Winch cable control system

Abstract

The present application relates to winch cable arrangement technical field, specifically disclose a kind of winch cable arrangement control system, the control system includes winch controller, it is configured to perform as follows automatic cable arrangement process: obtain the theoretical basic walking speed of cable arrangement guide pulley slide base;Obtain cable steady-state elastic elongation compensation amount;Obtain cable transient strain rate compensation amount;Obtain dynamic tension feedforward compensation amount;Obtain angle correction weight and position correction weight;Obtain corresponding angle compensation speed, and calculate the first product between angle compensation speed and angle correction weight;Obtain corresponding position compensation speed, and calculate the second product between position compensation speed and position correction weight;Superimpose first product and second product, obtain correction compensation speed;Superimpose theoretical basic walking speed, dynamic tension feedforward compensation amount and correction compensation speed, generate cable arrangement speed control instruction.The present application realizes the high-precision, high-reliability cable arrangement of winch.

Description

Technical Field

[0001] This invention relates to the field of marine engineering winch technology, and in particular to a winch cable laying control system. Background Technology

[0002] A winch is a common mechanical transmission device used in various industries such as lifting equipment, aerostats, and deep-sea exploration. It neatly stores cables on the winch or performs normal cable laying from the winch. The umbilical cable, as a comprehensive functional "lifeline" connecting surface vessels and deep-sea equipment (such as underwater robots and deep-sea towing systems), integrates power supply, communication, and fluid transmission. It is characterized by its large weight, long distance, and high value, which places extremely high demands on the precision of winch cable laying operations. In long-term continuous deployment and retrieval operations under heavy loads in deep water, deviations in cable laying position can easily lead to localized compression, cable skipping, jamming, or even severe cable tangling within the cable groove. This not only causes wear on the outer sheath of the umbilical cable and pressure fracture of the fragile internal signal fiber core, but in severe cases, it can even lead to catastrophic cable breakage accidents, directly threatening the system safety and operational progress of deep-sea equipment.

[0003] Existing cable control methods are mostly based on ideal quasi-static geometric kinematic models, typically employing mechanical semi-open-loop following or rigid correction triggered solely by displacement and angular deviations, which have significant limitations. On the one hand, in complex sea conditions during deep-sea operations (such as severe heave and swell of the mother ship and deep-sea hydrodynamic disturbances), high-frequency tension fluctuations cause transient elastic strain and micro-pitch changes in the cable. Traditional pure geometric closed-loop control cannot cope with this highly nonlinear dynamic characteristic and is prone to producing following phase lag. On the other hand, during multi-layer winding, the extremely high compression stiffness of the bottom layer and the long free section of the outer layer can cause drastic changes in the sensor signal-to-noise ratio. Traditional hard-switching correction is prone to causing severe oscillations in the servo system at the moment of layer change or disturbance. Summary of the Invention

[0004] To address the aforementioned technical problems, the present invention aims to provide a winch cable laying control system that considers high-frequency abrupt changes in cable tension. It superimposes a dynamic tension feedforward compensation amount, including a tension differential term, onto the drive cable laying command of the cable laying inverter to eliminate the cable laying lag caused by high-frequency tension abrupt changes. Simultaneously, based on the Sigmoid function, it adaptively allocates angle correction weights and position correction weights according to the real-time dynamic changes in the number of winding layers, solving the problems of drastic changes in signal-to-noise ratio and control oscillation under multi-layer winding, thus achieving high-precision cable laying.

[0005] To achieve the above-mentioned objectives, the present invention employs the following technical solution:

[0006] This application relates to a winch cable laying control system, comprising:

[0007] A cable storage drum control device includes a drum frequency converter for driving the cable storage drum to rotate, a drum frequency converter, a first reducer, and a braking device for braking the cable storage drum. The drum frequency converter is sequentially connected to the first reducer and the main shaft of the cable storage drum.

[0008] A cable laying control device includes a cable laying variable frequency motor, a cable laying variable frequency converter, a second reducer, a lead screw, and a cable laying guide wheel slide block slidably arranged on the lead screw for guiding the cable. The cable laying variable frequency motor is sequentially connected to the second reducer and the lead screw.

[0009] The measuring component includes a first encoder, a second encoder, a tension sensor, and a cable deflection angle sensor. The first encoder is used to measure the rotational speed and cumulative number of turns of the cable storage drum in real time. The second encoder is used to measure the current position of the cable guide wheel slide on the lead screw. The tension sensor is used to measure the transient tension value of the cable during cable guiding. The cable deflection angle sensor is used to measure the angle deviation signal of the cable during cable laying.

[0010] The winch controller is configured to perform the following automatic cable laying process:

[0011] Obtain the theoretical travel speed of the cable guide wheel slide block;

[0012] Based on the theoretical basis of walking speed, and the difference between the transient tension value fed back by the tension sensor and the preset benchmark working tension, the steady-state elastic elongation compensation amount of the cable is obtained, and based on the tension change rate and the length of the suspended free section of the cable at the current moment, the transient strain rate compensation amount of the cable is obtained.

