Winding cable anomaly detection device based on ultrasonic ranging

Abstract

The utility model relates to the technical field of measurement and testing, in particular to metering equipment which is characterized by adopting infrasonic wave, acoustic wave and ultrasonic vibration. According to the technical scheme, the cable winding anomaly detection device based on ultrasonic ranging comprises a switch assembly and ultrasonic detection devices, the ultrasonic detection devices are located at the two ends of a cable reel in the running direction, and each ultrasonic detection device comprises an ultrasonic sensor and a driving mechanism; the driving mechanism drives the ultrasonic sensor to rotate through the rotating holder mechanism, and the switch assembly comprises a pressure switch and an over-loose and over-tight limiting switch. The problems of complex structure, low accuracy and slow response speed in the prior art are solved, and the purposes of high accuracy, good reliability, long service life, low cost and multiple protection mechanisms are achieved.

Description

Technical Field

[0001] The utility model relates to the technical field of measurement and testing, in particular to a measuring device characterized by adopting infrasonic waves, sound waves and ultrasonic vibrations. Background Art

[0002] Currently, some large rail-mounted mobile equipment, such as bucket wheel excavators, ship loaders, and cranes, primarily relies on cable reels for power supply. As the equipment moves along the tracks toward the power supply point, the cable reel rotates using its own motor, winding the excess cable onto the reel layer by layer. As the equipment moves away from the power supply point, the layers of cable are pulled from the reel by tension and deposited into cable troughs parallel to the tracks. As the equipment reciprocates, the reel repeats this process of winding and unwinding the cable. However, during this repeated tightening, the cable reel can become over-tightened or under-tightened, and in severe cases, can even break the high-voltage cable, leading to serious safety incidents. Currently, the reel relies on built-in limit switches for over-tightening and under-tightening, as well as manual inspections of the cable reel. However, due to limitations in installation location and limit switches, false alarms or the absence of alarm signals can occasionally lead to cable breakage or cable slipping off the cable reel. Manual inspections cannot cover the entire operating time and detect abnormalities in real time. For example, Chinese Patent Publication No. CN113252781B discloses an ultrasonic automatic detection device and a method for detecting internal cable damage. The technical solution is as follows: The present invention discloses an ultrasonic automatic detection device and a method for detecting internal cable damage. The inspection device includes an ultrasonic detection module and a robotic arm movement device. The ultrasonic detection module includes a pressure sensor, a first connecting plate, a hydraulic expansion tube, a second connecting plate, a distance sensor, and an ultrasonic transceiver. The first connecting plate is mounted at the end of the robotic arm movement device via a pressure sensor. The second connecting plate is connected to the first connecting plate via multiple hydraulic expansion tubes. The hydraulic expansion tubes are evenly spaced along the circumference of the axis of the first connecting plate. A helical restricting layer is provided in the sidewalls of the hydraulic expansion tubes. Each hydraulic expansion tube is connected to a hydraulic source and can independently control the filling and discharge of fluid. An ultrasonic transceiver and multiple distance sensors are mounted on the outer side of the second connecting plate. The range-finding sensors are evenly distributed along the circumference of the ultrasonic transceiver. This invention enables automated inspection of flexible structures, eliminating the need for manual operation of the ultrasonic detection device and effectively improving work efficiency. However, the aforementioned automatic ultrasonic inspection device and method for detecting internal cable damage suffer from low anomaly detection accuracy, lack multiple protection mechanisms, and are complex and costly. Utility Model Content

[0003] The utility model solves the problem of complex structure, low accuracy and slow response speed in the prior art, and achieves the purposes of high accuracy, good reliability, long service life, low cost and multiple protection mechanisms.

[0004] To achieve the above object, the utility model adopts the following technical scheme:

[0005] A kind of cable winding abnormality detection device based on ultrasonic ranging, including cable reel and cable guiding device, further including switch component and ultrasonic detection device, the ultrasonic detection device is located at the both ends of the cable reel operating direction, the ultrasonic detection device includes ultrasonic sensor and drive mechanism, the drive mechanism is rotated by rotating turret mechanism and drives the ultrasonic sensor rotation, the switch component includes pressure switch and over-tightness limit switch.

