Broken wire trigger detection device and method

Abstract

The invention discloses a broken wire trigger detection device and method. The broken wire trigger detection device comprises a pay-off system, an internal detection unit, a signal receiving system, a control system and an execution mechanism. The pay-off system comprises a pay-off rack, at least one wire breaking device is installed on the pay-off rack, and each wire breaking device comprises a rotary induction pressing plate and a photoelectric sensing assembly. The internal detection unit is a tubular eddy current detection unit and is composed of a non-magnetic metal tube shell and an internal eddy current sensor array; the signal receiving system is used for receiving signals of the photoelectric sensing assembly and the eddy current sensor array and transmitting the signals to the control system; the control system is in signal connection with the execution mechanism. Precise judgment, quantitative evaluation and precise positioning of the broken wires are achieved, stopping can be triggered when the broken wires occur, defective products are reduced from the source, the production cost is reduced, meanwhile, the production automation level and the equipment mobility are improved, and data support is provided for quality tracing and process improvement.

Description

Technical Field

[0001] This invention relates to the field of wire rope production technology, and in particular to a broken wire trigger detection device and method. Background Technology

[0002] In the steel wire rope manufacturing industry, the double twisting machine is the core equipment for twisting steel strands. During the production process, broken steel strands are a key hidden danger affecting product quality. If broken strands are not detected in time, defective products will flow into subsequent processes, which will not only increase production costs, but may also cause safety accidents due to insufficient steel wire rope strength. Therefore, broken strand detection is an indispensable key link in the double twisting machine production process.

[0003] Wire breakage detection technology refers to the technology that monitors the steel strands for defects such as wire breakage and missing wires in real time during the production of steel strands using a double twisting machine, and triggers alarms and shutdown operations in a timely manner. Its core objective is to ensure the quality of steel strand production, improve production efficiency, and reduce safety risks.

[0004] In existing technologies, wire breakage detection in double-twisting machines often employs a single detection method: some solutions achieve indirect detection by monitoring the rotation of the pay-off reel, using a sensor to detect whether the reel is rotating; if the reel stops rotating, a wire breakage is determined. Other solutions directly detect the steel strand itself using a single sensor, such as a single-point eddy current sensor to detect the surface condition of the steel strand. Furthermore, the detection units of existing detection devices are mostly fixed structures, making it difficult to adapt to the working scenario where the overtwisting device inside the double-twisting machine drives the steel strand to rotate 360°, and there is a lack of flexible power supply solutions for different installation scenarios.

[0005] In summary, the shortcomings of the existing technology include: First, single detection methods are prone to misjudgment and missed detection. Monitoring only the rotation of the wheel cannot identify situations where the steel strand is partially broken but the wheel has not stopped. Detecting only the steel strand itself is susceptible to external interference, leading to signal misjudgment and insufficient detection reliability. Second, the detection unit has poor structural adaptability. Fixed detection units cannot achieve all-round detection of rotating steel strands and are prone to creating detection blind spots. Third, the coordination between detection signal transmission and processing is poor, making it impossible to achieve efficient linkage between detection, judgment, and execution. This results in the inability to trigger a stop in time after a wire breakage, leading to the continuous generation of defective products. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a wire breakage trigger detection device and method. This invention achieves accurate determination, quantitative assessment, and precise location of wire breakage through a dual detection mode that combines external wheel rotation status monitoring and internal steel strand eddy current detection. It can trigger a shutdown the moment wire breakage occurs, reducing defective products and production costs from the source. At the same time, it improves the level of production automation and equipment availability, and provides data support for quality traceability and process improvement.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: In a first aspect, the present invention provides a wire breakage trigger detection device, comprising: The cable laying system, internal detection unit, signal receiving system, control system, and actuators; The wire feeding system includes a wire feeding frame, on which at least one set of wire breaking devices are installed. The wire breaking device includes a rotating induction pressure plate and a photoelectric sensing component. The internal detection unit is a tubular eddy current detection unit, which can be either a rotary tubular eddy current detection unit or a fixed tubular eddy current detection unit, both of which consist of a non-magnetic metal tube shell and an internal eddy current sensor array. The signal receiving system is used to receive signals from the photoelectric sensing component and the eddy current sensor array and transmit them to the control system. The control system is signal-connected to the actuator.

