Steel wire rope cold and hot composite straightening device and method

Abstract

The invention discloses a steel wire rope cold and hot composite straightening device and method. The device comprises a rack, a plurality of groups of straightening roller wheel assemblies and adjusting bolt assemblies, the roller assembly comprises a hollow roller and a hollow rotating shaft, a medium circulating flow channel is arranged in the roller, and a liquid inlet channel and a liquid return channel are arranged in the rotating shaft; the multiple sets of roller assemblies are sequentially divided into a preheating section roller set, a constant-temperature straightening section roller set and a cooling shaping section roller set. The rack is of a block splicing structure, and a thermal medium distribution main channel, a cold medium distribution main channel and a liquid return main channel which are isolated from one another are arranged in the rack. The preheating section roller set is communicated with the main thermal medium distribution channel, the constant-temperature straightening section roller set is communicated with the main thermal medium distribution channel through an independent temperature control branch, and the cooling shaping section roller set is communicated with the main cold medium distribution channel. The method comprises the steps of composite preheating, constant-temperature straightening, slow cooling shaping and closed-loop temperature control. Through gradient type precise temperature control straightening, residual stress is effectively eliminated, and straightness and structure uniformity of the steel wire rope are guaranteed.

Description

Technical Field

[0001] This invention relates to the field of wire rope processing technology, specifically to a wire rope cold and hot composite straightening device and method. Background Technology

[0002] As a critical load-bearing component, steel wire rope is widely used in mining, ports, bridges, elevators, and other fields. Its straightness, residual stress distribution, and internal structure directly determine its performance and safety. During the twisting, drawing, and subsequent processing of steel wire rope, bending deformation and residual stress inevitably occur, requiring straightening to correct these issues. Traditional straightening methods mainly employ multi-roller mechanical straightening devices, using staggered rollers to repeatedly bend the wire rope, making its plastic deformation more uniform to achieve straightness. However, simple cold mechanical straightening has significant drawbacks: high residual stress after straightening, internal structural damage, and severe springback. Especially for high-strength steel wire ropes, cold straightening easily leads to cracks or wire breakage risks.

[0003] To improve straightening performance, existing technologies have developed hot or warm straightening solutions. Some solutions use a monolithic heating furnace to heat the wire rope to a certain temperature before straightening, or preheat the wire rope surface using induction heating. However, existing technologies still have the following shortcomings: First, monolithic heating methods are energy-intensive, slow to heat up, and have poor temperature control accuracy. Furthermore, the wire rope temperature continuously decreases during straightening, making it difficult to maintain a constant temperature during straightening, resulting in unstable straightening quality. Second, in existing hot straightening devices, the rollers only act as mechanical extrusion elements and cannot actively control the temperature of the wire rope. There is a lack of temperature connection between the preheating and straightening sections, leading to a large temperature gradient that affects the straightening effect. Third, the cooling process after straightening lacks effective control, and the cooling rate does not match the phase transformation of the microstructure, easily generating new residual stress or microstructural defects. Fourth, although some devices attempt to set cooling channels inside the rollers, these are mostly simple single paths, unable to achieve segmented and zoned independent temperature control, making it difficult to meet the comprehensive requirements of high-precision straightening processes for temperature gradient, temperature fluctuation, and cooling rate. Summary of the Invention

[0004] To address the aforementioned problems in the prior art, this invention provides a steel wire rope cold and hot composite straightening device and method.

[0005] The objective of this invention can be achieved through the following technical solutions: A steel wire rope cold and hot composite straightening device includes a frame, multiple sets of straightening roller assemblies arranged vertically and horizontally, and an adjusting bolt assembly for adjusting the gap between the rollers; the straightening roller assembly is rotatably mounted on the frame along the direction of travel of the steel wire rope; The straightening roller assembly includes a hollow straightening roller and a hollow rotating shaft for supporting the straightening roller. The straightening roller has a media circulation channel inside, and the hollow rotating shaft has a liquid inlet channel and a liquid return channel that are isolated from each other. The media circulation channel is connected to the liquid inlet channel and the liquid return channel of the corresponding rotating shaft. The multiple sets of straightening roller assemblies are sequentially divided into a preheating section roller group, a constant temperature straightening section roller group, and a cooling and shaping section roller group along the direction of the wire rope travel; The frame is provided with a hot medium distribution main channel, a cold medium distribution main channel and a return liquid main channel that are isolated from each other. Each of the medium main channels is connected to the hollow rotating shaft of the corresponding roller group through a branch flow channel to form a medium circulation loop. The preheating section roller assembly is connected to the main channel for heat medium distribution; the constant temperature straightening section roller assembly is connected to the main channel for heat medium distribution through at least one set of independent temperature control branches, each independent temperature control branch including an independent circulating pump, a proportional regulating valve, and a temperature controller, used to independently regulate the flow rate and temperature of the medium flowing into the constant temperature straightening section roller assembly; the cooling and shaping section roller assembly is connected to the main channel for cold medium distribution.

