Load color development type mining trailing cable

Abstract

The invention relates to a load color development type mining trailing cable which comprises a cable core, an inner sheath, a load color development belt and a light-transmitting outer sheath which are sequentially arranged from inside to outside. The load color developing tape is formed by compounding a current sensing module, an LED driving unit and an optical enhancement layer. The current sensing module collects the current of the cable core in real time, the LED driving unit drives the multi-color LED to emit light according to a preset current-color mapping logic, and the optical enhancement layer reflects an optical signal and performs continuous light emission enhancement; the current state is directly converted into a visual light color signal, real-time and visual self-diagnosis of the cable load is realized, the problem of lagging of traditional temperature monitoring is solved, and the cable load self-diagnosis device has the advantages of beforehand early warning, no need of external equipment and all-weather visibility, and is particularly suitable for complex and severe environments such as mines and tunnels.

Description

Technical Field

[0001] This invention relates to the field of mining cable technology, and in particular to a load-indicating color-changing mining drag cable. Background Technology

[0002] Mining drag cables, as key power transmission carriers in heavy working environments such as mines and tunnels, often face the challenges of complex mechanical stress, frequent dragging, and harsh environmental conditions. During cable operation, abnormal current states such as overload and short circuit can easily cause the insulation layer to overheat, age, or even break down, which can lead to fires, equipment damage, and production safety accidents in severe cases. Currently, the monitoring of the operating status of mining cables mainly relies on the following methods: An external current sensor and monitoring system transmits the current signal to the back-end monitoring unit for analysis by connecting a current transformer or Hall sensor in series in the cable line. This method requires additional wiring and configuration of the acquisition module, which is complex and costly, and is not suitable for mobile towing application scenarios. Temperature monitoring uses thermocouples, infrared thermometry, or distributed fiber optic sensing technology to monitor changes in the surface or internal temperature of the cable. However, the temperature response is lagging. When the temperature inside the conductor rises sharply due to overcurrent, it takes several minutes to tens of minutes for the heat to be conducted to the cable sheath. By this time, the insulation layer has already suffered irreversible damage. While improving the mechanical structure and materials of towed cables can enhance their wear resistance, tensile strength, and weather resistance, it cannot provide real-time feedback on the electrical status of the cable during operation, thus remaining a form of passive protection. In addition, existing monitoring methods all rely on external equipment, which is difficult to install and maintain in environments with insufficient lighting or limited space, such as underground mines and tunnels. Furthermore, early warning information often relies on audible and visual alarms or displays, which is not conducive to intuitive and long-distance identification by on-site personnel. Summary of the Invention

[0003] In view of this, the present invention provides a load-indicating color-coded mining drag cable that eliminates the need for complex external monitoring equipment, enabling real-time, intuitive, and visual early warning of the cable load status, and significantly improving the cable's safety and economy.

[0004] To achieve the above objectives, the present invention provides a load-indicating color-changing mining drag cable, comprising a cable core (1), an inner sheath (2), a load-indicating color-changing strip (3), and a TPU protective sheath (4) arranged sequentially from the inside to the outside. The cable core (1) includes, from the inside out, a stranded conductor (11), an insulation layer and an insulation shielding layer (12). The load color display strip (3) includes a current sensing module (31), a multi-color LED driving unit (32), and an optical enhancement layer (33). The current sensing module (31) is connected to the inner sheath (2) to collect the current signal flowing through the cable core in real time; The LED driving unit (32) is connected to the current sensing module and drives the multi-color LED to emit light according to the current signal. The LED driving unit (32) presets current-color logic, and the color of the light emitted by the multi-color LED changes with the magnitude of the current. The optical enhancement layer (33) covers the LED light-emitting area of ​​the LED driving unit (32) to enhance and maintain the visibility of the light signal.

[0005] Preferably, the insulating layer and the insulating shielding layer (12) are wrapped around the outside of the stranded conductor (11) by extrusion.

[0006] Preferably, the current sensing module (31) includes a sampling resistor. The high-side driver is a VN7003AH model, and the LED driving unit (32) includes an RGB LED driver, which is an LP5528 model.

