Cable secondary straightening device with real-time dynamic force feedback

Abstract

The invention discloses a cable secondary straightening device with a real-time dynamic force feedback function, and relates to the technical field of power construction tools. The device comprises a gun-shaped actuating mechanism and a control box which are separated from each other. The execution mechanism is driven by a servo gear motor and drives a quick-change clamping head at the front end to rotate through a transmission module. A dynamic torque sensor and a tension sensor are integrated in the device and used for monitoring torsion and axial tension in the straightening process in real time. A main control system in the control box receives signals of the sensors, real-time closed-loop control is carried out, and it is ensured that torsion and tension accurately conform to preset process parameters. By means of double-force real-time feedback, quick chuck replacement and ergonomics design, efficient, lossless and automatic cable straightening is achieved, and the problems that according to a traditional method, cables are prone to being damaged, and operation is inconvenient are effectively solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of power construction and maintenance tools, in particular to an automatic straightening device for secondary cables of a substation, which can dynamically feedback the torsion and tension in real time. BACKGROUND

[0002] In the cable wiring and maintenance work of a substation, straightening the secondary cable with multiple conductors is a key step to ensure reliable connection. The traditional straightening method mainly relies on manual operation, which has the problems of high labor intensity, low efficiency and easy damage to the cable core or insulation due to uneven force. At present, some electric cable straighteners on the market have achieved mechanization to some extent, but they generally have low automation, lack high-precision mechanical feedback, and have limited application range. Although some of the devices are equipped with sensors, they still rely on the experience of operators and cannot achieve real-time collaborative control and intelligent feedback of torsion and tension, making it difficult to achieve efficient and accurate straightening without damaging the cable. SUMMARY

[0003] The present application aims to overcome the shortcomings of the prior art and provide a secondary cable straightening device with real-time dynamic force feedback. The device uses high-precision sensors and a closed-loop control system to achieve accurate control and real-time protection of torsion and tension during straightening, solving the problems of low automation, easy damage to the cable, narrow application range and inconvenient operation of existing devices.

[0004] To this end, the present application provides a secondary cable straightening device with real-time dynamic force feedback, which comprises an execution mechanism and a control box arranged separately; the execution mechanism comprises a bottom plate, a servo reduction motor arranged on the bottom plate, a transmission module driven by the servo reduction motor, a quick-change clamping head for clamping the cable connected to the end of the transmission module, a dynamic torque sensor for real-time detection of the torsion applied to the cable, and a tension sensor for real-time detection of the axial tension applied to the cable; The control box is provided with a main control upper computer and a power supply module, the main control upper computer is signal connected with the dynamic torque sensor, the tension sensor and the servo reduction motor, for receiving the feedback signal of the sensor and performing closed-loop control on the servo reduction motor.

[0005] Preferably, the transmission module comprises a driving shaft and a driven shaft connected by belt transmission, chain transmission or gear transmission.

[0006] Preferably, the dynamic torque sensor is connected in series with the coupling two and the coupling one in the transmission path of the driven shaft, located between the servo reduction motor and the quick-change clamping head.

[0007] Preferably, the bottom plate is slidably connected with the handle seat for handheld through a guide rail and sliding block assembly; and the tension sensor is arranged between the bottom plate and the handle seat to detect the axial tension generated when the two relative slide.

[0008] Preferably, the guide rail and sliding block assembly comprises a sliding rail mounted on the handle seat and a pair of sliding blocks mounted on the bottom plate.

[0009] Preferably, the tension sensor is mounted on the bottom plate through a sensor fixing seat, and the detection end of the tension sensor is connected with the handle seat.

[0010] Preferably, the quick-change clamping head is of a replaceable structure and is configured with multiple specifications to adapt to cables of different diameters, and the inner wall thereof is designed to wrap around the outer surface of the cable to achieve non-damage clamping.

[0011] Preferably, the master control upper computer has a process parameter storage and calling function and can preset and store corresponding straightening torque values, tension values and alarm threshold values according to the cable diameter.

[0012] Preferably, when the values detected by the dynamic torque sensor or the tension sensor exceed the corresponding preset alarm threshold values, the master control upper computer can trigger an alarm signal and control the servo reduction motor to adjust or stop running.

