A tension preset control system and method of an electric stretcher

Abstract

This invention discloses a tension preset control system and method for an electric tensioning machine. The system includes a control panel, a controller, a motor controller, a drive motor, several tensioning wheels and corresponding tailstocks, and sensors. The method utilizes a composite control switch on the control panel to achieve precise adjustment and confirmation control, and combines motor drive with hydraulic drive to improve tension preset accuracy, eliminate safety hazards caused by misoperation and potentiometer drift, thus adapting to the needs of different construction conditions.

Description

Technical Field

[0001] This invention belongs to the field of construction machinery technology for power grid overhead lines, and specifically relates to a tension preset control system and method for an electric tensioning machine. Background Technology

[0002] During the construction of overhead power lines, cable laying is one of the core procedures. It requires applying stable tension to the cables using tensioning equipment to ensure that the cables are in a preset tension state and to prevent the cables from falling to the ground, being worn, or being broken. At the same time, the maximum tension must be strictly limited to prevent safety accidents such as conductor damage and tower collapse caused by overload.

[0003] The existing traditional hydraulic tensioning machine tensioning preset scheme consists of a controller, control panel, and hydraulic actuator. It outputs an analog voltage signal to the controller via a potentiometer, which then drives an electro-hydraulic servo valve to adjust the working pressure of the relief valve, thereby indirectly setting the tensioning force of the machine. This scheme relies on the physical contact adjustment of the potentiometer, which is an analog control mode and has the following inherent technical defects: The existing scheme uses a potentiometer to indirectly adjust the secondary relief pressure of the electro-hydraulic servo valve. Because the potentiometer is a mechanical contact component, after long-term frequent operation, its internal contacts are prone to wear and oxidation, causing the potentiometer output signal to drift, resulting in a deviation from the preset tensioning value and failing to meet the requirements of high-precision line laying construction. Simultaneously, pressure fluctuations in the hydraulic system further affect the tensioning adjustment accuracy, leading to excessive deviation between the preset value and the actual tensioning force. Furthermore, the existing scheme uses a single potentiometer knob for operation, which is prone to operator errors during construction. Accidental touch of the potentiometer knob caused an unexpected change in the preset tension value, and the operator could not detect this change in real time. If the tension value increased unexpectedly, it could lead to the conductor breaking and the towers along the line overturning due to overload. If the tension value decreased unexpectedly, it could lead to insufficient cable tension, resulting in phenomena such as slippage and conductor falling to the ground, seriously threatening the personal safety of construction personnel and the integrity of construction equipment and cables, posing significant safety hazards. The existing solution relies on a hydraulic transmission system, which is affected by factors such as hydraulic oil viscosity and temperature, resulting in a slow response speed of tension and a limited adjustment range, making it unable to adapt to the preset tension requirements of different cable specifications and different construction conditions. Summary of the Invention

[0004] To address the shortcomings of existing technologies, one of the objectives of this invention is to provide a tension preset control system for an electric tensioning machine. This system achieves precise adjustment and confirmation control by employing a composite control switch combined with software algorithms. It also replaces hydraulic drive with motor drive, thereby improving the tension preset accuracy, eliminating safety hazards caused by misoperation and potentiometer drift, and adapting to the needs of different construction conditions.

[0005] The second objective of this invention is to provide a method for using the tension preset control system of the electric tensioner.

[0006] The present invention provides a tension preset control system for an electric tensioning machine, including a control panel, a controller, a motor controller, a drive motor, several tensioning wheels and corresponding tail frames, and sensors;

[0007] The controller's input is electrically connected to the control panel, and its output is electrically connected to the motor controller; the motor controller is connected to the drive motor; the drive motor rotates coaxially with the tension wheel; the sensors include a tension wheel speed sensor and a tailstock pressure sensor, which send sensor feedback signals to the controller.

[0008] The control panel includes a band selection switch, an electronic handwheel, a pulse generator, a confirmation button, and a confirmation indicator light.

[0009] The controller counts the pulses transmitted from the control panel and multiplies them by a preset multiplier to obtain the final tension preset value, which is then transmitted to the corresponding motor.

[0010] The band selection switch is used to switch the system operating mode; the system operating modes include traction adjustment mode, tension adjustment mode and tailstock pressure adjustment mode;

[0011] The electronic handwheel is used to adjust the preset value of the tension, and it adopts a single-axis digital pulse output method.

