A roller control system and a control method thereof

Abstract

The application discloses a kind of roller control system and control method thereof, the roller control system includes control module and multiple roller modules;Each roller module includes roller body, rotational speed acquisition module unit, tension acquisition unit, two-dimensional laser profile sensing unit, support unit and self-driving unit;Rotational speed acquisition module unit acquires the current rotational speed of roller body;Tension acquisition unit acquires the current support force of support unit to roller body;Two-dimensional laser profile sensing unit acquires current strand speed and current posture;Control module is electrically connected with tension acquisition unit block, two-dimensional laser profile sensing unit and support unit, for according to current support force, current strand posture and preset tension control support unit adjusts the support force of roller body;Control module is also electrically connected with rotational speed acquisition module unit and self-driving unit, and also for according to current rotational speed and current strand speed control self-driving unit the driving speed of roller body, to realize the adaptive adjustment of roller.

Description

Technical Field

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

[0002] Cable strand erection roller system is a key piece of equipment in the construction of long-span bridges such as suspension bridges and cable-stayed bridges. It is used to support and guide the cable strands to ensure the smooth progress of construction.

[0003] Figure 1 This is a schematic diagram of the structure of a single idler module in the prior art, such as... Figure 1 As shown, the traditional idler roller system has a relatively fixed structure, mainly consisting of the idler roller body 201', support unit 205', and a simple guiding device. The idler roller body 201' is usually made of ordinary steel or composite materials, with low surface hardness, easy wear, and short service life. The support unit 205' is mostly a rigid frame, lacking flexibility and difficult to adapt to complex terrain and construction conditions. It relies heavily on manual or simple mechanical drives, with a low degree of automation. Manual drives are labor-intensive, inefficient, and difficult to ensure uniform tension of the cable strands 100'; while mechanical drives can provide some power, their control precision is poor and they cannot adjust in real time according to the cable strand status. Summary of the Invention

[0004] This invention provides a roller control system and its control method to achieve adaptive adjustment of the roller module and improve the service life of the roller module.

[0005] In a first aspect, embodiments of the present invention provide a roller control system, which includes: a control module and multiple roller modules; each roller module includes a roller body, a speed acquisition module unit, a tension acquisition unit, a two-dimensional laser contour sensing unit, a support unit, and a self-driving unit. The rotation speed acquisition unit is used to acquire the current rotation speed of the idler roller body; The tension acquisition unit is used to acquire the current support force of the support unit on the roller body; The two-dimensional laser contour sensing unit is used to acquire the current strand speed and current strand posture; wherein the strand is located on one side of the idler body and is in contact with the idler body; The control module is electrically connected to the tension acquisition unit block, the two-dimensional laser contour sensing unit, and the support unit, and is used to control the support unit to adjust the support force on the idler body according to the current support force, the current strand posture, and the preset tension; the control module is also electrically connected to the speed acquisition unit and the self-driving unit, and is also used to control the driving speed of the self-driving unit on the idler body according to the current speed and the current strand speed.

[0006] Optionally, the self-driving unit includes a self-aligning bearing housing, a drive motor, a bevel gear at the roller shaft end, an auxiliary gear, a reducer, a spline sleeve, a spline shaft, and a bevel gear; the support unit includes a first hydraulic cylinder, a second hydraulic cylinder, a hydraulic pump station, a first piston rod, a first ball joint bracket, a second piston rod, a second ball joint bracket, and an integrated valve. The self-aligning bearing housing includes a first bearing portion and a second bearing portion disposed along a first direction; Along the first direction, the first hydraulic cylinder is located on one side of the second hydraulic cylinder, and the first hydraulic cylinder and the second hydraulic cylinder are connected by an oil pipe; one end of the first hydraulic cylinder is fixed to one end of the first piston rod, and the other end of the first piston rod is connected to the first bearing section through a first ball joint bracket; one end of the second hydraulic cylinder is fixed to one end of the second piston rod, and the other end of the second piston rod is connected to the second bearing section through a second ball joint bracket; Along the second direction, the drive motor and the hydraulic pump station are both located on one side of the first hydraulic cylinder and the second hydraulic cylinder; the second direction intersects the first direction; along the first direction, the idler roller body is located between the first bearing section and the second bearing section, and one end of the idler roller body is rotatably connected to the first bearing section, and the other end of the idler roller body is rotatably connected to the second bearing section; along the first direction, a roller shaft end bevel gear and an auxiliary gear are provided on the side of the second bearing section away from the first bearing section; the roller shaft of the idler roller body is connected to the roller shaft end bevel gear; the output shaft of the drive motor is connected to the input shaft of the reducer, and the output shaft of the reducer is connected to the spline sleeve; one end of the spline shaft is slidably connected to the spline sleeve; a bevel gear is provided on the other end of the spline shaft; along the second direction, the bevel gear is located between the roller shaft end bevel gear and the auxiliary gear, the end of the bevel gear away from the spline sleeve meshes with the roller shaft end bevel gear, and the end of the bevel gear near the spline sleeve meshes with the auxiliary gear; The hydraulic pump station is connected to the oil pipe via an oil passage and the integrated valve.

[0007] Optionally, the rotational speed acquisition unit is mounted on the auxiliary gear; The tension acquisition unit includes a first tension acquisition unit and a second tension acquisition unit; Along the second direction, the first tension acquisition unit is disposed on the side of the first bearing section near the first hydraulic cylinder, for acquiring the first current support force of the first bearing section on the idler roller body; Along the second direction, the second tension acquisition unit is disposed on the side of the second bearing section near the second hydraulic cylinder, for acquiring the second current support force of the second bearing section on the idler roller body; The control module is further configured to adjust the support force of the first bearing section on the idler body according to the first current support force, the second current support force and the current cable posture, and / or adjust the support force of the second bearing section on the idler body according to the first current support force, the second current support force and the current cable posture.

[0008] Optionally, the idler module also includes a power supply unit and an energy recovery unit; The power supply unit is electrically connected to the support unit and the self-driving unit, respectively. The energy recovery unit is connected to both the self-driving unit and the power supply unit. The control module is also electrically connected to the energy recovery unit, and is used to control the energy recovery unit to convert the mechanical energy output by the self-driving unit into electrical energy when the current rotation speed is greater than the current strand speed, and to store the converted electrical energy in the power supply unit.

[0009] In a second aspect, embodiments of the present invention also provide a roller control method, applied to the roller control method described in any one of the first aspects, the roller control method comprising: The current rotational speed of the idler body is acquired by the rotational speed acquisition unit, the current supporting force of the support unit on the idler body is acquired by the tension acquisition unit, and the current strand speed and current strand posture are acquired by the two-dimensional laser contour sensing unit. The support unit adjusts its support force on the idler roller body based on the current support force, the current strand posture, and the preset tension. The self-driving unit controls the driving speed of the idler roller body based on the current rotational speed and the current strand speed.

[0010] Optionally, the current support force of the support unit on the roller body, acquired by the tension acquisition unit, includes: The first current support force of the first bearing portion on the idler body, collected by the first tension acquisition unit, and the second current support force of the second bearing portion on the idler body, collected by the second tension acquisition unit, are obtained. Based on the current support force, the current strand posture, and the preset tension, the support unit adjusts its support force on the idler roller body, including: The current cable tension is determined based on the first current support force and the second current support force; When the difference between the current cable tension and the preset tension is less than or equal to the preset difference range, the support unit is controlled to adjust the support force on the idler body according to the current support force and the current cable tension. When the difference between the current cable tension and the preset tension is less than or equal to the preset difference range, the support force of the first bearing section on the idler body is adjusted according to the first current support force, the second current support force and the current cable posture, and / or the support force of the second bearing section on the idler body is adjusted according to the first current support force, the second current support force and the current cable posture.