[0013] Preferably, the execution mechanism is in a gun-shaped layout as a whole, and the control box is connected with the execution mechanism through a cable.

[0014] The cable secondary straightening device with real-time dynamic force feedback provided by the application has the following beneficial effects: 1) through the dynamic torque sensor and the tension sensor, dual real-time monitoring and closed-loop control of the torque and tension during the straightening process are realized, the straightening accuracy is ensured, and cable damage caused by over-torque or over-tension is effectively prevented. 2) The quick-change clamping head design can quickly adapt to cables of different diameters, and the wrapping clamping mode can evenly distribute the clamping force to avoid damage to the surface of the cable. 3) The gun-shaped design and the separation of the execution mechanism and the control box significantly reduce the handheld weight and labor intensity of the operator and facilitate one-handed operation. 4) When the monitored torque or tension value exceeds the preset safety range, the system can timely alarm and automatically adjust or stop the motor running, providing double safety protection.

[0015] In addition to the purposes, features and advantages described above, the present application has other purposes, features and advantages. The present application will be further described in detail below with reference to the drawings. BRIEF DESCRIPTION OF DRAWINGS

[0016] The drawings accompanying the specification of this application serve as further description of the application in which: Figure 1 Structure diagram of cable secondary straightening device with real-time dynamic force feedback of the present application Figure 1 ; Figure 2 Structure diagram of cable secondary straightening device with real-time dynamic force feedback of the present application Figure 2 ; Legend: 1, quick-change clamping head; 2, shaft coupling I; 3, dynamic torque sensor; 4, shaft coupling II; 5, servo reduction motor; 6, motor mounting bracket; 7, synchronous belt; 8, synchronous wheel; 9, support bearing seat; 10, bottom plate; 11, sliding block; 12, handle seat; 13, tension sensor; 14, sensor fixing seat; 15, handle shell; 16, rotating seat; 17, cable; 18, fixed end; 19, control box. DETAILED DESCRIPTION

[0017] It should be noted that the embodiments in the present application and the features in the embodiments can be combined with each other without conflict. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0018] As shown in Figures 1-2 , the cable secondary straightening device with real-time dynamic force feedback of the present application comprises an actuator and a control box 19; the actuator adopts a gun-type design and is separated from the control box to reduce the weight of the handheld part.

[0019] The actuator comprises a power module, a transmission module, a torque detection module, a clamping module, and a tension detection module. Among them, the power module: provides rotary power by a servo reduction motor. The transmission module: transmits power to the execution end through synchronous belt, synchronous wheel, and shaft coupling. The torque detection module: a dynamic torque sensor is connected in series on the transmission path, which is used to monitor and feedback the torque value applied on the cable in real time.

[0020] The clamping module: the front end is provided with a quick-change clamping head, which is used to adapt and clamp cable harnesses of different diameters, and is designed not to damage the harness. The tension detection module: the entire power and transmission module is installed on a bottom plate, which is connected with the handle seat through a guide rail sliding block assembly; a tension sensor is arranged between the bottom plate and the handle seat, which is used to monitor and feedback the axial tension value applied on the cable in real time. The actuator as a whole adopts a gun-type layout, and the control box is connected with the actuator through a cable.

[0021] The control box is internally provided with a main control host computer and a power supply module, the main control host computer is signal connected with the dynamic torque sensor, the tension sensor and the servo reduction motor, is used for receiving the feedback signal of the sensor and performing closed loop control on the servo reduction motor. The main control host computer has process parameter storage and calling function, can preset and store corresponding straightening torque value, tension value and alarm threshold according to the cable diameter.

[0022] Specifically, the bottom plate 10 is provided with a quick-change clamping head 1, a rotating seat 16, a coupling 2, a dynamic torque sensor 3, a coupling 4, a support bearing seat 9 and a synchronous wheel 8 which are sequentially transmission connected at the upper end of the bottom plate 10; the synchronous wheel 8 and the rotating seat 16 are supported by the support bearing seat 9 respectively, the support bearing seat 9 is provided with a servo reduction motor 5 at the upper end through a motor mounting frame 6, the servo reduction motor 5 drives the driving shaft and the driven shaft through the synchronous wheel 8 and the synchronous belt 7, and the rotating power is transmitted to the quick-change clamping head 1 to straighten the cable 17 clamped at the front end of the quick-change clamping head 1.

