Steel wire rope full-process safety protection type hoist type hoist machine

Abstract

The application belongs to the technical field of hoist, especially to a steel wire rope full-process safety protection type hoist type gate hoist, comprising a bottom plate, the upper end of the bottom plate is provided with a hoist body, the hoist body comprises a motor, the side of the motor is provided with a roller shaft, the surface of the roller shaft is wound with a steel wire rope, and the lower end of the motor is provided with a damping block. The hoist type gate hoist is provided with a flattening mechanism, the roller shaft is driven to rotate synchronously by a chain wheel and a chain, the guide block slides along the spiral sliding groove of the reciprocating screw rod, the guide wheel is driven to move reciprocatingly along the reciprocating screw rod, the steel wire rope is uniformly wound on the surface of the roller shaft, the local stacking or disorder of the steel wire rope on the roller shaft is effectively avoided, the limiting ring moves synchronously with the fixed ring, the direction of the steel wire rope is limited, the arc surface of the guide wheel is ensured to be always attached to the steel wire rope, and the stability and service life of the steel wire rope are improved.

Description

Technical Field

[0001] This invention relates to the field of winch technology, and in particular to a wire rope full-process safety protection type winch gate opener. Background Technology

[0002] Winch-type gate hoists are crucial equipment in water conservancy and hydropower projects for opening and closing gates. They typically use steel wire ropes as the lifting device, and the rotation of the drum raises and lowers the gate by winding and unwinding the rope. However, existing winch-type gate hoists suffer from the following problems during operation:

[0003] First, the problem of uneven wire rope winding on the drum is quite prominent. During operation, the wire rope of a winch-type gate hoist needs to be wound repeatedly on the drum surface. Due to the lack of an effective rope guiding device, the wire rope is prone to overlapping, oblique winding, and tangling. Especially in the case of multi-layer winding, ordinary winding methods can also result in defects such as dents and rope biting. Uneven wire rope arrangement not only aggravates the compression and wear between wire ropes, but may also cause the wire rope to jump out of the drum baffle, posing a serious safety hazard. Although some existing technologies attempt to solve the problem of uneven wire rope winding by using arrangement blocks or wiring components, their structures are complex and cannot form an effective linkage with the winch body.

[0004] Secondly, there is a lack of effective methods for damage detection and safety monitoring of wire ropes. During repeated passage through pulleys or drums, the numerous bends of the wire rope can easily cause fatigue, reduced toughness, and ultimately, wire breakage. Corrosion and deformation are also common forms of damage to wire ropes. Corrosion not only reduces the effective cross-sectional area of ​​the strands but also exacerbates wear and compression between the wire ropes, weakening their toughness and breaking strength. In daily use, internal damage such as broken sub-wires is not easily detected. If abnormal stress or damage conditions are not detected in time, wire rope breakage accidents can easily occur. Hydropower stations have experienced accidents where wire rope entanglement in fixed winch gates prevented normal gate operation, as well as wire rope breakage accidents, indicating a significant deficiency in the current equipment's comprehensive safety monitoring of wire ropes.

[0005] Third, the fall protection performance of winch-type gate hoists needs improvement. After hoisting a gate or hydraulic dam to a designated position, winch-type gate hoists typically rely solely on the brake to maintain the gate's position, lacking an effective mechanical self-locking function. If the brake fails or the hydraulic system leaks, the gate or dam may unexpectedly fall, causing a serious safety accident. While some existing technologies employ ratchet and pawl-type fall protection devices, most are structurally complex and lack linkage control with wire rope status monitoring, failing to achieve intelligent fall protection that automatically triggers based on the real-time operating status of the wire rope.

[0006] To address the aforementioned problems, this invention proposes a wire rope-driven winch-type gate opener with full-process safety protection. Summary of the Invention

[0007] Based on the existing technical problems of uneven wire rope winding, insufficient damage detection methods, and lack of fall protection safety performance, this invention proposes a wire rope full-process safety protection winch-type gate opener.

[0008] This invention proposes a wire rope full-process safety protection type winch gate hoist, including a base plate, a winch body is provided at the upper end of the base plate, the winch body includes a motor, a roller is provided on one side of the motor, a wire rope is wound on the surface of the roller, a shock-absorbing block is provided at the lower end of the motor, an anti-fall mechanism is provided between the motor and the roller, and a leveling mechanism is provided on one side of the roller.

[0009] Preferably, the fall protection mechanism includes a hydraulic cylinder embedded inside the shock absorber block. A bracket is symmetrically arranged on one side of the shock absorber block. The output shaft of the winch body reducer is rotatably connected to the body of one of the brackets via a bearing. An auxiliary frame is rotatably connected to the opposite surfaces of the two brackets via bearings. A ratchet is fixedly connected to one end of the output shaft of the winch body reducer. A locking block is engaged with the surface of the ratchet. One end of the locking block is rotatably connected to the upper end of the auxiliary frame via a pin. A limit post is fixedly connected to one end of the locking block. A strong spring is hung on the surface of the limit post. An L-shaped rod is fixedly connected to the outer side of the auxiliary frame. One end of the strong spring is fixedly engaged with one end of the L-shaped rod. A connecting rod is rotatably connected to the lower end of the auxiliary frame. The lower end of the connecting rod is fixedly connected to one end of the piston rod of the hydraulic cylinder.

