Variable Frequency Tensioning Winch Test System and Method

Abstract

This disclosure relates to the field of mechanical testing technology, and in particular provides a variable frequency tensioning winch testing system and method. The system includes: a control unit, a frequency converter, a brake pump station, and sensors. The control unit is connected to the frequency converter, the brake pump station, and the sensors respectively. The control unit is used to send a first control command to the frequency converter, wherein the frequency converter is used to control the start and stop of the motor of the test winch in response to the first control command. The control unit is used to send a second control command to the brake pump station, wherein the brake pump station is used to control the release or braking of the brake of the test winch in response to the second control command. The sensors are used to collect the operating status parameters of the test winch and feed the operating status parameters back to the control unit to determine the test results. This disclosure improves the accuracy and reliability of winch testing.

Description

Technical Field

[0001] This disclosure relates to the field of mechanical testing technology, and in particular to a variable frequency tension winch testing system and method. Background Technology

[0002] Variable frequency tensioning winches are the core equipment of coal mine belt conveyors. The winches rely on brakes to achieve reliable braking and release of the drums, which is a key component to ensure the smooth start and stop of the belt conveyor. The braking performance of the brakes is directly related to the safety of mine transportation.

[0003] In related technologies, the brake testing of winches before leaving the factory mainly adopts the static sealing test method, that is, applying hydraulic pressure to the brake alone in a powerless state and observing whether there is any leakage. Some manufacturers also use independent pressure gauges or force measuring devices for auxiliary inspection.

[0004] However, the brake testing scheme provided in the relevant technology before the winch leaves the factory has two problems: first, it cannot simulate the dynamic coordination between the motor and the brake under actual starting, reversing, and stopping conditions, which makes it impossible to detect faults such as incomplete brake release or delayed response; second, the workshop lacks a dedicated 500V test power supply, and forced testing under pressure poses a serious risk of high-voltage electric shock. Summary of the Invention

[0005] This disclosure is made in view of the above problems and provides a variable frequency tensioning winch testing system and method, which improves the accuracy and reliability of winch testing.

[0006] According to a first aspect of this disclosure, a variable frequency tensioning winch testing system is provided, comprising a control unit, a frequency converter, a brake pump station, and sensors. The control unit is connected to the frequency converter, the brake pump station, and the sensors respectively. The control unit is configured to send a first control command to the frequency converter, wherein the frequency converter is configured to control the start and stop of the motor of the test winch in response to the first control command. The control unit is configured to send a second control command to the brake pump station, wherein the brake pump station is configured to control the release or braking of the brake of the test winch in response to the second control command. The sensors are configured to collect operating status parameters of the test winch and feed back the operating status parameters to the control unit to determine the test results.

[0007] According to a second aspect of this disclosure, a method for testing a variable frequency tensioning winch is provided. The method is applied to a variable frequency tensioning winch testing system as described in the first aspect. The method includes: after receiving a test command, a control unit sends a first start control command to a frequency converter, wherein the frequency converter, in response to the first start control command, controls the motor of the test winch to start operation and returns the motor's operating parameters to the control unit; the control unit determines a delayed start duration for the brake pump station based on the frequency converter's operating parameters, and after the delayed start duration, sends a second start control command to the brake pump station to release the brake of the test winch; a sensor collects first operating state parameters of the test winch and feeds them back to the control unit, wherein the control unit determines the brake release test result of the test winch based on the first operating state parameters.

[0008] The variable frequency tensioning winch testing system and method provided in this disclosure, through the unified coordination of the frequency converter and the brake pump station by the control unit, can accurately control the start and stop of the test winch motor and the release and braking action of the brake. With the cooperation of sensors to collect and feedback the operating status parameters in real time, it can simulate the actual operating conditions of the winch to complete dynamic coordinated testing, effectively avoid the risks of high voltage power supply, improve the accuracy and reliability of braking performance testing, solve the problem that traditional static testing cannot detect brake coordination faults, and reduce the factory failure rate of winches.

[0009] It should be understood that both the foregoing general description and the following detailed description are exemplary and intended to provide further illustration of the claimed technology. Attached Figure Description

[0010] The above and other objects, features, and advantages of this disclosure will become more apparent from the more detailed description of the embodiments thereof in conjunction with the accompanying drawings. The drawings are provided to further illustrate the embodiments of this disclosure and form part of the specification. They are used together with the embodiments of this disclosure to explain the disclosure and do not constitute a limitation thereof. In the drawings, the same reference numerals generally represent the same components or steps.

[0011] Figure 1 This is an architectural diagram of a variable frequency tensioning winch testing system according to an embodiment of this disclosure.

[0012] Figure 2 This is an architectural diagram of another variable frequency tension winch testing system according to an embodiment of the present disclosure.

[0013] Figure 3 This is a flowchart of a variable frequency tensioning winch testing method according to an embodiment of the present disclosure.

[0014] Figure 4 This is a schematic diagram of a test data display interface according to an embodiment of the present disclosure.

[0015] Figure 5 This is a schematic diagram of a computer program product according to an embodiment of the present disclosure.

[0016] Figure 6 This is a hardware block diagram of an electronic device according to an embodiment of the present disclosure. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this disclosure more apparent, exemplary embodiments according to this disclosure will now be described in detail with reference to the accompanying drawings. Obviously, the described embodiments are merely some embodiments of this disclosure, and not all embodiments of this disclosure. It should be understood that this disclosure is not limited to the exemplary embodiments described herein.

