A steel wire rope surface rust removal and coating integrated device

Abstract

This invention discloses an integrated rust removal and coating device for steel wire ropes, belonging to the technical field of offline maintenance and treatment equipment for steel wire ropes. It includes a fixed frame, on which, along the steel wire rope's travel path, are arranged coaxially: an unwinding mechanism, a pre-inspection module, a front untwisting clamping unit, a fully enclosed rotary rust removal mechanism, a negative pressure dust removal and cleaning module, a rear resetting and twisting unit, an intelligent penetrating coating mechanism, a gradient curing module, a finished product re-inspection module, and a winding mechanism, all supported by an intelligent central control system. This invention achieves dynamic continuous untwisting and precise resetting and twisting of the steel wire rope through a symmetrical structure, opposite rotation, and real-time linkage between the front untwisting and rear resetting units and the steel wire rope's travel speed. Combined with a composite rust removal structure and a penetrating coating structure, it improves the rust removal effect and coating quality without damaging the original mechanical properties of the steel wire rope, thus extending the service life of the steel wire rope.

Description

Technical Field

[0001] This invention belongs to the technical field of wire rope maintenance and treatment equipment, specifically relating to an integrated equipment for rust removal and coating of wire rope surfaces. Background Technology

[0002] Steel wire rope is a helical bundle of steel wires twisted together according to certain rules, meeting specific mechanical properties and geometric dimensions. Due to its high strength, light weight, stable operation, and resistance to sudden breakage, it is widely used in lifting, traction, mining, construction, and marine engineering. However, steel wire rope is prone to oxidation and corrosion during production, storage, and transportation. In particular, the gaps between strands and wires formed during twisting easily accumulate moisture and develop hidden corrosion. Without thorough rust removal and protective coating, the tensile strength and service life of the steel wire rope will be significantly reduced, potentially even leading to safety accidents.

[0003] In the existing technology,

[0004] Chinese patent CN201910657915B, entitled "A Rust Removal Device for Rusty Steel Wire Rope," discloses a technical solution that uses a wire rope separation clamping device to clamp and rotate the ends of the wire rope to achieve untwisting, thus dispersing the wire rope bundle to remove rust from the internal wires. However, this solution can only achieve single-end fixed untwisting, preventing continuous movement of the wire rope and limiting its processing to fixed lengths, thus hindering continuous mass production. Furthermore, the solution completely lacks a resetting twisting structure, which damages the original twisting structure of the wire rope after untwisting, significantly reducing its mechanical properties and load-bearing safety. The treated wire rope cannot meet the requirements for load-bearing use.

[0005] Chinese patent CN215919974U, entitled "A Rust Removal Device for Variable Diameter Steel Wire Rope," discloses a variable diameter grinding and rust removal structure that can adapt to steel wire ropes of different diameters. However, it can only grind and remove rust from the outer surface of the steel wire rope and cannot penetrate into the gaps between the strands and wires, resulting in incomplete rust removal. It is extremely ineffective for steel wire ropes with moderate or severe rust. In addition, the solution does not have a fully enclosed protective and dust removal structure, and the rust dust generated during the rust removal process is prone to overflow, which does not meet the requirements of environmentally friendly production.

[0006] Chinese patent CN213590801U, entitled "A Steel Wire Rope Lubrication Coating Device", discloses a related structure for coating the surface of steel wire rope with grease. However, it can only coat the outer surface of the steel wire rope, and the rust-preventive grease cannot penetrate into the internal gaps of the steel wire rope, resulting in limited protective effect. Moreover, this solution is a single coating device and does not work in depth with the rust removal process. The process is disconnected, and the treated steel wire rope is prone to problems such as insufficient coating adhesion and easy peeling of the protective layer.

[0007] Chinese patent CN217045978U, entitled "An Integrated Machine for Rust Removal and Coating of Steel Wire Ropes," discloses an integrated machine that simply combines rust removal and coating processes. However, it relies on manual setting of process parameters and cannot adaptively adjust the processing technology according to the diameter, lay length, and rust level of the steel wire rope. When dealing with steel wire ropes of different specifications, the processing quality fluctuates greatly. At the same time, it does not have a full-process detection and closed-loop control structure, which easily leads to problems such as missed rust removal and uneven coating thickness, and lacks stable quality control capabilities.

[0008] In summary, existing technologies cannot simultaneously achieve the core requirements of thoroughly removing rust from the gaps between strands and wires of steel wire ropes, ensuring that the treatment process does not damage the original mechanical structure of the steel wire rope, enabling continuous and coordinated operation of the entire rust removal and coating process, adaptive adjustment of process parameters, and closed-loop quality control throughout the entire process. They cannot meet the requirements for batch, high-quality rust removal and protection treatment of offline steel wire ropes, and there is an urgent need for targeted technical solutions to address the above-mentioned industry pain points. Summary of the Invention

[0009] To solve the above problems, the present invention adopts the following technical solution.

[0010] An integrated rust removal and coating device for steel wire rope surfaces includes a fixed frame. Along the offline processing path of the steel wire rope, the fixed frame is arranged coaxially and at the same center height as the following components: an unwinding mechanism, a pre-inspection module, a front untwisting clamping unit, a fully enclosed rotary rust removal mechanism, a negative pressure dust removal and cleaning module, a rear reset twisting unit, an intelligent penetration coating mechanism, a gradient curing module, a finished product re-inspection module, and a winding mechanism. The device also includes an intelligent central control system electrically connected to all electrical components.

[0011] The front untwisting clamping unit and the rear resetting twisting unit are symmetrical in structure and are both split-type semi-ring clamping structures. Both include a fixed support, a rotating clamping cylinder, a clamping drive assembly, and a rotating servo drive assembly. The fixed support is fixedly connected to a fixed frame. The rotating clamping cylinder is coaxially mounted in the fixed support via high-precision bearings. At least three sets of radially extending clamping claws are evenly distributed circumferentially on the inner wall of the rotating clamping cylinder. The clamping drive assembly is driven by the clamping claws and is used to drive the clamping claws to synchronously extend and retract radially to clamp or release the wire rope. The rotating servo drive assembly is fixed on the fixed support, and its output end is driven by the rotating clamping cylinder and is used to drive the rotating clamping cylinder to rotate around the wire rope axis. The rotating servo drive assembly of the front untwisting clamping unit and the rotating servo drive assembly of the rear resetting twisting unit rotate in opposite directions, and their rotation speeds are matched in real time with the wire rope travel speed and the original twist pitch of the wire rope.

