Novel reel type video monitoring device for lining trolley

Abstract

The invention discloses a novel reel type video monitoring device for a lining trolley, and belongs to the technical field of tunnel construction equipment. According to the device, the video monitoring assembly integrating the camera and the composite cable is automatically wound and unwound through the reel mechanism, the control unit controls the driving motor to operate, the camera is fixed to the wall face of the tunnel through the clamp at the bottom of the camera, rapid deployment and recovery of the tunnel construction video monitoring equipment are achieved, and the monitoring efficiency and reliability are improved.

Description

Technical Field

[0001] This invention relates to the field of tunnel construction equipment technology. More specifically, this invention relates to a novel reel-type video monitoring device for a lining trolley. Background Technology

[0002] During tunnel construction, the deployment and retrieval of video surveillance equipment typically rely on manual operation. Operators must manually drag cables to fix the cameras near the work surface, and then manually retrieve the cables after construction is completed. This process is inefficient, and the frequent manual operations increase the labor intensity of construction workers.

[0003] Because cable winding and unwinding rely on manual control, it's difficult to maintain stable cable tension. Excessive tension in the cable can damage internal conductors or wear down the outer sheath; conversely, excessive looseness can lead to tangling or knotting, affecting equipment operation. Disorderly cable winding and unwinding can also result in uneven cable distribution on the reel, further exacerbating wear.

[0004] The tunnel environment is complex, with adverse factors such as dust and humidity. Ordinary camera equipment may experience reduced reliability due to environmental corrosion over long-term use. Furthermore, cable routing within the confined space often requires navigating around obstacles, increasing the risk of cables getting stuck or scratched. Traditional wired transmission methods also limit the flexibility of camera placement, and long-distance transmission may lead to signal attenuation.

[0005] Previous attempts to improve the system have encountered several difficulties. Achieving automatic cable retraction and deployment while maintaining stable tension requires addressing the coordination between the mechanical structure and control strategy. Ensuring reliable operation in harsh environments necessitates consideration of special requirements such as explosion-proof and protective features. Furthermore, integrating an automatic retraction and deployment mechanism within a limited space while maintaining structural compactness presents a design challenge. Summary of the Invention

[0006] One object of the present invention is to solve at least the above-mentioned problems and to provide at least the advantages that will be described later.

[0007] To achieve these objectives and other advantages according to the present invention, a novel reel-type video monitoring device for lining trolleys is provided, comprising: The reel mechanism is fixedly mounted on the traveling gantry of the lining trolley by a bracket; A drive motor is mounted on the traveling gantry of the lining trolley and located next to the support. It drives the reel mechanism to rotate and reel in the wire through a transmission mechanism. A video surveillance component includes a camera and an integrated cable wound on the reel mechanism, the cable being a composite cable integrating power and signal lines. The control unit is electrically connected to the drive motor and is used to control the start, stop and direction of the drive motor to automatically retract and extend the cable; The camera is equipped with a clamp at its bottom for clamping onto the initial support or temporary support of the tunnel.

[0008] Preferably, a reciprocating lead screw and a guide rod are provided parallel to one side of the winding mechanism. The reciprocating lead screw is synchronously driven by the drive motor through the transmission mechanism. The same slider is connected to the reciprocating lead screw and the guide rod. The slider has a threaded hole adapted to the reciprocating lead screw and a through hole adapted to the guide rod. The slider is also provided with a cable guide with a wire hole for guiding the cable. When the drive motor rotates, it synchronously drives the winding mechanism and the reciprocating lead screw to rotate, causing the slider to move along the axial direction of the reciprocating lead screw, thereby realizing the orderly and uniform winding of the cable on the winding mechanism.

[0009] Preferably, the transmission mechanism is a gear set or a synchronous belt pulley set, and the output shaft of the drive motor is connected to both the rotating shaft of the winding mechanism and one end of the reciprocating lead screw through the transmission mechanism.

[0010] Preferably, the rotating shaft center of the reel mechanism integrates a conductive slip ring, the inner end of the composite cable passes through the rotating shaft center and is connected to the rotor of the conductive slip ring, and the stator of the conductive slip ring is connected to an external power supply and signal processing equipment.

[0011] Preferably, the control unit includes a tension detection module, a microprocessor, and a current detection module; The tension detection module is located at the cable guide or near the reel mechanism and is used to detect the real-time tension value F of the cable. The current detection module is connected to the microprocessor and is used to collect the armature current value I of the drive motor in real time; The microprocessor is electrically connected to the tension detection module and the drive motor, respectively, and is used to receive the tension signal from the tension detection module and, based on the set target tension value F... 目标 With real-time tension value F 实际 The real-time tension deviation e is used to output a control signal to the drive motor to maintain stable cable tension, and the target tension value F is... 目标 This is a constant safety value set based on the cable breaking tensile force.

[0012] Preferably, the microprocessor executes an adaptive PID algorithm based on fuzzy rules, the algorithm comprising the following steps: The real-time tension deviation *e* and the deviation change rate *ec* are mapped to predefined fuzzy domains for deviation *e* and deviation change rate *ec*, respectively, using quantization factors to complete the fuzzification process. The deviation change rate *ec* = (e... n –e n-1 ) / Δt, where e n e represents the tension deviation value at the current sampling time. n-1 Δt represents the tension deviation value at the previous sampling time, and Δt is the fixed sampling period set by the microprocessor. Based on a pre-stored fuzzy rule base, fuzzy inference is performed. The fuzzy rule base defines fuzzy states with real-time tension deviation e and deviation change rate ec as conditions, and PID parameter adjustment amount ΔK. p , ΔK i , ΔK d Several rules for the conclusion; The fuzzy output obtained from the inference is defuzzified to obtain precise PID parameter adjustment values, which are used to correct the parameters of the PID controller in real time.

