A tail rope automatic winding and unwinding system and method based on double-drum winch

Abstract

The application discloses a tail rope automatic winding and unwinding system and method based on double-drum winching, and belongs to the field of electric power construction machinery. The system comprises a central controller and at least two tail frame modules. Each tail frame module comprises an independent intelligent drive controller, a main drive motor connected with the intelligent drive controller, a tension sensor for detecting the tension of a steel wire rope, and a rotary encoder for detecting the winding state. The central controller is in communication connection with the intelligent drive controllers of the tail frame modules, thereby forming a distributed control system. The intelligent drive controller can receive the cooperative control instruction of the central controller during normal operation, and can independently control the operation of the main drive motor based on local sensor data when the communication with the central controller is interrupted. The method comprises a pre-tightening starting stage, a cooperative operation steady state stage, an active unwinding and safety protection stage, and an intelligent wire arranging stage. The application improves the flexibility, reliability and adaptability to complex working conditions of the system.

Description

Technical Field

[0001] This invention relates to the field of power construction machinery technology, and in particular to an automatic tail rope winding and unwinding system and method based on a double-drum winch. Background Technology

[0002] The erection of power transmission towers is a crucial step in the construction of power transmission lines, and its operational safety and construction efficiency directly affect the overall progress and quality of the power grid project. During tower erection, the tail rope (also known as the balance guy wire) serves as an important stabilizing device, primarily used to balance the overturning moment generated by the main hoisting system (such as gantry cranes and hoists) when lifting tower materials, ensuring overall stability during construction. Traditional tail rope deployment and retraction operations largely rely on manual operation of winch equipment, achieving rough control of the tail rope tension through experience and manual adjustment. This process encompasses multiple technical aspects, including wire rope deployment and retraction control, dynamic tension adjustment, and drum winding, representing a typical mechanical-electrical collaborative operation scenario, making technological upgrades increasingly urgent.

[0003] With the development of ultra-high voltage and long-span power transmission projects, the height of transmission tower structures and the weight of individual tower pieces have increased significantly, placing more stringent demands on the load-bearing capacity, control precision, and automation level of tail rope retrieval systems. However, the tail rope retrieval devices currently widely used in the power construction field still suffer from the following prominent technical problems: (1) Rigid system control architecture: Most existing devices adopt a centralized "one-control-many" control mode, that is, a single controller drives multiple winches to operate synchronously. Under this architecture, each execution unit lacks autonomous decision-making ability and relies entirely on central instructions, which leads to the overall failure of the system when communication is interrupted or the main control fails, and it is difficult to make differentiated and adaptive adjustments for different working conditions and tail rope tension requirements.

[0004] (2) Insufficient tension control precision: Traditional manual operation relies on the operator's experience, resulting in significant dynamic response delays and making it difficult to achieve real-time closed-loop tension adjustment. Especially under external environmental disturbances (such as sudden gusts of wind or load swings), sudden changes in tension are likely to occur, leading to wire rope slack or overload. This not only affects the stability of hoisting but may also cause construction risks such as pulley slippage and component instability.

[0005] (3) Weak safety assurance mechanism: Conventional equipment is mostly equipped with mechanical overload protection and rear braking devices, which have a long response time and cannot achieve rapid and flexible braking intervention under high-speed rope release or sudden tension changes. The impact load generated during high-speed braking can easily cause hidden damage to the wire rope and transmission mechanism, affecting the service life of the equipment and operational safety.

[0006] (4) The arrangement of wire ropes on the drum mainly relies on manual intervention, which can easily lead to uneven distribution, interlacing between layers, or even tangled ropes. This not only aggravates the wear of the rope and reduces its service life, but also affects the stability and control accuracy of the rope winding and unwinding process to a certain extent.

[0007] The aforementioned technical shortcomings collectively restrict the operational efficiency and safety level of tower erection construction, resulting in extended construction periods, increased equipment maintenance costs, and heightened potential safety risks.

[0008] Therefore, there is an urgent need to develop an automatic tail rope reeling and deployment system and method with autonomous coordination and control capabilities, high-precision tension adjustment, multi-level safety protection, and intelligent cable laying functions, so as to promote the upgrading of power construction equipment towards automation and intelligence and meet the high standards of modern power grid construction. Summary of the Invention

[0009] The technical problem to be solved by this invention is to provide an automatic tail rope winding and unwinding system and method based on a double-drum winch. By using a single-unit single-control system, dynamic tension algorithm and three-level protection mechanism, it breaks through the rigid centralized control mode of traditional one-to-many systems (such as one-to-four). Under the single-unit single-control system architecture, each tail frame module (winch slave) can be both part of the overall system and subject to the coordinated scheduling of the central controller, and also has the ability to operate independently. This solves the problem that all tail frame modules in the previous device could not be autonomously controlled, and greatly improves the system's flexibility, reliability and adaptability to complex working conditions.

[0010] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: An automatic tail rope take-up and release system based on a dual-drum winch includes: a central controller and at least two tailstock modules; each tailstock module includes: an independent intelligent drive controller, a main drive motor connected to the intelligent drive controller, a tension sensor for detecting wire rope tension, and a rotary encoder for detecting the take-up status; the central controller is communicatively connected to the intelligent drive controllers of each tailstock module to form a distributed control system; wherein, the intelligent drive controller is capable of: receiving cooperative control commands from the central controller during normal operation; and autonomously controlling the main drive motor based on local sensor data when communication with the central controller is interrupted.

