A smart metering and synchronous control device for rope winding and its usage method

Abstract

This invention discloses an intelligent metering and synchronous control device and method for rope winding, relating to the field of rope winding technology. The proposed solution includes: a weight metering unit for monitoring weight changes in the coil at the unwinding end; a length metering unit for adjusting rope tension and measuring length; comprising: a measuring roller group with movable rollers that move with rope tension changes; a tensioner with at least two pairs of elastic clamping members with adjustable clamping spacing; a bidirectional transmission component for converting the unidirectional displacement of the movable rollers into bidirectional adjustment that drives the clamping spacing of the elastic clamping members to increase or decrease; and a control unit for processing data based on received weight and length signals. This allows the tensioner to automatically adapt to the tension requirements of different wire diameters and materials, solving the problem of existing spring-type tensioners relying on manual adjustment and lacking adaptive adjustment.

Description

Technical Field

[0001] This invention relates to the field of rope winding technology, and in particular to a smart metering and synchronous control device for rope winding and its usage method. Background Technology

[0002] Rope winding equipment is widely used in the production and processing of wires and cables, textile fibers, packaging materials and other fields. In the rope winding process, accurate measurement of wire length and stable control of tension are key factors to ensure product quality. In the existing technology, common length measurement methods include encoder length measurement method and weight conversion method, while tension control mostly adopts mechanical tensioner or electronic tensioner. However, existing technologies have the following shortcomings: First, traditional reed tensioners typically only have one pair of reeds, and the tension is changed by manually adjusting the clamping distance between the reeds. This adjustment method relies entirely on the operator's experience, which is not only cumbersome and inefficient, but also makes it difficult to ensure the consistency of tension between different batches of wire, especially when the wire diameter changes or the wire thickness is uneven. Secondly, although some tensioners are equipped with two pairs of springs, there is no effective linkage mechanism between the pairs of springs. Either they are controlled independently, resulting in inconsistent clamping force, or although they are controlled in a unified manner, it is impossible to ensure that the displacement of each clamping point is equal. This causes uneven force on the wire when it passes through, which can easily cause shaking or deviation, affecting the accuracy of subsequent measurement. Third, existing tensioners cannot automatically adjust the clamping force according to the real-time tension changes of the wire. For elastic or uneven wires, it is difficult to maintain a constant working tension, resulting in a large error in length measurement. In addition, the single-mode measurement method that relies solely on encoder length measurement or weight conversion is prone to cumulative errors due to uneven wire density, slippage, and other factors, which cannot meet the requirements of high-precision measurement. Summary of the Invention

[0003] In view of this, the purpose of the present invention is to solve the above-mentioned problems.

[0004] To achieve the above-mentioned technical objectives, the present invention provides an intelligent metering and synchronous control device for rope winding, characterized in that it includes: The weight measurement unit is used to monitor the weight change of the wire coil at the unwinding end and output a weight signal; The length measuring unit is used to adjust the tension and measure the length of the rope and output a length signal; The control unit is connected to the weight measuring unit and the length measuring unit respectively, and is used to perform data processing based on the received weight signal and length signal; The length measuring unit 20 includes: The measuring roller assembly has movable rollers that can move according to changes in rope tension; A tensioner having at least two pairs of elastic clamping elements with adjustable clamping spacing for applying pre-tension force to a rope or cable; A bidirectional transmission component, connected between the movable roller and the tensioner, is used to convert the unidirectional displacement of the movable roller into bidirectional adjustment that drives the clamping distance of the elastic clamping component to increase or decrease. The bidirectional transmission component has a first transmission path and a second transmission path. When the displacement of the movable roller is in the first range, the first transmission path is activated, driving the clamping distance to change in the decreasing direction. When the displacement of the movable roller is in the second range, the second transmission path is activated, driving the clamping distance to change in the increasing direction.

[0005] Preferably, the measuring roller assembly further includes a connecting frame and two guide rollers; The connecting frame is fixed to the machine frame, and a guide groove is provided on its upper part along the vertical direction; One end of the movable roller is slidably fitted into the guide groove via a sliding connecting seat; The two guide rollers are arranged in parallel on both sides of the movable roller and are rotatably connected to the connecting frame.