[0006] As a preferred embodiment of the present invention, it further includes an inlet guide seat and an outlet guide seat fixed at both ends of the frame; the preheating section roller group corresponds to multiple sets of staggered rollers on the inlet side, the cooling and shaping section roller group corresponds to multiple sets of staggered rollers on the outlet side, and the constant temperature straightening section roller group corresponds to the straightening rollers located between the preheating section roller group and the cooling and shaping section roller group.

[0007] As a preferred embodiment of the present invention, the hollow shaft is provided with a rotary sealing joint at its end, and the rotary sealing joint is installed in the bearing housing mounting cavity at both ends of the frame; a heat-insulating sealing structure is provided between the liquid inlet channel and the liquid return channel inside the hollow shaft.

[0008] As a preferred embodiment of the present invention, the frame adopts a modular splicing structure, including multiple frame modules spliced ​​along the length direction, and adjacent frame modules are connected by high-temperature resistant sealing gaskets and fasteners; the main channel for hot medium distribution, the main channel for cold medium distribution, and the main channel for liquid return are embedded in each frame module along the length direction of the frame, and are connected at the module splicing points by high-pressure sealing joints; the branch channels are set inside the roller mounting base.

[0009] As a preferred embodiment of the present invention, the adjusting bolt assembly is a hollow structure with a sensor wiring channel inside; a contact temperature sensor is provided at the connection between the lower end of the adjusting bolt and the roller mounting base to collect the working temperature of the corresponding roller group; in addition, a non-contact infrared temperature sensor with its collecting end facing the surface of the wire rope is provided between adjacent straightening roller assemblies; the signal lines of the contact temperature sensor and the non-contact infrared temperature sensor are led out through the wiring channel and connected to the wiring groove integrated inside the frame.

[0010] As a preferred embodiment of the present invention, an annular non-contact induction heating coil is embedded in the inner wall of the inlet guide seat. The induction heating coil is disposed in the internal cavity of the guide seat, and the wiring is led out along the wiring groove inside the frame. An annular cooling channel is embedded in the inner wall of the outlet guide seat. The annular cooling channel is disposed inside the guide seat body and is connected to the main channel for cold medium distribution and the main channel for liquid return of the frame to form a circulating cooling circuit.

[0011] A method for combined cold and hot straightening of steel wire ropes, applied to a combined cold and hot straightening device for steel wire ropes as described in any one of claims 1 to 6, includes the following steps: Step S1, Preheating and softening: The wire rope is preheated in combination by the induction heating coil of the inlet guide seat and the heat medium roller of the preheating section roller group, heating the wire rope to a preheating temperature range of 250℃-350℃, controlling the surface temperature uniformity of the wire rope within ±5℃, and controlling the temperature difference between the actual temperature of the wire rope at the outlet of the preheating section and the set target temperature at the inlet of the constant temperature straightening section to not exceed 20℃. Step S2, Constant Temperature Straightening: The preheated wire rope is fed into the constant temperature straightening section roller group and repeatedly bent and straightened in multiple rounds within the constant temperature straightening temperature range of 300℃~450℃. The temperature fluctuation range of the constant temperature straightening section is controlled within ±1.5℃ through an independent temperature control branch. The constant temperature straightening section roller group provides auxiliary heating through heat medium circulation to maintain a constant temperature state. Step S3, Slow Cooling and Shaping: The straightened wire rope is fed into the cooling and shaping section roller group and cooled to room temperature at a cooling rate of 10℃ / s-30℃ / s. During the cooling process, straightening pressure is continuously applied through the straightening roller assembly to achieve shaping. Step S4, Closed-loop temperature control: The surface temperature of the wire rope in each straightening section is collected in real time by temperature sensors. The collected temperature value is compared with the set target value of the corresponding section. The flow rate of the hot medium or the cold medium in each straightening section is adjusted independently according to the temperature deviation, so that the temperature of each straightening section is maintained within its set temperature range.