[0006] The advantage of such design is that it can achieve double-end comprehensive monitoring and accurate control, improve the accuracy of detection and overall reliability.

[0007] Preferably, the rotating turret mechanism includes rotating turret and rotating support, the ultrasonic sensor is fixed on the rotating support, the rotating support is rotatably connected with the rotating turret, and the rotating turret includes bearing and rotating turret gear.

[0008] The advantage of such design is that it ensures that the ultrasonic sensor can rotate stably and flexibly, improves the detection range and response speed.

[0009] Preferably, the drive mechanism includes drive motor and drive gear, the drive gear is driven by the drive motor and engaged with the rotating turret gear.

[0010] The advantage of such design is that it realizes accurate control of the drive mechanism, ensures the stability and synchronization of sensor rotation.

[0011] Preferably, the bearing outside is connected with encoder assembly through mounting flange, the encoder assembly includes encoder support and shaft coupling connected with the mounting flange, and encoder.

[0012] The advantage of such design is that it provides accurate rotation position feedback, enhances the overall monitoring accuracy and control ability.

[0013] Preferably, the over-tightness limit switch is arranged on the cable guiding device, and the pressure switch is arranged below the cable guiding device and on the left and right sides.

[0014] The advantage of such design is that the arrangement position of the switch is optimized, and the redundancy configuration can ensure that the protection mechanism is triggered in time in different situations, thereby improving the overall safety.

[0015] Preferably, an encoder protective cover is arranged outside the encoder assembly, and the coupling is connected to the encoder support at one end and to the encoder at the other end.

[0016] The advantage of such design is that the encoder assembly is protected from external environment interference and damage, thereby prolonging the service life of the equipment.

[0017] Preferably, a sensor protective cover is arranged outside the ultrasonic sensor.

[0018] The advantage of such design is that the sensor is prevented from being mechanically damaged and affected by environmental factors, thereby ensuring the stability and reliability of detection.

[0019] Preferably, the bearing is fixed on a bearing support, the bearing support is mounted on a bottom plate, the driving motor is fixed on a motor support, and the motor support is mounted on the bottom plate.

[0020] The advantage of such design is that the stable installation of each component is ensured, the error caused by vibration and displacement is reduced, and the overall stability and durability are improved.

[0021] Compared with the prior art, the utility model has the beneficial effects that.

[0022] 1. The utility model combines pressure sensor and over-tight and over-loose limit switches to form a multiple detection and protection system. The pressure sensor is arranged on both sides of the drum guide device and can detect the pressure of the cable on the cable guide device on the guide frame in real time. The limit switch works cooperatively to ensure that the whole can respond quickly and take measures when abnormal stress occurs. Such redundant design not only improves the overall reliability, but also effectively prolongs the service life of the cable and the drum, and prevents major safety accidents caused by failure of a single protection device.

[0023] 2. The utility model is equipped with left and right ultrasonic sensors, which can monitor the position and deformation of the cable in the reel in real time and accurately. Through the accurate control of the rotating pan-tilt mechanism and the stepping motor, the sensor can scan comprehensively within the set angle range, ensuring that abnormal conditions such as over-tight or over-loose can be captured in time. Compared with the traditional limit switch, the technology reduces the possibility of false positives and false negatives, greatly improves the accuracy and response speed of detection, and provides reliable protection for the safe operation of the equipment. BRIEF DESCRIPTION OF DRAWINGS

[0024] Figure 1 It is an isometric view of the ultrasonic detection device of the utility model.

[0025] Figure 2 It is the front view of the ultrasonic detection device of the utility model.

[0026] Figure 3 It is the sectional view of the ultrasonic detection device of the utility model.

[0027] Figure 4 It is the structural schematic view of the cable reel and cable guiding device in one embodiment of the utility model.