[0018] To address the aforementioned problems, this disclosure provides a variable frequency tensioning winch testing system, such as... Figure 1 As shown, Figure 1 This diagram illustrates the architecture of a variable frequency tensioning winch testing system according to an embodiment of the present disclosure. The system includes: a control unit 101, a frequency converter 102, a brake pump station 103, and a sensor 104. The control unit 101 is connected to the frequency converter 102, the brake pump station 103, and the sensor 104. The control unit 101 sends a first control command to the frequency converter 102, wherein the frequency converter 102, in response to the first control command, controls the start and stop of the test winch motor. The control unit 101 also sends a second control command to the brake pump station 103, wherein the brake pump station 103, in response to the second control command, controls the release or braking of the test winch brake. The sensor 104 collects the operating status parameters of the test winch and feeds these parameters back to the control unit 101 to determine the test results.

[0019] The inverter 102 is a power electronic device that adjusts the motor speed and torque by changing the frequency of the motor power supply, used to drive the motor of the test winch to start and stop. The brake pump station 103 is a hydraulic power unit used to control the release or braking of the brake of the test winch, used to generate and control the hydraulic oil supplied to the brake. The control unit 101 is a programmable logic controller (PLC) or industrial computer used to receive sensor signals, perform logical operations, and send control commands to various execution components. The first control command output by the control unit 101 to the inverter 102 can be a first start control command or a first stop control command. The first start control command is used to instruct the motor of the test winch to start running, and the first stop control command is used to instruct the motor of the test winch to stop running. The second control command sent by the control unit 101 to the brake pump station 103 can be a second start control command or a second stop control command. The second start control command is used to instruct the brake pump station 103 to release the brake, and the second stop control command is used to instruct the brake pump station 103 to brake.

[0020] In summary, the variable frequency tensioning winch testing system provided in this embodiment of the present disclosure, through the unified coordination of the frequency converter and the brake pump station by the control unit, can accurately control the start and stop of the test winch motor and the release and braking actions of the brake. With the cooperation of sensors to collect and feedback operating status parameters in real time, it can simulate the actual operating conditions of the winch to complete dynamic coordinated testing, effectively avoid the risks of high voltage power supply, improve the accuracy and reliability of braking performance testing, solve the problem that traditional static testing cannot detect brake coordination faults, and reduce the factory failure rate of winches.

[0021] It should be noted that, in this embodiment of the disclosure, after receiving the test command, the control unit sends a first control command to the frequency converter. The test command may include operating condition simulation parameters (such as target tension value, reversing cycle, acceleration and deceleration time, used to simulate the actual operating load and motion law of the winch), test process control parameters (such as the number of test cycles, stop triggering conditions, used to specify the order of test execution and termination logic), and safety and judgment threshold parameters (such as release pressure threshold, tension safety upper limit, temperature rise and vibration limit, used by the control unit for real-time protection and final test result qualification judgment), etc. Specifically, these parameters can be determined based on the different requirements of each test, and this embodiment of the disclosure does not limit them.

[0022] In one alternative implementation, such as Figure 2 As shown, Figure 2 This diagram illustrates the architecture of another variable frequency tensioning winch testing system provided in this embodiment. The system further includes a display unit 105 connected to a control unit 101. The display unit 105 is used to issue test commands to the control unit 101 in response to a test start operation. By adding a display unit, the system can directly respond to test start operations and issue test commands to the control unit, achieving visualization and convenient control of the testing process. This allows operators to initiate tests intuitively and quickly, simplifying system operation steps, improving the human-computer interaction and ease of use of the testing platform, while ensuring accurate and timely issuance of test commands, further improving overall testing efficiency and operational reliability.

[0023] It should be noted that, in the embodiments of this disclosure, the display unit includes, but is not limited to, one or more combinations of industrial touch screen, human-machine interface, liquid crystal display screen, and host computer display. Specifically, it can be determined based on actual conditions or needs, and this disclosure does not limit it. The test start operation refers to the user configuring and confirming test parameters such as working condition simulation parameters, test process control parameters, and safety and judgment threshold parameters on the display unit.

[0024] Optionally, users can also send test commands to the control unit of the variable frequency tensioning winch test system through a user terminal. The user terminal can establish a wired or wireless connection with the variable frequency tensioning winch test system. In the winch test scenario, users can configure test-related parameters on the user terminal and send test commands to the variable frequency tensioning winch test system.

[0025] In one optional implementation, the sensor includes a tension sensor connected to a control unit, wherein the tension sensor is used to collect the tension value of the wire rope of the test winch. By setting a tension sensor connected to the control unit in the variable frequency tension winch testing system, the tension value of the wire rope of the test winch is collected in real time and fed back to the control unit. This allows for accurate acquisition of the real tension change data of the test winch under conditions such as brake braking, release, and / or electrode reversal. This provides a quantitative basis for brake performance judgment and test result analysis, enabling accurate detection and evaluation of the test winch status, and effectively improving the accuracy and reliability of the test.

