Energy storage control system for an electric tensioner

Abstract

The application discloses an energy storage control system of an electric tension machine, and relates to the technical field of electric tension machines.The application realizes efficient recovery of mechanical energy by formulating accurate working condition judgment, cooperating with rectification filtering and energy conversion modules, greatly improves energy utilization efficiency; carries precise calculation models, realizes accurate protection of lithium battery overcharging in combination with full power threshold, realizes whole-process protection of circuit protection elements, prolongs the service life of the energy storage core and improves system operation safety; three different principle elements are used for temperature redundant monitoring of the braking resistor, errors are eliminated through independent calibration, the overheat alarm threshold is 1.1, at least two groups of data are determined to alarm overheat, the false alarm probability is greatly reduced, the temperature abnormal condition is processed in stages, the temperature of the braking resistor is finely controlled, and the system stability and fault tolerance are significantly improved.

Description

Technical Field

[0001] This invention relates to the field of electric tension machine technology, and more specifically to an energy storage control system for an electric tension machine. Background Technology

[0002] Electric tensioners are used in power engineering and cable laying operations, involving both transmission and cable laying. During transmission, they consume electrical energy, while during cable laying, they generate electricity. In the cable laying phase, the mechanical energy of the rotating wheel assembly is typically dissipated as heat through the braking resistor, resulting in significant energy waste and potentially causing excessive temperature rise in the braking resistor, leading to safety hazards. To address this, some existing electric tensioners incorporate energy storage systems, using lithium battery packs as the core and energy conversion modules to recover and store mechanical energy as electrical energy.

[0003] However, such systems still have many technical shortcomings: First, operating condition detection relies heavily on simple speed sensing, lacking precise formulaic calculation logic, resulting in large errors in operating condition judgment, leading to untimely switching of servo motor power generation modes and low energy recovery efficiency; Second, lithium battery pack power monitoring mostly uses simple voltage acquisition methods, lacking accurate remaining power information. The calculation model suffers from several problems. First, overcharge protection relies solely on a fixed voltage threshold, making it susceptible to overcharging or undercharging due to voltage fluctuations, which can affect the lifespan of the lithium battery pack. Second, temperature monitoring of the braking resistor often uses a single sensor, and a single sensor failure can easily lead to false or missed overheating alarms. Furthermore, the lack of standardized temperature calibration and multi-dimensional judgment logic results in poor accuracy and reliability of overheating alarms, which can easily cause equipment failures or even safety accidents due to resistor overheating. Third, the system lacks a coordinated control unit between its modules. Functions such as energy recovery, overcharge protection, and temperature monitoring operate independently, resulting in a low overall level of automation and an inability to adapt to the complex actual working conditions of the electric tension machine.

[0004] To address the shortcomings of the existing technologies, developing an electric tensioner energy storage control system that is highly efficient in energy utilization, safe and stable in operation, accurate in monitoring and alarm, and highly automated has become an urgent technical problem to be solved in this field. Summary of the Invention

[0005] The purpose of this invention is to solve the problems of low energy recovery efficiency, poor accuracy of lithium battery power monitoring and overcharge protection, and inaccurate overheat control caused by single-sensor monitoring of braking resistor temperature, which is prone to false alarms and missed alarms.

[0006] To achieve the above objectives, the present invention specifically adopts the following technical solution:

[0007] An energy storage control system for an electric tension machine includes an energy storage core, an energy conversion module, a servo motor, a braking resistor, a power monitoring device, a working condition detection element, a resistance temperature monitoring element, an alarm device, a rectifier and filter circuit, a heat dissipation device, circuit protection elements, and a main controller.

[0008] The energy storage core is used to store electrical energy and provide a stable power supply for the entire system;

[0009] The energy conversion module is electrically connected to the energy storage core and servo motor to realize bidirectional transmission of electrical energy and can perform voltage stabilization and current limiting on electrical energy.

[0010] The servo motor is linked with the energy conversion module and switches to power generation mode during the wire laying process to convert mechanical energy into electrical energy.

[0011] The braking resistor is electrically connected to the energy conversion module and is used to consume the excess electrical energy output by the energy conversion module when the energy storage core is fully charged, so as to avoid overcharging of the energy storage core.