[0028] Illustration: 1 ultrasonic sensor, 2 rotating holder mechanism, 2.1 rotating support, 2.2 rotating holder gear, 2.3 bearing, 3.1 drive gear, 3.2 drive motor, 4 encoder assembly, 5 bottom plate, 6 cable reel, 7 cable guiding device, 8.1 pressure switch, 8.2 too loose too tight limit switch, 8.3 guider. DETAILED DESCRIPTION

[0029] In order to make the purpose, technical scheme and advantages of the present disclosure more clear, the following will combine the drawings to make further detailed description to the embodiments of the present disclosure. The proportion of each component is not drawn according to the true proportion, the proportion and size shown in the drawings should not limit the essential technical scheme of the utility model, these embodiments do not describe all the details, and the utility model is not limited to the specific embodiments described.

[0030] Referring to Figures 1-4 As shown in the figure, a cable winding abnormality detection device based on ultrasonic ranging includes a cable reel and a cable guiding device, further includes a switch assembly and an ultrasonic detection device, the ultrasonic detection device is located at both ends of the running direction of the cable reel, the ultrasonic detection device includes an ultrasonic sensor and a driving mechanism, the driving mechanism drives the ultrasonic sensor to rotate through a rotating holder mechanism, and the switch assembly includes a pressure switch and a too loose too tight limit switch.

[0031] As Figure 1 shown in one embodiment, Figure 1The utility model discloses an isometric view of ultrasonic detection device. The utility model discloses a kind of cable winding abnormality detection device based on ultrasonic ranging, including cable reel and cable guiding device, and further configured switch component and ultrasonic detection device.Ultrasonic detection device is arranged at the both ends of the operating direction of cable reel, to ensure that abnormal situation in the process of winding cable is monitored in all directions.Ultrasonic detection device is composed of ultrasonic sensor and driving mechanism, wherein driving mechanism rotates ultrasonic sensor and drives rotating operation by rotating turret mechanism.Rotating turret mechanism includes rotating turret and rotating support, ultrasonic sensor is fixed on rotating support, rotating support is connected with rotating turret, and flexible rotating motion can be realized.In addition, ultrasonic sensor is equipped with sensor protective cover outside, for protecting sensor from interference and mechanical damage of external environment.

[0032] Switch component includes pressure switch and over-tightness limit switch, is responsible for detecting cable over-tightness in the process of winding cable and cable winding or loosening state respectively.When cable is tightened to over-tightness state on reel, pressure switch can sense the pressure change of both sides of guiding device in real time, ensure that alarm signal can be sent in time when cable is over-tightness abnormal stress.Meanwhile, over-tightness limit switch is set on the upper portion of cable guiding device, when winding cable is too tight or too loose, limit switch can respond quickly and trigger corresponding protection mechanism, prevent cable from breaking or sliding out of reel, guarantee the safe operation of equipment.

[0033] The design of the utility model has multiple protection mechanisms, first, by arranging ultrasonic sensor at both ends of cable reel, the position and deformation of cable can be monitored comprehensively and accurately.Ultrasonic sensor can not only measure the distance between cable and reel in real time, but also can cover larger detection area through flexible rotation of rotating turret mechanism, greatly improve the accuracy and response speed of detection.Secondly, combined with the use of pressure switch and limit switch, a double-insurance protection system is formed.When cable appears abnormal stress on reel, pressure switch can immediately feedback the pressure change of both sides of guiding device, while limit switch triggers protection mechanism when cable winding or loosening exceeds the set range, ensure that system can respond quickly under various abnormal conditions, prevent potential safety hazard.

[0034] In addition, the protective cover outside the ultrasonic sensor is designed, further enhancing the durability and reliability of the sensor. In the actual application environment, the cable reel may be affected by various adverse factors such as dust, moisture, mechanical impact, etc. The sensor protection cover can effectively isolate these disturbances, prolong the service life of the sensor, and ensure its long-term stable operation. The precise cooperation of the rotating holder and the driving motor ensures that the sensor can rotate smoothly within the set angle range, achieving efficient detection coverage, improving the detection capability of the system, reducing the frequency of maintenance and calibration, and reducing the overall operation and maintenance cost.