[0012] As a preferred technical solution of the present invention, in step S2, the constant temperature straightening section is divided into 2 to 3 independent temperature control zones along the direction of the wire rope travel. The temperature of each temperature control zone is adjusted independently, and the temperature gradient between adjacent temperature control zones does not exceed 3℃ / m.

[0013] As a preferred technical solution of the present invention, in step S1, during composite preheating, the wire rope is first preheated to 250℃-320℃ by induction heating coil, and then the wire rope is heated to the target preheating temperature by contact heating of the preheating section roller group, and the radial temperature difference of the wire rope is controlled to not exceed 8℃.

[0014] As a preferred technical solution of the present invention, in step S3, during the cooling and shaping process, the annular cooling channel of the outlet guide seat is used to assist in cooling, and the circumferential temperature uniformity of the wire rope is controlled within ±8℃.

[0015] The beneficial effects of this invention are as follows: By dividing the straightening roller assembly into a preheating section roller group, a constant temperature straightening section roller group, and a cooling and shaping section roller group in sequence, and integrating mutually isolated main channels for hot medium distribution, cold medium distribution, and return liquid within the frame, an independent medium circulation loop is formed, achieving gradient temperature control throughout the entire wire rope straightening process. The constant temperature straightening section roller group independently adjusts the medium flow rate and temperature through an independent temperature control branch, controlling temperature fluctuations within ±1.5℃. The frame adopts a modular splicing structure, reducing the processing difficulty of complex flow channels and ensuring sealing reliability. By setting contact temperature sensors and non-contact infrared temperature sensors, combined with a temperature difference compensation algorithm model, and using the infrared measured temperature as a benchmark to calibrate the conduction hysteresis of contact temperature measurement in real time, high-precision closed-loop control of the wire rope surface temperature is achieved.

[0016] In terms of process, the steel wire rope is heated to 250℃-350℃ through composite preheating, and the surface temperature uniformity is controlled within ±5℃. The temperature difference between the preheating section outlet and the constant temperature straightening section inlet does not exceed 20℃, achieving a smooth connection of process parameters. Multiple rounds of repeated bending and straightening are performed in the constant temperature straightening range of 300℃-450℃, followed by uniform slow cooling and shaping at a cooling rate of 10℃ / s-30℃ / s, so that the steel wire rope is always in the ideal temperature range. With the induction heating coil of the inlet guide seat and the annular cooling channel of the outlet guide seat, precise temperature control and microstructure performance regulation are achieved throughout the preheating, straightening, and cooling process, which significantly improves the straightening accuracy and straightness, effectively eliminates residual stress, and ensures the microstructure uniformity and reliability of the finished steel wire rope. Attached Figure Description

[0017] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0018] Figure 1This is a schematic diagram of the overall structure of a steel wire rope cold and hot composite straightening device according to the present invention.

[0019] Figure 2 This is a front view cross-sectional structural diagram of a steel wire rope cold and hot composite straightening device according to the present invention.

[0020] Figure 3 This is an enlarged structural diagram of the straightening roller of a steel wire rope cold and hot composite straightening device according to the present invention.

[0021] Figure 4 This is a schematic diagram of the process of a steel wire rope cold and hot composite straightening method according to the present invention.

[0022] Reference numerals: 100, frame; 200, inlet guide seat; 300, outlet guide seat; 400, straightening roller; 401, hollow rotating shaft; 411, liquid inlet channel; 412, liquid return channel; 402, medium circulation channel; 500, adjusting bolt assembly; 600, preheating section roller group; 700, constant temperature straightening section roller group; 800, cooling and shaping section roller group. Detailed Implementation

[0023] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided.