[0010] Preferably, the leveling mechanism includes fixed blocks symmetrically arranged on the upper end of the base plate, a reciprocating screw rotatably connected between the opposing surfaces of the two fixed blocks, a guide wheel slidably sleeved on the reciprocating screw, the surface of the guide wheel slidably connected to the surface of the wire rope, a fixed ring provided on the inner ring of the guide wheel, a bearing one provided between the outer ring of the fixed ring and the inner ring of the guide wheel, a bearing two provided on the inner ring of the fixed ring, a guide block adapted to a groove formed on the surface of the reciprocating screw on the inner ring of the inner ring of the inner ring of the inner ring of the inner ring of the inner ring of the inner ring of the inner ring of the inner ring of the inner ring of the inner ring of the inner ring of the outer ... inner ring of the outer ring of the inner ring of the inner ring of the inner ring of the outer ring of the inner ring of the inner ring of the inner ring of the outer ring of the inner ring of the inner ring of the inner ring of the inner ring of the outer ring of the inner ring of the inner ring of the inner ring of the inner ring of the outer ring of the inner ring of the inner ring of the inner ring of the inner ring of the inner ring of the outer ring of the inner ring of the inner ring of the inner ring of the inner ring of the inner ring of the inner ring of the outer ring of the inner ring of the inner ring of the inner ring of the inner ring of the inner ring of the inner ring of the outer ring of the inner ring of the inner ring of the inner ring of the inner ring of the inner ring of the outer ring of the inner ring of the inner ring of

[0011] Preferably, the body of the fixing ring passes through a limiting rod, the surface of the limiting rod is slidably connected to the body of the fixing ring, the two ends of the limiting rod are respectively fixedly connected to the opposite surfaces of the two fixing blocks, L-shaped fixing rods are respectively fixedly connected to the two outer sides of the fixing ring, a limiting ring is fixedly connected between the two L-shaped fixing rods, the surface of the limiting ring is slidably connected to the surface of the wire rope, and the limiting ring is a split structure, including a first half-ring and a second half-ring arranged opposite each other, one end of the first half-ring and the second half-ring are hinged to each other, and the other end is detached and connected by an elastic buckle.

[0012] Preferably, sprockets are fixedly connected to one end of the reciprocating screw located outside the fixed block and the other end of the screw body located at the center of the roller shaft, respectively. A chain meshes between the two sprockets. A support base is provided on the outer side of one of the fixed blocks. A T-shaped frame is provided on the upper end of the support base. An auxiliary sprocket is rotatably connected to the upper end of the T-shaped frame. The surface of the auxiliary sprocket meshes with the surface of the chain. Bolts are provided at both ends of the T-shaped frame. The bolts are rotatably connected to both ends of the T-shaped frame through bearings. The lower end of the bolt is threadedly fixed to the upper end of the support base.

[0013] Preferably, the opposing surfaces of the guide wheels are all set as arc-shaped surfaces, and pressure sensors are evenly distributed along the circumference on the inner side of the limiting ring.

[0014] Preferably, a motor fixing sleeve is fixedly sleeved on the outer surface of the motor, a collar is fixedly connected to the upper end of the motor fixing sleeve, a pull rope is fixedly connected to one end of the collar, one end of the pull rope is fixedly connected to the surface of the locking block, a return spring is sleeved on the surface of the pull rope, and the two ends of the return spring are fixedly connected to the surfaces of the collar and the locking block, respectively.

[0015] Preferably, a control system is also provided at the upper end of the base plate. The control system consists of a signal acquisition module, a pressure data processing module, a damage judgment module, a fall protection execution control module, a drive regulation module, and an audible and visual alarm module. The signal acquisition module is electrically connected to the pressure sensor inside the limit ring and is used to collect pressure signals at various points inside the limit ring in real time and synchronously convert them into digital pressure values. The data is then transmitted to the pressure data processing module, which has built-in logic for calculating the mean, range, and fluctuation amplitude. This module calculates the pressure data collected by all sensors at the same time and outputs the real-time uniformly distributed pressure on the wire rope. Maximum pressure at a single point Pressure fluctuation difference Three sets of core parameters; the damage determination module has built-in the steel wire rope safety threshold database and damage determination calculation formula, receives the output parameters of the pressure data processing module, and automatically determines whether the steel wire rope has broken wires, warped wires, or extrusion overload faults by comparing it with the preset safety threshold.

[0016] The fall protection execution control module is electrically connected to the hydraulic cylinder, the motor, and the pull rope, respectively. It receives the fault signal and the gate position signal output by the damage judgment module, and automatically outputs locking / unlocking control commands to drive the fall protection mechanism 3 to act.

[0017] The drive control module is communicatively connected to the motor drive unit and adaptively adjusts the motor lifting speed according to the wire rope pressure fluctuation data to reduce wire rope wear.

[0018] The audible and visual alarm module receives the over-limit signal from the damage determination module and simultaneously triggers a high-decibel buzzer and a red warning light.