[0012] The fully enclosed rotary rust removal mechanism is located between the front untwisting clamping unit and the rear resetting twisting unit, and includes a fully enclosed outer cylinder, a rotating inner cylinder, a rust removal drive motor, and multiple sets of variable-diameter rust removal actuators. The fully enclosed outer cylinder is fixedly connected to a fixed frame, and the rotating inner cylinder is coaxially mounted inside the fully enclosed outer cylinder via bearings. The rust removal drive motor is fixed to the outer wall of the fully enclosed outer cylinder, and its output end is connected to the rotating inner cylinder via a gear pair. The variable-diameter rust removal actuators are evenly distributed along the circumference of the inner wall of the rotating inner cylinder. Each set of variable-diameter rust removal actuators includes a servo electric push rod, a floating mounting base, and a composite rust removal head. The fixed end of the servo electric push rod is fixedly connected to the inner wall of the rotating inner cylinder, and the telescopic end is fixedly connected to the floating mounting base. The composite rust removal head is mounted on the floating mounting base, and the servo electric push rod is electrically connected to the intelligent central control system.

[0013] The intelligent penetrating coating mechanism includes a preheating unit, a high-voltage electrostatic spraying unit, an ultrasonic penetrating unit, and a thickness-fixed coating unit arranged coaxially along the travel path. The preheating unit, the high-voltage electrostatic spraying unit, the ultrasonic penetrating unit, and the thickness-fixed coating unit are all split semi-ring structures coaxial with the steel wire rope, and are all fixedly connected to a fixed frame.

[0014] Furthermore, the rotating clamping cylinder is divided into a front half-cylinder and a rear half-cylinder that are coaxially connected. The front half-cylinder and the rear half-cylinder are hinged on one side by a hinge and detachably fixed on the other side by a locking bolt, forming an openable split structure. The clamping drive assembly includes pneumatic push rods that correspond one-to-one with the clamping claws. The cylinder of the pneumatic push rod is fixed to the outer wall of the rotating clamping cylinder. The telescopic rod of the pneumatic push rod radially penetrates the cylinder wall of the rotating clamping cylinder and is movably connected to the back of the clamping claw through a universal joint. All pneumatic push rods are connected to the air source through a synchronous air circuit to realize the synchronous radial extension and retraction of the clamping claws.

[0015] Furthermore, the rotary servo drive assembly includes a servo motor, a drive gear, and an external gear ring. The external gear ring is coaxially fixedly sleeved on the outer wall of the rotary clamping cylinder. The servo motor is fixed on the side wall of the fixed support. The drive gear is coaxially fixed on the output shaft of the servo motor, and the drive gear meshes with the external gear ring. The servo motors of the front untwisting clamping unit and the rear resetting twisting unit are both electrically connected to the intelligent central control system. The intelligent central control system calculates and outputs the rotational speed and direction parameters of the two servo motors in real time based on the original twist pitch and travel speed of the wire rope.

[0016] Furthermore, the composite rust removal head includes a physical grinding unit and an ultrasonic rust removal unit. The physical grinding unit is an elastic steel wire wheel, and the ultrasonic rust removal unit includes a high-frequency ultrasonic transducer and a vibrating rust removal head. The high-frequency ultrasonic transducer is fixed on a floating mounting base, and the vibrating rust removal head is fixedly connected to the output end of the high-frequency ultrasonic transducer. The inner wall of the rotating inner cylinder is also fixed with an annular array of atomizing nozzles. The atomizing nozzles are connected to an environmentally friendly rust remover storage tank through a high-pressure anti-corrosion pump, and the spray direction of the atomizing nozzles is towards the travel path of the steel wire rope.

[0017] Furthermore, the negative pressure dust removal and cleaning module includes a high-pressure negative pressure fan, a multi-stage dust collection box, and an annular purge nozzle. The bottom of the fully enclosed outer cylinder is connected to the air inlet of the multi-stage dust collection box through a dust removal pipe, and the air inlet of the high-pressure negative pressure fan is connected to the air outlet of the multi-stage dust collection box. The annular purge nozzle is coaxially arranged at the discharge end of the fully enclosed rotary rust removal mechanism, and the air outlet of the annular purge nozzle faces the surface of the wire rope. The annular purge nozzle is connected to a clean air source through a high-pressure air pump.

[0018] Furthermore, the preheating unit is an infrared heating tube in a ring array, equipped with a non-contact infrared temperature sensor. Both the infrared heating tube and the infrared temperature sensor are electrically connected to the intelligent central control system. The high-voltage electrostatic spraying unit includes an electrostatic spraying nozzle in a ring array. The electrostatic spraying nozzle is sequentially connected to a high-voltage electrostatic generator, a high-voltage metering pump, and a rust-preventive grease tank. Both the high-voltage metering pump and the high-voltage electrostatic generator are electrically connected to the intelligent central control system.

[0019] Furthermore, the ultrasonic penetration unit includes a ring array of high-frequency ultrasonic transducers. The front end of the high-frequency ultrasonic transducer contacts the surface of the steel wire rope through a flexible coupling ring. The high-frequency ultrasonic transducer is electrically connected to the intelligent central control system. The thickness-fixed coating unit includes multiple sets of pneumatic scrapers distributed circumferentially. The telescopic ends of the pneumatic scrapers face the axis of the steel wire rope. The pneumatic scrapers are electrically connected to the intelligent central control system. The bottom of the thickness-fixed coating unit is provided with a liquid collection tank. The liquid collection tank is connected to the anti-rust grease storage tank through a three-stage filtration unit.