[0008] As a further technical solution, the wire feeding system also includes an I-beam reel with a steel wire rope wound on it; the rotating sensing pressure plate of each set of wire breaking devices is fixed on the through shaft of the wire feeding frame and rotates synchronously with the rotation of the I-beam reel; the photoelectric sensing component is used to sense the rotation signal of the rotating sensing pressure plate.

[0009] As a further technical solution, the non-magnetic metal tube shell of the tubular eddy current detection unit has a tubular structure, and the steel wire rope passes through the inside of the non-magnetic metal tube shell. The eddy current sensor array is arranged around the inside of the tube shell to detect the passing steel wire rope.

[0010] As a further technical solution, the signal receiving system is connected to the photoelectric sensing component, the eddy current sensor array, and the control system respectively; the actuator includes a traction device and a take-up device.

[0011] As a further technical solution, the power supply system is used to power various electrical components. The power supply system includes a micro generator and a main power supply. The micro generator is used to power the rotary tubular eddy current detection unit, and the main power supply is used to power the fixed tubular eddy current detection unit.

[0012] As a further technical solution, an encoder is also included; the encoder is connected to the control system via a signal connection to determine the location of the broken wire.

[0013] In a second aspect, the present invention provides a method for detecting wire breakage triggering, based on a wire breakage triggering detection device according to any one of the first aspects, comprising: The traction device drives the I-beam reel on the wire-laying frame to rotate, and the wire rope passes through the tubular eddy current detection unit and is connected to the take-up device. The external and internal detection are started simultaneously, generating two detection signals, which are transmitted to the control system in real time. The control system makes a judgment based on the detection signals. If any detection method triggers the alarm threshold, the alarm is immediately executed and a stop command is issued.

[0014] As a further technical solution, the external detection includes the following: when the I-beam wheel rotates, the rotating sensing pressure plate fixed on the through shaft rotates synchronously. Every half rotation, the photoelectric sensing component senses a signal and transmits it to the signal receiving system, which then transmits the signal to the control system. If the control system continuously receives the signal, it determines that the wire feeding is normal. When wire breakage occurs, the I-beam wheel stops rotating, the rotating sensing pressure plate stops moving, the photoelectric sensing component stops sending signals, and if the control system does not receive a signal within a preset time, it determines that the wire breakage is abnormal.

[0015] As a further technical solution, the internal detection includes a steel wire rope passing through the non-magnetic metal shell of a tubular eddy current detection unit at a constant speed. The eddy current sensor array is energized to generate a high-frequency alternating magnetic field, and eddy current signals are induced on the surface of the steel wire rope. The eddy current sensor array receives the eddy current signals and transmits them to a signal receiving system. The signal receiving system then transmits the signals to the control system. If the signal received by the control system is stable, it is considered normal. When there is a defect in the steel wire rope, the eddy current signal received by the control system is distorted. The control system calculates the length of the steel strand and locates the broken wire position by combining the encoder signal. At the same time, it immediately executes an alarm and issues a stop command.

[0016] As a further technical solution, the calculation of the steel strand length is expressed as follows: ; This refers to the length of the steel strand, specifically the length corresponding to the location of the broken wire. The speed of the traction or take-up device obtained by the encoder. This refers to the operating time of the equipment from startup to triggering the wire breakage alarm. The pitch of the steel strand. This refers to the twist ratio.

[0017] One or more technical solutions of the present invention have the following beneficial effects: This invention indirectly monitors the rotational state of the sheave by using a broken wire device, while directly detecting the physical state of the wire rope itself using an internal tubular eddy current detection unit. This dual-detection structure forms a complementary verification logic. Compared to existing single-detection methods, it effectively avoids the shortcomings of monitoring only sheave rotation and failing to identify localized broken wires, and the susceptibility to interference and misjudgment when only detecting the steel strand itself. This significantly reduces the probability of false alarms and missed alarms, and substantially improves the accuracy and reliability of broken wire detection.

[0018] This invention features two types of internal detection units: a rotary type and a fixed type. The rotary tubular eddy current detection unit is suitable for use in double-twisting machines where the overtwisting device drives the steel strand to rotate 360°. Combined with a surround eddy current sensor array, it achieves omnidirectional, blind-spot-free detection of the steel strand. The fixed type meets conventional installation requirements. Both types flexibly adapt to different production equipment structures, solving the problem that existing fixed-structure detection units cannot cover the detection of rotating steel strands and are prone to creating blind spots. Furthermore, the tubular eddy current detection unit of this invention can not only determine the occurrence of wire breakage but also quantitatively assess the number of broken wires through signal analysis. Combined with an encoder, it can accurately locate the wire breakage point, providing data support for quality traceability and process improvement.