[0006] Preferably, the rope passes over the top of one of the guide rollers, the bottom of the movable roller, and the top of the other guide roller to form a "U"-shaped winding path.

[0007] Preferably, the tensioner includes a first reed drive shaft, a second reed drive shaft, and spring plates respectively disposed on the first reed drive shaft and the second reed drive shaft; The first and second spring drive shafts are linked by a transmission gear set to ensure that the clamping distance of the two pairs of springs changes synchronously.

[0008] Preferably, the transmission gear set includes a driving gear, a driven gear, and a reversing gear; The driving gear is fixed to one end of the first reed drive shaft, the driven gear is fixed to one end of the second reed drive shaft, and the reversing gear is rotatably supported in the housing and simultaneously meshes with the driving gear and the driven gear. The ratio of the number of teeth of the driving gear to the number of teeth of the driven gear is set according to the ratio of the effective lever arm lengths of the two pairs of spring plates, so as to ensure that the displacement of the clamping points of the two pairs of clamping members is equal.

[0009] Preferably, it further includes a synchronizing element, which includes a timing pulley, a reversing pulley, and a timing belt; The two synchronous pulleys are respectively fixed to the ends of the first and second reed drive shafts away from the transmission gear set. The two reversing pulleys are rotatably supported in the housing and located between the two synchronous pulleys. The synchronous belt passes around one of the synchronous pulleys, the two reversing pulleys and the other synchronous pulley in sequence to form a closed loop.

[0010] Preferably, the bidirectional transmission component includes a first rack and a second rack, both of which are arranged in a vertical direction and selectively mesh with an adjusting gear fixed on the first spring drive shaft; The length of the first rack is twice the length of the second rack, and the positions of their teeth are staggered and complementary, so that the adjusting gear meshes with the first rack or the second rack individually in different ranges of the movable roller displacement.

[0011] Preferably, the upper part of the first rack has continuous teeth, and the lower part is a smooth section without teeth; the second rack has continuous teeth, and the position of its teeth corresponds to the smooth section of the first rack. The first rack and the second rack are located on both sides of the adjusting gear and mesh with it.

[0012] Preferably, the control unit has preset linear density data corresponding to different wire diameters, and is configured as follows: In the length measurement mode, length measurement is the primary method, while the length measurement results are verified based on weight changes. In the weight measurement mode, weight measurement is the primary method, while the weight measurement results are verified based on length measurement.

[0013] A method for intelligent metering and synchronous control of rope winding, applied to the aforementioned intelligent metering and synchronous control device for rope winding, includes the following steps: The change in rope tension is sensed by the measuring roller group, and the movable roller produces a corresponding vertical displacement; The unidirectional displacement of the movable roller is converted into a bidirectional adjustment that increases or decreases the clamping distance of the elastic clamping component of the driving tensioner by a bidirectional transmission component, so that the rope tension is kept constant. The cumulative length of the rope passing through is detected in real time by the length measuring unit, and the length signal is transmitted to the control unit. The weight measurement unit monitors the weight change of the wire coil at the pay-off end in real time and transmits the weight signal to the control unit. The control unit performs dual-core processing on the received length and weight signals based on preset line density data, and issues a control command when the set target is reached.

[0014] As can be seen from the above technical solutions, this application has the following beneficial effects: 1. By setting a transmission gear set, the first spring drive shaft and the second spring drive shaft are linked together, and a synchronizing element is set to ensure that the two spring plates on the same drive shaft move synchronously. At the same time, the ratio of the number of teeth of the driving gear to the number of teeth of the driven gear is set according to the ratio of the effective lever arm lengths of the two pairs of spring plates, ensuring that the displacement of the clamping point of the two pairs of spring plates is always equal. 2. By setting up a structure that coordinates the measuring roller group with the bidirectional transmission component, the movement roller's own weight is used to sense changes in wire tension. The unidirectional displacement of the movement roller is converted into a bidirectional adjustment signal that drives the elastic clamping component to increase or decrease the clamping distance through the first and second transmission paths of the bidirectional transmission component. This enables the movement roller to drive the clamping distance to change in the direction of decreasing or increasing when the displacement is in different ranges, allowing the tensioner to automatically adapt to the tension requirements of wires of different diameters and materials. This solves the problem of existing reed-type tensioners relying on manual adjustment and being unable to self-adjust. 3. By setting up a control unit that coordinates the weight measurement unit and the length measurement unit, the control unit presets linear density data corresponding to different wire diameters and configures it to prioritize length measurement and supplement weight verification in length measurement mode, and prioritize weight measurement and supplement length verification in weight measurement mode, thus realizing dual verification measurement. Attached Figure Description