[0012] The power monitoring device is electrically connected to the energy storage core and the main controller, and is used to collect data such as voltage, current and remaining power of the energy storage core in real time, and transmit the collected data to the main controller.

[0013] The operating condition detection element is installed on the output shaft of the servo motor and electrically connected to the main controller. It is used to detect the speed, direction and pulse signal of the servo motor, and to provide data support for operating condition judgment.

[0014] The resistance temperature monitoring element is electrically connected to the braking resistor and the main controller, and is used to monitor the temperature of the braking resistor in real time and transmit the monitored temperature data to the main controller.

[0015] The alarm device is electrically connected to the main controller and is used to receive alarm commands output by the main controller and output alarm signals to realize fault warning.

[0016] The rectifier and filter circuit is connected in series between the servo motor generator and the energy conversion module. It is used to convert the AC power generated by the servo motor into DC power, and to filter out noise and stabilize the voltage.

[0017] The heat dissipation device is electrically connected to the main controller to reduce the temperature of the braking resistor and improve system safety in conjunction with the overheat protection logic.

[0018] The circuit protection element is connected in series or in parallel with the main circuit and power supply terminal of the system to realize overload, short circuit and voltage spike protection, and prevent damage to core components.

[0019] The main controller, as the core control unit of the system, is electrically connected to all the above-mentioned components. It is used to receive data transmitted by each monitoring element and detection element, process the data, and output control commands and alarm commands, and to coordinate the work of each component.

[0020] Furthermore, the operating condition detection element collects the operating data of the servo motor and, in conjunction with the data processing of the main controller, determines the transmission operating condition and the wire-laying operating condition, as well as the actual motor speed. The calculation formula is:

[0021] ;

[0022] in, The number of pulses per revolution of the operating condition detection element. This is the motor reduction ratio. The encoder output pulse frequency, when When the wire feeding wheel reverses, it is in transmission mode. When the speed of the pay-off reel exceeds the rated speed 1.2 times that of the wire laying condition. When the main controller determines that the equipment is in the wire laying condition, it controls the servo motor to switch to the power generation mode.

[0023] Furthermore, after the servo motor switches to the power generation mode, it converts the mechanical energy of the wheel assembly rotation into electrical energy through electromagnetic induction.

[0024] The electrical energy is first transmitted to the rectifier and filter circuit. After processing by the rectifier and filter circuit, the AC power is converted into DC power and noise is filtered out.

[0025] The filtered DC power is transmitted to the energy conversion module, where it is regulated and current limited before being finally transmitted to the energy storage core for storage, thus achieving energy recovery.

[0026] The main controller monitors the entire process to ensure the stability of power transmission and storage.

[0027] Furthermore, the main controller processes the data collected by the power monitoring equipment to calculate the remaining power of the energy storage core. The specific calculation formula is as follows:

[0028] ;

[0029] in To enable power monitoring equipment to collect real-time data on the individual cell voltages of the energy storage core. =1,2,..., , The number of individual cells connected in series in the energy storage core. For the total current, This represents the initial remaining power of the energy storage core. For the rated capacity of the energy storage core, For monitoring time, This is the voltage correction factor. The average voltage of all energy storage core cells. The calculation formula is:

[0030] ;

[0031] Set the full capacity threshold for the energy storage core When the main controller calculates When the energy storage system reaches its full charge, the main controller immediately outputs a control command to switch the circuit loop and direct the excess energy output from the energy conversion module into the braking resistor. The excess energy is safely consumed as heat through the braking resistor, avoiding the risk of overcharging in the energy storage core. At the same time, the power monitoring device triggers an overcharge warning signal and sends it back to the main controller for backup.

[0032] Furthermore, the resistance temperature monitoring element employs at least three monitoring elements based on different physical principles to achieve redundant monitoring of the braking resistor temperature. Each resistance temperature monitoring element synchronously monitors the braking resistor temperature in real time and independently transmits the collected temperature data to the main controller. This reduces the probability of false alarms caused by the failure of a single monitoring element and ensures the stability, reliability, and alarm accuracy of the monitoring data.

