Planetary roller bearing intelligent lead screw device and application method thereof in insulator replacement

Abstract

The invention discloses a planetary roller bearing intelligent lead screw device and an application method in insulator replacement, and belongs to the technical field of power system operation and maintenance equipment and special operation machinery. The device comprises a screw rod, a planetary roller gear mechanism, a ratchet wrench, a pressure sensor module, a supporting block and a glass connecting plate connecting piece. And the screw rod penetrates through the components and is rigidly connected with the connecting piece. The planetary roller gear mechanism is composed of a screw cylinder with inner and outer teeth and a plurality of threaded rollers annularly distributed in the screw cylinder, and gear-thread coupling transmission is formed. And the ratchet wrench drives the screw cylinder to rotate to drive the roller to rotate, so that the rotary motion is converted into the linear lifting motion of the screw rod, and the stable transfer of the insulator string load is realized. The integrated pressure sensor module monitors the load in real time and gives an over-limit alarm, and data is wirelessly transmitted to a terminal and a background. According to the method, through cooperative operation of the devices, labor saving, controllability, rapidness and intelligentization of insulator replacement operation are achieved.

Description

Technical Field

[0001] This invention belongs to the technical field of power system operation and maintenance equipment and special operation machinery, specifically relating to a planetary roller bearing intelligent screw device and its application method in the replacement of insulators in transmission lines. This device integrates high-precision planetary roller screw transmission, real-time intelligent load monitoring, and a rapid assembly / disassembly structure, and is specifically designed to achieve safe, efficient, and intelligent transfer and replacement of insulator string loads. Background Technology

[0002] In the operation and maintenance of power transmission lines, insulators are key components ensuring the insulation performance and operational safety of the lines. Long-term exposure to harsh environments makes insulators prone to aging and damage, necessitating regular replacement. Traditional replacement work is highly manual, typically using a method of "manual lifting combined with ropes and crowbars for temporary fixation" to transfer the load on the insulator strings. This method is not only labor-intensive and inefficient, but also lacks effective monitoring and control during load transfer, easily leading to uneven stress causing insulator strings to sway or fall off, resulting in serious safety accidents such as falls from heights or equipment damage. Furthermore, traditional tools are mostly universal, with poor compatibility with different specifications of crossarms and glass connecting plates, requiring frequent parts replacements, further extending the time spent working at heights and increasing safety risks.

[0003] To address these issues, the industry has proposed several technical solutions. For example, Chinese patent CN108879477B discloses a special tool for replacing linear insulators, which uses a power and winding mechanism to transfer load, but it still fails to solve the problems of low transmission accuracy and uncontrollable process. US patent US5377402A provides a stress relief tool that reduces manual labor intensity through leverage, but its simple structure lacks load monitoring and rapid assembly / disassembly functions. The research paper "Research on Automatic Replacement Tool for Linear Insulators for Live-Line Working" proposes a high-precision mechanical positioning scheme, but does not disclose specific precision transmission and integrated monitoring designs. Other technologies, such as US8782885B2 and CN203398647U, focus on support structures or fixing clamps, which improve installation stability but fail to achieve mechanical amplification of the transmission mechanism and data monitoring of the operation process. Furthermore, although technologies such as US5235861A achieve load monitoring of transmission lines, it is independent of the replacement operation and cannot be integrated with the mechanical actuator.

[0004] In summary, existing insulator replacement technologies generally suffer from the following common shortcomings: 1. Crude transmission mechanism: It mostly uses simple mechanisms such as winding and levers, and lacks a high transmission ratio and a smooth and controllable power conversion device, resulting in laborious operation and low precision; 2. Blind operation during operation: There is a general lack of integrated, real-time load monitoring and safety early warning functions. Load transfer relies on human experience and judgment, which poses a high safety risk. 3. Low efficiency in adaptation and assembly / disassembly: The tool structure is highly versatile but lacks specialization. Adaptation and adjustment for different site conditions are cumbersome, and the assembly / disassembly process is complex, which affects the overall work efficiency. 4. Process is not traceable: The lack of automatic data collection and remote transmission capabilities makes it difficult to standardize work management and post-event analysis.

[0005] Therefore, the current power operation and maintenance field urgently needs a special insulator replacement equipment that features high-efficiency and precise transmission, real-time controllable load, rapid assembly and disassembly adaptation, and traceable and monitorable data, in order to fundamentally improve the safety, efficiency, and intelligence level of operations. Summary of the Invention

[0006] To overcome the shortcomings of existing technologies, this invention provides a planetary roller bearing intelligent screw device and its application method in insulator replacement. This invention uses a high-ratio, high-rigidity planetary roller screw as the core load-bearing and transmission mechanism, deeply integrating an integrated intelligent monitoring unit and a rapid-adaptive assembly / disassembly structure. The aim is to construct a dedicated operating system that integrates mechanical amplification, real-time sensing, intelligent early warning, and rapid operation, systematically solving key technical problems in traditional insulator replacement operations such as high labor intensity, high safety risks, low efficiency, and uncontrollable processes.

