Cable torsion testing mechanism and operation method

Abstract

The invention relates to the field of wind power generation application, in particular to a cable torsion testing mechanism and an operation method.The cable torsion testing mechanism comprises a torsion end, a traction end, a tension adjusting assembly and a swing sliding frame guide structure, and the torsion end is used for clamping and driving one end of a cable to conduct reciprocating or continuous torsion; the traction end and the torsion end are coaxially arranged at an interval and are used for applying constant axial tension to the other end of the cable; according to the tension adjusting assembly, a manual screw is matched with a pulling nut to achieve accurate tension adjustment, and the tension value is fed back in real time through a dynamometer. The swing sliding frame guide structure is arranged in the traction end and used for supporting a cable fixing point and achieving independent transmission of vertical loads and horizontal tension. The device is simple in structure, does not need external energy, is accurate in tension control, is reliable in measurement, and solves the problems of test distortion and insufficient reliability verification caused by the difficulty in accurately reproducing the composite working condition of the cable twisting device of the wind turbine generator under the laboratory condition in the prior art.

Description

Technical Field

[0001] This invention relates to the field of wind power generation applications, and in particular to a cable torsion testing mechanism and operating method. Background Technology

[0002] The wind turbine cable twisting device is used in wind power generation systems and is a structural device for holding and fixing the power transmission cable inside the wind turbine.

[0003] When used at the top of a wind turbine tower, the cable twisting device is installed on the platform of the top rotating platform. The wind turbine's wiring cable passes vertically through and is fixed to the twisting device, with a cable hanging height of approximately 12 meters. The upper end of the cable rotates slowly and controllably with the wind turbine nacelle, while the lower end remains fixed. Cable twisting devices are a new technology in the wind power generation field. To assess and test their safety capabilities, testing in this application scenario is necessary to verify the suitability and reliability of the cable and the twisting device.

[0004] Under current conditions, it is not possible to conduct tests directly on wind power generation towers. Furthermore, the qualification requirements, construction difficulties, construction costs, and safety risks associated with building a 12-meter-high test platform make it infeasible to test the cable and twisting device combination in its original state.

[0005] Publication No.: CN220040033U A tensile testing device for cable materials includes an electric slide rail, a tensile testing unit (including a tensile sensor), a torsion testing unit (including a servo motor), and a pair of clamping units. The device achieves tension by moving the torsion end away from the fixed end via the electric slide rail, and simultaneously achieves torsion by rotating the servo motor. It can be used for testing the tensile and torsional properties of short cable samples. The cable samples are arranged horizontally, eliminating the influence of hanging weight. However, this technical solution does not disclose how to address the problem of gravity affecting the test results during horizontal tensile testing of long cables.

[0006] Therefore, there is an urgent need for a new cable torsion testing mechanism and method to solve the problem that existing technologies cannot accurately reproduce the complex working conditions of wind turbine cable torsion devices under laboratory conditions, resulting in test distortion and insufficient reliability verification. Summary of the Invention

[0007] In view of this, the present invention aims to propose a cable torsion testing mechanism and operating method to solve the problem that the existing technology is unable to accurately reproduce the complex working conditions of the wind turbine cable torsion device under laboratory conditions, resulting in test distortion and insufficient reliability verification.

[0008] Existing cable testing equipment is mostly used for verifying single mechanical properties, such as tension or bending alone. This fails to replicate the actual service environment of the cable torsion device atop a wind turbine tower—the complex state of a 12-meter suspended cable simultaneously bearing constant axial tension and its own weight during ±400° reciprocating torsion. Direct testing on the wind turbine is impractical, and constructing a 12-meter high platform presents practical obstacles such as high cost, significant risk, and poor repeatability. Furthermore, in traditional testing devices, the cable's own weight directly acts on the force sensor, causing the tension reading to include a component perpendicular to the cable, resulting in severe distortion.

[0009] This invention transforms the failure resistance testing of cables and cable twisting devices from testing under vertical installation conditions to simulated testing under horizontal conditions. By precisely setting a 12-meter test interval, using an inclined installation frame to compensate for geometric deviations, and applying a constant tension equal to the cable's own weight, it achieves a high degree of realism in the actual working conditions. This solves the problem of existing technologies being unable to accurately reproduce the complex working conditions of wind turbine cable twisting devices under laboratory conditions, leading to test distortion and insufficient reliability verification. It innovatively introduces various forms of pendulum guide structures, such as parallelogram linkages, slide rod-sleeve, linear guide rail-bearing, or roller-raceway, so that the pendulum slide only transmits horizontal tension to the force gauge, while the vertical load is entirely borne by the guide components. This ensures that the force measurement path is strictly collinear, and there is zero interference with the vertical force. The tension control accuracy can reach within ±1%, which is significantly better than existing equipment. Meanwhile, it abandons complex hydraulic or servo systems and adopts a manual adjustment mechanism with a long screw, double nuts, and a pulling nut, combined with real-time force feedback, to achieve passive, high-precision tension setting. It also features a safety locking mechanism with alternating hooks between a ladder rod and double locking claws, supporting half-step movement and step-by-step unloading, completely eliminating the risk of rebound during high-tension release. In addition, the swing carriage has a multi-hole layout, which can clamp 1 to 3 cables simultaneously for synchronous testing, greatly improving test efficiency.

[0010] The technical solution of this invention is implemented as follows:

[0011] One object of the present invention is to disclose a cable torsion testing mechanism, comprising:

[0012] The torsion end is used to clamp and drive one end of the cable under test to reciprocate or continuously twist.

[0013] The pulling end, which is spaced apart from the torsion end along the same axis, is used to apply and maintain a constant axial tension to the other end of the cable;

[0014] The tension adjustment assembly is used to manually adjust the magnitude of the axial tension and is equipped with a force gauge to provide real-time feedback of the tension value.

[0015] The pendulum guide structure, located inside the pulling end, is used to support the cable fixing point and realize the independent transmission of vertical load and horizontal tension.