[0015] 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 only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0016] Figure 1 A schematic diagram of the overall structure of a rope winding intelligent metering and synchronous control device provided by the present invention; Figure 2 A schematic diagram of the overall structure of the length measuring unit of a rope winding intelligent measuring and synchronous control device provided by the present invention; Figure 3 A schematic diagram of the overall structure of a tensioner in a rope winding intelligent metering and synchronous control device provided by the present invention; Figure 4 A schematic diagram of the overall structure of the tensioner in a rope winding intelligent metering and synchronous control device provided by the present invention; Figure 5 A schematic diagram of the overall structure of a bidirectional transmission component for a rope winding intelligent metering and synchronous control device provided by the present invention; Figure 6 A partial cross-sectional view of the tensioner structure of an intelligent metering and synchronous control device for rope winding provided by the present invention; Figure 7 A schematic diagram of the overall structure of the first spring drive shaft of a rope winding intelligent metering and synchronous control device provided by the present invention; Figure 8 This is a schematic diagram of the overall structure of the second reed drive shaft of a rope winding intelligent metering and synchronization control device provided by the present invention. Attached image description: 10. Weight Measurement Department; 20. Length Measurement Department; 21. Rack; 22. Measuring roller assembly; 221. Connecting frame; 2221. Guide groove; 222. Sliding connecting seat; 223. Movable roller; 224. Guide roller; 23. Tensioner; 231. Housing; 232. First spring drive shaft; 233. Second spring drive shaft; 2331. Extension arm; 2332. Fixed clamping roller; 234. Transmission gear set; 2341. Driving gear; 2342. Driven gear; 2343. Reversing gear; 235. Synchronizing element; 2351. Synchronous pulley; 2352. Reversing pulley; 2353. Synchronous belt; 236. Spring plate; 237. Adjusting gear; 24. Bidirectional transmission component; 241. First rack; 242. Second rack; 25. Horn wire nozzle; 26. Measuring wheel; 27. Guide wheel assembly; 28. Ceramic wire sleeve; 30. Control unit. Detailed Implementation

[0018] The following description is exemplary in nature and is not intended to limit the scope, application, or use of this disclosure. It should be understood that in all these figures, the same or similar reference numerals indicate the same or similar parts and features. The figures are merely schematic representations of the concept and principles of embodiments of this disclosure and do not necessarily show the specific dimensions and scale of the various embodiments of this disclosure. Certain details or structures of embodiments of this disclosure may be exaggerated in particular portions of certain figures.

[0019] Example 1, see Figures 1-8 As shown, a rope winding intelligent metering and synchronous control device includes a weight metering unit 10, a length metering unit 20, and a control unit 30. The weight metering unit 10 is used to monitor the weight change of the coil at the unwinding end in real time and transmit the weight signal to the control unit 30. The length metering unit 20 is used to adjust the tension and measure the length of the passing rope and transmit the length signal to the control unit 30. The control unit 30 performs data processing based on the received weight and length signals to achieve accurate metering and synchronous control of the rope winding process.