[0019] Preferably, the pressure data processing module uses the following formula to perform data calculations: Where n is the total number of pressure sensors within the limiting ring, For the i-th sensor, the pressure (MPa) is collected in real time. The average contact pressure of the entire wire rope; the formula for calculating the pressure difference at a single point: , These represent the maximum and minimum pressure values ​​of the sensor within the same data acquisition period, respectively. The formula for calculating the amplitude of single-cycle pressure fluctuation is: (The formula is not provided in the original text.) ,in These represent the pressure fluctuation of the wire rope during continuous winding and unwinding, the average pressure of the current acquisition cycle, and the average pressure of the previous acquisition cycle, respectively. The pressure data processing module drives the control module to complete one round of all sensor data acquisition and the above formula calculation every 100ms.

[0020] Preferably, the wire rope damage determination module incorporates a three-level determination logic and a safety threshold determination formula, and the specific control determination method is as follows:

[0021] Normal operating conditions: ,in This refers to the upper limit threshold of the single-point pressure during normal operation of the wire rope. This is the allowable difference due to normal uneven stress distribution. The control system determines that the wire rope is normal when all conditions are met, based on the allowable pressure fluctuation threshold for normal winding and unwinding, and drives the control module to maintain the set rated speed.

[0022] Warning conditions: , The upper limit threshold for early warning pressure, To warn of uneven force difference threshold, when the condition is met, the control system triggers a low-frequency intermittent alarm from the audible and visual alarm module, and the drive control module automatically reduces the motor lifting speed to 60% of the rated speed, allowing the current gate lifting cycle to be completed.

[0023] Hazardous operating conditions: If any of the above conditions are met, the control system will immediately control the drive control module to cut off the motor output, and the roller will stop rotating.

[0024] The anti-fall execution control module outputs a locking command, which controls the hydraulic cylinder piston rod to extend rapidly, push the locking block to clamp the ratchet, and forcibly lock the roller to prevent the gate from falling.

[0025] The beneficial effects of this invention are as follows:

[0026] 1. By setting up an anti-fall mechanism, when the piston rod of the hydraulic cylinder extends, it pushes the auxiliary frame to rotate through the connecting rod, causing the locking block to engage in the tooth groove of the ratchet, restricting the rotation of the reducer and roller shaft, so that the hydraulic dam body is stably held in the designated position, effectively preventing the dam body from falling accidentally due to hydraulic system leakage or the elastic elongation of the wire rope; when lowering the hydraulic dam, the piston rod of the hydraulic cylinder retracts, causing the auxiliary frame to rotate in the opposite direction. The upper end of the auxiliary frame and the loosened pull rope work together to make the locking block smoothly disengage from the ratchet tooth groove, restoring the roller shaft to the free rotation state, realizing the automatic control of locking in place and unlocking when lowering, which is convenient and reliable to operate.

[0027] 2. By setting up a leveling mechanism, the roller shaft drives the reciprocating screw to rotate synchronously through the sprocket and chain. The guide block slides along the spiral groove of the reciprocating screw, driving the guide wheel to move back and forth along the axial direction of the reciprocating screw, so that the wire rope is evenly wound on the surface of the roller shaft, effectively avoiding local stacking or tangling of the wire rope on the roller shaft. At the same time, the limiting ring moves synchronously with the fixed ring, constraining and limiting the direction of the wire rope output, ensuring that the wire rope is always in contact with the arc surface of the guide wheel, improving the stability and service life of the wire rope winding and unwinding operation. Pressure sensors evenly distributed along the circumference of the inner side of the limiting ring can detect the pressure value of the wire rope on the inner wall of the limiting ring in real time. When the sub-wire of the wire rope breaks or the protruding sub-wire squeezes the inner wall of the limiting ring, the pressure sensor promptly collects the pressure change signal and transmits it to the controller, realizing the safety monitoring and abnormal early warning of the entire wire rope process. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of a wire rope full-process safety protection type winch gate opener proposed in this invention;

[0029] Figure 2This is a diagram showing the position of the motor fixing sleeve of a wire rope full-process safety protection winch gate opener proposed in this invention.

[0030] Figure 3 A perspective view of the ratchet mechanism of a wire rope hoist with full-process safety protection proposed in this invention;

[0031] Figure 4 This is a diagram showing the position of the auxiliary sprocket of a wire rope-driven hoist with full-process safety protection, as proposed in this invention.

[0032] Figure 5 This is a perspective view of the guide block of a wire rope full-process safety protection winch gate hoist proposed in this invention;

[0033] Figure 6 This is a perspective view of the guide wheel of a wire rope hoist with full-process safety protection proposed in this invention.

[0034] In the diagram: 1. Base plate; 2. Winch body; 20. Motor; 21. Roller; 22. Wire rope; 23. Shock absorber; 3. Anti-fall mechanism; 31. Hydraulic cylinder; 32. Bracket; 33. Auxiliary frame; 34. Ratchet; 35. Locking block; 36. Limiting post; 37. Strong spring; 38. Connecting rod; 39. Motor fixing sleeve; 310. Pull rope; 4. Leveling mechanism; 40. Fixing block; 41. Reciprocating screw; 42. Guide wheel; 43. Guide block; 44. Fixing ring; 45. Bearing 1; 46. Bearing 2; 47. Limiting rod; 48. Limiting ring; 49. L-shaped fixing rod; 410. Sprocket; 411. Chain; 412. T-shaped frame; 413. Bolt; 414. Auxiliary sprocket; 415. Support base. Detailed Implementation

[0035] 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.

