A tension cable position feedback system and method of using the same

Abstract

The present application relates to the technical field of marine engineering equipment and ship operation control, and particularly relates to a tension cable position feedback system and a use method thereof, which comprises a mechanical execution module, a sensor assembly, a hydraulic drive module and a data calculation module; the mechanical execution module comprises an A-shaped frame, a winch with heave compensation and a load placing frame, and is arranged in an operation area of a ship; the hydraulic drive module is arranged beside the mechanical execution module and is in transmission connection with a driving hydraulic cylinder of the A-shaped frame and the winch through a hydraulic pipeline; the sensor assembly comprises a proximity switch, a central control encoder, an incremental main shaft encoder, an absolute value main shaft encoder and a single-pulley tension sensor, and is arranged at a structural position of the mechanical execution module and the hydraulic drive module; and the data calculation module is connected with the mechanical execution module, the hydraulic drive module and the sensor assembly respectively. The method is low in cost, accurate in calculation and recyclable.

Description

Technical Field

[0001] This invention relates to the field of marine engineering equipment and ship operation control technology, specifically to a tension cable position feedback system and its usage method. Background Technology

[0002] With the rapid development of marine engineering projects such as deep-sea oil and gas exploration, floating wind power construction, underwater equipment positioning, and ship-borne load transfer, the demand for high-precision positioning of offshore vessels and floating platforms is becoming increasingly prominent. These types of equipment typically rely on dynamic positioning systems to counteract the heave, roll, and pitch caused by environmental disturbances such as wind, waves, and currents, maintaining their stability at the target operating position. The control accuracy of the dynamic positioning system directly depends on the real-time position deviation data provided by the tension cable position feedback system. As a key component connecting the surface vessel to the underwater reference point or load, the tension cable's position feedback system calculates the deviation between the vessel's current position and the target position by measuring the cable's length, angle, tension, and vessel attitude data, thus providing the dynamic positioning system with adjustment commands. Therefore, the performance of the tension cable position feedback system directly affects the safety and operational efficiency of marine engineering projects.

[0003] However, existing tension cable position feedback systems and their application methods have significant technical shortcomings in complex sea conditions. First, traditional systems lack high-precision sensor configurations and collaborative measurement mechanisms, resulting in lag in angle measurements and cumulative errors in length measurements. Second, the systems have insufficient dynamic interference compensation capabilities; the lack of integration between the winch tension compensation mechanism and the single pulley tension sensor during operation means that when the vessel experiences heave and sway due to wind and waves, the cable tension fluctuates violently, further exacerbating measurement errors and distorting the position feedback data. These technical deficiencies make it difficult for traditional systems to provide stable and accurate position feedback for dynamic positioning systems, affecting not only the accuracy of load transfer and underwater equipment positioning but also potentially leading to safety accidents such as cable breakage or equipment collisions. Therefore, there is an urgent need to develop a novel tension cable position feedback system and its application method based on high-precision sensing, dynamic compensation, and closed-loop collaborative design to improve the positioning accuracy of vessels at sea and meet the technical requirements of marine engineering. Summary of the Invention

[0004] To address the technical problems of traditional tension cable position feedback systems, such as insufficient tension control accuracy, susceptibility to sensor lag and cumulative errors, lack of dynamic heave compensation mechanisms, and poor coordination between mechanical execution and data processing, making them unsuitable for high-precision marine operations in complex sea conditions, this invention provides a tension cable position feedback system and its application method. This invention primarily utilizes a tension-compensated winch, a dual-drive A-frame, and a load anti-collision frame, combined with multiple types of waterproof and explosion-proof sensors to synchronously collect cable and attitude data. The data calculation module is linked with a preset model to adjust the A-frame attitude, winch tension, and deployment / retraction speed in real time, achieving closed-loop control. Simultaneously, sensor data feedback on the ship's attitude triggers automatic propeller adjustments, offsetting interference from both local and overall perspectives to ensure precise load positioning. This results in ultra-precise cable control, long-term stable load maintenance at the target position, and advantages such as high operational accuracy, extremely strong dynamic stability, and excellent sea condition adaptability.

[0005] The technical means employed in this invention are as follows:

[0006] A tension cable position feedback system includes: a mechanical actuation module, a sensor assembly, a hydraulic drive module, and a data calculation module; The mechanical actuation module includes an A-frame, a winch with heave compensation, and a load placement frame, and the mechanical actuation module is located in the operating area of ​​the ship; The hydraulic drive module is located next to the mechanical execution module and is connected to the drive hydraulic cylinder of the A-frame and the winch transmission via hydraulic pipelines. The sensor assembly includes a proximity switch, a hollow encoder, an incremental spindle encoder, an absolute spindle encoder, and a single pulley tension sensor. The sensor assembly is located in the structural position of the mechanical actuation module and the hydraulic drive module. The data calculation module is connected to the mechanical execution module, the hydraulic drive module, and the sensor assembly, respectively.

[0007] Furthermore, the A-frame includes two symmetrically arranged supports, a hydraulic cylinder, and a hinge shaft. The A-frame is rotatably connected to the ship's base via the hinge shaft. The piston rods of the hydraulic cylinders are respectively hinged to the outer sides of the middle of the two supports. The hydraulic cylinders are connected to a hydraulic drive module via hydraulic pipelines to adjust the opening and closing angle of the A-frame.

