Intelligent guide pulley system with tension real-time monitoring function

Abstract

The application discloses an intelligent guide pulley system with a tension real-time monitoring function, and aims at solving the technical problems of insufficient tension monitoring precision of the existing guide pulley, inability to synchronously realize automatic centering and deviation rectification of a wire body, easy to cause wire body eccentric wear and tension out of control. The system is characterized in that force signals are collected by pressure sensors symmetrically arranged at two ends of a floating shaft, the force signals are processed by a built-in temperature and rotating speed compensation wheel hub signal processing unit, the real-time tension value and the transverse offset of a driving wire are synchronously solved, a high-precision transverse adjusting mechanism is driven by an upper control unit to realize closed-loop automatic deviation rectification, and tension overrun early warning braking can be triggered. The application greatly improves the tension monitoring precision and the deviation rectification response speed, is suitable for complex working conditions, effectively reduces the wire body wear and failure risk, guarantees the stable operation of a transmission system, and prolongs the service life of equipment.

Description

Technical Field

[0001] This invention relates to the field of guide pulley technology, specifically to an intelligent guide pulley system with real-time tension monitoring function. Background Technology

[0002] In fields such as mine hoisting, industrial cable transmission, and cableway transportation, guide pulleys are core components that ensure the stable operation of drive lines such as wire ropes. Traditional guide pulleys only have basic guiding and direction-changing functions and cannot sense the operating status of the drive line in real time, making them unsuitable for the intelligent management and control needs of current industrial scenarios.

[0003] Existing tension monitoring solutions mostly employ single-point sensing or offline detection modes, which suffer from drawbacks such as limited detection parameters, inability to simultaneously identify lateral deviation of the drive line, and measurement results being easily affected by ambient temperature and pulley speed, with errors reaching over 5%. These solutions are ill-suited for complex operating conditions involving high speeds and wide temperature ranges. Regarding deviation issues, traditional passive mechanical correction methods suffer from sluggish response and low adjustment accuracy, easily leading to drive line derailment and abnormal wear of the rope groove. Manual adjustment is inefficient and cannot meet the requirements of continuous production. Summary of the Invention

[0004] To overcome the shortcomings of existing technical solutions, this invention provides an intelligent guide pulley system with real-time tension monitoring function, which can effectively solve the problems mentioned in the background technology.

[0005] The technical solution adopted by this invention to solve its technical problem is:

[0006] An intelligent guide pulley system with real-time tension monitoring function includes a mounting base and a guide pulley assembly. The guide pulley assembly includes a pulley body and a floating shaft coaxially passing through the center of the pulley body. The two ends of the floating shaft are slidably mounted vertically within guide grooves of the mounting base, allowing the floating shaft to float vertically under the action of drive line tension. The system also includes:

[0007] The dual-channel pressure sensing unit includes a first pressure sensor and a second pressure sensor, which are respectively integrated between the two ends of the floating shaft and the mounting base. The first pressure sensor and the second pressure sensor are used to detect the vertical pressure on the two ends of the floating shaft, respectively.

[0008] A lateral adjustment mechanism is provided at the bottom of the mounting base for driving the mounting base to adjust its position along the lateral direction of the drive line;

[0009] The signal processing and transmission unit is integrated in the inner cavity of the pulley body hub and is electrically connected to the first pressure sensor and the second pressure sensor respectively. It is used to collect two pressure signals, calculate the real-time tension value of the drive line based on the sum of the two pressure signals, calculate the lateral offset of the drive line based on the difference between the two pressure signals, and wirelessly transmit the tension value and offset to the upper control unit.

[0010] The upper control unit is communicatively connected to the lateral adjustment mechanism and is used to generate control commands based on the lateral offset to drive the lateral adjustment mechanism to adjust the lateral position of the mounting base, so as to realize the automatic centering and correction of the drive line.

[0011] As a further description of the above technical solution, the signal processing and transmission unit also has a built-in temperature compensation module, which is used to collect ambient temperature data and perform temperature drift compensation on the pressure signal according to a preset temperature sensor drift compensation model, so as to correct the calculation error of the tension value.

[0012] As a further description of the above technical solution, the signal processing and transmission unit also has a built-in speed compensation module, which is used to collect the rotational angular velocity of the pulley body and perform centrifugal force compensation on the pressure signal according to the centrifugal force compensation model, so as to correct the tension calculation error under high-speed rotation conditions.

