Intelligent control device and method for tension of cargo cableway bearing cable

Abstract

The application discloses a kind of freight cableway bearing cable tension intelligent control equipment and method, belong to tension control technical field, including guide roller, guide roller is arranged in tow wheel frame, column type tension sensor is connected in tow wheel frame lower, column type tension sensor lower end is connected with lead screw, lead screw passes through ball screw drive box body below, ball screw drive box body is provided with ball screw pair, ball screw pair is connected with lead screw by thread.This application adopts the above-mentioned freight cableway bearing cable tension intelligent control equipment and method, the actual tension value of bearing cable is collected by column type tension sensor, the extension length of bearing cable is calculated by servo motor feedback, by PID control algorithm, drive servo motor rotation to adjust bearing cable length, realize the accurate and rapid regulation of freight cableway bearing cable tension.

Description

Technical Field

[0001] This invention relates to the field of tension control technology, and in particular to an intelligent control device and method for the tension of the load-bearing cable of a freight cableway. Background Technology

[0002] As ultra-high voltage power transmission lines and other projects extend to high-altitude and deep mountain valley areas, freight cableways have become core equipment for transporting tower materials and machinery in mountainous areas, and the tension of the cable bearings directly determines the safety and efficiency of cableway operation.

[0003] The tension of the cable bearing cable can change significantly due to external disturbances. The current mainstream cableway tensioning schemes are divided into three categories: counterweight type, hydraulic type, and winch type.

[0004] The counterweight tensioning system anchors the cableway at one end of a steel wire rope, and connects the other end to a counterweight after passing over a guide wheel. When the cableway moves due to changes in the line load, the counterweight moves up and down accordingly. Because the weight of the counterweight does not change, the tension of the cableway steel wire rope remains constant. The counterweight tensioning system can adapt to large displacement changes, has a simple structure and low cost, and operates smoothly and reliably. However, it is large in size, requires a lot of installation space, has a slow response, and cannot adjust the tension according to the working conditions, making it unable to adapt to dynamic tension fluctuations.

[0005] The hydraulic tensioning system uses a hydraulic pump to send hydraulic oil into a hydraulic cylinder, which pushes the piston rod to move the tensioning wheel or tensioning carriage, thereby changing the length of the wire rope and adjusting the tension. When the tension of the load-bearing cable changes, the piston movement of the hydraulic cylinder can be controlled to move the moving frame to tighten the load-bearing cable until the tension reaches the design requirements. The tension value can be obtained by reading the pressure gauge.

[0006] Hydraulic tensioning systems have a compact structure, stable performance, large tension force that is steplessly adjustable, and can display the tension force online. They can adapt to harsh working environments. However, the response speed and adjustment accuracy of hydraulic tensioning systems are affected by the frequency response of the hydraulic system, valve dead zone, and oil compressibility. When the tension of the carrier cable decreases rapidly, the hydraulic tensioning system's pressure compensation capacity is insufficient, and its adjustment capability is limited under rapidly changing disturbance conditions.

[0007] The winch-type tensioning system winds a steel wire rope around a winch drum and uses the forward and reverse rotation of the winch to raise and lower the rope length, thereby changing the length of the load-bearing lock and adjusting the tension. The winch-type tensioning system has a large tensioning stroke and a large traction force. The equipment structure is relatively simple, and the installation and operation are relatively convenient. It can provide a large range of rope length adjustment and is suitable for occasions with high requirements for tensioning stroke.

[0008] However, the winch system has a large inertia, and the starting and braking shocks are more obvious. It is difficult to match the opening of the brake with the action of the motor, and shock phenomena are prone to occur. Therefore, the winch tensioning is difficult to adjust the load-bearing lock tension quickly and dynamically. When the tension changes rapidly due to external disturbances, it is difficult to meet the control requirements.

[0009] All three tensioning schemes mentioned above can be used for the basic tensioning of cableway load-bearing cables. However, when the load-bearing cable tension changes rapidly due to external disturbances, their adjustment capabilities are still significantly insufficient. It is difficult to maintain the load-bearing cable tension within a suitable range, which can easily lead to safety hazards or reduced efficiency during transportation.