[0012] The confirmation button is used to confirm the adjusted parameters and is a normally open button. When the button is pressed, the confirmation indicator light illuminates and the system enters the tension preset state. If there is no operation within the set time, the confirmation indicator light will automatically turn off, the operation panel switch will become ineffective, and the electronic handwheel adjustment operation will be invalid.

[0013] The pulse generator sends digital pulses to the controller according to the adjustment range of the electronic handwheel.

[0014] When the system detects that the operator has adjusted the electronic handwheel speed below the preset threshold, the controller is in fine-tuning mode and uses the default preset multiplier to calculate the preset tension value; when the system detects that the operator has adjusted the electronic handwheel speed above the preset threshold, the controller switches to coarse-tuning mode and calls the preset coarse-tuning multiplier to calculate the preset tension value.

[0015] The present invention also provides a method for using the tension preset control system of the electric tensioning machine, comprising the following steps:

[0016] S1. Control the band selection switch to select the desired system operating mode. The system completes mode initialization, and the controller enters the tension preset preparation state.

[0017] S2. Press the confirmation button. The confirmation indicator light will stay on green, and the system will officially enter the tension preset state. The controller will unlock the adjustment authority of the electronic handwheel.

[0018] S3. The operator rotates the electronic handwheel, and the system automatically and smoothly switches between coarse adjustment mode and fine adjustment mode according to the rotation speed. The digital pulse signal output by the electronic handwheel is transmitted to the controller. The controller calculates the preset tension value according to "pulse number × preset ratio" and adjusts the control current output to the motor controller. The motor controller controls the drive motor to output the corresponding torque, thereby driving the tension wheel or tension wheel to generate the preset tension.

[0019] S4. Once the tension preset value is adjusted to the target range, exit the tension preset state, the preset parameters take effect and remain, and the tension preset control of the electric tensioner is completed.

[0020] In step S4, the exit from the tension preset state includes the following three methods:

[0021] A. Press the confirmation button again. The confirmation indicator light will turn off, the system will exit the tension preset state, the electronic handwheel adjustment authority will be locked, and the preset tension value will remain stable.

[0022] B. Rotate the band selection switch to switch to the non-tension adjustment mode, confirm that the indicator light is off, the system exits the tension preset state, and the electronic handwheel adjustment authority is locked;

[0023] C. After the electronic handwheel stops being turned, the system triggers the time relay delay mechanism. The indicator light flashes at a frequency of 1Hz for 5 seconds and then automatically turns off. The system exits the tension preset state and the electronic handwheel adjustment authority is locked. If the electronic handwheel is turned while the indicator light is flashing, the indicator light will return to a constant state and the system will return to the tension preset adjustment process.

[0024] This invention discloses a tension preset control system and method for an electric tensioning machine, which has the following beneficial effects:

[0025] 1. This invention uses a composite control switch on the control panel to achieve step-by-step control. After the tension preset value is adjusted, it must be confirmed by the confirmation button to take effect. After the confirmation button is powered off (or there is no operation after a delay), the electronic handwheel adjustment is invalid. From the operation logic, the problem of accidental touch leading to unexpected changes in the tension preset value is eliminated, effectively avoiding safety accidents such as tension overload damaging the conductor or tower, or insufficient tension causing the conductor to fall to the ground, thus ensuring the safety of construction personnel and equipment.

[0026] 2. This solution uses a motor drive instead of the traditional hydraulic drive. The motor current is controlled by a digital pulse signal output from an electronic handwheel, thereby precisely adjusting the motor's output torque and eliminating the signal drift problem caused by the physical contact of traditional potentiometers. Simultaneously, the electronic handwheel, combined with an intelligent rate switching algorithm, allows for rapid coarse and precise fine adjustments of the tension preset value on a single handle, with adjustment accuracy superior to traditional hydraulic adjustment solutions. Furthermore, the motor drive is unaffected by factors such as hydraulic oil viscosity and temperature, ensuring stable tension output and minimal deviation between the preset value and the actual tension, meeting the requirements of high-precision line laying construction.