[0008] Furthermore, the winch includes a drum, a tension compensation mechanism, and a cable laying linkage interface. The tension compensation mechanism includes a compensation hydraulic cylinder, a tension feedback interface, and a stroke limit block. The piston rod of the compensating hydraulic cylinder is connected to the rear end cover of the drum via a flange; the tension feedback interface communicates with the single pulley tension sensor via a signal line; and the cable guide linkage interface is connected to the gear set of the cable guide via a drive shaft. The winch is located below the pulley of the A-frame, and the load placement frame is located below the load end. The winch cable extends to the load end of the A-frame after being guided by the pulley and is connected to the load. The load is placed on the load placement frame.

[0009] Furthermore, the load end of the A-frame is provided with a load anti-collision frame, which includes an outer metal frame and an inner buffer assembly, the inner buffer assembly being a rubber pad.

[0010] Furthermore, the hydraulic drive module includes a hydraulic pump, a control valve group, and hydraulic pipelines. The output end of the hydraulic pump is connected to the control valve group through the hydraulic pipelines, the output port of the control valve group is connected to the hydraulic cylinder through the hydraulic pipelines, and the control valve group is also connected to the hydraulic oil tank through the return oil pipeline.

[0011] Furthermore, the proximity switch is located at the opening and closing position of the A-frame limiting plate, the winch drum end cover, and the load placement frame positioning slot. The proximity switch is connected to the data calculation module via a signal line. The hollow encoder is located at the cable outlet of the load end of the A-frame. The cable passes through the center hole of the hollow encoder. The hollow encoder is used to collect the rotation angle of the x-axis cable. The hollow encoder communicates with the data calculation module through a signal line. The incremental spindle encoder is located at the load end of the A-frame and is used to acquire the rotation angle of the y-axis cable. The absolute value spindle encoder is mounted on a bracket next to the winch and is used to detect the winch drum to obtain the cable length. The single pulley tension sensor is located on the cable path, and the single pulley tension sensor transmits cable tension data to the data calculation module through a signal line.

[0012] Furthermore, the data calculation module calculates the translation of the rope exit point based on the cable length, cable angle, and ship attitude angle. Based on this translation, it obtains the horizontal coordinate parameters and vertical height parameters for the ship positioning operation. The position of the ship's dynamic positioning system is then adjusted based on these parameters. The formula for calculating the translation of the rope exit point is:

[0013]

[0014]

[0015] in, x Let x be the translation along the x-axis. L The length of the cable. The x-axis represents the cable rotation angle. For ship pitching, The y-axis represents the cable rotation angle. For the ship to roll, y This represents the translation along the y-axis. H This represents the translation in the height direction.

[0016] Furthermore, the data calculation module is based on the cable tension data collected by the single pulley tension sensor. When the cable tension data is less than 95% of the preset tension threshold or greater than 105% of the preset tension threshold, the hydraulic drive module drives the hydraulic cylinder to perform an action to achieve cable tension adjustment.

[0017] The present invention also provides a method for using a tension cable position feedback system, which is based on the above-described tension cable position feedback system and includes the following steps: When the hydraulic drive module is started, the hydraulic pump outputs pressurized oil to the A-frame drive hydraulic cylinder and winch tension compensation mechanism through the control valve group; The sensor assembly starts synchronously and collects data: the proximity switch confirms whether each mechanical component is in the preset alignment position, the hollow encoder and the main shaft encoder measure the angle and length of the cable respectively, the single pulley tension sensor collects the cable tension data, and the MRU angle sensor collects the ship's attitude data. The data calculation module compares the cable tension data collected by the single pulley tension sensor with the preset tension threshold. When the cable tension data is less than 95% of the preset tension threshold or greater than 105% of the preset tension threshold, the hydraulic drive module drives the hydraulic cylinder to perform an action to achieve cable tension compensation. On the other hand, it adjusts the position of the ship's dynamic positioning system based on the cable length, cable angle, and ship attitude angle. The hydraulic drive module adjusts the opening and closing posture of the A-frame according to the control command. The winch, together with the cable laying device, realizes the uniform winding and unwinding of the cable. The tension compensation mechanism of the winch will adjust the compensation amount in real time according to the tension data transmitted by the single pulley tension sensor. In the event of an accident during load transfer, the load anti-collision frame acts as a buffer against the impact, ultimately ensuring a stable operation.

[0018] Furthermore, when the single pulley tension sensor detects that the cable tension exceeds the preset range, the compensation hydraulic cylinder in the tension compensation mechanism will adjust the position of the drum through extension and retraction, effectively offsetting the effect of the ship's heave motion on the cable tension in real time.

[0019] Compared with the prior art, the present invention has the following advantages: 1. Compared with traditional tension cable systems, this invention stabilizes cable tension in real time through a winch with tension compensation. At the same time, the data calculation module sends coordinated instructions to the ship's propeller control system, using propeller power to correct the ship's attitude, so that the load can maintain the target position even in wind, waves, and heave environments, improving operational stability. Moreover, the tension fluctuation is controlled within ±5% of the rated tension, avoiding the risk of cable breakage or platform drift.

[0020] 2. Compared with similar tension cable position feedback systems, this invention uses a combination of a hollow absolute encoder and an incremental spindle encoder to achieve lag-free measurement of cable angle and zero cumulative error measurement of length. It is equipped with a 9-axis MRU angle sensor to accurately capture the ship's attitude. At the same time, the control valve group and high-pressure pipeline of the hydraulic drive module have a short response time and can match changes in sea conditions in real time, ensuring a closed-loop efficient coordination of data acquisition, command output and action execution. It can meet the high-precision requirements of offshore equipment positioning, floating wind power installation and other applications.