[0020] Specifically, the length measuring unit 20 includes a frame 21, a measuring roller assembly 22, a tensioner 23, a bidirectional transmission component 24, a horn-shaped wire nozzle 25, a length measuring wheel 26, a guide wheel assembly 27, and a ceramic wire sleeve 28. The frame 21 serves as the mounting base and is used to support the above-mentioned components. Along the direction of rope travel, the measuring roller assembly 22, the horn-shaped wire nozzle 25, the tensioner 23, the ceramic wire sleeve 28, the guide wheel assembly 27, and the length measuring wheel 26 are arranged in sequence, and the bidirectional transmission component 24 is located behind the horn-shaped wire nozzle 25 and is linked with the tensioner 23 and the measuring roller assembly 22. The measuring roller assembly 22 includes a connecting frame 221, a sliding connecting seat 222, a movable roller 223, and two guide rollers 224. The connecting frame 221 is fixed to the frame 21, and a guide groove 2221 is formed vertically on its upper part. One end of the movable roller 223 is rotatably connected to the sliding connecting seat 222 via a bearing. The sliding connecting seat 222 is slidably fitted into the guide groove 2221, allowing the movable roller 223 to move up and down along the guide groove 2221. The two guide rollers 224 are arranged parallel to each other on both sides of the movable roller 223 and are rotatably connected to the connecting frame 221. After the rope is introduced from the unwinding end, it first passes over one of the guide rollers. Above 224, the rope passes from bottom to top around the underside of the movable roller 223, and finally exits from above another guide roller 224, thus forming a "U"-shaped winding path. Since the movable roller 223 has its own weight, when the rope passes through, the tension of the rope will overcome the self-weight of the movable roller 223 and make it move upward. Conversely, when the tension decreases, the movable roller 223 moves downward under its own weight. That is, the vertical displacement of the movable roller 223 is positively correlated with the tension of the rope. A connecting rod is fixed on the surface of the sliding connecting seat 222. The connecting rod is fixed to the bidirectional transmission component 24 and is used to transmit the displacement of the movable roller 223 to the tensioner 23.

[0021] The horn-shaped nozzle 25 is positioned above the measuring roller assembly 22. It has a horn-shaped inlet and a smaller diameter outlet. It is used to gather the rope coming out of the measuring roller assembly 22 and guide it onto a stable path to prevent the rope from deviating due to lateral swaying during unwinding. The outlet of the horn-shaped nozzle 25 faces the inlet of the tensioner 23. Tensioner 23 is used to apply a controllable pre-tension force to the rope to accommodate ropes of different diameters and materials, and to provide stable tension conditions for subsequent length measurement; tensioner 23 includes housing 231, first spring drive shaft 232, second spring drive shaft 233, transmission gear set 234, synchronizing element 235, spring plate 236 and adjusting gear 237. The outer casing 231 is fixed to the frame 21; the first spring drive shaft 232 and the second spring drive shaft 233 are rotatably supported inside the outer casing 231, parallel and spaced apart, and the axes of both are horizontal and perpendicular to the direction of rope travel; the first spring drive shaft 232 has two opposite shafts, and a spring plate 236 is fixed on each of the two first spring drive shafts 232. The two spring plates 236 are spaced apart along the axial direction to form a first pair of clamping members; the second spring drive shaft 233 also has two opposite shafts, and each one is fixed with a spring plate 236 to form a second pair of clamping members; In each pair of clamping components, the two spring plates 236 are arranged opposite each other in a figure-eight shape, with the free ends of the spring plates 236 facing the rope travel channel; the rope passes between the two pairs of spring plates 236. The clamping distance between the spring plates 236 determines the magnitude of its clamping force on the rope. That is, the smaller the distance between the free ends of the two spring plates 236 in the same pair, the greater the clamping force; conversely, the larger the clamping distance, the smaller the clamping force.

[0022] To achieve synchronous adjustment of the two pairs of clamping members, the transmission gear set 234 includes a driving gear 2341, a driven gear 2342, and a reversing gear 2343. The driving gear 2341 is fixed to one end of the first reed drive shaft 232, and the driven gear 2342 is fixed to one end of the second reed drive shaft 233. The gear ratio of the driving gear 2341 to the driven gear 2342 is set according to the ratio of the effective lever arm lengths of the first pair of clamping members and the second pair of clamping members, so as to ensure the clamping points of the two pairs of clamping members are aligned. The displacements are equal, and the effective lever arm length refers to the horizontal distance from the center of the drive shaft to the spring clamping point. The reversing gear 2343 is rotatably supported in the housing 231 and meshes with both the driving gear 2341 and the driven gear 2342. Its function is to reverse the rotation direction of the driving gear 2341 and transmit it to the driven gear 2342, so that the first spring drive shaft 232 and the second spring drive shaft 233 can rotate in opposite directions, thereby realizing the synchronous increase or decrease of the clamping distance between the two pairs of clamping members.

