Optical cable take-up and pay-off mechanism and system suitable for bridge-type grab ship unloader

Abstract

The present application relates to ship unloader technical field, specifically is a kind of optical cable take-up mechanism and system suitable for bridge type grab ship unloader.It includes optical cable reel independently arranged with the high-voltage cable reel of ship unloader, and the optical cable reel is arranged on the same side of the high-voltage cable reel and close to the cable bridge arrangement;It also includes PLC closed-loop electric control system, with PLC controller as core, matched with speed sensor, tension sensor and servo motor driving unit, docking ship unloader walking mechanism signal, with ship unloader running speed as core control variable, built-in PID algorithm adapted to the characteristics of bridge type grab ship unloader reciprocating walking, frequent acceleration and deceleration operation.Relying on exclusive mechanical layout, communication optical cable and high-voltage cable are arranged in staggered separation, which effectively avoids high-voltage electromagnetic interference, and through differentiated take-up control logic and PID algorithm adapted to frequent acceleration and deceleration working condition, optical cable take-up action and ship unloader walking action are realized accurately dynamic follow-up.

Description

Technical Field

[0001] This invention relates to the field of ship unloading machine technology, specifically to an optical cable take-up and release mechanism and system suitable for bridge grab ship unloaders. Background Technology

[0002] As a core piece of equipment in bulk cargo port operations, the stability of the communication system of the bridge grab unloader directly determines its operational efficiency and the effectiveness of intelligent upgrades. Currently, existing bridge grab unloaders generally use high-voltage cables paired with optical fibers to form the upper cable, which can simultaneously meet the equipment's power supply and communication transmission needs. The cable reel mechanism of the high-voltage cable of the bridge grab unloader is generally arranged on the second layer of the unloader, while the supporting cable tray is laid along both sides of the belt conveyor below the unloader. In actual operation, the bridge grab unloader needs to frequently perform actions such as traveling back and forth and lifting and lowering the grab bucket. The supporting optical fiber will simultaneously bear the tensile force, bending, and friction. After long-term operation, the probability of damage increases significantly. Frequent optical fiber damage leads to interruption of optical fiber transmission, which seriously affects the continuity of unloader operation.

[0003] To compensate for the transmission gap caused by damaged fiber optic cables, some bridge grab unloaders have adopted wireless communication as an alternative to wired transmission. However, this method has significant drawbacks and cannot meet the high requirements of communication stability for unloaders. On the one hand, wireless communication has poor stability and is easily affected by factors such as obstruction from high-altitude equipment in the port operation area, strong electromagnetic interference, and complex airflow. On the other hand, the communication capacity is insufficient, with wireless communication bandwidth only reaching 100Mbps, which cannot support the high-speed, zero-latency transmission of large amounts of data required for the intelligent operation of unloaders, such as equipment operating parameters (sampling frequency 10Hz), real-time operation video (1080P / 30 frames), and precise control commands (response latency ≤50ms).

[0004] In addition, the complex operating environment of bulk cargo terminals places extremely high demands on the practicality and reliability of optical cable transmission solutions. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the purpose of this invention is to provide an optical cable deployment and take-up mechanism and system suitable for bridge grab unloaders that improves the practicality and reliability of optical cable transmission schemes.

[0006] The technical solution adopted by this invention to solve its technical problem is:

[0007] A fiber optic cable winding and unwinding mechanism and system suitable for bridge grab unloaders includes a fiber optic cable drum separately set up from the high-voltage cable reel of the unloader. The fiber optic cable drum is arranged on the same side as the high-voltage cable reel and close to the cable tray. The fiber optic cable drum is driven by a servo motor. The fiber optic cable drum is equipped with a slip ring box and a gravity brake. A rope coiler is matched to the cable outlet end of the fiber optic cable drum. The outlet side of the rope coiler is equipped with an adjustment track and a cable guide frame that can adjust the position of the fiber optic cable outlet, so as to realize the staggered and separated arrangement of the fiber optic cable and the high-voltage cable. The cable guide frame integrates a photoelectric sensor limit for real-time monitoring of the tension of the fiber optic cable.

