by the PWM pulse width modulation power amplifier and then converted into a digital signal by the AD conversion circuit, which meets the digital operation requirements of the controller, reduces signal attenuation and interference, and ensures accurate and reliable data transmission. At the same time, a complete tension closed-loop control loop is formed. The controller processes the data through digital operation. The modular design makes the functions of each module independent, which is convenient for debugging, maintenance and upgrades.

[0016] Furthermore, the tension sensor includes a sliding rheostat and a varistor connected in series with the sliding rheostat. By adjusting the sliding rheostat, the output voltage of the tension sensor changes proportionally to the input voltage.

[0017] Through the above technical solution, in the practical application of tension sensors, their performance may be affected by various factors, such as power supply voltage fluctuations, ambient temperature changes, and circuit noise. These interferences may cause the input voltage to be unstable, thereby causing changes in the sensitivity of the tension sensor and affecting the measurement accuracy. By introducing a sliding rheostat as an adjustment element, the input signal can be dynamically compensated under voltage fluctuations, so that the input voltage is maintained in a relatively stable state. This maximizes the stability and reliability of the tension sensor in complex working environments and ensures the accuracy of the measurement results.

[0018] Furthermore, the two fixed pulleys have the same diameter.

[0019] The above technical solution ensures that the fixed pulleys have the same diameter, which means that the bending radius of the rope on the two fixed pulleys is consistent, thus ensuring that the stress distribution of each section of the rope is more uniform.

[0020] Furthermore, the movable pulley and the fixed pulley have the same diameter.

[0021] The above technical solution, with the same diameter for both the movable and fixed pulleys, allows the rope to maintain a uniform curvature during winding, reducing localized excessive bending or stretching caused by pulleys of different diameters. This lowers the rope's fatigue damage and wear rate, ensuring its service life. Simultaneously, the identical diameter ensures a consistent contact area between the rope and the pulley, resulting in a more uniform force distribution. This avoids additional friction or tension fluctuations caused by contact differences, ensuring the stability of tension detection and control, and aligning with the system's closed-loop control logic to improve overall tension control accuracy.

[0022] Furthermore, the drive motor includes a ring with a mounting groove, an armature winding disposed in the mounting groove, and a slot wedge. Both ends of the slot wedge extend out of the mounting groove. One end of the slot wedge is used to connect to the armature winding, and the other end of the slot wedge is used to change the direction of the current.

[0023] Through the above technical solution, the slot wedge not only plays a role in fixing and insulation, but also integrates electrical connection and commutation functions, reducing the need for additional wiring terminals or commutator assemblies. Attached Figure Description

[0024] The present invention will be further described below with reference to the accompanying drawings: Figure 1 This is a structural diagram of the automatic take-up tension control system of the present invention; Figure 2 This is a schematic diagram illustrating the unbalanced force on the movable pulley of the present invention; Figure 3 This is a schematic diagram illustrating the force balance of the movable pulley according to the present invention; Figure 4 This is a schematic diagram of the internal mechanism of the drive motor of the present invention; Figure 5 The diagram shows the mechanical and adjustment characteristics of the torque motor of the present invention. Figure 6 This is a schematic diagram of the tension sensor of the present invention. Figure 7 This is a schematic diagram of the PWM drive device control principle of the present invention; Figure 8 This is an electromechanical model diagram of the drive motor of the present invention; Figure 9 This is a schematic diagram of the tension control system of the present invention; Figure 10 This is a schematic diagram of the structure of the take-up reel of the present invention; Figure 11 This is a partial structural diagram of the take-up reel of the present invention; In the diagram, 10 is the rope; 11 is the turntable; 12 is the take-up reel; 13 is the drive motor; 131 is the iron core; 132 is the stator; 133 is the armature winding; 134 is the slot wedge; 14 is the fixed pulley; 15 is the movable pulley; 16 is the tension sensor; 17 is the PWM power amplifier; 18 is the AD conversion circuit; 19 is the controller; 20 is the motor driver; 21 is the sliding rheostat; 22 is the varistor; 23 is the weight; 24 is the constant frequency waveform generator; 25 is the pulse width modulation circuit; 26 is the pulse distribution circuit; 27 is the base drive circuit; 28 is the protection circuit; 29 is the take-up frame; 30 is the cable guide; 31 is the caster; 32 is the reducer; and 33 is the level. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0026] The terms "first," "second," "third," "fourth," etc. (if present) in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein.