[0023] Synchronizing element 235 is used to ensure that the two spring plates 236 on the same drive shaft move synchronously. Specifically, synchronizing element 235 includes a synchronous pulley 2351, a reversing pulley 2352, and a synchronous belt 2353. The two synchronous pulleys 2351 are respectively fixed to the ends of the first spring plate drive shaft 232 and the second spring plate drive shaft 233 away from the transmission gear set 234. There are two reversing pulleys 2352, which are rotatably supported in the housing 231 and located between the two synchronous pulleys 2351. The synchronous belt 2353 passes around one of the synchronous pulleys 2351, the two reversing pulleys 2352, and the other synchronous pulley 2351 in sequence to form a closed loop. Through the synchronous belt drive, when the first spring plate drive shaft 232 rotates, the second spring plate drive shaft 233 also rotates synchronously and in the opposite direction, thereby ensuring that the clamping distance of the two pairs of clamping members is always equal.

[0024] An extension arm 2331 is also fixedly connected to the second reed drive shaft 233. The end of the extension arm 2331 is provided with a fixed clamping roller 2332. The extension arm 2331 is used to transmit the rotation of the second reed drive shaft 233 to the fixed clamping roller 2332. By setting the extension arm 2331, the rotation center of the second reed drive shaft 233 can be shifted outward relative to the clamping point of the spring 236 on it, while ensuring that the two pairs of spring plates 236 have the same length, width and thickness. This achieves a compact layout of the overall structure of the tensioner 23 and avoids increasing the size of the equipment due to the excessive distance between the drive shafts.

[0025] An adjusting gear 237 is fixed to the end of the first reed drive shaft 232. This adjusting gear 237 meshes with the bidirectional transmission member 24 and is used to receive displacement signals from the measuring roller group 22, thereby automatically adjusting the clamping distance. The bidirectional transmission member 24 includes a first rack 241 and a second rack 242, both arranged vertically, with the length of the first rack 241 being twice the length of the second rack 242. The first rack 241 and the second rack 242 are arranged parallel and spaced apart on both sides of the adjusting gear 237. The upper part of the first rack 241 has continuous teeth, and the lower part is a smooth, toothless section. The second rack 242 has continuous teeth, filling in the smooth section of the first rack 241. The first rack 241 and the second rack 242 respectively mesh with the adjusting gear 237. The two sides of the gear 237 mesh, and the teeth of the two sides are staggered, so that the first rack 241 or the second rack 242 drives the adjusting gear 237 to rotate in different ranges of the displacement of the movable roller 223, thereby realizing segmented adjustment. Specifically, when the movable roller 223 is in a low position, the teeth of the first rack 241 mesh with the adjusting gear 237. As the movable roller 223 moves upward, the first rack 241 drives the adjusting gear 237 to rotate at a certain angle, and then the teeth of the first rack 241 disengage. At the same time, the teeth of the second rack 242 begin to mesh with the adjusting gear 237, driving it to rotate in the opposite direction. In this way, the unidirectional displacement of the movable roller 223 can be converted into the bidirectional rotation of the adjusting gear 237, thereby realizing both increasing and decreasing the clamping distance. For example, when a thin, soft thread, such as a 0.5mm diameter cotton thread, is threaded through, its upward lifting force on the movable roller 223 is relatively small due to its thin diameter and soft material. The movable roller 223 is only lifted to a low height, within the first adjustment range. At this time, the teeth of the first rack 241 are engaged with the adjusting gear 237. As the movable roller 223 is lifted, the first rack 241 moves upward, driving the adjusting gear 237 to rotate. This rotation is transmitted to the two pairs of spring plates 236 through the transmission chain, reducing the clamping distance. The reduced clamping distance means that the clamping force of the spring plates 236 on the thread increases, thereby increasing the friction when the thread passes through, causing the thread tension to rise. When the thread tension rises to a certain level, the movable roller 223 is lifted further until a certain equilibrium height is reached, and the system tends to stabilize. When the thick, stiff wire is inserted, its large diameter and high stiffness result in a significant upward lifting force on the movable roller 223. The movable roller 223 is lifted to a considerable height and enters the second adjustment zone. As the movable roller 223 moves from the first zone to the second zone, the teeth of the first rack 241 gradually disengage from the adjusting gear 237, while the teeth of the second rack 242 begin to engage with the adjusting gear 237. As the movable roller 223 continues to move upward, the second rack 242 moves upward, driving the adjusting gear 237 to rotate in the opposite direction. This reverse rotation increases the clamping distance and reduces the clamping force of the spring plate 236 on the wire, thereby reducing the friction when the wire passes through and causing the wire tension to decrease. When the wire tension decreases to a certain level, the movable roller 223 slightly falls back until it reaches a certain equilibrium height, and the system tends to stabilize. For elastic wires, the tension may frequently change during operation due to factors such as speed fluctuations and the wire's own expansion and contraction. If the wire tension suddenly increases at a certain moment, the movable roller 223 is quickly lifted. If the lifting height exceeds the first interval and enters the second interval, the second rack 242 drives the adjusting gear 237 to rotate in the opposite direction, increasing the clamping distance and decreasing the clamping force, thereby suppressing further tension increases and causing the tension to drop. Conversely, if the tension suddenly decreases, the movable roller 223 descends and re-enters the first interval. The first rack 241 drives the adjusting gear 237 to rotate in the forward direction, decreasing the clamping distance and increasing the clamping force, causing the tension to rise again. In this way, the system maintains automatic tension adjustment throughout the dynamic process, keeping the tension stable near the target value. As can be seen from the above example, this segmented adjustment mechanism utilizes the unidirectional displacement of the movable roller 223, combined with the alternating meshing of the first rack 241 and the second rack 242, to achieve bidirectional adjustment of the clamping distance. This allows the tensioner 23 to automatically adapt to the tension requirements of wires of different diameters and materials, maintaining a relatively constant working tension. This adjustment process is entirely achieved by the mechanical structure, without the need for electronic sensors and control programs, and features fast response, high reliability, and low cost.