[0033] Furthermore, the three resistance temperature monitoring elements based on different physical principles are a thermistor based on the negative temperature coefficient principle, an infrared temperature sensor based on the infrared thermal radiation principle, and a thermocouple sensor based on the thermoelectric effect principle. The thermistor is used to reflect the temperature change of the braking resistor by the change of its own resistance value, the infrared temperature sensor is used to convert the infrared radiation intensity on the surface of the braking resistor into temperature data, and the thermocouple sensor is used to convert the thermoelectric electromotive force generated by the contact of two different metals into temperature data.

[0034] Furthermore, after receiving the temperature data transmitted by each resistive temperature monitoring element, the main controller performs independent calibration processing on each set of temperature data to eliminate monitoring errors. The calibration formula is as follows:

[0035] ;

[0036] ;

[0037] ;

[0038] in , , These are the original monitoring temperatures of the three sets of resistance temperature monitoring elements. , , These are the calibrated values ​​for three sets of temperature data. , , These represent the calibration deviations of the three sets of resistance temperature monitoring elements.

[0039] Furthermore, based on the calibrated temperature data and in conjunction with preset judgment logic, the main controller analyzes whether the braking resistor is overheating and sets a safe temperature threshold for the braking resistor. The allowable range for temperature difference is The overheat alarm threshold is ;

[0040] Temperature ≥ after single-group calibration This data set is considered overheated.

[0041] Temperature ≥ after single-group calibration And <1.1 Or, the difference between a single set of data and the average data of the other two sets is greater than 1. This is considered an anomaly in the data set.

[0042] If the difference between a single set of data and the average data of the other two sets is greater than the preset fault threshold, the temperature monitoring element is considered to be faulty.

[0043] Furthermore, the judgment formulas and logic for the three sets of monitoring data are as follows:

[0044] Normal state:

[0045] ;

[0046] Overheat alarm status:

[0047] and (1)

[0048] and (2)

[0049] and (3)

[0050] and and (4)

[0051] If any one of (1), (2), (3), or (4) above is met, an immediate overheating alarm will be triggered;

[0052] In addition to normal and overheat alarm states, if only a single set of data meets the criteria for overheating, abnormality, or fault, an abnormal signal will be output for the corresponding resistance temperature monitoring element, prompting the repair or replacement of the abnormal element.

[0053] Furthermore, in the overheat alarm state, the main controller immediately outputs an audible and visual alarm command to the alarm device, simultaneously and quickly cuts off the power input circuit of the braking resistor, stops excess power consumption, and activates the emergency heat dissipation components in the heat dissipation device until the temperature drops to a safe range after three sets of calibrations. Then, the main controller restores the system to normal operation and stops the alarm.

[0054] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0055] 1. This invention uses a formulaic and precise calculation of the actual speed of the motor, combined with a clear speed threshold to achieve accurate judgment of braking and wire feeding conditions. The servo motor's power generation mode switching is timely, and with the help of rectification and filtering and energy conversion modules, mechanical energy is efficiently recovered and stored into electrical energy. This effectively converts the originally wasted mechanical energy into usable electrical energy, greatly reduces equipment energy consumption, and improves the energy utilization efficiency of the electric tension machine.

[0056] 2. This invention sets a precise remaining capacity of the lithium battery pack. The calculation model, combined with a voltage correction coefficient to compensate for individual cell voltage differences, achieves high power monitoring accuracy. At the same time, a clear full-capacity threshold is set to trigger overcharge protection, and excess power is safely consumed through a braking resistor, avoiding the risk of overcharging the lithium battery pack and extending the service life of the energy storage core. Furthermore, the circuit protection components operate throughout the entire process, achieving comprehensive protection against overload, short circuit, and voltage spikes, further enhancing the safety of system operation.