[0011] Optionally, controlling the support unit to adjust the support force on the idler roller based on the current support force and the current strand tension includes: When the current support force is equal to the current strand tension, the support unit is controlled to maintain the current support force on the idler body; When the current support force is greater than the current strand tension, the support unit is controlled to reduce the support force on the idler body; When the current support force is less than the current strand tension, the support unit is controlled to increase the support force on the idler roller body.

[0012] Optionally, adjusting the support force of the first bearing portion on the idler body based on the first current support force, the second current support force, and the current cable strand posture, and / or adjusting the support force of the second bearing portion on the idler body based on the first current support force, the second current support force, and the current cable strand posture, includes: When the first current support force is equal to the second current support force, the first bearing section and the second bearing section are controlled to maintain the support force on the roller body according to the current cable posture. When the first current support force is greater than the second current support force, the first bearing section is controlled to reduce the support force on the roller body according to the current cable posture; When the first current support force is less than the second current support force, the second bearing section is controlled to reduce the support force on the idler body according to the current cable posture.

[0013] Optionally, controlling the driving speed of the self-driving unit on the idler body based on the current rotational speed and the current strand speed includes: When the current strand speed is equal to the current rotational speed, the self-driving unit is controlled to maintain the current driving speed of the idler body; When the current strand speed is greater than the current rotational speed, the self-driving unit is controlled to increase the driving speed of the idler roller body; When the current strand speed is less than the current rotation speed, the energy recovery unit is controlled to convert the mechanical energy output by the self-driving unit into electrical energy, and the converted electrical energy is stored in the power supply unit.

[0014] Optionally, before acquiring the current rotational speed of the idler body acquired by the rotational speed acquisition unit, the current supporting force of the support unit on the idler body acquired by the tension acquisition unit, and the current strand speed and current strand posture acquired by the two-dimensional laser contour sensing unit, the method further includes: Obtain the preset identifier for each of the idler roller modules; Based on the preset identifier, determine whether each component unit in each idler roller module has malfunctioned; Determine the preset identifier, fault unit, and fault type of the faulty idler module corresponding to the faulty module; A maintenance prompt signal is output based on the preset identifier corresponding to the faulty idler module, the faulty unit, and the fault type.

[0015] The technical solution provided in this invention allows the control module to adjust the support force on the idler body based on the current support force, the current strand posture, and the preset tension control support unit. Specifically, by dynamically adjusting the support force on the idler body 201 through the control support unit 205, stepless adjustment of the support force and strand posture of the idler body 201 can be achieved. The support force fluctuation is reduced from ±1kN to ±0.3kN, and it dynamically adapts to strand tension fluctuation scenarios, reducing strand position deviation. This ensures the support effect of the support unit adjusting the support on the idler body, achieving the desired support effect of the idler body on the strand. The control module can control the driving speed of the self-driving unit on the idler body based on the current rotational speed and the current strand speed, thus allowing for control of the self-driving unit's driving speed on the idler body according to actual needs. For example, when it is necessary to increase the driving speed of the self-driving unit on the idler body, the self-driving unit is controlled to increase the driving speed of the idler body; when acceleration is not required, the self-driving unit is controlled to maintain the driving speed of the idler body; when deceleration is required, the self-driving unit is controlled to reduce the driving speed of the idler body or stop the machine, thereby achieving adaptive adjustment of the idler. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the content of the embodiments of the present invention and these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the structure of a single idler module in the prior art; Figure 2 This is a schematic diagram of the electrical connection of the control module in the idler roller control system provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of a roller module provided in an embodiment of the present invention; Figure 4 A partial front view schematic diagram of a roller module provided in an embodiment of the present invention; Figure 5 This is a partial side view of a roller module provided in an embodiment of the present invention; Figure 6 This is a schematic diagram of another idler roller module provided in an embodiment of the present invention; Figure 7 A flowchart illustrating the first idler roller control method provided in an embodiment of the present invention; Figure 8 A schematic flowchart of the second idler roller control method provided in an embodiment of the present invention; Figure 9 A flowchart illustrating the third idler roller control method provided in this embodiment of the invention; Figure 10 This is a flowchart illustrating the fourth idler roller control method provided in an embodiment of the present invention. Detailed Implementation

[0018] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0019] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connection" and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0020] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above" the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0021] In the description of this embodiment, the terms "upper" and "lower," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. In addition, the terms "first" and "second" are used only for distinction in description and have no special meaning.

[0022] Figure 2 This is a schematic diagram of the electrical connections of the control module in the idler roller control system provided in an embodiment of the present invention. Figure 3 This is a schematic diagram of the structure of a roller module provided in an embodiment of the present invention. Figure 4 This is a partial front view schematic diagram of a roller module provided in an embodiment of the present invention. Figure 5 This is a partial side view schematic diagram of a roller module provided in an embodiment of the present invention, as shown below. Figures 2-5 As shown, the idler control system includes a control module 10 and multiple idler modules 20; each idler module 20 includes an idler body 201, a speed acquisition unit 202, a tension acquisition unit 203, a two-dimensional laser contour sensing unit 204, a support unit 205, and a self-driving unit 206; the speed acquisition unit 202 is used to acquire the current speed of the idler body 201; the tension acquisition unit 203 is used to acquire the current support force of the support unit 205 on the idler body 201; the two-dimensional laser contour sensing unit 204 is used to acquire the current strand speed and the current strand posture. The cable strand is located on one side of the idler body 201 and is in contact with the idler body 201. The control module 10 is electrically connected to the tension acquisition unit block 202, the two-dimensional laser contour sensing unit 204 and the support unit 205, and is used to adjust the support force on the idler body 201 according to the current support force, the current cable strand posture and the preset tension control support unit 205. The control module 10 is also electrically connected to the speed acquisition unit 202 and the self-drive unit 206, and is also used to control the driving speed of the self-drive unit 206 on the idler body 201 according to the current speed and the current cable strand speed.

[0023] The idler roller control system is applicable to scenarios such as the erection of cable strands (steel wire ropes, steel strands, etc.) in projects such as long-span bridges, power transmission tower cables, and cableways. Multiple idler roller modules 20 arranged at intervals of 3m-5m along the catwalk can meet the requirements.

[0024] Specifically, the cable strand is located above and in contact with the idler roller body 201, so that the idler roller body 201 can support the cable strand upwards. The direction of extension of the axis of the idler roller body 201 is perpendicular to the direction of extension of the cable strand. The idler roller body 201 and the cable strand are engaged in rolling friction transmission.

[0025] Specifically, the self-driving unit 206 is connected to the idler body 201. The control module 10 can output control signals to the self-driving unit 206, which can then output drive signals to rotate the idler body 201. The support unit 205 is connected to the idler body 201 and provides support force to it. The control module 10 can output control signals to the support unit 205, which can then adjust hydraulic power to adjust the posture of the idler body 201 according to the control signals.

[0026] The rotational speed acquisition unit 202 acquires the current rotational speed of the idler roller body 201 and transmits it to the control module 10. The two-dimensional laser profile sensing unit 204 is generally fixedly mounted on the top of the self-aligning bearing seat 2061, with the laser head angled downwards towards the contact area between the strand and the idler roller body 201, to acquire the current strand speed and current strand posture. The principle of the two-dimensional laser profile sensing unit 204 in detecting the current strand posture is that, since the two-dimensional laser profile sensing unit 204 continuously emits two-dimensional lasers towards the contact area between the strand and the idler roller body 201, the strand will cut off the cross-section of these laser rays when passing through them. This can reflect the degree of deformation of the strand pressing against the idler roller body 201 (e.g., if the support force of the idler roller body 201 on the strand is too high, the strand is severely compressed; if the support force of the idler roller body 201 on the strand is too low, the strand has just touched the idler roller or is even suspended). It can also detect whether the strand axis is centered on the idler roller body 201. The two-dimensional laser contour sensing unit 204 can transmit the current rotation speed and the current cable speed to the control module 10. In this way, the control module 10 can control the driving speed of the self-driving unit 206 on the idler body 201 according to the current rotation speed and the current cable speed, and thus control the driving speed of the self-driving unit 206 on the idler body 201 according to actual needs. For example, when it is necessary to increase the driving speed of the self-driving unit 206 on the idler body 201, the self-driving unit 206 is controlled to increase the driving speed of the idler body 201 to increase the rotational speed of the idler body 201; when acceleration is not required, the self-driving unit 206 is controlled to maintain the driving speed of the idler body 201 to maintain the rotational speed of the idler body 201; when deceleration is required, the self-driving unit 206 is controlled to decrease the driving speed of the idler body 201 or stop the machine to reduce the rotational speed of the idler body 201 or stop the rotation of the idler body 201. In this way, the idler control system can achieve synchronization between the idler and the cable strand, and the traction energy consumption is reduced by 30% compared with the traditional idler system.

