Secondary cable replacement gripper and non-power-cut replacement control system

Abstract

The invention relates to the field of non-power-cut maintenance, in particular to a secondary cable replacement gripper and a non-power-cut replacement control system. The mechanical gripper 1 is fixedly connected with the tail end of the insulating operating rod 11 and comprises a clamping mechanism 12, a rotating mechanism 13 and a control box 14, and a rotating motor 142 is mounted in the control box 14; the remote controller 2 is in electric control connection with the mechanical gripper 1. The data sensing module 4 comprises a torque sensing unit 41 and a pressure sensing unit 42; the motor control module 5 comprises a rotating motor 142 and a clamping motor 143; the main control circuit module 3 is electrically connected with the torque sensing unit 41, the pressure sensing unit 42, the rotating motor 142 and the clamping motor 143. According to the invention, the replacement time of the secondary cable is shortened from several days to several minutes through the non-power-off replacement technology and device, the unplanned power failure frequency and duration are reduced, the remote control and insulation operation design is adopted, an operator can work in a safe area several meters away from live-line equipment, the electric shock risk is completely eradicated, and the working efficiency is improved. And the clamping mechanism ensures accurate and firm clamping.

Description

Technical Field

[0001] This invention relates to the field of uninterrupted power supply maintenance, and in particular to a secondary cable replacement gripper and an uninterrupted power supply replacement control system. Background Technology

[0002] In the field of power distribution automation, secondary cables are a key component for the normal operation of power distribution automation terminals, responsible for transmitting control signals and data to ensure the monitoring and management of the power distribution network.

[0003] Currently, replacing secondary cables in power distribution automation terminals faces multiple technical challenges. First, because the aviation connectors of secondary cables are typically located near live parts of the primary equipment, replacement requires power outages or the construction of complex bypass systems to ensure safety. This process, from fault detection to completion, usually takes at least a week, resulting in low efficiency, severely impacting the continuous operation of the power distribution system, leading to power outages and significant economic losses. Second, traditional replacement methods require maintenance personnel to work near live equipment, posing a high risk of electric shock and personal safety hazards.

[0004] Furthermore, manual operation, limited by confined working spaces, limited field of vision, and operator fatigue, is prone to unstable clamping or improper tightening torque of nuts, leading to problems such as poor contact or thread damage, thus affecting the long-term reliability of secondary cable connections. These issues collectively result in low maintenance efficiency, high safety risks, and unstable connection quality.

[0005] Therefore, there is a need for a secondary cable replacement gripper and uninterrupted power replacement control system that can significantly improve maintenance efficiency, greatly increase the safety rate of operations, improve operational accuracy and adaptability, and is easy to use and highly adaptable to meet the needs of the current environment. Summary of the Invention

[0006] The purpose of this section is to outline some aspects of the embodiments of the present invention and to briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this section, as well as in the specification abstract and the title of the invention, to avoid obscuring the purpose of this section, the specification abstract, and the title of the invention. Such simplifications or omissions shall not be used to limit the scope of the invention.

[0007] Given that the traditional replacement process is inefficient, poses a significant risk of electric shock and personal safety hazards, and that manual operation is limited by narrow working spaces and limited field of vision, the aforementioned existing technologies are problematic.

[0008] Therefore, the technical problem to be solved by the present invention is to design a secondary cable replacement gripper and a non-power-off replacement control system that can significantly improve maintenance efficiency, greatly increase the safety rate of operation, improve operational accuracy and adaptability, and is simple to use and highly adaptable to meet the needs of the existing environment.

[0009] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a secondary cable replacement gripper, comprising, Mechanical gripper and remote control; The mechanical gripper is fixedly connected to the end of an insulated operating rod and includes a clamping mechanism, a rotating mechanism, and a control box. A rotary motor is installed inside the control box. The remote control is fixed to the handheld end of the insulated operating rod and is electrically connected to the mechanical gripper to control the clamping and rotating mechanisms.