[0007] Preferably, the input terminal of the high-side driver is connected to three thermistors, and the other end of the three thermistors is connected to the input terminal of the three-phase power supply. The output terminal interface 1, port 2, and port 3 of the high-side driver are connected to the first relay K1 and the input terminal of the RGB LED driver. The output terminal interface 1 of the RGB LED driver is connected to the green LED, the output terminal interface 2 of the RGB LED driver is connected to the yellow LED, and the output terminal interface 3 of the RGB LED driver is connected to the red LED.

[0008] Preferably, the sampling resistor The high-side driver acquires the sampling resistor in the current path connected in series in the stranded conductor (11). The voltage signals at both ends are processed and diagnosed through the current sensor module.

[0009] Preferably, the RGB LED driver is connected via I 2 The C or SMBus interface receives control commands and controls the PWM duty cycle of the red, green, and blue LEDs to mix the target color.

[0010] Preferably, the preset current-color logic is as follows: when the current is less than the first threshold, the LED is driven to emit a solid green light, indicating that the load is normal; when the current is between the first threshold and the second threshold, the LED is driven to emit a solid yellow light, indicating that the load is moderate and needs attention; when the current is greater than or equal to the second threshold, the LED is driven to emit a red flashing light in a high-frequency PWM manner, indicating that the load is overloaded or faulty and needs to be dealt with immediately. The first threshold and the second threshold are adjusted according to the usage scenario.

[0011] Preferably, the optical enhancement layer (33) includes a reflective strip and a phosphorescent material. The reflective strip adopts a micro-rhombic lattice and is embedded with high-refractive-index glass microspheres. The phosphorescent material is doped into the reflective strip or coated on the surface of the reflective strip.

[0012] Preferably, the TPU protective sleeve is made of translucent polyether polyurethane with a thickness of 5.0 mm.

[0013] Preferably, the load color developing strip (3) is spirally wound or longitudinally wrapped around the outer surface of the inner sheath (2).

[0014] Compared with the prior art, the beneficial effects of the present invention are: This invention directly collects current signals through a current sensing module and instantly converts them into light signals, completely overcoming the problem of delayed early warning caused by heat conduction delay in traditional "temperature monitoring". It can issue visual alarms in advance before overheating or insulation damage occurs inside the cable, truly realizing the leap from "post-event alarm" to "pre-event prevention". This invention transforms abstract current data into easily understandable color information through a preset current-color mapping logic (such as green / yellow / red). Without the need for professional personnel or instruments to interpret the data, on-site personnel can directly and quickly determine the cable load status (normal, caution, danger) from a distance, greatly improving emergency response speed and decision-making accuracy. This invention eliminates the costs of purchasing, installing, wiring, and maintaining external monitoring equipment. The cable itself is a complete diagnostic unit, significantly reducing the total lifecycle usage and maintenance costs. The optical enhancement layer combines reflective and phosphorescent properties to achieve visibility within 380m and continuous luminescence for 8 hours in dark environments. It is suitable for complex operating scenarios with insufficient lighting, such as underground mines and tunnels, making early warning signal transmission more efficient and maintaining high reliability even in complex and harsh environments. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this invention. For those skilled in the art, other embodiments can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of the cross-section of the cable structure of the present invention, wherein 1 is the cable core, 2 is the inner sheath, 3 is the load color-indicating tape, 4 is the TPU protective sheath, 11 is the stranded conductor, and 12 is the insulating shielding layer. Figure 2 This is a circuit block diagram of the color rendering layer of the present invention. Detailed Implementation