[0021] 3. This invention constructs an integrated precision control system. In the mechanical execution module, the winch with tension compensation can offset the impact of ship heave and sway on cable tension in real time. The A-frame achieves flexible adjustment of its opening and closing posture through dual-drive hydraulic cylinders. The load anti-collision frame provides collision buffer protection, and the cable reel ensures uniform cable winding and unwinding. The sensor assembly uses multiple types of waterproof and explosion-proof sensors to simultaneously collect data on cable angle, length, tension, and ship attitude, avoiding the lag and cumulative errors of traditional sensors. The hydraulic drive module provides stable power to the mechanical components. Combined with the preset mathematical model of the data calculation module, it converts the data collected by the sensors into precise control commands, adjusting the A-frame attitude, winch tension compensation, and cable winding and unwinding speed in real time, realizing closed-loop coordination of the tension cable position feedback system. At the same time, the sensor assembly transmits the ship attitude deviation data to the data calculation module, which synchronously generates adjustment commands for the ship's propeller, enabling the ship to actively adjust its position and attitude through propeller power. From the two dimensions of system local compensation and ship overall position and attitude correction, it greatly offsets the interference of wind, waves, heave and sway on the ship and load position. This invention significantly improves system reliability and environmental adaptability, reduces failure rate, and extends service life through redundant sensor design, waterproof and explosion-proof structure, and impact protection.

[0022] Based on the above reasons, this invention can be widely applied in the fields of marine engineering equipment and ship operation control. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is an overall structural diagram of the tension cable position feedback system of the present invention.

[0025] Figure 2 This is a front view of the tension cable position feedback system of the present invention.

[0026] Figure 3 This is a left view of the tension cable position feedback system of the present invention.

[0027] Figure 4 This is an isometric view of the tension cable position feedback system of the present invention.

[0028] Figure 5 This is a left and right isometric view of the tension cable position feedback system of the present invention.

[0029] Figure 6 This is a cross-sectional view of a key component of the tension cable position feedback system of the present invention.

[0030] In the diagram: 1. Mechanical actuation module; 2. Sensor assembly; 3. Hydraulic drive module; 4. Data calculation module; 5. Electrical control cabinet; 6. A-frame; 7. Motor; 8. Load anti-collision frame; 9. Load; 10. Cable; 11. Load placement frame; 12. A-frame drive hydraulic cylinder; 13. Proximity switch; 14. Single pulley tension sensor; 15. Incremental spindle encoder; 16. Hollow encoder; 17. Cable puller; 18. Winch; 19. Absolute spindle encoder. Detailed Implementation

[0031] To enable those skilled in the art to better understand the present invention, 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. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0032] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0033] like Figure 1-6 As shown, this invention provides a tension cable position feedback system, comprising: a mechanical actuation module 1, a sensor assembly 2, a hydraulic drive module 3, and a data calculation module 4. Each module works collaboratively via mechanical connections, hydraulic lines, or signal cables, and is installed as a whole on a deck base in the ship's operating area to achieve precise release and retraction of the cable 10 and stable transfer of the load 9.

[0034] In the embodiments of the present invention, the core components of the tension cable position feedback system are all fixed to the steel structure base of the ship's operating area by bolts or flanges. The base surface has pre-set positioning holes to ensure the relative position accuracy of each component. Specifically, the hydraulic drive module 3 is installed on one side of the base via a flange, adjacent to the A-frame 6. Its outer shell is made of 304 stainless steel with an IP67 protection rating, suitable for humid and salt spray marine environments. The A-frame 6 is installed in the middle of the base via a hinge shaft, symmetrically distributed on both sides of the cable 10's operating path. A guide pulley (suitable for the diameter of the cable 10) is welded to the top, and the bottom is hinged to the A-frame drive hydraulic cylinder. The motor 7 is fixed to the other side of the base via a motor 7 seat, adjacent to the winch 18. Its output shaft is connected to the main shaft of the winch 18 via a flexible coupling. An explosion-proof asynchronous motor 7 is selected to meet the explosion-proof requirements for marine operations. The winch 18 is installed in the lower middle position of the base via a bearing seat. The drum axis is parallel to the ship's deck, and the drum surface... The surface is machined with cable 10 winding grooves (groove depth 5mm, groove spacing matches the diameter of cable 10), and the rear end integrates a heave compensation mechanism (hydraulic type); the cable puller 17 is installed above the winch 18 via a guide rail, and its screw is linked to the main shaft of the winch 18 via a gearbox, and can move laterally along the guide rail to ensure that the cable 10 is evenly wound on the drum of the winch 18; the load anti-collision frame 8 is fixed to both sides of the load 9 transfer path by expansion bolts, and has a gate-shaped structure with a height level with the center of gravity of the load 9; the load placement frame is installed at the end of the base, and the surface is covered with rubber pads for storing the load 9 to be transferred or completed; each sensor is fixed next to the corresponding component by a waterproof bracket or threaded connection, and the signal cables are centrally run through a metal corrugated pipe and connected to the data calculation module 4.

[0035] The mechanical actuation module 1 includes an A-frame 6, a winch 18 with heave compensation, and a load placement frame. The mechanical actuation module 1 is located in the operating area of ​​the ship.

[0036] The A-frame 6 includes two symmetrically arranged supports, a hydraulic cylinder, and a hinge shaft. The A-frame 6 is rotatably connected to the ship's base via the hinge shaft. The piston rods of the hydraulic cylinders are respectively hinged to the outer middle of the two supports. The hydraulic cylinders are connected to the hydraulic drive module 3 via hydraulic pipelines to adjust the opening angle of the A-frame 6.