[0013] Preferably, the microprocessor is further configured to execute an anti-interference strategy, which includes: The rate of change of the armature current, dI / dt, is calculated in real time and compared with a preset current change rate threshold I. threshold Compare; Calculate the rate of change dF of the real-time tension value. 实际 / dt; When the rate of change of the armature current value dI / dt continuously exceeds I threshold Furthermore, the absolute value of the rate of change of the tension value, dF / dt, is lower than the preset threshold value of the rate of change of tension, F. threshold At that time, it was determined that the cable was stuck; The protection action is immediately triggered, controlling the drive motor to pause its current action and slightly reverse to release the jam.

[0014] Preferably, the camera of the video surveillance component is an explosion-proof PTZ camera that integrates a lighting supplement light.

[0015] Preferably, it also includes a wireless communication module, which is integrated with the camera and used to wirelessly transmit video signals to a receiver on the lining trolley or a remote monitoring center.

[0016] The present invention has at least the following beneficial effects: The lining trolley reel-type video monitoring device provided by this invention can realize the automatic cable winding and unwinding function, reducing manual operation and lowering the labor intensity of construction workers. Through the cooperation of the drive motor and transmission mechanism, the cable winding and unwinding are achieved smoothly, improving the efficiency of monitoring equipment deployment.

[0017] This device, through its cable management mechanism and tension control system, maintains stable cable tension, preventing the cable from becoming too tight or too loose. This control method helps reduce cable wear and damage, extends cable life, and prevents cable tangling and knotting.

[0018] By employing an integrated composite cable and conductive slip ring structure, continuous power and signal transmission is achieved during rotation. This design solves the wire tangling problem that easily occurs during rotation in traditional wiring methods, ensuring the stability and reliability of video signal transmission.

[0019] The application of explosion-proof cameras enables the equipment to adapt to the special environmental requirements of tunnel construction, and the integrated supplementary lighting function improves the monitoring effect under conditions of insufficient lighting in the tunnel. The addition of a wireless transmission module provides a more flexible installation method and reduces the wiring difficulties caused by wired transmission.

[0020] The control system's anti-interference strategy can promptly identify and handle abnormal situations such as cable jams, preventing equipment damage through automatic protection mechanisms. This intelligent control method improves system reliability and security while reducing equipment maintenance requirements.

[0021] Other advantages, objectives and features of the present invention will become apparent in part from the following description, and in part from those skilled in the art through study and practice of the invention. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the lining trolley described in this invention; Figure 2 This is a schematic diagram of the structure of the reel-type video surveillance device described in this invention. Detailed Implementation

[0023] The present invention will now be described in further detail with reference to the accompanying drawings, so that those skilled in the art can implement it based on the description.

[0024] It should be noted that in the description of this invention, the terms "lateral", "longitudinal", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0025] like Figure 1As shown, the present invention provides a novel reel-type video monitoring device for lining trolleys, comprising: The reel mechanism 2 is fixedly installed on the traveling gantry of the lining trolley 1 by a bracket 3; The drive motor 4 is mounted on the traveling gantry of the lining trolley 1 and located next to the support 3. It drives the reel mechanism 2 to rotate and reel in the wire through a transmission mechanism 5. The video surveillance component includes a camera 6 and an integrated cable 7, which is wound on the reel mechanism 2. The cable 7 is a composite cable that integrates power lines and signal lines. The control unit is electrically connected to the drive motor 4 and is used to control the start, stop and direction of the drive motor 4 to automatically retract and extend the cable 7. The bottom of the camera 6 is equipped with a clamp for clamping onto the initial support or temporary support of the tunnel.

[0026] Specifically, the novel reel-type video monitoring device for the lining trolley 1 includes a reel mechanism 2, which is fixedly installed on the traveling gantry of the lining trolley 1 via a bracket 3. The bracket 3 can be welded from Q235B steel and connected and fixed to the traveling gantry with bolts. The reel mechanism 2 can be a commonly available cable reel structure, with an outer diameter of 400mm to 600mm (e.g., 500mm) and a width of 200mm to 300mm (e.g., 250mm). The reel mechanism 2 is connected to the bracket 3 via a bearing seat and is installed on the upper part or side of the traveling gantry to facilitate the lead-out and retraction of the cable 7.

[0027] The drive motor 4 is mounted on the traveling gantry of the lining trolley 1, located next to the support 3, and drives the reel mechanism 2 to rotate and unload the wire via a transmission mechanism 5. The drive motor 4 can be an AC servo motor or a three-phase asynchronous motor, with a power range of 0.5kW to 1.5kW, for example, 1kW. The transmission mechanism 5 can be a gearbox or a synchronous belt drive, with a transmission ratio range of 10:1 to 20:1, for example, 15:1. The drive motor 4 is mounted on the traveling gantry via a flange or base, and its output shaft is connected to the input shaft of the transmission mechanism 5 via a coupling.

[0028] The video surveillance component includes a camera 6 and an integrated cable 7, which is wound on the reel mechanism 2. The cable 7 is a composite cable integrating power and signal lines. The outer diameter of the composite cable can be in the range of 8mm to 12mm, for example, 10mm, and the length can be selected in the range of 30m to 50m, for example, 40m, depending on actual construction needs. The camera 6 can be an integrated explosion-proof camera with a clamp at its bottom. The clamp can be made of aluminum alloy and is connected to the camera 6 housing by bolts. The clamp can be used to hold the steel mesh or temporary supporting steel on the initial support face of the tunnel. The installation height is generally in the range of 2m to 3m to facilitate monitoring of the tunnel working face.

[0029] The control unit is electrically connected to the drive motor 4 and is used to control the start, stop, and direction of the drive motor 4 to automatically reel in and unleash the cable 7. The control unit can be a PLC or an embedded controller and is installed in the electrical control cabinet of the lining trolley 1. The control unit is connected to the drive motor 4 and sensors via cables, receives tension signals and motor current signals, and outputs control signals to adjust the motor speed and direction, thereby achieving smooth reeling in and unleash of the cable 7.

[0030] The device operates as follows: After the control unit is activated, the drive motor 4 rotates the reel via the transmission mechanism 5, releasing or retracting the cable 7. The camera 6 moves along with the cable 7, is fixed to the tunnel wall by a clamp, collects video signals, and transmits them to the monitoring terminal via a composite cable. The control unit monitors the tension of the cable 7 in real time and maintains stable tension by adjusting the motor speed to prevent the cable 7 from being too tight or too loose.