[0020] Furthermore, both the pre-inspection module and the finished product re-inspection module include a high-definition industrial line scan camera, a 3D laser profile scanner, and an eddy current detector. The high-definition industrial line scan camera, the 3D laser profile scanner, and the eddy current detector are all electrically connected to the intelligent central control system. The intelligent central control system includes an edge computing module and a process parameter adaptive algorithm module. The process parameter adaptive algorithm module has a built-in database of wire rope twisting parameters and a database of rust removal and coating processes. It can adaptively output the operating process parameters of the equipment based on the wire rope parameters collected by the pre-inspection module, and perform closed-loop adjustments based on the detection data of the finished product re-inspection module.

[0021] Furthermore, the gradient curing module includes a room temperature homogenization section and a hot air curing section arranged sequentially along the travel path. The room temperature homogenization section is equipped with an annular flexible uniform brush, and the hot air curing section is equipped with an annular hot air nozzle. The annular hot air nozzle is connected to a clean air source through a hot air generator, and the hot air generator is electrically connected to the intelligent central control system.

[0022] Furthermore, both the unwinding mechanism and the winding mechanism include a variable frequency motor, a winding roller, and a tension sensor. The tension sensor is electrically connected to the intelligent central control system. The intelligent central control system adjusts the tension of unwinding and winding in real time through the variable frequency motor to ensure that the wire rope is in a constant tension straight state during its movement.

[0023] Compared with the prior art, the beneficial effects of this invention are as follows:

[0024] This invention utilizes a front untwisting clamping unit and a rear resetting twisting unit with symmetrical structure, opposite directions, and real-time linkage between rotation speed and travel speed to achieve continuous dynamic untwisting and precise resetting of the wire rope during its travel. While completely exposing the gaps between strands and wires of the wire rope to achieve thorough rust removal, the treatment also completely restores the original lay pitch, lay direction, and mechanical structure of the wire rope. This fundamentally solves the core problem of existing technologies that damage the mechanical properties of wire ropes after untwisting. The treated wire rope has no loss of mechanical properties and fully meets the requirements for load-bearing use.

[0025] This invention achieves multi-mode synergistic rust removal through a composite rust removal head. Combined with the untwisted and dispersed steel wire rope structure, it can remove rust from the outer surface and internal gaps of the steel wire rope without dead angles. It can handle heavily rusted steel wire ropes, and the rust removal effect far exceeds that of existing single grinding equipment. At the same time, it is equipped with a fully enclosed structure and a negative pressure dust removal module to achieve complete collection of rust dust, with zero fugitive emissions, which meets environmental protection requirements.

[0026] This invention deeply integrates rust removal and coating processes, simultaneously performing high-voltage electrostatic spraying during the wire rope rewinding process. This allows the rust-preventive grease to be fully incorporated into the internal gaps of the wire rope during the inter-strand twisting process. Combined with the high-frequency micro-cavitation effect of the ultrasonic penetration unit, the penetration depth and adhesion of the rust-preventive grease are significantly improved, coating uniformity is significantly enhanced, and the protective effect is greatly strengthened compared to existing equipment, effectively extending the service life of the wire rope. At the same time, the fixed-thickness scraping and filtration circulation structure significantly improves the utilization rate of the rust-preventive grease and reduces material costs.

[0027] This invention achieves closed-loop intelligent control of the entire process through a pre-inspection and finished product re-inspection module, combined with the process parameter adaptive algorithm module of the intelligent central control system. It can adaptively adjust all process parameters according to the diameter, lay length, and corrosion level of the wire rope, eliminating the need for repeated manual adjustments. It is compatible with wire ropes of conventional specifications and ensures good processing quality consistency. At the same time, in conjunction with the unwinding and rewinding mechanisms, it enables continuous batch processing of wire ropes, significantly improving work efficiency compared to existing equipment and making it suitable for large-scale industrial production. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0029] Figure 2 This is a front view of the front untwisting clamping unit and the rear resetting twisting unit of the present invention;

[0030] Figure 3 This is a side view of the front untwisting clamping unit and the rear resetting twisting unit of the present invention;

[0031] Figure 4 This is a schematic diagram of the clamping claw structure of the present invention;

[0032] Figure 5 This is a schematic diagram of the fully enclosed rotary rust removal mechanism of the present invention;

[0033] Figure 6 This is a cross-sectional view of the fully enclosed rotary rust removal mechanism of the present invention.

[0034] Explanation of reference numerals in the attached figures:

[0035] 1. Fixed frame; 2. Unwinding mechanism; 3. Pre-inspection module; 4. Front untwisting clamping unit; 401. Fixed support; 402. Rotary clamping cylinder; 4021. Front half cylinder; 4022. Rear half cylinder; 4023. Hinge; 4024. Locking bolt; 403. High-precision bearing; 404. Clamping claw; 405. Pneumatic push rod; 406. Rotary servo drive assembly; 4061. Servo motor; 4062. Drive gear; 4063. External gear ring; 5. Fully enclosed rotary rust removal mechanism; 501. Fully enclosed 502 Outer cylinder; 503 Rotating inner cylinder; 504 Rust removal drive motor; 505 Servo electric push rod; 506 Floating mounting base; 507 Composite rust removal head; 508 Atomizing nozzle; 6. Negative pressure dust removal and cleaning module; 7. Rear reset twisting unit; 8. Intelligent penetration coating mechanism; 801 Preheating unit; 802 High-voltage electrostatic spraying unit; 803 Ultrasonic penetration unit; 804 Fixed thickness scraping unit; 9. Gradient curing module; 10. Finished product re-inspection module; 11. Winding mechanism; 12. Tension sensor. Detailed Implementation

[0036] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0037] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "top / bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for 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 the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0038] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "sleeved / connected," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0039] Example

[0040] like Figure 1-6 As shown, an integrated rust removal and coating device for steel wire rope surfaces includes a fixed frame 1. The fixed frame 1 adopts a welded steel integrated structure and is arranged horizontally to ensure that the coaxiality error of all functional units meets the equipment operation accuracy requirements. Along the travel path of the offline processing of the steel wire rope on the fixed frame 1, from left to right, the following components are arranged coaxially and at the same center height: unwinding mechanism 2, pre-inspection module 3, front untwisting clamping unit 4, fully enclosed rotary rust removal mechanism 5, negative pressure dust removal and cleaning module 6, rear reset twisting unit 7, intelligent penetration coating mechanism 8, gradient curing module 9, finished product re-inspection module 10, and winding mechanism 11. An intelligent central control system electrically connected to all electrical components is also provided, and the control cabinet of the intelligent central control system is fixed on one side of the fixed frame 1.