[0008] It also includes a PLC closed-loop electrical control system, with the PLC controller as the core, equipped with speed sensors, tension sensors and servo motor drive units, and interfaces with the unloader's traveling mechanism signals. The unloader's traveling speed is the core control variable. It has a built-in PID algorithm adapted to the reciprocating travel and frequent acceleration and deceleration operation characteristics of the bridge grab unloader. It can dynamically correct the drum winding and unwinding speed and compensate for the synchronization deviation caused by the fluctuation of the equipment's traveling speed. Differentiated control logic is adopted for the cable winding and unwinding conditions. When winding, the servo motor is driven to work with the rope coiler to complete the neat winding and storage of the optical cable. When unwinding, the servo motor is controlled to maintain the excitation torque to achieve the smooth release of the optical cable by its own weight. It dynamically matches the drum winding and unwinding actions with the unloader's traveling acceleration and deceleration and uniform speed conditions, so as to achieve precise dynamic tracking between the drum winding and unwinding actions and the unloader's traveling actions.

[0009] The present invention, which adopts the above technical solution, has the following prominent features compared with the prior art:

[0010] By setting up a dedicated optical cable winding and unwinding mechanism independent of the high-voltage cable reel, and pairing it with a PLC closed-loop electrical control system adapted to the complex operating conditions of the ship unloader, the dedicated mechanical layout enables staggered and separated deployment of communication optical cables and high-voltage cables. This effectively avoids high-voltage electromagnetic interference and reduces optical cable bending and friction loss. At the same time, through differentiated winding and unwinding control logic and PID algorithms adapted to frequent acceleration and deceleration conditions, the optical cable winding and unwinding actions are precisely and dynamically synchronized with the movement of the ship unloader. This improves the problems of abnormal tension and stress damage caused by asynchronous winding and unwinding of traditional optical cables, completely eliminating the transmission shortcomings of wireless communication. It significantly improves the stability, bandwidth capacity, and operational adaptability of optical cable communication transmission, effectively ensuring the continuous and stable operation of the ship unloader and enhancing the reliability of intelligent equipment operation and practicality of on-site operations.

[0011] As a preferred embodiment, a further technical solution of the present invention is:

[0012] Preferably, the gravity brake is mounted on the end of the optical cable reel's through shaft, and a counterweight is configured to cooperate with the electric push rod to achieve braking switching. During normal operation of the unloader, the electric push rod actuates to lift the braking mechanism, releasing the gravity brake from locking the optical cable reel's through shaft, allowing the optical cable reel to rotate and unload the cable normally as the unloader moves. When the unloader is stationary, the electric push rod resets, and the gravity brake, relying on the weight of the counterweight, generates braking force to lock the optical cable reel's through shaft, achieving passive mechanical locking and preventing the reel from inertia. The servo motor synchronously outputs reverse braking force under braking and locking conditions, forming a dual electromechanical braking protection structure. It can rely on the electric push rod to realize the braking release in the working state and the passive mechanical locking in the stopping state. At the same time, it works with the reverse braking effect of the servo motor to form a dual electromechanical braking protection structure, which can effectively alleviate the problem of inertial rotation after the drum stops, reduce the occurrence of optical cable slack, scattering, and accumulation, improve the regularity and operational safety of optical cable winding and unwinding operations, and adapt to the operation scenarios of frequent start and stop of port equipment.

[0013] Preferably, the photoelectric induction limit uses a diffuse reflection photoelectric sensor, which is arranged at the cable guide frame outlet position to monitor the tension of the optical cable in real time. When the optical cable is abnormally loose or tight, it promptly feeds back a signal to the PLC, assisting the electrical control system to intervene and adjust in a timely manner. It can monitor the tension of the optical cable in real time during the cable winding and unwinding process, and can promptly capture abnormal loose or tight conditions of the optical cable and feed back control signals, which facilitates the electrical control system to make rapid adjustment and intervention, reduce wear and breakage problems caused by long-term abnormal stress on the optical cable, and further improve the protection capability of the optical cable operation.