[0037] Specifically, the A-frame 6 is a box-shaped steel structure (made of Q345 steel, with a wall thickness of 10mm), consisting of two symmetrical supports on the left and right. The middle of the supports is rotatably connected to the base ear plate via a hinge shaft, allowing for an opening and closing angle adjustment of + / -30°. The A-frame drive hydraulic cylinder is a double-acting single-rod hydraulic cylinder. The cylinder body is hinged to the base ear via a pin, and the piston rod end is hinged to the connecting ear in the middle of the A-frame 6 via a spherical bearing. The rodless chamber and rod chamber of the A-frame drive hydraulic cylinder are connected to the control valve group of the hydraulic drive module 3 via high-pressure hoses. The piston rod extends and retracts through the inflow and outflow of hydraulic oil, thereby driving the A-frame 6 to open and close, and adjusting the guide angle of the cable 10.

[0038] The winch 18 includes a drum, a tension compensation mechanism, and a linkage interface for the cable laying device 17. The tension compensation mechanism includes a compensation hydraulic cylinder, a tension feedback interface, and a stroke limit block.

[0039] The drum of winch 18 is made of 45# steel and heat treated. The main shafts at both ends are supported on bearing seats by tapered roller bearings. The heave compensation mechanism is integrated at the rear end of winch 18, including a compensation hydraulic cylinder, a displacement sensor and a tension feedback interface. The cylinder body of the compensation hydraulic cylinder is hinged to the base, and the piston rod is connected to the rear end cover of winch 18 through a flange. The tension feedback interface communicates with the single pulley tension sensor 14 through a shielded cable. When the tension of the cable 10 exceeds the preset range, the compensation hydraulic cylinder adjusts the axial position of winch 18 by extension and retraction to counteract the effect of ship heave on tension in real time.

[0040] The piston rod of the compensating hydraulic cylinder is connected to the rear end cover of the drum via a flange. The tension feedback interface communicates with the single pulley tension sensor 14 via a signal line. The linkage interface of the cable puller 17 is connected to the gear set of the cable puller 17 via a drive shaft.

[0041] The cable laying device 17 consists of a lead screw, a slider, a guide wheel, and a gearbox. The lead screw is mounted on both ends of the guide rail via bearings, and the slider is threadedly connected to the lead screw, with its bottom slidingly engaged with the guide rail. The input shaft of the gearbox is connected to the main shaft of the winch 18 via a coupling, and the output shaft meshes with the lead screw gear. The transmission ratio is 1:5, ensuring that the cable laying device 17 moves laterally by one groove pitch for every revolution of the winch 18, thus preventing the cable 10 from overlapping and wearing.

[0042] The winch 18 is located below the pulley of the A-frame 6, and the load placement frame is located below the load 9 end. The winch 18 cable 10 extends to the load 9 end of the A-frame 6 after being guided by the pulley, and is connected to the load 9. The load 9 is located on the load placement frame.

[0043] The load-bearing anti-collision frame 8 includes an outer metal frame and an inner buffer assembly. The buffer assembly is detachably connected to the outer frame by bolts, and the buffer stroke is not less than 50mm, which can absorb the impact force when the load 9 collides accidentally. The load placement frame is a rectangular steel structure with a 5mm thick nitrile rubber pad on the surface to prevent the load 9 from being damaged by hard contact with the frame. Limiting blocks are welded to the edges of the frame to ensure accurate positioning of the load 9.

[0044] The output shaft of motor 7 is connected to the main shaft of winch 18 via a flexible coupling, and a dust cover is installed on the outside of the coupling. An electromagnetic brake (power-off braking type) is also provided between motor 7 and winch 18. When the system stops or malfunctions, the brake clamps the main shaft of winch 18 to prevent cable 10 from slipping due to the weight of load 9.

[0045] The hydraulic drive module 3 is located next to the mechanical execution module 1 and is connected to the drive hydraulic cylinder of the A-frame 6 and the winch 18 via hydraulic pipelines.

[0046] The hydraulic drive module 3 includes a hydraulic pump, a control valve group, a hydraulic oil tank, and a cooler. The output end of the hydraulic pump is connected to the control valve group through a hydraulic pipeline, and the output port of the control valve group is connected to the hydraulic cylinder through a hydraulic pipeline. The control valve group is also connected to the hydraulic oil tank through a return oil pipeline.

[0047] Specifically, the power input end of the hydraulic pump is driven by an independent motor 7, and the oil outlet is connected to the oil inlet of the control valve group through a high-pressure pipeline; the two working oil ports of the control valve group are respectively connected to the rodless chamber and rod chamber of the A-frame drive hydraulic cylinder and the compensation hydraulic cylinder of the winch 18 lifting compensation mechanism; the return oil pipeline passes through the cooler and the return oil filter in sequence, and finally connects to the hydraulic oil tank. The pipeline is equipped with a pressure sensor to monitor the system pressure in real time.

[0048] The sensor assembly 2 includes a proximity switch 13, a hollow encoder 16, an incremental spindle encoder 15, an absolute spindle encoder 19, and a single pulley tension sensor 14. The sensor assembly 2 is located in the structural position of the mechanical actuation module 1 and the hydraulic drive module 3.

[0049] The proximity switch 13 is located at the opening and closing position of the limit plate of the A-frame 6, the end cover of the winch 18 drum, and the positioning slot of the load placement frame. The proximity switch 13 is connected to the data calculation module 4 through a signal line.

[0050] Specifically, the proximity switches 13 (9 in total, 2 times redundant) are M12 type inductive proximity switches with a detection distance of 5mm and an NPN normally open output signal. Four are installed at the limit plates of the A-frame 6 at -30° and 30° opening / closing positions, one at the end cover of the winch 18 drum, and one at the cable exit point of the A-frame 6 to detect the length of the cable 10 and determine the number of drum rotations. Three are used in the load placement rack positioning slots to detect whether the load 9 is in place. The connection is via threaded installation, with the signal cable connected to the IO interface of the data calculation module 4. The redundant design ensures that the system can still correctly determine the component position even if a single sensor fails.