[0035] The utility model discloses in the cable winding abnormality detection field and shows the remarkable technical advantage: adopt ultrasonic ranging technology, realized the real-time, accurate detection of the cable reel state, greatly improved the reliability and response speed of detection, double switch protection mechanism, ensure that the system can take protective measures quickly when cable stress is abnormal or the winding state is abnormal, prevent cable breakage or slip out, guarantee equipment safe operation, the application of sensor protection cover and rotating holder mechanism not only improves the durability and detection range of sensor, but also optimizes the protection performance and flexibility of overall structure, the automation design of system greatly reduces the dependence on artificial inspection, reduces the labor cost, and through real-time monitoring and alarm function, further improve the intelligent level and management efficiency of equipment operation.

[0036] As shown in one embodiment of Figure 2 With Figure 3 As shown in one embodiment of Figure 2 It is the front view of the ultrasonic detection device of the utility model. Figure 3 It is the section view of the ultrasonic detection device of the utility model. The utility model discloses a kind of cable winding abnormality detection device based on ultrasonic ranging, to effectively monitor the operating state of cable reel, timely detect and early warning abnormal situation of cable in the process of winding cable, ensure the safe operation of cable in the track movement process of large mechanical equipment such as bucket wheel machine, ship loader, crane etc. Mainly include cable reel, cable guide device, switch component and ultrasonic detection device four core parts, wherein ultrasonic detection device is arranged at the both ends of cable reel operating direction, to realize the comprehensive monitoring of cable in the position of reel two sides. Ultrasonic detection device at each end includes ultrasonic sensor and driving mechanism, wherein driving mechanism rotates ultrasonic sensor and carries out rotating operation by rotating holder mechanism. Rotating holder mechanism is composed of rotating holder and rotating support, ultrasonic sensor is fixedly installed on rotating support, rotating support and rotating holder are tightly combined by rotatable connection, ensure that sensor can be flexibly rotated at different angles, cover more extensive detection range.

[0037] The rotating holder further comprises a bearing and a rotating holder gear, wherein the bearing is connected to the encoder assembly through a mounting flange, and the encoder assembly is composed of an encoder support, a shaft coupling and an encoder.

[0038] The driving mechanism comprises a driving motor and a driving gear, and the driving gear is driven by the driving motor and engaged with the rotating holder gear, so that stable rotation of the rotating holder mechanism is realized through precise gear transmission.

[0039] In addition, the ultrasonic sensor is externally provided with a sensor protection cover, which effectively prevents the sensor from being eroded by dust, moisture and mechanical impact in the actual application environment, ensures that the sensor is always in the best working state, and improves the overall detection reliability of the system.

[0040] The design of the device not only realizes comprehensive monitoring of both ends of the cable reel, but also ensures that the sensor can rotate flexibly within different angle ranges through the accurate feedback of the rotating holder mechanism and the encoder of the ultrasonic sensor, fully covers the detection area of the cable, and improves the accuracy and response speed of the detection.

[0041] The protection cover design of the ultrasonic sensor effectively protects the sensor body, avoids the influence of dust, moisture and mechanical impact on the performance of the sensor, and ensures long-term stable operation. The protection cover of the encoder assembly also protects the encoder, avoids damage from the external environment, and ensures the angle feedback accuracy of the rotating holder mechanism. These protection measures not only prolong the service life of the equipment, but also reduce the maintenance cost and improve the overall economic efficiency of the system.

[0042] The precise meshing of the drive motor and the pan-tilt head gears enables precise control of the pan-tilt head, enabling the ultrasonic sensor to efficiently scan and detect within the set angle range. The encoder provides real-time feedback on the pan-tilt head's angular position, enabling the system to accurately determine the cable's current status based on the sensor's detection data, promptly identifying anomalies and implementing appropriate protective measures. This design not only improves the real-time and accuracy of detection, but also reduces the need for human intervention, achieving an automated and efficient monitoring process.