[0014] Preferably, the PLC closed-loop electrical control system uses the servo motor driving the optical cable drum as the execution terminal, and is equipped with speed sensors and tension sensors to form a closed-loop control link for signal acquisition, calculation and processing, and power execution. It collects the unloader's walking speed and the optical cable tension in real time, providing data support for the dynamic adjustment of optical cable winding and unwinding, ensuring the timeliness and accuracy of the electrical control system, and making the optical cable winding and unwinding actions adapt to the real-time operation status of the equipment.

[0015] Preferably, the PLC closed-loop electrical control system has start-up synchronization control logic. After the unloader's walking mechanism starts, the speed sensor immediately collects the walking signal and transmits it to the PLC. After signal processing, the PLC drives the servo motor to start synchronously, ensuring that the optical cable winding and unwinding start sequence matches the equipment walking start sequence. This can achieve precise matching between the unloader's walking start sequence and the optical cable winding and unwinding start sequence, avoiding abnormalities such as optical cable dragging, accumulation, or pulling during the equipment start-up phase, and ensuring the synchronization and stability of the entire optical cable winding and unwinding process.

[0016] Preferably, the PLC electrical control system has dynamic acceleration / deceleration tracking and constant speed steady-state control logic. Under the acceleration / deceleration conditions of the ship unloader, the PLC adjusts the servo motor speed in real time through PID calculation to adapt to speed changes. When the equipment is running at a constant speed, the PLC stabilizes the motor output speed and maintains stable optical cable tension. It can adjust the servo motor speed in real time during equipment speed fluctuations, stabilize the motor output state under constant speed conditions, and maintain the optical cable tension within a stable and reasonable range. This effectively adapts to the complex operation characteristics of port ship unloaders, which involve reciprocating and changing speeds, and reduces the impact of speed fluctuations on the service life of the optical cable.

[0017] Preferably, the PLC control system is equipped with a sensor signal redundancy fault tolerance mechanism. When the speed sensor or tension sensor loses or abnormally signals, the system automatically switches to the backup control mode to continuously control the drum operation. It can automatically switch to the backup control mode when the sensor signal is abnormal or lost, continuously maintain the stable operation of the optical cable drum, avoid system downtime and operation interruption caused by sensor failure, improve the continuity and fault tolerance of the entire system operation, and adapt to the uninterrupted operation requirements of the dock.

[0018] Preferably, the PLC electrical control system adopts a three-level fault handling logic of signal acquisition, logic judgment, and alarm output. It can identify synchronization faults such as the equipment walking and drum rotation being out of sync, and tension faults such as abnormal fiber optic cable tension. It outputs corresponding exclusive fault codes and audible and visual alarms. At the same time, it has fault data storage and traceability functions, which facilitates maintenance personnel to quickly troubleshoot and locate fault problems, improve equipment maintenance efficiency, and ensure the long-term stable operation of the system.

[0019] Preferably, the PLC system is equipped with an online monitoring function for optical cable transmission quality, which collects optical cable bit error rate and transmission bandwidth parameters in real time and triggers an early warning when the transmission performance does not meet the standards. It can also combine the electromagnetic interference monitoring results to maintain a reasonable spacing between the optical cable and the high-voltage cable by adjusting the position of the track fine-tuning cable guide frame, continuously reducing the negative impact of high-voltage electromagnetic interference on communication transmission, stabilizing the optical cable transmission quality, and ensuring the long-term stable transmission of intelligent data from the ship unloader. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the workflow of an embodiment of the present invention;

[0021] Figure 2 This is a schematic front view of an embodiment of the optical cable reel of the present invention;

[0022] Figure 3 This is a side view schematic diagram of an embodiment of the optical cable reel of the present invention;

[0023] Figure 4 This is a top view schematic diagram of an embodiment of the optical cable reel of the present invention.

[0024] Explanation of reference numerals in the attached diagram: 1. Optical cable reel; 2. Slip ring box; 3. Gravity brake; 4. Rope coiler; 5. Servo motor. Detailed Implementation

[0025] The present invention will be further illustrated below with reference to specific embodiments. The purpose of this illustration is solely to provide a better understanding of the invention. Therefore, the examples given do not limit the scope of protection of the present invention.