[0027] It should be understood that in the various embodiments of the present invention, the number of each process does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.

[0028] It should be understood that in this invention, "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion, for example, a process, method, system, product, or device that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such process, method, product, or device.

[0029] It should be understood that in this invention, "multiple" refers to two or more. "And / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, X and / or Y can represent: X alone, X and Y simultaneously, or Y alone. The character " / " generally indicates that the preceding and following related objects are in an "or" relationship. "Contains X, Y, and Z", "Contains X, Y, and Z" means that all three X, Y, and Z are contained; "Contains X, Y, or Z" means that one of X, Y, and Z is contained; "Contains X, Y, and / or Z" means that any one, two, or three of X, Y, and Z are contained.

[0030] The technical solution of the present invention will be described in detail below with reference to specific embodiments. The following specific embodiments may be combined or substituted with each other according to the actual situation, and the same or similar concepts or processes may not be described again in some embodiments.

[0031] like Figures 1 to 11 As shown, this invention provides an automatic take-up tension control system, including a rope 10, a turntable 11, a take-up reel 12, and a drive motor 13 for driving the take-up reel 12 to rotate. The fixed end of the rope 10 is wound around the take-up reel 12, and the free end of the rope 10 is wound around the turntable 11 and used to connect a weight 23. The automatic take-up tension control system also includes a control component and a tension detection mechanism. Two fixed pulleys 14 and a movable pulley 15 are provided between the take-up reel 12 and the turntable 11. The rope 10 between the take-up reel 12 and the turntable 11 is wound sequentially around the fixed pulleys 14 and the movable pulley 15. The detection end of the tension detection mechanism is connected to the movable pulley 15. When the drive motor 13 drives the take-up reel 12 to rotate for take-up, the rope 10 exerts tension on the movable pulley 15. The angle between the ropes 10 on both sides of the movable pulley 15 and the vertical direction is... and The tensile testing mechanism includes equipment for detecting included angles. and The level 33 and the force used to detect the pulley 15 The tension sensor 16, the control component calculates And compare the current tension With target tension ,like and If there is a difference, the control component adjusts the output torque of the drive motor 13 to make... and same.

[0032] By connecting the detection end of the tension detection mechanism to the movable pulley 15, the system can monitor the tension exerted by the rope 10 on the movable pulley 15 in real time. The angle between the ropes 10 on both sides of the movable pulley 15 and the vertical direction is measured using a level 33. and It can accurately obtain angle parameters, providing accurate basic data for subsequent tension calculations. The formula, combined with the detected angle and the tension F measured by the tension sensor 16, allows for a more accurate calculation of the actual tension of the rope 10, enabling the control components to perform comparisons. and At the same time, more precise torque adjustments are made to the drive motor 13. If a difference exists between the two, the control component will automatically adjust the output torque of the drive motor 13 to achieve the desired result. and This dynamic adjustment capability ensures that the tension of rope 10 remains within the set range under the influence of dynamic torques such as acceleration, deceleration, and friction, thereby improving the adaptability and stability of the system.

[0033] It should be noted that the take-up reel 12 is rotatably fixed on the take-up frame 29. The output end of the drive motor 13 is connected to the rotating shaft of the take-up reel 12 through the reducer 32. The take-up frame 29 is also provided with a cable guide 30 in front of the take-up reel 12. The cable guide 30 includes two guide wheels, and a guide channel is formed between the guide wheels for the rope 10 to pass through, which is used to guide the rope 10 to be wound on the take-up reel 12. The take-up frame 29 is also provided with casters 31 and handles. The entire take-up frame 29 forms a structure similar to a suitcase, which is convenient for movement.