[0016] Furthermore, the tension adjustment assembly includes a long screw, a pulling nut, and a perforated vertical support frame;

[0017] One end of the long screw is connected to the trolley frame of the pulling end, and the other end passes through the perforated vertical pull frame. The pulling nut is screwed onto the end of the long screw and is used to adjust the tension by moving the trolley frame by tightening or loosening it.

[0018] Furthermore, the long screw passes through the perforated crossbar on the trolley frame, and a locking nut one and a locking nut two are provided at the protruding end, which together form a double-nut anti-loosening structure.

[0019] Furthermore, the guide structure of the swing carriage is a parallelogram linkage mechanism, including four sets of swing rods. The two ends of each set of swing rods are respectively hinged to the trolley frame and the swing carriage, so that the upper surface of the swing carriage always remains horizontal during the swinging process.

[0020] Furthermore, the swing carriage is connected to the trolley frame via a horizontal guide assembly, which is a slide rod-sleeve, linear guide rail-linear bearing, or raceway-roller structure, used to allow the swing carriage to move in the horizontal direction and to achieve the separation and transmission of vertical load and horizontal tension.

[0021] Furthermore, the pulling end also includes a safety locking mechanism, which includes a vertically arranged ladder rod group and symmetrically arranged locking claw one and locking claw two; the locking claw one and locking claw two are alternately hooked on the adjacent columns of the ladder rod group to realize the unidirectional movement of the pulley or the step-by-step release of tension.

[0022] Furthermore, the mounting frame of the torsion end is inclined toward the pulling end relative to its first bottom frame, with the included angle being less than 90°, so that the axis of the cable is approximately parallel to the rotation axis of the torsion end.

[0023] Furthermore, the centers of the force gauge, the pulley frame tension hole, and the pendulum slide tension hole are collinear to ensure that the tension measurement path is free of angular deviation.

[0024] Another object of the present invention discloses an operating method for a cable torsion testing mechanism, which, based on any of the cable torsion testing mechanisms described above, includes the following steps:

[0025] S1: A cable twisting device that fixes one end of the cable to the twisting end and clamps the other end to the pulling end;

[0026] S2: Manually adjust the tension using the tension adjustment component and set it to the target tension value based on the reading of the force gauge;

[0027] S3: Start the torsion end and perform reciprocating torsion at the set angle;

[0028] S4: After the test, release the tension step by step through the safety locking mechanism and disassemble the cable.

[0029] Furthermore, before step S3, maintain the preset tension for 5 minutes. If the tension drops by more than 3%, re-tension to the target value. During the test, the ambient temperature is controlled between −20℃ and +60℃.

[0030] Compared with the prior art, the cable torsion testing mechanism and operating method of the present invention have the following advantages:

[0031] 1. This invention, by combining a tension adjustment component with a high-precision force gauge, and through the coordinated control of manual screw adjustment and real-time tension feedback, ensures that the cable maintains a constant and settable axial tension throughout the torsion test, avoiding unrealistic working conditions caused by tension fluctuations or relaxation. This effectively improves the accuracy and repeatability of test data and solves the problem of test distortion and insufficient reliability verification caused by the difficulty of accurately reproducing the complex working conditions of wind turbine cable torsion devices under laboratory conditions in existing technologies.

[0032] 2. By setting up a variety of selectable pendulum guide structures, this invention achieves complete separation and transmission of vertical load and horizontal tension, ensuring that the force gauge only responds to the real axial tensile force and is not affected by the vertical force generated by the cable's own weight, thus greatly improving the reliability of tension measurement. At the same time, the guide structure allows the cable to generate necessary micro-displacement during the torsion process, more realistically simulating the dynamic laying state in actual engineering, and enhancing the engineering applicability of the test results.

[0033] 3. This invention achieves safe tension release through a step-by-step anti-detachment mechanism composed of a ladder rod and double locking claws. Combined with the multi-hole layout on the swing slide to support the simultaneous clamping and testing of multiple cables, it not only significantly improves operational safety and testing efficiency, but also reduces the cost of a single test. The overall structure does not require hydraulic or electrical drive, is easy to maintain and operates stably, and is particularly suitable for the long-term torsional fatigue verification needs of high-reliability cables in fields such as wind power and rail transportation. Attached Figure Description

[0034] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0035] Figure 1 This is a simplified diagram of the cable torsion testing mechanism of the present invention.

[0036] Figure 2 This is a schematic diagram of the torsion end and cable structure of the cable torsion testing mechanism of the present invention;

[0037] Figure 3 This is a schematic diagram of the tension end and cable structure of the cable torsion testing mechanism of the present invention;

[0038] Figure 4 This is a schematic diagram of the torsion end structure of the cable torsion testing mechanism of the present invention;

[0039] Figure 5 This is a schematic diagram of the torsion support structure of the cable torsion testing mechanism of the present invention;

[0040] Figure 6 This is a side view of the torsion bracket of the cable torsion testing mechanism of the present invention;

[0041] Figure 7 This is a schematic diagram of the tension end structure of the cable torsion testing mechanism of the present invention;

[0042] Figure 8 This is a schematic diagram of the pulley structure of the cable torsion testing mechanism of the present invention;

[0043] Figure 9 This is a schematic diagram of the tension support structure of the cable torsion testing mechanism of the present invention;

[0044] Figure 10 This is a schematic diagram of the trolley frame structure of the cable torsion testing mechanism of the present invention;

[0045] Figure 11 This is a schematic diagram of the pendulum slide structure of the cable torsion testing mechanism of the present invention;

[0046] Figure 12 This is a schematic diagram of the cable fixing head structure of the cable torsion testing mechanism of the present invention;

[0047] Figure 13 This is a schematic diagram of the locking claw structure of the cable torsion testing mechanism of the present invention;

[0048] Figure 14 This is a schematic diagram of the locking claw two structure of the cable torsion testing mechanism of the present invention;

[0049] Figure 15 The attached figure shows an embodiment 2 of the cable torsion testing mechanism of the present invention;

[0050] Figure 16 The attached figure shows Embodiment 4 of the cable torsion testing mechanism of the present invention;

[0051] Figure 17 The attached figure shows Embodiment 5 of the cable torsion testing mechanism of the present invention;

[0052] Figure 18 The attached figure shows Embodiment 6 of the cable torsion testing mechanism of the present invention;

[0053] Figure 19 This is a schematic diagram of the cable torsion device structure of the cable torsion testing mechanism of the present invention;

[0054] Figure 20 This is a schematic diagram of the two cables tested by the cable torsion testing mechanism of the present invention;

[0055] Figure 21 This is a schematic diagram of the slewing bearing installation structure of the cable torsion testing mechanism of the present invention.