[0019] This invention's signal receiving system is specifically designed to interface with photoelectric sensing components and eddy current sensor arrays, centrally transmitting the two detection signals to the control system to form a highly efficient "detection-reception-judgment" linkage. The control system is directly signal-connected to the actuator, enabling a stop command to be issued instantly upon triggering the alarm threshold. This solves the problems of scattered signal transmission and poor coordination in existing technologies, which lead to delayed response after wire breakage and continuous generation of defective products, thus achieving rapid shutdown after wire breakage. Attached Figure Description

[0020] 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 improper limitation of the invention.

[0021] Figure 1 This is a schematic diagram of the interrupted wire trigger detection device of the present invention; Figure 2 For the present invention Figure 1 Enlarged portion of the schematic diagram of the wire breakage trigger detection device; Figure 3 This is a schematic diagram of the power supply system of the present invention; Figure 4 This is a schematic diagram of the eddy current detection unit of the present invention; Figure 5 This is the external receiver of the present invention; Among them, 1 is the wire breaking device, 2 is the rotary induction pressure plate, and 3 is the photoelectric sensing component. Detailed Implementation

[0022] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0023] Example 1 This embodiment provides a wire breakage trigger detection device, including: a wire feeding system, an internal detection unit, a signal receiving system, a control system, and an actuator.

[0024] In this embodiment, the pay-off system includes a pay-off frame and an I-beam reel. The pay-off frame is made of high-strength steel, and its structural strength is adapted to the load requirements of the double-twisting machine production scenario, such as... Figure 1 As shown, at least one set of wire breaking devices 1 is installed on the wire feeding frame. In this embodiment, seven sets of wire breaking devices are preset on the wire feeding frame (the number of sets can be adjusted according to actual production needs). Each set of wire breaking devices includes a rotary sensing pressure plate 2 and a photoelectric sensing component 3 (or proximity switch) for real-time monitoring of the rotation status of the I-beam reel.

[0025] A steel wire rope is wound around the I-beam reel; the rotating sensing plate of each set of wire breakage devices is fixed on the through shaft of the wire feeding frame and rotates synchronously with the rotation of the I-beam reel. A photoelectric sensing component (or proximity switch) is used to sense the rotation signal of the rotating sensing plate. Specifically, the photoelectric sensing component (or proximity switch) corresponds to the edge of the rotating sensing plate, ensuring that the photoelectric sensing component accurately senses and generates a pulse signal every half-turn of the rotating sensing plate.

[0026] like Figure 4 As shown, in this embodiment, the internal detection unit is a tubular eddy current detection unit, which is divided into a rotating tubular eddy current detection unit or a fixed tubular eddy current detection unit, both of which are composed of a non-magnetic metal tube shell and an internal eddy current sensor array.

[0027] If it is a rotary tubular eddy current testing unit, it is fixedly installed on the cradle device of the double twisting machine to ensure that the testing unit can rotate synchronously when the steel strand rotates 360° with the overtwist device, so as to achieve 360° all-round testing of the steel strand; if it is a fixed tubular eddy current testing unit, it is fixedly installed on the pay-off frame to ensure that the axis of the tube shell is consistent with the movement trajectory of the wire rope.

[0028] This embodiment also includes an energy storage device that supplies power to the rotary tubular eddy current detection unit via a slip ring, thereby achieving uninterrupted power supply for the detection signal. If a wire breakage occurs, the internal receiver sends a wire breakage signal to... Figure 5 (External receiver).

[0029] like Figure 5As shown, the external receiver is used to receive the internal wire breakage signal. After receiving the signal, it is transmitted to the PLC, which performs comprehensive processing and logical judgment on the signal.

[0030] In this embodiment, the non-magnetic metal shell of the tubular eddy current detection unit has a tubular structure, and the steel wire rope passes through the inside of the non-magnetic metal shell. The eddy current sensor array is arranged around the inside of the shell to detect the passing steel wire rope.

[0031] The signal receiving system is used to receive signals from the photoelectric sensing components and eddy current sensor array and transmit them to the control system (PLC). The control system is connected to the actuators via signals, and the actuators include traction equipment and take-up equipment.