[0034] It should be noted that the level 33 is connected to the detection end of the tension sensor 16 and tilts synchronously with the movable pulley 15 and the ropes 10 on both sides. It senses the deviation from the vertical direction through a built-in gravity sensing element, such as a MEMS accelerometer or a capacitive pendulum structure, and detects in real time the angles formed by the ropes 10 on both sides of the movable pulley 15 with the vertical direction. and These two angle signals are then transmitted to the control component, which uses the formula... Calculating the actual tension of rope 10 provides key angular parameters, thereby eliminating the influence of rope 10 tilt on the accuracy of tension detection.

[0035] The control components include a PWM power amplifier 17, an AD conversion circuit 18, a controller 19, and a motor driver 20. Tension data collected by the tension sensor 16 is transmitted to the control components, amplified by the PWM power amplifier 17, converted from analog to digital by the AD conversion circuit 18, and then output to the motor driver 20 after calculation by the controller 19. The motor driver 20 controls the drive motor 13, forming a complete tension closed-loop control circuit. The controller 19 processes the data through digital calculations. The modular design allows each module to function independently, facilitating debugging, maintenance, and upgrades.

[0036] It should be noted that the PWM power amplifier 17 is an electronic module combining pulse width modulation technology and power amplification function. It controls the amplification factor by adjusting the duty cycle of the output pulse signal, amplifying the weak analog electrical signal (typically in the millivolt range) output by the tension sensor 16 into a stronger, more interference-resistant analog signal. This provides a more stable and reliable input signal for the subsequent AD conversion circuit 18, ensuring that the tension data is not easily distorted during transmission and processing. The AD conversion circuit 18 is an electronic circuit that converts analog signals into digital signals. It receives the analog signal from the tension sensor 16 amplified by the PWM power amplifier 17 and converts the continuously changing analog quantity into a discrete digital signal recognizable by the controller 19 through quantization processing, providing accurate digital input for the controller 19 to perform tension calculations and logical judgments. The controller 19 is the core processing unit of the entire tension control system. It receives the digital tension signal transmitted by the AD conversion circuit 18, combines it with the angle data obtained by the level 33, and uses a preset algorithm... The actual tension is calculated and compared with the target tension. Then, a corresponding control command is generated based on the difference and output to the motor driver 20 to adjust the output torque of the drive motor 13, thereby realizing closed-loop control of the tension.

[0037] It needs to be explained, such as Figure 3 As shown, when the tension provided by the take-up reel 12 and the turntable 11 is equal, the movable pulley 15 and the two fixed pulleys 14 form an isosceles triangle. The two fixed pulleys 14 have the same diameter, meaning that the bending radius of the rope 10 on the two fixed pulleys 14 is consistent, ensuring a more uniform stress distribution across the rope 10. The identical diameter of the movable pulley 15 and the fixed pulleys 14 allows the rope 10 to maintain a uniform curvature during winding, reducing localized excessive bending or stretching caused by pulleys of different diameters, lowering fatigue damage and wear rate, and ensuring its service life. Simultaneously, the identical diameter ensures a consistent contact area between the rope 10 and the movable pulley 15 and fixed pulleys 14, resulting in a more uniform force distribution, avoiding additional friction or tension fluctuations due to contact differences, ensuring the stability of tension detection and control, adapting to the system's closed-loop control logic, and improving overall tension control accuracy.

[0038] In practical applications of the tension sensor 16, its performance may be affected by various factors, such as power supply voltage fluctuations, ambient temperature changes, and circuit noise. These interferences may cause the input voltage to be unstable, thereby causing changes in the sensitivity of the tension sensor 16 and affecting the measurement accuracy. Therefore, in this application, the tension sensor 16 includes a sliding rheostat 21 and a varistor 22 connected in series with the sliding rheostat 21. By adjusting the sliding rheostat 21, the output voltage of the tension sensor 16 is made to change proportionally with the input voltage. This enables dynamic compensation of the input signal under voltage fluctuations, keeping the input voltage in a relatively stable state. This maximizes the stability and reliability of the tension sensor 16 in complex working environments and ensures the accuracy of the measurement results.