[0011] A further improvement of the technical solution of the present invention is that the central controller includes: an ARM Cortex-A7 processor; dual redundant control channels, including a main communication link and a backup communication link; the dual redundant control channels can switch to the backup communication link within 10ms when the main communication link fails.

[0012] A further improvement of the technical solution of the present invention is that: the tailstock module further includes: a planetary gear reducer connected to the output shaft of the main drive motor and an electromagnetic clutch disposed between the main drive motor and the planetary gear reducer; the reduction ratio of the planetary gear reducer is 70:1, which is used to convert the high speed and low torque output of the main drive motor into the low speed and high torque drive required by the drum; When the electromagnetic clutch is in normal operation, it is energized and engaged, transmitting the power of the main drive motor to the planetary gear reducer. When the intelligent drive controller or central controller issues an emergency disengagement command, or when the system loses power, the electromagnetic clutch is immediately de-energized and quickly disengaged under the action of the spring, realizing the mechanical separation of the main drive motor from the planetary gear reducer and the subsequent transmission chain.

[0013] A further improvement to the technical solution of the present invention is that: the tailstock module further includes an automatic cable laying mechanism, a sprocket drive mechanism, and a sprocket tensioning mechanism; the automatic cable laying mechanism includes: Independent ribbon cable drive motor; The cable guide screw has adjustment handwheels at both ends for manually adjusting the stroke; A guide shaft is arranged parallel to the lead screw; A cable guiding mechanism that is slidably mounted on the cable guide screw and the guide shaft; At least two guide rollers are installed on the upper end of the cable guiding mechanism to guide the wire rope; And a visual recognition system for identifying the arrangement of wire ropes on a drum; The wire guide screw is driven to rotate by the wire guide motor, thereby driving the wire guide mechanism to move along the drum axis; the intelligent drive controller independently controls the operation of the wire guide motor according to the feedback signal of the vision recognition system, so as to realize the automatic and neat winding of the wire rope. The sprocket drive mechanism is used to transmit the power output by the planetary gear reducer to the drum spindle; The sprocket tensioning mechanism is connected to the sprocket transmission mechanism and is used to adjust the tension of the transmission chain; A further improvement of the technical solution of the present invention is that: the tension sensor is set at the axle of the guide wheel of the automatic wire rope laying mechanism, and is used to directly detect the real-time tension of the wire rope when it passes through the guide wheel; the sampling frequency of the tension sensor is ≥1kHz, and the tension control accuracy is ±1.5%.

[0014] A further improvement to the technical solution of the present invention is that the device further includes a three-level safety protection system, which is triggered collaboratively by a central controller and / or an intelligent drive controller based on the sensed state of the wire rope; the three-level safety protection system specifically includes: The primary sensing and early warning module, including a tension sensor and a triaxial accelerometer, is used to monitor the tension value, tension change rate, and lateral oscillation acceleration of the wire rope in real time. When an over-limit tension, a cable breakage signal, or abnormal vibration is detected, an audible and visual alarm is immediately triggered and the system enters an early warning state. The secondary power damping braking module includes a servo driver electrically connected to the main drive motor. After the primary warning, if the abnormal state continues or worsens, it applies a controllable reverse torque with reverse PWM modulation to the main drive motor to generate an adjustable damping force opposite to the direction of motion, thereby achieving deceleration and dynamic buffering of the wire rope. The three-stage ultimate mechanical braking module includes a normally closed hydraulic caliper disc brake mounted on the drum spindle or high-speed shaft, and an integrated hydraulic power unit for supplying oil and controlling the brake. The integrated hydraulic power unit is directly controlled by the intelligent drive controller and simultaneously receives emergency braking commands from the central controller. When either the intelligent drive controller or the central controller determines that ultimate braking needs to be initiated, it controls the integrated hydraulic power unit to depressurize, causing the brake to lock instantly under the action of the spring.

[0015] A further improvement of the technical solution of the present invention is that it also includes a laser rangefinder and a triaxial accelerometer; the laser rangefinder is fixedly installed on the frame and faces the suspended section of the wire rope to be retrieved, and is used for non-contact detection of the slack distance of the wire rope relative to the frame, with a measurement resolution of ≤1mm; the accelerometer is installed on the bearing seat of the guide wheel or the cable guide mechanism, and is used to detect the lateral swing and vibration acceleration of the wire rope.