[0041] In this embodiment, the unwinding mechanism 2 and the winding mechanism 11 are respectively arranged at both ends of the fixed frame 1. Both include a variable frequency motor, a winding roller and a tension sensor 12. The tension sensor 12 is installed at the wire exit end of the winding roller and is electrically connected to the intelligent central control system. The intelligent central control system adjusts the tension of unwinding and winding in real time through the variable frequency motor to ensure that the wire rope is in a constant tension straight state during the travel process. The travel speed can be steplessly adjusted according to the process requirements.

[0042] In this embodiment, both the pre-inspection module 3 and the finished product re-inspection module 10 include a high-definition industrial line scan camera, a 3D laser profile scanner, and an eddy current detector. These three components are arranged sequentially along the wire rope's travel path, fixedly connected to the fixed frame 1 via brackets, and electrically connected to the intelligent central control system. The high-definition industrial line scan camera is used to acquire images of the wire rope surface and identify corrosion levels and surface defects; the 3D laser profile scanner is used to measure the actual diameter, roundness, wear, actual lay length, and lay length deviation rate of the wire rope; and the eddy current detector is used to detect the metal cross-sectional loss and internal corrosion of the wire rope, achieving comprehensive quantitative inspection of the wire rope's condition.

[0043] In this embodiment, the front untwisting clamping unit 4 and the rear resetting twisting unit 7 are completely symmetrical in structure, both being split semi-ring clamping structures. Both include a fixed support 401, a rotating clamping cylinder 402, a clamping drive assembly, and a rotating servo drive assembly 406. The fixed support 401 is a one-piece cast steel structure, with its bottom fixedly connected to the fixed frame 1 by bolts. A through hole coaxial with the wire rope's travel path is opened at the center of the support, and a bearing mounting step is machined on the inner wall of the through hole. The rotating clamping cylinder 402 is coaxially rotatably mounted in the through hole of the fixed support 401 via a high-precision bearing 403. The high-precision bearing 403 is a double-row angular contact ball bearing, ensuring rotational accuracy and radial load-bearing capacity.

[0044] In this embodiment, the rotating clamping cylinder 402 is divided into a front half-cylinder 4021 and a rear half-cylinder 4022, which are coaxially connected. One side of the front half-cylinder 4021 and the rear half-cylinder 4022 are hinged by two sets of high-precision hinges 4023, and the other side is detachably fixed by two sets of high-strength locking bolts 4024, forming an openable split structure. This allows for quick loading of the wire rope without having to thread the rope through the end. The inner wall of the rotating clamping cylinder 402 has four sets of radially retractable clamping claws 404 evenly distributed circumferentially. The clamping surfaces of the clamping claws 404 are machined with anti-slip teeth that match the twist direction of the wire rope strands, and the material is wear-resistant rubber to prevent damage to the surface of the wire rope during clamping.

[0045] In this embodiment, the clamping drive assembly includes pneumatic push rods 405 corresponding to the clamping claws 404 one by one. The cylinder of the pneumatic push rod 405 is fixed to the outer wall of the rotating clamping cylinder 402 by a bracket. The telescopic rod of the pneumatic push rod 405 radially penetrates the cylinder wall of the rotating clamping cylinder 402 and is driven to the tail of the clamping claw 404 to ensure that the clamping claw 404 can adaptively conform to the surface of the wire rope. All pneumatic push rods 405 are connected to the air source through a synchronous air circuit. The synchronous air circuit is equipped with a precision pressure regulating valve, which can adjust the clamping force according to the diameter of the wire rope to realize the synchronous radial extension and retraction of the four sets of clamping claws 404 to adapt to wire ropes of different diameters. The non-drive end of the rotary clamping cylinder 402 is equipped with a rotary air connector. The fixed end of the rotary air connector is connected to the synchronous air path of the external air source, and the rotating end is connected to the air path of each pneumatic push rod 405. This ensures that the air path of the pneumatic push rod 405 is continuously open during the rotation of the rotary clamping cylinder 402, so that the clamping and releasing actions can be completed normally.

[0046] In this embodiment, the rotary servo drive assembly 406 includes a servo motor 4061, a drive gear 4062, and an external gear ring 4063. The external gear ring 4063 is coaxially fixedly sleeved on the outer wall of the rotary clamping cylinder 402, located on one side of the high-precision bearing 403, and is made of tempered alloy steel with high-frequency quenching of the tooth surface. The servo motor 4061 is fixed to the side wall of the fixed support 401 through a motor bracket, and the drive gear 4062 is coaxially fixed on the output shaft of the servo motor 4061. The drive gear 4062 meshes with the external gear ring 4063, and the rotational torque and accuracy are ensured by setting the transmission ratio. The servo motor 4061 of the front untwisting clamping unit 4 and the servo motor 4061 of the rear reset twisting unit 7 are both electrically connected to the intelligent central control system. The PLC controller of the intelligent central control system has a built-in electronic gear synchronization control function. It uses the travel encoder signals of the unwinding mechanism 2 and the winding mechanism 11 as the master signal and the servo motors 4061 of the front untwisting clamping unit 4 and the rear reset twisting unit 7 as slave shafts. The system calculates the electronic gear ratio of the master and slave shafts in real time according to the input wire rope original twist pitch to ensure that the servo motors of the front untwisting and the rear reset rotate in opposite directions and the speed is accurately matched. When the wire rope travels one original twist pitch length, the front untwisting and the rear reset units complete one revolution in the forward and reverse directions respectively, ensuring precise synchronization of untwisting and reset.