[0026] like Figure 1-2 As shown, this embodiment provides a fiber optic cable winding and unwinding mechanism and system suitable for bridge grab unloaders. It includes a fiber optic cable drum 1, which is set separately from the high-voltage cable reel of the unloader. The fiber optic cable drum 1 is arranged on the same side as the high-voltage cable reel and close to the cable tray. The fiber optic cable drum 1 is driven by a servo motor 5. The fiber optic cable drum 1 is equipped with a slip ring box 2 and a gravity brake 3. A rope coiler 4 is matched and arranged at the output end of the fiber optic cable drum 1. The output side of the rope coiler 4 is equipped with an adjustment track and a cable guide frame that can adjust the output position of the fiber optic cable, so as to realize the staggered and separated arrangement of the fiber optic cable and the high-voltage cable. The cable guide frame integrates a photoelectric sensor limit for real-time monitoring of the tension of the fiber optic cable.

[0027] It also includes a PLC closed-loop electrical control system, with the PLC controller as the core, equipped with speed sensors, tension sensors and servo motor 5 drive units, and interfaces with the unloader's traveling mechanism signals. The unloader's traveling speed is the core control variable. It has a built-in PID algorithm adapted to the reciprocating travel and frequent acceleration and deceleration operation characteristics of the bridge grab unloader. It can dynamically correct the drum winding and unwinding speed and compensate for the synchronization deviation caused by the fluctuation of the equipment's traveling speed. Differentiated control logic is adopted for the cable winding and unwinding conditions. When winding, the servo motor 5 is driven to work with the rope coiler 4 to complete the neat winding and storage of the optical cable. When unwinding, the servo motor 5 is controlled to maintain the excitation torque to achieve the smooth release of the optical cable by its own weight. It dynamically matches the drum winding and unwinding actions with the unloader's traveling acceleration and deceleration and uniform speed conditions, so as to achieve precise dynamic tracking between the drum winding and unwinding actions and the unloader's traveling actions.

[0028] This invention differs from the existing integrated structure of high-voltage cables and optical cables sharing a reel. It features a separate, independent optical cable reel 1 as a dedicated carrier for the winding and unwinding of communication optical cables. This design is specifically tailored to the protection needs of brittle communication optical cables, avoiding the problems of traditional composite reel power cables being pulled and subjected to electromagnetic interference, which affects the lifespan and communication stability of optical cables. The dedicated optical cable route extends from the electrical room of the ship unloader to the electrical control room of the ground substation. The cable is independently wound and unwound along the entire route, moving synchronously with the equipment. This design is suitable for the complex port conditions of bridge grab ship unloaders, which involve reciprocating movement, frequent starts and stops, and variable speed operations. The optical cable reel 1 is laid close to the cable tray, with a spacing controlled at 0.2-0.5m, effectively reducing optical cable bending losses and ensuring that the bending radius of the optical cable is always greater than 20 times the outer diameter of the optical cable, significantly reducing bending fatigue damage.

[0029] Preferably, the gravity brake 3 is mounted on the end of the through shaft of the optical cable reel 1, and is equipped with a counterweight and an electric push rod to achieve braking switching. During normal operation of the unloader, the electric push rod actuates to lift the braking mechanism, releasing the gravity brake 3 from the locking constraint on the through shaft of the optical cable reel 1, allowing the optical cable reel 1 to rotate and rewind the optical cable normally with the unloader's movement. When the unloader is stationary, the electric push rod resets, and the gravity brake 3, relying on the weight of the counterweight, generates braking force to lock the through shaft of the optical cable reel 1, achieving passive mechanical locking and preventing... The drum rotates idling due to inertia; the servo motor 5 outputs reverse braking force synchronously under braking and locking conditions, forming a dual electromechanical braking protection structure. It can rely on the electric push rod to realize the braking release in the working state and the passive mechanical locking in the stopping state. At the same time, it works with the reverse braking effect of the servo motor 5 to form a dual electromechanical braking protection structure, which can effectively alleviate the problem of inertial rotation after the drum stops, reduce the occurrence of optical cable slack, scattering, and accumulation, improve the regularity and operational safety of optical cable winding and unwinding operations, and adapt to the operation scenarios of frequent start and stop of port equipment.