[0026] In one optional embodiment, the sensor may further include a temperature sensor and / or a vibration sensor, which are respectively connected to the control unit. The temperature sensor is used to collect the temperature value of the test winch brake, and the vibration sensor is used to collect the vibration value of the test winch drum bearing housing. By adding a temperature sensor and a vibration sensor connected to the control unit to the variable frequency tension winch testing system, the temperature of the test winch brake and the vibration data of the drum bearing housing can be collected in real time and fed back to the control unit. This enables multi-dimensional monitoring of the operating status of key winch components, allowing for timely detection of potential faults such as overheating and abnormal vibration, ensuring test safety, and providing comprehensive quantitative indicators for the overall performance evaluation of the winch, thus improving the completeness and reliability of the test results.

[0027] In one alternative implementation, please refer to... Figure 2The brake pump station 103 includes a gear pump 1031, an accumulator 1032, a pressure sensor 1033, and a contactor 1034. The pressure sensor 1033 and the contactor 1034 are respectively connected to the control unit 101. The pressure sensor 1033 is installed on the hydraulic output circuit of the brake pump station 103. The oil outlet of the gear pump 1031 is connected to the accumulator 1032. The hydraulic output end of the brake pump station 103 is connected to the brake of the test winch via a reversing valve. The contactor 1034 is used to control the start and stop of the gear pump 1031 motor in response to the start and stop command sent by the control unit 101. After the gear pump 1031 starts, the high-pressure oil output is charged into the accumulator 1032 for storage through the pipeline. The control unit 101 is used to send a second control command to the reversing valve according to the pressure value sent by the pressure sensor 1033 to control the switching of the reversing valve, so as to realize the release and braking of the brake of the test winch. By integrating a gear pump, accumulator, pressure sensor, and contactor into the brake pump station, the contactor controls the start and stop of the gear pump and charges the accumulator with high-pressure oil to achieve a stable pressure supply. The pressure sensor collects the hydraulic output circuit pressure in real time and feeds it back to the control unit. The control unit drives the directional valve to switch according to the pressure signal, thereby reliably controlling the release and braking of the brake. This not only effectively suppresses hydraulic pressure fluctuations and avoids false triggering of control signals, but also achieves precise response and closed-loop control of brake action, significantly improving the stability, accuracy, and safety of brake performance testing.

[0028] In one optional implementation, after the test begins, the control unit 101 can first send a start command to the contactor 1034, causing the contactor 1034 to engage and start the gear pump 1031 motor. The gear pump 1031 then starts operating, charging high-pressure oil into the accumulator 1032 via pipeline until the pressure in the accumulator 1032 reaches the pressure threshold. The pressure threshold can be determined based on actual needs, and this embodiment does not limit it. This approach can establish a stable and sufficient hydraulic pressure source in advance, effectively absorbing pressure pulsations and reducing pressure fluctuations, avoiding insufficient or unstable pressure during the test. It also provides smooth and reliable hydraulic power for the release and braking of the brake, preventing false triggering of control signals and improving the stability of the test process and the accuracy of the test results.

[0029] Optionally, in scenarios requiring control of the release of the test winch's brake, the control unit 101 sends a second start control command to the reversing valve, causing the reversing valve to switch to the release position. At this time, the high-pressure oil stored in the accumulator 1032 and the high-pressure oil output by the gear pump 1031 flow together into the brake of the test winch through the hydraulic output end of the reversing valve, pushing the brake piston to move and releasing the brake. During the release of the test winch's brake, the pressure sensor 1033 collects the pressure value on the hydraulic output circuit in real time and feeds it back to the control unit 101. The control unit 101 confirms that the brake of the test winch has been completely released when it determines that the pressure value is greater than or equal to the release pressure threshold and remains stable within a preset time, thus completing the brake release control. The release pressure threshold and the preset time can be determined based on actual needs, and this embodiment does not limit them.

[0030] Optionally, in scenarios where it is necessary to control the brake of the test winch, the control unit 101 sends a braking command to the reversing valve, causing the reversing valve to switch to the braking position. At this time, the high-pressure oil inside the brake is depressurized and flows back to the oil tank through the return port of the reversing valve. Under the action of its own spring force, the brake quickly grips the drum of the test winch, achieving braking. During the braking process, the pressure sensor 1033 continuously monitors the pressure value on the hydraulic output circuit and feeds it back to the control unit 101. When the pressure value drops to the braking pressure threshold, the control unit 101 confirms that the brake has been fully applied.

[0031] In one alternative implementation, the variable frequency tensioning winch testing system can display the test data and / or test results via the display unit 105 for testing personnel to review.

[0032] This disclosure provides a method for testing a variable frequency tensioning winch, which is applied to the aforementioned variable frequency tensioning winch testing system. Figure 3 As shown, Figure 3 A flowchart of a variable frequency tension winch testing method provided in an embodiment of this disclosure is shown, the method comprising: In step S301, after receiving the test command, the control unit sends the first start control command to the frequency converter.

[0033] The frequency converter is used to respond to the first start control command, control the motor of the test winch to start running, and return the motor's operating parameters to the control unit.

[0034] In step S302, the control unit determines the delayed start time of the brake pump station based on the operating parameters of the frequency converter, and after the delayed start time, sends a second start control command to the brake pump station to release the brake of the test winch.

