Flexible pipe cable armour layer steel wire constant tension winding apparatus and control method

Abstract

The application discloses a flexible pipe cable armoring layer steel wire constant tension winding device and a control method, relates to the technical field of winding forming and tension control, and comprises a support frame body, a reel, a steel wire tension control assembly, a steel wire tension measuring assembly and a driving assembly. The steel wire tension control assembly comprises a roller one, a roller two, a displacement actuator and a master control roller. The steel wire tension measuring assembly comprises a support plate and a roller three. A force sensor is arranged on the support plate. When control is performed, the force sensor is used for detecting tension change. A servo system controls the displacement actuator to adjust the master control roller to maintain constant tension. The roller one and the roller two provided with ratchets limit reverse contraction of the steel wire. The application solves the problem of tension fluctuation in the prior art, guarantees winding uniformity, eliminates safety hazards and improves the performance of the pipe cable armoring layer.

Description

Technical Field

[0001] This invention relates to the field of winding molding and tension control technology, and in particular to a constant tension winding device and control method for steel wire in flexible cable armor layer. Background Technology

[0002] With the vigorous development of marine oil and gas, deep-sea mining, and offshore wind power resources, non-bonded flexible cables have become key equipment for connecting and transporting marine resources. The armor layer, consisting of multiple steel wires spirally wound at a specific angle around the cable's skeleton, is crucial for withstanding external tensile and torsional loads and is a key structure determining the overall cable's ultimate load-bearing capacity. In actual processing, the armor wires are often guided to the winding point by multiple sets of reels for spiral winding, and the quality of the winding directly determines the comprehensive mechanical properties of the armor layer. However, existing winding processes often suffer from instantaneous fluctuations or attenuations in wire tension due to factors such as reel inertia, frictional resistance fluctuations, and speed matching deviations. This makes it difficult to maintain a constant tension, resulting in uneven gaps or localized defects in the wound wires. This not only significantly reduces the load-bearing capacity of the armor layer but may also create abnormal contact stress between the wires, leading to premature failure or shortened lifespan of the cable during actual use, posing serious safety hazards. Therefore, in order to achieve uniform and tight winding of the armor layer steel wire and ensure the safe and reliable operation of the non-bonded flexible cable during service, there is an urgent need for a control method and device that can achieve constant tension winding of the armor layer steel wire to improve the consistency of steel wire winding, reduce manufacturing defects, ensure its long-term stable operation in complex marine environments, and improve the efficiency of marine resource development and utilization. Summary of the Invention

[0003] This application provides a constant tension winding device and control method for steel wire in the armor layer of flexible cable, which solves the technical problems of unstable unwinding speed caused by passive wire unwinding from the reel, easy loosening or tightening of the steel wire when the winding speed is constant, tension fluctuation, uneven winding gap, reduced load-bearing capacity of the armor layer, and safety hazards caused by reverse wire contraction. By setting up multiple ratchet rollers and a main control roller, force sensors and a floating device, after the force sensor detects the change in tension component, the servo system controls the displacement actuator to adjust the main control roller, and in conjunction with the drive component to drive the cable to move at a uniform speed and limit the ratchet, the constant tension spiral winding of the steel wire is achieved, ensuring winding uniformity, eliminating safety hazards, and improving the load-bearing capacity of the armor layer.

[0004] This application provides a flexible cable armor layer steel wire constant tension winding device and control method, including a support frame, a reel, a steel wire tension control component, a steel wire tension measurement component, and a drive component.

[0005] The reel has a wire feeding shaft on its side, which is mounted on the support frame. The reel is used to store and release the steel wire required for winding and forming.

[0006] The wire tension control assembly includes a displacement actuator and a main control roller. One or more main control rollers can be provided. The number of main control rollers can be flexibly configured according to actual working conditions. When winding wires with weak bending resistance or prone to slippage, multiple main control rollers can be added to increase the contact area with the wire, preventing excessive pressure from the main control rollers due to insufficient tension, which could cause the wire to bend and fail before it is wound into the cable. When winding wires with strong bending resistance or easily worn surfaces, the number of main control rollers can be appropriately reduced to avoid excessive friction between the main control rollers and the wire, thus protecting the integrity of the wire. The flexible configuration of the number of main control rollers ensures precise matching of different wire characteristics and product requirements while maintaining constant tension control, achieving the optimal balance between tension control and wire protection.