[0031] The above technical solution can realize the automatic retraction and positioning of the video monitoring cable 7 of the lining trolley 1, reduce manual intervention, improve the efficiency and reliability of the deployment of monitoring equipment, and is suitable for real-time visual monitoring in tunnel construction.

[0032] Furthermore, a reciprocating lead screw and a guide rod 9 are arranged parallel to one side of the winding mechanism 2. The reciprocating lead screw 8 is synchronously driven by the drive motor 4 through the transmission mechanism 5. The same slider 10 is connected to the reciprocating lead screw 8 and the guide rod 9. The slider 10 has a threaded hole adapted to the reciprocating lead screw 8 and a through hole adapted to the guide rod 9. The slider 10 is also provided with a cable guide 11, which has a wire hole for guiding the cable 7. When the drive motor 4 rotates, it synchronously drives the winding mechanism 2 and the reciprocating lead screw 8 to rotate, causing the slider 10 to move axially along the reciprocating lead screw 8, thereby realizing the orderly and uniform winding of the cable 7 on the winding mechanism 2.

[0033] Specifically, the reciprocating lead screw 8 is synchronously driven by the drive motor 4 through the transmission mechanism 5. The reciprocating lead screw can be a Tr-type trapezoidal threaded lead screw, with a lead range of 8mm to 12mm (e.g., 10mm) and a length range of 800mm to 1200mm (e.g., 1000mm). The guide rod 9 can be made of chrome-plated round steel, with a diameter range of 20mm to 30mm (e.g., 25mm), and a length matching the lead screw. The reciprocating lead screw and the guide rod 9 are mounted parallel to each other on the bracket 3 on the side of the reel mechanism 2 via bearing seats, with a center distance between them ranging from 150mm to 250mm (e.g., 200mm).

[0034] The reciprocating lead screw 8 and the guide rod 9 are connected to the same slider 10. The slider 10 has a threaded hole adapted to the reciprocating lead screw 8 and a through hole adapted to the guide rod 9. The slider 10 can be made of cast aluminum or engineering plastic material, and a copper nut is embedded inside to cooperate with the lead screw. The threaded hole can be machined into a trapezoidal thread that matches the reciprocating lead screw, and the diameter of the through hole can be 0.1 mm to 0.3 mm larger than the diameter of the guide rod 9, for example, 0.2 mm larger. The slider 10 cooperates with the lead screw through the threaded hole and with the guide rod 9 through the through hole, forming a sliding pair.

[0035] The slider 10 is also equipped with a cable guide 11, which has a wire hole for guiding the cable 7. The cable guide 11 can be made of aluminum alloy and is fixed to the slider 10 by bolts. A nylon or copper guide sleeve can be installed in the wire hole. The inner diameter of the guide sleeve can be 1mm to 2mm larger than the outer diameter of the cable 7, for example, 1.5mm larger. The cable guide 11 can be designed as an adjustable structure, and the position of the guide sleeve can be adjusted by screws to accommodate cables 7 of different diameters.

[0036] The working process of this component is as follows: When the drive motor 4 rotates, it simultaneously drives the winding mechanism 2 and the lead screw to rotate through the transmission mechanism 5. The rotational motion of the lead screw is converted into the linear motion of the slider 10, and the slider 10 drives the cable guide 11 to move back and forth along the axial direction of the reciprocating lead screw. The cable guide 7 is guided by the wire hole on the cable guide 11 to be wound evenly on the winding reel, avoiding overlap or crossing of the cable 7. The guide rod 9 plays a guiding and supporting role, ensuring the smooth movement of the slider 10.

[0037] The above technical solution enables automatic and orderly cable winding on the reel, preventing cable 7 from becoming tangled or twisted during winding and unwinding, thus improving the service life of the cable 7 and the reliability of the device. This structure is suitable for various applications requiring cable winding, especially industrial environments with high requirements for cable arrangement.

[0038] Furthermore, the transmission mechanism 5 is a gear set or a synchronous belt pulley set, and the output shaft of the drive motor 4 is connected to both the rotating shaft of the winding mechanism 2 and one end of the reciprocating lead screw 8 through the transmission mechanism 5.

[0039] Specifically, the transmission mechanism 5 is a gear set or a synchronous belt pulley set. The gear set can be a spur gear transmission, with the driving gear having a module in the range of 2mm to 3mm (e.g., 2.5mm) and a number of teeth in the range of 20 to 30 (e.g., 25 teeth). The driven gear has the same module as the driving gear, with a number of teeth in the range of 60 to 90 (e.g., 75 teeth), and a transmission ratio in the range of 1:2.5 to 1:4 (e.g., 1:3). The gear material can be 45# steel or 20CrMnTi alloy steel, which, after quenching and tempering and tooth surface hardening, achieves a hardness of HRC45-55.

[0040] Synchronous belt pulley sets can utilize arc-tooth synchronous belt drives. The number of teeth on the driving pulley can range from 24 to 30, for example, 28 teeth, while the number of teeth on the driven pulley can range from 72 to 90, for example, 84 teeth. The transmission ratio can range from 1:2.5 to 1:3.5, for example, 1:3. The synchronous belt can be a composite structure of neoprene rubber matrix and fiberglass rope core, with a belt width ranging from 20mm to 30mm, for example, 25mm. The synchronous pulleys can be made of aluminum alloy or 45# steel, and the tooth profile machining accuracy can meet the level specified in GB / T 13487.

[0041] The output shaft of the drive motor 4 is connected to both the rotating shaft of the winding mechanism 2 and one end of the reciprocating lead screw 8 via the transmission mechanism 5. The motor output shaft can be connected to the driving gear or driving pulley via a key connection or clamping sleeve. The rotating shaft of the winding mechanism 2 can be connected to the driven gear or driven pulley via a coupling, which can be a flexible pin coupling or a perforated flexible coupling. One end of the reciprocating lead screw 8 can be connected to another driven gear or driven pulley via a key connection. All transmission components are fixed to the bracket 3 via bearing seats to ensure the parallelism and center distance accuracy of each axis.