[0057] 3. This invention employs three monitoring elements based on different physical principles to achieve redundant monitoring of the braking resistor temperature, and uses an independent temperature data calibration formula to eliminate monitoring errors. The overheat alarm threshold is set to 1.1. =165℃, and strictly follows the judgment rule of "only alarming when at least two monitoring elements determine overheating", which greatly reduces the probability of false alarms caused by the failure of a single sensor. The accuracy and reliability of temperature monitoring and alarm are high. At the same time, a graded processing logic is set for element abnormality, overheat warning and overheat alarm, and the heat dissipation device is activated in stages to achieve fine control of the braking resistor temperature. This fundamentally avoids equipment failure and safety accidents caused by resistor overheating, and the stability and fault tolerance of the system are significantly improved. Detailed Implementation

[0058] The technical solutions of the present invention will be clearly and completely described below with reference to 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 of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0059] An energy storage control system for an electric tension machine is disclosed. The system uses a lithium battery pack as the energy storage core and is equipped with a bidirectional DC-DC converter to realize bidirectional flow of electrical energy. Through the coordinated operation of multiple modules, it completes functions such as working condition detection, energy recovery, power monitoring and overcharge protection, redundant monitoring of braking resistor temperature and overheating alarm, effectively improving the safety, stability and energy utilization efficiency of the system operation. Its overall structure and working logic are adapted to the actual working conditions of the electric tension machine, such as transmission and wire feeding.

[0060] In this embodiment, the core components include an energy storage core, an energy conversion module, a servo motor, a braking resistor, a power monitoring device, a working condition detection element, a resistance temperature monitoring element, an alarm device, a rectifier and filter circuit, a heat dissipation device, circuit protection elements, and a main controller. The specific selection, connection relationship, and basic functions of each component are as follows:

[0061] Energy storage core: The power type lithium iron phosphate battery pack is selected and set in series. It has a rated voltage of 51.2V and a rated capacity of 100Ah. As the only energy storage core of the system, it is used to store the electrical energy generated during the energy recovery process and provide a stable power supply for the entire system.

[0062] Energy conversion module: The XL6019 bidirectional DC-DC converter is selected, with an input voltage of 20-60V and an adjustable output voltage. It is electrically connected to the energy storage core and the servo motor respectively. The core realizes bidirectional transmission of electrical energy and can perform voltage stabilization and current limiting on the transmitted electrical energy to ensure the stability of the power transmission.

[0063] Servo motor: Linked with the energy conversion module, it is the power execution component of the electric tension machine. When the equipment is in the wire feeding mode, it can switch to the power generation mode and convert the mechanical energy of the wheel set rotation into electrical energy through electromagnetic induction to realize energy recovery.

[0064] Braking resistor: Electrically connected to the energy conversion module, it is used to consume excess electrical energy output by the energy conversion module when the energy storage core is fully charged, thus fundamentally avoiding the risk of overcharging of the energy storage core;

[0065] Power monitoring equipment: The BQ76952 lithium battery power monitoring chip is selected and electrically connected to the energy storage core and the main controller. It can collect data such as the individual cell voltage, total current and remaining power of the energy storage core in real time. The acquisition error is ≤±1%, and it has overcharge and over-discharge warning functions. All collected data are transmitted to the main controller in real time.

[0066] Operating condition detection element: The E6B2-CWZ6C incremental encoder is selected and installed on the output shaft of the servo motor. It is electrically connected to the main controller and can accurately detect the speed, direction and pulse signal of the servo motor, providing accurate and real-time data support for the main controller to judge the operating condition. The encoder has 1000 pulses per revolution.

[0067] Resistance temperature monitoring elements: Redundant monitoring is achieved using three monitoring elements based on different physical principles: an NTC 10KΩ thermistor, an MLX90614 infrared temperature sensor, and a K-type thermocouple. All three elements are electrically connected to the braking resistor and the main controller, synchronously monitoring the temperature of the braking resistor in real time, and independently transmitting the collected temperature data to the main controller. Specifically, the thermistor has a temperature measurement range of -40℃ to 125℃ and an accuracy of ±0.5℃, operating based on the negative temperature coefficient principle; the infrared temperature sensor has a temperature measurement range of -70℃ to 380℃ and an accuracy of ±0.3℃, operating based on the infrared thermal radiation principle; and the K-type thermocouple has a temperature measurement range of -200℃ to 1300℃ and an accuracy of ±1℃, operating based on the thermoelectric effect principle.

