Device for indirectly measuring tension of steel wire rope through pressure sensor

Abstract

The utility model discloses a device for indirectly measuring tension of a steel wire rope by a pressure sensor, which relates to the technical field of tension measurement and comprises a guide wheel component fixed between the bottom of a roller of an elevator and a lifting container, the pressure sensor mounted on the guide wheel component and a control system in signal connection with the pressure sensor. The guide wheel assembly comprises a mounting frame for fixing and a rotating shaft rotationally mounted on the mounting frame, and a guide wheel is fixedly mounted on the rotating shaft; a rope groove is formed in the wheel surface of the guide wheel; the steel wire rope is clamped in the rope groove and forms a certain wrap angle with the guide wheel; a pressure sensor is embedded in the rope groove, and when the steel wire rope ascends and descends, the steel wire rope can abut against the pressure sensor. Due to rotation of the guide wheel, real-time monitoring and measurement of the steel wire rope are achieved, and accidents are prevented; the steel wire rope is clamped in the rope groove and can stably contact with the pressure sensor, so that accurate measurement is realized. And during maintenance, only the pressure sensor needs to be detached and replaced, so that the maintenance cost and the maintenance difficulty of the equipment are reduced.

Description

Technical Field

[0001] This utility model relates to the field of tension measurement technology, and in particular to a device for indirectly measuring the tension of a steel wire rope using a pressure sensor. Background Technology

[0002] Excessive tension difference in wire ropes is a key factor that can cause major accidents such as wire rope slippage, rope derailment, and rope breakage in hoists. Therefore, accurate measurement of wire rope tension is crucial for ensuring mine safety.

[0003] Traditional wire rope tension measurement techniques have several drawbacks. For example, when using a force gauge, it is typically installed at the connection point of the hoisting container or on the wire rope to directly measure the tension of each wire rope. However, the harsh environment of mines, with its dust, high temperatures, and vibrations, can easily lead to sensor failure or reduced accuracy. Another method involves calculating rope tension by installing a torque sensor on a drum and combining it with the rotational speed, but this method requires complex mathematical models for calibration, resulting in significant measurement errors. Utility Model Content

[0004] The purpose of this invention is to provide a device for indirectly measuring wire rope tension using a pressure sensor, enabling real-time and accurate measurement of wire rope tension while reducing equipment maintenance costs and facilitating measurement operations.

[0005] To achieve the above objectives, this utility model provides a device for indirectly measuring wire rope tension using a pressure sensor. The device includes a guide wheel assembly fixed between the bottom of a hoist drum and a hoisting container, a pressure sensor mounted on the guide wheel assembly, and a control system connected to the pressure sensor signal. The guide wheel assembly includes a mounting bracket for fixing and a rotating shaft rotatably mounted on the mounting bracket. A guide wheel is fixedly mounted on the rotating shaft. A rope groove is provided on the surface of the guide wheel. The wire rope is inserted into the rope groove and forms a certain wrap angle with the guide wheel. A pressure sensor is embedded in the rope groove, and when the wire rope is raised or lowered, it can abut against the pressure sensor.

[0006] With the above structure, the rotation of the guide wheel enables real-time monitoring and measurement of the wire rope, preventing accidents. The wire rope, secured in the rope groove, maintains stable contact with the pressure sensor, ensuring accurate measurement. During maintenance, only the pressure sensor needs to be removed and replaced, reducing equipment maintenance costs and simplifying repairs.

[0007] Preferably, multiple pressure sensors are evenly arranged on the surface of the guide wheel, forming a ring array. This structure enables multi-source data complementarity, collecting circumferential stress data through the ring-distributed sensor array, avoiding measurement deviations caused by localized stress concentration (such as uneven wear or contact) from single-point sensors. Furthermore, the ring layout provides multi-path data support; even if some sensors fail (e.g., two sensors are damaged), the measurement value can still be reconstructed from the remaining sensors, preventing system failure.

[0008] Preferably, the wrap angle is 90° to 150°. This structural design balances measurement accuracy, friction requirements, and space constraints.

[0009] Preferably, when multiple wire ropes are arranged side by side on the lifting container, one guide wheel is installed for each wire rope. This structure allows for the measurement of each wire rope.

[0010] Preferably, multiple sets of guide wheels are fixedly mounted on the same rotating shaft. This structural design improves the integration of the device.

[0011] Preferably, multiple sets of guide wheels are fixedly mounted on different rotating shafts, and each rotating shaft is rotatably mounted on an independent mounting bracket. This structural arrangement allows for accurate measurement of the tension in each wire rope, avoiding discrepancies in measurement results caused by varying initial tensions.