[0013] Calculate the sum of the steady-state elastic elongation compensation and the transient strain rate compensation of the cable to obtain the dynamic tension feedforward compensation.

[0014] Based on the Sigmoid function, the angle correction weight of the angle correction speed and the position correction weight of the position correction speed are obtained according to the real-time dynamic change of the number of winding layers. The independent variable in the Sigmoid function is related to the current actual number of winding layers.

[0015] Based on the angle deviation signal, the corresponding angle compensation speed is obtained, and the first product between the angle compensation speed and the angle correction weight is calculated.

[0016] Based on the mechanical position error of the cable guide wheel slide, the corresponding position compensation speed is obtained, and the second product between the position compensation speed and the position correction weight is calculated.

[0017] By superimposing the first and second products, the correction compensation speed is obtained;

[0018] By superimposing the theoretically based walking speed, dynamic tension feedforward compensation amount, and correction compensation speed, a cable laying speed control command is generated, which is used by the cable laying frequency converter to drive the cable laying frequency converter motor for cable laying.

[0019] In some embodiments of this application, the winch controller is configured to have multiple cable laying modes:

[0020] Adaptive cable routing mode: In the adaptive cable routing mode, the automatic cable routing process is executed;

[0021] First degraded cable routing mode: When the tension sensor failure is detected, the first degraded cable routing mode is entered;

[0022] In the first degraded cabling mode, a time decay factor is preset;

[0023] The steady-state elastic elongation compensation of the cable is multiplied by the time decay factor and gradually decays to zero over time;

[0024] The transient strain rate compensation of the cable is multiplied by the time decay factor and gradually decays to zero over time;

[0025] Calculate the sum of the attenuated steady-state elastic elongation compensation and the attenuated transient strain rate compensation of the cable to obtain the attenuated dynamic tension feedforward compensation.

[0026] By superimposing the theoretical basis walking speed, the attenuated dynamic tension feedforward compensation amount, and the correction compensation speed, the degraded first row cable speed control command is generated.

[0027] Second degraded cable routing mode: When the cable routing angle sensor fails, the second degraded cable routing mode is entered.

[0028] In the second degraded cable routing mode, the angle correction weight is set to 0 and the position correction weight is set to 1.

[0029] Calculate the product between the position compensation speed and the position correction weight, and use it as the correction compensation speed after degradation;

[0030] By superimposing the theoretically based walking speed, dynamic tension feedforward compensation, and degraded correction compensation speed, a second cable speed control command is generated.

[0031] Third degraded cable routing mode: When both the tension sensor and the cable routing angle sensor are detected to be malfunctioning, the third degraded cable routing mode is entered.

[0032] In the third degraded cable routing mode, a time decay factor is preset, and the angle correction weight is set to 0 and the position correction weight is set to 1.

[0033] The steady-state elastic elongation compensation of the cable is multiplied by the time decay factor and gradually decays to zero over time;

[0034] The transient strain rate compensation of the cable is multiplied by the time decay factor and gradually decays to zero over time;

[0035] Calculate the sum of the attenuated steady-state elastic elongation compensation and the attenuated transient strain rate compensation of the cable to obtain the attenuated dynamic tension feedforward compensation.

[0036] Calculate the product between the position compensation speed and the position correction weight, and use it as the correction compensation speed after degradation;

[0037] By superimposing the theoretically based walking speed, the attenuated dynamic tension feedforward compensation amount, and the degraded correction compensation speed, a degraded third row cable speed control command is generated.

[0038] Emergency cable routing mode: In the emergency cable routing mode, the given frequency command for cable routing is sent manually to the cable routing inverter, and the sliding of the cable routing guide wheel slide is manually controlled.

[0039] In some embodiments of this application, the theoretical basic walking speed of the cable guide pulley slide is obtained. Specifically:

[0040] ;

[0041] in, The rotational speed of the cable storage drum is measured by the first encoder, and P is the physical pitch of the lead screw or the groove pitch of the cable storage drum. It is the mechanical reduction ratio and is a constant.

[0042] In some embodiments of this application, the length of the free suspension segment of the cable at the current time t is... The following formula is used to obtain it:

[0043] ;

[0044] in, The fixed physical distance from the center of the guide pulley to the main shaft of the cable storage cylinder. This represents the actual curl radius corresponding to the current winding layer. The spatial angle between the guide pulley and the main shaft of the cable storage cylinder;

[0045] Cable steady-state elastic elongation compensation The following formula is used to obtain it:

[0046] ;

[0047] in, The preset steady-state stretching ratio compensation coefficient, The transient tension value at time t is the feedback from the tension sensor. Preset reference working tension;

[0048] Cable transient strain rate compensation The following formula is used to obtain it:

[0049] ;

[0050] in, The preset transient rate of change feedforward coefficient, This is the equivalent tensile stiffness of the umbilical cable.

[0051] In some embodiments of this application, the angle correction weight for obtaining the angle correction speed is... Position correction weights and position correction speed Specifically:

[0052] ;

[0053] ;

[0054] in, This is the preset smoothing slope coefficient.