[0051] The hollow encoder 16 is located at the rope outlet of the load 9 end of the A-frame 6. The cable 10 passes through the central hole of the hollow encoder 16. The hollow encoder 16 is used to collect the rotation angle of the first cable 10. The hollow encoder 16 communicates with the data calculation module 4 through the signal line.

[0052] Specifically, the hollow encoder model 16 is a 58mm flange-type absolute encoder with a resolution of 1024 lines. The inner diameter of the encoder is adapted to the diameter of the cable 1010. The installation position is fixed to the base of the cable 10 outlet by a bracket. The cable 10 passes through the encoder inner hole without contact, and the distance between the detection end and the outer circumference of the cable 10 is ≤2mm. The sway angle of the cable 10 is collected in real time, and the absolute signal is output. There is no cumulative error, avoiding the lag problem of traditional angle sensors.

[0053] The incremental spindle encoder 15 is located at the load end 9 of the A-frame 6 and is used to collect the rotation angle of the second cable 10.

[0054] An absolute spindle encoder 19 is mounted on a bracket next to the winch 18 and is used to detect the drum of the winch 18 to obtain the length of the cable 10.

[0055] Specifically, the incremental spindle encoder 15, with a resolution of 2048 lines, is linked to the guide wheel shaft of the cable 10 via gear meshing and is installed next to the guide wheel to assist in measuring the length of the cable 10; the absolute spindle encoder 19, with a resolution of 4096 lines, is connected to the main shaft of the winch 18 via a spline and is installed at the front end of the winch 18 to directly collect the number of rotations of the winch 18 and calculate the length of the cable 10. The two work together to ensure that the measurement accuracy of the cable 10 length is less than ±1 mm per meter.

[0056] The single pulley tension sensor 14 is located on the path of the cable 10, and the single pulley tension sensor 14 transmits the cable 10 tension data to the data calculation module 4 through the signal line.

[0057] Specifically, the single pulley tension sensor 14 is a customized groove-type tension sensor with a pulley diameter of 100mm, which is compatible with the diameter of the cable 10. The installation position is fixed to the cable 10 path at the front end of the winch 18 by a pin. The cable 10 rests in the pulley groove, and the pulley can rotate freely to avoid wear on the cable 10. The tension data of the cable 10 is collected in real time and transmitted to the data calculation module 4 through a 4-20mA analog signal to provide a basis for the heave compensation of the winch 18.

[0058] In the embodiments of the present invention, the specific principle of the tension cable position feedback system is as follows: after the system is started, each sensor works synchronously—the proximity switch 13 confirms that the A-frame 6, winch 18, and load 9 are in their initial positions; the hollow encoder 16 collects the angle of the cable 10; the incremental spindle encoder 15 and the absolute spindle encoder 19 collect the length and angle of the cable 10; the single pulley tension sensor 14 collects the tension; and the data is transmitted to the data calculation module 4 through a shielded cable.

[0059] The data calculation module 4 is connected to the mechanical execution module 1, the hydraulic drive module 3, and the sensor assembly 2, respectively.

[0060] The data calculation module 4 has a built-in preset mathematical model. Based on the collected length, angle, and tension of the cable 10 and the ship attitude data provided by the ship's MRU system, it calculates the deviation between the real-time position of the load 9 and the target position, and generates two types of control commands: one to drive the control valve group of the hydraulic drive module 3, and the other to adjust the extension and retraction of the A-frame drive hydraulic cylinder to correct the guide angle of the cable 10 and the other to stabilize the tension of the winch 18 heave compensation mechanism. The other commands are sent to the ship's propeller control system through the ship's communication interface to control the propeller speed and direction, counteract the ship's position deviation, and ensure that the load 9 does not shift with the ship's swaying.

[0061] The hydraulic drive module 3 outputs pressurized oil according to the command, driving the A-frame 6 to open and close and the winch 18 to compensate for rise and fall; the motor 7 drives the winch 18 to rotate, and the cable laying device 17 moves laterally in sync, so as to achieve uniform winding and unwinding of the cable 10; during the transfer of the load 9, the load anti-collision frame 8 is ready to buffer accidental collisions at any time, and finally completes the stable placement of the load 9 at the target position.

[0062] The electrical control cabinet 5 integrates a signal processing unit, a power drive module, and a data calculation module 4. The electrical control cabinet 5 is connected to the sensor assembly 2 via a signal cable, collecting real-time data on the tension, angle, and system structural position of the cable 10. Its power output is connected to the hydraulic drive module 3, converting the logic commands generated by the data calculation module 4 into solenoid valve drive current, thereby controlling the physical movements of the drive hydraulic cylinder and the compensation hydraulic cylinder. Furthermore, the electrical control cabinet 5 serves as the system's human-machine interface, displaying the calculated pose parameters and compensation status in real time.

[0063] The data calculation module 4 calculates the translation of the rope exit point based on the length of the cable 10, the angle of the cable 10, and the ship's attitude angle. Based on the translation of the rope exit point, it obtains the horizontal coordinate parameters and vertical height parameters of the ship's positioning operation. Based on the horizontal coordinate parameters and vertical height parameters, it adjusts the position of the ship's dynamic positioning system.