[0026] Above the tensioner 23, a ceramic cable sleeve 28, a guide wheel assembly 27, and a length measuring wheel 26 are arranged in sequence. The ceramic cable sleeve 28 is U-shaped, and its inner wall is made of smooth ceramic material. It is used to guide the rope and reduce friction, and at the same time, the U-shaped structure stabilizes the direction of the rope. The guide wheel assembly 27 consists of multiple guide wheels. The specific number and arrangement of these guide wheels can be determined by those skilled in the art according to actual needs. Its main function is to ensure that the rope passes smoothly through the length measuring wheel 26. An encoder is coaxially connected to the length measuring wheel 26. The encoder is used to detect the number of rotations of the length measuring wheel 26, thereby calculating the cumulative length of the rope. The encoder transmits the length signal to the control unit 30 in real time.

[0027] The weight measuring unit 10 is an electronic scale with a 485 communication interface, which is connected to the control unit 30. The weight measuring unit 10 is used to measure the weight change of the wire coil at the unwinding end in real time and send the weight data to the control unit 30. The control unit 30 can verify the length measurement results or control the winding length according to the weight requirements based on the preset wire linear density (in grams per meter) and the length data fed back by the length measuring unit 20.

[0028] The control unit 30 includes an industrial control computer or a programmable logic controller, equipped with a touch-screen industrial control panel for parameter setting, data display, and operation command input; the control unit 30 internally stores a control program that can perform the following functions: It receives the weight signal sent by the weight measuring unit 10 and the length signal sent by the encoder of the length measuring wheel 26 in real time; Based on preset wire diameter or linear density parameters, the length and weight data are processed to calculate the cumulative length and remaining weight of the current wire roll. In length measurement mode, the encoder is used as the primary measure of length, while weight changes are used to verify the length measurement result. If the deviation between the two exceeds the set threshold, an alarm will be issued or the length measurement coefficient will be automatically corrected. In the weight measurement mode, the weight change is the primary factor, while the weight is verified by measuring the length using an encoder. According to the set target, such as target length or target weight, when the target value is reached, the control unit 30 sends a stop signal or outputs a control command to the drive device of the rear winding equipment to realize synchronous stop or roll change. The industrial control screen displays parameters such as current line length, line weight, and speed in real time, and supports historical data query.