[0068] Alarm equipment: The LTE-1101J audible and visual alarm module is selected and electrically connected to the main controller. It can receive various alarm commands output by the main controller and output different audible and visual alarm signals for three scenarios: overheating alarm, component abnormality, and system monitoring fault. The sound level is ≥85dB and the light is red solid / flashing mode to provide timely warnings for different fault levels.

[0069] Rectifier and filter circuit: The circuit consists of a KBPC3510 rectifier bridge and a capacitor filter module, connected in series between the servo motor generator and the energy conversion module. It is used to convert the AC power generated by the servo motor into DC power, filter out noise in the power, stabilize the voltage, ensure the stability of the power input to the energy storage core, and avoid voltage fluctuations that could damage the energy storage core.

[0070] Heat dissipation device: Includes a 12038 DC12V backup cooling fan and a 12038 DC24V emergency cooling fan, both of which are electrically connected to the main controller. The backup cooling fan starts when the braking resistor temperature is abnormal, and the emergency cooling fan starts when the braking resistor is overheated. It is dedicated to quickly reducing the temperature of the braking resistor and improves system safety in conjunction with the overheat protection logic.

[0071] Circuit protection components: Composed of an RT18-32 10A fuse and an SMBJ60CA transient suppression diode. The fuse is connected in series with the main circuit of the system to realize overload and short circuit protection and prevent excessive circuit current from damaging core components. The transient suppression diode is connected in parallel with the power supply terminal to suppress voltage spikes and protect the main controller, various monitoring components and other precision devices.

[0072] Main controller: The STM32F407VET6 microcontroller is selected as the core control unit of the system. It is electrically connected to all the above components. Its core function is to receive real-time data transmitted by each monitoring element and detection element, analyze, calculate and process the data, and output corresponding control commands and alarm commands according to the processing results, so as to link the various components to work together and realize the automated control of the system.

[0073] In the specific implementation of working condition detection and energy recovery, the main controller collects the operating data of the servo motor through the working condition detection element, calculates the actual speed of the motor through a preset formula, and judges the equipment working condition based on the speed result. The specific process is as follows:

[0074] Calculation of actual motor speed: Assume the unit frequency of the output pulse from the operating condition detection element is... The motor reduction ratio is The rated speed of the motor is The number of pulses per revolution of the operating condition detection element is The formula for calculating the actual speed n of the motor is:

[0075] ;

[0076] In this embodiment, the motor reduction ratio Take 10, the number of pulses per revolution of the operating condition detection element. All values ​​are 1000, and are fixed parameters.

[0077] Operating condition judgment logic: When the calculated actual motor speed When the wire feeding wheel is reversed, the corresponding equipment is in transmission mode and is in power consumption mode.

[0078] when When the servo motor speed exceeds 1.2 times the rated speed, the corresponding equipment is in the wire laying condition.

[0079] When the main controller determines that the equipment is in the wire laying condition, it immediately outputs a control command to control the servo motor to switch to the power generation mode.

[0080] Energy recovery process: After the servo motor switches to the power generation mode, it converts the mechanical energy of the wheel set rotation into AC power through electromagnetic induction. The AC power is first transmitted to the rectifier and filter circuit. After rectification by the rectifier bridge and filtering by the capacitor, it is converted into stable DC power and filtered out noise.

[0081] The filtered DC power is transmitted to a bidirectional DC-DC converter, where it is regulated and current-limited before being finally transmitted to the lithium battery pack for storage, thus completing energy recovery. Throughout the entire energy recovery process, the main controller monitors the process in real time to ensure the stability of power transmission and storage.

[0082] In the specific control logic of lithium battery pack power monitoring and overcharge protection, the power monitoring device continuously collects data such as the individual cell voltage and total current of the lithium battery pack and transmits it to the main controller in real time. The main controller calculates the remaining power of the lithium battery pack using a preset formula and implements overcharge protection based on the remaining power result. The specific process is as follows:

[0083] Remaining battery power Calculation: The main controller processes the data collected by the power monitoring equipment and calculates the remaining power of the energy storage core. The formula is:

[0084] ;