[0027] Specifically, the tension acquisition unit 203 can be located below the self-aligning bearing seat 2061 to acquire the current support force of the support unit 205 on the idler body 201 and transmit the current support force to the control module 10. The control module 10 adjusts the support force of the support unit 205 on the idler body 201 according to the current support force, the current strand posture, and the preset tension control. In this way, by controlling the support unit 205 to dynamically adjust the support force on the idler body 201, stepless adjustment of the support force and strand posture of the idler body 201 can be achieved. The support force fluctuation is reduced from ±1kN to ±0.3kN, and it dynamically adapts to the strand tension fluctuation scenario, reduces the strand position deviation, and ensures that the strand line shape accuracy error is ≤L / 10000 (L is the span of the installation). In addition, it helps to ensure the support effect of the support unit 205 on the idler body 201, so as to achieve the support effect of the idler body 201 on the strand.

[0028] It should be noted that the preset tension can be understood as the support force of the support unit 205 on the idler body 201 that is preset in the control module 10 at the initial moment, that is, before the cable strand contacts the idler body 201.

[0029] As a comparative example, compared with traditional idler modules in the prior art, the idler module provided in this embodiment of the invention does not require manual adjustment of the idler body position or assistance from an external power device for traction, thereby improving the control efficiency of the idler system and saving labor costs. At the same time, the strand wear rate is reduced to below 0.5%.

[0030] The idler roller control system provided in this embodiment of the invention allows the control module to adjust the support force on the idler roller body based on the current support force, the current strand posture, and the preset tension control support unit. Specifically, by dynamically adjusting the support force on the idler roller body 201 through the control support unit 205, stepless adjustment of the support force and strand posture of the idler roller body 201 can be achieved. The support force fluctuation is reduced from ±1kN to ±0.3kN, and it dynamically adapts to strand tension fluctuation scenarios, reducing strand position deviation. This ensures the support effect of the support unit adjusting the support on the idler roller body, achieving the desired support effect of the idler roller body for the strand. The control module can control the driving speed of the self-driving unit on the idler roller body based on the current rotational speed and the current strand speed, thus allowing for control of the self-driving unit's driving speed on the idler roller body according to actual needs. For example, when it is necessary to increase the driving speed of the self-driving unit on the idler body, the self-driving unit is controlled to increase the driving speed of the idler body; when acceleration is not required, the self-driving unit is controlled to maintain the driving speed of the idler body; when deceleration is required, the self-driving unit is controlled to reduce the driving speed of the idler body or stop the machine, thereby achieving adaptive adjustment of the idler.

[0031] Optional, continue to refer to Figure 3 and Figure 4 The self-driving unit 206 includes a self-aligning bearing housing 2061, a drive motor 2062, a roller shaft end bevel gear 2063, an auxiliary gear 2064, a reducer 2065, a spline sleeve 2066, a spline shaft 2067, and a bevel gear 2068; the support unit 205 includes a first hydraulic cylinder 2051, a second hydraulic cylinder 2052, a hydraulic pump station 2053, a first piston rod 2054, a first ball joint bracket 2055, a second piston rod 2056, a second ball joint bracket 2057, and an integrated valve 2058; the self-aligning bearing housing 2061 includes components along a first direction (e.g., ... Figure 2A first bearing section 20611 and a second bearing section 20612 are arranged in the first direction X (as shown in the X direction); along the first direction X, a first hydraulic cylinder 2051 is located on one side of the second hydraulic cylinder 2052, and the first hydraulic cylinder 2051 and the second hydraulic cylinder 2052 are connected by an oil pipe 30; one end of the first hydraulic cylinder 2051 is fixed to one end of the first piston rod 2054, and the other end of the first piston rod 2054 is connected to the first bearing section 20611 through a first ball joint bracket 2055; one end of the second hydraulic cylinder 2052 is fixed to one end of the second piston rod 2056, and the other end of the second piston rod 2056 is connected to the second bearing section 20612 through a second ball joint bracket 2057; along the second direction (as shown in the X direction)... Figure 2 In the Y direction shown, the drive motor 2062 and the hydraulic pump station 2053 are both located on one side of the first hydraulic cylinder 2051 and the second hydraulic cylinder 2052; the second direction Y intersects the first direction X; along the first direction X, the roller body 201 is located between the first bearing section 20611 and the second bearing section 20612, and one end of the roller body 201 is rotatably connected to the first bearing section 20611, and the other end of the roller body 201 is rotatably connected to the second bearing section 20612; along the first direction X, the side of the second bearing section 20612 away from the first bearing section 20611 is provided with a roller shaft end bevel gear 2063 and an auxiliary gear 2064; the roller shaft of the roller body 201 and the roller shaft end bevel gear 2063 are connected to the roller shaft end bevel gear 2064. Gear 2063 is connected; the output shaft of drive motor 2062 is connected to the input shaft of reducer 2065, and the output shaft of reducer 2065 is connected to spline sleeve 2066; one end of spline shaft 2067 is slidably connected to spline sleeve 2066; the other end of spline shaft 2067 is provided with bevel gear 2068; along the second direction Y, bevel gear 2068 is located between roller shaft end bevel gear 2063 and auxiliary gear 2064, the end of bevel gear 2068 away from spline sleeve 2066 meshes with roller shaft end bevel gear 2063, and the end of bevel gear 2068 close to spline sleeve 2066 meshes with auxiliary gear 2064; hydraulic pump station 2053 is connected to oil pipe 30 through oil passage 40 and integrated valve 2058.

[0032] Specifically, the output shaft of the drive motor 2062 is rigidly connected to the input shaft of the reducer 2065 via a flange. This reduces the speed of the drive motor 2062 and increases its output torque through the reducer 2065, thus driving the idler roller body 201 to rotate stably. The control signal output by the control module 10 can be transmitted to the drive motor 2062, allowing the drive motor 2062 to output a drive signal to the reducer 2065 and the spline sleeve 2066. The spline shaft 2067 moves up and down within the spline sleeve 2066 along the second direction Y, thereby adjusting the height of the idler roller body 201. The drive motor 2062 can drive the bevel gear 2068 at one end of the spline shaft 2067 to rotate, which in turn drives the idler roller shaft end bevel gear 2063 and auxiliary gear 2064, which mesh with the bevel gear 2068, to rotate, thereby achieving the rotation of the idler roller body 201. Furthermore, the idler roller shaft end bevel gear 2063 and auxiliary gear 2064 are synchronously driven without slippage.

[0033] It should be noted that the axial length of the internal tooth groove of the spline sleeve 2066 is set with redundancy to accommodate the axial displacement of the idler body 201 during attitude adjustment, ensuring that the spline shaft 2067 slides within the spline sleeve 2066 along with the idler body 201.

[0034] It should be noted that the rotational speed acquisition module 202 is mounted on the auxiliary gear 2064. By acquiring the rotational speed of the auxiliary gear 2064, the current rotational speed of the idler roller body 201 can be detected.