[0010] Therefore, there is an urgent need for an intelligent control device for freight cableway load-bearing cables that can quickly adapt to changes in tension and environment. Summary of the Invention

[0011] The purpose of this invention is to provide an intelligent control device and method for the tension of the load-bearing cable in a freight cableway. The device collects the actual tension value of the load-bearing cable using a column-type tension sensor, calculates the extension / retraction length of the load-bearing cable through feedback from a servo motor, and drives the servo motor to rotate via a PID control algorithm. This rotation is then transmitted through the motor shaft to a worm gear, which in turn drives the ball screw pair to rotate, thereby controlling the screw displacement and adjusting the length of the load-bearing cable. This achieves precise and rapid control of the tension of the load-bearing cable in the freight cableway.

[0012] To achieve the above objectives, the present invention provides an intelligent control device for the tension of the load-bearing cable of a freight cableway, including a guide roller, which is mounted on a tow wheel frame. A column-type tension sensor is connected to the lower part of the tow wheel frame, and a lead screw is connected to the lower end of the column-type tension sensor. The lead screw passes through a ball screw transmission housing, and a ball screw pair is provided in the ball screw transmission housing. The ball screw pair is threaded to the lead screw. A motor shaft housing is connected to the ball screw transmission housing, and a reducer is connected to one side of the motor shaft housing. A servo motor is connected to one side of the reducer.

[0013] Preferably, the ball screw transmission housing is mounted on the upper connecting plate, and the upper connecting plate is also provided with the motor shaft housing.

[0014] Preferably, an outer housing for the lead screw is connected below the upper connecting plate, the lead screw passes through the upper connecting plate, and the bottom end of the lead screw is located inside the outer housing for the lead screw.

[0015] Preferably, the lower end of the outer housing of the lead screw is provided with a housing fixing base flange, and the lower end of the housing fixing base flange is connected to a device base.

[0016] Preferably, the motor shaft housing is connected to the reducer via a servo motor flange.

[0017] Preferably, a motor shaft is provided in the motor shaft housing, and the motor shaft is connected to the reducer.

[0018] Preferably, a worm gear is provided on the motor shaft, and a turbine gear is provided on the outer side of the ball screw pair, with the turbine gear and the worm gear being connected in cooperation with each other.

[0019] Preferably, the ball screw drive housing is equipped with a bearing.

[0020] Preferably, the bearings are connected to the upper and lower ends of the ball screw assembly.

[0021] A method for using an intelligent control device for the tension of a freight cableway's supporting cable includes the following steps: S1. Equipment initialization and parameter configuration: Set the PID control algorithm parameters. The PLC controller reads the zero point value of the column tension sensor and the initial position of the lead screw. After confirming that there is no fault, it enters the standby control mode. S2. Data acquisition: The column tension sensor detects the tension transmitted by the support cable through the guide roller in real time and feeds it back to the PLC controller; at the same time, the PLC controller calculates the linear displacement of the lead screw based on the rotation angle fed back by the servo motor, and calculates the extension and retraction of the support cable. S3. Tension deviation calculation: The PLC controller calculates the deviation between the target tension value and the actual tension value fed back by the column tension sensor. The PID control algorithm generates a control signal for adjusting the tension of the load-bearing cable. S4. Adjust the tension of the load-bearing cable. The PLC controller outputs the control signal from the PID control algorithm to the servo motor, which drives the lead screw to move the guide roller, thereby changing the length of the load-bearing cable and completing the tension adjustment of the load-bearing cable. S5. Dynamic Judgment: During the adjustment process, the PLC controller continuously compares the actual tension value detected by the column tension sensor with the theoretical tension value corresponding to the extension and contraction of the bearing cable calculated based on the screw displacement fed back by the servo motor. When the difference between the two exceeds 0.2% of the rated working tension, the PLC controller performs zero-point calibration of the column tension sensor. When the tension fluctuation detected by the column tension sensor does not exceed 0.14% of the rated working tension within 500 milliseconds, the PLC controller determines that the current tension is in a steady state and then pauses the output of commands.