[0016] An automatic tail rope reeling and unwinding method based on a double-drum winch includes the following steps: Step 1, Pre-tensioning Start-up Stage: After receiving the system start command, the central controller starts the laser rangefinder and the tension sensor for initial detection; based on the initial slack of the wire rope detected by the laser rangefinder and the initial tension value fed back by the tension sensor, the intelligent drive controller calculates the optimal pre-tensioning force and acceleration curve under the current working condition through a preset adaptive neural network algorithm, and controls the main drive motor to drive the drum to wind up the rope in a uniform acceleration manner until the wire rope tension reaches the preset safe pre-tensioning value and remains stable; Step 2, Steady-state phase of collaborative operation: After entering the collaborative operation state of the main crane, the intelligent drive controller continuously monitors the tension sensor data; When the tension fluctuates within ±5% of the target set value, the speed and torque of the main drive motor are dynamically adjusted using a fuzzy PID control algorithm to achieve tension following. When the tension deviation is detected to exceed the ±5% range for an extended period, or the tension change rate exceeds the set threshold, the system immediately switches to constant tension priority control mode and uses high-frequency PWM technology to adjust the speed of the main drive motor at the microsecond level to quickly suppress tension fluctuations. Step 3, Active Rope Release and Safety Protection Stage: When the system needs to actively release the rope or follow the main hook descent, the central controller or the intelligent drive controller controls the main drive motor to enter the powered descent or controlled slip mode according to the preset rope release speed command; at the same time, through the real-time data linkage of the tension sensor and the triaxial accelerometer, a dynamic state model of the wire rope is constructed; if a sudden drop in tension, rope breakage characteristic frequency or abnormal acceleration is detected, multi-level alarms are triggered in sequence, the main drive motor's dynamic reverse torque buffer braking is activated, and the electromagnetic clutch is activated for emergency mechanical disengagement and braking after a set delay; Step 4, Intelligent Rope Laying Stage: During the rope winding and unwinding process, the vision recognition system acquires real-time images of the wire rope on the drum surface. The intelligent drive controller identifies the edge position of the outermost rope loop through image processing algorithms and controls the rope laying drive motor of the automatic rope laying mechanism accordingly, ensuring that the guide roller on the rope laying guide mechanism maintains a preset tracking distance with the edge of the rope loop. When the vision recognition system fails, it automatically switches to a mechanical logic rope laying mode based on the number of drum rotations and layers. The intelligent drive controller synchronously calculates the rotation speed of the main drive motor and the displacement of the rope laying drive motor to achieve neat winding of the wire rope.

[0017] A further improvement of the technical solution of the present invention is that: in the constant tension priority control mode, the intelligent drive controller adjusts the high-frequency PWM duty cycle of the main drive motor servo driver to achieve precise adjustment of its speed, with a steady-state control accuracy of 0.1 r / min.

[0018] A further improvement of the technical solution of the present invention is that the dynamic reverse torque buffer braking process includes: the intelligent dynamic controller injects a current vector with opposite phase to the servo driver of the main drive motor, and generates a continuously adjustable reverse torque on the output shaft of the main drive motor that is opposite to the current rotation direction through reverse PWM modulation; the control makes the rope release speed smoothly decay according to the preset deceleration curve in a closed loop, with an initial deceleration rate of not less than 50 r / min², until the speed drops to a safe threshold or the tension returns to stability.

[0019] The technological advancements achieved by this invention due to the adoption of the above technical solutions are as follows: 1. This invention constructs a distributed control architecture by configuring an independent intelligent drive controller for each tailstock module. This design enables each winch slave machine to operate and make decisions independently while being coordinated and scheduled by the central controller. This fundamentally solves the problem of system paralysis caused by a single point of failure of the main controller in traditional centralized "one-control-many" systems, and significantly enhances the robustness of the system.

[0020] 2. This invention employs a redundant communication design including primary and backup links. Combined with hardware support such as the ARM Cortex-A7 processor, it can achieve seamless switching within 10ms in the event of a primary link failure. This mechanism ensures the stability of the communication link under complex electromagnetic environments, long distances, or harsh construction conditions, guaranteeing long-term reliable system operation.

[0021] 3. In this invention, each intelligent drive controller performs autonomous closed-loop control based on real-time data from local high-frequency (≥1kHz) tension sensors, rotary encoders, etc., shortening the system response time to within 50ms and controlling the multi-machine synchronization error to the level of 0.3ms. This makes tension adjustment more timely and accurate, effectively suppressing tension fluctuations caused by sudden changes in wind speed and load swings, and improving the stability and construction efficiency of the hoisting process.

[0022] 4. The system in this invention supports autonomous control modes such as "constant tension priority." Even when the central controller experiences a communication interruption or failure, each slave unit can still maintain basic tension control and safe operation based on local sensor information, avoiding construction interruptions. This function significantly enhances the system's adaptability to complex and variable on-site conditions and its operational continuity.

[0023] 5. This invention integrates visual recognition and an automatic wire rope arrangement mechanism to achieve neat and automatic arrangement of wire ropes on the drum, avoiding wear and tangling caused by uneven manual wire rope arrangement. Combined with a three-level safety protection system (early warning, dynamic buffer braking, and mechanical emergency braking) based on tension and acceleration monitoring, it forms an integrated "intelligent wire rope arrangement - active protection" mechanism, which not only extends the lifespan of the wire rope but also further ensures construction safety.