[0085] in To enable power monitoring equipment to collect real-time data on the individual cell voltages of the energy storage core. =1,2,..., , This refers to the number of individual cells connected in series in the energy storage core. This represents the real-time total current of the energy storage core; it is positive during charging and negative during discharging. The initial remaining power of the energy storage core is calibrated and read by the power monitoring equipment when the system is powered on; In this embodiment, the rated capacity of the energy storage core is... ; For monitoring time, Heat dissipation device: Included in this embodiment This is used to compensate for the impact of individual unit voltage differences on the calculation of remaining power. The average voltage of all energy storage core cells is calculated using the following formula:

[0086] ;

[0087] Overcharge protection logic: Set the full charge threshold for the energy storage core. When the main controller calculates When the energy storage system reaches its full charge, the main controller immediately outputs a control command to switch the circuit loop and direct the excess energy output from the energy conversion module into the braking resistor. The excess energy is safely consumed as heat through the braking resistor, avoiding the risk of overcharging in the energy storage core. At the same time, the power monitoring device triggers an overcharge warning signal and feeds it back to the main controller for backup. Throughout the overcharge protection process, the circuit protection components are in working condition to prevent abnormal situations such as circuit overload, short circuit, and voltage spikes during overcharging.

[0088] In the specific control logic for braking resistor temperature monitoring and overheat alarm, three types of resistor temperature monitoring elements synchronously monitor the temperature of the braking resistor in real time and independently transmit the raw temperature data collected by each element to the main controller. After calibrating the data, the main controller analyzes whether the braking resistor is overheating through preset judgment logic and executes corresponding control actions based on the analysis results. It strictly follows the core rule that an alarm is only triggered when at least two monitoring elements determine overheating, and only an abnormal signal is output when only one element is determined to be overheating. The specific process is as follows:

[0089] Temperature data calibration: The main controller receives raw temperature data transmitted from three sets of resistance temperature monitoring elements. For the original temperature monitoring of the thermistor, For the original monitoring temperature of the infrared temperature sensor, To determine the original monitoring temperature of the type K thermocouple, each set of data is independently calibrated to eliminate monitoring errors. The calibration formula is as follows:

[0090] ;

[0091] ;

[0092] ;

[0093] in , , These are the calibrated values ​​for three sets of temperature data. , , These represent the calibration deviations of the three sets of resistance temperature monitoring elements, as described in this embodiment. , , All of these are calibrated fixed values.

[0094] The preset standard for overheat detection: The main controller sets the safe temperature threshold for the braking resistor to be [value missing]. The allowable range for temperature difference is The overheat alarm threshold is In this embodiment , The overheat alarm threshold is 165℃, and three types of judgment results are defined as follows:

[0095] Temperature ≥ after single-group calibration This data set is considered overheated.

[0096] Temperature ≥ after single-group calibration And <1.1 Or, the difference between a single set of data and the average data of the other two sets is greater than 1. This is considered an anomaly in the data set.

[0097] If the difference between a single set of data and the average data of the other two sets is greater than the preset fault threshold, the temperature monitoring element is considered to be faulty.

[0098] The judgment logic for the three sets of monitoring data: The main controller is based on the calibrated three sets of temperature data. , , Based on the above judgment criteria, the judgment logic is as follows:

[0099] Normal state:

[0100] ;

[0101] Overheat alarm status:

[0102] and (1)

[0103] and (2)

[0104] and (3)

[0105] and and (4)

[0106] If any one of (1), (2), (3), or (4) above is met, an immediate overheating alarm will be triggered;

[0107] Component abnormal signal: In addition to normal state and overheat alarm state, if only a single set of data meets the overheat judgment, abnormal judgment or component fault judgment, it is judged that the corresponding component is abnormal. The main controller only outputs the fault prompt of the abnormal resistance temperature monitoring component, without triggering any overheat alarm, and continuously monitors the component data. If the abnormal state continues, it prompts manual maintenance.

[0108] Actions following an overheat alarm: When the main controller determines that the braking resistor is in an overheat alarm state, it immediately outputs an audible and visual alarm command to the alarm device, which triggers the corresponding overheat audible and visual alarm signal. Simultaneously, the main controller quickly cuts off the power input circuit of the braking resistor, stopping the input of excess power to the braking resistor to prevent the temperature from continuing to rise, and starts the emergency cooling fan in the heat dissipation device to forcibly cool the braking resistor. This process continues until the temperature drops to the preset safe range after three calibrations. , , Only then will the main controller restore the system to normal operation and control the alarm devices to stop alarming.