[0056] Figure label:

[0057] 1.0 Torsion end; 1.1 Torsion bracket; 1.1.1 First bottom frame; 1.1.2 Mounting frame; 1.1.3 Support rod; 1.1.4 Centering seat; 1.1.4.1 Centering circle; 1.1.5 Drive seat; 1.1.6 First foot plate; 1.2 Torsion disc; 1.2.1 Axial limit; 1.3 Drive device; 1.4 Slewing bearing; 1.5 Gear pair; 1.5.1 Pinion; 1.5.2 Gear; 2.0 Pulling end; 2.1 Pulling bracket; 2.1.1 Second bottom frame; 2.1.2 Intermediate guide frame; 2. 1.3 Ladder rod; 2.1.4 Second foot plate; 2.1.5 Perforated vertical support frame; 2.2 Trolley; 2.2.1 Trolley frame; 2.2.1.1 First hinge hole; 2.2.1.2 Locking claw shaft; 2.2.1.3 First traction hole; 2.2.1.4 Crossbeam; 2.2.1.5 Base frame; 2.2.1.6 Perforated crossbar; 2.2.1.7 Slide rod; 2.2.1.8 Slide rod seat; 2.2.1.9 Linear guide rail; 2.2.1.10 Guide rail mounting plate; 2.2.1.11 Roller track; 2.2.2 Swing slide; 2.2.2.1 2.2.2.1 Second hinge hole; 2.2.2.2 Second pull hole; 2.2.2.4 Linear bearing; 2.2.2.5 Bearing mounting plate; 2.2.2.6 Roller; 2.2.2.7 Sliding sleeve; 2.2.3 Positioning rod; 2.2.4 Pin; 2.2.5 Rotating sleeve; 2.2.6 Pull screw; 2.2.7 Pull nut; 2.2.8 Locking claw one; 2.2.8.1 First hook; 2.2.8.2 First pin hole; 2.2.8.3 First unlocking handle; 2.2.9 Locking claw two; 2.2.9.1 Second... 2.2.9.2 Hook; 2.2.9.3 Second unlocking handle; 2.2.10 Limiting block; 2.2.11 Force gauge; 3.0 Cable fixing head; 3.1 Fixing seat; 3.2 Pressure block; 3.3 Semi-conical sleeve; 3.4 Positioning pin; 3.5 Screw; 4.0 Fixing bolt; 5.0 Cable twisting device; 5.1 Base plate; 5.2 Seat groove; 5.3 Clamping piece; 5.4 Clamping screw; 5.5 Fixing screw; 6.0 Cable; 7.1 Long screw; 7.2 Locking nut one; 7.3 Locking nut two; 7.4 Pulling nut. Detailed Implementation

[0058] To make the technical means and objectives and effects of the present invention easier to understand, the embodiments of the present invention will be described in detail below with reference to specific illustrations.

[0059] It should be noted that all directional and positional terms used in this invention, such as "up," "down," "left," "right," "front," "back," "vertical," "horizontal," "inner," "outer," "top," "lower," "lateral," "longitudinal," and "center," are only used to explain the relative positional relationships and connections between components in a specific state. They are merely for the convenience of describing the invention and do not require the invention to be constructed and operated in a specific orientation; therefore, they should not be construed as limitations on the invention. Furthermore, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated.

[0060] In the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0061] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0062] like Figures 1-21 As shown, this invention discloses a cable torsion testing mechanism, comprising:

[0063] The torsion end 1.0 is used to clamp and drive one end of the cable under test 6.0 to reciprocate or continuously twist;

[0064] The tension end 2.0, spaced apart from the torsion end 1.0 along the same axis, is used to apply and maintain a constant axial tension on the other end of the cable 6.0;

[0065] The tension adjustment assembly includes a long screw 7.1, a pull nut 7.4, and a force gauge 2.2.11, which is used to manually adjust the tension and provide real-time feedback of the tension value through the force gauge 2.2.11;

[0066] The swing carriage guide structure, located inside the pulling end 2.0, is used to support the cable 6.0 fixing point and achieve decoupled transmission of vertical load and horizontal tension.

[0067] The torsion end 1.0 drives the cable 6.0 to rotate according to control commands, simulating the torsional load on the cable 6.0 during the yaw process of a wind turbine. The response is rapid and the angle is controllable. The tension end 2.0 applies stable tension to the cable 6.0 through a mechanical structure, ensuring that the cable 6.0 remains under controlled tension throughout the test, avoiding unrealistic conditions caused by slack. The tension adjustment component uses a screw and nut manual adjustment method, requiring no hydraulic or pneumatic power source, resulting in a simple structure, low cost, and high adjustment accuracy. The force gauge 2.2.11 independently measures axial tension, providing reliable real-time data. The pendulum guide structure effectively separates vertical gravity from horizontal tension, preventing interference with force measurement accuracy, while allowing slight displacement of the cable 6.0 during torsion, improving test realism. This setup, through a collaborative design of mechanical decoupling, manual precision adjustment, and real-time feedback, solves problems such as large tension fluctuations, measurement distortion, and severe structural interference in traditional testing devices, significantly improving the accuracy, repeatability, and engineering applicability of the cable 6.0 torsional fatigue test.

[0068] Specifically, the torsion end 1.0 consists of a torsion bracket 1.1, a torsion disc 1.2, a drive device 1.3, a slewing bearing 1.4, and a gear pair 1.5.