[0039] Specifically, such as Figure 6 As shown: Vs represents the power supply voltage provided to the tension sensor 16. The sliding rheostat 21 and four varistor 22 are connected in series. The sliding rheostat 21 is R1, and the four varistor 22 are R2, R3, R4, and R5. The input voltage Vin is adjusted by regulating the sliding rheostat 21. When the tension force on the tension sensor 16 remains constant, the output voltage Vout changes proportionally to the input voltage Vin. However, during use, the tension sensor 16 is affected by internal and external conditions, such as unstable power supply voltage Vs, causing voltage fluctuations. These fluctuations will change the input voltage Vin, thus altering the sensitivity. Therefore, by adjusting the sliding rheostat 21 to keep the input voltage Vin stable, the tension sensor 16 can operate within a specific linear range.

[0040] It should be noted that when the supply voltage Vs increases, the total voltage of the series circuit increases. In this case, increasing the resistance of the sliding rheostat 21 increases the voltage across it, correspondingly reducing the voltage across the varistor, i.e., the input voltage Vin, thus offsetting the effect of the increased supply voltage Vs. Conversely, when the supply voltage Vs decreases, decreasing the resistance of the sliding rheostat 21 reduces its voltage, correspondingly increasing the voltage across the varistor, i.e., the input voltage Vin, thus offsetting the effect of the decreased supply voltage Vs. Through this dynamic adjustment, the sliding rheostat 21 acts as a voltage compensator, ensuring that the input voltage Vin across the varistor 22 remains stable regardless of fluctuations in the supply voltage Vs. This ensures that the tension sensor 16 operates under a stable input voltage, minimizing sensitivity changes caused by power supply fluctuations.

[0041] like Figure 4As shown, the drive motor 13 includes a rotor and a stator 132. The stator 132 includes an iron core 131, an annular ring with mounting slots, an armature winding 133 disposed in the mounting slots, and slot wedges 134. The iron core 131 is formed by stacking magnetic laminations, and the slot wedges 134 are made of copper plates. Both ends of the slot wedges 134 extend out of the mounting slots. One end of the slot wedges 134 is used for wiring with the armature windings 133, and the other end of the slot wedges 134 is used to change the current direction, reducing the need for additional terminals or commutator assemblies. All components on the rotor are encapsulated as a whole with high-temperature epoxy resin. The drive motor 13 is a DC torque motor, such as... Figure 5 As shown, the maximum armature current, along with the corresponding locked-rotor torque, armature voltage, and input power, that ensures a stable temperature rise of the DC torque motor within the specified ambient temperature during long-term operation is called the continuous locked-rotor current. Continuous stall torque Continuous stall voltage Continuous stall power The following relationship exists between them: ; ; In the formula: —Armature circuit resistance. Static characteristics of a linear torque motor: When the control voltage and load torque remain constant, and the current and speed of the linear torque motor reach stable values, the linear torque motor is said to be in a static state. The characteristics of the linear torque motor at this time are called static characteristics. The mechanical characteristics of a linear torque motor refer to the relationship between torque and speed under a certain input voltage, while the regulation characteristics refer to the relationship between output torque and armature voltage, such as... Figure 5 As shown.

[0042] Torque sensitivity: The characteristic curve of a DC torque motor has high linearity, and the output torque is directly proportional to the armature current. The ratio of the two is called torque sensitivity. The following relationship exists: .

[0043] like Figure 8 As shown, the formula for the armature circuit terminal voltage of a DC torque motor is: In the tension control system, the DC torque motor is actually in a reverse generating state under the drive of rope 10. The direction of the induced electromotive force is the same as that of the applied control voltage, and the magnitude of the induced electromotive force is directly proportional to the armature speed. Because the linear torque motor in the take-up reel 12 of the rope 10 is constantly alternating between stalled and forward operation, and the speed of the linear torque motor is constantly changing, the induced current generated by the induced electromotive force is considered as interference to the armature current circuit. When the magnetic flux of the permanent magnet motor remains constant, the electromagnetic torque is proportional to the armature current, that is: The motor driver 20 of the control component changes the armature current of the drive motor 13 to adjust the output torque of the drive motor 13. This eliminates the need for complex conversions, allowing for a more timely response to tension adjustment needs, improving the real-time performance and accuracy of tension control, and enabling faster tension adaptation during wire winding and unwinding. In the formula, the electromagnetic torque of the drive motor 13 is... In the figure, T t That is The armature current of drive motor 13 is , —Total armature circuit resistance —Armature circuit inductance —back potential constant, —Armature rotation speed.