[0024] 6. The distributed control architecture proposed in this invention achieves an organic combination of centralized management and scheduling and decentralized autonomous execution. This architecture not only has good overall coordination, but also facilitates subsequent functional expansion (such as adding modules or connecting to higher-level scheduling systems), providing a scalable and highly reliable technical foundation for the automation and intelligent upgrading of power tower erection construction. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Figure 1 This is a top view of the tailstock module provided in an embodiment of the present invention; Figure 2 This is a side view of the tailstock module provided in an embodiment of the present invention; Figure 3 This is a three-dimensional structural diagram of the tailstock module provided in an embodiment of the present invention; The components include: 1. Main drive motor; 2. Planetary gear reducer; 3. Adjusting handwheel; 4. Cable guide screw; 5. Cable guide mechanism; 6. Guide roller; 7. Guide shaft; 8. Sprocket transmission mechanism; 9. Transmission block; 10. Rope guide disc; 11. Frame; and 12. Sprocket tensioning mechanism. Detailed Implementation

[0026] It should be noted that the terms "comprising" and "having" and any variations thereof in the specification, claims and accompanying drawings of this invention are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such processes, methods, products or devices.

[0027] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0028] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments: like Figure 1 , Figure 2 , Figure 3 As shown, an automatic tail rope deployment and retraction system based on a dual-drum winch includes a central controller and at least two tailstock modules; each tailstock module includes: Independent intelligent drive controller; Main drive motor 1 is connected to the intelligent drive controller; Tension sensor, used to detect the tension of wire rope; A rotary encoder is used to detect the rope winding status; the central controller communicates with the intelligent drive controllers of each tailstock module to form a distributed control system; the intelligent drive controller is capable of: During normal operation, it receives coordinated control commands from the central controller; When communication with the central controller is interrupted, the main drive motor 1 is autonomously controlled to run based on local sensor data.

[0029] Furthermore, the central controller includes: an ARM Cortex-A7 processor; dual redundant control channels, including a primary communication link and a backup communication link; the dual redundant control channels can switch to the backup communication link within 10ms in the event of a failure of the primary communication link.

[0030] Furthermore, such as Figure 1 , Figure 2 , Figure 3 As shown, the tailstock module also includes: a planetary gear reducer 2 connected to the output shaft of the main drive motor 1 and an electromagnetic clutch located between the main drive motor 1 and the planetary gear reducer 2; the planetary gear reducer 2 has a reduction ratio of 70:1, which is used to convert the high speed and low torque output of the main drive motor 1 into the low speed and high torque drive required by the drum. When the electromagnetic clutch is in normal operation, it is in an energized and engaged state, transmitting the power of the main drive motor 1 to the planetary gear reducer 2. When the intelligent drive controller or central controller issues an emergency disengagement command, or when the system is powered off, the electromagnetic clutch is immediately de-energized and quickly disengaged under the action of the spring, realizing the mechanical separation of the main drive motor 1 from the planetary gear reducer 2 and the subsequent transmission chain.

[0031] Furthermore, the tailstock module also includes an automatic cable routing mechanism, a sprocket drive mechanism 8, and a sprocket tensioning mechanism 12; the automatic cable routing mechanism includes: Independent ribbon cable drive motor; The cable guide screw 4 has adjustment handwheels 3 at both ends for manually adjusting the stroke; A guide shaft 7 is arranged parallel to the cable thread screw 4; A cable guiding mechanism 5 is slidably mounted on the cable guide screw 4 and the guide shaft 7; At least two guide rollers 6 are installed on the upper end of the cable guide mechanism 5 to guide the wire rope; And a visual recognition system for identifying the arrangement of wire ropes on a drum; Among them, the wire guide screw 4 is driven to rotate by the wire guide motor, thereby driving the wire guide mechanism 5 to move along the drum axis; the intelligent drive controller independently controls the operation of the wire guide motor according to the feedback signal of the vision recognition system, so as to realize the automatic and neat winding of the wire rope. The sprocket drive mechanism 8 is used to transmit the power output from the planetary gear reducer 2 to the drum spindle; The sprocket tensioning mechanism 12 is connected to the sprocket transmission mechanism 8 and is used to adjust the tension of the transmission chain; The tailstock module also includes a drum assembly, which comprises: a drum spindle connected to the output end of the planetary gear reducer 2 via a sprocket drive mechanism 8, and two rope guide discs 10 fixedly mounted on the drum spindle. The two rope guide discs 10 are respectively fixed to both sides of the drum body. A transmission block 9 is provided between the sprocket drive mechanism 8 and the output end of the planetary gear reducer 2.

[0032] The sprocket drive mechanism 8 is connected to the drum shaft via a transmission block 9. Wire reels 10 are located on both sides of the drum. Furthermore, a tension sensor is installed at the axle of the guide roller 6 of the automatic wire rope laying mechanism to directly detect the real-time tension of the wire rope as it passes through the guide roller 6; the sampling frequency of the tension sensor is ≥1kHz, and the tension control accuracy is ±1.5%.

[0033] Furthermore, the device also includes a three-level safety protection system, which is collaboratively triggered by the central controller and / or intelligent drive controller based on the sensed state of the wire rope; the three-level safety protection system specifically includes: (1) Primary sensing and early warning module, including tension sensor and triaxial accelerometer, is used to monitor the tension value, tension change rate and lateral swing acceleration of wire rope in real time; when tension exceeds the limit, cable breakage characteristic signal or abnormal vibration is detected, an audible and visual alarm is immediately triggered and the system enters the early warning state. Specifically, the system continuously monitors the wire rope's condition through the linkage of a tension sensor and a triaxial accelerometer. Once a sudden drop in tension (≤50% of the set value) or an abnormal increase in the speed of the main drive motor 1 (≥150 r / min) is detected, the system will immediately trigger multi-level alarms, including on-site audible and visual alarms and remote SMS notifications, to remind operators to intervene in a timely manner.