[0030] The gravity brake 3 adopts a combination of pure gravity passive braking and electric auxiliary braking. The rated torque is not less than 150 N·m. In the shutdown state, no power is required. Reliable locking can be achieved by relying on the self-weight of the 25 kg counterweight, avoiding the risk of brake failure under power failure conditions. In the operation and walking state, the electric push rod has a lifting stroke of 10 mm and an active unlocking braking structure to ensure that the drum rotation is smooth. The switching between braking and unlocking conditions is completely matched with the start and stop logic of the ship unloader. The braking response time is no more than 200 ms. At the same time, in the braking condition, the servo motor 5 outputs 25% of the rated torque as reverse braking force. The dual braking methods work together to effectively suppress the problems of fiber optic cable loosening and cable routing disorder caused by the inertial rotation of the drum.

[0031] Preferably, the photoelectric induction limit uses a diffuse reflection photoelectric sensor, which is arranged at the cable guide frame outlet position to monitor the tension of the optical cable in real time. When the optical cable is abnormally loose or tight, it promptly feeds back a signal to the PLC, assisting the electrical control system to intervene and adjust in a timely manner. It can monitor the tension of the optical cable in real time during the cable winding and unwinding process, and can promptly capture abnormal loose or tight conditions of the optical cable and feed back control signals, which facilitates the electrical control system to make rapid adjustment and intervention, reduce wear and breakage problems caused by long-term abnormal stress on the optical cable, and further improve the protection capability of the optical cable operation.

[0032] The diffuse reflection photoelectric sensor monitors the optical cable's outgoing status in real time using a non-contact detection method, with a response time of no more than 10ms. It is suitable for complex operating environments such as dust and humidity in ports, avoiding the squeezing and abrasion damage to the fragile optical cable sheath caused by contact detection. It can capture abnormal working conditions such as slack and tightness of the optical cable in real time. When the optical cable tension deviates from the optimal working range of 5-8N, it can trigger signal feedback, providing a precise trigger signal for the electronic control system to dynamically adjust the tension and correct the take-up and release speed.

[0033] Preferably, the PLC closed-loop electrical control system uses the servo motor 5 that drives the optical cable drum 1 as the execution terminal, and is equipped with speed sensors and tension sensors to form a closed-loop control link for signal acquisition, calculation and processing, and power execution. It collects the unloader's walking speed and the optical cable tension in real time, providing data support for the dynamic adjustment of optical cable winding and unwinding, ensuring the timeliness and accuracy of the electrical control system, and making the optical cable winding and unwinding actions adapt to the real-time operation status of the equipment.

[0034] The entire closed-loop control chain forms a complete closed-loop system of signal acquisition, logic operation, and power execution. It abandons the traditional crude control mode of single speed following and is equipped with a speed sensor with a sampling frequency of 100Hz and a measurement accuracy of ±0.1m / s and a tension sensor with a measurement range of 0-20N and an accuracy of ±0.2N. Combined with the linkage control of dual parameters of walking speed and optical cable tension, it can accurately adapt to the dynamic walking conditions of the ship unloader, avoid the problems of optical cable tension imbalance and excessive synchronization deviation caused by single parameter control, and ensure the accuracy and stability of the take-up and release control.

[0035] Preferably, the PLC closed-loop electrical control system has start-up synchronous control logic. After the unloader's walking mechanism starts, the speed sensor immediately collects the walking signal and transmits it to the PLC. After signal processing, the PLC drives the servo motor 5 to start synchronously, ensuring that the optical cable winding and unwinding start sequence is synchronized with the equipment walking start sequence. This can achieve precise matching between the unloader's walking start sequence and the optical cable winding and unwinding start sequence, avoiding abnormal optical cable dragging, accumulation, or pulling during the equipment start-up phase, and ensuring the synchronization and stability of the entire optical cable winding and unwinding process.

[0036] By eliminating the action time difference at the moment of equipment startup through dedicated startup synchronization logic, the speed signal is processed by PLC for 100ms before outputting control commands. The startup delay of servo motor 5 is no more than 300ms. This solves the problem of instantaneous pulling and stacking of optical cables caused by the traditional equipment starting with the movement first and then the retraction or release, or vice versa. It realizes the synchronous start and stop of equipment movement and optical cable retraction and release, ensuring that the optical cable is subjected to uniform force and the cable is neatly routed during the startup phase.