[0022] Therefore, the present invention adopts the above-mentioned intelligent control device and method for the tension of the load-bearing cable of a freight cableway. The actual tension value of the load-bearing cable is collected by a column-type tension sensor, the extension and retraction length of the load-bearing cable is calculated by a servo motor, and the servo motor is driven to rotate by a PID control algorithm. The rotation is then transmitted through the motor shaft to the worm gear, which in turn drives the ball screw pair to rotate, thereby controlling the screw displacement and adjusting the length of the load-bearing cable. This achieves precise and rapid control of the tension of the load-bearing cable of the freight cableway.

[0023] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of an embodiment of the intelligent control device and method for the tension of the load-bearing cable of a freight cableway according to the present invention; Figure 2 This is a schematic diagram of the rear structure of an embodiment of the intelligent control device and method for the tension of a freight cableway bearing cable according to the present invention; Figure 3 This is a schematic diagram of the internal structure of an embodiment of the intelligent control device and method for the tension of a freight cableway bearing cable according to the present invention; Figure 4 This is a schematic diagram of the internal rear structure of an embodiment of the intelligent control device and method for the tension of a freight cableway bearing cable according to the present invention.

[0025] Figure Labels 1. Guide roller; 2. Drag roller frame; 3. Column-type tension sensor; 4. Lead screw; 5. Motor shaft housing; 6. Upper connecting plate; 7. Reducer; 8. Servo motor; 9. Motor shaft; 10. Lead screw outer housing; 11. Housing fixing base flange; 12. Ball screw transmission housing; 13. Servo motor flange; 14. Device base; 15. Worm gear; 16. Bearing; 17. Ball screw pair; 18. Turbine. Detailed Implementation

[0026] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0027] Unless otherwise defined, the technical or scientific terms used in this invention shall have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "first," "second," and similar terms used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0028] Example 1 This invention provides an intelligent control device and method for the tension of the load-bearing cable in a freight cableway, such as... Figure 1 Figure 2As shown, the device includes a guide roller 1, which is mounted on the towing frame 2. The guide roller 1 is in direct contact with the load-bearing cable and is used to support and guide the load-bearing cable. A column-type tension sensor 3 is connected below the towing frame 2 to detect the tension transmitted by the load-bearing cable through the guide roller 1 in real time, convert the force signal into an electrical signal and feed it back to the PLC controller to provide a basis for PID regulation.

[0029] like Figure 3 Figure 4 As shown, the lower end of the column tension sensor 3 is connected to a lead screw 4, and the lead screw 4 passes through the ball screw drive housing 12. A ball screw pair 17 is provided in the ball screw drive housing 12, and a bearing 16 is provided inside the ball screw drive housing 12. The upper and lower ends of the ball screw pair 17 are connected to the bearing 16, which allows the ball screw pair 17 to rotate relative to the lead screw drive housing 12. The ball screw pair 17 is connected to the lead screw 4 by a thread, and the rotation of the ball screw pair 17 can drive the lead screw 4 to move up and down.

[0030] The ball screw drive housing 12 is connected to the motor shaft housing 5. A reducer 7 is connected to one side of the motor shaft housing 5, and a servo motor 8 is connected to one side of the reducer 7. The ball screw drive housing 12 is mounted on the upper connecting plate 6, which is also mounted on the upper connecting plate 6. A motor shaft 9 is mounted in the motor shaft housing 5. The motor shaft 9 is connected to the reducer 7. A worm gear 15 is mounted on the motor shaft 9. A worm wheel 18 is mounted on the outside of the ball screw pair 17. The worm wheel 18 and the worm gear 15 are connected to each other. The motor shaft housing 5 is connected to the reducer 7 through the servo motor flange 13.