[0069] The torsion bracket 1.1, serving as the foundational support structure for the entire torsion end 1.0, is constructed by welding or bolting together a first bottom frame 1.1.1, a mounting frame 1.1.2, a support rod 1.1.3, a centering seat 1.1.4, a drive seat 1.1.5, and a first foot plate 1.1.6, forming a rigid whole. The first bottom frame 1.1.1 provides an interface to the ground; the mounting frame 1.1.2 supports the upper components; the support rod 1.1.3 connects the bottom and upper structures, enhancing overall stability; the centering seat 1.1.4, located in the center of the bracket, precisely positions the rotation center; the drive seat 1.1.5, located on the side, secures the drive unit 1.3; and the first foot plate 1.1.6 facilitates leveling and anchor bolt fixing. This multi-component integrated bracket structure exhibits high rigidity and excellent torsional resistance, effectively resisting the reaction torque generated during testing and preventing structural swaying from affecting test accuracy.

[0070] Preferably, the mounting frame 1.1.2 and the first bottom frame 1.1.1 are not perpendicular in the longitudinal direction, with an angle between them slightly less than 90 degrees (e.g., 88° to 89.5°), causing the mounting frame 1.1.2 to be slightly inclined towards the pulling end 2.0. The purpose of this inclined design is that when the cable 6.0 extends from the torsion end 1.0 to the pulling end 2.0, its axis of rotation can be nearly parallel to the axis of rotation of the torsion disc 1.2, thereby effectively avoiding additional bending stress caused by the height difference or angle deviation at both ends, more realistically simulating the actual cable 6.0 laying state between the rotating platform at the top of the tower and the fixed point at the bottom of the nacelle in a wind turbine generator set, and improving the engineering representativeness of the test conditions.

[0071] The torsion disc 1.2 is equipped with an axial limiter 1.2.1, which is an annular flange or hook-shaped structure that hooks onto the outer ring edge of the slewing bearing 1.4 located on the side of the centering seat 1.1.4, to limit the outward axial displacement of the torsion disc 1.2. This limiter structure cooperates with the slewing bearing 1.4 to ensure that the torsion disc 1.2 can maintain axial position stability when subjected to high torque and tension reaction force, preventing gear meshing failure or cable 6.0 loosening due to axial movement.

[0072] The drive unit 1.3 is mounted on the drive base 1.1.5 and provides rotational power. The pinion 1.5.1 is fixedly mounted on the output shaft of the drive unit 1.3, serving as its power output end. The pinion 1.5.1 meshes with the large gear 1.5.2, forming a reduction gear pair. When the drive unit 1.3 is started, the pinion 1.5.1 drives the large gear 1.5.2 to rotate, which in turn drives the torsion disk 1.2, which is fixedly connected to it, to reciprocate or continuously rotate around its axis of rotation.

[0073] Preferably, the drive device 1.3 can be one of a handwheel, a servo motor, or a hydraulic motor.

[0074] The cable twisting device 5.0 is fixedly mounted on the end face of the twisting disc 1.2, and has a cable clamping interface on the side facing the pulling end 2.0 (i.e., the downward side when applied to the top of the wind turbine tower). One end of the cable 6.0 passes through the cable twisting device 5.0 and is securely clamped. When the twisting disc 1.2 drives the cable twisting device 5.0 to rotate, the cable 6.0 twists around the rotation axis of the twisting disc 1.2, thereby accurately simulating the torsional load applied to the cable 6.0 by the rotating platform at the top of the wind turbine tower during yaw.

[0075] The cable twisting device 5.0 is a special interface device applied to the top of the wind power tower to allow the cable 6.0 to pass through and to provide reliable clamping and axial fixation to prevent slippage or loosening during twisting.

[0076] Specifically, the cable twisting device 5.0 includes a base plate 5.1, multiple seat grooves 5.2, several clamping components 5.3, and clamping screws 5.4. The base plate 5.1 is fixed to the end face of the twisting disc 1.2 by fixing screws 5.5 or welding. The multiple seat grooves 5.2 are distributed circumferentially or radially along the base plate 5.1 and are integrally formed or welded to the base plate 5.1. Each seat groove 5.2 has a long through-hole, and one side of the through-hole has a raised stop to limit the axial displacement of the clamping components 5.3.

[0077] The clamping element 5.3 has a semi-circular split structure, with an inner diameter matching the outer diameter of the cable 6.0 being tested, and is used to wrap around and conform to the surface of the cable 6.0. Multiple clamping elements 5.3 can be installed side by side in a single seat groove 5.2 to accommodate different lengths or segmented clamping requirements and improve clamping stability.

[0078] The clamping screw 5.4 is screwed into the threaded hole on one side of the seat groove 5.2, with its end pressing against the outer side of the clamping member 5.3. When the clamping screw 5.4 is tightened, the clamping member 5.3 is pushed against the stop in the seat groove 5.2, thereby firmly clamping the cable 6.0 in the semi-circular cavity, achieving high-friction anti-slip fixation. This structure allows for quick installation and removal of the cable 6.0, and the clamping force can be adjusted by the preload of the clamping screw 5.4, making it suitable for testing cables 6.0 with various outer diameter specifications.

[0079] It should be noted that, Figure 19 The diagram only schematically shows one set of clamping components 5.3 and one cable 6.0. In actual applications, multiple clamping units can be configured according to testing requirements to achieve synchronous twisting of single or multiple cables, such as... Figure 20 As shown, it can hold two cables 6.0.

[0080] This structure achieves near-parallel alignment of the cable 6.0 axis with the rotation axis through an inclined mounting frame 1.1.2. Combined with axial limiting 1.2.1 to prevent the torsion disc 1.2 from shifting, gear pair 1.5 to provide smooth high-torque transmission, and cable twisting device 5.0 that rotates directly with the disc, it together constructs a high-precision, high-reliability, and highly realistic cable 6.0 torsion loading system. It is particularly suitable for the durability verification of power cables 6.0, control cables 6.0, and fiber optic composite cables under ±400° yaw conditions in the wind power industry, and is significantly superior to traditional vertically aligned or tilt-compensated testing devices.

[0081] Gear pair 1.5 includes a pinion 1.5.1 and a large gear 1.5.2. The pinion 1.5.1 is connected to the output shaft of the drive unit 1.3 and is driven to rotate by a motor or hydraulic motor. The large gear 1.5.2 has a ring structure, and its external teeth mesh with the pinion 1.5.1 to achieve speed reduction and torque increase transmission. The large gear 1.5.2 is fixedly connected to the torsion disc 1.2 by bolts or a keyway structure, and the two rotate synchronously. The torsion disc 1.2 is used to mount cable clamps and directly drives the tested cable 6.0 to rotate.