[0035] In one optional implementation, the operating parameter is the motor torque value. The process by which the control unit determines the delayed start-up time of the brake pump station based on the inverter's operating parameters includes: reading a pre-stored torque-delay relationship model; and then, determining the delayed start-up time of the brake pump station based on the current torque value and the torque-delay relationship model. By using the motor torque value as the basis for delay calculation and calling the pre-established torque-delay relationship model, the delayed start-up time of the brake pump station can be accurately matched with the real-time torque. This allows for dynamic adaptation of the brake release timing according to the actual load of the test winch, avoiding the impact, stuttering, or uncoordinated response problems caused by fixed delays. This achieves precise timing coordination between the motor and the brake, further improving the realism of the test conditions, control accuracy, and reliability of the test results.

[0036] It should be noted that, in the embodiments of this disclosure, the torque-delay relationship model can be a predetermined table or function model. The table may include the delayed start-up time corresponding to different torques or torque ranges. The function model may be a torque-delay relationship model determined according to the engineering characteristics of the winch. Specifically, it can be determined based on the actual engineering characteristics, and this disclosure does not limit it.

[0037] For example, the torque-delay relationship model is as follows: Δt= K × (T_set - T_actual); (Formula 1) In Formula 1, Δt is the delayed start-up time, T_set is the safe release torque threshold, T_actual is the current real-time torque value, and K is the engineering coefficient. The engineering coefficient and the safe release torque threshold can be determined based on actual needs, and this embodiment does not limit them.

[0038] In one optional implementation, before the control unit determines the delayed start-up duration of the brake pump station based on the operating parameters of the frequency converter, the control unit may further: after determining that the current torque value is greater than a preset safety release threshold, determine the delayed start-up duration of the brake pump station based on the operating parameters of the frequency converter. The preset safety release threshold can be determined based on actual needs, and this embodiment does not limit this. The brake of the test winch can be released after the motor has achieved safe driving capability to prevent slippage or impact, thereby improving the safety and reliability of the test.

[0039] Optionally, the operating parameter is the motor current value. When the operating parameter is the motor current value, the process of the control unit determining the delayed start-up time of the brake pump station based on the operating parameters of the frequency converter can be referred to in the above embodiment, where the operating parameter is the motor torque value, and the control unit determines the delayed start-up time of the brake pump station based on the operating parameters of the frequency converter. This disclosure embodiment will not elaborate on this.

[0040] In step S303, the sensor collects the first operating status parameters of the test winch and feeds them back to the control unit.

[0041] In this embodiment of the disclosure, during the brake release process of the test winch, the first operating state parameters of the test winch collected by the sensors may include: the pressure value of the hydraulic output circuit monitored by the pressure sensor, and the tension value of the wire rope monitored by the tension sensor; the control unit determines the brake release test result of the test winch based on the first operating state parameters.

[0042] In one optional implementation, the process by which the control unit determines the brake release test result of the test winch based on the first operating state parameters includes: the control unit determining the moment when the pressure value fed back by the pressure sensor reaches the preset release threshold and the moment when the tension value fed back by the tension sensor continues to rise from the initial baseline; simultaneously, the control unit analyzes the smoothness of the tension rise curve during the brake release process of the test winch, determines whether there is jitter or jamming during the release process, thereby determining the release stability, and determines the brake release test result based on the two indicators of release response time and release stability.

[0043] The control unit can determine the smoothness of the tension rise curve by analyzing the fluctuation amplitude of the first derivative of the tension rise curve; the brake release test result can be qualified or unqualified.

[0044] It should be noted that, in the embodiments of this disclosure, the strategy of the control unit to determine the smoothness of the tension rise curve based on the fluctuation amplitude of the first derivative of the tension rise curve is predetermined, and the embodiments of this disclosure do not limit this strategy; and the strategy of determining the brake release test result based on the two indicators of release response time and release stability is also predetermined, and the embodiments of this disclosure do not limit this strategy.

[0045] In summary, the variable frequency tensioning winch testing method provided in this disclosure involves the control unit first starting the frequency converter to drive the motor of the test winch after receiving the test command. Then, it intelligently determines the brake release delay time based on the real-time operating parameters of the motor, and controls the brake pump station to release the brake after a delay. This achieves dynamic timing coordination between motor startup and brake release, avoiding slippage or impact that might occur with a fixed delay. By acquiring the motor status in real time and calculating the delay, the brake is always released only after the motor has built up sufficient torque, protecting the equipment and simulating real-world operating conditions. Simultaneously, the release effect is confirmed through sensor feedback closed-loop verification, enabling precise quantitative testing of the test winch.

[0046] In one optional implementation, after the brake remains released and the motor operates stably, the control unit sends a commutation command to the frequency converter. The frequency converter responds to the commutation command by controlling the motor to decelerate to zero and then accelerate in the reverse direction. Simultaneously, sensors collect second operating state parameters of the test winch during the motor commutation process and send these parameters to the control unit. The control unit then determines the drum commutation test result of the test winch based on these second operating state parameters. Under the condition of the brake remaining released and the motor operating stably, the control unit controls the frequency converter to drive the motor to decelerate and stop, then accelerates in the reverse direction, simulating the drum commutation condition. Simultaneously, by collecting operating state parameters in real time during the commutation process and feeding them back to the control unit, the dynamic operating performance of the winch during forward and reverse switching can be fully detected, obtaining reliable commutation condition data, accurately determining the drum commutation effect, improving the coverage of test items, and enhancing the overall comprehensiveness and accuracy of the test.