[0043] The baseplate, the fundamental structure of the equipment, supports the bearing bracket and motor bracket, ensuring the stability and seismic resistance of the entire device. The stable baseplate mounting structure effectively reduces component displacement and loosening caused by vibration or external forces during operation, ensuring stable operation of the equipment under various complex operating conditions.

[0044] like Figure 4 In one embodiment shown, Figure 4 This is a schematic diagram of the cable reel and cable guide assembly in one embodiment of the present invention. The switch assembly consists of a pressure switch and over-tension limit switches. The over-tension limit switches are mounted on either side of the upper portion of the cable guide assembly, while the pressure switches are located on the left and right sides of the lower portion. In conventional designs, over-tension protection primarily relies on the guide assembly swinging left and right when the cable is over-tightened, triggering the over-tension limit switches to protect the cable reel. However, due to the guide assembly's short swing stroke, this approach struggles to ensure effective triggering of the over-tension limit switches. To address this issue, additional pressure switches are installed beneath the hard rubber on the left and right sides of the lower portion of the cable guide assembly to more reliably monitor over-tension conditions. When the cable is tightened, the pressure switches detect the force exerted by the cable on the hard rubber edge of the cable guide assembly. If the force exceeds a set value, the pressure switches immediately transmit an over-tension signal to the PLC. Based on the received signal, the PLC determines whether to interlock the bucket wheel excavator with a forward or reverse command, thereby preventing cable breakage due to excessive force.

[0045] The over-loose limit switch is primarily used to monitor the cable drum for excessive looseness. When the cable drum becomes loose, causing the cable to slip off the drum, the over-loose limit switch is triggered and issues an over-loose signal. This signal is then transmitted to the PLC, which determines whether to control the interlocking direction of the bucket wheel excavator to prevent equipment malfunctions caused by excessive cable looseness.

[0046] In an embodiment, the utility model discloses a kind of cable winding abnormal diagnosis devices based on ultrasonic ranging, mainly including two ultrasonic detection devices of two sides, pressure switch, over-tight limit switch, over-loose limit switch, PLC control system etc..The PLC control system refers to the PLC part of the full-automatic control system of bucket wheel machine, is used to analyze and process the data collected, and receives the instruction of host computer and automatically generates instruction, indicates the action control of each mechanism of bucket wheel machine and other related systems.

[0047] Ultrasonic detection device is arranged in the trolley before and after the cable drum respectively, for detecting cable drag deformation degree.

[0048] Ultrasonic detection device includes ultrasonic sensor, rotating cloud platform mechanism, drive motor, absolute value encoder and support etc.Mechanism.Ultrasonic sensor detects cable distance, and absolute value encoder detects rotating cloud platform rotation angle.Ultrasonic sensor, drive motor, absolute value encoder are connected to PLC, and cable distance, rotating cloud platform angle data are uploaded to PLC in real time.Drive motor receives PLC operation instruction, rotates rotating cloud platform mechanism through gear device, and drives ultrasonic sensor to reciprocate rotation between [0, alpha] (alpha is 0-90 DEG).Absolute value encoder is used to detect rotating cloud platform rotation angle, corresponding ultrasonic sensor rotation angle [0, alpha].

[0049] In the embodiment, drive motor uses step motor, and the motion range of step motor is obtained by debugging, and corresponds to rotating cloud platform rotation angle range 0~alpha.Under the control of PLC, drive motor drives rotating cloud platform to reciprocate rotation in 0~alpha range.

[0050] Under the current design, over-loose over-tight limit switch is installed on the both sides of the upper part of cable guiding device.Over-tight protection mainly triggers over-tight limit switch through left and right swing of guide when cable is over-tight to protect cable drum.But because the swing stroke of guide is short, it is difficult to guarantee that over-tight limit switch triggers well, and the utility model patent optimizes cable drum guide, and pressure switch is arranged below hard rubber on the left and right sides below cable guiding device to detect over-tight state.When cable is tensioned, pressure switch can detect the force applied to hard rubber of cable guiding device by cable.When detecting that force is too large, immediately provide over-tight signal and upload to PLC, and PLC judges interlock bucket wheel machine forward and backward instruction to prevent cable from being pulled off due to too large force.