[0064] The data calculation module 4 has the following built-in preset mathematical model: First, define the ship coordinate system as follows: , The axis is horizontal and parallel to the ground. With the axis perpendicular to the ground, the position of the rope exit point of the tension cable position feedback system in the shipboard MRU coordinate system is: Cable wrapped The angle of rotation of the axis is (Measurement values ​​from the hollow encoder), cable winding The angle of rotation of the axis is (Measurement value of incremental spindle encoder), the length of the extended cable is... (Measurement values ​​from an absolute spindle encoder) In reality, due to the weight of the cable itself, the cable's shape is approximately an arc, and the ship's roll is... The boat rocked back and forth. The bow of the ship rocked. , ( (Measured by the shipborne MRU). Let be the translation of the point where the rope exits in the ship's coordinate system. From this, we can derive the following relationship:

[0065]

[0066]

[0067] From the above three formulas, we can derive the translation of the rope exit point in the ship coordinate system:

[0068]

[0069]

[0070] in, x Let x be the translation along the x-axis. L The length of the cable. The x-axis represents the cable rotation angle. For ship pitching, The y-axis represents the cable rotation angle. For the ship to roll, y This represents the translation along the y-axis. HThis represents the translation in the height direction.

[0071] The final calculation results reflected on the ship are as follows:

[0072] in, The value depends on the installation location of the tension cable position feedback system on the ship. For inclusion The rotation matrix.

[0073] The sway, roll, and heave parameters calculated by the above formulas are directly converted into motion control commands for the system. First, the dynamic positioning command: the data calculation module transmits the calculation results in real time to the ship's dynamic positioning system via a communication interface, serving as the target feedback value for propeller thrust adjustment and correcting the overall ship attitude. Second, the actuator command: this result serves as a feedback signal sent from the electrical control cabinet to the hydraulic drive module, instructing the hydraulic cylinders to adjust the A-frame opening and closing angle in real time, and coordinating with the winch tension compensation mechanism to achieve motion cancellation in the local dimension. This dual-feedback mechanism ensures that the system can cancel interference from both local and overall dimensions.

[0074] Meanwhile, based on the tension data of the cable 10 collected by the single pulley tension sensor 14, the data calculation module 4 drives the hydraulic cylinder to perform actions when the tension data of the cable 10 is less than 95% of the preset tension threshold or greater than 105% of the preset tension threshold, thereby realizing local tension compensation for the ship's heave motion.

[0075] This invention also includes a method for using a tension cable position feedback system, implemented based on the aforementioned tension cable position feedback system, comprising the following steps: S1. When the hydraulic drive module 3 is started, the hydraulic pump outputs pressure oil to the A-frame drive hydraulic cylinder and the tension compensation mechanism of the winch 18 through the control valve group.

[0076] When the system is started, the motor 7 drives the main shaft of the winch 18 to rotate and outputs a stable torque. At the same time, the hydraulic pump of the hydraulic drive module 3 outputs pressure oil to the hydraulic cylinder of the A-frame drive and the lifting and sinking compensation mechanism of the winch 18 through the control valve group.

[0077] S2. Sensor assembly 2 starts synchronously and collects data: proximity switch 13 confirms whether each mechanical component is in the preset alignment position, hollow encoder 16 and main shaft encoder measure the angle and length of cable 10 respectively, single pulley tension sensor 14 collects the tension data of cable 10, and MRU angle sensor collects the attitude data of the ship.

[0078] The sensor assembly 2 works synchronously, and nine 2x redundant proximity switches 13 confirm that the A-frame 6, winch 18, and load 9 are in the preset initial position. The hollow encoder 16 collects the swing angle of the cable 10. The incremental spindle encoder 15 and the absolute spindle encoder 19 work together to measure the length and angle of the cable 10. The single pulley tension sensor 14 captures the tension data of the cable 10 in real time. All parameters are transmitted to the data calculation module 4 through shielded cables.

[0079] S3. The data calculation module 4 compares the tension data of the cable 10 collected by the single pulley tension sensor 14 with the preset tension threshold. When the tension data of the cable 10 is less than 95% of the preset tension threshold or greater than 105% of the preset tension threshold, the hydraulic drive module 3 drives the hydraulic cylinder to perform an action to achieve local tension compensation for the ship's heave motion. On the other hand, based on the length of the cable 10, the angle of the cable 10 and the ship's attitude angle, the position of the ship's dynamic positioning system is adjusted.

[0080] The data calculation module 4 is integrated into the electrical control cabinet 5. Based on a preset mathematical model, it classifies and calculates the collected sensor data, and adjusts the actions of each component according to the calculation results in the following path: The A-frame attitude adjustment logic is based on the x-axis cable rotation angle collected by the hollow encoder 16 and the y-axis cable rotation angle collected by the main shaft encoder to calculate the angular displacement deviation of the load 9 relative to the ship's centerline. The electrical control cabinet 5 sends control signals to the proportional directional valve of the hydraulic drive module 3 to adjust the extension and retraction of the A-frame drive hydraulic cylinder 12, thereby changing the opening and closing angle of the A-frame 6 and correcting the guiding direction of the cable 10 in real time.

[0081] The winch tension local compensation logic monitors the tension value fed back by the single pulley tension sensor 14 in real time. When the tension fluctuation exceeds ±5% of the preset rated value, the electrical control cabinet 5, after calculation by the data calculation module 4, outputs a proportional electrical signal to the proportional directional flow valve in the hydraulic drive module 3. The electrical control cabinet 5 linearly adjusts the valve core opening of the proportional directional flow valve by changing the current amplitude of the output proportional electrical signal, thereby precisely controlling the flow rate of pressure oil entering the compensation hydraulic cylinder to adjust the compensation speed; at the same time, it changes the inlet and outlet flow direction of the pressure oil by switching the polarity of the electrical signal or by commanding the valve core, thereby controlling the reciprocating motion of the drum. By adjusting the opening of the proportional valve in real time, the changes in cable length caused by the heave of the ship are offset, ensuring that the tension of the cable 10 remains constant.