[0032] In this embodiment, the wire breakage trigger detection device further includes a power supply system and an encoder. The power supply system includes a micro generator and a main power supply. The micro generator is used to power the rotary tubular eddy current detection unit, and the main power supply is used to power the fixed tubular eddy current detection unit.

[0033] The micro generator is connected to the guide wheel via a coupling. The guide wheel contacts the wire rope, ensuring that the rotation of the wire rope drives the guide wheel to rotate, thereby driving the generator to generate electricity for mechanical energy and achieving energy self-sufficiency.

[0034] The encoder is connected to the control system via a signal to determine the location of the broken wire.

[0035] Example 2 This embodiment provides a method for detecting wire breakage triggering, based on a wire breakage triggering detection device provided in Embodiment 1, including: The traction device drives the I-beam reel on the wire-laying frame to rotate, and the wire rope passes through the tubular eddy current detection unit and is connected to the take-up device. The external and internal detection are started simultaneously, generating two detection signals, which are transmitted to the control system in real time. The control system makes a judgment based on the detection signals. If any detection method triggers the alarm threshold, the alarm is immediately executed and a stop command is issued.

[0036] Specifically: External detection includes the synchronous rotation of the rotating induction pressure plate fixed on the through shaft when the H-beam rotates. Every half rotation, the photoelectric sensor component senses a signal and transmits it to the signal receiving system, which then transmits the signal to the control system. If the control system continuously receives the signal, it determines that the wire feeding is normal. When wire breakage occurs, the H-beam stops rotating, the rotating induction pressure plate stops moving, the photoelectric sensor component stops sending signals, and if the control system does not receive a signal within a preset time, it determines that the wire breakage is abnormal.

[0037] The internal detection process involves a steel wire rope passing through the non-magnetic metal shell of a tubular eddy current detection unit at a constant speed. An eddy current sensor array, when energized, generates a high-frequency alternating magnetic field, inducing eddy current signals on the surface of the steel wire rope. The eddy current sensor array receives these signals and transmits them to a signal receiving system, which then transmits them to the control system. If the signal received by the control system is stable, it is considered normal. When the steel wire rope has defects (broken wires, cracks), the eddy current signal received by the control system is distorted, causing changes in the signal strength and phase. Combined with the encoder signal, the system calculates the strand length and locates the broken wire position (not only determining the occurrence of a broken wire but also quantitatively assessing the number of broken wires and accurately locating the broken wire's position relative to the starting point or encoder). Simultaneously, an alarm is immediately triggered, and a stop command is issued.

[0038] In this embodiment, the calculation of the steel strand length is expressed as: ; This refers to the length of the steel strand, specifically the length corresponding to the location of the broken wire. The speed of the traction or take-up device obtained by the encoder. This refers to the operating time of the equipment from startup to triggering the wire breakage alarm. The pitch of the steel strand. This refers to the twist ratio.

[0039] External and internal inspections operate simultaneously, with the control system performing comprehensive logical judgments on the two inspection signals. Whether the external inspection triggers a broken wire alarm (no photoelectric signal received for 5 seconds) or the internal inspection triggers a broken wire alarm (excessive number of broken wires or signal distortion), as long as either inspection method reaches the preset alarm threshold, the control system immediately executes an alarm operation, issuing an audible and visual alarm prompt and stopping the actuator to ensure that defective products do not flow into subsequent processes.

[0040] This embodiment combines indirect monitoring of the "wheel rotation state" with direct detection of the "physical state of the wire rope itself." This dual-judgment logic significantly reduces false alarms and missed alarms caused by misjudgments from a single sensor, resulting in a significantly higher accuracy than traditional single-detection methods. Dual detection is performed both externally and internally. Externally, at the wire feeding frame, detection begins at the source wire to prevent wire breakage caused by external wire breakage. Internally, eddy current units detect the steel strands to eliminate potential quality issues arising after twisting. These two dual-detection methods effectively prevent steel strand quality problems.

[0041] It achieves fully automated, uninterrupted online inspection, eliminating the need for frequent manual inspections, significantly reducing the physical labor of operators and the pressure on equipment monitoring, and improving equipment uptime and production efficiency. It can trigger a shutdown the instant a wire breaks, effectively preventing defective products from continuing into subsequent processes, fundamentally reducing the generation of defective products, lowering quality risks, and reducing production costs.