[0109] Special fault handling: If two or more of the three sets of resistance temperature monitoring elements fail simultaneously, the main controller will immediately control the alarm device to output a system monitoring fault alarm signal to prompt manual emergency troubleshooting, thus avoiding the risk of overheating missed due to monitoring element failure; throughout the entire temperature monitoring and overheating alarm process, the circuit protection element will work continuously to prevent abnormal circuit damage to core components.

[0110] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. The scope of patent protection of the present invention shall be determined by the claims. Similarly, any equivalent structural changes made based on the content of the present invention's specification shall also be included within the scope of protection of the present invention.

Claims

1. An energy storage control system for an electric tension machine, characterized in that: It includes an energy storage core, energy conversion module, servo motor, braking resistor, power monitoring equipment, operating condition detection element, resistance temperature monitoring element, alarm device, rectifier filter circuit, heat dissipation device, circuit protection element and main controller; The energy storage core is used to store electrical energy and provide a stable power supply for the entire system; The energy conversion module is electrically connected to the energy storage core and servo motor to realize bidirectional transmission of electrical energy and can perform voltage stabilization and current limiting on electrical energy. The servo motor is linked with the energy conversion module and switches to power generation mode during the wire laying process to convert mechanical energy into electrical energy. The braking resistor is electrically connected to the energy conversion module and is used to consume the excess electrical energy output by the energy conversion module when the energy storage core is fully charged, so as to avoid overcharging of the energy storage core. The power monitoring device is electrically connected to the energy storage core and the main controller, and is used to collect data such as voltage, current and remaining power of the energy storage core in real time, and transmit the collected data to the main controller. The operating condition detection element is installed on the output shaft of the servo motor and electrically connected to the main controller. It is used to detect the speed, direction and pulse signal of the servo motor, and to provide data support for operating condition judgment. The resistance temperature monitoring element is electrically connected to the braking resistor and the main controller, and is used to monitor the temperature of the braking resistor in real time and transmit the monitored temperature data to the main controller. The alarm device is electrically connected to the main controller and is used to receive alarm commands output by the main controller and output alarm signals to realize fault warning. The rectifier and filter circuit is connected in series between the servo motor generator and the energy conversion module. It is used to convert the AC power generated by the servo motor into DC power, and to filter out noise and stabilize the voltage. The heat dissipation device is electrically connected to the main controller to reduce the temperature of the braking resistor and improve system safety in conjunction with the overheat protection logic. The circuit protection element is connected in series or in parallel with the main circuit and power supply terminal of the system to realize overload, short circuit and voltage spike protection, and prevent damage to core components. The main controller, as the core control unit of the system, is electrically connected to all the above-mentioned components. It is used to receive data transmitted by each monitoring element and detection element, process the data, and output control commands and alarm commands, and to coordinate the work of each component.

2. The energy storage control system for an electric tension machine according to claim 1, characterized in that: The operating condition detection element collects the operating data of the servo motor and, in conjunction with the data processing of the main controller, determines the transmission and unloading conditions, as well as the actual motor speed. The calculation formula is: ； in, The number of pulses per revolution of the operating condition detection element. This is the motor reduction ratio. The encoder output pulse frequency, when When the wire feeding wheel reverses, the device is in transmission mode and consumes power. When the motor speed exceeds the rated speed 1.2 times that of the wire laying condition. When the main controller determines that the equipment is in the wire laying condition, it controls the servo motor to switch to the power generation mode.

3. The energy storage control system for an electric tensioner according to claim 1, characterized in that: After the servo motor switches to power generation mode, it converts the mechanical energy of the wheel assembly rotation into electrical energy through electromagnetic induction. The electrical energy is first transmitted to the rectifier and filter circuit. After processing by the rectifier and filter circuit, the AC power is converted into DC power and noise is filtered out. The filtered DC power is transmitted to the energy conversion module, where it is regulated and current limited before being finally transmitted to the energy storage core for storage, thus achieving energy recovery. The main controller monitors the entire process to ensure the stability of power transmission and storage.