[0023] The quick-change clamping head 1 is a quick-change clamping head used for clamping drill bits and milling cutters in machining, which has the same structure. Different quick-change clamping heads 1 are suitable for cables of different diameters, so that the outer surface of the cable is almost completely wrapped. However, if a variable-diameter clamping head of the same specification is used to clamp a large-diameter cable, the outer surface of the cable will inevitably have a position that is not under stress, which may cause damage to the outer skin of the cable or even the core of the cable during the straightening process.

[0024] The bottom plate 10 is provided with a guide rail sliding block assembly extending along the length direction at the lower end, so that the bottom plate 10 is slidably connected with the handle seat 12 through the guide rail sliding block assembly. Meanwhile, the bottom plate 10 is provided with a tension sensor 13 at the lower end through a sensor fixing seat 14. The detection end of the tension sensor 13 is connected with the handle seat 12, so that the axial tension generated by the sliding of the bottom plate 10 relative to the handle seat 12 can be measured. The guide rail sliding block assembly includes a sliding rail installed on the handle seat 12 and a pair of sliding blocks 11 installed on the bottom plate 10. Meanwhile, the handle seat 12 is provided with an ergonomic handle shell 15 on the outside, which is convenient for the operator to hold tightly.

[0025] During the cable straightening process, the quick-change clamping head 1 is replaced according to the diameter of the cable, one end of the cable 17 is clamped through the quick-change clamping head 1, the fixed end 18 of the cable 17 is fixed through other structures, and then the servo reduction motor 5 transmits power to the quick-change clamping head 1 through the synchronous wheel 8, the synchronous belt 7, the coupling 4, the dynamic torque sensor 3, the coupling 2, the rotating seat 16 and the quick-change clamping head 1 in sequence to rotate and tighten the cable 17. The dynamic torque sensor 3 measures the torque in the rotating and tightening process to determine whether it exceeds the set value, and outputs a control signal and an alarm signal to the servo reduction motor 5.

[0026] During the screwing process, the worker holds the handle seat 12 and pulls it backward, giving the cable 17 an axial pulling force, the bottom plate 10 slides relative to the handle seat 12, and the pulling force sensor 13 monitors the pulling force applied to the cable 17. High-precision sensors are used to collect and monitor the pulling force value and the torque value in real time, and precise operation is achieved through feedback control. After real-time filtering and processing of the collected signals, the main control upper computer is fed, the pulling force and the torque are calculated in real time, and the motion state of the motor is accurately controlled, so that the best straightening effect is achieved.

[0027] During the straightening process of the cable, accurate torque needs to be applied to the wire to ensure that the cable is not over-tightened. The device can collect the straightening torque value and communicate with the upper computer to control the motor current and adjust the straightening torque in real time. While rotating and straightening, the pulling force sensor actually detects the cable pulling force value, and timely alarm is prompted when the set value is exceeded to avoid damaging the cable. The device can complete the holding of different diameter wire harnesses without damaging the wire harness by quickly replacing the clamping head. The gun-type design separates the actuator from the control box, reducing the weight of the actuator and the labor intensity of single-handed operation. The control system has a process parameter storage and calling function, and can preset the straightening parameters according to the cable diameter.

[0028] The core principle of the cable secondary straightening device is to accurately control the pulling force and torque of the cable wire through a servo drive system and high-precision dynamic torque detection device and pulling force measurement device, so as to realize effective straightening of the cable wire. At the same time, the design of replacing the clamping head can adapt to different wire diameters without damaging the wire harness, and the automatic straightening of the cable wire can be completed according to the set process parameters.

[0029] In another implementation, the servo reduction motor 5 in the transmission module drives the driving shaft and the driven shaft through the synchronous wheel 8 and the synchronous belt 7. It can also be driven by a chain wheel and a chain, or a transmission gear is installed on the driving shaft and the driven shaft to realize the transmission function.