[0034] (2) Secondary power easing braking module, including a servo driver electrically connected to the main drive motor 1, is used to apply a controllable reverse torque with reverse PWM modulation to the main drive motor 1 after the primary warning, so as to generate an adjustable damping force opposite to the direction of motion, thereby realizing the deceleration and dynamic buffering of the wire rope. Specifically, when an anomaly occurs, the system does not immediately apply abrupt braking, but first activates a dynamic buffering algorithm. Through reverse PWM modulation, it actively controls the main drive motor 1 to generate reverse torque, smoothly attenuating the rope release speed at a maximum deceleration rate of ≥50 r / min². This process effectively absorbs the system's kinetic energy, preventing the wire rope from violently jumping, slackening, or even dislodging from the pulley due to a sudden loss of tension, thus achieving "soft braking" and providing a smooth transition for heavy-duty equipment.

[0035] (3) The three-stage ultimate mechanical braking module includes a normally closed hydraulic caliper disc brake installed on the drum spindle or high-speed shaft, and an integrated hydraulic power unit for supplying oil and controlling the brake; the integrated hydraulic power unit is directly controlled by the intelligent drive controller and simultaneously receives emergency braking commands from the central controller; when either the intelligent drive controller or the central controller determines that ultimate braking needs to be initiated, it controls the integrated hydraulic power unit to depressurize, causing the brake to lock instantly under the action of the spring.

[0036] Specifically, this is the last and most reliable safety line. When secondary protection is insufficient to control the situation or detects severe over-limits, the system triggers a normally closed hydraulic caliper disc brake. This brake provides a braking torque of ≥800Nm and a response time of ≤0.1s, enabling forced equipment shutdown. Simultaneously, the system employs a dual-redundancy scheme to monitor the remaining rope length: the primary scheme uses a high-precision photoelectric encoder (resolution 0.1m), and the backup scheme uses a reliable mechanical limit switch (trigger stroke ≤5cm), ensuring safe shutdown under any extreme conditions. This multi-protection design concept aligns with the principle of a "2.5 times safety factor" for hydraulic lightweight lifting equipment, reducing the construction accident rate to 0.01 times / 100 hours and improving safety performance by 60%.

[0037] Furthermore, it also includes a laser rangefinder and a triaxial accelerometer; the laser rangefinder is fixedly installed on the frame 11 and faces the suspended section of the wire rope to be retrieved, and is used for non-contact detection of the slack distance of the wire rope relative to the frame 11, with a measurement resolution of ≤1mm; the accelerometer is installed on the bearing seat of the guide wheel 6 or on the cable guide mechanism 5, and is used to detect the lateral swing and vibration acceleration of the wire rope.

[0038] Specifically, the system adopts an advanced distributed control architecture, achieving an organic combination of centralized management and decentralized execution. This multi-mill collaborative control system architecture mainly consists of the following parts: (1) The central controller (intelligent control box) is the brain of the system. Its core uses a high-performance ARM Cortex-A7 processor with a main frequency of 1.2GHz and 1GB of memory, ensuring the smooth operation of complex algorithms. It runs a real-time operating system based on the time-triggered architecture (T-Framework), and the control cycle is strictly controlled within ≤2ms to ensure the real-time performance of the control. The central controller is responsible for aggregating the data of each tail frame module, executing advanced control strategies (such as multi-machine synchronization algorithms), and providing human-machine interaction interfaces. It is also designed with dual redundant control channels (main channel and backup channel). When the main communication link fails, the system can seamlessly switch to the backup link within ≤10ms, which greatly improves the reliability in harsh construction environments. As described in Document 1, the control cabinet panel integrates a 7-inch high-definition LCD screen as the main human-machine interaction terminal.

[0039] (2) Tailstock Module (Single Unit Single Control Core): Each tailstock module has a built-in independent intelligent drive controller. This intelligent drive controller directly drives the main drive motor 1 and collects signals from the tension sensor (sampling frequency ≥ 1kHz) and rotary encoder in real time. Even if communication with the central controller 1 is interrupted, the intelligent drive controller of the tailstock module can still autonomously complete the basic control of the wire rope tension (constant tension mode) according to preset parameters and local sensor information, maintaining the basic operation of the system and avoiding the risk of a single point of failure leading to the paralysis of the entire line in the traditional one-control-four system. This is precisely the embodiment of the value of "single unit single control".

[0040] (3) Communication network: The system supports multiple communication methods, including wireless (such as modules supporting the LoRaWAN protocol with a transmission rate of ≥100kbps and a remote control distance of up to 50m) and wired (such as RS485, CAN, LAN and other multi-functional communication ports). These ports can not only send control commands, but also obtain the working status of each tailstock in real time, realizing bidirectional transparent data transmission.