[0042] Various modifications and variations of this invention will be apparent to those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A wire breakage trigger detection device, characterized in that, include: The cable laying system, internal detection unit, signal receiving system, control system, and actuators; The wire feeding system includes a wire feeding frame, on which at least one set of wire breaking devices are installed. The wire breaking device includes a rotating induction pressure plate and a photoelectric sensing component. The internal detection unit is a tubular eddy current detection unit, which can be either a rotary tubular eddy current detection unit or a fixed tubular eddy current detection unit, both of which consist of a non-magnetic metal tube shell and an internal eddy current sensor array. The signal receiving system is used to receive signals from the photoelectric sensing component and the eddy current sensor array and transmit them to the control system. The control system is signal-connected to the actuator.

2. The wire breakage trigger detection device as described in claim 1, characterized in that, The wire feeding system also includes an I-beam reel with a steel wire rope wound on it; the rotating sensing pressure plate of each set of wire breaking devices is fixed on the through shaft of the wire feeding frame and rotates synchronously with the rotation of the I-beam reel; the photoelectric sensing component is used to sense the rotation signal of the rotating sensing pressure plate.

3. The wire breakage trigger detection device as described in claim 1, characterized in that, The tubular eddy current detection unit has a non-magnetic metal tube shell with a tubular structure. A steel wire rope passes through the inside of the non-magnetic metal tube shell, and an eddy current sensor array is arranged around the inside of the tube shell to detect the passing steel wire rope.

4. The wire breakage trigger detection device as described in claim 1, characterized in that, The signal receiving system is connected to the photoelectric sensing component, the eddy current sensor array, and the control system respectively; the actuator includes a traction device and a take-up device.

5. The wire breakage trigger detection device as described in claim 1, characterized in that, It also includes a power supply system for supplying power to various electrical components; the power supply system includes a micro generator and a main power supply, wherein the micro generator is used to supply power to the rotary tubular eddy current detection unit, and the main power supply is used to supply power to the fixed tubular eddy current detection unit.

6. The wire breakage trigger detection device as described in claim 1, characterized in that, It also includes an encoder; the encoder is connected to the control system via a signal connection to determine the location of the broken wire.

7. A method for detecting wire breakage triggering, based on the wire breakage triggering detection device according to any one of claims 1-6, characterized in that, include: The traction device drives the I-beam wheel on the wire feeding frame to rotate, and the wire rope passes through the tubular eddy current detection unit and is connected to the take-up device; The system simultaneously initiates external and internal detection, generating two detection signals, which are then transmitted to the control system in real time. The control system makes judgments based on the detection signals. If any detection method triggers the alarm threshold, an alarm is immediately triggered and a stop command is issued.

8. The wire breakage trigger detection method as described in claim 7, characterized in that, The external detection includes the synchronous rotation of a rotating sensing pressure plate fixed on the through shaft when the H-beam rotates. Every half rotation, the photoelectric sensing component senses a signal and transmits it to the signal receiving system, which then transmits the signal to the control system. If the control system continuously receives the signal, it determines that the wire feeding is normal. When wire breakage occurs, the H-beam stops rotating, the rotating sensing pressure plate stops moving, the photoelectric sensing component stops sending signals, and if the control system does not receive a signal within a preset time, it determines that the wire breakage is abnormal.

9. The wire breakage trigger detection method as described in claim 7, characterized in that, The internal detection involves a steel wire rope passing through the non-magnetic metal shell of a tubular eddy current detection unit at a constant speed. The eddy current sensor array is energized to generate a high-frequency alternating magnetic field, inducing eddy current signals on the surface of the steel wire rope. The eddy current sensor array receives the eddy current signals and transmits them to a signal receiving system, which then transmits the signals to a control system. If the signal received by the control system is stable, it is considered normal. If there is a defect in the steel wire rope, the eddy current signal received by the control system is distorted. The control system calculates the length of the steel strand and locates the broken wire by combining the encoder signal. At the same time, it immediately executes an alarm and issues a stop command.

10. The wire breakage trigger detection method as described in claim 9, characterized in that, The calculated length of the steel strand is expressed as follows: ; This refers to the length of the steel strand, specifically the length corresponding to the location of the broken wire. The speed of the traction or take-up device obtained by the encoder. This refers to the operating time of the equipment from startup to triggering the wire breakage alarm. The pitch of the steel strand. This refers to the twist ratio.

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