[0035] Specifically, the control signal output by the control module 10 can also be transmitted to the hydraulic pump station 2053, thereby adjusting the hydraulic power and driving the idler body 201 to make fine adjustments up, down, left and right through the ball joint bracket (to adapt to the cable posture), while providing support force for the idler body 201 so as to balance with the cable tension.

[0036] Furthermore, the first bearing section 20611 is connected via the first ball joint bracket 2055, and the second bearing section 20612 is connected via the second ball joint bracket 2057. This allows for an adaptation to inclinations of 0°-15°, a rated load of 50kN-100kN, and support requirements to accommodate changes in cable tension. The protection level is IP65, and a reserved oil pipe channel is provided for short-distance connection with the upper layer.

[0037] For example, the drive motor 2062 and the reducer 2065 are covered with an anti-corrosion coating. A wide-temperature-range bearing is provided at the connection position between the output shaft of the drive motor 2062 and the input shaft of the reducer 2065. A wide-temperature-range bearing is also provided at the connection position between the output shaft of the reducer 2065 and the spline sleeve 2066.

[0038] For example, the diameter of the oil passage 40 can be 8mm; the oil pipe 30 can be a Φ10 cold-drawn seamless copper pipe, and the two ends of the oil pipe 30 are connected by compression fittings.

[0039] Optional, continue to refer to Figure 3 The support unit 205 can be fixed to the integrated base 50. For example, the bottom of the first hydraulic cylinder 2051 and the second hydraulic cylinder 2052 can be fixed to the base plate of the integrated base 50 by bolts. Figure 6 This is a schematic diagram of another idler roller module provided in an embodiment of the present invention, as shown below. Figure 6 As shown, components such as the first hydraulic cylinder 2051, the second hydraulic cylinder 2052, the hydraulic pump station 2053, and the integrated valve 2058 can all be located inside the sealed box 200 to improve the service life of the idler roller module.

[0040] For example, continue to refer to Figure 3 and Figure 6 Both the integrated base 50 and the sealing box 200 can adopt a carbon fiber-titanium alloy composite frame. The integrated base 50 has a layered quick-release design, supporting rapid disassembly and assembly and multi-unit series connection. The first hydraulic cylinder 2051 and the second hydraulic cylinder 2052 can be fixedly set at the bottom layer of the integrated base 50, the hydraulic pump station 205 can be set at the middle layer of the integrated base 50, and the self-aligning bearing seat 2061 and the roller body 201 can be set at the top layer of the integrated base 50 to ensure the stability and reliability of the roller module 20.

[0041] It should be noted that the orthographic projection of the drive motor 2062 on the integrated base 50 does not overlap with the orthographic projection of the first hydraulic cylinder 2051 on the integrated base 50, nor does it overlap with the orthographic projection of the second hydraulic cylinder 2052 on the integrated base 50. That is, along the second direction Y, the drive motor 2062 and the hydraulic cylinder are staggered, which helps to avoid mechanical interference between the two during operation, thereby ensuring that the power transmission efficiency is greater than or equal to 95%, thus improving the performance of the idler roller module.

[0042] Optional, continue to refer to Figure 3The integrated valve 2058 includes an electro-hydraulic proportional valve 20581, a directional valve 20582, and a flow divider valve 20583 arranged in series. The flow divider valve 20583 is located in the connecting pipeline between the oil pipe 30 and the directional valve 20582, and is used to split the oil pipe 30 into two channels, each corresponding to one of the two hydraulic cylinders. The directional valve 20582 is located in the connecting pipeline between the flow divider valve 20583 and the electro-hydraulic proportional valve 20581, and the opening degree of the directional valve 20582 determines the lifting height of the support unit 205 on the idler roller body 201. The electro-hydraulic proportional valve 20581 is located in the pipeline between the directional valve 20582 and the oil passage 40, and the opening degree of the electro-hydraulic proportional valve 20581 determines the supporting force of the support unit 205 on the idler roller body 201. The integrated valve 2058 can be electrically connected to the control module 10. The control module 10 can control the opening degree of the integrated valve 2058, thereby extending and retracting the ball joint bracket and dynamically adjusting the support force and posture of the support unit 205 on the idler body 201.

[0043] Optional, continue to refer to Figure 2 , Figure 4 and Figure 5 The rotational speed acquisition unit 202 is mounted on the auxiliary gear 2064; the tension acquisition unit 203 includes a first tension acquisition unit 2031 and a second tension acquisition unit 2032; along the second direction Y, the first tension acquisition unit 2031 is located on the side of the first bearing section 20611 near the first hydraulic cylinder 2051, and is used to acquire the first current support force of the first bearing section 20611 on the idler body 201; along the second direction Y, the second tension acquisition unit 2032 is located on the side of the second bearing section 20612 near the second hydraulic cylinder 2052, and is used to acquire the second current support force of the second bearing section 20612 on the idler body 201; the control module 10 is also used to adjust the support force of the first bearing section 20611 on the idler body 201 according to the first current support force, the second current support force and the current cable posture, and / or, adjust the support force of the second bearing section 20612 on the idler body 201 according to the first current support force, the second current support force and the current cable posture.

[0044] Specifically, the first tension acquisition unit 2031 is located below the first bearing section 20611 and is fixed to the first bearing section 20611 by bolts. It is used to acquire the first current support force of the first bearing section 20611 on the idler body 201, which can be understood as the left support force of the support unit 205 on the idler body 201. The second tension acquisition unit 2032 is located below the second bearing section 20612 and is fixed to the second bearing section 20612 by bolts. It is used to acquire the second current support force of the second bearing section 20612 on the idler body 201, which can be understood as the right support force of the support unit 205 on the idler body 201.

[0045] Furthermore, the control module 10 is electrically connected to the first tension acquisition unit 2031 and the second tension acquisition unit 2032, respectively. The control module 10 can adjust the support force of the first bearing section 20611 on the roller body 201, and / or adjust the support force of the second bearing section 20612 on the roller body 201 based on the first current support force, the second current support force, and the current cable strand posture. This ensures that the first current support force equals the second current support force, thereby ensuring that the support force on the left and right sides of the roller body 201 remains balanced. This ensures that the cable strand is in contact with the roller body at the middle position, thus stabilizing the cable strand posture and avoiding positional deviations caused by cable strand dragging. The cable strand trajectory offset is reduced from the traditional 10mm-15mm to ±5mm, achieving a leading level of linear accuracy less than or equal to L / 10000. Force-attitude coordinated control reduces support force fluctuations to ±0.3kN, improves overall construction accuracy by 200%, and increases quality traceability efficiency by 80%.

[0046] Optional, continue to refer to Figure 2 and Figure 4 The idler module 20 also includes a power supply unit 60 and an energy recovery unit 70; the power supply unit 60 is electrically connected to the support unit 205 and the self-driving unit 206 respectively; the energy recovery unit 70 is connected to the self-driving unit 206 and the power supply unit 206 respectively; the control module 10 is also electrically connected to the energy recovery unit 70, and is used to control the energy recovery unit 70 to convert the mechanical energy output by the self-driving unit 206 into electrical energy when the current rotation speed is greater than the current strand speed, and to store the converted electrical energy in the power supply unit 60.

[0047] Specifically, the power supply unit 60 can supply power to the support unit 205 and the self-driving unit 206, thereby ensuring the normal operation of the idler roller module 20. The energy recovery unit 70 is connected to both the self-driving unit 206 and the power supply unit 206, so that the energy recovery unit 70 can convert the mechanical energy generated during the operation of the self-driving unit 206 into electrical energy, and then store the converted electrical energy in the power supply unit 60.