[0007] The axial center of the main control roller is kept in the same plane as the reel. The main control roller is connected to the displacement actuator, which is mounted on the support frame.

[0008] The wire tension control assembly also includes a roller one mounted on a rotating shaft one and a roller two mounted on a rotating shaft two; the rotating shaft one and the rotating shaft two are kept in the same vertical plane; the rotating shaft one and the rotating shaft two are set on the support frame and close to the reel; the roller one and the roller two are provided with ratchet.

[0009] The first and second rollers have annular grooves on their arc surfaces to prevent the steel wire from deviating; the main control roller has annular grooves on its arc surface, and the depth of the first annular groove is greater than the depth of the second annular groove.

[0010] The wire tension measuring assembly includes a support plate and a roller three with a ratchet inside. The support plate is mounted on a support frame and has a floating device installed on it. The roller three is assembled inside the floating device, which is installed on the same horizontal plane as the rotating shaft two. The roller three can move up and down slightly through the action of the floating device. A force sensor is set on the upper surface of the support plate and is located directly below the roller three. The force sensor is connected to a displacement actuator through a servo system.

[0011] The roller three has an annular groove three on its arc surface, and its depth is greater than that of annular groove two but less than that of annular groove one. Annular groove two is the shallowest. Its main function is to provide precise initial guidance and basic positioning. After the steel wire is drawn out from the reel, it first passes through roller one and roller two. The shallow groove can gently restrict the steel wire in the groove, preventing it from sliding or deviating laterally in the early stage of entering the system. This ensures that the steel wire enters the subsequent tension control area at an accurate tangential angle. Since this stage mainly plays a guiding role, there is no need to apply excessive pressure. The shallow groove design avoids unnecessary frictional resistance and provides a stable initial state for subsequent active tension adjustment.

[0012] A deeper annular groove means that the steel wire is embedded more deeply, and the contact arc length and normal pressure increase accordingly. The deeper groove provides a more stable wrapping for the steel wire under large tension changes, preventing the steel wire from coming out of the groove during violent adjustments, and ensuring the stability and safety of the control process.

[0013] The depth of the third annular groove is between that of the first and second annular grooves. Its design is designed to ensure the accuracy of tension measurement and the buffer function of the floating device. The medium-depth groove can effectively prevent the steel wire from deviating at the measurement point, ensuring the accuracy of the tension detection direction, while avoiding the excessive and unstable friction caused by an excessively deep groove that would interfere with the measurement results. The third annular groove allows the tension of the steel wire to be transmitted to the force sensor below more effectively. Furthermore, the design of the medium-depth groove allows the steel wire to maintain good contact with the groove wall during micro-movement, preventing it from coming out due to a shallow groove or getting stuck due to a deep groove. This ensures that the force sensor can detect minute changes in tension in real time and with high sensitivity.

[0014] The floating device includes a hollow outer frame, a spring body, and bushings. The outer frame is symmetrically arranged on the top of the support plate, and the end of the outer frame away from the support plate is an arc-shaped structure. The bottom surface of the hollow structure of the outer frame is provided with a spring body, and the top of the spring body is fixed with a bushing. Two bushings are slidably connected in the hollow structure of the corresponding outer frame, and the two ends of the roller three are rotatably connected in the corresponding bushings. Limit plates are fixed on the top of the two outer frames, and a limit arc groove is opened in the middle of the bottom surface of the limit plate to prevent the steel wire from deviating.

[0015] A U-shaped frame is also fixed between the two bushings, and the U-shaped frame does not directly contact the roller.

[0016] The function of the drive assembly is to provide rotation and axial movement during the process of winding and forming the steel wire on the cable. It includes a mounting frame, a first motor, a second motor, and a moving plate. The mounting frame is set on a horizontal working area or a horizontal ground. The top of the mounting frame has a cavity. The first motor is installed at one end of the mounting frame. A connecting shaft is rotatably connected inside the cavity of the mounting frame. The connecting shaft has an external thread. The output shaft of the first motor passes through the mounting frame and is fixedly connected to one end of the connecting shaft.

[0017] The movable plate is slidably connected in the cavity of the mounting frame. A circular groove is opened on the movable plate near the bottom of the mounting frame, and an internal thread is provided in the circular groove. The movable plate is threadedly connected to the connecting shaft through the circular groove.

[0018] The top surface of the movable plate is fixed with a second motor and a limiting plate at both ends, and one end of the cable is set on the output shaft of the second motor, while the other end is rotatably connected to one end of the limiting plate.