[0082] Specifically, when the tension data of cable 10 is less than 95% of the preset tension threshold, the electrical control cabinet 5 calculates the cable winding speed command and outputs a proportional current for cable winding. The proportional current drives the solenoid coil of the proportional valve, pushing the valve core to move in the winding direction, causing pressurized oil to flow into the rod chamber of the hydraulic cylinder, and the piston rod begins to retract. When the tension data of cable 10 is greater than 105% of the preset tension threshold, the electrical control cabinet 5 calculates the cable unwinding speed command and outputs a proportional current for cable unwinding. The proportional current drives the solenoid coil of the proportional valve, pushing the valve core to move in the unwinding direction, causing pressurized oil to flow into the rodless chamber of the hydraulic cylinder, and the piston rod is forced to extend.

[0083] The aforementioned electrical control cabinet 5 generates the rope winding speed command using electro-hydraulic proportional closed-loop control, with a built-in closed-loop controller employing a PID algorithm. When the tension data collected by the single pulley tension sensor 14 exceeds a preset threshold, the PID algorithm calculates the rope winding speed compensation amount, which is then output as a corresponding proportional current via the internal PWM drive module. This current drives the solenoid coil of the proportional directional valve, causing the valve core to shift and adjusting the flow of pressurized oil towards the rod chamber of the compensating hydraulic cylinder. The retraction of the piston rod performs a radial position compensation action, thereby achieving real-time automatic tension adjustment.

[0084] The overall attitude coordination logic combines the cable extension length L obtained by the absolute spindle encoder 19 with the ship attitude angle provided by the MRU sensor to calculate the ship's sway, roll, and heave translation in three-dimensional space using formulas. This calculation result is sent as a motion command to the propeller control system via the ship's communication interface, and the overall ship attitude is corrected by adjusting the propeller speed and propulsion direction.

[0085] S4. The hydraulic drive module 3 adjusts the opening and closing posture of the A-frame 6 according to the control command. The winch 18, together with the cable laying device 17, realizes the uniform winding and unwinding of the cable 10. The tension compensation mechanism of the winch 18 will adjust the compensation amount in real time according to the tension data transmitted by the single pulley tension sensor 14.

[0086] During this process, when the winch 18 rotates, the cable guide 17 is linked to the main shaft of the winch 18 through the gearbox and moves laterally along the guide rail to guide the cable 10 to be evenly wound in the drum groove of the winch 18, so as to avoid the cable 10 overlapping and wearing. If the load 9 is accidentally deviated during the transfer, the inner buffer component of the load anti-collision frame 8 can absorb the collision force and protect the integrity of the load 9 and the system structure.

[0087] When motor 7 is connected to the main shaft of winch 18 via a flexible coupling, motor 7 needs to output a stable speed. The specific speed is determined by the user based on the weight of load 9 and the target transfer speed. Furthermore, the electromagnetic brake between motor 7 and winch 18 immediately engages the main shaft in case of system shutdown or failure, preventing cable 10 from slipping due to the weight of load 9. The A-frame 6 of the tension cable position feedback system is rigidly connected to the base of the ship's operating area, and winch 18 is fixed via bearing seats to ensure overall motion stability. The core of the system employs hydraulic drive, high-precision sensing, and closed-loop data control. The hydraulic pipeline transmission has a fast response, and the sensor measurements are lag-free, ensuring smooth and accurate positioning of load 9 during transfer.

[0088] S5. In the event of an accident during the transfer of load 9, the load anti-collision frame 8 acts as a buffer against the collision, ultimately completing a stable operation process.

[0089] Furthermore, when the single pulley tension sensor 14 detects that the tension of the cable 10 exceeds the preset range, the compensation hydraulic cylinder in the tension compensation mechanism will adjust the position of the drum through extension and retraction, effectively offsetting the effect of the ship's heave motion on the tension of the cable 10 in real time.

[0090] This method utilizes the coordinated power supply of motor 7 and hydraulic drive module 3, combined with real-time data feedback from sensor assembly 2, to effectively control the tension, length, angle of cable 10 and the position of load 9, facilitating stable transfer of load 9 under complex sea conditions. The core components of the system support customized adjustments; for example, the pulley groove size of single pulley tension sensor 14 can be customized according to the diameter of cable 10, the opening angle of A-frame 6 can be adapted to different operating scenarios through hydraulic parameters, and the drum length of winch 18 can be adjusted according to the capacity requirements of cable 10, increasing the system's applicability and scalability. The core of this system is to transform ship motion disturbances into precise control actions through the dual coordination of local tension adjustment and overall ship posture correction, ultimately achieving stable holding of load 9 at the target position. Furthermore, by changing the limiting structure of the load placement frame and the type of buffer components of the load anti-collision frame 8, it can adapt to loads 9 of different shapes and weights. Alternatively, by adjusting the mathematical model parameters of data calculation module 4, it can be applied to scenarios such as deep-sea mooring and floating platform positioning; functional expansion can be achieved simply by replacing the corresponding adaptable components.