[0013] As a further description of the above technical solution, the lateral adjustment mechanism includes a linear drive module and a sliding platform that is pulsatorically connected to the linear drive module. The mounting base is fixedly disposed on the top of the sliding platform, and the linear drive module is used to drive the sliding platform to perform high-precision linear displacement adjustment in the lateral direction.

[0014] As a further description of the above technical solution, the linear drive module is a ball screw drive module with a drive resolution of not less than 0.01mm, which is used to realize the micron-level position adjustment of the mounting base.

[0015] As a further description of the above technical solution, both the first pressure sensor and the second pressure sensor are miniature piezoelectric pressure sensors with a sampling frequency of not less than 1 kHz, used to realize high-frequency dynamic monitoring of tension and offset.

[0016] As a further description of the above technical solution, the signal processing and transmission unit adopts a low-power Bluetooth wireless communication module with a data transmission delay of no more than 10ms, which is used to realize the real-time transmission of tension and offset data.

[0017] As a further description of the above technical solution, the upper control unit also has a built-in abnormal warning module, which is used to generate a warning signal and trigger the emergency braking operation of the drive line when the calculated real-time tension value exceeds the preset safety threshold.

[0018] Compared with the prior art, the beneficial effects of the present invention are:

[0019] The intelligent guide pulley system with real-time tension monitoring function of the present invention has at least one of the following beneficial effects during use:

[0020] It can simultaneously achieve high-precision real-time monitoring of drive line tension and automatic lateral alignment and correction of the cable, comprehensively improving the operational stability and reliability of the flexible traction transmission system. Relying on the vertical floating force structure of the floating shaft and the dual-path symmetrical pressure sensing design, a single structure can simultaneously calculate the real-time tension and lateral offset of the drive line, effectively avoiding the industry defects of traditional single-point detection, such as easy force imbalance, data distortion, and inability to identify line offset. The high-frequency sampling characteristics can be adapted to high-speed dynamic operating conditions.

[0021] The hub-integrated signal processing unit shortens the signal transmission path, significantly reducing interference loss, and, in conjunction with low-latency wireless communication, ensures real-time uploading of operating data. The upper-level control system, in close-loop linkage with a high-precision lateral adjustment mechanism, actively and adaptively corrects cable misalignment, preventing cable wear, delamination, and stress concentration faults. It can also quickly respond to tension over-limit anomalies and trigger safety protection, significantly extending the service life of the drive cable and pulley. Its compact structure is adaptable to a wide range of scenarios, completely solving the technical pain points of traditional guide pulleys, such as lagging monitoring, passive correction, and high failure rate. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of an intelligent guide pulley system with real-time tension monitoring function according to the present invention;

[0023] Figure 2 This is a top view schematic diagram of an intelligent guide pulley system with real-time tension monitoring function according to the present invention;

[0024] Figure 3 This is a side view of an intelligent guide pulley system with real-time tension monitoring function according to the present invention.

[0025] Figure 4 This is a partial perspective structural diagram of an intelligent guide pulley system with real-time tension monitoring function according to the present invention.

[0026] Numbering on the map:

[0027] 1. Lateral adjustment mechanism; 101. Linear drive module; 102. Upper control unit; 103. Sliding platform; 2. Mounting base; 201. Guide pulley assembly; 202. Floating shaft; 203. Dual-channel pressure sensing unit; 204. Pulley body; 205. First pressure sensor; 206. Second pressure sensor; 207. Signal processing and transmission unit. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] like Figure 1-4 As shown, the present invention provides an intelligent guide pulley system with real-time tension monitoring function, including a mounting base 2 and a guide pulley assembly 201. The guide pulley assembly 201 includes a pulley body 204 and a floating shaft 202 coaxially passing through the center of the pulley body 204. The two ends of the floating shaft 202 are slidably mounted in the guide groove of the mounting base 2 in the vertical direction, so that the floating shaft 202 can float in the vertical direction under the action of the drive line tension.

[0030] This embodiment addresses the problems of traditional guiding devices being unable to perceive the real-time operating status of drive lines (such as steel wire ropes, industrial cables, etc.), and being prone to deviation, derailment, rope breakage, and overload. It innovatively integrates functions such as floating force perception, dual-path sensing, adaptive error compensation, closed-loop automatic deviation correction, and safety warning, realizing full-dimensional intelligent control of the drive line's operating status.