[0007] The technical solution adopted in this invention is as follows: A planetary roller bearing intelligent lead screw device includes a lead screw, a planetary roller gear mechanism, a ratchet wrench, a pressure sensor module, a support block, and a glass connecting plate connector; The lead screw passes through the planetary roller gear mechanism, the pressure sensor module, and the support block in sequence, and its end is rigidly connected to the glass connecting plate connector; the pressure sensor module fixing plate is installed on the support block, and the lower surface of the roller gear mechanism abuts against the pressure sensor module. The planetary roller gear mechanism includes a screw barrel, inside which several rollers are rotatably mounted. A ratchet wrench is fitted on the outer wall of the screw barrel and is connected to the ratchet wrench in a transmission manner. The inner wall of the screw barrel is connected to each roller in a transmission manner. The several rollers are arranged in a ring and are threaded with the lead screw. When the ratchet wrench rotates, it drives the screw barrel to rotate, and the screw barrel drives each roller to rotate, so that the lead screw drives the glass connecting plate to move vertically up and down relative to the support block, pressure sensor module and planetary roller gear mechanism to transfer the load of the insulator string.

[0008] Furthermore, there are 6 rollers with the same shape and size. The 6 rollers are rotatably mounted between two mounting plates. The middle section of the roller is threaded to cooperate with the lead screw, and the upper and lower ends of the roller are formed with toothed sections to cooperate with the screw barrel.

[0009] Furthermore, the screw barrel has a cylindrical structure, with a first toothed ring at the upper and lower ends of its inner wall that engages with rollers. The first toothed ring is connected to six rollers via the toothed ring, and a second toothed ring is provided on its outer wall that engages with a ratchet wrench. The mounting plate and rollers are installed inside the screw barrel and can rotate relative to the screw barrel.

[0010] Furthermore, the ratchet wrench includes a long cylindrical handle and a wrench head; the wrench head has a ring-shaped structure, which is fitted onto the screw cylinder, and a ratchet stop that engages with the second toothed ring on the outer wall of the screw cylinder and a reversing switch that controls the direction of the ratchet stop are installed inside it.

[0011] Furthermore, the wrench head is provided with a detachable dust cover, which allows the second toothed ring on the outer wall of the screw barrel to be located inside the wrench head.

[0012] Furthermore, the lead screw serves as the sun gear, the rollers as planetary gears, and the screw barrel as an annular gear, forming a coupling between the planetary gear system and the threaded transmission, thereby realizing the conversion of rotary motion into linear motion.

[0013] Furthermore, the pressure sensor module integrates a pressure sensor, a battery, a circuit board, and a wireless transmission module; the pressure sensor is located below the planetary roller gear mechanism, which contacts and monitors the load pressure in real time, and issues a warning signal when the pressure exceeds a preset threshold, and wirelessly transmits the data to a handheld receiver and a back-end system.

[0014] Furthermore, the support block adopts an inverted U-shaped structure, which is placed upside down above the crossarm of the pole to quickly position the planetary roller bearing intelligent screw device and ensure structural stability.

[0015] A method for replacing insulators using the aforementioned planetary roller bearing intelligent lead screw device includes the following steps: Step 1: Place the support block above the crossarm of the pole to quickly position the planetary roller bearing intelligent screw device; connect the glass connecting plate connector to the glass connecting plate and lock it with the pin to complete the connection between the screw and the insulator; Step 2: Rotate the ratchet wrench. The ratchet wrench drives the screw barrel to rotate. At the same time, the rotation of the screw barrel drives several rollers to rotate. The rotation of the rollers drives the lead screw to move upward in a straight line through the thread engagement, tightening the glass connecting plate and transferring the load of the insulator string. At the same time, the pressure sensor module monitors the load pressure in real time and issues a warning when it exceeds the preset threshold. Step 3: After the load has been stably transferred, remove the old insulators and install new insulators; Step 4: After the replacement is completed, turn the ratchet wrench to the reverse position. The ratchet wrench will rotate in the opposite direction, causing the screw to rotate in the opposite direction. At the same time, the screw will rotate in the opposite direction, causing several rollers to rotate in the opposite direction. The rotation of the rollers will drive the screw to move downward in a straight line through the threaded engagement, loosening the glass connecting plate and releasing the load. The pressure sensor module will wirelessly transmit the load data to the handheld receiver and the back-end system to realize operation recording and monitoring.

[0016] The beneficial effects of this invention are: This invention, through the innovative integration of a planetary roller screw transmission mechanism, integrated pressure sensing, and a quick-assembly / disassembly structure, fundamentally transforms the insulator replacement operation mode, specifically manifested in the following prominent beneficial effects: 1. High transmission efficiency and significantly reduced operating effort: This invention employs a planetary roller screw as the core transmission mechanism, combining the high transmission ratio characteristics of planetary gears with the precise linear motion of the threaded pair to form a highly efficient force amplification mechanism. Operators only need to apply a small torque using a ratchet wrench to drive the screw and generate a significant linear lifting force, easily and smoothly transferring the load on the insulator string. This greatly reduces the high physical exertion associated with traditional manual lifting or prying methods, alleviating labor burdens and improving the sustainability of long-term operations.