[0048] Furthermore, to ensure the stable operation of the idler roller control system, the rotational speed of the idler roller body needs to be consistent with the speed of the cable strand. When the current rotational speed is greater than the current cable strand speed, the mechanical energy output by the self-drive unit 206 can be converted by the energy recovery unit 70 to reduce the rotational speed of the idler roller body. That is, the control module 10 can control the energy recovery unit 70 to convert the mechanical energy output by the self-drive unit 206 into electrical energy, and store the converted electrical energy in the power supply unit 60. The electrical energy stored in the power supply unit 60 can then continue to power other units, extending the operating range of the power supply unit 60. This ensures the stable operation of the idler roller control system and improves energy utilization efficiency, achieving energy conservation, environmental protection, and energy recovery. Setting up the energy recovery unit 70 helps to reduce traction energy consumption by 30%, achieve a kinetic energy recovery efficiency of greater than or equal to 95%, and a comprehensive energy saving rate of greater than or equal to 40%, thereby saving costs. At the same time, the system can operate continuously for 24 hours, fully covering the daily operational needs of bridge construction.

[0049] For example, the power supply unit 60 can be a 12V / 100Ah wide-temperature-range lithium battery pack. The energy recovery unit 70 can be a DC-DC energy recovery module. Both the power supply unit 60 and the energy recovery unit 70 can be housed within a battery protection box.

[0050] Optionally, a flexible solar panel 80 is fixed to the outside of the side plate of the integrated base 50. The power supply unit 60 can be used with a 120W flexible solar panel (photovoltaic conversion efficiency greater than or equal to 22%); the solar panel is attached to the outside of the side plate of the integrated base 50 with pressure-sensitive adhesive and connected to the lithium battery pack. The side wall of the battery protection box is provided with heat dissipation holes, and with the wide temperature range bearing, it ensures the reliability of operation under extremely cold conditions of -50℃ or strong winds of level 7.

[0051] Optionally, the idler control system may also include a display module for displaying data information collected by the speed acquisition module, tension acquisition module, and two-dimensional laser contour sensing unit in each idler module.

[0052] Optionally, embodiments of the present invention can also perform multi-condition simulation and pre-play of the entire construction process on a digital twin cloud platform, generate and distribute a globally optimal driving strategy set offline, and transform construction control from "human experience intervention" to "data model driven".

[0053] Optionally, each idler module may also include a positioning unit and a communication unit to ensure the normal operation of the digital twin cloud platform.

[0054] It should be noted that, Figure 2This diagram only shows a partial electrical connection between the control module 10 and some components in one idler module 20. Since the idler control system includes multiple idler modules 20, the control module 10 can be electrically connected to the components that need to be connected within each idler module 20. For example, the control module 10 can be electrically connected to the idler module 20 within each idler module 20.

[0055] In summary, the idler control system provided in this embodiment of the invention features concealed wiring for electrical components within each idler module, equipped with waterproof covers achieving IP65 protection. Quick-release connections in each area and a modular quick-release design reduce the assembly / disassembly time per unit to ≤5 minutes, improving deployment efficiency by 300%. Furthermore, a speed synchronization error of less than or equal to 2% reduces cable strand wear rate from 3%-5% to below 0.5%, lowering the cost per cable strand by 90%. Equipment lifespan is extended from 2 years to over 5 years, with a turnover rate of 90% and a 60% reduction in overall maintenance costs. The system employs a wide temperature range (-50℃~80℃) and ultra-strong corrosion resistance (salt spray resistance greater than or equal to 2000h), combined with holographic perception and early warning, reducing the failure rate in extreme environments from over 15% to below 1%, and minimizing construction disturbance in ecologically sensitive areas by 70%. Moreover, automated adjustment reduces high-altitude manual labor by 80%, increasing safety by 3 times.

[0056] Based on the same inventive concept, this invention also provides a roller control method, applied to the roller control system described in the above embodiments. Figure 7 A flowchart illustrating the first idler roller control method provided in this embodiment of the invention is shown below. Figure 7 As shown, the idler roller control method includes: S101. Obtain the current rotational speed of the idler body collected by the rotational speed acquisition unit, the current supporting force of the support unit on the idler body collected by the tension acquisition unit, and the current cable speed and current cable posture collected by the two-dimensional laser contour sensing unit.

[0057] For details, please refer to [link / reference]. Figures 2-5The rotational speed acquisition unit 202 acquires the current rotational speed of the idler roller body 201 and transmits it to the control module 10. The two-dimensional laser profile sensing unit 204 is generally fixedly mounted on the top of the self-aligning bearing seat 2061, with the laser head angled downwards towards the contact area between the strand and the idler roller body 201, to acquire the current strand speed and current strand posture. The principle of the two-dimensional laser profile sensing unit 204 in detecting the current strand posture is that, since the two-dimensional laser profile sensing unit 204 constantly emits two-dimensional lasers towards the contact area between the strand and the idler roller body 201, the strand will cut off the cross-section of these laser rays when passing through them. This can reflect the degree of deformation of the strand pressing against the idler roller body 201 (e.g., if the support force of the idler roller body 201 on the strand is too high, the strand is severely compressed; if the support force of the idler roller body 201 on the strand is too low, the strand has just touched the idler roller or is even suspended). It can also detect whether the strand axis is centered on the idler roller body 201. The two-dimensional laser contour sensing unit 204 can transmit the current rotational speed and current strand speed to the control module 10. The tension acquisition unit 203 can be located below the self-aligning bearing seat 2061 to acquire the current support force of the support unit 205 on the idler body 201 and transmit the current support force to the control module 10.

[0058] S102. Adjust the support force on the idler body according to the current support force, the current cable posture, and the preset tension control support unit.

[0059] For details, please refer to [link / reference]. Figures 2-5 The control module 10 adjusts the support force on the idler body 201 based on the current support force, the current strand posture, and the preset tension control support unit 205. By dynamically adjusting the support force on the idler body 201 through the control support unit 205, stepless adjustment of the support force and strand posture of the idler body 201 can be achieved. The support force fluctuation is reduced from ±1kN to ±0.3kN, and it dynamically adapts to strand tension fluctuation scenarios, reducing strand position deviation and ensuring that the strand alignment accuracy error is ≤L / 10000 (L is the span). Furthermore, this helps ensure the effectiveness of the support unit 205 in adjusting the support of the idler body 201, thereby achieving the desired support effect of the idler body 201 on the strand.

[0060] S103. Control the driving speed of the self-driving unit on the idler body according to the current rotation speed and the current cable speed.

[0061] For details, please refer to [link / reference]. Figures 2-5The control module 10 can control the driving speed of the self-drive unit 206 on the idler body 201 according to the current rotational speed and the current strand speed, and thus control the driving speed of the self-drive unit 206 on the idler body 201 according to actual needs. For example, when it is necessary to increase the driving speed of the self-drive unit 206 on the idler body 201, the self-drive unit 206 is controlled to increase the driving speed of the idler body 201 to increase the rotational speed of the idler body 201; when acceleration is not required, the self-drive unit 206 is controlled to maintain the driving speed of the idler body 201 to maintain the rotational speed of the idler body 201; when deceleration is required, the self-drive unit 206 is controlled to decrease the driving speed of the idler body 201 or stop the machine to reduce the rotational speed of the idler body 201 or stop the rotation of the idler body 201. In this way, the idler control system can achieve synchronization between the idler and the strand, and the traction energy consumption is reduced by 30% compared with the traditional idler system.

[0062] The idler control method provided in this invention adjusts the support force on the idler body based on the current support force, the current strand posture, and the preset tension control support unit, thereby ensuring the support effect of the support unit on the idler body and achieving the support effect of the idler body on the strand. The driving speed of the self-driving unit on the idler body is controlled based on the current rotational speed and the current strand speed, thereby achieving adaptive adjustment of the idler.

[0063] Optional, Figure 8 This is a flowchart illustrating the second idler roller control method provided in an embodiment of the present invention. Figure 8 Based on the above embodiments, the operation of the support unit to obtain the current support force of the support unit on the idler body acquired by the tension acquisition unit, and the operation of adjusting the support force of the support unit on the idler body according to the current support force, the current cable posture, and the preset tension control support unit are described in detail. Figure 8 As shown, the idler roller control method includes: S201. Obtain the current rotational speed of the idler body collected by the rotational speed acquisition unit and the current cable speed and current cable posture collected by the two-dimensional laser contour sensing unit.