4. The energy storage control system for an electric tension machine according to claim 3, characterized in that: The main controller processes the data collected by the power monitoring equipment and calculates the remaining power of the energy storage core. The specific calculation formula is as follows: ； in To enable power monitoring equipment to collect real-time data on the individual cell voltages of the energy storage core. =1,2,..., , The number of individual cells connected in series in the energy storage core. For the total current, This represents the initial remaining power of the energy storage core. For the rated capacity of the energy storage core, For monitoring time, This is the voltage correction factor. The average voltage of all energy storage core cells. The calculation formula is: ； Set the full capacity threshold for the energy storage core When the main controller calculates When the energy storage system reaches its full charge, the main controller immediately outputs a control command to switch the circuit loop and direct the excess energy output from the energy conversion module into the braking resistor. The excess energy is safely consumed as heat through the braking resistor, avoiding the risk of overcharging in the energy storage core. At the same time, the power monitoring device triggers an overcharge warning signal and sends it back to the main controller for backup.

5. The energy storage control system for an electric tensioner according to claim 1, characterized in that: The resistance temperature monitoring element employs at least three monitoring elements based on different physical principles to achieve redundant monitoring of the braking resistor temperature. Each resistance temperature monitoring element synchronously monitors the braking resistor temperature in real time and independently transmits the collected temperature data to the main controller. This reduces the probability of false alarms caused by the failure of a single monitoring element and ensures the stability, reliability, and accuracy of the monitoring data and alarms.

6. The energy storage control system for an electric tension machine according to claim 5, characterized in that: The three resistance temperature monitoring elements based on different physical principles are a thermistor based on the negative temperature coefficient principle, an infrared temperature sensor based on the infrared thermal radiation principle, and a thermocouple sensor based on the thermoelectric effect principle. The thermistor is used to reflect the temperature change of the braking resistor by the change of its own resistance value. The infrared temperature sensor is used to convert the infrared radiation intensity on the surface of the braking resistor into temperature data. The thermocouple sensor is used to convert the electromotive force generated by the temperature difference between two different metals in contact into temperature data.

7. The energy storage control system for an electric tension machine according to claim 5, characterized in that: After receiving the temperature data transmitted from each resistive temperature monitoring element, the main controller performs independent calibration on each set of temperature data to eliminate monitoring errors. The calibration formula is as follows: ； ； ； in , , These are the original monitoring temperatures of the three sets of resistance temperature monitoring elements. , , These are the calibrated values ​​for three sets of temperature data. , , These represent the calibration deviations of the three sets of resistance temperature monitoring elements.

8. The energy storage control system for an electric tension machine according to claim 7, characterized in that: Based on calibrated temperature data and pre-defined judgment logic, the main controller analyzes whether the braking resistor is overheating and sets a safe temperature threshold for the braking resistor. The allowable range for temperature difference is The overheat alarm threshold is ; Temperature ≥ after single-group calibration This data set is considered overheated. Temperature ≥ after single-group calibration And <1.1 Or, the difference between a single set of data and the average data of the other two sets is greater than 1. This is considered an anomaly in the data set. If the difference between a single set of data and the average data of the other two sets is greater than the preset fault threshold, the temperature monitoring element is considered to be faulty.

9. The energy storage control system for an electric tension machine according to claim 8, characterized in that: The formulas and logic for judging the three sets of monitoring data are as follows: Normal state: ; Overheat alarm status: and (1) and (2) and (3) and and (4) If any one of (1), (2), (3), or (4) above is met, an immediate overheating alarm will be triggered; In addition to normal and overheat alarm states, if only a single set of data meets the criteria for overheating, abnormality, or fault, an abnormal signal will be output for the corresponding resistance temperature monitoring element, prompting the repair or replacement of the abnormal element.

10. The energy storage control system for an electric tension machine according to claim 9, characterized in that: In the overheating alarm state, the main controller immediately outputs an audible and visual alarm command to the alarm device, simultaneously and quickly cuts off the power input circuit of the braking resistor, stops excess power consumption, and activates the emergency heat dissipation components in the heat dissipation device until the temperature drops to a safe range after three sets of calibrations. Then, the main controller restores the system to normal operation and stops the alarm.

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