[0017] 2. The load transfer process is smooth, controllable, and highly safe. On the one hand, planetary roller screw drives feature smooth movement and good self-locking properties, avoiding load slippage or impact that may occur with traditional simple tools, thus ensuring the stability and accuracy of load transfer. On the other hand, the pressure sensor module integrated into the transmission path can monitor the working load in real time and accurately, and immediately issue an audible and visual alarm when the load exceeds a preset safety threshold. This "data-driven" early warning mechanism transforms safety control from relying on human experience to objective data monitoring, effectively preventing serious safety accidents such as insulator string swaying, falling off, or even falling from heights due to overload or uneven stress, significantly improving the inherent safety level of high-altitude live-line work.

[0018] 3. The device is quick to assemble and disassemble, and has strong universal adaptability: To address the challenges of complex on-site working environments and poor tool adaptability, this invention designs a specialized glass connecting plate connector featuring an inverted U-shaped support block and an inverted U-shaped opening with a pin. This structural design achieves "placement and fixation" with the pole crossarm and "click-locking" with the glass connecting plate, simplifying assembly and disassembly operations. Typically, only three steps are required: "placement-click-lock," significantly reducing auxiliary work time. Furthermore, this design offers excellent versatility for crossarms and connecting plates of mainstream specifications, resolving the pain point of frequent parts replacement required with traditional tools and improving the tool's on-site adaptability and operational efficiency.

[0019] 4. Intelligent and traceable management of the work process: The intelligent monitoring unit integrated in this invention not only has local alarm functionality but also transmits real-time load data synchronously to the operator's handheld terminal and the remote operation and maintenance backend system via a built-in wireless transmission module. This function enables remote visual monitoring of the operation process and automatic data recording and retention, allowing for digital traceability of key information such as load status and operation progress. This not only provides real-time decision support for on-site operations but also provides a valuable data foundation for subsequent operation quality assessment, safety analysis, standardized management, and personnel training, promoting the development of power operation and maintenance towards intelligent and refined management.

[0020] 5. High degree of integration and high reliability: This invention integrates core functional modules such as precision transmission, intelligent monitoring, and rapid assembly / disassembly via a lead screw spindle, resulting in a compact and highly integrated structure. The collaborative operation of each module reduces external dependencies and connection points, lowering the probability of failure. The specialized design of the device enables it to exhibit higher reliability and durability in complex and harsh power operation and maintenance environments.

[0021] In summary, this invention not only significantly improves the safety, efficiency, and comfort of insulator replacement operations, but also provides effective equipment support for the digital transformation of power system operation and maintenance operations by introducing intelligent monitoring and data management functions, thus possessing significant practical value and promising prospects for widespread application. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0023] Figure 1 This is a schematic diagram of the overall structure of the planetary roller bearing intelligent lead screw device of the present invention. Figure 2 A schematic diagram of the structure of the planetary roller gear mechanism and the wheel wrench for the invention; Figure 3 This is a schematic diagram of the planetary roller gear mechanism of the present invention; Figure 4 This is a schematic diagram of the screw cylinder of the planetary roller gear mechanism of the present invention; Figure 5 This is a schematic diagram of the structure of the roller and mounting plate of the present invention; Figure 6 This is a schematic diagram of the structure of the roller of the present invention; Figure 7and Figure 8 This is a schematic diagram showing the installation positions of the dust cover and reversing switch for a ratchet wrench. In the diagram, 1-lead screw; 2-planetary roller gear mechanism; 3-ratchet wrench; 4-pressure sensor module; 5-support block; 6-glass connecting plate connector; 7-screw barrel; 8-roller; 9-first gear ring; 10-second gear ring; 13-gear; 14-threaded section; 15-mounting plate; 16-dust cover; 17-reversing switch. Detailed Implementation

[0024] 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. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0025] This embodiment provides a planetary roller bearing intelligent screw device specifically designed for insulator replacement operations in power transmission lines. The core innovation of this device lies in the deep integration of a high-precision, high-ratio planetary roller screw transmission mechanism with an integrated intelligent load monitoring system, coupled with a quick-assembly and disassembly mechanical interface. This aims to achieve smooth, controllable, and efficient transfer and replacement of insulator string loads.

[0026] like Figure 1 As shown, the planetary roller bearing intelligent lead screw device mainly comprises six core components: lead screw 1, planetary roller gear mechanism 2, ratchet wrench 3, pressure sensor module 4, support block 5, and glass connecting plate connector 6. These components are precisely axially connected and rigidly linked to form a compact and functionally coordinated integrated working unit.

[0027] The overall assembly relationship is as follows: The lead screw 1, serving as the central main axis of the device, is made of high-strength alloy steel such as 42CrMo. Its surface is precision ground and heat-treated, resulting in excellent wear resistance and fatigue strength. From top to bottom, the lead screw 1 passes through the planetary roller gear mechanism 2, the pressure sensor module 4, and the support block 5. Its end is rigidly connected to the glass connecting plate connector 6 via a threaded pair or pin. This through-type layout ensures that the load of the insulator string is transferred directly from the glass connecting plate connector 6 through the lead screw 1 along a clear mechanical path to the support block 5 and the lower pole crossarm, effectively avoiding eccentric loads and structural instability.