[0041] (4) Human-machine interface terminal: The operation interface is developed based on the Qt framework and has a high degree of integration. The operation interface can display information such as tension, speed, and take-up reel angle of each tailstock module in real time, supports the custom setting of parameters such as torque, speed, and cable laying mode, and can store more than 1,000 historical operation data for easy traceability and analysis. This design significantly improves the user experience and maintainability of the equipment.

[0042] An automatic tail rope reeling and unloading method based on a double-drum winch, using the aforementioned automatic tail rope reeling and unloading system based on a double-drum winch, includes the following steps: Step 1, Pre-tensioning Start-up Stage: After receiving the system start command, the central controller starts the laser rangefinder and tension sensor for initial detection; based on the initial slack of the wire rope detected by the laser rangefinder and the initial tension value fed back by the tension sensor, the intelligent drive controller calculates the optimal pre-tension force and acceleration curve under the current working condition through a preset adaptive neural network algorithm, and controls the main drive motor 1 to drive the drum to wind up the rope in a uniform acceleration manner until the wire rope tension reaches the preset safe pre-tension value and remains stable; Step 2, Steady-state phase of collaborative operation: After entering the collaborative operation state of the main crane, the intelligent drive controller continuously monitors the tension sensor data; When the tension fluctuates within ±5% of the target set value, the speed and torque of the main drive motor 1 are dynamically adjusted using a fuzzy PID control algorithm to achieve tension following. When the tension deviation is detected to be continuously exceeding ±5%, or the tension change rate exceeds the set threshold, the system immediately switches to constant tension priority control mode and uses high-frequency PWM technology to adjust the speed of the main drive motor 1 at the microsecond level to quickly suppress tension fluctuations. Step 3, Active Rope Release and Safety Protection Stage: When the system needs to actively release the rope or follow the main hook descent, the central controller or intelligent drive controller controls the main drive motor 1 to enter the power release or controlled slip mode according to the preset rope release speed command; at the same time, through the real-time data linkage of the tension sensor and the triaxial accelerometer, a dynamic state model of the wire rope is constructed; if a sudden drop in tension, rope breakage characteristic frequency or abnormal acceleration is detected, multi-level alarms are triggered in sequence, the main drive motor 1's dynamic reverse torque buffer braking is activated, and the electromagnetic clutch is activated for emergency mechanical disengagement and braking after a set delay; Step 4, Intelligent Rope Laying Stage: During the rope winding and unwinding process, the vision recognition system collects real-time images of the wire rope on the drum surface. The intelligent drive controller identifies the edge position of the outermost rope loop through image processing algorithms and controls the automatic rope laying mechanism's laying drive motor accordingly, ensuring that the guide roller 6 on the laying guide mechanism 5 maintains a preset tracking distance with the edge of the rope loop. When the vision recognition system fails, it automatically switches to a mechanical logic laying mode based on the number of drum rotations and layers. The intelligent drive controller synchronously calculates the rotation speed of the main drive motor 1 and the displacement of the laying drive motor to achieve neat winding of the wire rope.

[0043] Furthermore, in the constant tension priority control mode, the intelligent drive controller adjusts the high-frequency PWM duty cycle of the main drive motor 1 servo driver to achieve precise speed regulation, with a steady-state control accuracy of 0.1 r / min.

[0044] Furthermore, the dynamic reverse torque buffer braking process includes: the intelligent dynamic controller injects a current vector with opposite phase into the servo driver of the main drive motor 1, and generates a continuously adjustable reverse torque on the output shaft of the main drive motor that is opposite to the current rotation direction through reverse PWM modulation; the control makes the rope release speed smoothly decay according to the preset deceleration curve in a closed loop, with an initial deceleration rate of not less than 50 r / min², until the speed drops to a safe threshold or the tension returns to stability.

[0045] Specifically, this system implements refined dynamic control over the entire rope winding operation process, which is divided into three stages: (1) Pre-tensioning start-up stage (initial lifting, rapid pre-tensioning stage): The main goal of this stage is to eliminate the initial slack of the wire rope and avoid impact loads. The system detects the slack of the wire rope using a laser rangefinder (resolution ≤1mm) and, combined with data from the tension sensor, uses an adaptive neural network algorithm to quickly calculate the required pre-tensioning force. Subsequently, the central controller or the intelligent drive controller of the tailstock slave machine commands the main drive motor 8 to accelerate to a maximum rope winding speed of 30m / min, so that the wire rope is quickly tightened. This process significantly reduces tension fluctuations and equipment impacts caused by slow response of manual operation.

[0046] (2) Cooperative operation steady-state stage (steady-state stage, adaptive adjustment stage): After the wire rope is taut and enters the steady-state rope winding stage, the system enters the dual-mode adaptive adjustment state. The intelligent drive controller monitors the tension value in real time at a frequency of ≥50Hz.

[0047] (3) Active rope release and safety protection stage: Modal PID fine-tuning: When the tension fluctuates within ±5% of the set value, the system uses a fuzzy PID control algorithm to dynamically adjust the speed of the main drive motor 1, so that the tension quickly returns to the set value.