[0010] As an improvement of the present invention, The mechanical gripper also includes a transfer platform, which securely connects the mechanical gripper to the insulated operating rod. The rotating mechanism is installed at one end of the clamping mechanism and is driven by a rotary motor to rotate the nut.

[0011] As an improvement of the present invention, A rotary motor is fixedly connected to a drive wheel, and a driven wheel is meshed with the drive wheel. The driving wheel and driven wheel are located inside the transfer platform, and the driving wheel and driven wheel mesh with the rotating mechanism.

[0012] As an improvement of the present invention, The control box is electrically connected to the clamping motor, which is mounted at one end of the clamping mechanism to drive the clamping action. A limit switch is fixedly installed on one side of the clamping motor to limit the clamping action and prevent damage to the device.

[0013] Given that the existing technologies mentioned above are limited by narrow working space, limited field of vision and operator fatigue, they are prone to unstable clamping or improper tightening torque of nuts, which can lead to problems such as poor contact or thread damage, affecting the long-term reliability of secondary cable connections.

[0014] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a power-off switching control system, comprising, Main control circuit module, data sensing module and motor control module; The data sensing module includes a torque sensing unit and a pressure sensing unit, and the motor control module includes a rotary motor and a clamping motor. The main control circuit module is electrically connected to the torque sensing unit, pressure sensing unit, rotary motor and clamping motor to realize data acquisition and processing and motor drive control. The main control circuit module is connected to the remote control via a wireless communication module.

[0015] As an improvement of the present invention, The main control circuit module includes an MCU, a signal conditioning circuit, a motor drive circuit, and a wireless communication circuit; The MCU acts as the control center, electrically connected to the signal conditioning circuit, motor drive circuit, and wireless communication circuit; it is responsible for the acquisition, processing, and transmission and reception of torque and pressure signals.

[0016] As an improvement of the present invention, One end of the signal conditioning circuit is connected to the torque sensing unit and the pressure sensing unit, and the other end is connected to the MCU; The signal conditioning circuit converts the signals from the torque sensing unit and the pressure sensing unit into the MCU for acquisition. The torque sensing unit and pressure sensing unit are connected to and acquire signals from the rotary motor and clamping motor, respectively, and then output the signals.

[0017] As an improvement of the present invention, One end of the motor drive circuit is connected to the clamping motor and the rotary motor, and the other end is connected to the MCU. The motor drive circuit converts the PWM signal of the MCU to realize the rotation control of the clamping motor and the rotary motor; The wireless communication circuit is located between the wireless communication module and the MCU to enable communication.

[0018] As an improvement of the present invention, The remote control includes a slave control module, which contains a slave MCU and a slave wireless communication circuit that are compatible with the master control circuit module. The slave control module includes a power supply circuit, a power supply circuit connected to the slave MCU, a slave wireless communication circuit, and a button circuit; After receiving a manual action signal, the button circuit transmits the command to the main control circuit module through the slave control module and the slave wireless communication circuit. The battery is connected to the power supply circuit.

[0019] The beneficial effects of this invention are as follows: By using uninterrupted power replacement technology, the device reduces the replacement time of secondary cables from several days to several minutes, significantly reducing the number and duration of unplanned power outages. With remote control and insulated operation design, operators can work in a safe area several meters away from live equipment, fundamentally eliminating the risk of electric shock. The clamping mechanism ensures the accuracy and firmness of clamping, and the automatic torque adjustment function intelligently adjusts the tightening force according to different screw specifications to avoid poor contact or thread stripping problems. Single-person operation simplifies the work process, and it can also adapt to various aviation connector specifications. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Wherein: Figure 1 This is a hardware architecture diagram of the secondary cable replacement gripper in this invention.

[0021] Figure 2 This is a partial connection diagram of the secondary cable replacement gripper in this invention.

[0022] Figure 3 This is a diagram of the internal transmission structure of the secondary cable replacement gripper in this invention.