[0028] The spatial layout and installation of each component are as follows: The planetary roller gear mechanism 2 is mounted on the upper part of the device and is the core of the power conversion. Its outer shell, namely the screw barrel 7, and the internal roller assembly are positioned by precision bearings and are integrally fitted onto the upper threaded section of the lead screw 1.

[0029] The ratchet wrench 3 is directly mounted on the second gear ring 10 on the outer wall of the screw barrel 7 of the planetary roller gear mechanism 2, providing manual drive input.

[0030] The pressure sensor module 4 is located directly below the planetary roller gear mechanism 2. Its top bearing surface is in close contact with the lower surface of the mechanism housing, and its bottom fixing plate is connected to the support block 5 by bolts. This design ensures that the entire working load borne by the device must flow through the sensor, guaranteeing the accuracy and directness of the monitoring data.

[0031] Support block 5 is located in the lower middle part of the device. Its inverted U-shaped structure sits directly across and is stably placed on the pole crossarm, serving as the installation base and load-bearing foundation for the entire device.

[0032] The glass connecting plate connector 6 is located at the bottom of the lead screw 1. Its U-shaped opening is used to quickly insert the glass connecting plate of the insulator string and is locked by a pin.

[0033] The assembly process is as follows: During assembly, the straightness and thread accuracy of the lead screw 1 must be ensured first. The internal rollers 8 of the planetary roller gear mechanism 2 are precisely aligned with the threaded section of the lead screw 1 and pre-tightened to eliminate meshing backlash. Then, the pressure sensor module 4 and support block 5 are sequentially inserted, and the module's fixing bolts are tightened. After the ratchet wrench 3 is fully engaged, a dust cover 16 is applied. Finally, the glass connecting plate connector 6 is reliably connected to the end of the lead screw 1. The entire assembly process emphasizes coaxiality to ensure smooth, unobstructed movement of the lead screw. The total weight of this planetary roller bearing intelligent lead screw device is controlled between 8-12 kg, balancing structural strength with portability for high-altitude transport.

[0034] The planetary roller bearing intelligent screw device is designed for power transmission lines with voltage levels of 10kV and above. The structural parameters of its support block 5 and connector 6 have been optimized to be compatible with the width of the crossarm of the pole of 50-200mm and the thickness of the standard glass connecting plate of 10-30mm, which are the mainstream specifications in China, thus realizing the universal compatibility of special tools.

[0035] Lead screw 1: like Figure 1 As shown, in this embodiment, the lead screw 1 plays a dual role as both a "sun gear" and a final actuator, and is a key component that converts rotary motion into linear motion and bears the entire working load.

[0036] The lead screw 1 is made of high-quality alloy structural steel. After quenching and tempering, the core retains its toughness, and the surface undergoes high-frequency quenching or nitriding to achieve a high hardness of HRC 58-62 and a wear-resistant layer. Its typical design diameter is 30mm, and the effective thread length is not less than 500mm. The preferred thread type is a multi-start trapezoidal thread with a lead of 8mm. The multi-start design ensures self-locking performance while improving transmission efficiency and reducing the number of input turns required to achieve the same lifting height.

[0037] The lead screw 1 is precisely located on the geometric center axis of the device. Its upper threaded section simultaneously engages with the threaded sections 14 of all the rollers 8 in the planetary roller gear mechanism 2, forming a multi-threaded helical pair. The middle section passes through the central through hole of the pressure sensor module 4 and the guide hole of the support block 5, and the two sections have a precise sliding fit with the lead screw, ensuring both guiding accuracy and allowing the lead screw to move freely. The lower end is threaded to the glass connecting plate connector 6, and a lock nut or cotter pin is used to prevent loosening, forming a rigid connection that cannot be disengaged.

[0038] The core function of the lead screw 1 is to convert the rotational motion output from the planetary roller gear mechanism 2 into its own precise linear lifting motion through the threaded pair, thereby pulling or releasing the insulator string. Its functions are: First, to provide mechanical amplification, transforming the small torque input from the ratchet wrench 3 into a large axial force output from the lead screw. The amplification factor depends on the transmission ratio and thread lead of the planetary roller mechanism, greatly saving manpower. Second, to ensure smooth movement and self-locking. The trapezoidal threaded pair has a large friction angle and reliable self-locking properties, allowing it to safely stop at any position and preventing accidental load drop.

[0039] By adopting a high-precision and high-strength screw design, the lead screw 1 fundamentally solves the problems of rough transmission, easy slippage, and poor accuracy of traditional tools, and realizes a smooth, accurate and controllable load transfer process.

[0040] Planetary roller gear mechanism 2: As attached Figure 2-6 As shown, the planetary roller gear mechanism 2 is the core transmission unit of the planetary roller bearing intelligent screw device. It creatively combines planetary gear transmission with the principle of roller screw, achieving high rigidity, high load-bearing capacity and high-efficiency transmission.

[0041] The planetary roller gear mechanism 2 mainly includes a screw barrel 7, rollers 8, a first gear ring 9, a second gear ring 10, and a mounting plate 15.