[0064] S202. Obtain the first current support force of the first bearing section on the idler body collected by the first tension acquisition unit and the second current support force of the second bearing section on the idler body collected by the second tension acquisition unit.

[0065] For details, please refer to [link / reference]. Figure 2 , Figure 4 and Figure 5The first tension acquisition unit 2031 is located below the first bearing section 20611 and is fixed to the first bearing section 20611 by bolts. It is used to acquire the first current support force of the first bearing section 20611 on the idler body 201, which can be understood as the left support force of the support unit 205 on the idler body 201. The second tension acquisition unit 2032 is located below the second bearing section 20612 and is fixed to the second bearing section 20612 by bolts. It is used to acquire the second current support force of the second bearing section 20612 on the idler body 201, which can be understood as the right support force of the support unit 205 on the idler body 201.

[0066] S203. Determine the current cable tension based on the first current support force and the second current support force.

[0067] First, the current support force is determined based on the first and second current support forces. For example, the current support force can be determined based on the average of the left and right support forces. Since, theoretically, the current support force and the current cable tension are related as action and reaction forces, the current cable tension can be determined based on the current support force.

[0068] S204. When the difference between the current cable tension and the preset tension is less than or equal to the preset difference range, the support unit is controlled to adjust the support force on the idler body according to the current support force and the current cable tension.

[0069] Specifically, the preset tension can be understood as the initial moment, that is, the supporting force of the support unit on the idler body before the cable strands contact the idler body. At the instant the cable strands contact the idler body, the current supporting force of the support unit on the idler body can be detected. Since the deviation between the current supporting force and the preset tension is relatively small, the support unit can fine-tune the supporting force on the idler body based on the preset tension, thereby obtaining the current supporting force of the support unit on the idler body.

[0070] It should be noted that, theoretically, the current support force and the current cable tension are related as action and reaction forces, and the current cable tension can be determined based on the current support force. However, since the current support force is dynamic, there will be a deviation between the current support force and the current cable tension.

[0071] The preset difference range can be understood as the range of difference between the current cable tension and the preset tension. For example, when the difference between the current cable tension F1 and the preset tension F0 satisfies |F1-F0|≤0.5kN, the support unit adjusts the support force on the idler roller body according to the current support force and the current cable tension to ensure that the current support force and the current cable tension remain balanced.

[0072] S205. When the difference between the current cable tension and the preset tension is less than or equal to the preset difference range, adjust the support force of the first bearing section on the idler body according to the first current support force, the second current support force and the current cable posture, and / or adjust the support force of the second bearing section on the idler body according to the first current support force, the second current support force and the current cable posture.

[0073] Specifically, the support force of the first bearing section on the idler body is adjusted according to the first current support force, the second current support force and the current strand posture, and / or the support force of the second bearing section on the idler body is adjusted according to the first current support force, the second current support force and the current strand posture, so as to ensure that the first current support force and the second current support force remain in balance, which in turn helps to ensure the balance of the idler body, and thus helps the strand axis to always be in contact with the center position of the idler body.

[0074] S206. Control the driving speed of the self-driving unit on the idler body according to the current rotation speed and the current strand speed.

[0075] The idler control method provided in this embodiment of the invention adjusts the support force on the idler body according to the current support force and the current strand tension when the difference between the current strand tension and the preset tension is less than or equal to the preset difference range. Furthermore, it adjusts the support force of the first bearing portion on the idler body according to the first current support force, the second current support force, and the current strand posture, and / or adjusts the support force of the second bearing portion on the idler body according to the first current support force, the second current support force, and the current strand posture. This ensures that the current support force and the current strand tension remain balanced, and also ensures that the first current support force and the second current support force remain balanced, thereby facilitating the balance of the idler body and ensuring that the strand axis is always in contact with the center position of the idler body.

[0076] Optional, Figure 9 This is a flowchart illustrating the third idler roller control method provided in an embodiment of the present invention. Figure 9 Based on the above embodiments, the operation of adjusting the support force of the idler roller body according to the current support force and the current cable tension of the control support unit is described in detail, such as... Figure 7 As shown, the idler roller control method includes: S301. Obtain the current rotational speed of the idler body acquired by the rotational speed acquisition unit and the current cable speed and current cable posture acquired by the two-dimensional laser contour sensing unit.

[0077] S302. Obtain the first current support force of the first bearing section on the idler body collected by the first tension acquisition unit and the second current support force of the second bearing section on the idler body collected by the second tension acquisition unit.

[0078] S303. Determine the current cable tension based on the first current support force and the second current support force.

[0079] S304. When the difference between the current cable tension and the preset tension is less than or equal to the preset difference range, and when the current support force is equal to the current cable tension, the control support unit maintains the current support force on the idler roller body.

[0080] Specifically, when the current support force equals the current cable tension, this means that the current support force of the support unit on the idler body is balanced with the current cable tension, and there is no need to adjust the current support force of the control support unit on the idler body. That is, the control support unit can simply maintain the current support force on the idler body.

[0081] S305. When the difference between the current cable tension and the preset tension is less than or equal to the preset difference range, and when the current support force is greater than the current cable tension, the control support unit reduces the support force on the idler roller body.

[0082] Specifically, when the current support force is greater than the current cable tension, it indicates that the current support force of the support unit on the idler body is unbalanced with the current cable tension. By controlling the support unit to reduce the support force on the idler body, the current support force of the support unit on the idler body can be reduced, thereby ensuring that the current support force and the current cable tension are balanced.

[0083] S306. When the difference between the current cable tension and the preset tension is less than or equal to the preset difference range, and when the current support force is less than the current cable tension, the control support unit increases the support force on the idler roller body.

[0084] Specifically, when the current support force is less than the current cable tension, it indicates that the current support force of the support unit on the idler body is unbalanced with the current cable tension. By controlling the support unit to increase the support force on the idler body, the current support force of the support unit on the idler body can be improved, thereby ensuring that the current support force and the current cable tension are balanced.

[0085] S307. When the difference between the current cable tension and the preset tension is less than or equal to the preset difference range, and when the first current support force is equal to the second current support force, the first bearing section is controlled to maintain the support force on the roller body and the second bearing section is controlled to maintain the support force on the roller body according to the current cable posture.

[0086] Specifically, when the first current support force equals the second current support force, it indicates that the idler body is in a state of left-right balance, and the current cable posture is in the middle position of the idler body. Therefore, there is no need to adjust the left-right support force of the support unit on the idler body. That is, it is sufficient to control the first bearing portion to maintain the support force on the idler body and the second bearing portion to maintain the support force on the idler body.

[0087] S308. When the difference between the current cable tension and the preset tension is less than or equal to the preset difference range, and when the first current support force is greater than the second current support force, the first bearing section is controlled to reduce the support force on the idler roller body according to the current cable posture.

[0088] Specifically, when the first current support force is greater than the second current support force, the idler body will tilt to one side. In order to keep the idler body in a balanced state, it is necessary to control the first bearing section to reduce the support force on the idler body according to the current strand posture, so as to reduce the strand position deviation.

[0089] S309. When the difference between the current cable tension and the preset tension is less than or equal to the preset difference range, and when the first current support force is less than the second current support force, the second bearing section is controlled to reduce the support force on the roller body according to the current cable posture.

[0090] Specifically, when the first current support force is less than the second current support force, the idler body will tilt to one side. In order to keep the idler body in a balanced state, it is necessary to control the second bearing distribution to reduce the support force on the idler body according to the current strand posture, so as to reduce the strand position deviation.

[0091] S310. When the current thread speed is equal to the current rotation speed, the self-driving control unit maintains the current driving speed of the idler roller body.

[0092] Specifically, when the current cable speed equals the current rotation speed, that is, when the idler system is operating stably, the self-driving unit can maintain the current driving speed of the idler body.