[0024] Please see Figures 1-3 This invention provides a steel wire rope cold and hot composite straightening device, including a frame 100, an inlet guide seat 200 and an outlet guide seat 300 fixed at both ends of the frame 100 along the direction of steel wire rope travel, multiple sets of straightening roller assemblies, and adjusting bolt assemblies 500 corresponding to each set of straightening roller assemblies. The multiple sets of straightening roller assemblies are arranged alternately, and the rotation axis of each set of straightening roller assemblies is perpendicular to the direction of steel wire rope travel, and they are rotatably mounted on the frame 100 through roller mounting seats.

[0025] The straightening roller assembly includes a hollow straightening roller 400 and a hollow rotating shaft 401 for supporting the straightening roller 400. The straightening roller 400 and the hollow rotating shaft 401 rotate synchronously. The straightening roller 400 has a media circulation channel 402 inside, and the hollow rotating shaft 401 has a liquid inlet channel 411 and a liquid return channel 412 that are isolated from each other inside. The two ends of the media circulation channel 402 are sealed and connected to the corresponding liquid inlet channel 411 and liquid return channel 412 of the hollow rotating shaft 401, respectively, thereby forming a circulation path for the media inside the straightening roller 400. By introducing a heating or cooling medium into the liquid inlet channel 411 of the hollow rotating shaft 401, the medium flows through the medium circulation channel 402 inside the straightening roller 400 and then flows out from the liquid return channel 412 of the hollow rotating shaft 401, thus achieving active temperature control of the straightening roller 400. This allows the straightening roller 400 to regulate the temperature of the wire rope while it is in contact with and pressing it.

[0026] The multiple straightening roller assemblies are sequentially divided into a preheating section roller group 600, a constant-temperature straightening section roller group 700, and a cooling and shaping section roller group 800 along the direction of wire rope travel. The preheating section roller group 600 corresponds to multiple sets of staggered rollers on the inlet side and is used to preheat and soften the wire rope entering the straightening device. The constant-temperature straightening section roller group 700 corresponds to the straightening rollers 400 located between the preheating section roller group 600 and the cooling and shaping section roller group 800 and is used to repeatedly bend and straighten the wire rope under constant temperature conditions. The cooling and shaping section roller group 800 corresponds to multiple sets of staggered rollers on the outlet side and is used to cool and shape the straightened wire rope.

[0027] The frame 100 contains three isolated main channels for hot and cold media distribution, and a main channel for liquid return, embedded along its length. To reduce the difficulty of deep-hole machining of the long flow channels inside the large frame 100 and to avoid the risk of high-pressure media leakage, in this embodiment, the frame 100 adopts a modular assembly structure, consisting of 3 to 5 frame 100 modules assembled along its length. Each frame 100 module independently has its media channel section drilled through machining. Adjacent frame 100 modules are fastened together at the splicing end face using high-temperature resistant metal spiral wound gaskets and high-strength bolts. High-pressure flange sealing joints are provided at the module splicing points for the hot, cold, and liquid return main channels to ensure sealed connectivity of each main channel, thereby achieving modular manufacturing and reliable assembly of the complex long flow channels.

[0028] The main heat medium distribution channel distributes heat medium to the preheating section roller group 600 and the constant temperature straightening section roller group 700, while the main cold medium distribution channel distributes cold medium to the cooling and shaping section roller group 800. The main return channel collects the medium returning from each roller group. The roller mounting base has branch channels connected to the corresponding main medium channels. Each hollow shaft 401 has a rotary sealing joint at both ends, fixed to the bearing housing cavity of the corresponding roller mounting base. The inlet channel 411 and return channel 412 of the hollow shaft 401 are connected to the corresponding branch channels via the corresponding rotary sealing joints, forming an independent medium circulation loop for each individual straightening roller assembly. The rotary sealing joints ensure normal rotation of the hollow shaft 401 while preventing medium leakage under high pressure. A heat-insulating sealing structure is installed between the inlet channel 411 and the return channel 412 inside the hollow shaft 401 to prevent heat exchange between the inlet and return channels from affecting temperature control accuracy.