[0019] The specific method for controlling the constant tension winding of steel wires in the armor layer of flexible cable is as follows: S1. Wind the armor layer steel wire onto the reel and draw out the steel wire.

[0020] S2. The steel wire is first passed through the annular groove 2 between roller 1 and roller 2 (the annular groove 2 ensures that the steel wire always exits straight out tangentially along roller 1 and roller 2 during the process of being wound by the cable, avoiding lateral slippage). Then, it passes horizontally below the annular groove 1 of the main control roller, and finally exits between the limiting arc groove of the limiting plate and the annular groove 3 of roller 3, maintaining a constant downward angle and connecting and fixing it to the end of the cable on one side. At this time, roller 3 moves downward under the action of the steel wire, driving the bushing to press down the spring body. The bushing drives the U-shaped frame to press down, so that the U-shaped frame contacts the force sensor. Among them, the rotating shaft 2 and the floating device are on the same horizontal plane, so the part of the steel wire between roller 1 and roller 2, and between the limiting plate and roller 3 remains horizontal.

[0021] S3. Turn on motor one and motor two, drive the connecting shaft to rotate, and move the moving plate to the right. This causes the cable on the moving plate to rotate and step at a constant speed away from motor one along the axial direction. At this time, the steel wire spirals around the outer edge of the cable (the speed at which the cable is wound by the steel wire is called the take-up speed; the linear speed of the steel wire on the reel is called the unwinding speed. Because the reel is passively unwinding, the unwinding speed of the steel wire is unstable. When the take-up speed is stable, the steel wire will become loose or tight depending on whether the unwinding speed is too large or too small, causing the tension to decrease or increase). The presence of the limit plate can prevent the steel wire from slipping out due to excessive lateral shear force during startup, and limit the steel wire to ensure safety.

[0022] S4. During the winding process, the vertical plane where the roller three and the limiting plate are located has an angle with the steel wire that is passed through. Since the cable moves to the right at a constant speed, this angle remains unchanged during winding. If the tension of the steel wire that is passed through is constant, the force sensor will detect that the vertical downward tension component is also constant.

[0023] S5. When the force sensor detects a change in the vertically downward tension component of the wire, it indicates a change in the wire winding tension. At this point, the tension information is transmitted to the displacement actuator via the servo system. If the force sensor detects a decrease in tension, the displacement actuator moves downward, causing the main control roller to press against the horizontal wire, tightening it (the downward pressing action increases the normal force between the wire and the main control roller, thereby increasing friction, tightening the wire, and increasing tension). When the wire tension increases to the set value, the displacement actuator stops moving downward. If an increase in tension is detected, the displacement actuator moves upward, causing the main control roller to move away from the horizontal wire, relaxing it (the lifting action reduces the normal force, lowers friction, allowing the wire to relax, and reducing tension). When the wire tension decreases to the set value, the displacement actuator stops moving. During this process, the floating device supports the roller's slight displacement, which then acts on the force sensor.

[0024] S6. When the cable is finished winding, turn off motor 1 and motor 2 to stop their stepping and rotation, and disconnect the steel wire from the cable side. At this time, due to inertia, the steel wire that is still under tension will shrink in the opposite direction along the laying direction, which may cause safety hazards. Therefore, roller 1, roller 2 and roller 3 are all equipped with ratchet to limit the reverse rotation of the rollers, and thus use friction to effectively limit the reverse shrinkage of the steel wire.