[0082] One end of the slewing bearing 1.4 is connected to the inner ring or end face of the large gear 1.5.2, and the other end is fixedly connected to the centering seat 1.1.4. The slewing bearing 1.4 bears all the radial and axial loads of the torsion disc 1.2 and the large gear 1.5.2, ensuring smooth rotation without wobble.

[0083] Specifically, the centering seat 1.1.4 has a centering circle 1.1.4.1, the geometric center of which is the designed axis of rotation. The inner / outer ring mounting surfaces of the slewing bearing 1.4 are strictly collinear with the axis of rotation of the centering circle 1.1.4.1. At the same time, the rotation center of the large gear 1.5.2 is also collinear with this axis. Thus, the slewing bearing 1.4, the large gear 1.5.2, and the centering seat 1.1.4 are coaxially assembled.

[0084] This coaxial design ensures that the rotation center height of the entire torsion system is consistent, effectively avoiding vibration, noise, and additional bending moment caused by assembly eccentricity. The slewing bearing 1.4 provides high-precision rotational support, and together with the smooth transmission of the gear pair 1.5, it makes the torsion action precise and controllable. The rigid torsion bracket 1.1 provides a stable foundation for the above-mentioned precision movements. In summary, the torsion end 1.0 structure has the advantages of high rigidity, high coaxiality, low friction, and high torque output, and can reliably complete stringent testing tasks such as ±400° reciprocating torsion, meeting the long life and high reliability verification requirements of wind power cables 6.0.

[0085] Specifically, the tension end 2.0 consists of a tension bracket 2.1, a pulley 2.2, a cable fixing head 3.0, and a fixing bolt 4.0. It is used to apply and maintain a constant axial tension to the cable under test 6.0, while allowing it to generate necessary micro-displacement during torsion, thus avoiding the introduction of unreal stress.

[0086] The traction support 2.1, serving as the rigid base of the traction end, is stably connected by the second bottom frame 2.1.1, the intermediate guide frame 2.1.2, the ladder rod 2.1.3, and the second foot plate 2.1.4. The lower surface of the second foot plate 2.1.4 is in direct contact with the ground and is firmly anchored to the concrete ground with anchor bolts to ensure that the entire traction system does not shift or overturn under high tension conditions. The intermediate guide frame 2.1.2 is installed above the second bottom frame 2.1.1, with sufficient space reserved between its lower surface and the ground to facilitate the movement of the trolley 2.2. The ladder rod 2.1.3, composed of multiple vertical columns arranged at equal intervals, is located on the side away from the torsion end 1.0 and serves as a cooperating component of the safety locking mechanism, used to realize the step-by-step retraction of the trolley and the mechanical anti-derailment function.

[0087] The trolley 2.2 is the core actuator of the pulling end, which is composed of the trolley frame 2.2.1, the swing slide 2.2.2, the swing rod 2.2.3, the pin 2.2.4, the rotating sleeve 2.2.5, the pulling screw 2.2.6, the pulling nut 2.2.7, the locking claw one 2.2.8, the locking claw two 2.2.9, the limiting block 2.2.10, and the force gauge 2.2.11.

[0088] The trolley frame 2.2.1 includes a crossbeam 2.2.1.4 and a base frame 2.2.1.5, the upper and lower surfaces of which are flush, forming a horizontal reference plane; the trolley frame 2.2.1 is provided with a first hinge hole 2.2.1.1, the center of which is located on a horizontal plane parallel to the upper surfaces of the crossbeam 2.2.1.4 and the base frame 2.2.1.5, for connecting the swing rod 2.2.3.

[0089] The upper surface of the slide 2.2.2 is provided with evenly arranged screw holes 2.2.2.1. Cable fixing heads 3.0 are fitted into these screw holes by fixing bolts 4.0, and can be flexibly installed at any position on the slide 2.2.2. Typically, 1 to 3 cable fixing heads 3.0 can be fixed simultaneously on the same slide 2.2.2, enabling synchronous torsion testing of multiple cables and significantly improving testing efficiency. The slide 2.2.2 is also provided with a second hinge hole 2.2.2.2, the center of which is also located on a horizontal plane parallel to the upper surface of the slide 2.2.2.

[0090] The tensioning of cable 6.0 is achieved by prying the trolley 2.2 to move it away from the torsion end 1.0. Each time the trolley 2.2 is moved half the distance between ladder bars 2.1.3, locking claw 1 2.2.8 (or locking claw 2.2.9) automatically hooks onto one ladder bar 2.1.3. When the trolley 2.2 is moved again by half the distance between ladder bars 2.1.3, locking claw 2.2.9 (or locking claw 2.2.8) automatically hooks onto the next ladder bar 2.1.3. This alternating movement of the trolley 2.2 provides continuous tension to cable 6.0.

[0091] Locking claw one 2.2.8 is provided with a first hook 2.2.8.1, a first pin hole 2.2.8.2, and a first unlocking handle 2.2.8.3; locking claw two 2.2.9 is provided with a second hook 2.2.9.1, a second pin hole 2.2.9.2, and a second unlocking handle 2.2.9.3. The first pin hole 2.2.8.2 and the second pin hole 2.2.9.2 are both fitted onto the locking claw shaft 2.2.1.2 provided on the trolley frame 2.2.1, so that the two locking claws can rotate around the shaft.

[0092] When not obstructed by the ladder bars, locking claws 2.2.8 and 2.2.9 hang naturally under their own weight, and their hooks automatically engage with the column section of ladder bar 2.1.3, forming a mechanical stop. When tension needs to be released, the operator can pry upwards the first unlocking handle 2.2.8.3 or the second unlocking handle 2.2.9.3, which will lift the corresponding hook and disengage it from the ladder bar, allowing the trolley 2.2 to move back half a ladder bar spacing in the torsional direction. Because the two locking claws work alternately, it ensures that at least one locking claw of the trolley 2.2 is in a hooked state at any position, achieving intrinsically safe protection.