[0031] Also includes:

[0032] The dual-path pressure sensing unit 203 includes a first pressure sensor 205 and a second pressure sensor 206, which are respectively integrated between the two ends of the floating shaft 202 and the mounting base 2. The first pressure sensor 205 and the second pressure sensor 206 are used to detect the vertical pressure on the two ends of the floating shaft 202, respectively.

[0033] The floating shaft 202 of the guide pulley can slide vertically along the guide groove of the mounting base 2. When the drive line passes around the pulley body 204, the tension of the drive line will exert downward pressure on the pulley, causing the floating shaft 202 to press down and transmit the tension force to the pressure sensors at both ends.

[0034] A lateral adjustment mechanism 1 is disposed at the bottom of the mounting base 2 and is used to drive the mounting base 2 to adjust its position along the lateral direction of the drive line;

[0035] The lateral adjustment mechanism 1 adopts a ball screw linear drive module 101 with a drive resolution of not less than 0.01mm. It can drive the sliding platform 103 and the mounting base 2 to achieve micron-level lateral displacement adjustment, automatically adjust the center position of the pulley to align with the drive line, thereby achieving automatic centering of the drive line and correcting the deviation problem from the root.

[0036] The entire closed-loop control link has a fast response speed and high adjustment accuracy, which can offset the deviation disturbance during the operation of the drive line in real time and avoid problems such as drive line derailment and abnormal wear.

[0037] The signal processing and transmission unit 207 is integrated in the inner cavity of the pulley body 204 hub and is electrically connected to the first pressure sensor 205 and the second pressure sensor 206 respectively. It is used to collect two pressure signals, calculate the real-time tension value of the drive line based on the sum of the two pressure signals, calculate the lateral offset of the drive line based on the difference between the two pressure signals, and wirelessly transmit the tension value and offset to the upper control unit 102.

[0038] The first and second pressure sensors 206 at both ends of the floating shaft 202 collect the vertical pressure signals F1 and F2 from both ends, respectively. Tension calculation: The sum of the two pressure signals, Fsum = F1 + F2, corresponds to the total normal force exerted by the drive line on the pulley. According to the principle of pulley force balance, the real-time tension T of the drive line and the total normal force satisfy the relationship: Fsum = 2T·sin(α / 2), where α is the fixed wrap angle of the drive line on the pulley. Therefore, the real-time tension value of the drive line can be directly calculated from the total force.

[0039] Offset calculation: The difference between the two pressures, Fdiff = F1 - F2, corresponds to the eccentric load force of the drive line. When the drive line deviates laterally from the center of the pulley, it will generate an eccentric load torque on the pulley, resulting in unequal pressures at both ends. The offset is linearly positively correlated with the pressure difference, so the lateral offset of the drive line can be directly calculated from the pressure difference.

[0040] With just two pressure sensors, the two core parameters of tension and displacement can be detected simultaneously without the need for additional displacement sensors or vision inspection modules, which greatly simplifies the system structure.

[0041] The strain gauge characteristics of piezoelectric pressure sensors are easily affected by ambient temperature, causing zero-point drift and resulting in measurement errors. The system's temperature compensation module collects ambient temperature data in real time and corrects the original pressure signal based on a preset temperature drift compensation model (polynomial fitting compensation algorithm). This effectively eliminates temperature drift errors over a wide temperature range of -40℃ to 120℃, ensuring measurement stability under different environments.

[0042] When the pulley rotates at high speed, its own mass generates centrifugal force, which acts additionally on the floating shaft 202, causing the pressure sensor's measured value to be too high. Under high-speed conditions, this error can reach more than 10%. The system's speed compensation module collects the pulley's rotational angular velocity ω in real time, based on the centrifugal force compensation model: ftrue = fraw - m·ω²·r.

[0043] Where m is the equivalent mass of the pulley and r is the radius of rotation of the pulley's center of mass, the original pressure signal is corrected for centrifugal force error, effectively eliminating measurement deviations under high-speed rotation conditions, and realizing high-precision tension measurement across the entire speed range from low speed to high speed.