[0029] The branch channels of the preheating section roller assembly 600 are connected to the main channel for heat medium distribution, allowing the heat medium to flow into each straightening roller assembly of the preheating section roller assembly 600 for contact preheating of the wire rope. The branch channels of the constant-temperature straightening section roller assembly 700 are connected to the main channel for heat medium distribution via an independent temperature control branch. This independent temperature control branch includes an independent circulating pump, a heat exchange unit, and a proportional regulating valve connected sequentially in the fluid passage, and also includes a temperature controller electrically connected to the independent circulating pump, heat exchange unit, and proportional regulating valve. The independent temperature control branch is used to independently regulate the flow rate and temperature of the medium flowing into the constant-temperature straightening section roller assembly 700, thereby achieving precise temperature control of the constant-temperature straightening section.

[0030] In a preferred embodiment, the constant temperature straightening section roller group 700 is divided into 2 to 3 independent temperature control zones along the direction of the wire rope travel. Each temperature control zone corresponds to a set of straightening roller assemblies, and each temperature control zone is connected to the main heat medium distribution channel through an independent temperature control branch. Each independent temperature control branch includes an independent circulating pump, a proportional regulating valve, and a temperature controller, which are used to independently adjust the medium flow rate and temperature of the corresponding temperature control zone.

[0031] The branch flow channel corresponding to the cooling and shaping section roller group 800 is connected to the main channel for distributing the cold medium, so that the cold medium can flow into each straightening roller assembly of the cooling and shaping section roller group 800 to perform contact cooling on the wire rope.

[0032] The main channels for hot and cold medium distribution, as well as the main channel for liquid return, are all prefabricated channels embedded in the frame 100 using seamless steel pipes. High-pressure sealing joints are installed between the ports of the branch channels and the corresponding main channels to ensure the sealing reliability of the media channels under high-pressure conditions. The main channels for hot and cold medium distribution, and the main channel for liquid return are arranged embedded along the length of the frame 100, while the branch channels are located inside the roller mounting bases, resulting in a compact overall structure and facilitating media flow.

[0033] The adjusting bolt assembly 500 is a hollow structure with an axial sensor wiring channel inside its rod. The lower end of the adjusting bolt assembly 500 is rotatably connected to the corresponding roller mounting base, used to adjust the gap between the straightening roller assemblies to accommodate wire ropes of different specifications. A contact temperature sensor is installed on the roller mounting base at the working surface position corresponding to the straightening roller 400, used to collect the reference working temperature of the corresponding roller assembly and bearing housing in real time. Due to the thermal conduction hysteresis of contact measurement, to accurately reflect the true temperature of the wire rope during high-speed travel, this device also adds a non-contact infrared temperature sensor on the side wall of the frame 100 between adjacent straightening roller assemblies, with its acquisition end directly facing the surface of the wire rope. The surface temperature of the wire rope in each straightening section is collected in real time by the non-contact infrared temperature sensor.

[0034] The signal lines of the two types of sensors mentioned above are led out through the sensor wiring channel inside the adjusting bolt assembly 500, connected to the wiring slot integrated inside the frame 100, and then connected to the temperature control module. The temperature control module has a built-in temperature difference compensation algorithm model. During operation, this model uses the real-time surface temperature of the steel wire rope collected by the non-contact infrared temperature sensor as a reference to calculate the dynamic temperature difference between it and the roller mounting seat temperature collected by the contact temperature sensor, and establishes a heat conduction hysteresis compensation curve. This allows for real-time calibration of the feedback signal from the contact sensor, effectively overcoming the hysteresis of indirect temperature measurement and achieving stable temperature signal transmission and high-precision closed-loop control.

[0035] As a preferred embodiment, the temperature difference compensation algorithm model adopts the following control logic: Let T IR The real-time surface temperature of the steel wire rope is collected by a non-contact infrared temperature sensor, T c The temperature of the roller mounting base is collected by a contact temperature sensor, and Δt is the preset sampling period. The temperature control module first calculates the dynamic temperature difference ΔT = T. IR -T c And establish the heat conduction hysteresis compensation function ΔT(t)=a·(1-e -t / τ ), where a is the steady-state temperature difference coefficient and τ is the time constant. Based on this compensation function, the temperature control module corrects the feedback signal from the contact sensor in real time and outputs the corrected temperature value T. comp =T c+ΔT(t) is used as the input for closed-loop control. This algorithm model can dynamically adjust the opening of the independent circulating pump and the proportional control valve using PID control, so that the deviation between the measured temperature and the set target value approaches zero.