[0093] S311. When the current strand speed is greater than the current rotation speed, control the self-drive unit to increase the driving speed of the idler roller body.

[0094] Specifically, when the current strand speed is greater than the current rotation speed, in order to ensure that the rotation speed of the idler body matches the current strand speed, the control module needs to control the self-drive unit to increase the driving speed of the idler body, so as to accelerate the rotation speed of the idler body.

[0095] S312. When the current cable speed is less than the current rotation speed, the control energy recovery unit converts the mechanical energy output by the self-driving unit into electrical energy and stores the converted electrical energy in the power supply unit.

[0096] Specifically, when the current cable speed is lower than the current rotational speed, to ensure the stable operation of the idler roller control system, the rotational speed of the idler roller body needs to be consistent with the cable speed. When the current rotational speed is higher than the current cable speed, the energy recovery unit 70 can convert the mechanical energy output by the self-drive unit 206 to reduce the rotational speed of the idler roller body. That is, the control module 10 can control the energy recovery unit 70 to convert the mechanical energy output by the self-drive unit 206 into electrical energy, and store the converted electrical energy in the power supply unit 60. The electrical energy stored in the power supply unit 60 can then continue to power other units, extending the power supply unit 60's operating range. This ensures the stable operation of the idler roller control system and improves energy utilization, achieving energy conservation, environmental protection, and energy recovery. Setting up the energy recovery unit 70 helps to reduce traction energy consumption by 30%, achieve a kinetic energy recovery efficiency of greater than or equal to 95%, and a comprehensive energy saving rate of greater than or equal to 40%, thereby saving costs. At the same time, the system can operate continuously for 24 hours, fully covering the daily operational needs of bridge construction.

[0097] The idler roller control method provided in this invention maintains a balance between the first and second current support forces and matches the current strand speed with the current rotational speed, thereby ensuring the stability and reliability of the idler roller system. Furthermore, when the current strand speed is less than the current rotational speed, the energy recovery unit converts the mechanical energy output from the self-driving unit into electrical energy and stores the converted electrical energy in the power supply unit, achieving energy recovery and utilization, and thus saving costs.

[0098] Optional, Figure 10 This is a flowchart illustrating the fourth idler roller control method provided in an embodiment of the present invention. Figure 10 Based on the above embodiments, the operations prior to acquiring the current rotational speed of the idler body from the rotational speed acquisition unit, the current support force of the idler body from the support unit from the tension acquisition unit, and the current cable speed and current cable posture from the two-dimensional laser contour sensing unit are described in detail, such as... Figure 10 As shown, the idler roller control method includes: S401. Obtain the preset identifier for each idler module.

[0099] Specifically, since the idler control system includes multiple idler modules, each idler module has a preset identifier to distinguish it from other idler modules.

[0100] For example, the preset identifier may be a pre-defined identification code for each idler module.

[0101] S402. Determine whether any component unit in each idler roller module has malfunctioned based on the preset markings.

[0102] Specifically, based on preset identifiers, the rotation speed acquisition module unit, tension acquisition unit, two-dimensional laser contour sensing unit, support unit, and self-driving unit in each idler roller module are diagnosed to determine whether each component is operating normally.

[0103] For example, it can be determined whether the hydraulic pump station can be used normally, whether the support unit is stuck, whether the drive motor can start normally, whether each acquisition unit is working normally, and whether the bevel gear, auxiliary gear and bevel gear at the roller shaft end are meshing and linked normally, etc.

[0104] S403. Determine the preset identifier, fault unit, and fault type of the faulty idler module corresponding to the faulty module.

[0105] Specifically, the control module obtains the preset identifier corresponding to the faulty idler module, as well as the faulty unit in the faulty idler module and the fault type.

[0106] For example, the idler system includes 30 idler modules, each with a preset identifier from 001, 002, 003 to 030. When the idler module with preset identifier 010 malfunctions, the specific unit within that idler module that malfunctions is determined, such as a malfunction in the speed acquisition module, and the malfunction type of that speed acquisition module is determined to be the inability to acquire the speed of the idler body. In this case, the control module cannot obtain the current speed acquired by the speed acquisition module in the idler module with preset identifier 010.

[0107] S404. Output a maintenance prompt signal based on the preset identifier, fault unit, and fault type corresponding to the faulty idler module.

[0108] For example, when the speed acquisition module unit in the idler module with the preset identifier 010 fails to acquire the speed of the idler body, the control module outputs a maintenance prompt signal so that maintenance personnel can perform maintenance on the speed acquisition module unit.

[0109] It should be noted that the control module can also determine the severity of a fault based on the fault type of the faulty unit. For example, when the control module determines that a faulty unit has a minor fault, it controls the unit to automatically calibrate and reset. When the control module determines that a faulty unit has a severe fault, it controls the system to shut down and cut off power. A minor fault refers to a non-hardware damage fault that occurs during system operation, does not affect core functions or operational safety, only causes slight deviations in performance indicators, and can be automatically repaired through automatic system calibration, parameter reset, unit restart, redundancy switching, etc. Typical scenarios include: self-driving unit speed deviation in the range of 2% to 5%, support unit response time in the range of 0.1s to 0.3s, data acquisition error of the speed acquisition module unit, tension acquisition unit, or two-dimensional laser contour sensing unit in the range of 0.5% to 2%, abnormal single-module parameters, or occasional communication packet loss, etc. A severe fault refers to a hardware damage or core function failure fault that occurs during system operation, affects core functions, poses safety hazards, cannot be automatically repaired by software, and requires shutdown and manual intervention. Typical scenarios include: the rotational speed deviation of the self-driving unit is greater than 5% or the drive motor idles without the roller rotating; the response time of the support unit is greater than 0.3s or there is no action after multiple adjustments; the data acquisition error of the rotational speed acquisition module unit, tension acquisition unit or two-dimensional laser contour sensing unit is greater than 2% or there is no data output; mechanical structure jamming / damage; core control logic collapse, etc.

[0110] It should be noted that before acquiring the current rotational speed of the idler body from the rotational speed acquisition unit, the current supporting force of the support unit on the idler body from the tension acquisition unit, and the current strand speed and current strand posture from the 2D laser contour sensing unit, the response time of the support unit can be checked to see if it is less than or equal to 0.1s. If the response time of the support unit is greater than 0.1s, the support unit needs to be inspected. Furthermore, the rotational speed acquisition unit, tension acquisition unit, or 2D laser contour sensing unit can each acquire 10 sets of data. By analyzing whether the error of the 10 sets of data exceeds 0.5%, if the error of any acquisition unit exceeds 0.5%, that acquisition unit needs to be inspected.

[0111] It should be noted that the control module can also transmit the preset identifier, fault unit, and fault type corresponding to the faulty idler module to the display module so that the display module can display this information, and then the maintenance personnel can locate the fault point based on the content displayed on the display module.

[0112] S405. Obtain the current rotational speed of the idler body collected by the rotational speed acquisition unit, the current supporting force of the support unit on the idler body collected by the tension acquisition unit, and the current cable speed and current cable posture collected by the two-dimensional laser contour sensing unit.

[0113] S406. Adjust the support force on the idler body according to the current support force and the preset tension control support unit.

[0114] S407. Control the driving speed of the self-driving unit on the idler body according to the current rotation speed and the current strand speed.

[0115] The idler control method provided in this embodiment of the invention performs fault checks on each idler module before acquiring the collected parameters, thereby ensuring the stability and reliability of the idler control system.