[0025] One or more technical solutions provided in this application have at least the following technical effects or advantages: The reel, in conjunction with the pay-off shaft, stably stores and releases the steel wire. A force sensor detects the downward vertical tension component of the steel wire in real time, and a servo system, linked to a displacement actuator, drives the main control rollers to rapidly adjust the wire tension, ensuring constant tension during winding. The number of main control rollers can be adjusted according to actual conditions: multiple rollers can be added to increase the contact area when winding steel wires with weak bending resistance or prone to slippage; the number of rollers can be reduced to avoid excessive friction between the rollers and the wire when winding steel wires with strong bending resistance or easily worn surfaces. A floating device supports three micro-motions of the rollers, improving tension detection accuracy. The ratchet mechanisms of rollers one, two, and three effectively limit the reverse shrinkage of the steel wire, eliminating safety hazards. Motors one and two work together to drive the cable to rotate at a uniform speed and move axially, ensuring uniform spiral winding of the steel wire and improving the load-bearing capacity of the armor layer. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the structure of a flexible cable armor layer steel wire constant tension winding device and control method according to the present invention; Figure 2 This is a schematic diagram of the roller structure of a flexible cable armor layer steel wire constant tension winding device and control method according to the present invention. Figure 3This is a schematic diagram of the roller structure of a flexible cable armor layer steel wire constant tension winding device and control method according to the present invention. Figure 4 This is a schematic diagram of the U-shaped frame structure of the flexible cable armor layer steel wire constant tension winding device and control method of the present invention; Figure 5 This is a schematic diagram of the limiting plate structure of a flexible cable armor layer steel wire constant tension winding device and control method according to the present invention. Figure 6 This is a schematic diagram of the displacement actuator structure of a flexible cable armor layer steel wire constant tension winding device and control method according to the present invention. Figure 7 This is a schematic diagram of the main control roller structure of a flexible cable armor layer steel wire constant tension winding device and control method according to the present invention.

[0027] In the picture: 100. Support frame; 101. Reel; 102. Pay-off shaft; 103. Mounting frame; 104. Cable conduit; 105. Circular groove; 110. Limiting plate; 120. Motor 1; 121. Motor 2; 122. Connecting shaft; 123. Moving plate; 200. Displacement actuator; 201. Main control roller; 2011. Annular groove 1; 210. Roller 1; 2101. Annular groove 2; 211. Rotating shaft 1; 212. Roller 2; 213. Rotating shaft 2; 220. Limiting plate; 2201. Limiting arc groove; 221. Support plate; 230. Roller 3; 2301. Annular groove 3; 231. Force sensor; 232. Floating device; 233. Outer frame; 234. Spring body; 235. Bushing; 236. U-shaped frame. Detailed Implementation

[0028] To facilitate understanding of the present invention, a more complete description of this application will be given below with reference to the accompanying drawings, which illustrate preferred embodiments of the invention. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to enable a more thorough and complete understanding of the disclosure of the present invention.

[0029] It should be noted that the terms "vertical," "horizontal," "up," "down," "left," "right," and similar expressions used in this article are for illustrative purposes only and do not represent the only possible implementation.

[0030] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains; the terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to limit the invention; the term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0031] Example 1: As Figures 1 to 7 As shown, this application discloses a flexible cable armor layer steel wire constant tension winding device and control method, including a support frame 100, a reel 101, a steel wire tension control component, a steel wire tension measurement component, and a drive component.

[0032] The side end of the reel 101 has a wire feeding shaft 102 that cooperates with it. The wire feeding shaft 102 is set on the support frame 100. The reel 101 is used to store and release the steel wire required for winding and forming.

[0033] The wire tension control assembly includes a displacement actuator 200 and a main control roller 201. One or more main control rollers 201 can be provided, and their number can be flexibly configured according to actual working conditions. When winding wires with weak bending resistance or prone to slippage, multiple main control rollers 201 can be added to increase the contact area with the wire, preventing excessive pressure from the main control rollers 201 due to insufficient tension, which could cause the wire to bend and fail before reaching the cable 104. When winding wires with strong bending resistance or easily worn surfaces, the number of main control rollers 201 can be appropriately reduced to avoid excessive friction between the rollers and the wire, thus protecting the integrity of the wire. The flexible configuration of the number of main control rollers 201 ensures precise matching of different wire characteristics and product requirements while maintaining constant tension control, achieving the optimal balance between tension control and wire protection.

[0034] The axial center of the main control roller 201 is kept in the same plane as the reel 101. The main control roller 201 is connected to the displacement actuator 200, which is mounted on the support frame 100.

[0035] The wire tension control assembly also includes a roller 210 mounted on a rotating shaft 211 and a roller 212 mounted on a rotating shaft 213; the rotating shaft 211 and the rotating shaft 213 are kept in the same vertical plane; the rotating shaft 211 and the rotating shaft 213 are arranged on the support frame 100 and close to the reel 101; the roller 210 and the roller 212 are provided with ratchet wheels.

[0036] The arc surfaces of roller 210 and roller 212 are provided with annular grooves 2101 to prevent the steel wire from deviating; the arc surface of the main control roller 201 is provided with annular groove 2011, the depth of which is greater than the depth of annular groove 2101.