[0036] Reference Figures 1-6 A wire rope full-process safety protection type winch gate hoist includes a base plate 1, a winch body 2 is provided at the upper end of the base plate 1, the winch body 2 includes a motor 20, a roller 21 is provided on one side of the motor 20, a wire rope 22 is wound on the surface of the roller 21, a shock-absorbing block 23 is provided at the lower end of the motor 20, an anti-fall mechanism 3 is provided between the motor 20 and the roller 21, and a leveling mechanism 4 is provided on one side of the roller 21.

[0037] In this embodiment, the fall arrest mechanism 3 includes a hydraulic cylinder 31 embedded inside the shock absorber 23. A bracket 32 ​​is symmetrically arranged on one side of the shock absorber 23. The output shaft of the reducer of the winch body 2 is rotatably connected to the body of one of the brackets 32 via a bearing. An auxiliary frame 33 is rotatably connected to the opposite surfaces of the two brackets 32 via bearings. A ratchet 34 is fixedly connected to one end of the output shaft of the reducer of the winch body 2. A locking block 35 is engaged on the surface of the ratchet 34. One end of the locking block 35 is rotatably connected to the upper end of the auxiliary frame 33 via a pin. A limit post 36 is fixedly connected to one end of the locking block 35. A strong spring 37 is hung on the surface of the limit post 36. An L-shaped rod is fixedly connected to the outer side of the auxiliary frame 33. One end of the strong spring 37 is fixedly engaged with one end of the L-shaped rod. A connecting rod 38 is rotatably connected to the lower end of the auxiliary frame 33. The lower end of the connecting rod 38 is fixedly connected to one end of the piston rod of the hydraulic cylinder 31.

[0038] Specifically, when the hydraulic dam body is lifted to the designated position, the controller controls the motor 20 to stop rotating. At the same time, the controller controls the piston rod of the hydraulic cylinder 31 to extend, which pushes the auxiliary frame 33 to rotate around the hinge point between it and the support 32 through the connecting rod 38. The auxiliary frame 33 drives the locking block 35 to move towards the ratchet 34 and lock into the tooth groove of the ratchet 34, restricting the rotation of the reducer and the roller 21, so that the hydraulic dam body is stably held in the designated position. When the hydraulic dam is lowered, the controller controls the piston rod of the hydraulic cylinder 31 to retract, which drives the connecting rod 38 to pull the auxiliary frame 33 to rotate in the opposite direction. The upper end of the auxiliary frame 33 and the pull rope 310 work together to make the locking block 35 disengage from the tooth groove of the ratchet 34, restoring the free rotation state of the roller 21.

[0039] In this embodiment, the leveling mechanism 4 includes fixed blocks 40 symmetrically arranged on the upper end of the base plate 1. A reciprocating screw 41 is rotatably connected between the opposite surfaces of the two fixed blocks 40. A guide wheel 42 is slidably sleeved on the reciprocating screw 41. The surface of the guide wheel 42 is slidably connected to the surface of the wire rope 22. A fixed ring 44 is provided on the inner ring of the guide wheel 42. A bearing 45 is provided between the outer ring of the fixed ring 44 and the inner ring of the guide wheel 42. A bearing 46 is provided on the inner ring of the fixed ring 44. The inner ring of the bearing 46 is adapted to a guide block 43 with a groove on the surface of the reciprocating screw 41. The surface of the guide block 43 is slidably connected to the inner wall of the groove on the surface of the reciprocating screw 41.

[0040] Specifically, when the reciprocating screw 41 rotates, the guide block 43 slides along the spiral groove opened on the surface of the reciprocating screw 41, driving the fixed ring 44 and the guide wheel 42 to reciprocate along the axial direction of the reciprocating screw 41. The arrangement of bearing 1 45 and bearing 2 46 allows the guide wheel 42 to move axially with the fixed ring 44 and to rotate freely relative to the fixed ring 44, thereby reciprocatingly guiding the wire rope 22 during the winding and unwinding process, so that the wire rope 22 is evenly wound on the surface of the roller 21, avoiding local stacking or tangling of the wire rope 22 on the roller 21, and ensuring the flatness of the wire rope 22 during the winding and unwinding process.

[0041] In this embodiment, the body of the fixing ring 44 passes through the limiting rod 47, the surface of the limiting rod 47 is slidably connected to the body of the fixing ring 44, the two ends of the limiting rod 47 are respectively fixedly connected to the opposite surfaces of the two fixing blocks 40, and L-shaped fixing rods 49 are respectively fixedly connected to the two outer sides of the fixing ring 44. A limiting ring 48 is fixedly connected between the two L-shaped fixing rods 49, and the surface of the limiting ring 48 is slidably connected to the surface of the wire rope 22.