[0093] Alternatively, tension adjustment can be achieved using a screw mechanism. Specifically, a perforated vertical support 2.1.5 is added to the side of the tension bracket 2.1 away from the torsion end 1.0, and a perforated crossbar 2.2.1.6 is added to the side of the trolley bracket 2.2.1 away from the torsion end 1.0. One end of a long screw 7.1 passes through the perforated crossbar 2.2.1.6 and is fixed to the outside of the crossbar by a double-nut structure consisting of locking nut 7.2 and locking nut 7.3 to prevent axial loosening. The other end of the long screw 7.1 passes through the perforated vertical support 2.1.5, and a pulling nut 7.4 is screwed onto its outside. Tightening the pulling nut 7.4 pulls the trolley bracket 2.2.1 away from the torsion end 1.0, thus tightening the cable 6.0; loosening the pulling nut 7.4 in the opposite direction relaxes the cable. This purely mechanical adjustment method requires no external power source, is easy to operate, highly accurate, and has good stability.

[0094] One end of the force gauge 2.2.11 is connected to the second tension hole 2.2.2.3 on the pendulum slide 2.2.2, and the other end is connected to the first tension hole 2.2.1.3 on the trolley frame 2.2.1. When the pendulum slide guide structure is in the initial vertical state, the second tension hole 2.2.2.3, the first tension hole 2.2.1.3, and the force measuring axis of the force gauge 2.2.11 are strictly collinear. At this time, the reading of the force gauge 2.2.11 is the true axial tension of the cable (ignoring secondary friction factors).

[0095] To achieve effective decoupling between vertical load and horizontal tension, this invention provides various pendulum carriage guide structure schemes, as follows:

[0096] Example 1: The trolley moves by a lever-driven motion.

[0097] The tensioning of cable 6.0 is achieved by prying the trolley 2.2 to move it away from the torsion end 1.0. Each time the trolley 2.2 is moved half the distance between ladder bars 2.1.3, locking claw 1 2.2.8 (or locking claw 2.2.9) automatically hooks onto one ladder bar 2.1.3. When the trolley 2.2 is moved again by half the distance between ladder bars 2.1.3, locking claw 2.2.9 (or locking claw 2.2.8) automatically hooks onto the next ladder bar 2.1.3. This alternating movement of the trolley 2.2 provides continuous tension to cable 6.0.

[0098] Example 2: The trolley is pulled by a screw.

[0099] The above-mentioned screw adjustment and force measurement are designed to be collinear, ensuring accurate tension setting and long-term stability.

[0100] Example 3: Parallelogram Linkage Guiding Structure

[0101] like Figure 3 As shown, four sets of swing rods 2.2.3 are hinged to the first hinge hole 2.2.1.1 of the trolley frame 2.2.1 and the second hinge hole 2.2.2.2 of the swing slide 2.2.2 via pins 2.2.4, forming a parallelogram linkage mechanism. Since the rods are of equal length and symmetrically arranged, when the cable undergoes vertical displacement due to torsion, the swing slide 2.2.2 can swing around a virtual center, but its upper surface always remains parallel to the upper surfaces of the crossarm 2.2.1.4 and the base frame 2.2.1.5. This structure ensures the stability of the cable clamping point and avoids introducing additional bending moments; the vertical load is entirely borne by the swing rods 2.2.3 and is not transmitted to the force gauge 2.2.11, achieving complete force decoupling.

[0102] Example 4: Slide Rod-Sleeve Guide Structure

[0103] This embodiment omits the swing rod 2.2.3. A sliding rod 2.2.1.7 and a sliding rod seat 2.2.1.8 are vertically mounted on the trolley frame 2.2.1; a sliding sleeve 2.2.2.7 is fixed to the bottom of the pendulum slide 2.2.2. The sliding sleeve 2.2.2.7 fits around the outer periphery of the sliding rod 2.2.1.7, allowing the pendulum slide 2.2.2 to slide freely vertically while limiting horizontal offset. The vertical load is borne by the sliding rod-sleeve pair, while the horizontal tension is still independently measured by the force gauge 2.2.11 through a collinear force measurement path. This scheme has a compact structure and high guiding rigidity, making it suitable for low-cost testing scenarios.

[0104] Example 5: Linear Guide Rail – Linear Bearing Guiding Structure

[0105] This embodiment also omits the swing rod 2.2.3. A linear guide rail 2.2.1.9 is mounted on the trolley frame 2.2.1 and fixed by the guide rail mounting plate 2.2.1.10. A linear bearing 2.2.2.4 is provided on the pendulum slide 2.2.2 and connected by the bearing mounting plate 2.2.2.5. The linear bearing 2.2.2.4 slides with the linear guide rail 2.2.1.9, guiding the pendulum slide 2.2.2 in vertical linear motion. The vertical force is transmitted to the guide rail via the bearing, and the horizontal tension is independently measured by the force gauge 2.2.11. This structure has high guiding accuracy and low frictional resistance, making it suitable for high dynamic or long-life testing.

[0106] Example 6: Roller-Raceway Guide Structure

[0107] This embodiment also omits the swing rod 2.2.3. A raceway 2.2.1.11 is provided on the trolley frame 2.2.1, and a roller 2.2.2.6 is installed at the bottom of the swing slide 2.2.2. The roller 2.2.2.6 rolls in cooperation with the raceway 2.2.1.11, supporting the vertical movement of the swing slide 2.2.2 and bearing the gravity load. The horizontal tension force path is still collinearly transmitted through the second tension hole 2.2.2.3 → force gauge 2.2.11 → first tension hole 2.2.1.3, ensuring accurate tension measurement. This scheme has a low coefficient of friction and is easy to maintain, making it particularly suitable for heavy-duty cables, harsh environments, or high-frequency testing conditions.

[0108] Note: All six guiding structures above ensure that when the tension hole and the force gauge 2.2.11 are collinear, the measured force value is the true horizontal tension, and the vertical force does not interfere with the measurement.