[0023] Figure 4 This is a block diagram of the electrical system control for the uninterrupted power replacement control system in this invention.

[0024] Figure 5 This is a block diagram of the main control circuit module of the uninterrupted power replacement control system in this invention.

[0025] Figure 6 This is a control block diagram of the remote control system for the uninterrupted power replacement control system in this invention.

[0026] Figure 7 This is a schematic diagram of the MCU circuit for the uninterrupted power replacement control system in this invention.

[0027] Figure 8 This is a schematic diagram of the signal conditioning circuit of the uninterrupted power replacement control system in this invention.

[0028] Figure 9 This is a schematic diagram of the motor drive circuit of the uninterrupted power replacement control system in this invention.

[0029] Figure 10 This is a schematic diagram of the wireless communication circuit of the uninterrupted power replacement control system in this invention.

[0030] Figure 11 This is a schematic diagram of the torque sensing unit circuit of the uninterrupted power replacement control system in this invention.

[0031] Figure 12 This is a schematic diagram of the slave MCU circuit of the uninterrupted power replacement control system in this invention.

[0032] Figure 13 This is a schematic diagram of the slave wireless communication circuit of the uninterrupted power replacement control system in this invention.

[0033] Figure 14 This is a schematic diagram of the power supply circuit of the uninterrupted power replacement control system in this invention.

[0034] Figure 15 This is a schematic diagram of the button circuit of the uninterrupted power replacement control system in this invention. Detailed Implementation

[0035] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0036] As one embodiment provided, Reference Figures 1-6 This embodiment provides a secondary cable replacement gripper.

[0037] This embodiment provides a secondary cable replacement gripper, facilitating the uninterrupted disassembly and installation of aviation connectors for secondary cables in power distribution automation terminals. Through the coordinated design of the mechanical gripper 1 and remote controller 2, combined with the insulated operating rod 11, this gripper allows operators to remotely control the operation from a safe distance, avoiding the power outages and safety hazards caused by proximity to live parts in traditional methods. The entire gripper is compact and lightweight, making it easy to carry and operate on-site, significantly improving maintenance efficiency and safety.

[0038] The mechanical gripper 1 is fixedly connected to the end of the insulated operating rod 11. It is connected by a special threaded or snap-fit ​​structure to ensure a stable installation, withstand torque and tension during operation, prevent electrical conduction, and ensure the insulation isolation between the operator and the live equipment.

[0039] The main components of the mechanical gripper 1 include a clamping mechanism 12, a rotating mechanism 13, and a control box 14. The clamping mechanism 12 is designed to link the gripper to a clamping motor 143 via a linkage mechanism. When the clamping motor 143 receives a control signal, the gripper retracts evenly towards the center, achieving precise clamping of the aviation connector. This ensures a uniform distribution of clamping force and avoids slippage or damage caused by eccentricity in traditional manual clamping, thereby improving operational accuracy and connection reliability.

[0040] The rotating mechanism 13 and clamping mechanism 12 are integrated into a compact execution unit. The internal drive of the rotating mechanism 13 is connected to the rotary motor 142 via gear transmission. After the clamping mechanism 12 completes clamping, the rotating mechanism 13 can drive the rotary motor 142 to rotate forward or reverse according to the control signal, thereby tightening or loosening the nut. The rotary motor 142 is installed inside the control box 14 and uses a high-torque, low-speed DC motor. Real-time monitoring by the built-in torque sensing unit 41 ensures that the tightening torque is compatible with different specifications of aviation connectors, preventing excessive tightening that could cause thread stripping or excessive loosening that could lead to poor contact. This integrated design links the actions of the rotating mechanism 13 and the clamping mechanism 12, allowing clamping before rotation, thus avoiding the risk of loosening during operation.

[0041] The control box 14, as the core control and power unit of the mechanical gripper 1, is located at the rear end of the clamping mechanism 12 and the rotating mechanism 13. It is protected by a sealed and insulated shell and contains components such as the rotating motor 142, the clamping motor 143, the main control circuit module 3, and supporting sensors.