[0047] In this embodiment, the fully enclosed rotary rust removal mechanism 5 is located between the front untwisting clamping unit 4 and the rear resetting twisting unit 7, and includes a fully enclosed outer cylinder 501, a rotary inner cylinder 502, a rust removal drive motor 503, and four sets of variable-diameter rust removal actuators. The fully enclosed outer cylinder 501 adopts a split-type structure, and the connecting flanges of the upper and lower cylinders are detachably fixedly connected by high-strength bolts. Coaxial through holes for steel wire ropes to pass through are opened on the end plates at both ends, and wear-resistant and dustproof sealing rings are installed at the through holes, which not only facilitates the rapid feeding of steel wire ropes, but also ensures a fully enclosed effect during the rust removal process and prevents rust dust from overflowing. The rotary inner cylinder 502 is coaxially mounted inside the fully enclosed outer cylinder 501 through double-row self-aligning bearings. The rust removal drive motor 503 is a variable frequency reduction motor, fixed on the top outer wall of the fully enclosed outer cylinder 501. Its output end meshes with the driven gear ring fixed on the outer wall of the rotary inner cylinder 502 through the driving gear, driving the rotary inner cylinder 502 to rotate. The rotation speed can be steplessly adjusted according to process requirements.

[0048] In this embodiment, four sets of variable-diameter rust removal actuators are evenly distributed circumferentially along the inner wall of the rotating inner cylinder 502. Each set of variable-diameter rust removal actuators includes a servo electric push rod 504, a floating mounting base 505, and a composite rust removal head 506. The fixed end of the servo electric push rod 504 is fixedly connected to the inner wall of the rotating inner cylinder 502, and the telescopic end is fixedly connected to the floating mounting base 505. Guide sliders are fixed on both sides of the floating mounting base 505, and radially extending guide grooves are opened at corresponding positions on the inner wall of the rotating inner cylinder 502. The guide sliders slide in cooperation with the guide grooves to ensure that when the servo electric push rod 504 drives the floating mounting base 505 to extend or retract, the floating mounting base 505 moves smoothly radially without circumferential deflection, ensuring stable contact between the composite rust removal head 506 and the surface of the wire rope. The composite rust removal head 506 is installed on the floating mounting base 505. The servo electric push rod 504 is electrically connected to the intelligent central control system, which can adjust the extension amount in real time according to the diameter of the wire rope to achieve variable-diameter adaptation. The composite rust removal head 506 includes a physical grinding unit and an ultrasonic rust removal unit. The physical grinding unit is an elastic steel wire wheel, which is rotatably mounted on the front end of the floating mounting base 505 via a rotating shaft. The ultrasonic rust removal unit includes a high-frequency ultrasonic transducer and a vibrating rust removal head. The high-frequency ultrasonic transducer is fixed on the floating mounting base 505, and the vibrating rust removal head is fixedly connected to the output end of the high-frequency ultrasonic transducer. The working frequency can be adjusted according to process requirements. The inner wall of the rotating inner cylinder 502 is also fixed with a ring-shaped array of atomizing nozzles 507. The atomizing nozzles 507 are connected to an environmentally friendly rust remover storage tank via a high-pressure anti-corrosion pump. The spray direction of the atomizing nozzles 507 is towards the steel wire rope, which can evenly atomize the rust remover and spray it into the gaps of the untwisted steel wire rope.

[0049] In this embodiment, the negative pressure dust removal and cleaning module 6 includes a high-pressure negative pressure fan, a multi-stage dust collection box, and an annular blowing nozzle. A dust collection port is opened at the bottom of the fully enclosed outer cylinder 501, which is connected to the air inlet of the multi-stage dust collection box through a dust collection pipe. The air inlet of the high-pressure negative pressure fan is connected to the air outlet of the multi-stage dust collection box. The multi-stage dust collection box adopts a first-stage cyclone dust removal and a second-stage HEPA high-efficiency filter to ensure the dust removal effect. The annular blowing nozzle is coaxially arranged at the discharge end of the fully enclosed rotary rust removal mechanism 5 and is fixedly connected to the fixed frame 1 through a bracket. The air jet of the annular blowing nozzle faces the surface of the wire rope and is arranged at an inclined angle with the direction of the wire rope's travel. The annular blowing nozzle is connected to a clean air source through a high-pressure air pump, which can perform high-pressure blowing on the surface of the rust-removed wire rope to remove residual rust dust and waste rust remover.

[0050] In this embodiment, the intelligent penetrating coating mechanism 8 includes a preheating unit 801, a high-voltage electrostatic spraying unit 802, an ultrasonic penetrating unit 803, and a thickness-fixed scraping unit 804 arranged coaxially along the travel path. All four units are split-ring structures coaxial with the steel wire rope and are fixedly connected to the fixed frame 1 via brackets. The preheating unit 801 is a ring array of infrared heating tubes, equipped with a non-contact infrared temperature sensor. Both the infrared heating tubes and the infrared temperature sensor are electrically connected to the intelligent central control system 12, which can heat the steel wire rope to a set temperature, with temperature control accuracy meeting process requirements. The split-type semi-ring structure of the high-voltage electrostatic spraying unit 802 includes two openable semi-shells. One side of the two semi-shells is hinged, and the other side is locked by a buckle. Each semi-shell contains a semi-ring electrostatic spraying nozzle. When the upper and lower semi-shells are closed, the two semi-ring nozzles align to form a complete annular spraying cavity, which is arranged around the outer circumference of the steel wire rope to ensure that there are no dead angles in the spraying. The electrostatic spraying nozzle is connected in sequence to the high-voltage electrostatic generator, the high-voltage metering pump, and the anti-rust grease tank. The high-voltage metering pump and the high-voltage electrostatic generator are both electrically connected to the intelligent central control system 12. The spraying pressure and electrostatic voltage can be adjusted according to process requirements.