[0044] The upper control unit 102 is communicatively connected to the lateral adjustment mechanism 1 and is used to generate control commands according to the lateral offset to drive the lateral adjustment mechanism 1 to adjust the lateral position of the mounting base 2 so as to realize the automatic centering and correction of the drive line.

[0045] The signal processing unit transmits the calculated tension value and lateral offset wirelessly to the upper control unit 102 via Bluetooth Low Energy, with a transmission delay of no more than 10ms, ensuring the real-time performance of the control.

[0046] The upper control unit 102 generates a high-precision position adjustment command based on the lateral offset, and drives the lateral adjustment mechanism 1 to operate.

[0047] In this embodiment, when the real-time tension value is detected to exceed the preset safety threshold (such as overload, sudden tension changes before rope breakage, or other abnormal working conditions), the system will immediately generate an early warning signal and simultaneously trigger the emergency braking operation of the drive line to cut off the power in time, preventing major safety accidents such as rope breakage and falling objects, and providing reliable protection for the safety of equipment and personnel.

[0048] Furthermore, the signal processing and transmission unit 207 also has a built-in temperature compensation module, which is used to collect ambient temperature data and perform temperature drift compensation on the pressure signal according to a preset temperature sensor drift compensation model to correct the calculation error of the tension value.

[0049] By collecting ambient temperature data and compensating for the temperature drift of the pressure sensor based on a preset model, tension detection errors caused by sensor zero-point and sensitivity drift under high and low temperature environments are effectively eliminated, improving the long-term stability and adaptability of tension monitoring to all environmental conditions and ensuring the accuracy of tension data under complex temperature conditions.

[0050] Furthermore, the signal processing and transmission unit 207 also has a built-in speed compensation module, which is used to collect the rotational angular velocity of the pulley body 204 and perform centrifugal force compensation on the pressure signal according to the centrifugal force compensation model, so as to correct the tension calculation error under high-speed rotation conditions.

[0051] By collecting the angular velocity of the pulley rotation and correcting the pressure signal based on the centrifugal force compensation model, the interference of centrifugal force on the force detection of the floating shaft 202 when the pulley rotates at high speed is eliminated, the problem of tension calculation deviation under high-speed conditions is solved, and accurate tension monitoring in different speed ranges is achieved, which is suitable for the stable operation requirements of high-speed transmission scenarios.

[0052] Furthermore, the lateral adjustment mechanism 1 includes a linear drive module 101 and a sliding platform 103 that is connected to the linear drive module 101 in a transmission manner. The mounting base 2 is fixedly disposed on the top of the sliding platform 103. The linear drive module 101 is used to drive the sliding platform 103 to perform high-precision linear displacement adjustment in the lateral direction.

[0053] The transmission cooperation between the linear drive module 101 and the sliding platform 103 provides the mounting base 2 with a stable and controllable lateral displacement adjustment capability, and provides a reliable mechanical execution basis for the automatic centering and correction of the drive line, ensuring the smoothness of the correction action and the controllability of the position adjustment, and avoiding impact or jamming during the correction process.

[0054] Furthermore, the linear drive module 101 is a ball screw drive module with a drive resolution of not less than 0.01 mm, used to achieve micron-level position adjustment of the mounting base 2.

[0055] By adopting a ball screw drive module with a drive resolution of not less than 0.01mm, the micron-level lateral position adjustment of the mounting base 2 is achieved, which greatly improves the accuracy of correction control, effectively eliminates the slight deviation of the drive line, avoids long-term off-center load wear of the line, and extends the service life of the drive line and pulley components.

[0056] Furthermore, both the first pressure sensor 205 and the second pressure sensor 206 are miniature piezoelectric pressure sensors with a sampling frequency of not less than 1 kHz, used to achieve high-frequency dynamic monitoring of tension and offset.

[0057] Employing a miniature piezoelectric pressure sensor with a sampling frequency of no less than 1kHz, it achieves high-frequency dynamic monitoring of tension and lateral offset, capturing instantaneous tension fluctuations and sudden offsets during the operation of the drive line, adapting to the real-time monitoring needs under high-speed and dynamic working conditions, and avoiding the omission of key working condition data.

[0058] Furthermore, the signal processing and transmission unit 207 employs a low-power Bluetooth wireless communication module with a data transmission delay of no more than 10ms, enabling real-time transmission of tension and offset data.