[0042] Screw barrel 7 Figure 4 As shown: The screw barrel 7 is a cylindrical component. A precision internal gear is machined at each of its upper and lower ends, forming the first gear ring. An external gear, the second gear ring 10, is machined in the middle of its outer wall, for engagement with the ratchet wrench 3.

[0043] Roller 8 Figure 6 As shown: In this embodiment, six "planetary wheels" are arranged. Each roller is divided into three sections: the two ends are gear sections 13, whose module matches the first gear ring 9 of the screw barrel 7, and are used for meshing transmission; the middle section is a threaded section 14, whose thread parameters are completely consistent with the thread of the lead screw 1, and are used to form a helical pair.

[0044] Mounting plate 15 Figure 5 As shown: There are two mounting plates 15, one on the top and one on the bottom, which are annular plates that support the journals at both ends of the six rollers 8 through bearings. The mounting plates 15 ensure the relative positional accuracy between all the rollers 8 and between the rollers and the lead screw 1, so that they can move as a whole assembly within the screw barrel 7.

[0045] The entire planetary roller gear mechanism 2 is integrated as a module, mounted on the upper part of the planetary roller bearing intelligent lead screw device via its screw barrel 7. Six rollers 8 are evenly distributed in a ring via mounting plates 15 at both ends, collectively engaging with the central lead screw 1. The gear sections 13 at both ends of the rollers 8 mesh with the first gear ring 9 on the inner wall of the screw barrel 7; the threaded section 14 in the middle of the rollers 8 meshes with the thread of the lead screw 1. The screw barrel 7 is connected to the ratchet wrench 3 via the second gear ring 10 on its outer wall.

[0046] The planetary roller gear mechanism 2 achieves two-stage motion conversion and force amplification. The first stage is gear reduction and torque amplification: the ratchet wrench 3 drives the screw barrel 7 to rotate, which in turn drives six rollers 8 to rotate around their own axes via the first gear ring 9. Since the number of teeth on the gear section 13 of the rollers 8 is much smaller than that on the first gear ring 9 of the screw barrel, a single reduction is achieved. The second stage is thread motion conversion: the rotating rollers 8 drive the central lead screw 1 to perform axial linear motion through the threaded section 14 in their middle section. The planetary roller gear mechanism 2 offers the following advantages: High load-bearing capacity: The load is shared by six rollers, resulting in multiple contact points, uniform stress distribution, and a load-bearing capacity far exceeding that of a single-start lead screw. High rigidity: Multiple threaded pairs in parallel provide extremely high axial and radial rigidity, strong resistance to impact and eccentric loads. Smooth transmission: The planetary layout counteracts radial forces, resulting in low operating noise and minimal wear.

[0047] The planetary roller gear mechanism 2 completely replaces crude transmission methods such as winding and levers, providing a smooth, efficient and reliable core power conversion. It is a key technology carrier for solving the problems of crude transmission mechanisms and laborious operation.

[0048] Ratchet wrench 3: like Figure 2 , 7 As shown in Figure 8, the ratchet wrench 3 is the human-machine interface of the planetary roller bearing intelligent screw device, providing safe, labor-saving, and reversible manual drive.

[0049] The ratchet wrench 3 includes a long handle and a wrench head. The handle is a hollow steel tube, approximately 500mm in length, covered with a non-slip rubber sleeve for easy gripping and torque application. The wrench head is an annular housing with a drive pawl mechanism machined into its inner cavity, engaging with a second gear ring 10 on the outer wall of the screw barrel 7. This mechanism includes a reversible ratchet stop, controlled by an exposed reversing switch 17, allowing switching between "clockwise drive / free rotation" and "counter-clockwise drive / free rotation" modes. The ratchet stop and reversing switch 17 are common structures in existing ratchet wrenches. A removable dust cover 16 is fitted to the end face of the wrench head to seal and protect the internal gears and pawl mechanism.

[0050] The wrench head is directly fitted onto the second gear ring 10 on the outer wall of the screw barrel 7 of the planetary roller gear mechanism 2, so that it can only rotate around the screw barrel 7 and cannot move axially. The dust cover 16 is fixed to the wrench head by threads or snaps.

[0051] The ratchet wrench 3 provides controllable torque input for the entire device. The operator reciprocates the handle, converting the oscillation into continuous unidirectional rotation of the screw 7 via a pawl mechanism. A reversing switch 17 allows the same handle oscillation to drive the screw upwards or downwards. Its advantages are: Effortless operation: Utilizing the lever principle and the intermittent motion of the ratchet, the operator can apply force at the optimal handle oscillation angle, easily generating the required torque. Safety: The ratchet mechanism has unidirectional transmission characteristics and automatically locks when operation stops, preventing the screw from accidentally falling back due to reverse load. Efficiency: Reciprocating oscillation is more suitable for operation in confined spaces at heights than continuous rotation.

[0052] The ratchet wrench 3 replaces the laborious method of continuous and forceful turning or prying in traditional operations. Through ingenious mechanical design, it significantly reduces labor intensity and provides reliable operational safety.

