Intelligent monitoring and early warning method and system for pulling force of drag chain system

Abstract

The invention relates to a drag chain system tension intelligent monitoring and early warning method and system, and the method comprises the steps: collecting drag chain operation tension data in real time, and comparing the drag chain operation tension data with an alarm threshold value which can be customized by a user, thereby achieving the over-limit alarm; meanwhile, the system integrates the functions of total operation time statistics, maintenance cycle reminding and historical data recording and analysis, and a set of complete full-life-cycle intelligent operation and maintenance scheme from real-time monitoring, early warning, maintenance management to data analysis is formed. The problems that a traditional drag chain system cannot be maintained in a predictive mode and fault response lags behind are solved, cable damage and equipment shutdown caused by abnormal tension can be effectively prevented, the reliability and safety of the system are remarkably improved, the driving motor can be automatically turned off when the tension seriously exceeds the limit, and active safety protection is provided.

Description

Technical Field

[0001] This invention relates to the field of industrial automation equipment condition monitoring and fault diagnosis technology, specifically to a method and system for intelligent monitoring and early warning of tension in cable drag chain systems. Background Technology

[0002] Cable chain systems are used in equipment such as gantry cranes and automated machine tools to support and protect moving cables and hoses. In actual operation, cable chains may experience abnormally increased tension due to track deformation, internal cable jamming, or external resistance. Prolonged overload or sudden tensile impacts can drastically shorten the lifespan of both the cables and the cable chain itself, even leading to cable breakage, sudden equipment shutdown, and significant economic losses. Currently, most cable chain systems lack effective real-time monitoring methods, and maintenance relies on periodic inspections or reactive repairs, failing to achieve predictive maintenance and resulting in severely delayed fault response. Therefore, there is an urgent need for a solution capable of real-time monitoring of cable chain tension, intelligent early warning, and guidance for maintenance. Summary of the Invention

[0003] In view of the above situation, in order to solve the problems existing in the above technology, the present invention proposes a method and system for monitoring the tensile force of a cable chain system that can monitor in real time, provide intelligent early warning, and support full life cycle operation and maintenance management.

[0004] A method for intelligent monitoring and early warning of tension in a cable chain system includes the following steps: Real-time acquisition of tension values ​​during the operation of the cable chain; The real-time tension value is compared with a preset alarm threshold; When the real-time tension value exceeds the alarm threshold, an alarm action is generated and executed; and when the real-time tension value exceeds a preset higher-level safety shutdown threshold, a motor power shutdown control signal is generated and output. The total operating time of the cable chain system is accumulated, and maintenance reminder information is generated based on the preset maintenance cycle; Record and store historical tensile data, alarm events, and the total running time.

[0005] According to the present application, a method for intelligent monitoring and early warning of tension in a cable chain system provides a user interface through which at least one of the following operations can be implemented: custom setting of alarm threshold, global switch of alarm function, system language switching, and one-click reset to clear alarm status.

[0006] According to the present application, a method for intelligent monitoring and early warning of tension in a cable chain system generates a tension change trend curve within a specific time period based on recorded historical tension data, and outputs it to a display device and / or storage device through a data export interface.

[0007] According to the present application, a method for intelligent monitoring and early warning of tension in a cable chain system is provided, wherein the safety shutdown threshold is set based on the maximum permissible tension of the cable chain drive motor or the breaking tension of the cable.

[0008] According to the present application, a method for intelligent monitoring and early warning of tension in a cable chain system further includes a calibration step: by receiving the weight value of a weight input by the user and collecting the reading of the tension sensor when the weight is attached, the tension measurement system is calibrated.

[0009] According to the present application, a method for intelligent monitoring and early warning of tension in a cable chain system includes alarm actions including: triggering a visual alarm on the user interface, triggering an on-site audible and visual alarm, and recording at least one of the following alarm events: alarm start time, end time, and peak tension value.

[0010] A cable chain system tension intelligent monitoring and early warning system includes the following modules: The tension sensing module is used to collect the cable chain tension value in real time; The data processing and control module is communicatively connected to the tension sensing module and is used to perform data comparison, logical judgment and generate control commands. The human-computer interaction module is communicatively connected to the data processing and control module and is used to display information, set parameters, and issue reminders. The data storage module is used to store preset parameters, historical tensile data, and alarm records; The safety control output module is used to output a control signal to shut off the power supply to the drag chain drive motor when a shutdown command is received. The tension sensing module, safety control output module, human-machine interaction module, and data storage module are respectively connected to the data processing and control module.