[0051] In this embodiment, the ultrasonic penetration unit 803 includes a ring array of high-frequency ultrasonic transducers. The front end of the high-frequency ultrasonic transducer contacts the surface of the wire rope through a flexible coupling ring. The high-frequency ultrasonic transducer is electrically connected to the intelligent central control system 12, which can drive the wire rope to generate high-frequency micro-vibration, allowing the anti-rust grease to fully penetrate into the internal gaps of the wire rope. The thickness-fixed coating unit 804 includes four sets of pneumatic scrapers distributed circumferentially. The telescopic ends of the pneumatic scrapers face the axis of the wire rope. The pneumatic scrapers are electrically connected to the intelligent central control system 12 and can adjust the extension amount according to the set coating thickness. The bottom of the thickness-fixed coating unit 804 is provided with a liquid collection tank. The liquid collection tank is connected to the anti-rust grease storage tank through a three-stage filtration unit, namely impurity filtration, oil-water separation, and fine filtration, to realize the recycling of excess grease.

[0052] In this embodiment, the gradient curing module 9 includes a room temperature homogenization section and a hot air curing section arranged sequentially along the travel path. The room temperature homogenization section is equipped with an annular flexible uniform brush, which can perform secondary homogenization on the coating layer. The hot air curing section is equipped with an annular hot air nozzle, which is connected to a clean air source through a hot air generator. The hot air generator is electrically connected to an intelligent central control system. The hot air temperature can be adjusted according to process requirements, which can quickly cure the coating layer and improve the adhesion of the anti-rust grease.

[0053] In this embodiment, the PLC controller of the intelligent central control system adopts Siemens S7-1500 series industrial PLC, and the edge computing module adopts NVIDIA Jetson OrinNX industrial-grade edge computing box. The two achieve real-time data interaction through Profinet industrial bus, and the communication delay with all sensors and actuators of the equipment is ≤10ms, ensuring the real-time performance and synchronization of process control. The process parameter adaptive algorithm module runs on Linux real-time operating system and uses C++ to write executable programs. All algorithm logic is implemented using conventional programming methods in the field of industrial control, and can be reproduced without creative labor.

[0054] In this embodiment, the specific judgment rules of the wire rope condition judgment standard library are as follows:

[0055] Slight corrosion: The corrosion area accounts for ≤5%, with only surface rust and no pitting corrosion, and the metal cross-sectional loss rate is ≤1%;

[0056] Moderate corrosion: 5%-20% of the area is corroded, with scattered pitting corrosion. The pitting depth is ≤5% of the wire diameter, and the metal cross-sectional loss rate is 1%-3%.

[0057] Severe corrosion: rust area accounts for 20%-40%, pitting corrosion is dense, pitting depth is ≤10% of the wire diameter, and metal cross-section loss rate is 3%-5%;

[0058] Normal twisting: Actual twist deviation rate ≤ ±2%; Slight twist deviation: Actual twist deviation rate ±2%-±5%; Severe twist deviation: Actual twist deviation rate > ±5%.

[0059] In this embodiment, the specific preset ratio for dynamic correction of process parameters is:

[0060] When the rust level is increased from moderate to severe, the speed of the rust removal drive motor 503 is increased by 30% from the baseline value, the wire rope travel speed is reduced by 40% from the baseline value, and the ultrasonic power of the composite rust removal head 506 is increased to 90% of the rated value.

[0061] For every 1% increase in the twist deviation rate, the servo motor speeds of the front untwisting clamping unit 4 and the rear resetting twisting unit 7 are adjusted by 1% to ensure the synchronization accuracy of untwisting and resetting.

[0062] For every 1m / min increase in the wire rope's travel speed, the output flow of the high-pressure metering pump increases by a preset unit flow rate to ensure a constant coating amount per unit length of wire rope.

[0063] The working process of this embodiment:

[0064] Step 1, feeding and parameter setting: Open the split structure of the front untwisting clamping unit 4, the rear resetting twisting unit 7, the fully enclosed rotary rust removal mechanism 5, and the intelligent penetration coating mechanism 8. Install the wire rope to be treated on the unwinding mechanism 2. Pass the end of the wire rope through all the functional units in sequence and finally fix it on the winding roller of the winding mechanism 11. Close all the split structures and lock them. Input the nominal diameter, structure type, twist direction, nominal twist pitch, and material strength grade of the wire rope through the human-machine interaction touch screen, and start the equipment.

[0065] The second step is pre-inspection and adaptive matching of the process: The wire rope travels at a set speed and first passes through the pre-inspection module 3. The high-definition industrial line scan camera, 3D laser contour scanner and eddy current detector perform full-dimensional inspection of the wire rope and transmit the data to the intelligent central control system 12. The process parameter adaptive algorithm module automatically calculates and outputs the full process parameters such as the wire rope travel speed, untwisting / resetting speed, rust removal head extension, rust removal motor speed, spraying pressure, and preheating temperature based on the detection data. All components are automatically adjusted to the corresponding state.

[0066] The third step is dynamic untwisting and synergistic rust removal: When the wire rope travels to the front untwisting clamping unit 4, the clamping claws 404 extend synchronously to clamp the wire rope. The servo motor 4061 drives the rotating clamping cylinder 402 to rotate, continuously and dynamically untwisting the wire rope while it is moving, evenly dispersing the twisted wire strands and completely exposing the gaps between strands and wires. After untwisting, the wire rope enters the fully enclosed rotating rust removal mechanism 5. The rotating inner cylinder 502 drives the composite rust removal head 506 to rotate at high speed around the wire rope. The elastic wire wheel physically polishes the surface of the wire rope, and the high-frequency ultrasonic transducer drives the vibrating rust removal head to generate high-frequency vibration. Combined with the rust remover sprayed by the atomizing nozzle 507, the gaps in the wire rope are deeply rusted, achieving multi-mode synergistic rust removal. The rust dust generated during the rust removal process is all sucked into the dust collection box through the negative pressure dust removal module. After rust removal, the wire rope is blown by the annular blowing nozzle to remove residual impurities from the surface.