[0037] The wire tension measuring assembly includes a support plate 221 and a roller 230 with a ratchet inside. The support plate 221 is mounted on the support frame 100 and is equipped with a floating device 232. The roller 230 is assembled inside the floating device 232, which is installed on the same horizontal plane as the rotating shaft 213. The roller 230 can move up and down slightly through the action of the floating device 232. A force sensor 231 is also provided on the upper surface of the support plate 221 and is located directly below the roller 230. The force sensor 231 is connected to the displacement actuator 200 through a servo system.

[0038] The roller 3 230 has an annular groove 3 2301 on its arc surface. The depth of the annular groove 2 2101 is greater than that of the annular groove 2 2101 but less than that of the annular groove 1 2011. The annular groove 2 2101 is the shallowest. Its main function is to provide precise initial guidance and basic positioning. After the steel wire is drawn out from the reel 101, it first passes through roller 1 210 and roller 2 212. The shallow groove can confine the steel wire in the groove, preventing it from sliding or deviating laterally in the early stage of entering the system. This ensures that the steel wire enters the subsequent tension control area at an accurate tangential angle. Since this stage mainly plays a guiding role, there is no need to apply excessive pressure. The shallow groove design avoids unnecessary frictional resistance and provides a stable initial state for subsequent active tension adjustment.

[0039] The deeper groove of the annular groove (2011) means that the steel wire is embedded deeper, and the contact arc length and normal pressure are increased accordingly. The deeper groove provides a more stable wrapping for the steel wire under large tension changes, preventing the steel wire from coming out of the groove during violent adjustment, and ensuring the stability and safety of the control process.

[0040] The depth of annular groove 3 2301 is between that of annular groove 1 2011 and annular groove 2 2101. Its design is in line with the accuracy of tension measurement and the buffering function of floating device 232. The medium-depth groove can effectively prevent the steel wire from deviating at the measurement point and ensure the accuracy of tension detection direction. It also avoids the excessive and unstable friction caused by an excessively deep groove from interfering with the measurement results. Annular groove 3 2301 allows the tension of the steel wire to be transmitted to the force sensor 231 below more effectively. In addition, the design of the medium-depth groove allows the steel wire to maintain good contact with the groove wall during micro-movement. It will not come out due to the groove being too shallow, nor will it be stuck due to the groove being too deep. This ensures that the force sensor 231 can detect small changes in tension in real time and with sensitivity.

[0041] The floating device 232 includes a hollow outer frame 233, a spring body 234, and a bushing 235. The outer frame 233 is symmetrically arranged on the top of the support plate 221, and the end of the outer frame 233 away from the support plate 221 is an arc-shaped structure. The bottom surface of the hollow structure of the outer frame 233 is provided with the spring body 234, and the top of the spring body 234 is fixed with the bushing 235. The two bushings 235 are slidably connected in the hollow structure of the corresponding outer frame 233, and the two ends of the roller 230 are rotatably connected in the corresponding bushing 235. The top of the two outer frames 233 is fixed with a limit plate 220, and the bottom surface of the limit plate 220 has a limit arc groove 2201 in the middle to prevent the steel wire from deviating.

[0042] A U-shaped frame 236 is also fixed between the two bushings 235, and the U-shaped frame 236 does not directly contact the roller 230.

[0043] The driving assembly provides rotation and axial movement for the steel wire during the winding and forming process on the cable 104. It includes a mounting frame 103, a first motor 120, a second motor 121, and a moving plate 123. The mounting frame 103 is set on a horizontal work site or a horizontal ground. The top of the mounting frame 103 has a cavity. The first motor 120 is installed at one end of the mounting frame 103. A connecting shaft 122 is rotatably connected inside the cavity of the mounting frame 103. The connecting shaft 122 has an external thread. The output shaft of the first motor 120 passes through the mounting frame 103 and is fixedly connected to one end of the connecting shaft 122.

[0044] The movable plate 123 is slidably connected in the cavity of the mounting bracket 103. The movable plate 123 has a through groove 105 near the bottom of the mounting bracket 103, and the through groove 105 is provided with an internal thread. The movable plate 123 is threadedly connected to the connecting shaft 122 through the through groove 105.

[0045] The top surface of the movable plate 123 is fixed with a motor 121 and a limiting plate 110 at both ends. One end of the cable 104 is set on the output shaft of the motor 121, and the other end is rotatably connected to one end of the limiting plate 110.

[0046] The specific method for controlling the constant tension winding of steel wires in the armor layer of flexible cable is as follows: S1. Wrap the armor layer steel wire around the reel 101 and lead out the steel wire.