[0044] The control principle diagram of the PWM drive device is as follows: Figure 7 As shown, control voltage The DC voltage is applied to the bridge power conversion circuit, and the high-power transistors V1-V4 are alternately turned on under the control of the control circuit, converting the DC voltage... The control circuit modulates a square wave pulse voltage with the same frequency as the given voltage and applies it to the two ends of the drive motor 13 to provide energy to the drive motor 13. The control circuit needs to have a ground terminal GND. The control circuit consists of a constant frequency waveform generator 24, a pulse width modulation circuit 25, a pulse distribution circuit 26, a base drive circuit 27, and a protection circuit 28. When the control signal voltage... When increased, it is related to a triangular wave voltage of a fixed frequency. The comparison produces a width and The proportionally modulated pulse voltage, after pulse transformation, increases the forward conduction time of the high-power transistor in the excitation main circuit of the base drive circuit 27, thereby increasing the average voltage across the drive motor 13, and thus increasing the voltage on the output bridge power conversion circuit. i1 -u i4 This changes the output torque of drive motor 13.

[0045] The tension of the take-up reel 12 is The pulling force of turntable 11 is ,when and When they are the same, it indicates that the wire rope is in force balance between the take-up reel 12 and the turntable 11. and Similarly, during system debugging or calibration, operators only need to ensure that the tension of both is consistent to confirm that the tension setting is in place, without the need to measure complex parameters, which greatly simplifies the initial setup and maintenance process of the equipment.

[0046] The winding tension of rope 10 is generated by the traction action of drive motor 13 on take-up reel 12, causing tension to be generated on rope 10 when it is on turntable 11. When taking rope 10 in place, the radius of the take-up reel 12 as it winds rope 10... The tension of rope 10 increases with the number of winding layers, affecting its tension. The linear density and length of rope 10 also influence its tension. When rope 10 accelerates, the tension increases; conversely, when it decelerates, the tension may decrease or even drop to zero. Therefore, in this embodiment, This allows the control system to more accurately match actual working conditions, thereby improving the stability and response speed of tension adjustment. Specifically, the real-time radius of the rope 10 on the take-up reel 12 is... The moment of inertia of the fixed pulley 14 is The linear density of rope 10 is The acceleration of rope 10 is The length of rope 10 is .

[0047] It should be noted that since the magnitude of acceleration has certain limits, we consider different situations of velocity change and take its limiting value, i.e., acceleration. Take three values: during acceleration. The value is 0 when moving at a constant speed and 0 when decelerating. . .

[0048] Furthermore, the rope 10 itself is elastic, and the situation is quite complex due to factors such as different impregnation methods, varying degrees of dryness and wetness, and the degree of adhesion between the rope 10 and the guide pulley being affected by random factors. A more comprehensive and realistic tension target expression was constructed, taking into account various frictional effects and dynamic inertial changes in the system. This allows tension control to not only reflect the current tension state but also more accurately predict and compensate for the effects caused by changes in motion state, differences in material properties, and mechanical structure response. The viscous friction torque of rope 10 is... The dry friction torque of rope 10 is The moment of inertia of the take-up reel 12 and the rope 10 is The linear velocity of rope 10 is .