[0012] Preferably, the mounting bracket is slidably mounted on the shaft sidewall with upper and lower limits. A drive device is also installed on the shaft sidewall, which drives the mounting bracket to slide up and down. The drive device is connected to the control system via a signal connection. This structure allows for fine-tuning of the guide wheel's vertical position, thereby balancing the initial tension differences between different wire ropes.

[0013] Preferably, the mounting bracket is fixedly mounted on a hydraulic frame. The hydraulic frame includes a fixed frame fixed to the sidewall of the shaft and a sliding frame that slides vertically on the fixed frame. The drive device includes a hydraulic device installed between the fixed frame and the sliding frame, which drives the sliding frame to slide vertically along the fixed frame. The mounting bracket is fixed on the sliding frame. This structure enables automated control of the guide wheel's vertical position, facilitating debugging.

[0014] Preferably, the bottom of the rope groove has a recess, in which a pressure sensor is embedded; a fixing base for pressing the pressure sensor into the recess is fixedly installed on the side wall of the rope groove. This structure enables quick fixing and disassembly of the pressure sensor, reducing the difficulty of assembly and disassembly.

[0015] After adopting the above technical solution, the beneficial effects of this utility model are:

[0016] This invention relates to a device for indirectly measuring wire rope tension using a pressure sensor. This device solves the technical problem in the prior art that wire rope tension cannot be measured in real time and accurately. This invention enables real-time and accurate measurement of wire rope tension, while reducing equipment maintenance costs and facilitating measurement operations. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of a pressure sensor device for indirectly measuring the tension of a steel wire rope according to this utility model;

[0018] Figure 2 This is a schematic diagram of the structure in Embodiment 2, in which all the guide wheels are fixed on the same axle;

[0019] Figure 3 This is a schematic diagram of the installation structure of the pressure sensor;

[0020] Figure 4 This is a side view of the hydraulic frame and guide wheel assembly during installation;

[0021] Figure 5 yes Figure 4 Isometric view;

[0022] Figure 6 This is a schematic diagram of the guide wheel assembly;

[0023] Figure 7 This is a structural schematic diagram of the hydraulic frame.

[0024] In the diagram, 1. Hoisting drum, 2. Hoisting container, 3. Guide wheel assembly, 31. Mounting frame, 32. Rotary shaft, 33. Guide wheel, 34. Hydraulic frame, 341. Fixed frame, 342. Sliding frame, 35. Drive device, 4. Pressure sensor, 41. Fixed base, 411. Arc plate, 412. Baffle, 5. Wire rope. Detailed Implementation

[0025] The present invention will be further described below with reference to the accompanying drawings.

[0026] The orientations mentioned in this specification are based on the orientation of the device for indirectly measuring wire rope tension by a pressure sensor under normal operation. They do not limit the orientation during storage and transportation, but only represent relative positional relationships, not absolute positional relationships.

[0027] Example 1:

[0028] like Figures 1-3 As shown, a device for indirectly measuring wire rope tension using a pressure sensor includes a guide wheel assembly 3 fixed between the bottom of a hoist drum 1 and a hoisting container 2, a pressure sensor 4 mounted on the guide wheel assembly 3, and a control system that is signal-connected to the pressure sensor 4.

[0029] The guide wheel assembly 3 includes a mounting bracket 31 for fixing and a rotating shaft 32 rotatably mounted on the mounting bracket 31. A guide wheel 33 is fixedly mounted on the rotating shaft 32. A rope groove is provided on the wheel surface of the guide wheel 33, and the wire rope 5 is inserted into the rope groove and forms a certain wrap angle with the guide wheel 33. A pressure sensor 4 is embedded in the rope groove, and the wire rope 5 can abut against the pressure sensor 4 when it is raised or lowered.

[0030] A groove is provided at the bottom of the rope groove, and a pressure sensor 4 is embedded in the groove. In this embodiment, the pressure sensor 4 is a thin-film pressure sensor. To prevent the pressure sensor 4 from falling out, a fixing base 41 is provided on the side wall of the rope groove and fixed with bolts. The fixing base 41 includes an arc-shaped plate 411 covering the outside of the side wall of the rope groove and a baffle 412 provided on one side of the arc-shaped plate 411 and extending towards the bottom of the rope groove. The baffle 412 abuts against the pressure sensor 4 and presses the pressure sensor 4 firmly into the groove to prevent it from falling out. The arc-shaped plate 411 is fixed to the side wall of the rope groove with bolts; there are two fixing bases 41, located on the two side walls of the rope groove respectively.