[0029] Example 2, based on Example 1, describes a method for using a smart metering and synchronous control device for rope winding, further illustrating a dual-core control method using weight and length metering; the control unit 30 has preset linear density data corresponding to different wire diameters, in grams per meter, and the operator can select the currently used wire diameter through the industrial control screen or manually input the linear density value; When the device aims to measure length, i.e., the target product is measured in meters, the control unit 30 executes the following steps: Retrieve the corresponding preset linear density value based on the selected wire diameter; Start winding, and the encoder of length measuring wheel 26 accumulates the number of pulses in real time, which is then converted to obtain the current wound length L; Meanwhile, the weight measurement unit 10 monitors the weight change of the wire coil at the pay-off end in real time and obtains the consumed weight ΔW. The control unit 30 calculates the theoretical weight consumption ΔW based on the preset linear density ρ. theory =L×ρ; Compare ΔW with ΔW theory If the difference between the two is within the allowable error range, the winding continues; if the difference exceeds the threshold, the control unit 30 corrects the length measurement according to the actual weight change, such as correcting the pulse equivalent of the encoder, or issuing an alarm to prompt the operator to check whether the wire is abnormal. When the cumulative length L reaches the set target length, the control unit 30 issues a stop signal and records the final length and the actual weight consumed. When the device aims to measure weight, i.e., the target product is in grams, the control unit 30 executes the following steps: Retrieve the corresponding preset linear density value based on the selected wire diameter; Start winding, and the weight metering unit 10 monitors the weight change in real time to obtain the consumed weight ΔW; Simultaneously, the encoder accumulates the length L in real time; Control unit 30 calculates the theoretical length L based on the preset linear density ρ. theory =ΔW / ρ; Compare L and L theory If the difference between the two is within the allowable error range, the winding continues; if the difference exceeds the threshold, the weight measurement is corrected or an alarm is triggered based on the actual length. When the cumulative weight ΔW reaches the set target weight, the control unit 30 issues a stop signal; Through the aforementioned dual-core mechanism, this embodiment can effectively compensate for measurement errors caused by factors such as uneven wire density and tension changes, thereby achieving high-precision rope winding measurement.

[0030] The permissible error range shall be determined by those skilled in the art based on the actual circumstances.

[0031] The exemplary implementation of the solution proposed in this disclosure has been described in detail above with reference to preferred embodiments. However, those skilled in the art will understand that various modifications and alterations can be made to the above specific embodiments without departing from the spirit of this disclosure, and various combinations can be made to the various technical features and structures proposed in this disclosure without exceeding the protection scope of this disclosure, which is determined by the appended claims.

Claims

1. A smart metering and synchronous control device for rope winding, characterized in that: include: The weight measuring unit (10) is used to monitor the weight change of the wire coil at the unwinding end and output a weight signal; The length measuring unit (20) is used to adjust the tension and measure the length of the rope and output a length signal; The control unit (30) is connected to the weight measuring unit (10) and the length measuring unit (20) respectively, and is used to perform data processing based on the received weight signal and length signal; The length measuring unit (20) includes: The measuring roller assembly (22) has a movable roller (223) that can move with the change of rope tension; Tensioner (23) has at least two pairs of elastic clamps with adjustable clamping spacing for applying pre-tension force to the rope; A bidirectional transmission component (24) is connected between the movable roller (223) and the tensioner (23) to convert the unidirectional displacement of the movable roller (223) into bidirectional adjustment that drives the clamping distance of the elastic clamping component to increase or decrease. The bidirectional transmission component (24) has a first transmission path and a second transmission path. When the displacement of the movable roller (223) is in the first interval, the first transmission path is connected, driving the clamping distance to change in the decreasing direction. When the displacement of the movable roller (223) is in the second interval, the second transmission path is connected, driving the clamping distance to change in the increasing direction.

2. The intelligent metering and synchronous control device for rope winding according to claim 1, characterized in that, The measuring roller assembly (22) also includes a connecting frame (221) and two guide rollers (224). The connecting frame (221) is fixed on the frame (21), and a guide groove (2221) is provided on its upper part in the vertical direction. One end of the movable roller (223) is slidably fitted into the guide groove (2221) via the sliding connecting seat (222); The two guide rollers (224) are arranged in parallel on both sides of the movable roller (223) and are rotatably connected to the connecting frame (221).