[0042] The working process of the transmission mechanism 5 is as follows: When the drive motor 4 rotates, it drives the driving gear or driving pulley to rotate through the output shaft. The driving component transmits power to the driven gear or driven pulley through meshing, thereby synchronously driving the rotating shaft of the winding mechanism 2 and the reciprocating screw 8 to rotate. Gear transmission has high transmission accuracy and load-bearing capacity, while synchronous belt transmission has better buffering and vibration absorption performance and noise control characteristics. Both transmission methods can ensure the synchronous operation of the winding reel and the screw, ensuring the coordinated operation of the cable guide 11 and the winding reel speed.

[0043] The above technical solution provides reliable power transmission and motion synchronization, ensuring coordinated movement between the reel's winding and unwinding and the cable guide 11. This transmission structure boasts high transmission accuracy and stability, adapting to vibrations and load variations in the tunnel construction environment, thus guaranteeing the long-term reliable operation of the video monitoring device. Furthermore, a conductive slip ring 12 is integrated at the center of the rotating shaft of the reel mechanism 2. The inner end of the composite cable 7 passes through the center of the rotating shaft and is connected to the rotor of the conductive slip ring 12. The rotor rotates together with the rotating shaft. The stator of the conductive slip ring 12 is connected to an external power supply and signal processing equipment. The stator is fixed on the bracket 3 and does not rotate with the rotating shaft.

[0044] Specifically, the rotating shaft of the reel mechanism 2 is hollow, and a conductive slip ring 12 is integrated inside. The rotating shaft can be made of 45# steel, with an outer diameter ranging from 50mm to 80mm, for example, 60mm, and an inner diameter ranging from 20mm to 40mm, for example, 30mm. The rotating shaft is supported on the bracket 3 by a pair of deep groove ball bearings, which can be model 6208 or 6308, and the bearing housing can be made of cast iron. One end of the rotating shaft is connected to the driven member of the transmission mechanism 5 via a key, and the other end is threaded to fix the conductive slip ring 12.

[0045] The conductive slip ring 12 can be a through-hole structure, with an outer diameter ranging from 25mm to 35mm (e.g., 30mm) and a length ranging from 80mm to 120mm (e.g., 100mm). The number of slip ring circuits can range from 12 to 24 (e.g., 18), with the power supply circuit configured to have a current carrying capacity of 5A to 10A (e.g., 8A) and the signal circuit configured to have a current carrying capacity of 1A to 2A (e.g., 1.5A). The contact material can be gold or silver alloy, the insulating material can be polytetrafluoroethylene (PTFE) or ceramic, and the housing can be stainless steel or aluminum alloy. The conductive slip ring 12 is fixed in the inner hole of the rotating shaft by press-fitting or threaded connection. The stator is fixed to the bracket 3 by a locating pin, and the rotor rotates together with the rotating shaft.

[0046] The inner end of the composite cable 7 passes through the center of the rotating shaft and connects to the rotor of the conductive slip ring 12. The wire at the inner end of the cable 7 can be connected to the terminals of the rotor of the conductive slip ring 12 by welding or crimping. The terminals can be made of copper and plated with silver or gold. Sealing devices can be installed at both ends of the rotating shaft. These sealing devices can be rotary oil seals or labyrinth seals, and the sealing material can be nitrile rubber or fluororubber to prevent dust and moisture from entering the shaft. The space for the cable 7 within the rotating shaft can be filled with insulating glue or a cable 7 guide device can be installed to prevent the cable 7 from rubbing against the inner wall of the rotating shaft during rotation.

[0047] The stator of the conductive slip ring 12 is connected to an external power supply and signal processing equipment. The stator leads can be multi-core shielded cables, with lengths ranging from 1m to 3m (e.g., 2m) depending on installation requirements. The leads connect to external equipment via waterproof connectors, which can be M12 or M16 aviation plugs with an IP67 protection rating. The external power supply can be a 24VDC or 220VAC switching power supply, and the signal processing equipment can be a video encoder or a network switch, installed within the electrical control cabinet of the lining trolley 1.

[0048] The working process of this component is as follows: When the reel mechanism 2 rotates, the rotating shaft drives the rotor part of the conductive slip ring 12 to rotate together, while the stator part remains stationary. Power and signal transmission are achieved during rotation through the sliding contact of the conductive slip ring 12. The power line in the composite cable provides power to the camera 6 through the slip ring, and the video signal line transmits signals to external devices through the slip ring. This structure allows the reel to rotate continuously during cable winding and unwinding without causing the cable 7 to become tangled or broken.

[0049] The above technical solution enables continuous power and signal transmission during rotation, solving the problem of tangling that easily occurs during rotation in traditional wiring methods. This structure exhibits excellent reliability and durability, adapting to the humid and dusty environments of tunnel construction and ensuring the stable operation of the video surveillance system.

[0050] Furthermore, the control unit includes a tension detection module, a microprocessor, and a current detection module; The tension detection module is located at the cable tray 11 or near the reel mechanism 2, and is used to detect the real-time tension value F of the cable 7; The current detection module is connected to the microprocessor and is used to collect the armature current value I of the drive motor 4 in real time; The microprocessor is electrically connected to the tension detection module and the drive motor 4, respectively, and is used to receive the tension signal from the tension detection module and, based on the set target tension value F... 目标 With real-time tension value F 实际 The real-time tension deviation e is used to output a control signal to the drive motor 4 to maintain the stability of the cable tension 7, and the target tension value F is... 目标 This is a constant safety value set based on the breaking tensile force of cable 7.

[0051] Specifically, the tension detection module can use an S-type tension sensor or a spoke-type tension sensor, with a measurement range of 0 to 200N (e.g., 0 to 100N) and an accuracy of ±0.5%FS. The sensor can be installed near the cable tray 11 or at the outlet of the reel mechanism 2, and fixed by the mounting bracket 3. The installation position should ensure that the sensor and cable 7 maintain perpendicular contact. The sensor signal line uses a shielded cable connected to the microprocessor. The cable length can be determined based on the actual installation distance, ranging from 2m to 5m (e.g., 3m).