[0055] In some embodiments of this application, based on the angle deviation signal Specifically, a PID controller is used to process the angle deviation signal. Convert to corresponding angle compensation speed .

[0056] In some embodiments of this application, the mechanical position error of the cable guide pulley slide is used. Obtain the corresponding position compensation speed Specifically:

[0057] The cumulative number of revolutions measured by the first encoder is collected and multiplied by the cable groove pitch of the cable storage drum to obtain the theoretical mechanical position that the cable guide pulley slide should reach. ;

[0058] Calculate theoretical mechanical position The current position of the cable guide pulley slide measured by the second encoder. The difference is used to obtain the mechanical position deviation. ;

[0059] Using PID control, mechanical position error is reduced. Convert to corresponding position compensation velocity .

[0060] In some embodiments of this application, the winch controller is provided with a first protection mechanism, a second protection mechanism, and / or a third protection mechanism;

[0061] The first protection mechanism specifically involves: real-time monitoring of the tension value fed back by the tension sensor; when the tension value reaches a first preset value, an over-limit warning is issued; when the tension value reaches a second preset value higher than the first preset value, it indicates that the physical limit has been exceeded; the winch controller cuts off the drive enable for the drum inverter and the cable conveying inverter, and controls the braking device to brake the cable storage drum.

[0062] The second protection mechanism specifically involves limiting the travel of the cable guide pulley slide block on the lead screw.

[0063] The third protection mechanism is as follows: when the signal fed back by the tension sensor is abnormal, it switches to the first degraded cable routing mode; when the signal fed back by the cable routing angle sensor is abnormal, it switches to the second degraded cable routing mode; and when both the signal fed back by the tension sensor and the signal fed back by the cable routing angle sensor are abnormal, it switches to the third degraded cable routing mode.

[0064] In some embodiments of this application, the cable storage cylinder is provided with a removable double-folded rope groove.

[0065] In some embodiments of this application, the winch cable laying control system is also equipped with a touch screen, through which different cable laying modes are triggered.

[0066] The winch cable laying control system provided in this application has the following advantages and beneficial effects:

[0067] Considering the high-frequency abrupt changes in cable tension, the cable laying speed control command of the cable laying inverter of the cable laying variable frequency motor is superimposed with a dynamic tension feedforward compensation amount containing the tension differential term. This eliminates the cable laying lag problem caused by high-frequency abrupt changes in tension. At the same time, based on the Sigmoid function, the angle correction weight and position correction weight are adaptively allocated according to the real-time dynamic change of the number of winding layers. This eliminates the control oscillation problem caused by the drastic change in sensor signal-to-noise ratio and the change in stiffness of multi-layer winding when changing layers, thus achieving high-precision cable laying.

[0068] Other features and advantages of the present invention will become clearer after reading the detailed embodiments of the invention in conjunction with the accompanying drawings. Attached Figure Description

[0069] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0070] Figure 1 This invention provides a flowchart illustrating the automatic cable laying process performed by the winch controller in an embodiment of the winch cable laying control system proposed in this application.

[0071] Figure 2 The flowchart illustrates the switching of various cable laying modes in an embodiment of the winch cable laying control system proposed in this application. Detailed Implementation

[0072] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0073] Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without inventive effort are within the scope of protection of this invention. In the description of this invention, it should be understood that the terms "center," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0074] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. In the description of the above embodiments, specific features, structures, materials, or characteristics can be combined in any suitable manner in one or more embodiments or examples.

[0075] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0076] To address the issues of follow-phase lag caused by the strong nonlinear dynamic characteristics of cables in complex deep-sea operations, as well as the drastic changes in sensor signal-to-noise ratio and severe control oscillations caused by multi-layer cable entanglement, this application relates to a winch cable laying control system.

[0077] Combination Figure 1This describes the process by which the winch cable laying control system performs automatic cable laying.

[0078] Before describing the automatic cable laying process, the hardware structure of the winch cable laying control system (not shown) will be described first.

[0079] In some embodiments of this application, the winch cable laying control system includes a cable storage drum control device, a cable laying control device, and a winch controller.

[0080] In some embodiments of this application, the cable storage drum control device includes a drum frequency converter, a drum frequency converter motor, a first reducer, and a braking device.

[0081] The cable storage drum combines a large-diameter drum with a LEBUS double-folded grooved sheath. The drum is rolled and welded from high-strength steel plate, and its diameter is designed according to the minimum bending radius of the umbilical cable, satisfying both the bending requirements of the umbilical cable and the overall structural rigidity and weight. The double-folded grooved sheath uses segmented bolt connections, facilitating adjustment of the groove type when replacing umbilical cables of different specifications. The double-folded grooved sheath ensures that the layers of the umbilical cable are neatly arranged when wound in multiple layers, avoiding misalignment and crossing.

[0082] The main shaft of the reel is supported on the steel structure frame by large rolling bearings at both ends. A hollow channel is set at one end of the main shaft on the non-motor side of the drum to arrange the central slip ring and electric slip ring device, so as to realize the reliable transmission of electrical energy and signal when the drum rotates. The first encoder is installed at the end of the drum to measure the drum speed and cumulative number of turns in real time, providing basic data for cable laying control.