[0031] After the servo motor 8 rotates and is reduced in speed by the reducer 7, it drives the motor shaft 9 to rotate, which in turn drives the worm gear 15 to rotate, thereby driving the worm 18 to rotate, and in turn driving the ball screw pair 17 to rotate up and down. The servo motor 8, as the drive actuator, rotates according to the PID control signal output by the PLC controller, and can provide feedback on its own rotation angle or number of revolutions to the PLC controller, thereby calculating the displacement distance of the screw 4, and further calculating the extension length of the supporting cable.

[0032] The upper connecting plate 6 is connected to the outer housing 10 of the lead screw. The lead screw 4 passes through the upper connecting plate 6, and the bottom end of the lead screw 4 is set inside the outer housing 10. The outer housing 10 is used to protect the lower moving section of the lead screw 4 and prevent dust from entering the transmission part. At the same time, it guides and limits the linear movement of the lead screw 4. The lower end of the outer housing 10 is provided with a housing fixing base flange 11. The lower end of the housing fixing base flange 11 is connected to a device base 14. The device base 14 is used for the installation and fixing of the equipment and bears the working load transmitted by the load-bearing cable.

[0033] A method for using an intelligent control device for the tension of a freight cableway's supporting cable includes the following steps: S1. Equipment initialization and parameter configuration: Set the basic proportional parameters, integral parameters and derivative parameters of the PID control algorithm. The PLC controller reads the zero point value of the column tension sensor 3 and the initial position of the lead screw 4 calculated from the initial rotation angle fed back by the servo motor 8. After confirming that there is no fault, it enters the standby control mode. S2. Data acquisition: The column tension sensor 3 detects the tension transmitted by the bearing cable through the guide roller 1 in real time, converts the force signal into an electrical signal and feeds it back to the PLC controller; at the same time, the PLC controller calculates the linear displacement of the lead screw 4 based on the rotation angle fed back by the servo motor 8, and calculates the extension and retraction of the bearing cable. S3. Tension deviation calculation: The PLC controller calculates the deviation between the target tension value and the actual tension value fed back by the column tension sensor 3. The proportional element of the PID control algorithm responds to the instantaneous deviation, the integral element eliminates long-term static tension error, and the derivative element makes a prediction based on the trend of deviation change, thereby generating a control signal for adjusting the tension of the load-bearing cable. S4. Adjusting the tension of the load-bearing cable: The PLC controller outputs the control signal from the PID control algorithm to the servo motor 8. The servo motor 8 rotates and, after being reduced in speed by the reducer 7, drives the motor shaft 9 to rotate. Through the worm gear 15 and the worm 18, the worm gear 18 drives the ball screw pair 17 to rotate. The ball screw pair 17 drives the screw 4 to make linear motion through the thread. The screw 4 drives the guide roller 1 to move, changing the length of the load-bearing cable and completing the tension adjustment of the load-bearing cable. S5. Dynamic Judgment: During the adjustment process, the PLC controller continuously compares the actual tension value detected by the column tension sensor 3 with the theoretical tension value corresponding to the extension and contraction of the bearing cable calculated based on the displacement of the lead screw 4 fed back by the servo motor 8. When the difference between the two exceeds 0.2% of the rated working tension, the PLC controller performs zero-point calibration of the column tension sensor 3. When the tension fluctuation detected by the column tension sensor 3 does not exceed 0.14% of the rated working tension within 500 milliseconds, the PLC controller determines that the current tension is in a steady state, and then the PLC controller pauses the output of commands.

[0034] Therefore, the present invention adopts the above-mentioned intelligent control device and method for the tension of the load-bearing cable of a freight cableway. The actual tension value of the load-bearing cable is collected by a column-type tension sensor, the extension and retraction length of the load-bearing cable is calculated by a servo motor, and the servo motor is driven to rotate by a PID control algorithm. The rotation is then transmitted through the motor shaft to the worm gear, which in turn drives the ball screw pair to rotate, thereby controlling the screw displacement and adjusting the length of the load-bearing cable. This achieves precise and rapid control of the tension of the load-bearing cable of the freight cableway.