[0011] According to the present application, a cable chain system tension intelligent monitoring and early warning system includes a human-machine interaction module comprising a local touch screen display. The interface displayed on the screen includes a real-time tension display area, an alarm status indication area, a total running time display area, a maintenance reminder information area, and a parameter setting entry.

[0012] According to the present application, a cable chain system tension intelligent monitoring and early warning system further includes a data export module, which is controlled and connected to the data storage module and the data processing and control module. The data export module is configured to allow users to export stored historical data to an external storage device in a common file format.

[0013] According to the present application, a cable chain system tension intelligent monitoring and early warning system is provided, wherein the data processing and control module is configured to perform a weight calibration process, that is, to automatically calculate and correct the measurement coefficient of the tension sensor based on the known weight of the weight.

[0014] After adopting the technology proposed in this invention, the intelligent monitoring and early warning method and system for cable chain system tension according to the embodiments of this invention have the following beneficial effects.

[0015] 1. Enable predictive maintenance: By monitoring changes in tension in real time, early warnings can be issued before a failure occurs, reminding users to intervene in a timely manner, transforming passive maintenance into proactive maintenance.

[0016] 2. Enhance safety and reliability: Immediate audible and visual alarms can quickly alert operators, preventing equipment from continuing to operate under abnormal conditions and avoiding catastrophic failures.

[0017] 3. Intelligent Operation and Maintenance Management: The integrated Total Uptime (TOT) and maintenance reminder functions make equipment maintenance plans more reliable and management more scientific.

[0018] 4. Facilitates fault diagnosis and optimization: The historical curve and data export functions provide valuable data support for analyzing the causes of faults and optimizing equipment operating parameters.

[0019] 5. Flexible and convenient operation: Supports parameter customization, one-click reset, and multi-language switching, providing a user-friendly experience and adapting to various application scenarios.

[0020] 6 By introducing a graded safety response mechanism and automatically shutting off the motor power supply in case of extreme overload, serious secondary accidents such as cable breakage and equipment damage caused by uncontrolled tension can be fundamentally avoided, achieving a leap from early warning to proactive safety protection. Attached Figure Description

[0021] Figure 1 A hardware block diagram of a cable chain system tension intelligent monitoring and early warning system according to an embodiment of the present invention is shown; Figure 2 A flowchart illustrating the steps of a method for intelligent monitoring and early warning of tension in a cable chain system according to an embodiment of the present invention is shown. Figure 3 An example diagram of the main monitoring screen of the human-machine interface of the intelligent monitoring and early warning system for cable chain tension according to an embodiment of the present invention is shown. Detailed Implementation

[0022] Preferred embodiments of the invention will now be described with reference to the accompanying drawings. The following description, with reference to the accompanying drawings, is provided to aid in understanding exemplary embodiments of the invention as defined by the claims and their equivalents. It includes various specific details to aid understanding, but these should be considered exemplary only. Therefore, those skilled in the art will recognize that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of the invention. Furthermore, detailed descriptions of functions and structures well known in the art will be omitted to make the specification clearer and more concise.

[0023] A cable chain system tension intelligent monitoring and early warning system includes the following modules: The tension sensing module is used to collect the cable chain tension value in real time; The data processing and control module is communicatively connected to the tension sensing module and is used to perform data comparison, logical judgment and generate control commands. The human-computer interaction module is communicatively connected to the data processing and control module and is used to display information, set parameters, and issue reminders. The data storage module is used to store preset parameters, historical tensile data, and alarm records; The safety control output module is used to output a control signal to shut off the power supply to the drag chain drive motor when a shutdown command is received. The tension sensing module, safety control output module, human-machine interaction module, and data storage module are respectively connected to the data processing and control module.

[0024] The human-machine interaction module includes a local touch screen display. The interface displayed on the display includes a real-time tensile force display area, an alarm status indication area, a total running time display area, a maintenance reminder information area, and a parameter setting entry.

[0025] It also includes a data export module, which is connected to the data storage module and the data processing and control module. The data export module is configured to allow users to export stored historical data to an external storage device in a common file format.

[0026] The data processing and control module is configured to perform a weight calibration process, that is, to automatically calculate and correct the measurement coefficient of the tension sensor based on the known weight of the weight.