[0083] The first speed reducer is a helical gear reducer, which uses high-precision helical gear transmission and features high load capacity, smooth transmission, and low noise. Its output shaft is directly connected to the drum spindle, realizing forward and reverse drive of the drum. Furthermore, the variable frequency motor can smoothly adjust the speed over a wide range, is compatible with different grid voltages and frequencies, and meets the requirements of ship power stations in different sea areas such as North America and Europe.

[0084] The braking system is a hydraulic band brake, with one set installed on each side of the drum. The structure can be a brake band wrapped around the outer ring of the drum. The braking system consists of brake pads, cylinders, levers, and springs. The cylinders push the levers to tighten or loosen the steel band, operating in a spring-assisted braking and hydraulic release mode. When the hydraulic system loses pressure or the power station fails, the steel band automatically tightens under the action of the spring, achieving normally closed braking and reliably braking the drum. During normal operation, the hydraulic pump station provides pressure to overcome the spring force and release the brake.

[0085] In addition, a spring brake is installed at the low-speed end of the first reducer, which is connected in series with the hydraulic band brake to form a dual braking system. When a rapid stop or emergency braking is required, they can be used simultaneously to further improve the safety of the winch.

[0086] In some embodiments of this application, the cable laying control device includes a cable laying variable frequency motor, a cable laying frequency converter, a second reducer, a lead screw, a cable laying guide wheel slide, and a guide rail.

[0087] The lead screw is made of alloy steel with a moderate diameter and precise lead, and is mounted on the frame at both ends via bearing seats.

[0088] The cable laying frequency converter motor is installed on one side of the frame and is connected to the input shaft of the second reducer through a coupling. The output shaft of the second reducer is connected to the lead screw, and the cable laying frequency converter motor drives the lead screw to rotate through the second reducer.

[0089] The cable guide pulley slide block includes a guide pulley and a slide block. The guide pulley is fixed on the slide block, which engages with the lead screw via a nut. The slide block reciprocates linearly on the guide rail to change the direction of the umbilical cable, guiding it into the drum's cable groove at an approximately right angle. The diameter of the guide pulley is designed based on the minimum bending radius of the umbilical cable, and an anti-slip structure is incorporated to prevent the umbilical cable from detaching from the guide pulley under heavy load or impact conditions. Limit switches are located at both ends of the slide block to detect when the lead screw reaches its limit position, triggering the cable delivery frequency converter motor to reverse, thus achieving automatic reversing.

[0090] In some embodiments of this application, the cable routing variable frequency motor is an AC servo motor with encoder feedback (denoted as the second encoder). The second encoder is used to measure the current actual position of the cable routing guide pulley slide on the lead screw.

[0091] A cable deflection sensor is installed on the cable guide pulley slide block to measure the angular deviation signal of the umbilical cable at the guide pulley; a pin-type tension sensor is installed at the shaft end of the guide pulley to detect the transient tension value of the umbilical cable in real time.

[0092] Figure 1 This diagram shows a flowchart of the automatic cable laying process performed by the winch cable laying control system. (See also...) Figure 1 The process of automatic cable laying by the winch cable laying control system is described in detail below.

[0093] The automatic cable laying process can be controlled by a winch controller to be executed at fixed intervals (e.g., 10 seconds).

[0094] The automatic cable laying process introduces a tension feedforward compensation loop based on a nonlinear dynamics model of the cable and a nonlinear variable weight fusion law based on the number of cable winding layers and the Sigmoid function. The tension feedforward compensation loop compensates for the cable deformation error caused by wave heave by extracting the tension change rate in advance (as shown in S2 to S4 below). The nonlinear variable weight fusion law based on the Sigmoid function adaptively assigns weights to the position correction speed and angle correction speed through the Sigmoid function (as shown in S5 to S7 below), eliminating the control oscillation caused by the change in stiffness of the multi-layer cable winding.

[0095] Before performing steps S1 to S8, the winch controller needs to collect the cable drum rotation speed measured by the first encoder in real time. The cumulative number of revolutions, and the current position of the cable guide pulley slide on the lead screw measured by the second encoder. The transient tension value of the cable at the current time t, measured by the tension sensor. The angle deviation signal measured by the cable deflection sensor .

[0096] The real-time data acquisition mentioned above can be performed by the winch controller at fixed intervals.

[0097] S1: Obtain the theoretical basis for the walking speed of the cable guide pulley slide.

[0098] The theoretical basis of cable guide pulley slide block: walking speed This indicates that when the cable has no elastic deformation and no external interference, the cable storage drum rotates one revolution and the cable guide pulley slide moves strictly laterally by one pitch, which serves as the basic reference data.

[0099] In some embodiments of this application, the winch controller uses real-time reads of the drum rotation speed. Mechanical reduction ratio Given the preset physical pitch of the lead screw or the cable groove pitch P of the cable storage drum, the theoretical basic travel speed of the cable guide pulley slide is calculated using the following formula. .

[0100] (1).