[0017] To further illustrate the technical means and effects adopted in this embodiment to achieve the intended purpose of the invention, the following detailed description of the specific implementation methods, structures, features and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0018] Example 1 like Figure 1 As shown, this embodiment provides a load-indicating color-changing mining drag cable, which includes a cable core (1), an inner sheath (2), a load-indicating color-changing tape (3), and a TPU protective sheath (4) arranged sequentially from the inside to the outside. The TPU protective case (4) is made of light-transmitting polyether polyurethane with a thickness of 5.0 mm. It protects the internal color band and ensures that the LED light signal is transmitted efficiently without affecting the optical effect. The cable core (1) includes a stranded conductor (11), an insulation layer and an insulation shielding layer (12) from the inside to the outside. The insulation layer and the insulation shielding layer (12) are wrapped around the outside of the stranded conductor (11) by extrusion. The insulation shielding layer is preferably an extruded shielding layer made of semi-conductive material. The load color display strip (3) includes a current sensing module (31), a multi-color LED driving unit (32) and an optical enhancement layer (33). The load color display strip (3) is spirally wound or longitudinally wrapped around the outer surface of the inner sheath (2). The current sensing module (31) includes a sampling resistor. The high-side driver is a VN7003AH model, and the LED driver unit (32) includes an RGB LED driver, which is an LP5528 model. The input terminal of the high-side driver is connected to three thermistors, and the other end of the three thermistors is connected to the input terminal of the three-phase power supply. The output terminal interface 1, port 2, and port 3 of the high-side driver are connected to the first relay K1 and the input terminal of the RGB LED driver. The output terminal interface 1 of the RGB LED driver is connected to the green LED, the output terminal interface 2 of the RGB LED driver is connected to the yellow LED, and the output terminal interface 3 of the RGB LED driver is connected to the red LED. sampling resistor The high-side driver acquires the sampling resistor in the current path connected in series with the stranded conductor (11). The voltage signals at both ends are processed and diagnosed through the current sensor module. The VN7003AH high-side driver serves as the core of current sensing and diagnosis, integrating a high-precision current sensor module with diagnostic functions such as overcurrent, overtemperature, and short circuit. The current sensing module (31) is connected to the inner sheath (2) to collect the current signal flowing through the cable core in real time. The working principle of the current sensing module is as follows: when the current flows through the sampling resistor At this time, a voltage drop proportional to the current is generated. The VN7003AH high-side driver amplifies the voltage signal through an internal amplifier and converts it into a standard analog voltage output. , The signal reflects the current magnitude in real time and is input to the control unit (such as a microcontroller or comparator circuit). At the same time, the internal diagnostic circuit of the VN7003AH high-side driver continuously monitors the operating status. Once overcurrent, short circuit or overheating is detected, a flag signal is immediately triggered (such as the fault output pin being pulled low) for the control unit to respond. The LED driving unit (32) is connected to the current sensing module and drives the multi-color LED to emit light according to the current signal. The LED driving unit (32) presets the current-color logic, and the color of the light emitted by the multi-color LED changes with the magnitude of the current. The preset current-color logic is as follows: when the current is less than the first threshold, the LED is driven to emit a solid green light, indicating that the load is normal; when the current is between the first threshold and the second threshold, the LED is driven to emit a solid yellow light, indicating that the load is moderate and needs attention; when the current is greater than or equal to the second threshold, the LED is driven to emit a red flashing light in a high-frequency PWM mode, indicating that the load is overloaded or faulty and needs to be dealt with immediately. The first and second thresholds are adjusted according to the usage scenario. In this embodiment, the first threshold is 30A and the second threshold is 100A. Therefore, the current-color logic is as follows: Current <30A: Output "green solid light" command, indicating normal load; When the current is between 30A and 100A: the output "yellow solid light" command indicates that the load is moderate and should be monitored. When the current >100A or the diagnostic flag is triggered: output a "red flashing" command, indicating an overload or fault that requires immediate attention; The LP5528 RGB LED driver uses I 2 The C or SMBus interface receives control commands to control the PWM duty cycle of the red, green, and blue LEDs respectively, mixing the target color. Always on green: Sets the green PWM duty cycle to 100%, while red and blue are 0%; Yellow constant light: Simultaneously turn on the red and green LEDs, and mix them to produce yellow by adjusting the PWM ratio (e.g., red:green ≈ 1:1); Red flashing: Under overload conditions, the flashing mode is activated: the red LED switches on and off rapidly at a 20KHz PWM frequency and a 94% duty cycle. The 20KHz high-frequency PWM ensures that the human eye perceives a smooth flashing, avoiding visual fatigue caused by low-frequency flashing; the 94% duty cycle ensures high brightness display, while retaining a 6% off interval to enhance the warning effect. Blinking mode implementation: The LP5528 integrates a blinking control register, which can be programmed to set the blinking frequency and duty cycle, without the need for continuous external MCU intervention, thus reducing system complexity; The optical enhancement layer (33) covers the LED light-emitting area of ​​the LED driving unit (32) to enhance and maintain the visibility of the light signal. The optical enhancement layer (33) includes Tratos reflective strips and phosphorescent materials. The reflective strips adopt micro-rhomboid lattice and are embedded with high-refractive-index glass microspheres, which can reflect about 80% of the incident light along the original path. The maximum visibility distance is 380m, ensuring long-distance visibility during the day or under good lighting conditions. The phosphorescent materials (such as aluminate-based phosphors) are doped into the reflective strips or coated on the surface of the reflective strips. In the dark environment, they absorb the light energy emitted by the LED and continue to emit light. The afterglow time can reach 8 hours, ensuring continuous warning in dark environments such as night, tunnels or underground. The load color strip (3) converts the physical state of the cable current into an optical signal in real time. The load state is directly reflected by the color change of the multi-color LED, realizing the "cable self-diagnosis" function. In high-power DC charging lines, it realizes overcurrent warning and user visual prompts, avoiding the lag of traditional temperature monitoring (evidence shows that the core wire temperature has exceeded the critical point when it is conducted to the sheath). It upgrades from "post-event alarm" to "pre-event prevention". The system is simplified: the cable has its own optical diagnosis, and there is no need for external infrared temperature measurement, fiber optic sensing and other additional equipment, which reduces wiring and maintenance costs and provides clear visual warnings for users.