[0027] 3. This solution uses motor drive instead of traditional hydraulic drive. The response speed of motor drive is far superior to that of hydraulic drive. After the tension preset value is adjusted, the motor can quickly respond and output the corresponding torque to achieve rapid stabilization of tension. The band switch can switch between multiple working modes to adapt to different adjustment requirements such as tension, tension, and tailstock pressure. At the same time, the adjustment range of the electronic handwheel can be flexibly set to adapt to the usage requirements of different cable specifications and different construction conditions, making it highly versatile.

[0028] 4. This system eliminates easily damaged components such as electro-hydraulic servo valves and relief valves found in traditional hydraulic transmission systems, replacing potentiometers with electronic control components. These components have a low failure rate and a long service life. At the same time, the electronic control components are easy to maintain, eliminating the need for regular hydraulic oil replacement and hydraulic component maintenance, effectively reducing equipment maintenance costs and improving the reliability of the equipment during operation. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the system of the present invention;

[0030] Figure 2 This is a flowchart illustrating the method of the present invention. Detailed Implementation

[0031] This invention provides a tension preset control system for an electric tensioning machine, the structural schematic of which is shown in the figure below. Figure 1 As shown, it includes a control panel, controller, motor controller, drive motor, several tension wheels and corresponding tailstock, and sensors;

[0032] The controller's input is electrically connected to the control panel, and its output is electrically connected to the motor controller; the motor controller is connected to the drive motor; the drive motor rotates coaxially with the tension wheel; the sensors include a tension wheel speed sensor and a tailstock pressure sensor, which send sensor feedback signals to the controller.

[0033] The control panel includes a band selection switch, an electronic handwheel, a pulse generator, a confirmation button, and a confirmation indicator light.

[0034] The controller counts the pulses transmitted from the control panel and multiplies them by a preset multiplier to obtain the final tension preset value, which is then transmitted to the corresponding motor.

[0035] The band selection switch is used to switch the system operating mode; the system operating modes include traction adjustment mode, tension adjustment mode and tailstock pressure adjustment mode;

[0036] The electronic handwheel is used to adjust the preset value of the tension, and it adopts a single-axis digital pulse output method.

[0037] The confirmation button is used to confirm the adjusted parameters and is a normally open button. When the button is pressed, the confirmation indicator light illuminates and the system enters the tension preset state. If there is no operation within the set time, the confirmation indicator light will automatically turn off, the operation panel switch will become ineffective, and the electronic handwheel adjustment operation will be invalid.

[0038] The pulse generator sends digital pulses to the controller according to the adjustment range of the electronic handwheel.

[0039] When the system detects that the operator has adjusted the electronic handwheel speed below the preset threshold, the controller is in fine-tuning mode and uses the default preset multiplier to calculate the preset tension value; when the system detects that the operator has adjusted the electronic handwheel speed above the preset threshold, the controller switches to coarse-tuning mode and calls the preset coarse-tuning multiplier to calculate the preset tension value.

[0040] The present invention also provides a method for using the tension preset control system of the electric tensioning machine, the flowchart of which is shown below. Figure 2 As shown, it includes the following steps:

[0041] S1. Control the band selection switch to select the desired system operating mode. The system completes mode initialization, and the controller enters the tension preset preparation state.

[0042] S2. Press the confirmation button. The confirmation indicator light will stay on green, and the system will officially enter the tension preset state. The controller will unlock the adjustment authority of the electronic handwheel.

[0043] S3. The operator rotates the electronic handwheel, and the system automatically and smoothly switches between coarse adjustment mode and fine adjustment mode according to the rotation speed. The digital pulse signal output by the electronic handwheel is transmitted to the controller. The controller calculates the preset tension value according to "pulse number × preset ratio" and adjusts the control current output to the motor controller. The motor controller controls the drive motor to output the corresponding torque, thereby driving the tension wheel or tension wheel to generate the preset tension.

[0044] S4. Once the tension preset value is adjusted to the target range, exit the tension preset state, the preset parameters take effect and remain, and the tension preset control of the electric tensioner is completed.

[0045] In step S4, the exit from the tension preset state includes the following three methods:

[0046] D. Press the confirmation button again. The confirmation indicator light will turn off, the system will exit the tension preset state, the electronic handwheel adjustment authority will be locked, and the preset tension value will remain stable.