[0036] A wear-resistant insulating bushing is fixed to the inner hole of the inlet guide seat 200. An annular non-contact induction heating coil, fitted outside the wear-resistant insulating bushing, is embedded inside the body of the inlet guide seat 200 for non-contact preheating of the wire rope entering the straightening device. The wiring of the induction heating coil is led out along the wiring groove inside the frame 100 and connected to an external power supply. A wear-resistant bushing is fixed to the inner hole of the outlet guide seat 300. An annular cooling channel, fitted outside the wear-resistant bushing, is embedded inside the body of the outlet guide seat 300. The two ends of the annular cooling channel are connected to the main cooling medium distribution channel and the main return liquid channel, respectively, forming a circulating cooling circuit for auxiliary temperature equalization cooling of the wire rope after straightening.

[0037] Based on the above-mentioned cold and hot composite straightening device for steel wire ropes, please refer to... Figure 4 This invention also provides a method for cold and hot composite straightening of steel wire rope, comprising the following steps.

[0038] Step S1, Preheating and Softening: The wire rope is preheated in a combined manner through the induction heating coil of the inlet guide seat 200 and the heat medium rollers of the preheating section roller group 600, heating the wire rope to a preheating temperature range of 250℃ to 350℃, controlling the surface temperature uniformity of the wire rope within ±5℃. During this process, the temperature difference between the actual temperature of the wire rope at the preheating section outlet and the set target temperature at the inlet of the constant temperature straightening section is strictly controlled to not exceed 20℃. Raising the lower limit of the preheating temperature from the conventional 200℃ to 250℃ and imposing a temperature difference limit effectively avoids the difficulty of instantaneous heating caused by excessive temperature difference when the wire rope enters the constant temperature straightening section. This not only ensures a smooth transition of temperature parameters between the two sections but also significantly reduces the auxiliary heating load of the constant temperature straightening section roller group 700, preventing thermal stress concentration on the surface of the wire rope caused by instantaneous high-power heating. During composite preheating, the wire rope is first preheated to 250°C to 320°C using an induction heating coil, and then heated to the target preheating temperature using the contact heating of the preheating section roller group 600, while simultaneously controlling the radial temperature difference of the wire rope to not exceed 8°C. This composite preheating method combines the speed of non-contact induction heating with the uniformity of contact roller heating, resulting in a more uniform temperature distribution between the core and surface of the wire rope.

[0039] Step S2, Constant Temperature Straightening: The preheated wire rope is fed into the constant temperature straightening section roller group 700, and undergoes multiple rounds of repeated bending and straightening within the constant temperature straightening temperature range of 300℃ to 450℃. The temperature fluctuation range of the constant temperature straightening section is controlled within ±1.5℃ through an independent temperature control branch. Since a good temperature connection has been achieved in step S1, the high-temperature heat medium circulating inside the constant temperature straightening section roller group 700 mainly plays a strong auxiliary heating and heat preservation role, compensating for the heat loss of the wire rope during bending deformation and contact with air, thus easily maintaining a high-precision constant temperature state of ±1.5℃. The constant temperature straightening section is divided into 2 to 3 independent temperature control zones along the direction of wire rope travel. The temperature of each temperature control zone is adjusted independently, and the temperature gradient between adjacent temperature control zones does not exceed 3℃ / m. Through segmented independent temperature control, fine adjustment can be made according to the actual temperature changes of the wire rope during the straightening process, ensuring the stability and uniformity of the temperature field of the entire straightening section.

[0040] Step S3, Slow Cooling and Shaping: The straightened wire rope is fed into the cooling and shaping roller assembly 800 and cooled to room temperature at a uniform rate of 10℃ / s to 30℃ / s. During the cooling process, straightening pressure is continuously applied through the straightening roller assembly for shaping. During the cooling and shaping process, the annular cooling channel of the outlet guide seat 300 assists in cooling, controlling the circumferential temperature uniformity of the wire rope within ±8℃. The moderate cooling rate of slow cooling and shaping effectively locks in the straightened shape while avoiding structural stress that may be caused by rapid cooling, ensuring the structural uniformity of the wire rope.