[0042] Specifically, the limiting rod 47 passes through the body of the fixed ring 44 and is slidably connected to the fixed ring 44, playing a guiding and limiting role for the fixed ring 44, ensuring that the fixed ring 44 and the guide wheel 42 will not deflect when they reciprocate along the axial direction of the reciprocating screw 41. The limiting ring 48 is fixedly connected to the fixed ring 44 through the L-shaped fixing rod 49 and reciprocates synchronously with the fixed ring 44. The wire rope 22 passes through the inner hole of the limiting ring 48 and then slides in contact with the surface of the guide wheel 42.

[0043] In this embodiment, a sprocket 410 is fixedly connected to one end of the reciprocating screw 41 located outside the fixed block 40 and the other end of the screw body located at the center of the roller shaft 21. A chain 411 meshes between the two sprockets 410. A support base 415 is provided on the outer side of one of the fixed blocks 40. A T-shaped frame 412 is provided on the upper end of the support base 415. An auxiliary sprocket 414 is rotatably connected to the upper end of the T-shaped frame 412. The surface of the auxiliary sprocket 414 meshes with the surface of the chain 411. Bolts 413 are provided at both ends of the T-shaped frame 412. The bolts 413 are rotatably connected to both ends of the T-shaped frame 412 through bearings. The lower end of the bolts 413 is threadedly fixed to the upper end of the support base 415.

[0044] Specifically, when the roller 21 rotates, the power of the roller 21 is transmitted to the reciprocating screw 41 through the chain drive between the sprocket 410 fixedly connected to the outer end of the rod at the center of the roller 21, the chain 411, and the sprocket 410 fixedly connected to the end of the reciprocating screw 41, so that the reciprocating screw 41 rotates synchronously with the roller 21, thereby enabling the leveling mechanism 4 to work without an additional power source; the auxiliary sprocket 414 meshes with the chain 411 on the outside of the chain 411, which plays the role of tensioning the chain 411 and ensuring the smoothness of the chain drive; the height of the T-shaped frame 412 can be adjusted by rotating the bolt 413, thereby adjusting the tension of the auxiliary sprocket 414 on the chain 411 to adapt to the transmission requirements under different working conditions.

[0045] In this embodiment, the opposite surfaces of the guide wheels 42 are all set as arc-shaped surfaces.

[0046] Specifically, the arc-shaped surface of the guide wheel 42 is adapted to the outer circular surface of the wire rope 22, which increases the contact area between the guide wheel 42 and the wire rope 22, making the force on the wire rope 22 more uniform when it slides on the guide wheel 42, reducing local wear on the surface of the wire rope 22. At the same time, the arc-shaped surface plays a good centering and guiding role for the wire rope 22, preventing the wire rope 22 from slipping off the surface of the guide wheel 42, and ensuring that the wire rope 22 maintains stable operation during the reciprocating leveling process.

[0047] In this embodiment, pressure sensors are evenly distributed along the circumference on the inner side of the limiting ring 48.

[0048] Specifically, the pressure sensor is used to detect in real time the pressure value applied by the wire rope 22 to the inner wall of the limiting ring 48 when it passes through the limiting ring 48. When the sub-wire of the wire rope 22 breaks, the upturned sub-wire squeezes the inner wall of the limiting ring 48, or the sensor receives abnormal pressure and exceeds the threshold, the pressure sensor can collect the pressure change signal in time and transmit the signal to the external controller for processing. The controller judges that the wire rope 22 has abnormal force and issues a corresponding warning command, thereby realizing the safety monitoring and abnormal early warning of the wire rope 22 throughout the process.

[0049] In this embodiment, a motor fixing sleeve 39 is fixedly sleeved on the outer surface of the motor 20. A collar is fixedly connected to the upper end of the motor fixing sleeve 39. A pull rope 310 is fixedly connected to one end of the collar. One end of the pull rope 310 is fixedly connected to the surface of the locking block 35.

[0050] Specifically, when the hydraulic dam is lowered, the upper end of the auxiliary frame 33 works together with the loosened pull rope 310 to allow the locking block 35 to smoothly disengage from the tooth groove of the ratchet 34, ensuring a smooth and reliable unlocking action.

[0051] In this embodiment, a return spring is sleeved on the surface of the pull rope 310, and the two ends of the return spring are fixedly connected to the surfaces of the collar and the locking block 35, respectively.

[0052] Specifically, the return spring is sleeved on the outer surface of the pull rope 310, and its two ends are fixedly connected to the surfaces of the collar and the locking block 35, respectively. During normal operation, the return spring is in a natural state or a slightly stretched state, maintaining the tension of the pull rope 310. When the hydraulic dam is lowered and the piston rod of the hydraulic cylinder 31 controlled by the controller retracts to disengage the locking block 35 from the ratchet 34, the return spring further ensures that the locking block 35 is fully reset to the initial position, realizing the reliable reset of the fall protection mechanism 3.

[0053] In this embodiment, the limiting ring 48 is a split structure, including a first half ring and a second half ring arranged opposite to each other. One end of the first half ring and the second half ring are hinged to each other, and the other end is detached and connected by an elastic buckle.