[0037] Preferably, the PLC electrical control system has dynamic acceleration / deceleration tracking and constant speed steady-state control logic. Under the acceleration / deceleration conditions of the ship unloader, the PLC adjusts the speed of the servo motor 5 in real time through PID calculation to adapt to speed changes. When the equipment is running at a constant speed, the motor output speed is stabilized to maintain stable optical cable tension. The servo motor 5 speed can be adjusted in real time during equipment speed fluctuations, and the motor output state is stabilized under constant speed conditions to maintain optical cable tension within a stable and reasonable range. This effectively adapts to the complex operation characteristics of port ship unloaders, which involve reciprocating and changing speeds, and reduces the impact of speed fluctuations on the service life of optical cables.

[0038] The system is equipped with a dedicated PID control logic adapted to the frequent acceleration, deceleration, and reciprocating travel conditions of the bridge grab unloader. The fixed optimized tuning parameters are proportional coefficient P=2.5, integral time I=0.8s, and derivative time D=0.2s. It can dynamically compensate for the synchronization deviation caused by the fluctuation of the equipment's travel speed, and the speed synchronization error can be controlled within 5%. Unlike the general fixed parameter PID control method, it can dynamically correct the output speed of servo motor 5 under the working conditions of 0-0.5m / s² acceleration and 0-0.8m / s² deceleration of the unloader. The speed adjustment response time is ≤50ms. It can follow the speed in real time under variable speed conditions and maintain steady-state voltage stability with speed fluctuation ≤0.3r / min under constant speed conditions. It can continuously maintain the standard working tension of 5-8N for optical cable, avoiding the fatigue damage of optical cable caused by tension <3N (too loose) or tension >12N (too tight) and speed fluctuation. Under cable laying conditions, servo motor 5 maintains 30% of the rated torque of the excitation torque, and the deviation between the cable laying speed and the unloader's travel speed is ≤0.2m / s.

[0039] Preferably, the PLC electrical control system is equipped with a sensor signal redundancy fault tolerance mechanism. When the speed sensor or tension sensor loses or abnormally transmits a signal, the system automatically switches to the backup control mode to continuously control the drum operation. It can automatically switch to the backup control mode when the sensor signal is abnormal or lost, continuously maintain the stable operation of the optical cable drum 1, avoid system downtime and operation interruption caused by sensor failure, improve the continuity and fault tolerance of the entire system operation, and adapt to the uninterrupted operation requirements of the dock.

[0040] The redundancy fault-tolerant mechanism can effectively deal with faults such as sensor signal interference, instantaneous loss, and signal distortion under complex port conditions. When the speed sensor or tension sensor signal is lost for more than 200ms, the system can automatically switch to the backup control mode without stopping maintenance. Relying on the ship unloader's preset travel speed of 0-3m / s, the system continuously controls the drum to run stably, maximizing its adaptability to the production needs of continuous loading and unloading operations in the port and improving the system's operational reliability.

[0041] Preferably, the PLC electrical control system adopts a three-level fault handling logic of signal acquisition, logic judgment, and alarm output. It can identify synchronization faults such as the equipment walking and drum rotation being out of sync, and tension faults such as abnormal fiber optic cable tension. It outputs corresponding exclusive fault codes and audible and visual alarms. At the same time, it has fault data storage and traceability functions, which facilitates maintenance personnel to quickly troubleshoot and locate fault problems, improve equipment maintenance efficiency, and ensure the long-term stable operation of the system.

[0042] The three-level fault handling logic enables proactive fault identification, accurate judgment, and timely early warning and handling. When the unloader's travel speed is >0.1m / s for more than 1 second, and the drum speed is <0.1r / min or the speed deviation is >0.5m / s for more than 500ms, it is judged as a synchronization fault, triggering the E01 fault code and outputting an audible and visual alarm with a volume ≥80dB and a flashing frequency of 1 time / second. When the abnormal optical cable tension signal lasts for more than 300ms, it is judged as an optical cable too loose or too tight fault, triggering the E02 and E03 fault codes respectively and power-off protection. At the same time, the system can store fault data for nearly 30 days, recording the fault type, occurrence time and operating parameters, providing effective data support for subsequent equipment operation and maintenance, operating condition optimization and fault tracing, and reducing the difficulty of equipment operation and maintenance.