[0053] Pressure sensor module 4: Pressure sensor module 4 is the intelligent hub of the planetary roller bearing intelligent screw device, realizing the data and visualization of the operation process.

[0054] The pressure sensor module 4 is a highly integrated package. The housing is made of aluminum alloy and achieves an IP65 protection rating. Internally, it integrates: a core sensing unit using a high-precision resistance strain gauge pressure sensor with a range of 0-20 tons and an overall accuracy better than ±0.5%FS; a signal processing unit containing amplification circuits, filtering circuits, and an analog-to-digital converter, converting weak strain signals into stable digital signals; a microcontroller (MCU) responsible for data acquisition, threshold judgment, alarm control, and communication protocol processing; a power management unit with a built-in rechargeable lithium battery supporting over 10 hours of continuous operation, and a power switch and USB-C charging port; a wireless communication unit using a low-power Bluetooth BLE or LoRa module for wireless data transmission; and a human-machine interface unit including multi-color LED status indicators and a buzzer for local audible and visual alarms.

[0055] The pressure sensor module 4 is connected in series at a critical location in the load transfer path. Its top is a high-rigidity bearing platform that directly contacts the lower end face of the screw cylinder 7 of the planetary roller gear mechanism 2. Its bottom is rigidly connected to the upper surface of the support block 5 via a fixing plate and multiple high-strength bolts. The lead screw 1 passes through a through-hole in the center of the pressure sensor module 4 but does not experience any load-bearing relationship with the module.

[0056] The core function of pressure sensor module 4 is to monitor the load on the insulator string in real time and online. When the lead screw 1 tightens the insulator string, the load is transmitted to the top of sensor module 4 through the housing of planetary roller gear mechanism 2, and the sensor then outputs a corresponding pressure signal. The MCU processes the signal: local display and alarm: the load status is indicated by LED color, and when the load exceeds the preset safety threshold, an audible and visual alarm is triggered to remind the operator. Wireless data transmission: real-time load values, timestamps, and other information are packaged and sent to the smart terminal carried by the operator via the wireless module, and can be further uploaded to the remote operation and maintenance management platform via mobile network.

[0057] The pressure sensor module 4 fundamentally solves the two major pain points of "blind operation" and "lack of process traceability". It transforms the load from an invisible force into visualized data, realizing the leap from "experience judgment" to "data-driven" safety early warning, and providing a solid data foundation for standardized operation management and digital traceability.

[0058] Support block 5: Support block 5 serves as the connecting bridge between the planetary roller bearing intelligent screw device and the on-site infrastructure. Its core design principles are speed, stability, and versatility.

[0059] Support block 5 is cast or forged in an inverted U-shape. The main body is a rectangular block with a rectangular tenon protruding downwards from the center of the lower surface. The height and width of the protrusion are calculated to ensure stable surface contact and limiting with the top and sides of most angle steel or channel steel crossbeams. The upper surface is a flat mounting platform with bolt holes machined to correspond to the mounting plate of pressure sensor module 4. The overall material can be ductile iron or high-strength engineering plastics, ensuring strength while reducing weight.

[0060] Support block 5 is located at the bottom of the device. During operation, it is placed upside down on the crossarm of the pole. Its convex structure effectively prevents the device from moving or tipping over in the horizontal direction. Its upper surface is rigidly connected to the pressure sensor module 4 by bolts, and its central through hole provides final guidance for the lead screw 1.

[0061] Support block 5 enables rapid positioning and load-bearing, allowing for immediate installation of the device by placement, eliminating complex clamping and fastening steps, and significantly reducing the time required for high-altitude auxiliary operations. Its universal structural design avoids the hassle of replacing special parts for different crossarms. Support block 5 directly addresses the problem of "low efficiency in adaptation and disassembly" by achieving rapid and reliable adaptation of tools to the on-site structure through innovative mechanical structural design.

[0062] Glass connecting plate connector 6: The glass connecting plate connector 6 is the connection terminal between the device and the insulator string of the work object. It is required that the connection be quick, reliable and without damaging the connecting plate.

[0063] The main body of the glass connecting plate connector 6 is a forged U-shaped fork with the opening facing upwards, forming an inverted U-shape. The width of the U-shaped opening is slightly larger than the thickness of a standard glass connecting plate. The inside of the opening can be lined with an engineering plastic protective sleeve to prevent metal from directly scratching the fiberglass. Coaxial pin holes are opened on the two side arms of the U-shaped fork. A high-strength pin is provided, with one end having a hinge or chain connecting it to the connector body to prevent loss, and the other end having a spring pin or cotter pin hole for locking.

[0064] The glass connecting plate 6 is rigidly connected to the end of the lead screw 1 through its internal threaded hole or welded sleeve. During operation, the glass connecting plate at the top of the insulator string is placed horizontally into the U-shaped opening, and then the pin is passed through the pin holes of the two arms to "lock" the connecting plate in the connecting piece.