[0041] Step S4, Closed-loop temperature control: The surface temperature of the wire rope in each straightening section is collected in real time by temperature sensors. The collected temperature values ​​are compared with the set target values ​​for the corresponding sections. Based on the temperature deviation, the flow rate of the hot or cold medium in each straightening section is adjusted independently to maintain the temperature of each straightening section within its set temperature range. The closed-loop temperature control system responds to temperature changes in real time and dynamically adjusts the medium flow rate to ensure that the temperature throughout the straightening process remains within the optimal process window.

[0042] The closed-loop temperature control system has a built-in temperature difference compensation algorithm model that receives signals from contact and non-contact temperature sensors in real time. Using the surface temperature of the wire rope collected by the non-contact infrared temperature sensor as a reference, it calculates the dynamic temperature difference between the wire rope surface temperature and the roller mounting temperature collected by the contact sensor. The thermal conduction hysteresis compensation function corrects the conduction hysteresis of the contact measurement and outputs a high-precision temperature feedback value. Then, the PID controller adjusts the medium flow rate of each straightening section to form a closed-loop control.

[0043] In summary, the wire rope cold-heat composite straightening device and method of the present invention, through the combination of three-section partitioning and independent temperature control branches, achieves gradient-based precise temperature control straightening throughout the entire wire rope straightening process. Composite preheating ensures the temperature uniformity of the wire rope before entering the straightening section, constant-temperature straightening ensures temperature stability during the straightening process, slow cooling and shaping effectively locks in the straightened shape and avoids structural stress, and closed-loop temperature control achieves precise temperature management throughout the entire process. The present invention effectively eliminates residual stress after wire rope straightening, ensures the straightness and structural uniformity of the wire rope, and significantly improves the straightening quality.

[0044] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A steel wire rope cold and hot composite straightening device, characterized in that: It includes a frame, multiple sets of straightening roller assemblies arranged in an alternating manner, and an adjusting bolt assembly for adjusting the roller gap; the straightening roller assembly is rotatably mounted on the frame along the direction of travel of the wire rope; The straightening roller assembly includes a hollow straightening roller and a hollow rotating shaft for supporting the straightening roller. The straightening roller has a media circulation channel inside, and the hollow rotating shaft has a liquid inlet channel and a liquid return channel that are isolated from each other. The media circulation channel is connected to the liquid inlet channel and the liquid return channel of the corresponding rotating shaft. The multiple sets of straightening roller assemblies are sequentially divided into a preheating section roller group, a constant temperature straightening section roller group, and a cooling and shaping section roller group along the direction of the wire rope travel; The frame is provided with a hot medium distribution main channel, a cold medium distribution main channel and a return liquid main channel that are isolated from each other. Each of the medium main channels is connected to the hollow rotating shaft of the corresponding roller group through a branch flow channel to form a medium circulation loop. The preheating section roller assembly is connected to the main channel for heat medium distribution; the constant temperature straightening section roller assembly is connected to the main channel for heat medium distribution through at least one set of independent temperature control branches, each independent temperature control branch including an independent circulating pump, a proportional regulating valve, and a temperature controller, used to independently regulate the flow rate and temperature of the medium flowing into the constant temperature straightening section roller assembly; the cooling and shaping section roller assembly is connected to the main channel for cold medium distribution.

2. The steel wire rope cold and hot composite straightening device according to claim 1, characterized in that: It also includes an inlet guide seat and an outlet guide seat fixed at both ends of the frame; the preheating section roller group corresponds to multiple sets of staggered rollers on the inlet side, the cooling and shaping section roller group corresponds to multiple sets of staggered rollers on the outlet side, and the constant temperature straightening section roller group corresponds to the straightening rollers located between the preheating section roller group and the cooling and shaping section roller group.

3. The steel wire rope cold and hot composite straightening device according to claim 1, characterized in that: The hollow shaft is provided with a rotary sealing joint at its end, and the rotary sealing joint is installed in the bearing housing mounting cavity at both ends of the frame; a heat-insulating sealing structure is provided between the liquid inlet channel and the liquid return channel inside the hollow shaft.