[0047] S2. The steel wire is first passed through the annular groove 2101 between roller 1 210 and roller 2 212 (the annular groove 2101 ensures that the steel wire always passes straight out along the tangent of roller 1 210 and roller 2 212 during the winding process of the cable 104, avoiding lateral slippage). Then, it passes horizontally under the annular groove 2011 of the main control roller 201, and finally passes out between the limiting arc groove 2201 of the limiting plate 220 and the annular groove 2301 of roller 3 230, and is connected and fixed to the end of the cable 104 at a constant downward angle. At this time, roller 3 230 moves downward under the action of the steel wire, which drives the bushing 235 to press down the spring body 234. The bushing 235 drives the U-shaped frame 236 to press down, so that the U-shaped frame 236 contacts the force sensor 231. Among them, the second rotating shaft 213 and the floating device 232 are on the same horizontal plane, so the part of the steel wire between the first roller 210 and the second roller 212, the limiting plate 220 and the third roller 230 remains horizontal.

[0048] S3. Start motor 120 and motor 21, drive connecting shaft 122 to rotate, and drive moving plate 123 to move to the right, so that the cable 104 on moving plate 123 rotates and steps uniformly away from motor 120 along the axial direction. At this time, the steel wire spirally winds around the outer edge of cable 104 (the speed at which cable 104 is wound by steel wire is called the take-up speed; the steel wire linear speed of reel 101 is called the unwinding speed. Since reel 101 is passively unwinding, the unwinding speed of steel wire is unstable. When the take-up speed is stable, the steel wire will become loose or tight as the unwinding speed is too large or too small, causing the tension to decrease or increase). The presence of limit plate 220 can prevent the steel wire from slipping out due to excessive lateral shear force when starting, limit the steel wire and ensure safety.

[0049] S4. During the winding process, the vertical plane where the roller 230 and the limiting plate 220 are located has an angle with the steel wire that is passed through. Since the cable 104 moves to the right at a constant speed, this angle remains unchanged during winding. If the tension of the steel wire that is passed through is constant, the force sensor 231 will detect that the vertical downward tension component is also constant.

[0050] S5. When the force sensor 231 detects a change in the vertically downward tension component of the wire, it indicates a change in the wire winding tension. At this time, the tension information is transmitted to the displacement actuator 200 via the servo system. If the force sensor 231 detects a decrease in tension, the displacement actuator 200 moves downward, causing the main control roller 201 to press against the horizontal wire, making it taut (the downward pressing action increases the normal force between the wire and the main control roller 201, thereby increasing the friction, making the wire taut and increasing the tension). When the wire tension increases to the set value, the displacement actuator 200 stops moving downward. If an increase in tension is detected, the displacement actuator 200 moves upward, causing the main control roller 201 to move away from the horizontal wire, making it loose (the lifting action reduces the normal force, reduces the friction, allowing the wire to loosen and the tension to decrease). When the wire tension decreases to the set value, the displacement actuator 200 stops moving. During the above process, the floating device 232 is used to support the roller 230 to produce a small displacement, which then acts on the force sensor 231.

[0051] S6. When the cable 104 is finished winding, turn off motor 120 and motor 2121 to stop their stepping and rotation, and disconnect the steel wire from the cable 104 side. At this time, due to inertia, the steel wire that is still under tension will shrink in the opposite direction along the laying direction, which may cause safety hazards. Therefore, roller 1210, roller 212 and roller 3230 are all equipped with ratchet to limit the reverse rotation of the rollers, and thus use friction to effectively limit the reverse shrinkage of the steel wire.

[0052] One or more technical solutions provided in this application have at least the following technical effects or advantages: The coordinated operation of the reel 101 and the wire feeding shaft 102 not only safely stores the steel wire required for the armor layer processing, but also provides continuous and stable wire feeding support during the winding operation, avoiding wire feeding jamming, accumulation or pulling, and providing initial protection for subsequent constant tension adjustment.

[0053] The force sensor 231 has a high-sensitivity tension detection capability, which can capture the vertical downward tension component change of the steel wire in real time. The detection signal is quickly fed back to the displacement actuator 200 through the servo system, providing accurate data for tension adjustment.