[0116] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art will be able to make various obvious changes, readjustments, and substitutions without departing from the scope of protection of the present invention. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A roller control system, characterized in that, include: Control module and multiple idler roller modules; Each of the aforementioned idler roller modules includes an idler roller body, a speed acquisition module unit, a tension acquisition unit, a two-dimensional laser contour sensing unit, a support unit, and a self-driving unit; The rotation speed acquisition unit is used to acquire the current rotation speed of the idler roller body; The tension acquisition unit is used to acquire the current support force of the support unit on the roller body; The two-dimensional laser contour sensing unit is used to acquire the current strand speed and current strand posture; wherein the strand is located on one side of the idler body and is in contact with the idler body; The control module is electrically connected to the tension acquisition unit block, the two-dimensional laser contour sensing unit, and the support unit, and is used to control the support unit to adjust the support force on the idler body according to the current support force, the current strand posture, and the preset tension; the control module is also electrically connected to the speed acquisition unit and the self-driving unit, and is also used to control the driving speed of the self-driving unit on the idler body according to the current speed and the current strand speed.

2. The idler roller control system according to claim 1, characterized in that, The self-driving unit includes a self-aligning bearing housing, a drive motor, a bevel gear at the roller shaft end, an auxiliary gear, a reducer, a spline sleeve, a spline shaft, and a bevel gear; the support unit includes a first hydraulic cylinder, a second hydraulic cylinder, a hydraulic pump station, a first piston rod, a first ball joint bracket, a second piston rod, a second ball joint bracket, and an integrated valve; The self-aligning bearing housing includes a first bearing portion and a second bearing portion disposed along a first direction; Along the first direction, the first hydraulic cylinder is located on one side of the second hydraulic cylinder, and the first hydraulic cylinder and the second hydraulic cylinder are connected by an oil pipe; one end of the first hydraulic cylinder is fixed to one end of the first piston rod, and the other end of the first piston rod is connected to the first bearing section through a first ball joint bracket; one end of the second hydraulic cylinder is fixed to one end of the second piston rod, and the other end of the second piston rod is connected to the second bearing section through a second ball joint bracket; Along the second direction, the drive motor and the hydraulic pump station are both located on one side of the first hydraulic cylinder and the second hydraulic cylinder; the second direction intersects the first direction; along the first direction, the idler roller body is located between the first bearing section and the second bearing section, and one end of the idler roller body is rotatably connected to the first bearing section, and the other end of the idler roller body is rotatably connected to the second bearing section; along the first direction, a roller shaft end bevel gear and an auxiliary gear are provided on the side of the second bearing section away from the first bearing section; the roller shaft of the idler roller body is connected to the roller shaft end bevel gear; the output shaft of the drive motor is connected to the input shaft of the reducer, and the output shaft of the reducer is connected to the spline sleeve; one end of the spline shaft is slidably connected to the spline sleeve; a bevel gear is provided on the other end of the spline shaft; along the second direction, the bevel gear is located between the roller shaft end bevel gear and the auxiliary gear, the end of the bevel gear away from the spline sleeve meshes with the roller shaft end bevel gear, and the end of the bevel gear near the spline sleeve meshes with the auxiliary gear; The hydraulic pump station is connected to the oil pipe via an oil passage and the integrated valve.

3. The idler roller control system according to claim 2, characterized in that, The rotation speed acquisition unit is mounted on the auxiliary gear; The tension acquisition unit includes a first tension acquisition unit and a second tension acquisition unit; Along the second direction, the first tension acquisition unit is disposed on the side of the first bearing section near the first hydraulic cylinder, for acquiring the first current support force of the first bearing section on the idler roller body; Along the second direction, the second tension acquisition unit is disposed on the side of the second bearing section near the second hydraulic cylinder, for acquiring the second current support force of the second bearing section on the idler roller body; The control module is further configured to adjust the support force of the first bearing section on the idler body according to the first current support force, the second current support force and the current cable posture, and / or adjust the support force of the second bearing section on the idler body according to the first current support force, the second current support force and the current cable posture.

4. The idler roller control system according to claim 1, characterized in that, The idler roller module also includes a power supply unit and an energy recovery unit; The power supply unit is electrically connected to the support unit and the self-driving unit, respectively. The energy recovery unit is connected to both the self-driving unit and the power supply unit. The control module is also electrically connected to the energy recovery unit, and is used to control the energy recovery unit to convert the mechanical energy output by the self-driving unit into electrical energy when the current rotation speed is greater than the current strand speed, and to store the converted electrical energy in the power supply unit.

5. A roller control method, applied in the roller control system according to any one of claims 1-4, characterized in that, include: The current rotational speed of the idler body is acquired by the rotational speed acquisition unit, the current supporting force of the support unit on the idler body is acquired by the tension acquisition unit, and the current strand speed and current strand posture are acquired by the two-dimensional laser contour sensing unit. The support unit adjusts its support force on the idler roller body based on the current support force, the current strand posture, and the preset tension. The self-driving unit controls the driving speed of the idler roller body based on the current rotational speed and the current strand speed.

6. The idler roller control method according to claim 5, characterized in that, The tension acquisition unit acquires the current support force of the support unit on the roller body, including: The first current support force of the first bearing portion on the idler body, collected by the first tension acquisition unit, and the second current support force of the second bearing portion on the idler body, collected by the second tension acquisition unit, are obtained. Based on the current support force, the current strand posture, and the preset tension, the support unit adjusts its support force on the idler roller body, including: The current cable tension is determined based on the first current support force and the second current support force; When the difference between the current cable tension and the preset tension is less than or equal to the preset difference range, the support unit is controlled to adjust the support force on the idler body according to the current support force and the current cable tension. When the difference between the current cable tension and the preset tension is less than or equal to the preset difference range, the support force of the first bearing section on the idler body is adjusted according to the first current support force, the second current support force and the current cable posture, and / or the support force of the second bearing section on the idler body is adjusted according to the first current support force, the second current support force and the current cable posture.

7. The idler roller control method according to claim 6, characterized in that, Controlling the support unit to adjust the support force on the idler roller based on the current support force and the current cable tension includes: When the current support force is equal to the current strand tension, the support unit is controlled to maintain the current support force on the idler body; When the current support force is greater than the current strand tension, the support unit is controlled to reduce the support force on the idler body; When the current support force is less than the current strand tension, the support unit is controlled to increase the support force on the idler roller body.

8. The idler roller control method according to claim 6, characterized in that, Adjusting the support force of the first bearing section on the idler body based on the first current support force, the second current support force, and the current cable posture, and / or adjusting the support force of the second bearing section on the idler body based on the first current support force, the second current support force, and the current cable posture, including: When the first current support force is equal to the second current support force, the first bearing section and the second bearing section are controlled to maintain the support force on the roller body according to the current cable posture. When the first current support force is greater than the second current support force, the first bearing section is controlled to reduce the support force on the roller body according to the current cable posture; When the first current support force is less than the second current support force, the second bearing section is controlled to reduce the support force on the idler body according to the current cable posture.

9. The idler roller control method according to claim 5, characterized in that, Controlling the driving speed of the self-driving unit on the idler body based on the current rotational speed and the current strand speed includes: When the current strand speed is equal to the current rotational speed, the self-driving unit is controlled to maintain the current driving speed of the idler body; When the current strand speed is greater than the current rotational speed, the self-driving unit is controlled to increase the driving speed of the idler roller body; When the current strand speed is less than the current rotation speed, the energy recovery unit is controlled to convert the mechanical energy output by the self-driving unit into electrical energy, and the converted electrical energy is stored in the power supply unit.

10. The idler roller control method according to claim 5, characterized in that, Before acquiring the current rotational speed of the idler body acquired by the rotational speed acquisition unit, the current supporting force of the support unit on the idler body acquired by the tension acquisition unit, and the current strand speed and current strand posture acquired by the two-dimensional laser contour sensing unit, the following steps are also included: Obtain the preset identifier for each of the idler roller modules; Based on the preset identifier, determine whether each component unit in each idler roller module has malfunctioned; Determine the preset identifier, fault unit, and fault type of the faulty idler module corresponding to the faulty module; A maintenance prompt signal is output based on the preset identifier corresponding to the faulty idler module, the faulty unit, and the fault type.

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