[0109] The pendulum slide 2.2.2 is connected to the trolley frame 2.2.1 via a horizontal guide assembly. The horizontal guide assembly is a slide rod-sleeve, linear guide rail-linear bearing, or raceway-roller structure, which allows the pendulum slide 2.2.2 to move in the horizontal direction and realizes the separation and transmission of the horizontal axial load on the cable from the load perpendicular to the cable. The load perpendicular to the cable is balanced by the support force of the horizontal guide assembly, ensuring that the force gauge 2.2.11 measures the horizontal axial load on the cable and the frictional force generated between the horizontal guide assembly. When the frictional resistance between the horizontal guide assembly is sufficiently small to be ignored compared with the above-mentioned horizontal axial load, the force gauge 2.2.11 measures the axial tensile force on the cable.

[0110] In addition, locking claw 1 2.2.8 and locking claw 2 2.2.9 are symmetrically installed on both sides of the trolley frame 2.2.1 and can be alternately hooked onto the column of the ladder rod 2.1.3. When the tension is released, they can achieve a half-step movement and a double-safety mechanical anti-disengagement function. The limiting block 2.2.10 is used to limit the position of locking claw 1 2.2.8 and locking claw 2 2.2.9 to prevent the safety function from failing.

[0111] In summary, this tensioning end achieves vertical / horizontal load decoupling through diverse guiding structures, supports multi-cable synchronous testing through a multi-screw hole layout, ensures accurate tension measurement through collinear force measurement paths, and provides intrinsic safety protection through a ladder rod and dual locking claws. It constructs a high-precision, high-safety, and highly versatile cable tension loading platform, which works in conjunction with the torsion end 1.0 to fully meet the stringent verification requirements for cable torsional fatigue performance in fields such as wind power and rail transit.

[0112] Specifically, when cable 6.0 is firmly clamped between cable fixing head 3.0 and cable twisting device 5.0, and its two ends are at similar heights and the whole cable is pulled off the ground and suspended in the air, the value measured by force gauge 2.2.11, ignoring the errors caused by minor factors such as internal friction and air resistance, is equivalent to the actual axial tension borne by cable 6.0 at cable twisting device 5.0.

[0113] The key to this equivalence relationship being valid lies in:

[0114] (1) When the pendulum slide guide structure is in the initial state, the direction of the horizontal tension force at the second tension hole 2.2.2.3 strictly passes through the center of the first tension hole 2.2.1.3 and the force measuring axis of the force gauge 2.2.11, so that the force transmission path is collinear;

[0115] (2) The vertical load on the pendulum slide 2.2.2 (including the weight of the cable 6.0 and the weight of the pendulum slide 2.2.2 itself) is entirely borne by the guide structure (pendulum rod 2.2.3, sliding sleeve 2.2.2.7, guide rail 2.2.1.10 or roller 2.2.2.6) and is not transmitted to the force gauge 2.2.11;

[0116] (3) The distance between the torsion end 1.0 and the tension end 2.0 is fixed, and the cable is in a static equilibrium state with no acceleration effect.

[0117] Based on this, the operator can adjust the tension nut 2.2.7 or pull the nut 7.4 to move the position of the trolley 2.2 and the pendulum slide 2.2.2, so that the force value displayed by the force gauge 2.2.11 is equal to the weight of the suspended portion of the cable 6.0 at the test length (e.g., the self-weight of a 12-meter cable), or set to other verification values ​​according to specific test standards (e.g., 1.5 times self-weight, rated working tension, etc.). Subsequently, the torsion end 1.0 is started to perform reciprocating torsional motion, which can effectively verify the structural stability, insulation fatigue resistance, and conductor torsional resistance of the cable under the realistic simulation of cable suspension + torsion combined working conditions.

[0118] This setting method not only conforms to the actual stress state of cables at the top of towers or masts in fields such as wind power and marine engineering, but also avoids problems such as abnormal damage caused by excessive tension or loosening and knotting caused by insufficient tension, which significantly improves the engineering credibility of test results and the product certification pass rate.

[0119] Preferably, the installation spacing between the torsion end 1.0 and the tension end 2.0 is 12 meters. This distance is set according to wind power cable testing standards such as IEC 61400-23, which can accurately reflect the actual stress length of the cable when the wind turbine nacelle yaws; the 12-meter spacing ensures a sufficient bending radius while avoiding tension attenuation or vibration interference due to excessive length; at the same time, it is compatible with standard laboratory site layouts, facilitating equipment installation and maintenance. This setting makes the test results have direct engineering guidance significance and improves the product certification pass rate.

[0120] Preferably, the cable fixing head 3.0 includes a fixing base 3.1, a pressure block 3.2, a two-part semi-conical sleeve 3.3, a positioning pin 3.4, and a screw 3.5. The fixing base 3.1 and pressure block 3.2 have semi-conical holes that match the outer conical surface of the semi-conical sleeve 3.3. When the screw 3.5 is tightened, the pressure block 3.2 presses down, causing the semi-conical sleeve 3.3 to wedge in along the conical surface, generating a strong radial clamping force. This conical self-locking structure utilizes the wedging principle to convert axial pressure into several times the radial clamping force, resulting in high clamping force and excellent anti-slip performance. It is suitable for high-tension (≥5kN) testing scenarios. Disassembly and assembly only require loosening the screw, making operation quick and easy. The semi-conical sleeve 3.3 can be replaced with different inner diameter specifications to adapt to various cable outer diameters. This design balances high reliability and high versatility, significantly improving testing efficiency.

[0121] Another object of the present invention discloses an operating method for a cable torsion testing mechanism, which, based on any of the above-mentioned cable torsion testing mechanisms, specifically includes the following steps:

[0122] Step 1: Pre-set the test parameters, including test length (e.g., 12 m), target tension value, torsion angle (e.g., ±400°), and number of cycles (e.g., 5000 times).

[0123] Step 2: Install the cable. Fix one end of the cable 6.0 to the cable clamp 5.0 at the twist end 1.0, and pass the other end through the cable fixing head 3.0 at the pull end 2.0 and clamp it.