[0049] The automatic take-up tension control system relies on rope 10 to provide tension transmission. The weight 23 is attached to the front end of rope 10, and it winds several times around the front turntable 11. Then, rope 10 passes through the front fixed pulley 14, the movable pulley 15, and the rear fixed pulley 14 before reaching the take-up reel 12. The rear end of rope 10 is fixed inside the take-up reel 12. When the front turntable 11 begins to pull the weight 23, the friction between the turntable 11 and rope 10 creates tension on one side of rope 10, pulling the weight 23. Simultaneously, the rear take-up reel 12 begins to rotate, and the friction between the take-up reel 12 and rope 10 creates tension on the other side of rope 10. The tension on both sides is ultimately transmitted to the tension sensor 16 through the movable pulley 15. When the left and right tensions are unbalanced, for example, the right side tension is greater than the left side tension, the movable pulley 15 tilts to the right due to the right side tension. At this point, the tension data collected by the tension sensor 16 is transmitted to the control component. The signal is amplified by the PWM pulse width modulation power amplifier 17, and the AD conversion circuit 18 converts the analog signal into a digital signal. The controller 19 then calculates the signal and outputs it to the motor driver 20. The motor driver 20 controls the drive motor 13 to control the take-up reel 12, causing it to accelerate or decelerate. Finally, tension balance is achieved. The movable pulley 15 is readjusted to the middle position by the tension, at which point the movable pulley 15 and the two fixed pulleys 14 form an isosceles triangle.

[0050] In addition to the preferred embodiments described above, the present invention has other embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection claimed by the present invention.

Claims

1. An automatic take-up tension control system, comprising a rope, a turntable, a take-up reel, and a drive motor for driving the take-up reel to rotate, wherein the fixed end of the rope is wound around the take-up reel, and the free end of the rope is wound around the turntable and used to connect a weight, characterized in that, The automatic take-up tension control system also includes a control component and a tension detection mechanism. Two fixed pulleys and a movable pulley located between the take-up reel and the turntable are provided. The rope between the take-up reel and the turntable is sequentially wound around the fixed pulleys and the movable pulley. The detection end of the tension detection mechanism is connected to the movable pulley. When the drive motor drives the take-up reel to rotate for take-up, the rope exerts tension on the movable pulley. The angle between the ropes on both sides of the movable pulley and the vertical direction is... and The tensile testing mechanism includes a component for detecting the included angle. and A level and a device for detecting the tension of the movable pulley. And transmits the data to the tension sensor of the control component, which calculates... And compare the current tension With target tension ,like and If there is a difference, the control component adjusts the output torque of the drive motor to make... and same.

2. The automatic take-up tension control system according to claim 1, characterized in that, The electromagnetic torque of the drive motor is The armature current of the drive motor is The torque sensitivity of the drive motor is , The control component changes the armature current of the drive motor to adjust the output torque of the drive motor.

3. The automatic take-up tension control system according to claim 2, characterized in that, The pulling force of the take-up reel is The tension of the turntable is ,when and At the same time, the and same.

4. The automatic take-up tension control system according to claim 3, characterized in that, The real-time radius of the rope on the take-up reel is: The moment of inertia of the fixed pulley is The linear density of the rope is The acceleration of the rope is The length of the rope is , .

5. The automatic take-up tension control system according to claim 3, characterized in that, The real-time radius of the rope on the take-up reel is: The acceleration of the rope is The length of the rope is The viscous friction torque of the rope is The dry friction torque of the rope is The moment of inertia of the take-up reel and the rope is The linear velocity of the rope is , .

6. The automatic take-up tension control system according to claim 1, characterized in that, The control component includes a PWM pulse width modulation power amplifier, an AD conversion circuit, a controller, and a motor driver. The tension data collected by the tension sensor is transmitted to the control component, amplified by the PWM pulse width modulation power amplifier, and converted from analog to digital by the AD conversion circuit. The controller then calculates the digital signal and outputs it to the motor driver, which controls the drive motor.

7. The automatic take-up tension control system according to claim 6, characterized in that, The tension sensor includes a sliding rheostat and a varistor connected in series with the sliding rheostat. By adjusting the sliding rheostat, the output voltage of the tension sensor changes proportionally to the input voltage.

8. The automatic take-up tension control system according to claim 1, characterized in that, The two fixed pulleys have the same diameter.

9. The automatic take-up tension control system according to claim 1, characterized in that, The movable pulley and the fixed pulley have the same diameter.

10. The automatic take-up tension control system according to claim 1, characterized in that, The drive motor includes a ring with a mounting slot, an armature winding disposed in the mounting slot, and a slot wedge. Both ends of the slot wedge extend out of the mounting slot. One end of the slot wedge is used to connect to the armature winding, and the other end of the slot wedge is used to change the direction of the current.

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