[0030] The working principle of the cable secondary straightening device with real-time dynamic force feedback of the present application is briefly described below.

[0031] The cable secondary straightening device proposed in the present application has the core function of straightening the multiple wires in the secondary cable through the electric straightening device without damaging the single wire, thereby improving the work efficiency in the cable wiring process. The structure develops a device that uses a controllable DC motor to provide radial pulling force and rotary torque, ensuring that the straightening operation of the cable wire is accurate and does not damage the single wire.

[0032] The cable secondary straightening device provided by the application simultaneously introduces high-precision torque and tension sensors, dynamically collects rotating torque and wire harness tension in real time, and the operation interface can call preset torque and tension values; the straightening device also completes the clamping of wire harnesses of different diameters without damaging the wire harnesses through the mode of quickly replacing the clamping head; the power supply module device provides stable operating power, ensuring the normal operation of the entire system under different load conditions. The overall debugging and optimization of the equipment, the optimization of the control algorithm, and the high efficiency and stability of the equipment under various working conditions are ensured.

[0033] The above only describes the preferred embodiments of the present application and is not intended to limit the present application. Those skilled in the art can make various changes and modifications to the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A cable secondary straightening device with real-time dynamic force feedback, characterized in that, This includes separately configured actuators and control boxes; The actuator includes a base plate (10), a servo geared motor (5) mounted on the base plate (10), a transmission module driven by the servo geared motor (5), a quick-change clamping head (1) connected to the end of the transmission module for clamping the cable (17), a dynamic torque sensor (3) for real-time detection of the torque applied to the cable (17), and a tension sensor (13) for real-time detection of the axial tension applied to the cable (17). The control box contains a main control host computer and a power supply module. The main control host computer is connected to the dynamic torque sensor (3), the tension sensor (13) and the servo geared motor (5) for receiving feedback signals from the sensors and performing closed-loop control on the servo geared motor (5).

2. The cable secondary straightening device with real-time dynamic force feedback according to claim 1, characterized in that, The transmission module includes a drive shaft and a driven shaft that are driven by belt, chain, or gear.

3. The cable secondary straightening device with real-time dynamic force feedback according to claim 2, characterized in that, The dynamic torque sensor (3) is connected in series in the transmission path of the driven shaft through coupling two (4) and coupling one (2), and is located between the servo geared motor (5) and the quick-change clamping head (1).

4. The cable secondary straightening device with real-time dynamic force feedback according to claim 1, characterized in that, The base plate (10) is slidably connected to the handle seat (12) for hand use via a guide rail slider assembly; and the tension sensor (13) is disposed between the base plate (10) and the handle seat (12) to measure the axial tension generated when the two slide relative to each other.

5. The cable secondary straightening device with real-time dynamic force feedback according to claim 4, characterized in that, The guide rail slider assembly includes a slide rail mounted on the handle seat (12) and a pair of sliders (11) mounted on the base plate (10).

6. The cable secondary straightening device with real-time dynamic force feedback according to claim 4, characterized in that, The tension sensor (13) is mounted on the base plate (10) via a sensor mounting base (14), and the detection end of the tension sensor (13) is connected to the handle base (12).

7. The cable secondary straightening device with real-time dynamic force feedback according to claim 1, characterized in that, The quick-change clamping head (1) is a replaceable structure and is available in various specifications to accommodate cables (17) of different diameters. Its inner wall is designed to wrap around the outer surface of the cable (17) to achieve non-damaging clamping.

8. The cable secondary straightening device with real-time dynamic force feedback according to claim 1, characterized in that, The host computer has the function of storing and recalling process parameters, and can preset and store the corresponding straightening torque value, tensile force value and alarm threshold according to the cable diameter.

9. The cable secondary straightening device with real-time dynamic force feedback according to claim 8, characterized in that, When the value detected by the dynamic torque sensor (3) or the tension sensor (13) exceeds its corresponding preset alarm threshold, the host computer can trigger an alarm signal and control the servo geared motor (5) to adjust or stop running.

Images