4. The steel wire rope cold and hot composite straightening device according to claim 1, characterized in that: The frame adopts a modular splicing structure, including multiple frame modules spliced ​​along the length direction. Adjacent frame modules are connected by high-temperature resistant sealing gaskets and fasteners. The main hot medium distribution channel, the main cold medium distribution channel, and the main return liquid channel are embedded in each frame module along the length direction of the frame and are connected at the module splicing points by high-pressure sealing joints. The branch flow channels are set inside the roller mounting base.

5. The steel wire rope cold and hot composite straightening device according to claim 2, characterized in that: The adjusting bolt assembly has a hollow structure with a sensor wiring channel inside. A contact temperature sensor is installed at the connection between the lower end of the adjusting bolt and the roller mounting base to collect the working temperature of the corresponding roller group. In addition, a non-contact infrared temperature sensor with its collecting end facing the surface of the wire rope is also installed between adjacent straightening roller assemblies. The signal lines of the contact temperature sensor and the non-contact infrared temperature sensor are led out through the wiring channel and connected to the wiring groove integrated inside the frame.

6. The steel wire rope cold and hot composite straightening device according to claim 2, characterized in that: The inner wall of the inlet guide seat is embedded with an annular non-contact induction heating coil, which is located in the internal cavity of the guide seat and the wiring is led out along the wiring groove inside the frame. The inner wall of the outlet guide seat is embedded with an annular cooling channel, which is located inside the guide seat body and is connected to the main channel for cold medium distribution and the main channel for liquid return of the frame to form a circulating cooling circuit.

7. A method for combined cold and hot straightening of steel wire ropes, applied to a combined cold and hot straightening device for steel wire ropes as described in any one of claims 1 to 6, characterized in that, Includes the following steps: Step S1, Preheating and softening: The wire rope is preheated in combination by the induction heating coil of the inlet guide seat and the heat medium roller of the preheating section roller group, heating the wire rope to a preheating temperature range of 250℃-350℃, controlling the surface temperature uniformity of the wire rope within ±5℃, and controlling the temperature difference between the actual temperature of the wire rope at the outlet of the preheating section and the set target temperature at the inlet of the constant temperature straightening section to not exceed 20℃. Step S2, Constant Temperature Straightening: The preheated wire rope is fed into the constant temperature straightening section roller group and repeatedly bent and straightened in multiple rounds within the constant temperature straightening temperature range of 300℃~450℃. The temperature fluctuation range of the constant temperature straightening section is controlled within ±1.5℃ through an independent temperature control branch. The constant temperature straightening section roller group provides auxiliary heating through heat medium circulation to maintain a constant temperature state. Step S3, Slow Cooling and Shaping: The straightened wire rope is fed into the cooling and shaping section roller group and cooled to room temperature at a cooling rate of 10℃ / s-30℃ / s. During the cooling process, straightening pressure is continuously applied through the straightening roller assembly to achieve shaping. Step S4, Closed-loop temperature control: The surface temperature of the wire rope in each straightening section is collected in real time by temperature sensors. The collected temperature value is compared with the set target value of the corresponding section. The flow rate of the hot medium or the cold medium in each straightening section is adjusted independently according to the temperature deviation, so that the temperature of each straightening section is maintained within its set temperature range.

8. The method for combined cold and hot straightening of steel wire rope according to claim 7, characterized in that: In step S2, the constant temperature straightening section is divided into 2 to 3 independent temperature control zones along the direction of the wire rope. The temperature of each temperature control zone is adjusted independently, and the temperature gradient between adjacent temperature control zones does not exceed 3℃ / m.

9. The method for combined cold and hot straightening of steel wire rope according to claim 8, characterized in that: In step S1, during composite preheating, the wire rope is first preheated to 250℃-320℃ by induction heating coil, and then the wire rope is heated to the target preheating temperature by contact heating of the preheating section roller group, controlling the radial temperature difference of the wire rope to not exceed 8℃.

10. The method for combined cold and hot straightening of steel wire rope according to claim 7, characterized in that: In step S3, during the cooling and shaping process, the annular cooling channel of the outlet guide seat is used to assist in cooling, and the circumferential temperature uniformity of the wire rope is controlled within ±8℃.

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