[0101] This formula represents the following logic of an ideal "electronic gear ratio".

[0102] in, The unit is m / s. The unit of is r / min, and the unit of P is m. It is a constant.

[0103] S2: Obtain the steady-state elastic elongation compensation of the cable. .

[0104] In deep-sea operations under complex sea conditions, hydrodynamic disturbances can cause frequent abrupt changes in cable tension. Increased tension leads to micro-elastic elongation of the cable, resulting in a smaller actual winding pitch. To compensate for the changes in cable elastic strain and micro-pitch caused by sea state disturbances, and to eliminate the following phase lag caused by this physical deformation, the winch controller needs to intervene with advanced speed control before speed errors occur.

[0105] In some embodiments of this application, walking speed is based on theoretical principles. and the transient tension value fed back by the tension sensor. and preset benchmark working tension The difference, to obtain .

[0106] The specific calculation is performed using the following formula: (2).

[0107] in, The preset steady-state tensile proportional compensation coefficient can be obtained through calibration during the factory tensile test. This is the preset equivalent tensile stiffness of the umbilical cable.

[0108] This represents the physical strain rate of the cable caused by tension deviation, and it is related to... Multiplication represents the steady-state geometric misalignment error caused by the cable being stretched.

[0109] S3: Obtain the transient strain rate compensation of the cable. .

[0110] In some embodiments of this application, the tension change rate (i.e., abrupt change trend) and the length of the suspended free segment of the cable at the current time t are used as the basis. Obtain the transient strain rate compensation of the cable. .

[0111] This represents a predictive velocity pulse calculated at the instant when the tension increases dramatically due to the impact of a wave.

[0112] First, use the following formula to calculate the length of the free suspension segment of the cable at the current time t. .

[0113] (3).

[0114] in, The fixed physical distance from the center of the guide pulley to the main shaft of the cable storage cylinder. This represents the actual curl radius corresponding to the current winding layer. The spatial angle between the guide pulley and the main shaft of the cable storage cylinder.

[0115] Should It can be obtained by analyzing the cumulative number of revolutions measured by the first encoder.

[0116] Then, calculate using the following formula: (4).

[0117] in, The preset transient rate of change feedforward coefficient can be obtained through dynamic sea trials.

[0118] S4: Obtain the dynamic tension feedforward compensation amount.

[0119] The information obtained in S2 And obtained in S3 By superimposing the values, the dynamic tension feedforward compensation amount can be obtained. .

[0120] The dynamic tension feedforward compensation amount The advanced control command to be superimposed on the cable-laying variable frequency motor is used to accelerate or decelerate in advance, eliminating external disturbances in advance.

[0121] S5: Obtain the angle correction weight of the angle correction speed and the position correction weight of the position correction speed.

[0122] During the bottom layer winding, the cable is severely compressed, and the cable deflection sensor measures only "false deflection angles" (high-frequency noise) caused by localized deformation. However, during the outer layer winding, the cable has a longer free section, and the cable deflection sensor is very sensitive and accurate. Therefore, changing layers causes a drastic change in the sensor's signal-to-noise ratio and triggers control oscillations.

[0123] To eliminate the above-mentioned effects, in some embodiments of this application, angle correction weights based on the Sigmoid function are introduced. and position correction weights Adaptive assignment is performed so that when the cable is wound at the bottom layer, the winch controller automatically assigns a larger position correction weight. As the number of winding layers increases, the angle correction weight increases non-linearly along the Sigmoid curve, achieving a non-linear smooth transition.

[0124] The independent variable of the Sigmoid function is related to the current actual number of winding layers, where i represents the current actual number of winding layers of the cable.

[0125] In some embodiments of this application, the independent variable of the Sigmoid function is designed as follows: Where N is the maximum total number of winding layers in the cable storage cylinder design.

[0126] In some embodiments of this application, the following formula can be used for calculation:

[0127] , (5).

[0128] in, This is the preset smoothing slope coefficient.

[0129] When the entanglement occurs at the bottom layer, i.e., when i is much smaller than N / 2, the exponential term of the Sigmoid function is extremely large. Approaching 0, Approaching 1, the system automatically filters out angular noise, forcibly trusts the position signal given by the second encoder, and uses a rigid mechanical closed loop to resist the squeezing interference on the cable during the bottom layer winding; when laying the cable to the outer layer winding... Approaching 1, Approaching zero, the system smoothly trusts the cable deflection sensor, achieving unobstructed and smooth fusion of position and angle multi-source data, eliminating the problem of drastic changes in sensor signal-to-noise ratio and control oscillations during layer switching.

[0130] S6: Obtain the corresponding angle compensation speed and the corresponding position compensation speed.

[0131] In some embodiments of this application, the winch controller receives the angular deviation signal fed back by the cable deflection sensor. Convert to angle-compensated speed and corresponding angle correction weights Multiply to obtain the compensated angle-compensated speed. .

[0132] In some embodiments of this application, a PID control is used to control the angle deviation signal. Directly converted to angle-compensated speed See below:

[0133] (6).