[0054] Specifically, the first and second half-rings are connected by a hinged end, and the elastic locking end locks the first and second half-rings together to form a complete annular limiting structure during normal operation. When the wire rope 22 needs to be replaced or maintained, the first and second half-rings can be rotated open around the hinged end simply by opening the elastic locking end, making it easy to remove the wire rope 22 from the limiting ring 48 without disassembling other parts, making maintenance convenient and efficient. At the same time, when the wire rope 22 experiences an abnormal situation that causes the limiting ring 48 to be subjected to an impact force exceeding the design range, the elastic locking end can actively disengage to open the limiting ring 48, releasing the radial constraint on the wire rope 22 and preventing the wire rope 22 from breaking due to being jammed by the limiting ring 48.

[0055] In this embodiment, a control system is also provided on the upper end of the base plate 1. The control system consists of a signal acquisition module, a pressure data processing module, a damage judgment module, a fall prevention execution control module, a drive regulation module, and an audible and visual alarm module. The signal acquisition module is electrically connected to the pressure sensor inside the limit ring 48 and is used to collect the pressure signal at each point inside the limit ring 48 in real time, convert it into digital pressure value and transmit it to the pressure data processing module. The pressure data processing module has built-in calculation logic for mean, range and fluctuation amplitude. It calculates the pressure data collected by all sensors at the same time and outputs three sets of core parameters: real-time uniform pressure of the wire rope 22, maximum pressure at a single point and pressure fluctuation difference. The damage judgment module has built-in safety threshold database and damage judgment calculation formula for the wire rope 22. It receives the output parameters of the pressure data processing module and compares them with the preset safety threshold to automatically determine whether the wire rope 22 has broken wire, warped wire, or extrusion overload faults.

[0056] The anti-fall execution control module is electrically connected to the hydraulic cylinder 31, the motor 20, and the pull rope 310 respectively. It receives the fault signal and the gate position signal output by the damage judgment module, and automatically outputs the locking / unlocking control command to drive the anti-fall mechanism 3 to act.

[0057] The drive control module is connected to the drive unit of motor 20 and adaptively adjusts the lifting speed of motor 20 according to the pressure fluctuation data of wire rope 22 to reduce the wear of wire rope 22.

[0058] The audible and visual alarm module receives the over-limit signal from the damage assessment module and simultaneously triggers a high-decibel buzzer and a red warning light.

[0059] In this embodiment, the pressure data processing module uses the following formula to perform data calculations: Where n is the total number of pressure sensors within the limiting ring 48, For the i-th sensor, the pressure (MPa) is collected in real time. The formula for calculating the overall average contact pressure of wire rope 22; the formula for calculating the pressure difference at a single point: , These represent the maximum and minimum pressure values ​​of the sensor within the same data acquisition period, respectively. The formula for calculating the amplitude of single-cycle pressure fluctuation is as follows: (This refers to the difference in stress unevenness of wire rope 22). ,in These represent the pressure fluctuation of the wire rope during continuous winding and unwinding, the average pressure of the current acquisition cycle, and the average pressure of the previous acquisition cycle, respectively. The pressure data processing module drives the control module to complete one round of all sensor data acquisition and the above formula calculation every 100ms.

[0060] In this embodiment, the wire rope 22 damage determination module incorporates a three-level determination logic and a safety threshold determination formula. The specific control determination method is as follows:

[0061] Normal operating conditions: ,in This refers to the upper limit threshold of single-point pressure for normal operation of wire rope 22. This is the allowable difference due to normal uneven stress distribution. To ensure normal wire rope operation, the control system determines that the wire rope 22 is normal when all conditions are met, and drives the control module to maintain the set rated speed.

[0062] Warning conditions: , The upper limit threshold for early warning pressure, To warn of uneven force difference threshold, when the condition is met, the control system triggers the audible and visual alarm module to trigger a low-frequency intermittent alarm, and the drive control module automatically reduces the motor lifting speed by 20 to 60% of the rated speed, allowing the current gate lifting cycle to be completed.

[0063] Hazardous operating conditions: If any of the above conditions are met, the control system will immediately control the drive control module to cut off the output of motor 20, and the roller will stop rotating.

[0064] The anti-fall execution control module outputs a locking command, which controls the piston rod of the hydraulic cylinder 31 to extend rapidly, push the locking block 35 to lock the ratchet 34, and forcibly lock the roller shaft 21 to prevent the gate from falling.

[0065] Reference Figures 1-6 The specific safety protection steps for a wire rope-operated winch-type gate hoist with full-process safety protection are as follows:

[0066] Step 1: Normal winding and unwinding operation and leveling guidance: Motor 20 drives roller 21 to rotate, and the wire rope 22 on roller 21 is wound and unwound, causing the hydraulic dam body to rise or fall; at the same time, roller 21 drives reciprocating screw 41 to rotate synchronously through sprocket 410 and chain 411, and guide block 43 slides along the spiral groove of reciprocating screw 41, causing fixed ring 44 and guide wheel 42 to move back and forth along the axial direction of reciprocating screw 41. The arc surface of guide wheel 42 provides leveling guidance for wire rope 22, so that wire rope 22 is evenly wound on the surface of roller 21; limit ring 48 moves synchronously with fixed ring 44 to constrain and limit the direction of wire rope 22, ensuring that wire rope 22 is always in contact with the arc surface of guide wheel 42; pressure sensor inside limit ring 48 monitors the pressure value of wire rope 22 on limit ring 48 in real time and transmits the monitoring signal to controller;