[0047] The second operating status parameters received by the control unit mainly include the tension impact peak value collected by the tension sensor and the hydraulic pressure fluctuation value collected by the pressure sensor. The process by which the control unit determines the drum reversing test result of the test winch through the second operating status parameters includes: comparing the measured tension impact peak value with the tension safety upper limit; if the measured tension impact peak value does not exceed the tension safety upper limit, the reversing impact is determined to be qualified; at the same time, the control unit analyzes whether the pressure fluctuation value is within the allowable pressure fluctuation threshold; if the pressure fluctuation is not within the pressure fluctuation threshold, the brake stability is determined to be abnormal; and the control unit can also determine the time required for the tension to drop from the forward stable value to zero and then rise to the reverse stable value as the reversing time, and if the reversing time exceeds the reversing time threshold, the motor reversing is determined to be abnormal. Finally, the reversing impact qualification, brake stability abnormality, and motor reversing abnormality are determined as the drum reversing test results.

[0048] It should be noted that, in the embodiments of this disclosure, the tension safety upper limit, the pressure fluctuation threshold, and the reversal time threshold can be determined based on actual needs, and the embodiments of this disclosure do not limit them.

[0049] In one optional implementation, after the test is completed, the control unit sends a first stop control command to the frequency converter and a second stop control command to the brake pump station, causing the brake of the test winch to switch to the braking state. Sensors collect a third operating status parameter of the test winch during the braking process and send this parameter to the control unit. The control unit determines the brake's stopping test result based on the third operating status parameter. At the end of the test, the control unit simultaneously sends stop commands to both the frequency converter and the brake pump station, causing the brake to quickly switch to the braking state. Simultaneously, sensors collect operating status parameters during the braking process in real time and feed them back to the control unit. This realistically simulates the winch's stopping condition and accurately detects the brake's stopping performance, obtaining reliable braking effect data and enabling a quantitative assessment of the brake's braking capacity, further improving the completeness and reliability of the test results.

[0050] During the stop test, the third operating state parameters received by the control unit mainly include: the tension decrease curve fed back by the tension sensor and the pressure release curve fed back by the pressure sensor. The process of determining the stop test result of the brake through the third operating state parameters includes: determining the duration between the moment the second stop control command is issued and the moment the tension value decreases, thus obtaining the stop response time; at the same time, the control unit monitors the residual tension value after the tension decreases to a stable value, and compares the measured stop response time with the stop allowable time threshold, and compares the residual tension value with the upper limit of the residual tension value. If both indicators are within the qualified range, the brake stop test result is determined to be qualified; otherwise, it is unqualified, and the brake stop test result is obtained.

[0051] It should be noted that, in the embodiments of this disclosure, the second stop control command is used to control the reversing valve to switch to the braking position; the stop allowable time threshold and the upper limit of the residual tension value can be determined based on actual needs, and the embodiments of this disclosure do not limit them.

[0052] In one optional implementation, throughout the entire process from motor startup to test completion, the control unit receives temperature values ​​from the temperature sensor and vibration values ​​from the vibration sensor. Based on these values, it determines the brake temperature test result and the vibration test result of the drum bearing housing of the test winch, respectively. Throughout the entire process, the control unit continuously receives real-time data from the temperature and vibration sensors, thereby completing the full-process monitoring and result determination of the brake temperature and drum bearing housing vibration status. This allows for a comprehensive understanding of the operating status of key winch components under continuous working conditions, timely identification of potential hazards such as overheating and abnormal vibration, and simultaneous detection of multiple indicators and comprehensive performance evaluation, significantly improving the integrity, safety, and reliability of the test results.

[0053] Throughout the testing process, the control unit continuously collects the brake temperature value from the temperature sensor and the roller bearing housing vibration value from the vibration sensor. For the temperature test results, the control unit records the initial temperature and monitors temperature changes in real time, calculating the maximum temperature rise during the test. If the maximum temperature rise exceeds the temperature threshold, it is determined that the brake has abnormalities such as incomplete release, dragging, or poor heat dissipation. For the vibration test results, the control unit extracts the amplitude of the vibration signal and compares it with the vibration threshold. If the measured vibration amplitude continuously or periodically exceeds the vibration threshold, it is determined that the roller bearing housing or related rotating components are unbalanced, loose, or damaged. Finally, the control unit outputs the brake temperature test results (pass / fail) and the roller bearing housing vibration test results (pass / fail), respectively.

[0054] It should be noted that, in the embodiments of this disclosure, the maximum temperature rise is the difference between the highest temperature and the initial temperature, the amplitude of the vibration signal is the effective value of the vibration signal velocity or the peak value of the acceleration, the brake temperature test result is qualified or unqualified, and the roller bearing seat vibration test result is qualified or qualified; the temperature rise threshold and vibration threshold can be determined based on actual needs, and the embodiments of this disclosure do not limit them.