[0043] Preferably, the PLC system is equipped with an online monitoring function for optical cable transmission quality, which collects optical cable bit error rate and transmission bandwidth parameters in real time and triggers an early warning when the transmission performance does not meet the standards. It can also combine the electromagnetic interference monitoring results to maintain a reasonable spacing between the optical cable and the high-voltage cable by adjusting the position of the track fine-tuning cable guide frame, continuously reducing the negative impact of high-voltage electromagnetic interference on communication transmission, stabilizing the optical cable transmission quality, and ensuring the long-term stable transmission of intelligent data from the ship unloader.

[0044] The system monitors the core transmission performance parameters of the optical cable in real time, with a bit error rate of ≤10⁻ 9 A transmission bandwidth of ≥1000Mbps is used as the judgment threshold. An alarm will be triggered if the parameter is abnormal for 10 seconds. At the same time, the position of the cable guide frame can be finely adjusted by adjusting the travel of 0-30cm and the adjustment accuracy of ±5mm to ensure that the minimum distance between the optical cable and the high-voltage cable is not less than 30cm, control the interference voltage within 5mV, and continuously avoid high voltage and strong electromagnetic interference. This solves the industry shortcomings of traditional wired transmission being susceptible to interference and wireless transmission having only 100Mbps bandwidth and poor stability. It ensures high-speed and stable transmission of intelligent data such as parameters of the 10Hz sampling equipment of the ship unloader, 1080P / 30fps operation video, and ≤50ms low latency control commands.

[0045] By setting up a dedicated optical cable winding and unwinding mechanism independent of the high-voltage cable reel, and pairing it with a PLC closed-loop electrical control system adapted to the complex operating conditions of the ship unloader, the dedicated mechanical layout enables staggered and separated deployment of communication optical cables and high-voltage cables. This effectively avoids high-voltage electromagnetic interference and reduces optical cable bending and friction loss. At the same time, through differentiated winding and unwinding control logic and PID algorithms adapted to frequent acceleration and deceleration conditions, the optical cable winding and unwinding actions are precisely and dynamically synchronized with the movement of the ship unloader. This improves the problems of abnormal tension and stress damage caused by asynchronous winding and unwinding of traditional optical cables, completely eliminating the transmission shortcomings of wireless communication. It significantly improves the stability, bandwidth capacity, and operational adaptability of optical cable communication transmission, effectively ensuring the continuous and stable operation of the ship unloader and enhancing the reliability of intelligent equipment operation and practicality of on-site operations.

[0046] The above description is merely a preferred embodiment of the present invention and does not limit the scope of the present invention. All equivalent changes made based on the description and drawings of the present invention are included within the scope of the present invention.

Claims

1. A fiber optic cable take-up and release mechanism and system suitable for bridge-type grab unloaders, characterized in that: The optical cable reel is set up separately from the high-voltage cable reel of the ship unloader. The optical cable reel is arranged on the same side as the high-voltage cable reel and close to the cable tray. The optical cable reel is driven by a servo motor. The optical cable reel is equipped with a slip ring box and a gravity brake. A rope coiler is matched with the cable reel's output end. The output side of the rope coiler is equipped with an adjustment track and a cable guide frame that can adjust the position of the optical cable output, so as to realize the staggered and separated arrangement of the optical cable and the high-voltage cable. The cable guide frame integrates photoelectric sensor limit for real-time monitoring of the optical cable tension. It also includes a PLC closed-loop electrical control system, with the PLC controller as the core, equipped with speed sensors, tension sensors and servo motor drive units, and interfaces with the unloader's traveling mechanism signals. The unloader's traveling speed is the core control variable. It has a built-in PID algorithm adapted to the reciprocating travel and frequent acceleration and deceleration operation characteristics of the bridge grab unloader. It can dynamically correct the drum winding and unwinding speed and compensate for the synchronization deviation caused by the fluctuation of the equipment's traveling speed. Differentiated control logic is adopted for the cable winding and unwinding conditions. When winding, the servo motor is driven to work with the rope coiler to complete the neat winding and storage of the optical cable. When unwinding, the servo motor is controlled to maintain the excitation torque to achieve the smooth release of the optical cable by its own weight. It dynamically matches the drum winding and unwinding actions with the unloader's traveling acceleration and deceleration and uniform speed conditions, so as to achieve precise dynamic tracking between the drum winding and unwinding actions and the unloader's traveling actions.