[0048] The system employs a modal-two constant tension control system. If the tension exceeds the set range, the system immediately switches to a constant tension priority control mode. High-precision pulse width modulation (PWM) technology is used to finely adjust the motor speed (stepping accuracy up to 0.1 r / min) to ensure that the output torque (i.e., the wire rope tension) remains constant at the preset value. This process relies on real-time closed-loop feedback, such as when the intelligent drive controller reads the torque of the main drive motor 1 and compares it with the rope winding torque set in the parameters. When it approaches the set torque, it instructs the main drive motor 1 to reduce its speed until the output torque of the main drive motor 1 equals the parameter torque.

[0049] (4) Execution mechanism guarantee: The precise execution of the above control strategy relies on a high-performance mechanical transmission system. The core of the rope winding mechanism is the direct connection between the high-torque planetary gear reducer 2 (speed ratio 70:1, output torque ≥500Nm) and the main drive motor 1, which provides sufficient tension. With the electromagnetic clutch, it can achieve rapid disengagement in emergency situations, with a response time ≤0.2s. The automatic rope winding mechanism's lead screw 4 is driven to rotate by the rope winding drive motor. The arrangement position of the wire rope is controlled by a visual recognition system (resolution 1080p) or mechanical logic, effectively preventing rope tangling and jamming, and improving equipment stability by 40%.

[0050] In summary, this invention, through its innovative "single-unit, single-control" system architecture, refined dynamic control strategy, and comprehensive multi-level safety protection mechanism, successfully solves many shortcomings of traditional tail rope deployment and retrieval operations, providing reliable technical equipment support for achieving intelligent, safe, and efficient tower erection construction. Its key technical performance indicators all meet or exceed design targets: tension control accuracy is stable within ±1.5%, multi-machine synchronization error is no greater than 0.3ms, system response time is shortened to within 50ms, maximum output torque is no less than 500 N•m, and rope retrieval speed can reach 30m / min. The system's operating temperature range covers -30℃ to +60℃, and its protection level reaches IP67. Engineering applications show that this system reduces the average construction time for a single tower erection by more than 20%, significantly improving operational safety and economy.

[0051] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An automatic tail rope reeling and unwinding system based on a double-drum winch, characterized in that, It includes a central controller and at least two tailstock modules; each tailstock module includes: an independent intelligent drive controller, a main drive motor (1) connected to the intelligent drive controller, a tension sensor for detecting the tension of the wire rope, and a rotary encoder for detecting the rope winding state; the central controller is communicatively connected to the intelligent drive controllers of each tailstock module to form a distributed control system; wherein, the intelligent drive controller is capable of: receiving cooperative control commands from the central controller during normal operation; and autonomously controlling the operation of the main drive motor (1) based on local sensor data when communication with the central controller is interrupted.

2. The system according to claim 1, characterized in that, The central controller includes: an ARM Cortex-A7 processor; dual redundant control channels, including a primary communication link and a backup communication link; the dual redundant control channels can switch to the backup communication link within 10ms when the primary communication link fails.

3. The system according to claim 1, characterized in that, The tailstock module also includes: a planetary gear reducer (2) connected to the output shaft of the main drive motor (1) and an electromagnetic clutch disposed between the main drive motor (1) and the planetary gear reducer (2); the planetary gear reducer (2) has a reduction ratio of 70:1 and is used to convert the high speed and low torque output of the main drive motor (1) into the low speed and high torque drive required by the drum. When the electromagnetic clutch is in normal operation, it is in an energized and engaged state, transmitting the power of the main drive motor (1) to the planetary gear reducer (2). When the intelligent drive controller or central controller issues an emergency disengagement command, or when the system is powered off, the electromagnetic clutch is immediately de-energized and quickly disengaged under the action of the spring, thereby achieving mechanical separation of the main drive motor (1) from the planetary gear reducer (2) and the subsequent transmission chain.

4. The system according to claim 3, characterized in that, The tailstock module also includes an automatic cable laying mechanism, a sprocket drive mechanism (8), and a sprocket tensioning mechanism (12); the automatic cable laying mechanism includes: Independent ribbon cable drive motor; The cable guide screw (4) has adjustment handwheels (3) at both ends for manually adjusting the stroke. A guide shaft (7) is arranged parallel to the lead screw (4); A cable guide mechanism (5) is slidably mounted on the cable guide screw (4) and the guide shaft (7). At least two guide rollers (6) installed on the upper end of the cable guide mechanism (5) are used to guide the wire rope; And a visual recognition system for identifying the arrangement of wire ropes on a drum; The wire guide screw (4) is driven to rotate by the wire guide motor, thereby driving the wire guide mechanism (5) to move along the drum axis; the intelligent drive controller independently controls the operation of the wire guide motor according to the feedback signal of the vision recognition system, so as to realize the automatic and neat winding of the wire rope. The sprocket drive mechanism (8) is used to transmit the power output by the planetary gear reducer (2) to the drum spindle; The sprocket tensioning mechanism (12) is connected to the sprocket transmission mechanism (8) and is used to adjust the tension of the transmission chain.

5. The system according to claim 4, characterized in that, The tension sensor is located at the axle of the guide wheel (6) of the automatic wire rope laying mechanism and is used to directly detect the real-time tension of the wire rope when it passes through the guide wheel (6); the sampling frequency of the tension sensor is ≥1kHz and the tension control accuracy is ±1.5%.