[0055] For example, this embodiment of the disclosure uses a target tension of 15 tons, a reversing cycle of 30 seconds (i.e., 15 seconds of forward rotation and 15 seconds of reverse rotation), and a motor acceleration / deceleration time of 5 seconds as an example to illustrate the variable frequency tension winch testing method provided in this embodiment of the disclosure. In this method, the operator connects the winch to be tested to the test platform, inputs the operating parameters on the touch screen: target tension of 15 tons, reversing cycle of 30 seconds, motor acceleration / deceleration time of 5 seconds, and clicks the test start control. The touch screen then sends a test command to the control unit.

[0056] Furthermore, in response to receiving the test command, the control unit sends a first start control command to the frequency converter. This first start control command includes parameters such as a target frequency of 50Hz and an acceleration time of 5 seconds. Then, the frequency converter responds to the first start control command by driving the motor to start. Because the brake is initially in a braking state, the motor is stalled. The frequency converter returns the motor torque value to the control unit in real time. The control unit uses a torque-delay relationship model to calculate the delayed start time Δt, assuming Δt is 0.1 seconds. The control unit starts timing when the torque exceeds the preset safe release threshold after motor start. After 0.1 seconds, it determines the end of the delayed start time and sends a second start control command to the brake pump station to energize the reversing valve and switch it to the release position. Here, the accumulator and gear pump jointly supply oil to the brake. The pressure sensor reports that the pressure rises rapidly to the preset release threshold of 8MPa in 75ms. Simultaneously, the tension sensor records that the wire rope tension rises steadily from 0.1T. The control unit then determines the release response time to be 75ms, indicating excellent release stability, and obtains the brake release test result.

[0057] Next, the motor ran stably at 50Hz forward for 15 seconds. During this time, the control unit continuously collected temperature and vibration values. After 15 seconds, the control unit sent a commutation command to the frequency converter: decelerate for 0.5 seconds, stop for 0.2 seconds, and accelerate in the opposite direction for 0.5 seconds. During the motor commutation process, the tension sensor recorded a tension impact peak of 18T, and the pressure sensor recorded a pressure fluctuation that decreased from 8MPa to 7.9MPa. The control unit calculated that the commutation impact peak, pressure fluctuation, and commutation time of 1.2 seconds were all acceptable, thus obtaining the drum commutation test results.

[0058] Furthermore, after the motor has been running stably in reverse for 15 seconds, the control unit sends a first stop control command to the frequency converter and a second stop control command to the brake pump station. The control unit detects brake depressurization, with the pressure dropping from 8MPa to 0.5MPa in 0.12 seconds; the tension drops from -15T to 0.1T, the stop response time is 20ms, and the residual tension is 0.05T, thus obtaining the stop test results.

[0059] It should be noted that from the start of the motor to the end of the test, the control unit recorded the temperature and vibration every 0.5 seconds. The initial temperature was 25℃, and the highest temperature rose to 42℃, with a maximum temperature rise of 17℃, which is acceptable. Also, the vibration peak value during commutation was 2.8mm / s, and the remaining values ​​were ≤1.5mm / s, with a maximum vibration amplitude of 2.8mm / s.

[0060] Optionally, the control unit can automatically generate a test report after a test is completed, which includes six indicators: release response time 75ms, excellent release stability, stop response time 20ms, residual tension 0.05T, reversing impact peak 18T, reversing time 1.2s, pressure fluctuation ±0.1MPa, maximum temperature rise 17℃, and maximum vibration 2.8mm / s.

[0061] For example, such as Figure 4 As shown, Figure 4 A schematic diagram of a test data display interface is shown, including three core parameters: braking pressure, intermediate voltage, and wire rope tension. This allows operators to intuitively grasp the operating status of the equipment. The intermediate voltage refers to the DC-link voltage of the frequency converter.

[0062] Exemplary embodiments of this disclosure also provide an electronic device, which is a control unit in a variable frequency tension winch testing system, comprising: at least one processor; and a memory communicatively connected to the at least one processor. The memory stores a computer program executable by the at least one processor, which, when executed by the at least one processor, causes the electronic device to perform a method according to an embodiment of this disclosure.

[0063] Exemplary embodiments of this disclosure also provide a non-transitory computer-readable storage medium storing a computer program, wherein the computer program, when executed by a computer's processor, is used to cause the computer to perform a method according to embodiments of this disclosure.

[0064] like Figure 5 As shown, an exemplary embodiment of this disclosure also provides a computer program product 500, including a computer program 501, wherein the computer program, when executed by a computer's processor, is used to cause the computer to perform a method according to an embodiment of this disclosure.

[0065] refer to Figure 6 The following description serves as a structural block diagram of the electronic device 600 of this disclosure, which is an example of a hardware device applicable to various aspects of this disclosure. The electronic device is intended to represent various forms of digital electronic computer devices, such as laptop computers, desktop computers, workstations, personal digital assistants, servers, blade servers, mainframe computers, and other suitable computers. The electronic device can also represent various forms of mobile devices, such as personal digital processors, cellular phones, smartphones, wearable devices, and other similar computing devices. The components shown herein, their connections and relationships, and their functions are merely illustrative and are not intended to limit the implementation of the disclosure described and / or claimed herein.

[0066] like Figure 6 As shown, the electronic device 600 includes a computing unit 601, which can perform various appropriate actions and processes based on a computer program stored in a read-only memory (ROM) 602 or a computer program loaded from a storage unit 608 into a random access memory (RAM) 603. The RAM 603 may also store various programs and data required for the operation of the electronic device 600. The computing unit 601, ROM 602, and RAM 603 are interconnected via a bus 604. An input / output (I / O) interface 605 is also connected to the bus 604.