[0019] The working principle of the drag cable provided in this embodiment is as follows: S1. Current Sampling: The current in the cable conductor is sampled by a resistor. Converted into a voltage signal; S2. Signal Processing: The VN7003AH high-side driver amplifies and diagnoses the signal, outputting an analog voltage and fault indicator. S3, Logic Decision: The control unit executes current-color mapping logic based on the input signal to generate LED control instructions; S4, Light and Color Output: LP5528 drives RGB LEDs, mixes colors and controls blinking through PWM; S5, Optical Signal Enhancement: The optical enhancement layer reflects the LED light signal and emits light continuously, achieving all-weather visibility.

[0020] Example 2 This embodiment provides a specific production example of a load-indicating color-coded mining drag cable: A stranded conductor is obtained by first bundling (1*27 / 0.375) and second re-bundling (1*27 / 0.375+18*21 / 0.375) of tin-plated soft round copper single wire. The bundling direction is right-handed and the stranding pitch ratio is 12-14 times. The re-bundling direction is left-handed and the stranding pitch ratio is 9-10 times. The outer diameter of the conductor is controlled at 9.5±0.3mm. A semi-conductive nylon tape is wrapped around a stranded conductor. The tape is 30 mm wide and 0.14 mm thick, wrapped in a right-hand direction, with an overlap rate of 15% to 20%. Three layers of rubber material are extruded onto the stranded and wound conductor in a three-layer co-extrusion manner. From the inside out, they are semi-conductive inner screen rubber + ethylene propylene rubber + semi-conductive outer screen rubber. The thickness of the semi-conductive inner screen rubber is 0.6mm, the thickness of the ethylene propylene rubber layer is 5.5mm, and the thickness of the semi-conductive outer screen rubber is 0.8mm. The above insulated wire cores are twisted right-hand into a cable in a 3+3 structure, with a cable section diameter ratio of 8 to 9 times to obtain the cable core; A 5.5mm thick chlorinated polyethylene rubber inner sheath buffer layer is extruded onto the above cable core; Load color display tape installation: Loosely wrap the load color display tape around the inner sheath layer to ensure that the current sensing module is electrically connected to the conductor and that the LED driver unit is tightly bonded to the optical enhancement layer; On the load color layer, a layer of high wear-resistant and light-transmitting polyether polyurethane is extruded with a thickness of 5.0 mm to complete the cable preparation.