[0035] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the technical solutions of the present invention, and these modifications or equivalent substitutions cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

Claims

1. An intelligent control device for the tension of the load-bearing cable of a freight cableway, characterized in that: The device includes a guide roller mounted on a roller frame. A column-type tension sensor is connected to the lower part of the roller frame. A lead screw is connected to the lower end of the column-type tension sensor. The lead screw passes through a ball screw drive housing. A ball screw pair is installed in the ball screw drive housing. The ball screw pair is threaded to the lead screw. A motor shaft housing is connected to the ball screw drive housing. A reducer is connected to one side of the motor shaft housing. A servo motor is connected to one side of the reducer.

2. The intelligent control device for the tension of the load-bearing cable of a freight cableway according to claim 1, characterized in that: The ball screw transmission housing is mounted on the upper connecting plate, and the upper connecting plate is also provided with the motor shaft housing.

3. The intelligent control device for the tension of the load-bearing cable of a freight cableway according to claim 2, characterized in that: The upper connecting plate is connected to an outer housing of the lead screw, the lead screw passes through the upper connecting plate, and the bottom end of the lead screw is located inside the outer housing of the lead screw.

4. The intelligent control device for the tension of the load-bearing cable of a freight cableway according to claim 3, characterized in that: The lower end of the outer housing of the lead screw is provided with a housing fixing base flange, and the lower end of the housing fixing base flange is connected to the device base.

5. The intelligent control device for the tension of the load-bearing cable of a freight cableway according to claim 1, characterized in that: The motor shaft housing is connected to the reducer via a servo motor flange.

6. The intelligent control device for the tension of the load-bearing cable of a freight cableway according to claim 1, characterized in that: The motor shaft housing contains a motor shaft, which is connected to the reducer.

7. The intelligent control device for the tension of the load-bearing cable of a freight cableway according to claim 6, characterized in that: A worm gear is mounted on the motor shaft, and a worm wheel is mounted on the outer side of the ball screw pair. The worm wheel and the worm gear are connected to each other.

8. The intelligent control device for the tension of the load-bearing cable of a freight cableway according to claim 1, characterized in that: The ball screw drive housing contains bearings.

9. The intelligent control device for the tension of the load-bearing cable of a freight cableway according to claim 8, characterized in that: The ball screw assembly is connected to the bearings at both ends.

10. A method of using an intelligent control device for the tension of a freight cableway bearing cable as described in any one of claims 1-9, characterized in that, Includes the following steps: S1. Equipment initialization and parameter configuration: Set PID control algorithm parameters. The PLC controller reads the zero point value of the column tension sensor and the initial position of the lead screw. After confirming that there is no fault, it enters the standby control mode. S2. Data acquisition: The column tension sensor detects the tension transmitted by the support cable through the guide roller in real time and feeds it back to the PLC controller; at the same time, the PLC controller calculates the linear displacement of the lead screw based on the rotation angle fed back by the servo motor, and calculates the extension and retraction of the support cable. S3. Tension deviation calculation: The PLC controller calculates the deviation between the target tension value and the actual tension value fed back by the column tension sensor. The PID control algorithm generates a control signal for adjusting the tension of the load-bearing cable. S4. Adjust the tension of the load-bearing cable. The PLC controller outputs the control signal from the PID control algorithm to the servo motor, which drives the lead screw to move the guide roller, thereby changing the length of the load-bearing cable and completing the tension adjustment of the load-bearing cable. S5. Dynamic Judgment: During the adjustment process, the PLC controller continuously compares the actual tension value detected by the column tension sensor with the theoretical tension value corresponding to the extension and contraction of the bearing cable calculated based on the screw displacement fed back by the servo motor. When the difference between the two exceeds 0.2% of the rated working tension, the PLC controller performs zero-point calibration of the column tension sensor. When the tension fluctuation detected by the column tension sensor does not exceed 0.14% of the rated working tension within 500 milliseconds, the PLC controller determines that the current tension is in a steady state and then pauses the output of commands.

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