[0031] Preferably, multiple sets of pressure sensors 4 are evenly arranged on the surface of the guide wheel 33, and the multiple sets of pressure sensors 4 form a ring array. In this embodiment, four sets of pressure sensors 4 are provided. In practical applications, three or five sets can also be designed. This embodiment does not limit this.

[0032] The setup of multiple pressure sensors 4 ensures that even if some sensors fail (e.g., two are damaged), the remaining sensors can still provide effective measurements. As the guide wheel 33 rotates with the lifting container 2 connected to the wire rope 5, the pressure sensors 4 also rotate. Each pressure sensor 4 can collect the normal force exerted on the wire rope 5 by the groove of the guide wheel 33. After the wire rope 5 contacts the pressure sensor 4, the pressure signal is transmitted to the receiving device and then wirelessly to the control system. After processing the data, the control system converts the normal force between the groove of the guide wheel 33 and the wire rope 5 into the tension of the wire rope 5, thus completing the real-time measurement of the wire rope 5 tension. Based on the measured tension, the control system adjusts the tension of the wire rope 5, effectively reducing overload breakage and uneven wear of the wire rope 5, significantly reducing material loss.

[0033] This device enables real-time monitoring of wire rope tension, preventing accidents and solving the problem of real-time measurement limitations compared to mechanical force gauges. Furthermore, in terms of accuracy and stability, it employs an error dispersion and suppression approach, which involves two aspects: 1. Multi-source data complementarity: A ring-shaped sensor array collects circumferential stress data, avoiding measurement deviations caused by localized stress concentration (such as uneven wear or contact) from single-point sensors. 2. The ring layout provides multi-path data support; even if some sensors fail (e.g., two sensors are damaged), the measurement value can still be reconstructed from the remaining sensors, preventing system failure.

[0034] Because a larger wrap angle leads to more concentrated bending stress and accelerates fatigue, while a smaller wrap angle results in insufficient friction and slippage, the preferred wrap angle in this embodiment is 90° to 150°. In this embodiment, 90° is preferred, as this wrap angle balances measurement accuracy, friction requirements, and space constraints. In practical applications, the wrap angle can be reasonably selected based on measurement accuracy, friction requirements, and space constraints. The wrap angle size can be controlled by adjusting the installation position of the guide wheel assembly 3. Operators can select a reasonable wrap angle size and the installation position of the guide wheel assembly 3 after multiple adjustments based on experience.

[0035] Example 2:

[0036] Because the types of lifting containers 2 are different, the number of steel wire ropes 5 connected to each lifting container 2 is also different. In this embodiment, four steel wire ropes 5 are provided. In order to improve the integration of the device, when multiple steel wire ropes 5 are arranged side by side on the lifting container 2 in this embodiment, a guide wheel 33 is provided for each steel wire rope 5 in order to realize the measurement of each steel wire rope 5.

[0037] In this embodiment, to simplify the device, multiple sets of guide wheels 33 are fixedly installed on the same rotating shaft 32, which is fixed on the same mounting bracket 31.

[0038] Example 3:

[0039] picture Figures 4-7 As shown, to accommodate non-uniform tension adjustments and to facilitate debugging by adjusting the installation position of the guide wheels 33 according to the tension of different wire ropes 5, this embodiment differs from Embodiment Two in that multiple sets of guide wheels 33 are fixedly mounted on different rotating shafts 32 in this embodiment, and each rotating shaft 32 is rotatably mounted on an independent mounting bracket 31. This structural arrangement facilitates the adjustment of the tension of different wire ropes 5.

[0040] In this embodiment, the tension adjustment method of the different wire ropes 5 is as follows: the mounting frame 31 is slidably mounted on the side wall of the shaft with upper and lower limits, and a driving device 35 is also provided on the side wall of the shaft. The driving device 35 drives the mounting frame 31 to slide up and down.

[0041] The specific sliding installation method is as follows: the mounting frame 31 is fixedly installed on the hydraulic frame 34. The hydraulic frame 34 includes a fixed frame 341 fixed to the side wall of the wellbore and a sliding frame 342 slidably installed on the fixed frame 341. The fixed frame 341 is provided with a slide rail for the sliding frame 342 to slide up and down, and the sliding frame 342 is slidably installed in the slide rail. In this embodiment, the drive device 35 includes a hydraulic device installed between the fixed frame 341 and the sliding frame 342. The hydraulic device is a hydraulic cylinder, and its fixed end and output end are fixed to the fixed frame 341 and the sliding frame 342, respectively. Through the extension and retraction of the hydraulic cylinder, the sliding frame 342 slides up and down along the fixed frame 341; the mounting frame 31 is fixed on the sliding frame 342. In order to achieve the normal operation of the hydraulic cylinder, the hydraulic device is equipped with a hydraulic system to provide a stable pressure oil source for the hydraulic cylinder. The drive device 35 is connected to the control system. The operation of the hydraulic device is controlled by the control system.