3. The intelligent metering and synchronous control device for rope winding according to claim 2, characterized in that, The cord passes over the top of one of the guide rollers (224), the bottom of the movable roller (223), and the top of the other guide roller (224) to form a "U"-shaped winding path.

4. The intelligent metering and synchronous control device for rope winding according to claim 1, characterized in that, The tensioner (23) includes a first reed drive shaft (232), a second reed drive shaft (233), and spring plates (236) respectively disposed on the first reed drive shaft (232) and the second reed drive shaft (233). The first spring drive shaft (232) and the second spring drive shaft (233) are linked by a transmission gear set (234) to ensure that the clamping distance of the two pairs of spring plates (236) changes synchronously.

5. The intelligent metering and synchronous control device for rope winding according to claim 4, characterized in that, The transmission gear set (234) includes a driving gear (2341), a driven gear (2342), and a reversing gear (2343). The driving gear (2341) is fixed to one end of the first reed drive shaft (232), the driven gear (2342) is fixed to one end of the second reed drive shaft (233), and the reversing gear (2343) is rotatably supported in the housing (231) and simultaneously meshes with the driving gear (2341) and the driven gear (2342); The ratio of the number of teeth of the driving gear (2341) to the number of teeth of the driven gear (2342) is set according to the ratio of the effective lever arm lengths of the two pairs of spring plates (236) to ensure that the displacement of the clamping points of the two pairs of clamping members is equal.

6. The intelligent metering and synchronous control device for rope winding according to claim 4, characterized in that, It also includes a synchronizing element (235), which includes a timing pulley (2351), a reversing pulley (2352), and a timing belt (2353). The two synchronous pulleys (2351) are respectively fixed to the ends of the first reed drive shaft (232) and the second reed drive shaft (233) away from the transmission gear set (234). The two reversing pulleys (2352) are rotatably supported in the housing (231) and located between the two synchronous pulleys (2351). The synchronous belt (2353) passes around one of the synchronous pulleys (2351), the two reversing pulleys (2352) and the other synchronous pulley (2351) in sequence to form a closed loop.

7. The intelligent metering and synchronous control device for rope winding according to claim 1, characterized in that, The bidirectional transmission component (24) includes a first rack (241) and a second rack (242), both of which are arranged in a vertical direction and selectively mesh with an adjusting gear (237) fixed on the first spring drive shaft (232); The length of the first rack (241) is twice the length of the second rack (242), and the positions of their teeth are staggered and complementary, so that the adjusting gear (237) meshes with the first rack (241) or the second rack (242) individually in different ranges of the displacement of the movable roller (223).

8. The intelligent metering and synchronous control device for rope winding according to claim 7, characterized in that, The first rack (241) has continuous teeth on the upper part and a smooth section without teeth on the lower part; the second rack (242) has continuous teeth, and the position of its teeth corresponds to the smooth section of the first rack (241). The first rack (241) and the second rack (242) are located on both sides of the adjusting gear (237) and mesh with it.

9. The intelligent metering and synchronous control device for rope winding according to claim 1, characterized in that, The control unit (30) has preset linear density data corresponding to different wire diameters and is configured as follows: In the length measurement mode, length measurement is the primary method, while the length measurement results are verified based on weight changes. In the weight measurement mode, weight measurement is the primary method, while the weight measurement results are verified based on length measurement.

10. A method for intelligent metering and synchronous control of rope winding, applied to the intelligent metering and synchronous control device for rope winding as described in any one of claims 1 to 9, characterized in that, Includes the following steps: By sensing the change in rope tension through the measuring roller group (22), the movable roller (223) generates a corresponding vertical displacement; The unidirectional displacement of the movable roller (223) is converted into bidirectional adjustment of the clamping distance of the elastic clamping member of the driving tensioner (23) by the bidirectional transmission component (24), so that the rope tension is kept constant. The cumulative length of the rope passing through the length metering unit (20) is detected in real time, and the length signal is transmitted to the control unit (30). The weight change of the wire coil at the pay-off end is monitored in real time by the weight measuring unit (10), and the weight signal is transmitted to the control unit (30). The control unit (30) performs dual-core processing on the received length signal and weight signal according to the preset line density data, and issues a control command when the set target is reached.

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