[0067] Multiple components in electronic device 600 are connected to I / O interface 605, including: input unit 606, output unit 607, storage unit 608, and communication unit 609. Input unit 606 can be any type of device capable of inputting information to electronic device 600. Input unit 606 can receive input digital or character information and generate key signal inputs related to user settings and / or function control of electronic device. Output unit 607 can be any type of device capable of presenting information and may include, but is not limited to, a display, speaker, video / audio output terminal, vibrator, and / or printer. Storage unit 608 may include, but is not limited to, disks and optical discs. Communication unit 609 allows electronic device 600 to exchange information / data with other devices through computer networks such as the Internet and / or various telecommunications networks, and may include, but is not limited to, modems, network cards, infrared communication devices, wireless communication transceivers, and / or chipsets, such as Bluetooth™ devices, WiFi devices, WiMax devices, cellular communication devices, and / or the like.

[0068] The computing unit 601 can be a variety of general-purpose and / or special-purpose processing components with processing and computing capabilities. Some examples of the computing unit 601 include, but are not limited to, a central processing unit (CPU), a graphics processing unit (GPU), various special-purpose artificial intelligence (AI) computing chips, various computing units running machine learning model algorithms, a digital signal processor (DSP), and any suitable processor, controller, microcontroller, etc. The computing unit 601 performs the various methods and processes described above. For example, in some embodiments, the methods of the exemplary embodiments of this disclosure can be implemented as a computer software program tangibly contained in a machine-readable medium, such as storage unit 608. In some embodiments, part or all of the computer program can be loaded and / or installed on the electronic device 600 via ROM 602 and / or communication unit 609. In some embodiments, the computing unit 601 can be configured to perform the methods of the exemplary embodiments of this disclosure by any other suitable means (e.g., by means of firmware).

[0069] The program code used to implement the methods of this disclosure may be written in any combination of one or more programming languages. This program code may be provided to a processor or controller of a general-purpose computer, special-purpose computer, or other programmable data processing apparatus, such that when executed by the processor or controller, the program code causes the functions / operations specified in the flowcharts and / or block diagrams to be implemented. The program code may be executed entirely on a machine, partially on a machine, as a standalone software package partially on a machine and partially on a remote machine, or entirely on a remote machine or server.

[0070] In the context of this disclosure, a machine-readable medium can be a tangible medium that may contain or store a program for use by or in conjunction with an instruction execution system, apparatus, or device. A machine-readable medium can be a machine-readable signal medium or a machine-readable storage medium. A machine-readable medium can be, but is not limited to, electronic, magnetic, optical, electromagnetic, infrared, or semiconductor systems, apparatus, or devices, or any suitable combination of the foregoing. More specific examples of machine-readable storage media include electrical connections based on one or more wires, portable computer disks, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), optical fiber, portable compact disk read-only memory (CD-ROM), optical storage devices, magnetic storage devices, or any suitable combination of the foregoing.

[0071] As used in this disclosure, the terms "machine-readable medium" and "computer-readable medium" refer to any computer program product, device, and / or apparatus (e.g., disk, optical disk, memory, programmable logic device (PLD)) for providing machine instructions and / or data to a programmable processor, including machine-readable media that receive machine instructions as machine-readable signals. The term "machine-readable signal" refers to any signal for providing machine instructions and / or data to a programmable processor.

[0072] To provide interaction with a user, the systems and techniques described herein can be implemented on a computer having: a display device for displaying information to the user (e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor); and a keyboard and pointing device (e.g., a mouse or trackball) through which the user provides input to the computer. Other types of devices can also be used to provide interaction with the user; for example, feedback provided to the user can be any form of sensory feedback (e.g., visual feedback, auditory feedback, or tactile feedback); and input from the user can be received in any form (including sound input, voice input, or tactile input).

[0073] The systems and technologies described herein can be implemented in computing systems that include backend components (e.g., as a data server), or computing systems that include middleware components (e.g., an application server), or computing systems that include frontend components (e.g., a user computer with a graphical user interface or web browser through which a user can interact with implementations of the systems and technologies described herein), or any combination of such backend, middleware, or frontend components. The components of the system can be interconnected via digital data communication of any form or medium (e.g., a communication network). Examples of communication networks include local area networks (LANs), wide area networks (WANs), and the Internet.

[0074] In the above embodiments, implementation can be achieved, in whole or in part, through software, hardware, firmware, or any combination thereof. When implemented in software, it can be implemented, in whole or in part, as a computer program product. A computer program product includes one or more computer programs or instructions. When the computer program or instructions are loaded and executed on a computer, the processes or functions of the embodiments of this disclosure are performed, in whole or in part. The computer can be a general-purpose computer, a special-purpose computer, a computer network, a terminal, a user equipment, or other programmable device. The computer program or instructions can be stored in a computer-readable storage medium or transferred from one computer-readable storage medium to another. For example, a computer program or instructions can be transferred from one website, computer, server, or data center to another website, computer, server, or data center via wired or wireless means. The computer-readable storage medium can be any available medium that a computer can access or a data storage device such as a server or data center that integrates one or more available media. The available medium can be a magnetic medium, such as a floppy disk, hard disk, or magnetic tape; it can also be an optical medium, such as a digital video disc (DVD); or it can be a semiconductor medium, such as a solid-state drive (SSD).