[0134] In some embodiments of this application, the winch controller will detect mechanical position errors. Convert to position-compensated velocity and corresponding location correction weights Multiply to obtain the compensated position-compensated velocity. .

[0135] In some embodiments of this application, a PID control is used to control the mechanical position error. Directly converted to angle-compensated speed See below:

[0136] (7).

[0137] Mechanical position error as described above Since it cannot be directly measured, the theoretical mechanical position that the cable guide pulley should reach must first be calculated. Then compare the current position of the cable guide pulley slide measured by the second encoder. By subtracting, the mechanical position error is obtained. .

[0138] Among them, theoretical mechanical position The cumulative number of turns measured by the first encoder can be obtained by multiplying the cable groove pitch of the storage drum.

[0139] S7: Obtain the speed of correction compensation.

[0140] The compensated angle speed obtained in S6 Compensated position and compensated velocity By superimposing the data, the correction compensation speed can be obtained. .

[0141] Right now, (8).

[0142] S8: Generate cable laying speed control command.

[0143] The theoretical walking speed obtained from S1 is superimposed. The dynamic tension feedforward compensation amount obtained in S4 And the correction compensation speed obtained in S7 Generate cable laying speed control commands .

[0144] Right now, (9).

[0145] The cable laying speed control command The data can be sent to the cable laying frequency converter via the industrial communication bus, which will then drive the cable laying frequency converter motor to lay the cables accordingly.

[0146] This cable laying control system can comprehensively consider the problems caused by high-frequency tension changes and multi-layer entanglement of cables. It can control the cable laying according to the actual sea conditions and entanglement situation, and achieve high-precision, high-reliability and high-safety cable laying.

[0147] In some embodiments of this application, in order to adapt to complex deep-sea conditions and different operational needs, the control system is equipped with four redundant cable laying modes: adaptive cable laying mode, first degraded cable laying mode, second degraded cable laying mode, third degraded cable laying mode, and emergency cable laying mode.

[0148] In adaptive cable laying mode, processes S1 to S8 as described above can be executed, in which both the tension sensor and the cable laying angle sensor are working normally.

[0149] In some embodiments of this application, in order to achieve smooth degraded cabling by softly switching each cabling mode by defining parameters when certain sensors are damaged, and to avoid damage caused by mechanical hard switching.

[0150] See Figure 2 It shows a flowchart of various cable routing mode switching.

[0151] When the tension sensor fails, the system enters the first degraded cable laying mode; when the cable laying angle sensor fails, the system enters the second degraded cable laying mode; when both the cable laying angle sensor and the tension sensor fail, the system enters the third degraded cable laying mode; and in the event of extreme failures such as communication failure or winch controller main program crash, the system enters the emergency cable laying mode.

[0152] As mentioned in S2 to S4 above, the transient tension value measured by the tension sensor is involved. When the tension sensor failure is detected, in order to avoid a hard switch from the adaptive cable laying mode to the first degraded cable laying mode, a preset time decay factor is introduced in the first degraded cable laying mode, which smoothly decays to 0 along the slope over time.

[0153] When a tension sensor failure is detected, the steady-state elastic elongation compensation amount of the cable will be adjusted. Multiply by the time decay factor to obtain the gradually decaying steady-state elastic elongation compensation of the cable. ; The transient strain rate compensation amount of the cable Multiply by the time decay factor to obtain the compensation amount of the cable transient strain rate after gradual decay. .

[0154] Specifically, see formula (2), which can be used to... Multiplied by a time decay factor, within a preset time (e.g., 20 milliseconds), Smoothly decay to 0 along the slope; see formula (4), which can be used to... Multiplied by a time decay factor, within a preset time (e.g., 20 milliseconds), The dynamic tension feedforward compensation amount smoothly decreases to 0 along the slope. Smoothly decay to 0.

[0155] The control system then smoothly exited the tension feedforward compensation loop, and the degraded first row cable speed control command... .

[0156] As mentioned above, in S5 to S7 The issue involves the angle deviation measured by the cable routing angle sensor. When the cable routing angle sensor is detected to be faulty, in order to avoid a hard switch from the adaptive cable routing mode to the second degraded cable routing mode, the following measures are taken.

[0157] In the second downgraded cabling mode, the fixed order is... =0, =1, the control system instantly cut off the erroneous angle signal chain, and the disturbance-free operation degraded into a pure mechanical gear ratio following control relying solely on the position deviation signal. The degraded second-row cable speed control command At this point, the basic cable laying requirements are met.

[0158] When both the tension sensor and the cable routing angle sensor fail, the system enters the third degraded cable routing mode.

[0159] In the third degraded cable laying mode, the smooth exit tension feedforward compensation circuit method and the fixed command method from the second degraded cable laying mode are adopted. =0 and In the case of a value of 1, the speed control command for the third row of cables after degradation is executed. .

[0160] In emergency cable laying mode, the automatic closed-loop control of the cable laying inverter motor is cut off. The operator only manually sends the given frequency command for cable laying to the cable laying inverter, relies on manual visual observation of the cable deflection, and manually controls the sliding of the cable laying guide wheel slide to ensure that the deep-sea equipment is laid in the water in emergency situations (for example, when the deep-sea equipment cable is lowered to a position that may be close to the ship's side, if the program malfunctions, the emergency cable laying mode will be used to avoid collision due to the ship's sway).