[0067] Step 2: When the wire rope 22 continues to contract until the hydraulic dam body is lifted to the designated position, the controller controls the motor 20 to stop rotating. At the same time, the controller controls the piston rod of the hydraulic cylinder 31 to extend, which pushes the auxiliary frame 33 to rotate through the connecting rod 38. The auxiliary frame 33 drives the locking block 35 to engage in the tooth groove of the ratchet 34, restricting the rotation of the reducer and roller 21, so that the hydraulic dam body is stably held in the designated position, preventing the dam body from falling unexpectedly due to hydraulic system leakage or elastic elongation of the wire rope 22.

[0068] Step 3: When lowering the hydraulic dam, the controller controls the piston rod of the hydraulic cylinder 31 to retract, which drives the connecting rod 38 to pull the auxiliary frame 33 to rotate in the opposite direction. The upper end of the auxiliary frame 33 and the loosened pull rope 310 work together to disengage the locking block 35 from the tooth groove of the ratchet 34, restoring the roller 21 to its free rotation state.

[0069] Step 4: During the wire rope 22 winding and unwinding operation, when the pressure sensor inside the limit ring 48 detects that the pressure value of the wire rope 22 exceeds the preset threshold, the controller determines that the wire rope 22 is experiencing abnormal stress.

[0070] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A wire rope full-process safety protection type winch gate hoist, comprising a base plate (1), a winch body (2) is provided at the upper end of the base plate (1), the winch body (2) includes a motor (20), a roller (21) is provided on one side of the motor (20), a wire rope (22) is wound on the surface of the roller (21), and a shock-absorbing block (23) is provided at the lower end of the motor (20), characterized in that: A fall prevention mechanism (3) is provided between the motor (20) and the roller (21), and a leveling mechanism (4) is provided on one side of the roller (21).

2. The wire rope full-process safety protection type winch gate hoist according to claim 1, characterized in that: The fall arrestor (3) includes a hydraulic cylinder (31) embedded inside the shock absorber (23). A bracket (32) is symmetrically arranged on one side of the shock absorber (23). The output shaft of the winch body (2) reducer is rotatably connected to the body of one of the brackets (32) via a bearing. An auxiliary frame (33) is rotatably connected to the opposite surfaces of the two brackets (32) via bearings. A ratchet (34) is fixedly connected to one end of the output shaft of the winch body (2). A locking block (35) is engaged on the surface of the ratchet (34). One end of the locking block (35) is rotatably connected to the upper end of the auxiliary frame (33) via a pin. One end of the locking block (35) is fixedly connected to a limiting post (36). A strong spring (37) is attached to the surface of the limiting post (36). An L-shaped rod is fixedly connected to the outer side of the auxiliary frame (33). One end of the strong spring (37) is fixedly attached to one end of the L-shaped rod. A connecting rod (38) is rotatably connected to the lower end of the auxiliary frame (33). The lower end of the connecting rod (38) is fixedly connected to one end of the piston rod of the hydraulic cylinder (31).

3. The wire rope full-process safety protection type winch gate opener according to claim 2, characterized in that: The leveling mechanism (4) includes fixed blocks (40) symmetrically arranged on the upper end of the base plate (1). A reciprocating screw (41) is rotatably connected between the opposite surfaces of the two fixed blocks (40). A guide wheel (42) is slidably sleeved on the reciprocating screw (41). The surface of the guide wheel (42) is slidably connected to the surface of the wire rope (22). A fixed ring (44) is provided on the inner ring of the guide wheel (42). A bearing (45) is provided between the outer ring of the fixed ring (44) and the inner ring of the guide wheel (42). A bearing (46) is provided on the inner ring of the fixed ring (44). A guide block (43) is adapted to the groove on the surface of the reciprocating screw (41) on the inner ring of the bearing (46). The surface of the guide block (43) is slidably connected to the inner wall of the groove on the surface of the reciprocating screw (41).

4. The wire rope full-process safety protection type winch gate opener according to claim 3, characterized in that: The main body of the fixing ring (44) passes through the limiting rod (47). The surface of the limiting rod (47) is slidably connected to the main body of the fixing ring (44). The two ends of the limiting rod (47) are respectively fixedly connected to the opposite surfaces of the two fixing blocks (40). The two outer sides of the fixing ring (44) are respectively fixedly connected to L-shaped fixing rods (49). A limiting ring (48) is fixedly connected between the two L-shaped fixing rods (49). The surface of the limiting ring (48) is slidably connected to the surface of the wire rope (22). The limiting ring (48) is a split structure, including a first half ring and a second half ring arranged opposite to each other. One end of the first half ring and the second half ring are hinged to each other, and the other end is detached and connected by an elastic buckle.