6. The system according to claim 1, characterized in that, The device also includes a three-level safety protection system, which is triggered collaboratively by a central controller and / or an intelligent drive controller based on the sensed state of the wire rope; The three-level security protection system specifically includes: The primary sensing and early warning module, including a tension sensor and a triaxial accelerometer, is used to monitor the tension value, tension change rate, and lateral oscillation acceleration of the wire rope in real time. When an over-limit tension, a cable breakage signal, or abnormal vibration is detected, an audible and visual alarm is immediately triggered and the system enters an early warning state. The secondary power easing braking module includes a servo driver electrically connected to the main drive motor (1). After the primary warning, if the abnormal state continues or worsens, it applies a controllable reverse torque with reverse PWM modulation to the main drive motor (1) to generate an adjustable damping force opposite to the direction of motion, thereby achieving deceleration and dynamic buffering of the wire rope. The three-stage ultimate mechanical braking module includes a normally closed hydraulic caliper disc brake mounted on the drum spindle or high-speed shaft, and an integrated hydraulic power unit for supplying oil and controlling the brake. The integrated hydraulic power unit is directly controlled by the intelligent drive controller and simultaneously receives emergency braking commands from the central controller. When either the intelligent drive controller or the central controller determines that ultimate braking needs to be initiated, it controls the integrated hydraulic power unit to depressurize, causing the brake to lock instantly under the action of the spring.

7. The system according to claim 1, characterized in that, It also includes a laser rangefinder and a triaxial accelerometer; the laser rangefinder is fixedly installed on the frame (11) and facing the suspended section of the wire rope to be retrieved, and is used for non-contact detection of the slack distance of the wire rope relative to the frame (11), with a measurement resolution of ≤1mm; the accelerometer is installed on the bearing seat of the guide wheel (6) or the cable guide mechanism (5), and is used to detect the lateral swing and vibration acceleration of the wire rope.

8. A method for automatically retrieving and releasing a tail rope using the automatic tail rope retrieving and releasing system based on a double-drum winch as described in any one of claims 1-7, characterized in that, Includes the following steps: Step 1, Pre-tightening start-up phase: After receiving the system start command, the central controller starts the laser rangefinder and the tension sensor to perform initial detection; The intelligent drive controller, based on the initial slack of the wire rope detected by the laser rangefinder and the initial tension value fed back by the tension sensor, calculates the optimal preload and acceleration curve under the current working condition through a preset adaptive neural network algorithm, and controls the main drive motor (1) to drive the drum to wind up the rope in a uniform acceleration manner until the wire rope tension reaches the preset safe preload value and remains stable. Step 2, Steady-state phase of collaborative operation: After entering the collaborative operation state of the main crane, the intelligent drive controller continuously monitors the tension sensor data; When the tension fluctuates within ±5% of the target set value, the speed and torque of the main drive motor (1) are dynamically adjusted using a fuzzy PID control algorithm to achieve tension following. When the tension deviation is detected to exceed the ±5% range or the tension change rate exceeds the set threshold, the constant tension priority control mode is immediately switched to, and the main drive motor (1) is adjusted at the microsecond level through high-frequency PWM technology to quickly suppress tension fluctuations. Step 3, Active Rope Release and Safety Protection Stage: When the system needs to actively release the rope or follow the main hook down, the central controller or the intelligent drive controller controls the main drive motor (1) to enter the power release or controlled slip mode according to the preset rope release speed command; at the same time, the dynamic state model of the wire rope is constructed through the real-time data linkage of the tension sensor and the triaxial accelerometer; if a sudden drop in tension, rope breakage characteristic frequency or abnormal acceleration is detected, multi-level alarms, dynamic reverse torque buffer braking of the main drive motor (1), and emergency mechanical disengagement and braking of the electromagnetic clutch are triggered in sequence after a set delay; Step 4, Intelligent Wire Laying Stage: During the winding and unwinding process, the visual recognition system collects images of the wire rope on the surface of the drum in real time. The intelligent drive controller identifies the position of the outermost rope loop edge through the image processing algorithm and controls the wire laying drive motor of the automatic wire laying mechanism accordingly, so that the guide wheel (6) on the wire laying guide mechanism (5) maintains a preset tracking distance with the edge of the rope loop. When the visual recognition system fails, it automatically switches to the mechanical logic wire laying mode based on the number of drum rotations and layers. The intelligent drive controller synchronously calculates the rotation speed of the main drive motor (1) and the displacement of the wire laying drive motor to achieve neat winding of the wire rope.

9. The method according to claim 8, characterized in that, In the constant tension priority control mode, the intelligent drive controller adjusts the high-frequency PWM duty cycle of the main drive motor (1) servo driver to achieve precise adjustment of its speed, with a steady-state control accuracy of 0.1 r / min.

10. The method according to claim 8, characterized in that, The dynamic reverse torque buffer braking process includes: the intelligent dynamic controller injects a current vector with opposite phase into the servo driver of the main drive motor (1), and generates a continuously adjustable reverse torque on the output shaft of the main drive motor that is opposite to the current rotation direction through reverse PWM modulation; the control makes the rope release speed smoothly decay according to the preset deceleration curve in a closed loop, and its initial deceleration rate is not less than 50r / min², until the speed drops to the safety threshold or the tension recovers to stability.

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