[0161] In some embodiments of this application, trigger buttons for the four cable laying modes can also be set on a touch screen that is communicatively connected to the winch controller, so that the operator can manually trigger and select the corresponding cable laying mode.

[0162] In some embodiments of this application, in order to ensure the safety of the control system under harsh operating conditions, the system is provided with protection mechanisms: a first protection mechanism, a second protection mechanism, and / or a third protection mechanism.

[0163] The first protection mechanism is as follows: real-time monitoring of the tension value fed back by the tension sensor; when it reaches the first preset value, an over-limit warning is issued; when it reaches the second preset value which is higher than the first preset value, it indicates that the physical limit has been exceeded. The winch controller cuts off the drive enable to the drum inverter and the cable delivery inverter, and controls the braking device to brake the cable storage drum to prevent the cable from breaking.

[0164] The second protection mechanism specifically involves setting limit switches at both ends of the lead screw, as described above, to limit the travel of the cable guide pulley slide on the lead screw. When the cable guide pulley slide touches the limit switch on either side, the winch controller immediately blocks the running command in that direction and issues an overtravel alarm. The operator can only resume operation by manually jogging in the opposite direction to prevent the mechanical mechanism from being damaged by a collision.

[0165] The third protection mechanism is as follows: when the feedback signal from the tension sensor is abnormal, it switches to the first degraded cable laying mode; when the feedback signal from the cable laying angle sensor is abnormal, it switches to the second degraded cable laying mode; and when both the feedback signals from the tension sensor and the cable laying angle sensor are abnormal, it injects the third degraded cable laying mode to ensure that the cable laying operation continues uninterrupted.

[0166] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions claimed by the present invention.

Claims

1. A winch cable laying control system, characterized in that, include: A cable storage drum control device includes a drum frequency converter for driving the cable storage drum to rotate, a drum frequency converter, a first reducer, and a braking device for braking the cable storage drum. The drum frequency converter is sequentially connected to the first reducer and the main shaft of the cable storage drum. A cable laying control device includes a cable laying variable frequency motor, a cable laying variable frequency converter, a second reducer, a lead screw, and a cable laying guide wheel slide block slidably arranged on the lead screw for guiding the cable. The cable laying variable frequency motor is sequentially connected to the second reducer and the lead screw. The measuring component includes a first encoder, a second encoder, a tension sensor, and a cable deflection angle sensor. The first encoder is used to measure the rotational speed and cumulative number of turns of the cable storage drum in real time. The second encoder is used to measure the current position of the cable guide wheel slide on the lead screw. The tension sensor is used to measure the transient tension value of the cable during cable guiding. The cable deflection angle sensor is used to measure the angle deviation signal of the cable during cable laying. The winch controller is configured to perform the following automatic cable laying process: Obtain the theoretical travel speed of the cable guide wheel slide block; Based on the aforementioned theoretical foundation, the walking speed, and the difference between the transient tension value fed back by the tension sensor and the preset benchmark working tension, the steady-state elastic elongation compensation amount of the cable is obtained. Based on the rate of change of tension and the length of the free section of the cable at the current moment, the transient strain rate compensation of the cable is obtained. Calculate the sum of the steady-state elastic elongation compensation and the transient strain rate compensation of the cable to obtain the dynamic tension feedforward compensation. Based on the Sigmoid function, the angle correction weight of the angle correction speed and the position correction weight of the position correction speed are obtained according to the real-time dynamic change of the number of winding layers. The independent variable in the Sigmoid function is related to the current actual number of winding layers. Based on the angle deviation signal, the corresponding angle compensation speed is obtained, and the first product between the angle compensation speed and the angle correction weight is calculated. Based on the mechanical position error of the cable guide wheel slide, the corresponding position compensation speed is obtained, and the second product between the position compensation speed and the position correction weight is calculated. By superimposing the first and second products, the correction compensation speed is obtained; By superimposing the theoretically based walking speed, dynamic tension feedforward compensation amount, and correction compensation speed, a cable laying speed control command is generated, which is used by the cable laying frequency converter to drive the cable laying frequency converter motor for cable laying.