[0042] During installation and commissioning, the initial tension of multiple wire ropes 5 may vary due to various reasons. If all guide wheels 33 are installed on the same mounting frame 31, all guide wheels 33 will rise and fall synchronously during adjustment, which is not conducive to balancing the tension differences between different wire ropes. In this embodiment, each guide wheel 33 is installed on a different mounting frame 31, which facilitates individual adjustment to select the most suitable wrap angle and make the measurement data more accurate. Of course, to facilitate automated adjustment, this embodiment uses a hydraulic system to drive a hydraulic cylinder for adjustment. Alternatively, manual adjustment can be used, such as by rotating a lead screw and lead screw nut. A rotating lead screw can be rotatably installed on a fixed frame 341, and a lead screw nut can be installed on the rotating lead screw to fix it to a sliding frame 342. Rotating the rotating lead screw drives the sliding frame 342 to rise and fall. After adjustment, the position can be locked by locking the position of the rotating lead screw.

[0043] By adjusting the position of the guide wheel 33 corresponding to different wire ropes 5, the tension of the wire ropes 5 can be finely adjusted so that the tension of each wire rope 5 is consistent, thereby ensuring that the tension can be adjusted according to the measurement structure during subsequent normal measurements.

[0044] Of course, the above description is not intended to limit the present utility model, and the present utility model is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the present utility model should also fall within the protection scope of the present utility model.

Claims

1. A device for indirectly measuring the tension of a steel wire rope using a pressure sensor, characterized in that: The system includes a guide wheel assembly fixed between the bottom of the elevator drum and the elevator container, a pressure sensor mounted on the guide wheel assembly, and a control system connected to the pressure sensor signal. The guide wheel assembly includes a mounting bracket for fixing and a rotating shaft rotatably mounted on the mounting bracket. A guide wheel is fixedly mounted on the rotating shaft. A rope groove is provided on the surface of the guide wheel. The wire rope is clamped in the rope groove and forms a certain wrap angle with the guide wheel. The pressure sensor is embedded in the rope groove, and when the wire rope is raised or lowered, it can rest against the pressure sensor.

2. The device for indirectly measuring wire rope tension using a pressure sensor according to claim 1, characterized in that: Multiple sets of pressure sensors are evenly arranged on the surface of the guide wheel, and the multiple sets of pressure sensors form a ring array.

3. The device for indirectly measuring wire rope tension using a pressure sensor according to claim 1, characterized in that: The angle of the wrap angle is 90° to 150°.

4. The device for indirectly measuring wire rope tension using a pressure sensor according to claim 1, characterized in that: When multiple steel wire ropes are arranged side by side on the lifting container, one guide wheel is provided for each steel wire rope.

5. The device for indirectly measuring wire rope tension using a pressure sensor according to claim 4, characterized in that: Multiple sets of guide wheels are fixedly installed on the same rotating shaft.

6. The device for indirectly measuring wire rope tension using a pressure sensor according to claim 4, characterized in that: Multiple sets of guide wheels are fixedly mounted on different rotating shafts, and each rotating shaft is rotatably mounted on an independent mounting bracket.

7. The device for indirectly measuring wire rope tension using a pressure sensor according to claim 6, characterized in that: The mounting bracket is slidably mounted on the side wall of the wellbore with upper and lower limits. A driving device is also provided on the side wall of the wellbore. The driving device drives the mounting bracket to slide up and down. The driving device is signal-connected to the control system.

8. The device for indirectly measuring wire rope tension using a pressure sensor according to claim 7, characterized in that: The mounting bracket is fixedly mounted on the hydraulic frame. The hydraulic frame includes a fixed frame fixed to the side wall of the shaft and a sliding frame that is slidably mounted on the fixed frame. The driving device includes a hydraulic device installed between the fixed frame and the sliding frame. The hydraulic device drives the sliding frame to slide up and down along the fixed frame. The mounting bracket is fixed to the sliding bracket.

9. The device for indirectly measuring wire rope tension using a pressure sensor according to claim 1, characterized in that: The bottom of the rope groove is provided with a groove, and the pressure sensor is embedded in the groove; a fixing base for pressing the pressure sensor into the groove is fixedly installed on the side wall of the rope groove.

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