[0054] After receiving the signal, the displacement actuator 200 can precisely drive the main control roller 201 to adjust its vertical displacement. When the wire tension is too low, the main control roller 201 applies downward pressure to tighten the wire. When the tension is too high, the main control roller 201 moves upward to release the excess tension, ensuring that the wire tension remains stable within the set range throughout the winding process. The number of main control rollers 201 can be increased or decreased according to the actual situation. Appropriately increasing the number of main control rollers 201 can increase the contact area between the main control rollers 201 and the wire, thereby increasing the friction. Appropriately reducing the number of main control rollers 201 can reduce the situation where the main control rollers 201 excessively compress the wire.

[0055] The spring body 234 inside the floating device 232 and the bushing 235 form a flexible micro-motion structure, which allows the roller 3 230 to move slightly up and down with the change of wire tension, so that the roller 3 230 always keeps in contact with the wire, greatly improving the accuracy of the data detected by the force sensor 231.

[0056] Motor 120 drives the connecting shaft 122 to rotate at a constant speed. Through the threaded engagement between the connecting shaft 122 and the moving plate 123, the moving plate 123 is driven to smoothly achieve axial stepping. At the same time, motor 21 drives the cable 104 to rotate at a constant speed. The two work together to ensure that the rotation and axial movement of the cable 104 are precisely synchronized, ensuring that the steel wire is wound around the outer edge of the cable 104 at a uniform spiral angle.

[0057] The annular groove 2011 of the main control roller 201, the annular groove 2101 of roller 210 and roller 212, and the annular groove 2301 of roller 230, with their different groove depths, are precisely adapted to the steel wire transmission requirements. Together with the limiting arc groove 2201 of the limiting plate 220, they effectively prevent the steel wire from shifting laterally or falling off, ensuring the accuracy of the winding path.

[0058] The U-shaped frame 236 is fixed between the two bushings 235. Although it does not directly contact the roller 3 230, it can indirectly limit the movement range of the roller 3 230, preventing it from excessive displacement due to sudden tension changes. At the same time, it protects the spring body 234 from abnormal pressure damage and extends the service life of the floating device 232.

[0059] The presence of the limit plate 220 can prevent the steel wire from slipping out due to excessive lateral shear force during startup, thereby limiting the steel wire and ensuring safety.

[0060] By cooperating with the steel wire tension winding device of the present invention and the control method described in the present invention, the tension of the armor layer steel wire is kept constant during the winding process. This significantly improves the uniformity and tightness of the armor layer steel wire winding, effectively reduces problems such as uneven steel wire gaps and local defects, greatly enhances the load-bearing capacity and structural stability of the armor layer of the cable 104, and ensures the long-term safe and reliable operation of the cable 104 in complex marine environments.

[0061] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. For those skilled in the art, the present invention can have various modifications and variations. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A constant tension winding device for steel wire in the armor layer of a flexible cable, characterized in that, It includes a support frame (100), a reel (101), a wire tension control component, a wire tension measuring component, and a drive component. The drive component provides rotation and axial movement for the wire during the winding and forming process on the cable (104). The side end of the reel (101) has a wire feeding shaft (102) that cooperates with it. The wire feeding shaft (102) is mounted on the support frame (100). The wire tension control assembly includes a displacement actuator (200) and a main control roller (201). One or more main control rollers (201) are provided. The main control rollers (201) are connected to the displacement actuators (200). The displacement actuators (200) are provided on the support frame (100). The wire tension control assembly also includes a roller (210) mounted on a rotating shaft (211) and a roller (212) mounted on a rotating shaft (213); the rotating shaft (211) and the rotating shaft (213) are mounted on the support frame (100) and are close to the reel (101). The wire tension measuring assembly includes a support plate (221) and a roller three (230); the support plate (221) is set on the support frame (100), the support plate (221) is equipped with a floating device (232), the roller three (230) is assembled in the floating device (232), and the floating device (232) is installed in the same horizontal plane as the rotating shaft two (213).

2. The flexible cable armor layer steel wire constant tension winding device as described in claim 1, characterized in that, The first rotating shaft (211) and the second rotating shaft (213) are kept in the same vertical plane; the axial centers of the main control roller (201), roller one (210), roller two (212) and roller three (230) are kept in the same plane as the reel (101).

3. The flexible cable armor layer steel wire constant tension winding device as described in claim 1, characterized in that, Each of the rollers (210), (212), and (230) is equipped with a ratchet.

4. The flexible cable armor layer steel wire constant tension winding device as described in claim 1, characterized in that, A force sensor (231) is provided on the upper surface of the support plate (221). The force sensor (231) is located directly below the roller three (230). The force sensor (231) is connected to the displacement actuator (200) through a servo system.