[0067] The fourth step is precise resetting and re-twisting: After rust removal, the wire rope enters the resetting and re-twisting unit 7, where the clamping claws clamp the wire rope. The servo motor drives the rotating clamping cylinder to rotate in the opposite direction and at the same speed as the previous untwisting unit, precisely resetting and re-twisting the untwisted wire rope, completely restoring the original lay pitch, lay direction and mechanical structure of the wire rope. The treated wire rope has no additional internal stress.

[0068] Step 5, Penetration Coating and Curing: After resetting, the wire rope enters the intelligent penetration coating mechanism 8. First, it is heated to the set temperature by the preheating unit to reduce the viscosity of the rust-preventive grease. Then, the high-voltage electrostatic spraying unit electrostatically sprays the wire rope, so that the rust-preventive grease is evenly adsorbed on the surface of the wire rope, and at the same time, it fully penetrates into the internal gaps of the wire rope during the twisting process. The ultrasonic penetration unit further enhances the penetration depth of the rust-preventive grease through high-frequency vibration. The thickness scraping unit scrapes off the excess grease to ensure uniform coating thickness, and the excess grease is recycled. The coated wire rope enters the gradient curing module to complete homogenization and rapid curing, forming a uniform and dense protective layer.

[0069] Step 6, Finished Product Re-inspection and Rewinding: After processing, the wire rope passes through the finished product re-inspection module 10, where it undergoes a second, comprehensive inspection of rust removal quality, coating thickness, and surface quality. The inspection data is uploaded to the intelligent central control system in real time. Qualified wire ropes are rewound by the rewinding mechanism. If any substandard areas are detected, the system automatically records the location. After the entire roll is processed, the system automatically controls the equipment to reverse its direction and perform secondary reprocessing on the substandard areas to ensure that the processing quality meets the requirements.

[0070] The above are merely preferred embodiments of the present invention; however, the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and its improved concept, should be covered within the scope of protection of the present invention.

Claims

1. An integrated equipment for rust removal and coating of steel wire rope surface, characterized in that, The system includes a fixed frame (1), on which, along the travel path of the wire rope, are arranged in sequence and at the same center height an unwinding mechanism (2), a pre-inspection module (3), a front untwisting clamping unit (4), a fully enclosed rotary rust removal mechanism (5), a negative pressure dust removal and cleaning module (6), a rear reset twisting unit (7), an intelligent penetration coating mechanism (8), a gradient curing module (9), a finished product re-inspection module (10), and a winding mechanism (11), and also includes an intelligent central control system electrically connected to all electrical components; The front untwisting clamping unit (4) and the rear resetting twisting unit (7) are both split-type semi-ring clamping structures, each including a fixed support (401), a rotating clamping cylinder (402), a clamping drive assembly, and a rotating servo drive assembly (406). The fixed support (401) is fixedly connected to the fixed frame (1), and the rotating clamping cylinder (402) is coaxially rotatably mounted in the fixed support (401) via a high-precision bearing (403). The inner wall of the rotating clamping cylinder (402) has at least three sets of radially extending clamping claws (404) evenly distributed circumferentially. The clamping drive assembly... The component is connected to the clamping claw (404) for driving the clamping claw (404) to synchronously extend and retract radially to clamp or release the wire rope; the rotary servo drive component (406) is fixed on the fixed support (401), and its output end is connected to the rotary clamping cylinder (402) for driving the rotary clamping cylinder (402) to rotate around the wire rope axis; the rotary servo drive component (406) of the front untwisting clamping unit (4) and the rotary servo drive component (406) of the rear resetting twisting unit (7) rotate in opposite directions, and their rotation speed is linked and matched with the wire rope travel speed and the original twist pitch of the wire rope in real time; The fully enclosed rotary rust removal mechanism (5) is located between the front untwisting clamping unit (4) and the rear resetting twisting unit (7), and includes a fully enclosed outer cylinder (501), a rotating inner cylinder (502), a rust removal drive motor (503), and multiple sets of variable diameter rust removal actuators; the fully enclosed outer cylinder (501) is fixedly connected to the fixed frame (1), the rotating inner cylinder (502) is coaxially mounted inside the fully enclosed outer cylinder (501) through bearings, and the rust removal drive motor (503) is fixed to the outer wall of the fully enclosed outer cylinder (501), and its output end is connected to the rotating inner cylinder (502) through a gear pair. 502) Transmission connection; The variable diameter rust removal actuator is evenly distributed along the inner wall of the rotating inner cylinder (502). Each variable diameter rust removal actuator includes a servo electric push rod (504), a floating mounting base (505), and a composite rust removal head (506). The fixed end of the servo electric push rod (504) is fixedly connected to the inner wall of the rotating inner cylinder (502), and the telescopic end is fixedly connected to the floating mounting base (505). The composite rust removal head (506) is installed on the floating mounting base (505). The servo electric push rod (504) is electrically connected to the intelligent central control system. The intelligent penetrating coating mechanism (8) includes a preheating unit (801), a high-voltage electrostatic spraying unit (802), an ultrasonic penetrating unit (803), and a thickness scraping unit (804) arranged coaxially along the travel path. The preheating unit (801), the high-voltage electrostatic spraying unit (802), the ultrasonic penetrating unit (803), and the thickness scraping unit (804) are all split semi-ring structures coaxial with the steel wire rope, and are all fixedly connected to the fixed frame (1).