[0059] A low-power Bluetooth wireless communication module with a transmission latency of no more than 10ms is used to realize the real-time transmission of tension and offset data, ensuring that the upper control unit 102 can quickly respond to changes in working conditions, support the timeliness of closed-loop correction and abnormal warning, and at the same time reduce equipment power consumption and improve module endurance.

[0060] Furthermore, the upper control unit 102 also has a built-in abnormal warning module, which generates a warning signal and triggers the emergency braking operation of the drive line when the calculated real-time tension value exceeds a preset safety threshold.

[0061] The upper control unit 102 has a built-in abnormal early warning module, which can quickly generate an early warning signal and trigger emergency braking of the drive line when the real-time tension value exceeds the safety threshold, so as to avoid safety accidents such as drive line breakage and pulley damage in a timely manner, and improve the safety and fault protection capability of the system operation.

[0062] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. An intelligent guide pulley system with real-time tension monitoring function, comprising a mounting base and a guide pulley assembly, wherein the guide pulley assembly includes a pulley body and a floating shaft coaxially passing through the center of the pulley body, characterized in that, The two ends of the floating shaft are slidably mounted vertically within the guide grooves of the mounting base, allowing the floating shaft to float vertically under the action of drive line tension. The system also includes: The dual-channel pressure sensing unit includes a first pressure sensor and a second pressure sensor, which are respectively integrated between the two ends of the floating shaft and the mounting base. The first pressure sensor and the second pressure sensor are used to detect the vertical pressure on the two ends of the floating shaft, respectively. A lateral adjustment mechanism is provided at the bottom of the mounting base for driving the mounting base to adjust its position along the lateral direction of the drive line; The signal processing and transmission unit is integrated in the inner cavity of the pulley body hub and is electrically connected to the first pressure sensor and the second pressure sensor respectively. It is used to collect two pressure signals, calculate the real-time tension value of the drive line based on the sum of the two pressure signals, calculate the lateral offset of the drive line based on the difference between the two pressure signals, and wirelessly transmit the tension value and offset to the upper control unit. The upper control unit is communicatively connected to the lateral adjustment mechanism and is used to generate control commands based on the lateral offset to drive the lateral adjustment mechanism to adjust the lateral position of the mounting base, so as to realize the automatic centering and correction of the drive line.

2. The intelligent guide pulley system with real-time tension monitoring function according to claim 1, characterized in that: The signal processing and transmission unit also has a built-in temperature compensation module, which is used to collect ambient temperature data and perform temperature drift compensation on the pressure signal according to a preset temperature sensor drift compensation model to correct the calculation error of the tension value.

3. The intelligent guide pulley system with real-time tension monitoring function according to claim 1, characterized in that: The signal processing and transmission unit also has a built-in speed compensation module, which is used to collect the rotational angular velocity of the pulley body and perform centrifugal force compensation on the pressure signal according to the centrifugal force compensation model, so as to correct the tension calculation error under high-speed rotation conditions.

4. The intelligent guide pulley system with real-time tension monitoring function according to claim 1, characterized in that: The lateral adjustment mechanism includes a linear drive module and a sliding platform that is connected to the linear drive module. The mounting base is fixedly disposed on the top of the sliding platform. The linear drive module is used to drive the sliding platform to perform high-precision linear displacement adjustment in the lateral direction.

5. The intelligent guide pulley system with real-time tension monitoring function according to claim 4, characterized in that: The linear drive module is a ball screw drive module with a drive resolution of not less than 0.01 mm, used to achieve micron-level position adjustment of the mounting base.

6. The intelligent guide pulley system with real-time tension monitoring function according to claim 1, characterized in that: Both the first and second pressure sensors are miniature piezoelectric pressure sensors with a sampling frequency of not less than 1 kHz, used to achieve high-frequency dynamic monitoring of tension and offset.

7. The intelligent guide pulley system with real-time tension monitoring function according to claim 1, characterized in that: The signal processing and transmission unit uses a low-power Bluetooth wireless communication module with a data transmission delay of no more than 10ms, which is used to realize the real-time transmission of tension and offset data.

8. The intelligent guide pulley system with real-time tension monitoring function according to claim 1, characterized in that: The upper control unit also has a built-in abnormal warning module, which generates a warning signal and triggers the emergency braking operation of the drive line when the calculated real-time tension value exceeds the preset safety threshold.

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