[0021] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A load-indicating color-changing mining drag cable, characterized in that, It includes, from the inside out, a cable core (1), an inner sheath (2), a load color indicator strip (3), and a TPU protective sleeve (4). The cable core (1) includes, from the inside out, a stranded conductor (11), an insulation layer and an insulation shielding layer (12). The load color display strip (3) includes a current sensing module (31), a multi-color LED driving unit (32), and an optical enhancement layer (33). The current sensing module (31) is connected to the inner sheath (2) to collect the current signal flowing through the cable core in real time; The LED driving unit (32) is connected to the current sensing module and drives the multi-color LED to emit light according to the current signal. The LED driving unit (32) presets current-color logic, and the color of the light emitted by the multi-color LED changes with the magnitude of the current. The optical enhancement layer (33) covers the LED light-emitting area of ​​the LED driving unit (32) to enhance and maintain the visibility of the light signal.

2. The load-indicating color-changing mining drag cable according to claim 1, characterized in that, The insulating layer and the insulating shielding layer (12) are wrapped around the outside of the stranded conductor (11) by extrusion.

3. The load-indicating color-changing mining drag cable according to claim 1, characterized in that, The current sensing module (31) includes a sampling resistor. The high-side driver is a VN7003AH model, and the LED driving unit (32) includes an RGB LED driver, which is an LP5528 model.

4. A load-indicating color-changing mining drag cable according to claim 3, characterized in that, The input terminal of the high-side driver is connected to three thermistors, and the other end of the three thermistors is connected to the input terminal of the three-phase power supply. The output terminal interface 1, port 2, and port 3 of the high-side driver are connected to the first relay K1 and the input terminal of the RGB LED driver. The output terminal interface 1 of the RGB LED driver is connected to the green LED, the output terminal interface 2 of the RGB LED driver is connected to the yellow LED, and the output terminal interface 3 of the RGB LED driver is connected to the red LED.

5. A load-indicating color-changing mining drag cable according to claim 4, characterized in that, The sampling resistor The high-side driver acquires the sampling resistor in the current path connected in series in the stranded conductor (11). The voltage signals at both ends are processed and diagnosed through the current sensor module.

6. A load-indicating color-changing mining drag cable according to claim 3, characterized in that, The RGB LED driver is connected via I 2 The C or SMBus interface receives control commands and controls the PWM duty cycle of the red, green, and blue LEDs to mix the target color.

7. A load-indicating color-changing mining drag cable according to claim 1, characterized in that, The preset current-color logic is as follows: when the current is less than the first threshold, the LED is driven to emit a solid green light, indicating that the load is normal; when the current is between the first threshold and the second threshold, the LED is driven to emit a solid yellow light, indicating that the load is moderate and needs attention; when the current is greater than or equal to the second threshold, the LED is driven to emit a red flashing light in a high-frequency PWM mode, indicating that the load is overloaded or faulty and needs to be dealt with immediately. The first threshold and the second threshold are adjusted according to the usage scenario.

8. A load-indicating color-changing mining drag cable according to claim 1, characterized in that, The optical enhancement layer (33) includes a reflective strip and a phosphorescent material. The reflective strip adopts a micro-rhomboid lattice and is embedded with high-refractive-index glass microspheres. The phosphorescent material is doped into the reflective strip or coated on the surface of the reflective strip.

9. A load-indicating color-changing mining drag cable according to claim 1, characterized in that, The TPU protective case is made of translucent polyether polyurethane with a thickness of 5.0 mm.

10. A load-indicating color-changing mining drag cable according to claim 1, characterized in that, The load color developing strip (3) is spirally wound or longitudinally wrapped around the outer surface of the inner sheath (2).

Images