[0052] The current detection module can be a Hall effect current sensor or a shunt resistor current detector, with a range of 0 to 10A (e.g., 0 to 5A) and a response time of less than 1ms. The current detection module can be installed at the power input terminal of the drive motor 4, reflecting changes in motor load by detecting the armature current. The detection signal is transmitted to the microprocessor via analog input or digital communication, with a sampling frequency ranging from 1kHz to 10kHz (e.g., 5kHz). The current detection module can be powered by a 24VDC power supply, sharing a common ground with the microprocessor.

[0053] The microprocessor can be a high-performance MCU based on a 32-bit ARM Cortex-M4 core (such as STMicroelectronics' STM32F407 series or similar products), with a main frequency of no less than 168MHz, and a built-in single-precision FPU (floating-point unit) and DSP instruction set to efficiently execute the floating-point operations in the adaptive PID algorithm and anti-interference strategy. The microprocessor should have at least 512KB of Flash memory and 192KB of RAM for storing the control program, fuzzy rule base, and real-time data; and integrate at least two independent 12-bit precision ADC modules with a sampling rate of no less than 2.4 MSPS for synchronously acquiring tension and current signals. The microprocessor acquires sensor signals through the aforementioned ADCs at a fixed sampling period (e.g., 50ms) and generates a PWM wave with a frequency of 15kHz and a duty cycle adjustment accuracy of 0.1% to control and drive the motor 4.

[0054] The microprocessor is electrically connected to the tension detection module and the drive motor 4, respectively, and is used to receive the tension signal from the tension detection module and, based on the set target tension value F... 目标 With real-time tension value F 实际 The real-time tension deviation e is used to output a control signal to the drive motor 4. Target tension value F 目标The target tension can be set to 10% to 20% of the breaking tensile force of cable 7, for example, 15%. For cable 7 with a breaking tensile force of 1000N, the target tension can be set to 150N. The microprocessor can have a parameter storage function, saving control parameters through EEPROM or Flash memory. Parameter settings can be modified via RS485 or Ethernet interface.

[0055] The control unit operates as follows: After system startup, the microprocessor acquires signals from the tension sensor and the current detection module in real time. By calculating the deviation between the actual tension and the target tension, a PID control algorithm is used to adjust the speed and direction of the drive motor 4. When the tension of cable 7 is too high, the motor is controlled to loosen cable 7 appropriately; when the tension of cable 7 is too low, the motor is controlled to tighten cable 7. Simultaneously, by monitoring changes in motor current, abnormal situations can be detected promptly, and protective measures can be taken. The control cycle is consistent with the sampling cycle to ensure the real-time performance and stability of the control.

[0056] The above technical solution enables precise control of the tension of cable 7, maintaining stable tension during the winding and unwinding process. This control method avoids tensile damage caused by excessive tightness or tangling caused by excessive looseness of cable 7, extending the service life of cable 7 and improving system reliability. The control system has excellent dynamic response characteristics, enabling it to adapt to the complex and ever-changing working environment in tunnel construction.

[0057] Furthermore, the microprocessor executes an adaptive PID algorithm based on fuzzy rules, which includes the following steps: The real-time tension deviation *e* and the deviation change rate *ec* are mapped to predefined fuzzy domains for deviation *e* and deviation change rate *ec*, respectively, using quantization factors to complete the fuzzification process. The deviation change rate *ec* = (e... n –e n-1 ) / Δt, where e n e represents the tension deviation value at the current sampling time. n-1 Δt represents the tension deviation value at the previous sampling time, and Δt is the fixed sampling period set by the microprocessor. Based on a pre-stored fuzzy rule base, fuzzy inference is performed. The fuzzy rule base defines fuzzy states with real-time tension deviation e and deviation change rate ec as conditions, and PID parameter adjustment amount ΔK. p , ΔK i , ΔK d Several rules for the conclusion; The fuzzy output obtained from the inference is defuzzified to obtain precise PID parameter adjustment values, which are used to correct the parameters of the PID controller in real time.

[0058] Specifically, the adaptive PID algorithm based on fuzzy rules first maps the real-time tension deviation e and the deviation change rate ec to a predefined fuzzy universe of discourse using a quantization factor. The quantization factor can be set to k. e =0.2~0.5N⁻¹, for example 0.3N -1 k ec =0.1~0.3N -1 s -1 For example, 0.2 N -1 s -1 The fuzzy universe of discourse for the deviation *e* can be set to [-6, 6], divided into 7 fuzzy subsets: NB, NM, NS, ZO, PS, PM, and PB. The fuzzy universe of discourse for the rate of change of deviation *ec* is also set to [-6, 6], using the same 7 fuzzy subsets. The fuzzification process uses a triangular membership function, and the overlap can be set to 25%–50%, for example, 35%.

[0059] Fuzzy inference is performed based on a pre-stored fuzzy rule base, which can contain 49 rules, with fuzzy states of deviation e and deviation change rate ec as conditions, and PID parameter adjustment amount ΔK. p ΔK i ΔK d This is the conclusion. ΔK p The adjustment range can be set to -0.5 to +0.5, for example, ±0.3, ΔK i The adjustment range can be set to -0.05 to +0.05, for example, ±0.03, ΔK d The adjustment range can be set to -0.1 to +0.1, for example, ±0.06. The rule base can be established based on expert experience or experimental data, using the formula: if e is A and ec is B then ΔK. p is C, ΔK i is D, ΔK d The form is E, for example: If e is PB and ec is NB, then ΔK p is PB, ΔK i is NB, ΔK d "is PS" means that when the real-time tension deviation is positive (PB, i.e., cable 7 is very loose) and the rate of change of deviation is negative (NB, i.e., the tension is rapidly loosening), it indicates that cable 7 is in a state of rapid uncontrolled slack. The control rule at this time is: significantly increase the proportional coefficient (ΔK). p (is PB) to rapidly increase motor torque to tighten the cable 7; significantly reduce the integral coefficient (ΔK) i (is NB) to weaken the integral action and prevent integral saturation and overshoot during rapid adjustment; slightly increase the derivative coefficient (ΔK)d (is PS) to take full advantage of the tendency of tension to loosen and suppress further expansion of deviation in advance; for example: If e is PS and ec is ZO, then ΔK p is PS, ΔK i is ZO, ΔK d The value is NS, meaning that when the real-time tension deviation is positively small (PS, i.e., cable 7 is slightly loose) and the rate of change of deviation is zero (ZO, i.e., the tension is stabilizing), it indicates that the system is close to the target tension value and is in the fine-tuning stage. At this time, the control rule is: slightly increase the proportional coefficient (ΔK). p (is PS) to continue reducing the residual bias; keep the integral coefficient constant (ΔK) i (is ZO) to avoid introducing new fluctuations; slightly reduce the differential coefficient (ΔK) d (is NS), because the rate of change is very small at this point, the derivative action may introduce noise interference, and appropriately reducing it can make the control smoother. The weight of each rule can be set to 0.8 to 1.0, for example 0.9. The rule base is stored in the microprocessor's Flash memory, occupying about 2 to 4 KB of space.