[0091] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A tension cable position feedback system, characterized in that, include: Mechanical actuation module, sensor assembly, hydraulic drive module, and data computing module; The mechanical actuation module includes an A-frame, a winch with heave compensation, and a load placement frame, and the mechanical actuation module is located in the operating area of ​​the ship; The hydraulic drive module is located next to the mechanical execution module and is connected to the drive hydraulic cylinder of the A-frame and the winch transmission via hydraulic pipelines. The sensor assembly includes a proximity switch, a hollow encoder, an incremental spindle encoder, an absolute spindle encoder, and a single pulley tension sensor. The sensor assembly is located in the structural position of the mechanical actuation module and the hydraulic drive module. The data calculation module is connected to the mechanical execution module, the hydraulic drive module and the sensor assembly respectively. Based on the output data of the sensor assembly and the ship's attitude, the data calculation module realizes mechanical compensation control and ship attitude correction.

2. The tension cable position feedback system according to claim 1, characterized in that, The A-frame includes two symmetrically arranged supports, a hydraulic cylinder, and a hinge shaft. The A-frame is rotatably connected to the ship's base via the hinge shaft. The piston rods of the hydraulic cylinders are respectively hinged to the outer sides of the middle of the two supports. The hydraulic cylinders are connected to a hydraulic drive module via hydraulic pipelines to adjust the opening and closing angle of the A-frame.

3. The tension cable position feedback system according to claim 1, characterized in that, The winch includes a drum, a tension compensation mechanism, and a cable laying linkage interface. The tension compensation mechanism includes a compensation hydraulic cylinder, a tension feedback interface, and a stroke limit block. The piston rod of the compensating hydraulic cylinder is connected to the rear end cover of the drum via a flange; the tension feedback interface communicates with the single pulley tension sensor via a signal line; and the cable guide linkage interface is connected to the gear set of the cable guide via a drive shaft. The winch is located below the pulley of the A-frame, and the load placement frame is located below the load end. The winch cable extends to the load end of the A-frame after being guided by the pulley and is connected to the load. The load is placed on the load placement frame.

4. The tension cable position feedback system according to claim 1, characterized in that, The load end of the A-frame is equipped with a load anti-collision frame, which includes an outer metal frame and an inner buffer assembly, the inner buffer assembly being a rubber pad.

5. The tension cable position feedback system according to claim 1, characterized in that, The hydraulic drive module includes a hydraulic pump, a control valve group, and hydraulic pipelines. The output end of the hydraulic pump is connected to the control valve group through the hydraulic pipelines. The output port of the control valve group is connected to the hydraulic cylinder through the hydraulic pipelines. The control valve group is also connected to the hydraulic oil tank through the return oil pipeline.

6. The tension cable position feedback system according to claim 1, characterized in that, The proximity switch is located at the opening and closing position of the A-frame limiting plate, the winch drum end cover, and the load placement frame positioning slot. The proximity switch is connected to the data calculation module through a signal line. The hollow encoder is located at the cable outlet of the load end of the A-frame. The cable passes through the center hole of the hollow encoder. The hollow encoder is used to collect the rotation angle of the x-axis cable. The hollow encoder communicates with the data calculation module through a signal line. The incremental spindle encoder is located at the load end of the A-frame and is used to acquire the rotation angle of the y-axis cable. The absolute value spindle encoder is mounted on a bracket next to the winch and is used to detect the winch drum to obtain the cable length. The single pulley tension sensor is located on the cable path, and the single pulley tension sensor transmits cable tension data to the data calculation module through a signal line.

7. The tension cable position feedback system according to claim 1, characterized in that, The data calculation module calculates the translation of the rope exit point based on the cable length, cable angle, and ship attitude angle. Based on this translation, it obtains the horizontal coordinate parameters and vertical height parameters for the ship positioning operation. The position of the ship's dynamic positioning system is then adjusted based on these parameters. The formula for calculating the translation of the rope exit point is as follows: in, x Let x be the translation along the x-axis. L The length of the cable. The x-axis represents the cable rotation angle. For ship pitching, The y-axis represents the cable rotation angle. For the ship to roll, y This represents the translation along the y-axis. H This represents the translation in the height direction.

8. The tension cable position feedback system according to claim 1, characterized in that, The data calculation module is based on the cable tension data collected by the single pulley tension sensor. When the cable tension data is less than 95% of the preset tension threshold or greater than 105% of the preset tension threshold, the hydraulic drive module drives the hydraulic cylinder to perform an action to realize the tension adjustment of the cable.

9. A method of using a tension cable position feedback system, implemented based on the tension cable position feedback system according to any one of claims 1-8, characterized in that, Includes the following steps: When the hydraulic drive module is started, the hydraulic pump outputs pressurized oil to the A-frame drive hydraulic cylinder and winch tension compensation mechanism through the control valve group; The sensor assembly starts synchronously and collects data: the proximity switch confirms whether each mechanical component is in the preset alignment position, the hollow encoder and the main shaft encoder measure the angle and length of the cable respectively, the single pulley tension sensor collects the cable tension data, and the MRU angle sensor collects the ship's attitude data. The data calculation module compares the cable tension data collected by the single pulley tension sensor with the preset tension threshold. When the cable tension data is less than 95% of the preset tension threshold or greater than 105% of the preset tension threshold, the hydraulic drive module drives the hydraulic cylinder to perform an action to achieve cable tension compensation. On the other hand, it adjusts the position of the ship's dynamic positioning system based on the cable length, cable angle, and ship attitude angle. In the event of an accident during load transfer, the load anti-collision frame acts as a buffer against the impact, ultimately ensuring a stable operation.

10. The method of using the tension cable position feedback system according to claim 9, characterized in that, When the single pulley tension sensor detects that the cable tension exceeds the preset range, the compensation hydraulic cylinder in the tension compensation mechanism will adjust the position of the drum through extension and retraction to effectively counteract the effect of the ship's heave motion on the cable tension in real time.

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