5. A wire rope full-process safety protection type winch gate opener according to claim 4, characterized in that: The reciprocating screw (41) is fixedly connected to a sprocket (410) at one end outside the fixed block (40) and at the outer end of the rod body at the center of the roller (21). A chain (411) meshes between the two sprockets (410). A support base (415) is provided on the outer side of one of the fixed blocks (40). A T-shaped frame (412) is provided on the upper end of the support base (415). An auxiliary sprocket (414) is rotatably connected to the upper end of the T-shaped frame (412). The surface of the auxiliary sprocket (414) meshes with the surface of the chain (411). Bolts (413) are provided at both ends of the T-shaped frame (412). The bolts (413) are rotatably connected to both ends of the T-shaped frame (412) through bearings. The lower end of the bolts (413) is threadedly fixed to the upper end of the support base (415).

6. A wire rope full-process safety protection type winch gate hoist according to claim 5, characterized in that: The opposing surfaces of the guide wheels (42) are all set as arc surfaces, and pressure sensors are evenly distributed along the circumference on the inner side of the limiting ring (48).

7. A wire rope full-process safety protection type winch gate hoist according to claim 6, characterized in that: A motor fixing sleeve (39) is fixedly sleeved on the outer surface of the motor (20). A collar is fixedly connected to the upper end of the motor fixing sleeve (39). A pull rope (310) is fixedly connected to one end of the collar. One end of the pull rope (310) is fixedly connected to the surface of the locking block (35). A return spring is sleeved on the surface of the pull rope (310). The two ends of the return spring are fixedly connected to the surfaces of the collar and the locking block (35) respectively.

8. A wire rope full-process safety protection type winch gate hoist according to claim 7, characterized in that: The upper end of the base plate (1) is also equipped with a control system, which consists of a signal acquisition module, a pressure data processing module, a damage judgment module, a fall protection execution control module, a drive control module, and an audible and visual alarm module. The signal acquisition module is electrically connected to the pressure sensor inside the limit ring (48) and is used to collect the pressure signals at each point inside the limit ring (48) in real time and convert them into digital pressure values ​​synchronously. The data is then transmitted to the pressure data processing module, which has built-in logic for calculating the mean, range, and fluctuation amplitude. This module calculates the pressure data collected by all sensors at the same time and outputs the real-time uniform pressure of the wire rope (22). Maximum pressure at a single point Pressure fluctuation difference Three sets of core parameters, the damage judgment module has built-in the steel wire rope (22) safety threshold database and damage judgment calculation formula, receives the output parameters of the pressure data processing module, and automatically judges whether the steel wire rope (22) has broken wire, warped wire, or extrusion overload faults by comparing with the preset safety threshold; The anti-fall execution control module is electrically connected to the hydraulic cylinder (31), the motor (20), and the pull rope (310) respectively. It receives the fault signal and the gate position signal output by the damage judgment module and automatically outputs the locking / unlocking control command to drive the anti-fall mechanism 3 to act. The drive control module is connected to the motor (20) drive unit and adaptively adjusts the lifting speed of the motor (20) according to the pressure fluctuation data of the wire rope (22) to reduce the wear of the wire rope (22); The audible and visual alarm module receives the over-limit signal from the damage determination module and simultaneously triggers a high-decibel buzzer and a red warning light.

9. A wire rope full-process safety protection type winch gate opener according to claim 8, characterized in that: The pressure data processing module uses the following formula to perform data calculations: Where n is the total number of pressure sensors inside the limiting ring (48), For the i-th sensor, the pressure (MPa) is collected in real time. The formula for calculating the overall average contact pressure of the wire rope (22); the formula for calculating the pressure difference at a single point: , These represent the maximum and minimum pressure values ​​of the sensor within the same data acquisition period, respectively. The formula for calculating the uneven stress distribution of the wire rope (22) and the single-cycle pressure fluctuation amplitude is as follows: ,in The pressure fluctuation of the wire rope (22) during the continuous winding and unwinding process is respectively the average pressure of the current acquisition cycle and the average pressure of the previous acquisition cycle. The pressure data processing module drives the control module to complete one round of all sensor data acquisition and the above formula calculation every 100ms.

10. A wire rope full-process safety protection type winch gate opener according to claim 9, characterized in that: The steel wire rope (22) damage judgment module has a built-in three-level judgment logic and a safety threshold judgment formula. The specific control judgment method is as follows: Normal operating conditions: ,in The upper limit threshold of the single-point pressure for normal operation of the wire rope (22) is the threshold value. This is the allowable difference due to normal uneven stress distribution. To ensure normal release and retraction, the allowable pressure fluctuation threshold is met. When all conditions are met, the control system determines that the wire rope (22) is normal and drives the control module to maintain the set rated speed. Warning conditions: , The upper limit threshold for early warning pressure, To warn of the threshold of uneven force difference, when the conditions are met, the control system triggers the low-frequency intermittent alarm of the sound and light alarm module, and the drive control module automatically reduces the lifting speed of the motor (20) to 60% of the rated speed of the drive control module, allowing the current gate lifting cycle to be completed; Hazardous operating conditions: If any of the above conditions are met, the control system will immediately control the drive control module to cut off the output of the motor (20), and the roller will stop rotating; The anti-fall execution control module outputs a locking command, controls the piston rod of the hydraulic cylinder (31) to extend quickly, pushes the locking block (35) to lock the ratchet (34), and forcibly locks the roller (21) to prevent the gate from falling.

Images