[0060] The fuzzy output obtained from the inference is defuzzified to obtain the precise PID parameter adjustment. Defuzzification methods can include the centroid method or the maximum membership method, such as the centroid method. The scaling factor of the output can be set to k. Δp =0.1~0.3, for example 0.2, k Δi =0.01~0.03, for example 0.02, k Δd =0.05~0.15, for example 0.1. The initial parameters of the PID controller can be set to K. p0 =2.0~5.0, for example 3.5, K i0 =0.1~0.5, for example 0.3, K d0 =0.5~2.0, for example 1.2. The parameter update period can be consistent with the sampling period, for example 50ms, and the parameter adjustment range is limited to ±30%.

[0061] The algorithm works as follows: In each sampling period, the microprocessor acquires the signal from the tension sensor and calculates the current tension deviation *e* and the rate of change of deviation *ec*. The precise values ​​are converted into fuzzy quantities using a quantization factor, and inference is performed based on a fuzzy rule base to obtain a fuzzy output. After defuzzification, precise PID parameter adjustments are obtained, and the PID controller parameters are corrected in real time. This adaptive mechanism enables the control system to automatically adjust control parameters according to tension changes, improving the system's response speed and control accuracy.

[0062] The above technical solution enables adaptive adjustment of PID parameters, allowing the control system to maintain good control performance under different operating conditions. This control method has strong robustness, adapting to various situations of cable tension changes, thus improving system stability and reliability. The algorithm has moderate computational load and can run in real time on ordinary microprocessors, making it suitable for control applications in industrial settings.

[0063] Furthermore, the microprocessor is also used to execute an anti-interference strategy, which includes: The rate of change of the armature current, dI / dt, is calculated in real time and compared with a preset current change rate threshold I. threshold Compare; Calculate the rate of change dF of the real-time tension value. 实际 / dt; When the rate of change of the armature current value dI / dt continuously exceeds I threshold Furthermore, the absolute value of the rate of change of the tension value, dF / dt, is lower than the preset threshold value of the rate of change of tension, F. threshold At that time, it was determined that cable 7 was stuck; The protection action is immediately triggered, controlling the drive motor 4 to pause its current operation and slightly reverse to release the jam.

[0064] Specifically, an anti-interference strategy is implemented. This strategy calculates the rate of change of the armature current, dI / dt, in real time. The sampling interval can be set from 10ms to 50ms, for example, 20ms. The rate of change is calculated using the difference method: dI / dt = (I... n - I n-1 ) / Δt, where I n For the current sampled value, I n-1 The previous sampled value is given, and Δt is the sampling period. Current change rate threshold I. threshold It can be set to 5A / s to 15A / s, for example, 10A / s. This threshold is determined based on the motor's rated current and load characteristics. When dI / dt continuously exceeds this threshold, it indicates that an abnormal situation may have occurred.

[0065] Simultaneously calculate the rate of change of the real-time tension value, dF. 实际 / dt, the sampling interval is consistent with the current sampling. The tension change rate is also calculated using the differential method, dF 实际 / dt = (F 实际n - F 实际n-1 ) / Δt. Threshold for rate of change of tension F threshold The value can be set to 20 N / s to 50 N / s, for example, 30 N / s. This threshold is determined based on the elastic modulus of cable 7 and safety operating requirements. When the absolute value of dF / dt is lower than this threshold, it indicates that the tension changes abnormally slowly. The microprocessor determines the system status by comparing the trends of these parameters.

[0066] When the rate of change of armature current dI / dt continuously exceeds I threshold Furthermore, the absolute value of the rate of change of tension dF / dt is lower than F. threshold If cable 7 is found to be jammed, a protection action is immediately triggered, controlling drive motor 4 to pause its current operation and slightly reverse to release the jam. The duration of the judgment can be set to 3-5 sampling periods, for example, 100ms, i.e., 5 consecutive sampling periods, based on a fixed sampling period of 20ms. The "continuously exceeding" condition can be defined as the dI / dt values ​​of 5 consecutive sampling points being greater than I. threshold "Simultaneously" can be defined as satisfying the tension change rate condition at the same sampling time or adjacent sampling times. These time parameters can be adjusted according to the actual system response characteristics. The time judgment is based on the following: this duration is set much faster than a manual reaction, sufficient to prevent equipment damage, while also being long enough to avoid malfunctions caused by instantaneous load fluctuations in the tunnel (such as cables briefly rubbing against uneven walls). It is an optimized value determined through experimental verification after comprehensively considering the system's mechanical inertia, motor electrical response characteristics, and common interference situations in tunnel construction, achieving the best balance between sensitivity and anti-interference.

[0067] The pause time can be set from 0.5s to 1.5s, for example, 1s. The reversal amplitude can be set from 10% to 30% of the normal speed, for example, 20%, and the reversal time can be set from 0.3s to 0.8s, for example, 0.5s. After the protection action is executed, the system automatically returns to normal operation. If the jamming occurs repeatedly, the microprocessor can record the number of faults, and issue an alarm signal when the set number is reached (e.g., 3 times).