[0065] The glass connecting plate connector 6 enables rapid mechanical connection and separation from the insulator string. Its function is to simplify the complex binding and hooking operations into a two-step "clamp-pin" process, ensuring reliable connection and easy disassembly, greatly improving the efficiency of high-altitude operations and eliminating the risk of rope derailment. The glass connecting plate connector 6, together with the support block 5, solves the problem of low adaptation and assembly / disassembly efficiency, and is a key link in improving the overall efficiency of the work process.

[0066] The working principle of this planetary roller bearing intelligent lead screw device is as follows: The entire device operates on the principle of coupling planetary gear transmission and helical transmission. When the operator reciprocates the ratchet wrench 3, the pawl inside the wrench head drives the screw barrel 7 to rotate unidirectionally around its axis. The screw barrel 7 drives the six rollers 8 surrounding it to rotate synchronously through the first toothed ring 9 on its inner wall. Since the threaded section 14 in the middle of the roller 8 engages with the thread of the central lead screw 1, and the lead screw 1 is limited by the rotation of the insulator string, the rotation of the roller 8 is converted into the axial linear motion of the lead screw 1 relative to the screw barrel 7.

[0067] By switching the reversing switch 17 of the ratchet wrench 3, the rotation direction of the screw barrel 7 can be changed, thereby controlling the raising and lowering of the lead screw 1. During this process, the load of the insulator string is transmitted to the lead screw 1 through the glass connecting plate 6, then to the pressure sensor module 4 via the screw barrel 7 of the planetary roller gear mechanism 2, and finally acts on the pole crossarm through the support block 5. The pressure sensor module 4 monitors this load value in real time and performs local display, alarm, and remote data transmission.

[0068] The workflow for replacing insulators using this planetary roller bearing intelligent lead screw device is as follows: Installation preparation: Place the support block 5 stably in the appropriate position on the pole crossarm. Align the U-shaped opening of the glass connecting plate 6 with the glass connecting plate at the top of the insulator string, snap it in, insert and lock the pin.

[0069] Load Transfer: Check that the ratchet wrench 3 and reversing switch 17 are in the "lift" position. The operator begins to reciprocate the handle, driving the lead screw 1 to rise slowly and steadily, gradually tightening the insulator string. At this time, the indicator light on the pressure sensor module 4 and the handheld terminal will simultaneously display the real-time load. When the load reaches the working value and the slack force of the insulator string is completely transferred to this device, stop the operation.

[0070] Replacement procedure: After confirming that the load is stable and the device is normal, the operator disconnects the old insulator from the crossarm and conductor end, removes it, and installs a new insulator.

[0071] Unloading and Reset: After the new insulator is installed and initially tightened, switch the reversing switch 17 of the ratchet wrench 3 to the "lower" position. Swing the handle in the opposite direction to drive the lead screw 1 down slowly, gradually transferring the load back onto the new insulator string. Once the device is completely unloaded and the glass connecting plate is loosened, remove the pin, take off the glass connecting plate connector 6, and finally remove the support block 5. Key load data throughout the entire operation has been recorded and uploaded.

[0072] Based on the above structural description of the planetary roller bearing intelligent lead screw device and the insulator replacement procedure, the following problems have been specifically and thoroughly solved: Addressing the issues of "crude transmission mechanisms and laborious operation," this planetary roller bearing intelligent screw device is the first to apply a planetary roller screw mechanism 2 to the field of insulator replacement. Compared with traditional winches, levers, or ordinary screws, this mechanism has significant advantages such as a large transmission ratio, multiple contact points, high load capacity, high rigidity, and smooth operation. It amplifies the manual torque input by the operator through the ratchet wrench 3 in two stages, allowing the operator to generate several tons of lifting force with very little effort, fundamentally transforming high-intensity physical labor into convenient manual operation.

[0073] Addressing the challenges of "blind operation and high safety risks" during work, this planetary roller bearing intelligent lead screw device incorporates an integrated intelligent pressure sensor module 4. This module acts as the device's "sensory nerve," converting the invisible load force into visible, audible, and transmittable data in real time. Its local audible and visual over-threshold alarm function provides an immediate safety safeguard; the wireless data transmission function enables remote monitoring, allowing ground monitoring personnel or the command center to grasp the mechanical state of high-altitude operations in real time, transforming "blind operation" into "visual observation," and greatly reducing the risk of safety accidents caused by overload and imbalance.

[0074] Addressing the issue of "low efficiency in adaptation and assembly / disassembly": This planetary roller bearing intelligent lead screw device utilizes a set of quick mechanical interfaces—an inverted U-shaped support block 5 and an inverted U-shaped pin-type connector 6. These eliminate the cumbersome methods of traditional bolt tightening and rope binding, achieving "instant stability upon placement" with the crossarm and "instant locking upon insertion" with the connecting plate. The assembly / disassembly process, which previously required multiple tools and several minutes, is now completed in just tens of seconds without additional tools, significantly improving window utilization for high-altitude operations and reducing personnel exposure risks.

[0075] Addressing the issue of "untraceable processes": This planetary roller bearing intelligent lead screw device automatically generates an "electronic work order" for each operation through the wireless data recording and uploading function of the pressure sensor module 4. This work order includes key information such as time, location, maximum load, and load curve. This data provides valuable analytical material for operation and maintenance management, and can be used to verify operational compliance, evaluate tool usage efficiency, analyze insulator stress history, and even for predictive maintenance, truly achieving digital and traceable management of the operation process.