[0124] Step 3: Adjust the tension by tightening the pull nut 7.4 and monitoring it with the force gauge 2.2.11 until the target tension value is reached;

[0125] Step 4: Start the torsion test and control the servo motor 1.2 to perform reciprocating torsion at the set angle and speed;

[0126] Step 5: Monitor in real time and record the data from torque sensor 1.4 and force gauge 2.2.11. If the tension fluctuation is ≥±5%, suspend the inspection.

[0127] Step 6: After the test is completed, stop twisting, release the tension step by step through the safety locking mechanism, and disassemble the cable.

[0128] This method ensures controllable testing, reliable data, and safe operation through standardized procedures, dual monitoring, and safe unloading. It is particularly suitable for torsional fatigue verification of high-reliability cables in fields such as wind power and rail transportation.

[0129] Specifically, in step 3, before adjusting the tension, it is necessary to confirm that the centers of the force gauge 2.2.11, the first tension hole 2.2.1.3 of the trolley frame, and the second tension hole 2.2.2.3 of the pendulum slide 2.2.2 are collinear; in step S4, after the initial tension is applied, it is held for 5 minutes to observe whether it is stable. If the tension drops by more than 3%, it is re-tensioned to the target value; in step 5, the ambient temperature is controlled between −20℃ and +60℃ to simulate extreme climatic conditions.

[0130] This setup, through collinear calibration, pre-stretch steady-state testing, and environmental simulation, further enhances test accuracy and engineering representativeness, effectively addressing test deviations caused by installation errors, material creep, or temperature drift, and ensuring high consistency of test results across different batches.

[0131] In summary, this invention solves the problems of inaccurate tension control, severe structural interference, and high operational risks in existing cable torsion testing by combining multiple technical means such as tension mechanical adjustment, independent force feedback, vertical / horizontal load decoupling (including multiple optional guide structures), safety locking, and conical self-locking clamping. It achieves high-precision, high-safety, and high-simulation cable torsion fatigue testing, and has significant technological progress and broad industrial application prospects.

[0132] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A cable torsion testing mechanism, characterized in that, include: The twisting end (1.0) is used to clamp and drive one end of the cable under test (6.0) to reciprocate or continuously twist; The pulling end (2.0), which is spaced apart from the torsion end (1.0) along the same axis, is used to apply and maintain a constant axial tension to the other end of the cable (6.0); The tension adjustment assembly is used to manually adjust the magnitude of the axial tension and is equipped with a force gauge (2.2.11) to provide real-time feedback of the tension value; The swing carriage guide structure is located inside the pulling end (2.0) to support the cable fixing point and realize the independent transmission of vertical load and horizontal tension.

2. The cable torsion testing mechanism according to claim 1, characterized in that, The tension adjustment assembly includes a long screw (7.1), a pulling nut (7.4), and a perforated vertical support (2.1.5). One end of the long screw (7.1) is connected to the pulley frame (2.2.1) of the pulling end (2.0), and the other end passes through the perforated vertical pull frame ( 2.1.5), the pull nut (7.4) is screwed onto the end of the long screw (7.1) to adjust the tension by moving the trolley frame (2.2.1) by tightening or loosening it.

3. The cable torsion testing mechanism according to claim 2, characterized in that, The long screw (7.1) passes through the trolley frame ( The perforated crossbar (2.2.1.6) on 2.2.1) has a locking nut one (7.2) and a locking nut two (7.3) at the through end, which together form a double nut anti-loosening structure.

4. The cable torsion testing mechanism according to claim 1, characterized in that, The guide structure of the swing carriage is a parallelogram linkage mechanism, including four sets of swing rods (2.2.3). Each set of swing rods (2.2.3) is hinged at both ends to the trolley frame (2.2.1) and the swing carriage (2.2.2) respectively, so that the upper surface of the swing carriage (2.2.2) remains horizontal during the swinging process.

5. The cable torsion testing mechanism according to claim 4, characterized in that, The swing carriage (2.2.2) is connected to the trolley frame (2.2.1) via a horizontal guide assembly. The horizontal guide assembly is a slide rod-sleeve, linear guide rail-linear bearing, or raceway-roller structure, which allows the swing carriage (2.2.2) to move in the horizontal direction and realizes the separation and transmission of the horizontal axial load on the cable from the load perpendicular to the cable.

6. The cable torsion testing mechanism according to claim 1, characterized in that, The pulling end (2.0) also includes a safety locking mechanism, which includes a vertically arranged ladder rod group (2.1.3) and symmetrically arranged locking claw one (2.2.8) and locking claw two (2.2.9); the locking claw one (2.2.8) and locking claw two (2.2.9) are alternately hooked on the adjacent columns of the ladder rod group (2.1.3) to realize the unidirectional movement of the pulley (2.2) or the step-by-step release of tension.

7. The cable torsion testing mechanism according to claim 6, characterized in that, The mounting frame (1.1.2) of the torsion end (1.0) is inclined toward the pulling end (2.0) relative to its first bottom frame (1.1.1), with an included angle of less than 90°, so that the axis of the cable (6.0) is approximately parallel to the rotation axis of the torsion end (1.0).

8. The cable torsion testing mechanism according to claim 1, characterized in that, The force gauge (2.2.11) and the pulley frame tension hole ( 2.2.1.3) The centers of the three (2.2.2.3) are collinear to ensure that the tension measurement path is free of deviation.

9. An operating method for a cable torsion testing mechanism, characterized in that, Based on the cable torsion testing mechanism according to any one of claims 1-8, the following steps are included: S1: A cable twisting device (5.0) that fixes one end of the cable (6.0) to the twisting end (1.0) and the other end to the pulling end (2.0) and a cable fixing head (3.0). S2: Manually adjust the tension using the tension adjustment component and set it to the target tension value based on the reading of the force gauge (2.2.11); S3: Start the torsion end (1.0) and perform reciprocating torsion at the set angle; S4: After the test, release the tension step by step through the safety locking mechanism and disassemble the cable.

10. The operating method of the cable torsion testing mechanism according to claim 9, characterized in that, Before step S3, maintain the preset tension for 5 minutes. If the tension drops by more than 3%, re-tension to the target value. During the test, the ambient temperature is controlled between -20℃ and +60℃.

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