[0027] More specifically, see Figure 1 The intelligent monitoring and early warning system for cable chain tension according to an embodiment of the present invention mainly includes: a tension sensor (installed at key locations such as the floating head of the cable chain), a PLC or embedded microprocessor (as the core of data processing and control), an HMI touch screen (as the human-machine interface), an audible and visual alarm, and an SD card or chip memory (for data storage).

[0028] A method for intelligent monitoring and early warning of tension in a cable chain system includes the following steps: Real-time acquisition of tension values ​​during the operation of the cable chain; The real-time tension value is compared with a preset alarm threshold; When the real-time tension value exceeds the alarm threshold, an alarm action is generated and executed; and when the real-time tension value exceeds a preset higher-level safety shutdown threshold, a motor power shutdown control signal is generated and output. The total operating time of the cable chain system is accumulated, and maintenance reminder information is generated based on the preset maintenance cycle; Record and store historical tensile data, alarm events, and the total running time.

[0029] A user interface is provided, through which at least one of the following operations can be performed: custom setting of alarm threshold, global switch of alarm function, system language switching, and one-click reset to clear alarm status.

[0030] Based on recorded historical tensile data, a tensile change trend curve for a specific time period is generated and output to a display device and / or storage device through a data export interface.

[0031] The safety shutdown threshold is set based on the maximum permissible tensile force of the cable chain drive motor or the breaking tensile force of the cable, for example, 150% of the motor's rated tensile force or 80% of the cable's safe tensile force. The safety control output module is connected to the main power circuit of the cable chain drive motor via a relay, contactor, or solid-state relay. For example, one output point of the PLC controls an intermediate relay connected in series in the coil circuit of the motor's main contactor. This relay can be configured to require manual on-site reset after trigger shutdown to restart. It can automatically shut down the drive motor when the tensile force is severely exceeded, providing active safety protection.

[0032] It also includes a calibration step: by receiving the weight value of the weight input by the user and collecting the reading of the tension sensor when the weight is attached, the tension measurement system is calibrated.

[0033] The alarm actions include at least one of the following: triggering a visual alarm on the user interface, triggering an on-site audible and visual alarm, and recording an alarm event including alarm start time, end time, and peak tensile force value.

[0034] More specifically, see Figure 2According to an embodiment of the present invention, the intelligent monitoring and early warning method for cable chain system tension involves the following steps: after the system is powered on, the tension sensor continuously collects data, and the processor compares this data with a user-defined alarm limit. If the limit is exceeded, the alarm is activated and the event is recorded. Simultaneously, the processor continuously accumulates the running time, and when the preset maintenance cycle is approaching, a reminder message pops up on the HMI screen. The user can view the curve through the "Historical Data" interface on the HMI and export a CSV file via USB for in-depth analysis.

[0035] Please refer to the main monitoring screen of the human-machine interface of the intelligent tensile monitoring and early warning system for cable chain systems according to an embodiment of the present invention. Figure 3 The HMI main interface displays real-time tension values, total running time, and the next maintenance date. It also features alarm status indicator lights and a one-button reset button. The interface layout is intuitive, and key information is readily available.

[0036] The cable chain system tension intelligent monitoring and early warning method and system of this application collects cable chain operating tension data in real time and compares it with user-defined alarm thresholds to achieve over-limit alarms. Simultaneously, the system integrates total operating time statistics, maintenance cycle reminders, and historical data recording and analysis functions, forming a complete intelligent operation and maintenance solution covering the entire lifecycle from real-time monitoring, early warning, maintenance management to data analysis. This invention solves the problems of unpredictable maintenance and delayed fault response in traditional cable chain systems, effectively preventing cable damage and equipment downtime caused by abnormal tension, and significantly improving system reliability and safety.

[0037] The intelligent monitoring and early warning method and system for cable chain system tension according to this application has the following advantages: 1. Enable predictive maintenance: By monitoring changes in tension in real time, early warnings can be issued before a failure occurs, reminding users to intervene in a timely manner, transforming passive maintenance into proactive maintenance.

[0038] 2. Enhance safety and reliability: Immediate audible and visual alarms can quickly alert operators, preventing equipment from continuing to operate under abnormal conditions and avoiding catastrophic failures.

[0039] 3. Intelligent Operation and Maintenance Management: The integrated Total Uptime (TOT) and maintenance reminder functions make equipment maintenance plans more reliable and management more scientific.