2. The winch cable laying control system according to claim 1, characterized in that, The winch controller is configured to have multiple cable laying modes: Adaptive cable routing mode: In the adaptive cable routing mode, the automatic cable routing process is executed; First degraded cable routing mode: When the tension sensor failure is detected, the first degraded cable routing mode is entered; In the first degraded cabling mode, a time decay factor is preset; The steady-state elastic elongation compensation of the cable is multiplied by the time decay factor and gradually decays to zero over time; The transient strain rate compensation of the cable is multiplied by the time decay factor and gradually decays to zero over time; Calculate the sum of the attenuated steady-state elastic elongation compensation and the attenuated transient strain rate compensation of the cable to obtain the attenuated dynamic tension feedforward compensation. By superimposing the theoretical basis walking speed, the attenuated dynamic tension feedforward compensation amount, and the correction compensation speed, the degraded first row cable speed control command is generated. Second degraded cable routing mode: When the cable routing angle sensor fails, the second degraded cable routing mode is entered. In the second degraded cable routing mode, the angle correction weight is set to 0 and the position correction weight is set to 1. Calculate the product between the position compensation speed and the position correction weight, and use it as the correction compensation speed after degradation; By superimposing the theoretically based walking speed, dynamic tension feedforward compensation, and degraded correction compensation speed, a second cable speed control command is generated. Third degraded cable routing mode: When both the tension sensor and the cable routing angle sensor are detected to be malfunctioning, the third degraded cable routing mode is entered. In the third degraded cable routing mode, a time decay factor is preset, and the angle correction weight is set to 0 and the position correction weight is set to 1. The steady-state elastic elongation compensation of the cable is multiplied by the time decay factor and gradually decays to zero over time; The transient strain rate compensation of the cable is multiplied by the time decay factor and gradually decays to zero over time; Calculate the sum of the attenuated steady-state elastic elongation compensation and the attenuated transient strain rate compensation of the cable to obtain the attenuated dynamic tension feedforward compensation. Calculate the product between the position compensation speed and the position correction weight, and use it as the correction compensation speed after degradation; By superimposing the theoretically based walking speed, the attenuated dynamic tension feedforward compensation amount, and the degraded correction compensation speed, a degraded third row cable speed control command is generated. Emergency cable routing mode: In the emergency cable routing mode, the given frequency command for cable routing is sent manually to the cable routing inverter, and the sliding of the cable routing guide wheel slide is manually controlled.

3. The winch cable laying control system according to claim 1, characterized in that, The theoretical basis for the travel speed of the cable guide pulley slide is obtained. Specifically: ； in, The rotational speed of the cable storage drum is measured by the first encoder, and P is the physical pitch of the lead screw or the groove pitch of the cable storage drum. It is the mechanical reduction ratio and is a constant.

4. The winch cable laying control system according to claim 1, characterized in that, Length of the free suspension segment of the cable at current time t The following formula is used to obtain it: ； in, The fixed physical distance from the center of the guide pulley to the main shaft of the cable storage cylinder. This represents the actual curl radius corresponding to the current winding layer. The spatial angle between the guide pulley and the main shaft of the cable storage cylinder; Cable steady-state elastic elongation compensation The following formula is used to obtain it: ； in, The preset steady-state stretching ratio compensation coefficient, The transient tension value at time t is the feedback from the tension sensor. Preset reference working tension; Cable transient strain rate compensation The following formula is used to obtain it: ； in, The preset transient rate of change feedforward coefficient, This is the equivalent tensile stiffness of the umbilical cable.

5. The winch cable laying control system according to claim 1, characterized in that, Obtain the angle correction speed and angle correction weight Position correction weights and position correction speed Specifically: ； ； in, The preset smoothing slope coefficient, i represents the current actual number of layers of cable winding.

6. The winch cable laying control system according to claim 1, characterized in that, Based on angle deviation signal Specifically, a PID controller is used to process the angle deviation signal. Convert to corresponding angle compensation speed .

7. The winch cable laying control system according to claim 1, characterized in that, Based on the mechanical position error of the cable guide roller slide Obtain the corresponding position compensation speed Specifically: The cumulative number of revolutions measured by the first encoder is collected and multiplied by the cable groove pitch of the cable storage drum to obtain the theoretical mechanical position that the cable guide pulley slide should reach. ; Calculate theoretical mechanical position The current position of the cable guide pulley slide measured by the second encoder. The difference is used to obtain the mechanical position deviation. ; Using PID control, mechanical position error is reduced. Convert to corresponding position compensation velocity .

8. The winch cable laying control system according to claim 2, characterized in that, The winch controller is equipped with a first protection mechanism, a second protection mechanism, and / or a third protection mechanism; The first protection mechanism specifically involves: real-time monitoring of the tension value fed back by the tension sensor; when the tension value reaches a first preset value, an over-limit warning is issued; when the tension value reaches a second preset value higher than the first preset value, it indicates that the physical limit has been exceeded; the winch controller cuts off the drive enable for the drum inverter and the cable conveying inverter, and controls the braking device to brake the cable storage drum. The second protection mechanism specifically involves limiting the travel of the cable guide pulley slide block on the lead screw. The third protection mechanism is as follows: when the signal fed back by the tension sensor is abnormal, it switches to the first degraded cable routing mode; when the signal fed back by the cable routing angle sensor is abnormal, it switches to the second degraded cable routing mode; and when both the signal fed back by the tension sensor and the signal fed back by the cable routing angle sensor are abnormal, it switches to the third degraded cable routing mode.

9. The winch cable laying control system according to claim 1, characterized in that, The cable storage cylinder is equipped with a detachable double-folded rope groove.

10. The winch cable laying control system according to claim 2, characterized in that, The winch cable laying control system is also equipped with a touch screen, through which different cable laying modes can be triggered.

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