[0042] The control box 14 also integrates a torque sensing unit 41 and a pressure sensing unit 42. The pressure sensing unit 42 is installed at the base of the jaws of the clamping mechanism 12 to collect the clamping force in real time. The collected clamping force data will be converted into a digital signal by the signal conditioning circuit 32 and fed back into the main control circuit module 3. The torque sensing unit 41 is set on the output shaft of the rotary motor 142 to monitor the real-time torque value. The data processing of the main control circuit module 3 is mainly based on the MCU 31, integrating the signal conditioning circuit 32, the motor drive circuit 33, and the wireless communication circuit 34.

[0043] The remote control 2 is fixed to the handheld end of the insulated operating rod 11. It features an ergonomic design, is lightweight and non-slip, and is easy to hold with one hand. The remote control 2 has a built-in battery 75 and a slave MCU 71. The slave MCU 71 works in conjunction with the MCU 31 in the main control circuit module 3. The remote control 2 uses a built-in button circuit 74 to perform multiple operational functions, such as "clamp," "release," "forward," "reverse," and "stop." After a button is pressed, the control signal from the slave MCU 71 is input to the wireless communication circuit 34 of the mechanical gripper 1 via the slave wireless communication circuit 72, establishing an electrical connection between the two.

[0044] In the actual workflow, the operator first aligns the mechanical gripper 1 with the aviation connector of the secondary cable, and presses the "clamp" button via remote control 2. The clamping mechanism 12, driven by the clamping motor 143, self-centers and clamps the connector. The pressure sensing unit 42 automatically stops after detecting the preset pressure. Next, the operator presses the "reverse" button, and the rotating mechanism 13 drives the rotating motor 142 to loosen the nut. The torque sensing unit 41 ensures a smooth loosening process, preventing damage to the equipment from sudden torque. After removing the old cable, similar steps are repeated to install the new cable, and finally, the nut is tightened to the appropriate torque. The entire process requires no power outage and can be completed by a single operator within minutes, improving work efficiency.

[0045] As one embodiment provided, Reference Figures 1-3 This embodiment is based on the previous embodiment, and differs from the previous embodiment in that: The mechanical gripper 1 is fixedly mounted with a transfer platform 15. In this design, the transfer platform 15 has a rectangular structure and its surface is covered with an insulating coating to enhance electrical isolation performance. The transfer platform 15 connects the mechanical gripper 1 to the insulated operating rod 11 via quick-release clips or bolts. One end of the transfer platform 15 has a standardized interface for easy assembly or disassembly with insulated operating rods 11 of different lengths; the other end integrates a mounting base for the clamping mechanism 12 and the rotating mechanism 13, ensuring a compact overall structure and balanced center of gravity, preventing shaking during operation from affecting accuracy.

[0046] The rotating mechanism 13 is mounted at one end of the clamping mechanism 12 and is driven by a rotary motor 142 to rotate the aviation connector nut. The rotary motor 142 is fixedly connected to a drive wheel 1421, which is meshed with a driven wheel 1422. Both the drive wheel 1421 and the driven wheel 1422 are housed within the transfer platform 15 and fixed by bearings to reduce friction loss. They mesh with the output shaft of the rotating mechanism 13 for transmission. The output end of the driven wheel 1422 is connected to a flexible coupling, which then drives the sleeve portion of the rotating mechanism 13 to achieve clockwise or counterclockwise rotation. The entire transmission system is similar to a closed gearbox design; the multi-stage meshing structure improves torque output efficiency, reduces motor load, and extends the service life of the rotary motor 142.

[0047] The control box 14 is electrically connected to the clamping motor 143, enabling precise driving of the clamping mechanism 12. The clamping motor 143 is mounted at one end of the clamping mechanism 12, driving the opening and closing of the clamping jaws. The clamping mechanism 12 employs a double-jaw parallel clamping design, easily adapting to various aviation connector specifications. A limit switch 144 is fixedly mounted on one side of the clamping motor 143, installed at the end of the clamping jaw's stroke. When the clamping action reaches a preset position, the limit switch 144 triggers a disconnect signal, immediately stopping the motor's movement to prevent over-clamping and damage to the device or connector.