[0051] Over-loose limit switch provides protection for cable drum over-loose alarm.When cable drum is loose and slides out of drum, over-loose limit signal triggers.Over-loose signal is transmitted to PLC, and PLC judges interlock bucket wheel machine forward and backward instruction to prevent cable loose from causing equipment operation failure.

[0052] In the embodiment, the working principle of the device is as follows: when the bucket wheel machine is running, according to the position and the running direction of the bucket wheel machine, the PLC activates the corresponding ultrasonic detection device as the current detection equipment; the movable carrier moves to the left, and the right ultrasonic ranging sensor is activated; conversely, the same is true. According to the debugging result, the PLC controls the driving motor to act, drives the rotating holder to reciprocate in [0, a], and the absolute value encoder and the ultrasonic sensor data are sent to the PLC in real time. The PLC selects the detection distances of three rotating holder angle (for example, 0, 45, 90 angle positions) detection points, and compares them with the preset normal distance range. If the detection distance exceeds the normal distance range, it is too large or too small, the winding drum state is judged to be abnormal, and the alarm and the PLC control system interlocking brake are generated. The normal distance range corresponds to the rotating holder angle, and the range value is determined as the preset range during debugging. The pressure sensor and the limit switch are used as redundant detection devices, and the winding cable abnormality is diagnosed.

[0053] The utility model is not limited to the above-mentioned embodiment, no matter makes any change in its shape or material composition, adopts the structure design provided by the utility model, is a deformation of the utility model, and all should be considered in the utility model protection scope.

Claims

1. A cable anomaly detection device based on ultrasonic ranging, characterized in that: The invention comprises a switch assembly and an ultrasonic detection device, wherein the ultrasonic detection device is located at both ends of the cable reel in the running direction, the ultrasonic detection device comprises an ultrasonic sensor (1) and a driving mechanism, the driving mechanism drives the ultrasonic sensor (1) to rotate via a rotating pan-tilt mechanism (2), and the switch assembly comprises a pressure switch (8.1) and an over-loose or over-tight limit switch (8.2).

2. The cable winding anomaly detection device based on ultrasonic ranging according to claim 1, characterized in that: The rotating platform mechanism (2) comprises a rotating platform and a rotating bracket (2.1); the ultrasonic sensor (1) is fixed on the rotating bracket (2.1); the rotating bracket (2.1) is rotatably connected to the rotating platform; and the rotating platform comprises a bearing (2.3) and a rotating platform gear (2.2).

3. The cable winding anomaly detection device based on ultrasonic ranging according to claim 2, characterized in that: The driving mechanism comprises a driving motor (3.2) and a driving gear (3.1); the driving gear (3.1) is driven by the driving motor (3.2) and meshes with the rotating pan-tilt head gear (2.2).

4. A cable abnormality detection device based on ultrasonic ranging according to claim 2 or 3, characterized in that: The outer side of the bearing (2.3) is connected to an encoder assembly (4) via a mounting flange. The encoder assembly (4) comprises an encoder bracket and a coupling connected to the mounting flange, as well as an encoder.

5. The cable winding anomaly detection device based on ultrasonic ranging according to claim 2 or 3, characterized in that: The over-loose or over-tight limit switch (8.2) is arranged on the cable guide device, and the pressure switch (8.1) is arranged on the left and right sides below the cable guide device.

6. The cable winding anomaly detection device based on ultrasonic ranging according to claim 4, characterized in that: An encoder protection cover is provided on the outside of the encoder assembly (4); one end of the coupling is connected to the encoder bracket, and the other end is connected to the encoder.

7. The cable winding anomaly detection device based on ultrasonic ranging according to claim 1, characterized in that: A sensor protection cover is provided outside the ultrasonic sensor (1).

8. The cable winding anomaly detection device based on ultrasonic ranging according to claim 3, characterized in that: The bearing (2.3) is fixed on a bearing bracket, which is mounted on a base plate (5); the drive motor (3.2) is fixed on a motor bracket, which is mounted on the base plate (5).

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