5. The flexible cable armor layer steel wire constant tension winding device as described in claim 1, characterized in that, The first roller (210) and the second roller (212) have annular grooves (2101) on their arc surfaces to prevent the steel wire from deviating; the main control roller (201) has annular grooves (2011) on its arc surface, and the depth of annular grooves (2011) is greater than the depth of annular grooves (2101); the third roller (230) has annular grooves (2301) on its arc surface, and the depth of annular grooves (2101) is greater than the depth of annular grooves (2101) and less than the depth of annular grooves (2011).

6. The flexible cable armor layer steel wire constant tension winding device as described in claim 1, characterized in that, The floating device (232) includes a hollow outer frame (233), a spring body (234), and a bushing (235). The outer frame (233) is symmetrically arranged on the top of the support plate (221). The end of the outer frame (233) away from the support plate (221) is an arc-shaped structure. The bottom surface of the hollow structure of the outer frame (233) is provided with a spring body (234), and the top of the spring body (234) is fixed with a bushing (235). The two bushings (235) are slidably connected in the hollow structure of the corresponding outer frame (233), and the two ends of the roller three (230) are rotatably connected in the corresponding bushing (235).

7. The flexible cable armor layer steel wire constant tension winding device as described in claim 6, characterized in that, Limiting plates (220) are fixed to the top of the two outer frame bodies (233). A limiting arc groove (2201) is opened in the middle of the bottom surface of the limiting plate (220) to prevent the steel wire from deviating.

8. The flexible cable armor layer steel wire constant tension winding device as described in claim 6, characterized in that, A U-shaped frame (236) is also fixed between the two bushings (235), and the U-shaped frame (236) does not directly contact the roller three (230).

9. The flexible cable armor layer steel wire constant tension winding device as described in claim 1, characterized in that, The drive assembly includes a mounting frame (103), a first motor (120), a second motor (121), and a movable plate (123). The mounting frame (103) is set on a horizontal work site or a horizontal ground. The top of the mounting frame (103) has a cavity. The first motor (120) is installed at one end of the mounting frame (103). A connecting shaft (122) is rotatably connected inside the cavity of the mounting frame (103). The connecting shaft (122) has an external thread. The output shaft of the first motor (120) passes through the mounting frame (103) and is fixedly connected to one end of the connecting shaft (122). The movable plate (123) is slidably connected in the cavity of the mounting frame (103). A circular groove (105) is opened on the movable plate (123) near the bottom of the mounting frame (103), and an internal thread is provided in the circular groove (105). The movable plate (123) is threadedly connected to the connecting shaft (122) through the circular groove (105). The two ends of the top surface of the movable plate (123) are respectively fixed with a second motor (121) and a limiting plate (110). One end of the cable (104) is set on the output shaft of the second motor (121), and the other end is rotatably connected to one end of the limiting plate (110).

10. A method for controlling the constant tension winding of steel wires in the armor layer of a flexible cable, characterized in that, The control method includes the following steps: S1. Wind the armor layer steel wire onto the reel (101) and pull it out; S2. The steel wire passes sequentially between the second annular groove (2101) of roller one (210) and roller two (212), below the first annular groove (2011) of the main control roller (201), between the limiting arc groove (2201) of the limiting plate (220) and the third annular groove (2301) of roller three (230), and is fixed to one end of the cable (104) at a constant downward angle, so that the U-shaped frame (236) contacts the force sensor (231); S3. Turn on motor one (120) and motor two (121) to make the cable (104) rotate and step at a constant speed in the direction away from motor one (120) along the axis. At this time, the steel wire is spirally wound around the outer edge of the cable (104). S4. During the winding process, the force sensor (231) detects the vertical downward tension component of the steel wire; S5. When the force sensor (231) detects a change in the vertical downward tension component of the steel wire, the servo system transmits a signal to the displacement actuator (200). The displacement actuator (200) controls the main control roller (201) to press down or lift up to change the contact state with the steel wire. The pressing action increases the normal force between the steel wire and the main control roller (201), thereby increasing the friction force, making the steel wire taut and increasing the tension. The lifting action reduces the normal force, reduces the friction force, allows the steel wire to relax and the tension to decrease, so as to maintain the constant tension of the steel wire. S6. After winding is completed, turn off motor one (120) and motor two (121).

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