[0048] As one embodiment provided, Reference Figures 1-15 This embodiment is based on the previous embodiment, and differs from the previous embodiment in that: The uninterrupted power replacement control system integrates the main control circuit module 3, the data sensing module 4, and the motor control module 5, forming a complete closed-loop control network.

[0049] The main control circuit module 3 is electrically connected to the torque sensing unit 41, the pressure sensing unit 42, the rotary motor 142, and the clamping motor 143, and realizes signal transmission and power distribution through a dedicated interface.

[0050] The data sensing module 4 includes a torque sensing unit 41 and a pressure sensing unit 42. The torque sensing unit 41 is mounted on the output shaft of the rotary motor 142 and is used to collect torque signals in real time during the tightening / loosening process. The pressure sensing unit 42 is connected to the claw contact surface embedded in the clamping mechanism 12 and is used to monitor the dynamic changes in clamping force.

[0051] Both torque sensing unit 41 and pressure sensing unit 42 can be connected to the main control circuit module 3 via shielded cables. The motor control module 5 includes a rotary motor 142 and a clamping motor 143. The main control circuit module 3 is connected to the remote controller 2 via a wireless communication module 6 to achieve two-way communication for command issuance and status feedback.

[0052] The main control circuit module 3 is internally divided into an MCU 31, a signal conditioning circuit 32, a motor drive circuit 33, and a wireless communication circuit 34. These sub-circuits are tightly integrated through a multi-layer PCB layout to reduce signal delay. The MCU 31, as the control center, has multiple built-in I / O ports and is electrically connected to the signal conditioning circuit 32, the motor drive circuit 33, and the wireless communication circuit 34.

[0053] The MCU31 is responsible for acquiring and processing torque and pressure signals, logic control, and signal transmission and reception. Overload is avoided. One end of the signal conditioning circuit 32 is connected to the torque sensing unit 41 and the pressure sensing unit 42, and the other end is connected to the corresponding pin of the MCU31. The signal conditioning circuit 32 uses an operational amplifier and filter capacitor components to convert the current signal output by the sensor into a voltage signal and performs low-pass filtering to remove high-frequency noise, ensuring the accuracy of the data acquired by the MCU31. The torque sensing unit 41 and the pressure sensing unit 42 are respectively connected to and acquire the real-time signals of the rotary motor 142 and the clamping motor 143, and output them to the signal conditioning circuit 32, forming a feedback closed loop.

[0054] One end of the motor drive circuit 33 is connected to the clamping motor 143 and the rotary motor 142, and the other end is connected to the output pin of the MCU 31. The motor drive circuit 33 can convert the PWM signal generated by the MCU 31 into appropriate voltage and current, thereby realizing the rotation control of the motor. The wireless communication circuit 34 is located between the wireless communication module 6 and the MCU 31. It adopts a serial communication interface and is responsible for data encoding, decoding and modulation to achieve reliable wireless communication.

[0055] The remote control 2 includes a slave control module 7, which has a built-in slave MCU 71 and slave wireless communication circuit 72. The slave MCU 71 is responsible for local signal processing and works in conjunction with MCU 31. The slave control module 7 also includes a power supply circuit 73, which is connected to the slave MCU 71, the slave wireless communication circuit 72, and the button circuit 74.

[0056] The button circuit 74 consists of multiple touch or mechanical buttons, receives manual action signals, and encodes the commands into data packets via the slave control module 7 and slave wireless communication circuit 72, transmitting them to the main control circuit module 3. The battery 75 is connected to the power supply circuit 73 and supports USB charging, ensuring continuous operation of the remote control 2.