[0040] 4. Facilitates fault diagnosis and optimization: The historical curve and data export functions provide valuable data support for analyzing the causes of faults and optimizing equipment operating parameters.

[0041] 5. Flexible and convenient operation: Supports parameter customization, one-click reset, and multi-language switching, providing a user-friendly experience and adapting to various application scenarios.

[0042] 6 By introducing a graded safety response mechanism and automatically shutting off the motor power supply in case of extreme overload, serious secondary accidents such as cable breakage and equipment damage caused by uncontrolled tension can be fundamentally avoided, achieving a leap from early warning to proactive safety protection.

[0043] The present invention has been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of the present invention. The description of the above embodiments is only for the purpose of helping to understand the method and core ideas of the present invention. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of the present invention. Therefore, the content of this specification should not be construed as a limitation of the present invention.

[0044] Through the above description of the embodiments, those skilled in the art can clearly understand that the present invention is feasible. Of course, the situations listed above are merely examples, and the present invention is not limited thereto. Those skilled in the art should understand that other variations or simplifications of the technical solutions according to the present invention can be appropriately applied to the present invention and should be included within the scope of the present invention.

Claims

1. A method for intelligent monitoring and early warning of tension in a cable chain system, characterized in that, Includes the following steps: Real-time acquisition of tension values ​​during the operation of the cable chain; The real-time tension value is compared with a preset alarm threshold; When the real-time tension value exceeds the alarm threshold, an alarm action is generated and executed; and when the real-time tension value exceeds a preset higher-level safety shutdown threshold, a motor power shutdown control signal is generated and output. The total operating time of the cable chain system is accumulated, and maintenance reminder information is generated based on the preset maintenance cycle; Record and store historical tensile data, alarm events, and the total running time.

2. The intelligent monitoring and early warning method for tension in a cable chain system according to claim 1, characterized in that, A user interface is provided, through which at least one of the following operations can be performed: custom setting of alarm threshold, global switch of alarm function, system language switching, and one-click reset to clear alarm status.

3. The intelligent monitoring and early warning method for tension in a cable chain system according to claim 1, characterized in that, Based on recorded historical tensile data, a tensile change trend curve for a specific time period is generated and output to a display device and / or storage device through a data export interface.

4. The intelligent monitoring and early warning method for tension in a cable chain system according to claim 1, characterized in that, The safety shutdown threshold is set based on the maximum permissible tensile force of the cable chain drive motor or the breaking tensile force of the cable.

5. The intelligent monitoring and early warning method for tension in a cable chain system according to claim 1, characterized in that, It also includes a calibration step: by receiving the weight value of the weight input by the user and collecting the reading of the tension sensor when the weight is attached, the tension measurement system is calibrated.

6. The intelligent monitoring and early warning method for tension in a cable chain system according to claim 1, characterized in that, The alarm actions include at least one of the following: triggering a visual alarm on the user interface, triggering an on-site audible and visual alarm, and recording an alarm event including alarm start time, end time, and peak tensile force value.

7. A cable chain system tension intelligent monitoring and early warning system employing the method of any one of claims 1 to 6, characterized in that, Includes the following modules: The tension sensing module is used to collect the cable chain tension value in real time; The data processing and control module is used to perform data comparison, logical judgment and generate control commands; The human-computer interaction module is used to display information, set parameters, and issue reminders; The data storage module is used to store preset parameters, historical tensile data, and alarm records; The safety control output module is used to output a control signal to shut off the power supply to the drag chain drive motor when a shutdown command is received. The tension sensing module, safety control output module, human-machine interaction module, and data storage module are respectively connected to the data processing and control module.

8. The intelligent monitoring and early warning system for tension in a cable chain system according to claim 7, characterized in that, The human-machine interaction module includes a local touch screen display. The interface displayed on the display includes a real-time tensile force display area, an alarm status indication area, a total running time display area, a maintenance reminder information area, and a parameter setting entry.

9. The intelligent monitoring and early warning system for tension in a cable chain system according to claim 7, characterized in that, It also includes a data export module, which is connected to the data storage module and the data processing and control module. The data export module is configured to allow users to export stored historical data to an external storage device in a common file format.

10. The intelligent monitoring and early warning system for tension in a cable chain system according to claim 7, characterized in that, The data processing and control module is configured to perform a weight calibration process, that is, to automatically calculate and correct the measurement coefficient of the tension sensor based on the known weight of the weight.

Images