[0075] Although this disclosure has been described in conjunction with specific features and embodiments, it will be apparent that various modifications and combinations can be made therein without departing from the spirit and scope of this disclosure. Accordingly, this specification and drawings are merely exemplary illustrations of the disclosure as defined by the appended claims and are to be considered as covering any and all modifications, variations, combinations, or equivalents within the scope of this disclosure. It is obvious that those skilled in the art can make various alterations and modifications to this disclosure without departing from its spirit and scope. Thus, this disclosure is also intended to include any such modifications and modifications that fall within the scope of the claims of this disclosure and their equivalents.

Claims

1. A variable frequency tensioning winch testing system, characterized in that, The system includes a control unit, a frequency converter, a brake pump station, and sensors, wherein the control unit is connected to the frequency converter, the brake pump station, and the sensors respectively. The control unit is used to send a first control command to the frequency converter, wherein the frequency converter is used to control the start and stop of the test winch motor in response to the first control command; The control unit is configured to send a second control command to the brake pump station, wherein the brake pump station is configured to control the brake of the test winch to release or apply pressure in response to the second control command. The sensor is used to collect the operating status parameters of the test winch and feed the operating status parameters back to the control unit to determine the test results.

2. The variable frequency tensioning winch testing system according to claim 1, characterized in that, The variable frequency tensioning winch testing system also includes a display unit, which is used to send test commands to the control unit in response to a test start operation.

3. The variable frequency tensioning winch testing system according to claim 1, characterized in that, The brake pump station includes a gear pump, an accumulator, a pressure sensor, and a contactor. The pressure sensor and the contactor are respectively connected to the control unit. The pressure sensor is installed in the hydraulic output circuit of the brake pump station. The oil outlet of the gear pump is connected to the accumulator. The hydraulic output end of the brake pump station is connected to the brake of the test winch via a reversing valve. The contactor is used to control the start and stop of the gear pump motor in response to the start and stop command sent by the control unit. After the gear pump starts, the high-pressure oil output is charged into the accumulator for storage through the pipeline. The control unit is used to send a second control command to the reversing valve based on the pressure value sent by the pressure sensor, and control the switching of the reversing valve to realize the release and braking of the brake of the test winch.

4. The variable frequency tensioning winch testing system according to any one of claims 1 to 3, characterized in that, The sensor includes a tension sensor connected to the control unit, wherein the tension sensor is used to collect the tension value of the wire rope of the test winch.

5. The variable frequency tensioning winch testing system according to claim 4, characterized in that, The sensor further includes a temperature sensor and / or a vibration sensor, which are respectively connected to the control unit. The temperature sensor is used to collect the temperature value of the test winch brake, and the vibration sensor is used to collect the vibration value of the test winch drum bearing housing.

6. A test method for a variable frequency tensioning winch, characterized in that, The method is applied to the variable frequency tension winch testing system as described in any one of claims 1 to 5, and the method includes: After receiving the test command, the control unit sends a first start control command to the frequency converter, wherein the frequency converter is used to respond to the first start control command to control the motor of the test winch to start running and return the operating parameters of the motor to the control unit; Based on the operating parameters of the frequency converter, the control unit determines the delayed start time of the brake pump station, and after the delayed start time, sends a second start control command to the brake pump station to release the brake of the test winch. The sensor collects the first operating status parameters of the test winch and feeds them back to the control unit, wherein the control unit determines the brake release test result of the test winch based on the first operating status parameters.

7. The test method for a variable frequency tensioning winch according to claim 6, characterized in that, The operating parameter is the torque value of the motor. Determining the delayed start-up time of the brake pump station based on the operating parameters of the frequency converter includes: Read the pre-stored torque-delay relationship model; Based on the current torque value and the torque-delay relationship model, the delayed start-up time of the brake pump station is determined.

8. The test method for a variable frequency tensioning winch according to claim 6, characterized in that, The method further includes: After the brake remains in the released state and the motor runs stably, the control unit sends a commutation command to the frequency converter, and the frequency converter responds to the commutation command by controlling the motor to decelerate to zero and then accelerate in the opposite direction. The sensor collects the second operating status parameters of the test winch during the motor commutation process and sends the second operating status parameters to the control unit; The control unit determines the drum reversal test result of the test winch using the second operating status parameter.

9. The test method for a variable frequency tensioning winch according to claim 6, characterized in that, The method further includes: After the test is completed, the control unit sends a first stop control command to the frequency converter and a second stop control command to the brake pump station, so that the brake of the test winch is switched to the braking state. The sensor collects the third operating status parameters of the test winch during the braking process of the brake, and sends the third operating status parameters to the control unit; The control unit determines the braking test result of the brake through the third operating state parameter.

10. The test method for a variable frequency tensioning winch according to claim 6, characterized in that, The method further includes: Throughout the entire process from motor startup to test completion, the control unit receives temperature values ​​from the temperature sensor and vibration values ​​from the vibration sensor, and determines the brake temperature test result and the vibration test result of the drum bearing housing of the test winch based on the temperature and vibration values, respectively.

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