[0068] The anti-interference strategy works as follows: the microprocessor simultaneously monitors the rate of change of current and the rate of change of tension in each sampling cycle. When a special combination of a sharp increase in current and a slow change in tension is detected, it is determined that cable 7 is jammed. The system immediately stops the motor and performs a slight reverse operation to attempt to release the jam. This method based on multi-parameter joint judgment can effectively distinguish between normal load changes and abnormal jamming conditions, avoiding malfunctions.

[0069] The above technical solution can promptly detect and address cable jamming issues, preventing equipment damage and excessive stretching of cable 7. This protection strategy, based on the coordinated judgment of multiple physical parameters, boasts high reliability and effectively distinguishes between normal operating conditions and abnormal states. This protection mechanism can extend equipment lifespan and improve the safety and stability of system operation.

[0070] Furthermore, the camera 6 of the video surveillance component is an explosion-proof PTZ camera that integrates a lighting supplement light.

[0071] Specifically, the explosion-proof PTZ camera can use an intrinsically safe or flameproof explosion-proof structure, with an explosion-proof rating of Ex d IIC T6 Gb or Ex ib IIC T6 Gb. The protection rating can reach IP68, capable of withstanding immersion in 1 meter of water for 30 minutes. The horizontal rotation range of the PTZ is 0° to 355°, and the vertical rotation range is -30° to +90°. The rotation speed can be set from 0.1° to 60° / s horizontally and from 0.1° to 30° / s vertically. The camera weight can be from 3kg to 8kg, for example, 5kg, and the housing material can be 316L stainless steel or ADC12 aluminum alloy.

[0072] The camera integrates a supplementary lighting unit, which can use an LED light source with a power range of 10W to 30W, such as 20W. The illuminance can reach 5 to 10 lux at a maximum distance of 30 meters, and the color temperature is adjustable within the range of 3000K to 6000K, such as 4000K. The illumination angle of the supplementary lighting unit is adjustable within the range of 30° to 120°, such as 60°. The supplementary lighting unit rotates synchronously with the camera, uses a constant current drive, and has overcurrent and overtemperature protection functions. The housing of the supplementary lighting unit is integrated with the camera body, and its protection rating is consistent with the main unit.

[0073] The camera is mounted at the end of cable 7 on a reel and secured to the tunnel's initial support or temporary support using a bottom clamp. The installation height can range from 2m to 4m, for example, 3m, and the installation angle can be horizontally tilted downwards from 10° to 30°. The camera is powered via the power line in the composite cable, with an operating voltage ranging from DC12V to DC24V, for example, DC24V. The video signal is transmitted via the signal line in the composite cable, and can use HD-SDI or network video signal formats, with a resolution of up to 1920×1080 pixels and a frame rate of 25fps to 30fps.

[0074] The camera operates as follows: After the system is powered on, the camera begins operation, and the pan-tilt unit automatically rotates according to the preset cruise path. The supplementary lighting automatically adjusts its brightness based on the ambient light intensity and automatically turns on when the light is insufficient. The video signal collected by the camera is transmitted to the monitoring center via a composite cable, and operators can remotely adjust the pan-tilt angle, lens focal length, and supplementary lighting parameters through control software. During tunnel construction, the camera continuously monitors the work surface, providing visual assurance for construction safety.

[0075] The above technical solution provides reliable tunnel construction monitoring, and its explosion-proof design ensures safe operation in potentially explosive environments. Integrated supplementary lighting solves the problem of insufficient illumination inside the tunnel, while the pan-tilt structure provides a more comprehensive monitoring range. This camera is suitable for use in harsh environments such as tunnels and mines, providing clear and stable monitoring images.

[0076] Furthermore, it also includes a wireless communication module, which is integrated with the camera 6 and is used to wirelessly transmit video signals to a receiver on the lining trolley 1 or a remote monitoring center.

[0077] Specifically, the wireless communication module can be a Wi-Fi module or a 4G / 5G communication module, with an operating frequency in the range of 2.4GHz to 5.8GHz, for example, 5.8GHz. The transmission rate can be in the range of 100Mbps to 1Gbps, for example, 300Mbps, and the transmission distance under line-of-sight conditions can reach 100m to 300m, for example, 200m. The transmit power can be set to 100mW to 500mW, for example, 200mW, and the receive sensitivity can reach -90dBm to -75dBm, for example, -85dBm. The module operating voltage can be in the range of DC3.3V to DC5V, for example, DC3.3V, and the power consumption can be controlled in the range of 2W to 5W, for example, 3W.

[0078] The wireless communication module is integrated with camera 6 and can be installed either on-board or externally. The module size can be controlled within 50mm × 30mm × 10mm, and the weight should not exceed 50g. The antenna can be a built-in PCB antenna or an external omnidirectional antenna, with a gain in the range of 3dBi to 8dBi, for example, 5dBi. The module housing can be made of ABS engineering plastic or a metal shield, providing good electromagnetic compatibility and heat dissipation. The module connects to the camera 6 motherboard via a ribbon cable, and the interface can be a USB 2.0 or MIPICSI-2 standard interface. Inside camera 6, the module is mounted near the main control board and fixed by bracket 3 to avoid direct contact with heat-generating components.

[0079] This wireless communication module is used to wirelessly transmit video signals to a receiver on the lining trolley 1 or a remote monitoring center. The transmission protocol supports H.264 or H.265 video encoding formats, with a bitrate adjustable from 2Mbps to 10Mbps, for example, 4Mbps. The end-to-end transmission latency can be controlled within the range of 100ms to 300ms (typically 200ms), which fully meets the requirements for real-time monitoring of tunnel construction. Its applicability is based on the fact that this latency is far lower than the persistence of human vision (approximately 100-400ms) and the critical perception of human reaction to events (approximately 300-500ms). Monitoring personnel cannot perceive this level of latency, resulting in a smooth operating experience and enabling effective real-time monitoring and command of slowly changing construction processes such as trolley movement and concrete pouring. Supported network standards include IEEE 802.11ac / n / g / b or 3GPP R15 standards. Encryption methods support WPA2-PSK or AES-128 encryption to ensure transmission security. The receiver can be installed in the cab of the lining trolley 1 or in the monitoring center, and is equipped with the corresponding antenna and signal processing equipment.