[0076] In summary, this planetary roller bearing intelligent screw device provides a complete, efficient, safe, and intelligent insulator replacement solution through mechatronics and intelligent system innovation.

[0077] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A planetary roller bearing intelligent lead screw device, characterized in that, Includes lead screw, planetary roller gear mechanism, ratchet wrench, pressure sensor module, support block and glass connecting plate connector; The lead screw passes through the planetary roller gear mechanism, the pressure sensor module, and the support block in sequence, and its end is rigidly connected to the glass connecting plate connector; the pressure sensor module fixing plate is installed on the support block, and the lower surface of the roller gear mechanism abuts against the pressure sensor module. The planetary roller gear mechanism includes a screw barrel, inside which several rollers are rotatably mounted. A ratchet wrench is fitted on the outer wall of the screw barrel and is connected to the ratchet wrench in a transmission manner. The inner wall of the screw barrel is connected to each roller in a transmission manner. The several rollers are arranged in a ring and are threaded with the lead screw. When the ratchet wrench rotates, it drives the screw barrel to rotate, and the screw barrel drives each roller to rotate, so that the lead screw drives the glass connecting plate to move vertically up and down relative to the support block, pressure sensor module and planetary roller gear mechanism to transfer the load of the insulator string.

2. The planetary roller bearing intelligent lead screw device according to claim 1, characterized in that: The rollers consist of 6 rollers of the same shape and size. The 6 rollers are rotatably mounted between two mounting plates. The middle section of the roller is threaded to cooperate with the lead screw, and the upper and lower ends of the rollers are toothed sections that cooperate with the screw barrel.

3. The planetary roller bearing intelligent lead screw device according to claim 2, characterized in that: The screw barrel has a cylindrical structure with a first toothed ring at the upper and lower ends of its inner wall that engages with rollers. The first toothed ring is connected to six rollers via the toothed ring. The second toothed ring is provided on its outer wall to engage with a ratchet wrench. The mounting plate and rollers are installed inside the screw barrel and can rotate relative to the screw barrel.

4. The planetary roller bearing intelligent lead screw device according to claim 3, characterized in that: The ratchet wrench includes a long cylindrical handle and a wrench head; the wrench head has a ring-shaped structure, which is fitted onto a screw cylinder, and inside it is installed a ratchet stop that engages with a second toothed ring on the outer wall of the screw cylinder and a reversing switch that controls the direction of the ratchet stop.

5. The planetary roller bearing intelligent lead screw device according to claim 4, characterized in that: The wrench head is equipped with a removable dust cover, which allows the second toothed ring on the outer wall of the screw barrel to be located inside the wrench head.

6. The planetary roller bearing intelligent lead screw device according to claim 1, characterized in that, The lead screw serves as the sun gear, the rollers as planetary gears, and the screw barrel as an annular gear, forming a coupling between the planetary gear system and the threaded transmission, thereby realizing the conversion of rotary motion into linear motion.

7. The planetary roller bearing intelligent lead screw device according to claim 1, characterized in that: The pressure sensor module integrates a pressure sensor, a battery, a circuit board, and a wireless transmission module. The pressure sensor is located below the planetary roller gear mechanism, which contacts and monitors the load pressure in real time. When the load pressure exceeds a preset threshold, the sensor issues a warning signal and wirelessly transmits the data to a handheld receiver and a back-end system.

8. The planetary roller bearing intelligent lead screw device according to claim 1, characterized in that, The support block adopts an inverted U-shaped structure and is placed upside down on the crossarm of the pole to quickly position the planetary roller bearing intelligent screw device and ensure structural stability.

9. A method for replacing insulators using the planetary roller bearing intelligent screw device according to any one of claims 1-8, characterized in that: Includes the following steps: Step 1: Place the support block above the crossarm of the pole to quickly position the planetary roller bearing intelligent screw device; connect the glass connecting plate connector to the glass connecting plate and lock it with the pin to complete the connection between the screw and the insulator; Step 2: Rotate the ratchet wrench. The ratchet wrench drives the screw barrel to rotate. At the same time, the rotation of the screw barrel drives several rollers to rotate. The rotation of the rollers drives the lead screw to move upward in a straight line through the thread engagement, tightening the glass connecting plate and transferring the load of the insulator string. At the same time, the pressure sensor module monitors the load pressure in real time and issues a warning when it exceeds the preset threshold. Step 3: After the load has been stably transferred, remove the old insulators and install new insulators; Step 4: After the replacement is completed, turn the ratchet wrench to the reverse position. The ratchet wrench will rotate in the opposite direction, causing the screw to rotate in the opposite direction. At the same time, the screw will rotate in the opposite direction, causing several rollers to rotate in the opposite direction. The rotation of the rollers will drive the screw to move downward in a straight line through the threaded engagement, loosening the glass connecting plate and releasing the load. The pressure sensor module will wirelessly transmit the load data to the handheld receiver and the back-end system to realize operation recording and monitoring.

Images