[0047] E. Rotate the band selection switch to switch to the non-tension adjustment mode, confirm that the indicator light is off, the system exits the tension preset state, and the electronic handwheel adjustment authority is locked;

[0048] F. After the electronic handwheel stops being turned, the system triggers the time relay delay mechanism. The indicator light flashes at a frequency of 1Hz for 5 seconds and then automatically turns off. The system exits the tension preset state and the electronic handwheel adjustment authority is locked. If the electronic handwheel is turned while the indicator light is flashing, the indicator light will return to a constant state and the system will return to the tension preset adjustment process.

Claims

1. A system for presetting the tension of an electrically powered tensioner, characterized in that It includes a control panel, controller, motor controller, drive motor, several tension wheels and corresponding tailstock, and sensors; The controller's input is electrically connected to the control panel, and its output is electrically connected to the motor controller; the motor controller is connected to the drive motor; the drive motor rotates coaxially with the tension wheel; the sensors include a tension wheel speed sensor and a tailstock pressure sensor, which send sensor feedback signals to the controller. The control panel includes a band selection switch, an electronic handwheel, a pulse generator, a confirmation button, and a confirmation indicator light. The controller counts the pulses transmitted from the control panel and multiplies them by a preset multiplier to obtain the final tension preset value, which is then transmitted to the corresponding motor.

2. The tension preset control system for the electric tensioning machine according to claim 1, characterized in that, The band selection switch is used to switch the system operating mode; the system operating modes include traction adjustment mode, tension adjustment mode and tailstock pressure adjustment mode; The electronic handwheel is used to adjust the preset value of the tension, and it adopts a single-axis digital pulse output method. The confirmation button is used to confirm the adjusted parameters and is a normally open button. When the button is pressed, the confirmation indicator light illuminates and the system enters the tension preset state. If there is no operation within the set time, the confirmation indicator light will automatically turn off, the operation panel switch will become ineffective, and the electronic handwheel adjustment operation will be invalid. The pulse generator sends digital pulses to the controller according to the adjustment range of the electronic handwheel.

3. The control system for presetting the stretching force of an electric stretching machine according to claim 1, wherein When the system detects that the operator has adjusted the electronic handwheel speed below the preset threshold, the controller is in fine-tuning mode and uses the default preset multiplier to calculate the preset tension value; when the system detects that the operator has adjusted the electronic handwheel speed above the preset threshold, the controller switches to coarse-tuning mode and calls the preset coarse-tuning multiplier to calculate the preset tension value.

4. A method of using the pre-tension control system of the electric drawbench according to any one of claims 1 to 3, characterized in that, Includes the following steps: S1. Control the band selection switch to select the desired system operating mode. The system completes mode initialization, and the controller enters the tension preset preparation state. S2. Press the confirmation button. The confirmation indicator light will stay on green, and the system will officially enter the tension preset state. The controller will unlock the adjustment authority of the electronic handwheel. S3. The operator rotates the electronic handwheel, and the system automatically and smoothly switches between coarse adjustment mode and fine adjustment mode according to the rotation speed. The digital pulse signal output by the electronic handwheel is transmitted to the controller. The controller calculates the preset tension value according to "pulse number × preset ratio" and adjusts the control current output to the motor controller. The motor controller controls the drive motor to output the corresponding torque, which in turn drives the tension wheel or tension roller to generate a preset tension. S4. Once the tension preset value is adjusted to the target range, exit the tension preset state, the preset parameters take effect and remain, and the tension preset control of the electric tensioner is completed.

5. The method of claim 4, wherein, In step S4, the exit from the tension preset state includes the following three methods: A. Press the confirmation button again. The confirmation indicator light will turn off, the system will exit the tension preset state, the electronic handwheel adjustment authority will be locked, and the preset tension value will remain stable. B. Rotate the band selection switch to switch to the non-tension adjustment mode, confirm that the indicator light is off, the system exits the tension preset state, and the electronic handwheel adjustment authority is locked; C. After the electronic handwheel stops being turned, the system triggers the time relay delay mechanism. The indicator light flashes at a frequency of 1Hz for 5 seconds and then automatically turns off. The system exits the tension preset state and the electronic handwheel adjustment authority is locked. If the electronic handwheel is turned while the indicator light is flashing, the indicator light will return to a constant state and the system will return to the tension preset adjustment process.

Images