[0057] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A secondary cable replacement gripper characterized by: The utility model relates to a secondary cable replacement control system, including, Mechanical grab hand (1) and remote controller (2); Mechanical grab hand (1) fixed connection insulating operating rod (11) end, including clamping mechanism (12), rotating mechanism (13) and control box (14), control box (14) inside installation has rotating motor (142); Remote controller (2) is fixed in insulating operating rod (11) hand -held end, with mechanical grab hand (1) electric control connection, realizes the control to clamping mechanism (12) and rotating mechanism (13).

2. The secondary cable replacement grab hand according to claim 1, wherein: Mechanical grab hand (1) further includes adapter platform (15), and the adapter platform (15) is fixedly connected with the insulating operating rod (11) and the mechanical grab hand (1); Rotating mechanism (13) is installed at one end of clamping mechanism (12), and rotating mechanism (13) is driven by rotating motor (142), to realize the rotation of the nut.

3. The secondary cable replacement grab hand according to claim 2, wherein: Rotating motor (142) is fixedly connected with driving wheel (1421), and driving wheel (1421) is engaged with driven wheel (1422); Driving wheel (1421) and driven wheel (1422) are arranged in adapter platform (15), and driving wheel (1421) and driven wheel (1422) are engaged with rotating mechanism (13).

4. The secondary cable replacement grab hand according to claim 2 or 3, wherein: Control box (14) is electrically connected with clamping motor (143), and clamping motor (143) is installed at one end of clamping mechanism (12) to drive clamping action; Limit switch (144) is fixedly installed on one side of clamping motor (143) to limit detection of clamping action to prevent damage to the device.

5. An unpowered replacement control system, characterized by: The secondary cable replacement grab hand according to claim 4, and Master control circuit module (3), data sensing module (4) and motor control module (5); Data sensing module (4) includes torque sensing unit (41) and pressure sensing unit (42), and motor control module (5) includes rotating motor (142) and clamping motor (143); Master control circuit module (3) is electrically connected with torque sensing unit (41), pressure sensing unit (42), rotating motor (142) and clamping motor (143) to realize data acquisition and processing and motor drive control; Master control circuit module (3) is connected with remote controller (2) through wireless communication module (6).

6. The non-power-off replacement control system according to claim 5, wherein: Master control circuit module (3) includes MCU (31), signal conditioning circuit (32), motor drive circuit (33) and wireless communication circuit (34); MCU (31) is used as a control center and is electrically connected with signal conditioning circuit (32), motor drive circuit (33) and wireless communication circuit (34) to provide acquisition and processing of torque and pressure signals and signal transceiving.

7. The non-power-off replacement control system according to claim 6, wherein: One end of signal conditioning circuit (32) is connected with torque sensing unit (41) and pressure sensing unit (42), and the other end is connected with MCU (31). Signal conditioning circuit (32) converts torque sensor unit (41) and pressure sensor unit (42) signal input MCU (31) acquisition; Torque sensor unit (41) and pressure sensor unit (42) are connected respectively and collect rotary motor (142) and clamping motor (143) signal and export.

8. The control system of claim 6 or 7, wherein: Motor drive circuit (33) one end connects clamping motor (143) and rotary motor (142), the other end accesses MCU (31); Motor drive circuit (33) converts MCU (31) PWM signal, realizes the rotation control to clamping motor (133) and rotary motor (142); Wireless communication circuit (34) is located between wireless communication module (6) and MCU (31) and realizes communication.

9. The control system of claim 8, wherein: Remote controller (2) includes slave control module (7), slave MCU (71) and slave wireless communication circuit (72) in slave control module (7) are provided with matched master control circuit module (3); Slave control module (7) includes power supply circuit (73), power supply circuit (73) accesses slave MCU (71), slave wireless communication circuit (72) and key circuit (74); After key circuit (74) receives artificial action signal, through slave control module (7), slave wireless communication circuit (72) transmits command to master control circuit module (3); Battery (75) accesses power supply circuit (73).

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