2. The integrated rust removal and coating equipment for steel wire rope surface as described in claim 1, characterized in that, The rotating clamping cylinder (402) is divided into a front half-cylinder (4021) and a rear half-cylinder (4022) that are coaxially connected. One side of the front half-cylinder (4021) and the rear half-cylinder (4022) are hinged by a hinge (4023), and the other side is detachably fixed by a locking bolt (4024) to form an openable split structure. The clamping drive assembly includes pneumatic push rods (405) that correspond one-to-one with the clamping claws (404). The cylinder of the pneumatic push rod (405) is fixed to the outer wall of the rotating clamping cylinder (402). The telescopic rod of the pneumatic push rod (405) penetrates the cylinder wall of the rotating clamping cylinder (402) radially and is movably connected to the back of the clamping claws (404) through a universal joint. All pneumatic push rods (405) are connected to the air source through a synchronous air passage to realize the synchronous radial extension and retraction of the clamping claws (404).

3. The integrated rust removal and coating equipment for steel wire rope surface as described in claim 2, characterized in that, The rotary servo drive assembly (406) includes a servo motor (4061), a drive gear (4062), and an external gear ring (4063). The external gear ring (4063) is coaxially fixedly sleeved on the outer wall of the rotary clamping cylinder (402). The servo motor (4061) is fixed on the side wall of the fixed support (401). The drive gear (4062) is coaxially fixed on the output shaft of the servo motor (4061). The drive gear (4062) meshes with the external gear ring (4063). The servo motor (4061) of the front untwisting clamping unit (4) and the servo motor (4061) of the rear resetting twisting unit (7) are both electrically connected to the intelligent central control system. The intelligent central control system calculates and outputs the rotation speed and direction parameters of the two servo motors (4061) in real time according to the original twist pitch and travel speed of the wire rope.

4. The integrated rust removal and coating equipment for steel wire rope surface as described in claim 1, characterized in that, The composite rust removal head (506) includes a physical grinding unit and an ultrasonic rust removal unit. The physical grinding unit is an elastic steel wire wheel. The ultrasonic rust removal unit includes a high-frequency ultrasonic transducer and a vibration rust removal head. The high-frequency ultrasonic transducer is fixed on a floating mounting base (505), and the vibration rust removal head is fixedly connected to the output end of the high-frequency ultrasonic transducer. The inner wall of the rotating inner cylinder (502) is also fixed with an annular array of atomizing nozzles (507). The atomizing nozzles (507) are connected to the environmentally friendly rust remover storage tank through a high-pressure anti-corrosion pump. The spray direction of the atomizing nozzles (507) is towards the travel path of the steel wire rope.

5. The integrated rust removal and coating equipment for steel wire rope surface as described in claim 1, characterized in that, The negative pressure dust removal and cleaning module (6) includes a high-pressure negative pressure fan, a multi-stage dust removal box and an annular blowing nozzle. The bottom of the fully enclosed outer cylinder (501) is connected to the air inlet of the multi-stage dust removal box through a dust removal pipe, and the air inlet of the high-pressure negative pressure fan is connected to the air outlet of the multi-stage dust removal box. The annular blowing nozzle is coaxially arranged at the discharge end of the fully enclosed rotary rust removal mechanism (5). The air jet of the annular blowing nozzle faces the surface of the wire rope, and the annular blowing nozzle is connected to a clean air source through a high-pressure air pump.

6. The integrated rust removal and coating equipment for steel wire rope surface according to claim 1, characterized in that, The preheating unit (801) is an infrared heating tube in a ring array, equipped with a non-contact infrared temperature sensor. Both the infrared heating tube and the infrared temperature sensor are electrically connected to the intelligent central control system. The high-voltage electrostatic spraying unit (802) includes an electrostatic spraying nozzle in a ring array. The electrostatic spraying nozzle is connected in sequence to a high-voltage electrostatic generator, a high-voltage metering pump, and a rust-preventive grease tank. Both the high-voltage metering pump and the high-voltage electrostatic generator are electrically connected to the intelligent central control system.

7. The integrated rust removal and coating equipment for steel wire rope surface according to claim 6, characterized in that, The ultrasonic penetration unit (803) includes a ring array of high-frequency ultrasonic transducers. The front end of the high-frequency ultrasonic transducer contacts the surface of the steel wire rope through a flexible coupling ring. The high-frequency ultrasonic transducer is electrically connected to the intelligent central control system. The thickness coating unit (804) includes multiple sets of pneumatic scrapers distributed circumferentially. The telescopic ends of the pneumatic scrapers face the axis of the steel wire rope. The pneumatic scrapers are electrically connected to the intelligent central control system. The bottom of the thickness coating unit (804) is provided with a liquid collection tank. The liquid collection tank is connected to the anti-rust grease storage tank through a three-stage filtration unit.

8. The integrated rust removal and coating equipment for steel wire rope surface according to claim 1, characterized in that, Both the pre-inspection module (3) and the finished product re-inspection module (10) include a high-definition industrial line array camera, a 3D laser contour scanner and an eddy current detector. The high-definition industrial line array camera, the 3D laser contour scanner and the eddy current detector are all electrically connected to the intelligent central control system. The intelligent central control system includes an edge computing module and a process parameter adaptive algorithm module. The process parameter adaptive algorithm module has a built-in steel wire rope twisting parameter database and a rust removal and coating process database. It can adaptively output the operating process parameters of the equipment according to the steel wire rope parameters collected by the pre-inspection module (3) and perform closed-loop adjustment according to the detection data of the finished product re-inspection module (10).

9. The integrated rust removal and coating equipment for steel wire rope surface according to claim 1, characterized in that, The gradient curing module (9) includes a room temperature homogenization section and a hot air curing section arranged sequentially along the travel path. The room temperature homogenization section is provided with an annular flexible uniform brush, and the hot air curing section is provided with an annular hot air nozzle. The annular hot air nozzle is connected to a clean air source through a hot air generator, and the hot air generator is electrically connected to an intelligent central control system.

10. The integrated rust removal and coating equipment for steel wire rope surface according to claim 1, characterized in that, Both the unwinding mechanism (2) and the winding mechanism (11) include a variable frequency motor, a winding roller and a tension sensor. The tension sensor is electrically connected to the intelligent central control system. The intelligent central control system adjusts the tension of unwinding and winding in real time through the variable frequency motor to ensure that the wire rope is in a constant tension straight state during its movement.

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