2. The optical cable take-up and release mechanism and system for bridge grab unloaders according to claim 1, characterized in that: The gravity brake is mounted on the end of the optical cable reel shaft. A counterweight and an electric push rod work together to switch braking operations. During normal operation of the unloader, the electric push rod lifts the braking mechanism, releasing the gravity brake from its locking constraint on the optical cable reel shaft, allowing the reel to rotate and wind up and down the cable as the unloader moves. When the unloader is stationary, the electric push rod resets, and the gravity brake, relying on the weight of the counterweight, generates braking force, locking the optical cable reel shaft to achieve passive mechanical locking and prevent inertial idling. The servo motor synchronously outputs reverse braking force during the braking lock-up condition, forming a dual electromechanical braking protection structure.

3. The optical cable take-up and release mechanism and system for bridge grab unloaders according to claim 1, characterized in that: The photoelectric induction limit uses a diffuse reflection photoelectric sensor, which is placed at the cable guide frame outlet position to monitor the tension of the optical cable in real time. When the optical cable is abnormally loose or tight, it promptly feeds back a signal to the PLC to assist the electrical control system in timely intervention and regulation.

4. The optical cable take-up and release mechanism and system for bridge grab unloaders according to claim 1, characterized in that: The PLC closed-loop electrical control system uses a servo motor that drives the optical cable reel as the execution terminal. It is equipped with speed sensors and tension sensors to form a closed-loop control link for signal acquisition, processing, and power execution. It collects the unloader's travel speed and the optical cable tension status in real time, providing data support for the dynamic adjustment of optical cable winding and unwinding.

5. The optical cable take-up and release mechanism and system for bridge grab unloaders according to claim 1, characterized in that: The PLC closed-loop electrical control system has a start-up synchronous control logic. After the unloader's walking mechanism starts, the speed sensor immediately collects the walking signal and transmits it to the PLC. After signal processing, the PLC drives the servo motor to start synchronously, ensuring that the optical cable winding and unwinding start sequence matches the equipment walking start sequence synchronously.

6. The optical cable take-up and release mechanism and system for bridge grab unloaders according to claim 1, characterized in that: The PLC control system has dynamic acceleration / deceleration tracking and constant speed steady-state control logic. Under the acceleration / deceleration conditions of the ship unloader, the PLC adjusts the servo motor speed in real time through PID calculation to adapt to speed changes. When the equipment is running at a constant speed, the motor output speed is stabilized to maintain stable optical cable tension.

7. The optical cable take-up and release mechanism and system for bridge grab unloaders according to claim 1, characterized in that: The PLC electronic control system is equipped with a sensor signal redundancy fault tolerance mechanism. When the speed sensor or tension sensor loses or abnormally signals, the system automatically switches to the backup control mode to continue controlling the drum operation.

8. The optical cable take-up and release mechanism and system for bridge grab unloaders according to claim 1, characterized in that: The PLC electrical control system adopts a three-level fault handling logic of signal acquisition, logic judgment, and alarm output. It can identify synchronization faults such as asynchronous movement of equipment and drum rotation, and tension faults such as abnormal fiber optic cable tension. It outputs corresponding fault codes and audible and visual alarms, and also has fault data storage and traceability functions.

9. The optical cable take-up and release mechanism and system for bridge grab unloaders according to claim 1, characterized in that: The PLC system is equipped with an online monitoring function for optical cable transmission quality, which collects optical cable bit error rate and transmission bandwidth parameters in real time, and triggers an early warning when the transmission performance does not meet the standard. By combining the results of electromagnetic interference monitoring, the position of the track fine-tuning cable guide can be adjusted to maintain a reasonable spacing between the optical cable and the high-voltage cable.

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