[0080] The wireless communication module operates as follows: The video signal captured by camera 6 is encoded and compressed before being transmitted through the wireless communication module. The signal is transmitted in the form of radio waves, propagating through space to reach the receiving end. The receiving end demodulates and decodes the signal, restoring it as a video signal for monitoring purposes. The module has an automatic retransmission mechanism; when a data packet loss is detected, it automatically requests a retransmission to ensure the integrity of video transmission. It also supports automatic signal strength adjustment, dynamically adjusting the transmission power based on communication quality.

[0081] The above technical solution provides reliable wireless video transmission, reduces the complexity of cable laying, and improves the flexibility of system deployment. Wireless transmission allows for more flexible installation of monitoring equipment, avoiding signal attenuation issues caused by long-distance cable transmission. This module has good compatibility and stability, providing continuous and stable video transmission services in tunnel construction environments, and offering technical support for remote monitoring and security management.

[0082] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and illustrations shown and described herein.

Claims

1. A novel reel-type video monitoring device for lining trolleys, characterized in that, include: The reel mechanism is fixedly mounted on the traveling gantry of the lining trolley by a bracket; A drive motor is mounted on the traveling gantry of the lining trolley and located next to the support. It drives the reel mechanism to rotate and reel in the wire through a transmission mechanism. A video surveillance component includes a camera and an integrated cable wound on the reel mechanism, the cable being a composite cable integrating power and signal lines. The control unit is electrically connected to the drive motor and is used to control the start, stop and direction of the drive motor to automatically retract and extend the cable; The camera is equipped with a clamp at its bottom for clamping onto the initial support or temporary support of the tunnel.

2. The novel reel-type video monitoring device for lining trolleys as described in claim 1, characterized in that, A reciprocating lead screw and a guide rod are arranged parallel to one side of the winding mechanism. The reciprocating lead screw is synchronously driven by the drive motor through the transmission mechanism. The same slider is connected to the reciprocating lead screw and the guide rod. The slider has a threaded hole adapted to the reciprocating lead screw and a through hole adapted to the guide rod. The slider is also provided with a cable guide with a wire hole for guiding the cable. When the drive motor rotates, it synchronously drives the winding mechanism and the reciprocating lead screw to rotate, causing the slider to move along the axial direction of the reciprocating lead screw, thereby realizing the orderly and uniform winding of the cable on the winding mechanism.

3. The novel reel-type video monitoring device for lining trolleys as described in claim 2, characterized in that, The transmission mechanism is a gear set or a synchronous belt pulley set, and the output shaft of the drive motor is connected to both the rotating shaft of the winding mechanism and one end of the reciprocating lead screw through the transmission mechanism.

4. The novel reel-type video monitoring device for lining trolleys as described in claim 1, characterized in that, The rotating shaft of the reel mechanism is hollow, and a conductive slip ring is integrated inside. The inner end of the composite cable passes through the center of the rotating shaft and is connected to the rotor of the conductive slip ring. The stator of the conductive slip ring is connected to an external power supply and signal processing equipment.

5. The novel reel-type video monitoring device for lining trolleys as described in claim 2, characterized in that, The control unit includes a tension detection module, a microprocessor, and a current detection module; The tension detection module is located at the cable guide or near the reel mechanism and is used to detect the real-time tension value F of the cable. The current detection module is connected to the microprocessor and is used to collect the armature current value I of the drive motor in real time; The microprocessor is electrically connected to the tension detection module and the drive motor, respectively, and is used to receive the tension signal from the tension detection module and, based on the set target tension value F... 目标 With real-time tension value F 实际 The real-time tension deviation e is used to output a control signal to the drive motor to maintain stable cable tension, and the target tension value F is... 目标 This is a constant safety value set based on the cable breaking tensile force.

6. The novel reel-type video monitoring device for lining trolleys as described in claim 5, characterized in that, The microprocessor executes an adaptive PID algorithm based on fuzzy rules, which includes the following steps: The real-time tension deviation *e* and the deviation change rate *ec* are mapped to predefined fuzzy domains for deviation *e* and deviation change rate *ec*, respectively, using quantization factors to complete the fuzzification process. The deviation change rate *ec* = (e... n – e n-1 ) / Δt, where e n e represents the tension deviation value at the current sampling time. n-1 Δt represents the tension deviation value at the previous sampling time, and Δt is the fixed sampling period set by the microprocessor. Based on a pre-stored fuzzy rule base, fuzzy inference is performed. The fuzzy rule base defines fuzzy states with real-time tension deviation e and deviation change rate ec as conditions, and PID parameter adjustment amount ΔK. p , ΔK i , ΔK d Several rules for the conclusion; The fuzzy output obtained from the inference is defuzzified to obtain precise PID parameter adjustment values, which are used to correct the parameters of the PID controller in real time.

7. The novel reel-type video monitoring device for lining trolleys as described in claim 6, characterized in that, The microprocessor is also used to execute an anti-interference strategy, which includes: The rate of change of the armature current, dI / dt, is calculated in real time and compared with a preset current change rate threshold I. threshold Compare; Calculate the rate of change dF of the real-time tension value. 实际 / dt; When the rate of change of the armature current value dI / dt continuously exceeds I threshold Furthermore, the absolute value of the rate of change of the tension value, dF / dt, is lower than the preset threshold value of the rate of change of tension, F. threshold At that time, it was determined that the cable was stuck; The protection action is immediately triggered, controlling the drive motor to pause its current action and slightly reverse to release the jam.

8. The novel reel-type video monitoring device for lining trolleys as described in claim 1, characterized in that, The camera in the video surveillance component is an explosion-proof PTZ camera with integrated lighting.

9. The novel reel-type video monitoring device for lining trolleys as described in claims 1-7, characterized in that, It also includes a wireless communication module, which is integrated with the camera and is used to wirelessly transmit video signals to a receiver on the lining trolley or a remote monitoring center.

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