A wire rope derailment monitoring device
By combining magnetic and mechanical limit devices with a roller structure, the problem of false alarms caused by photoelectric limiters in harsh environments is solved, achieving high accuracy and stability in monitoring wire rope derailment.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- NANJING PORT MASCH & HEAVY IND MFG CO LTD
- Filing Date
- 2025-08-01
- Publication Date
- 2026-07-31
AI Technical Summary
Existing photoelectric limit devices are susceptible to foreign objects such as dust, oil, and natural light in harsh working environments, which can lead to false alarms and affect work efficiency.
The device employs both magnetic and mechanical limiting devices. Through rollers and a frame structure, it utilizes the lever principle to respond to the wire rope slippage, while combining magnetic attraction to maintain device stability, reduce external interference, and ensure monitoring accuracy.
The accuracy and stability of wire rope derailment monitoring have been improved in harsh environments, false alarms have been reduced, and the adaptability and monitoring accuracy of the device have been enhanced.
Smart Images
Figure CN224577935U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of monitoring device technology, specifically to a steel wire rope derailment monitoring device. Background Technology
[0002] The hoisting wire rope drum is a crucial component of a crane. One end of the wire rope is pressed against the drum by a wire rope pressure plate. The wire rope spirally winds around the drum along the rope grooves. The drum is driven by a motor to rotate, thus raising and lowering the wire rope. During the rotation of the drum, due to the stress on the wire rope, it may slack off or bounce, and may even jump out of its original rope groove—this is known as wire rope derailment. Wire rope derailment can cause damage to the wire rope, and if not detected in time, it can lead to more serious mechanical failures.
[0003] Currently, the common method for monitoring wire rope derailment involves installing a photoelectric limit device and a reflector below the wire rope drum. Under normal circumstances, the photoelectric limit device emits a laser, which is reflected by the reflector, and the received reflected signal indicates normal operation. When the wire rope derails, it blocks both the emitted and reflected laser light, and the photoelectric limit device fails to receive the reflected signal, indicating an abnormal condition and triggering an alarm to issue a shutdown command.
[0004] However, photoelectric limit switches have high requirements for the working environment. In harsh working environments, such as dust, oil stains, natural light and other foreign objects, the operation of photoelectric limit switches can be affected, leading to false alarms and affecting work efficiency. In actual use, they are quite inconvenient.
[0005] Therefore, there is an urgent need for a wire rope derailment monitoring device to solve the problem of monitoring wire rope derailment in harsh working environments. Utility Model Content
[0006] This invention addresses the shortcomings of existing technologies by providing a wire rope derailment monitoring device to solve the problem of monitoring wire rope derailment in harsh working environments.
[0007] To achieve the above objectives, the present invention adopts the following technical solution:
[0008] A wire rope derailment monitoring device includes a frame, a support, idlers, idler shafts, a counterweight, a limiting bracket, a magnetic limiting device, and a mechanical limiting device. The middle section of the frame is hinged to the support, and the front and rear ends of the frame can swing or rotate around the hinge. The front end of the frame is connected to an idler shaft parallel to the axial direction of the wire rope drum, and an idler is rotatably mounted on the idler shaft. A counterweight is installed at the rear end of the frame to keep the frame stationary. The magnetic limiting device and the mechanical limiting device are respectively installed below and above the rear end of the frame via the limiting bracket. The magnetic limiting device is used to magnetically connect to the lower side of the rear end of the frame when it is stationary. The idlers are used to be pushed downward by the derailed wire rope, and the mechanical limiting device is used to be triggered and send a signal by the corresponding upward movement of the rear end of the frame.
[0009] To optimize the above technical solution, the specific measures also include:
[0010] Furthermore, the frame includes a roller mounting frame, two connecting frames, and a counterweight mounting frame. The roller mounting frame is U-shaped, with its opening facing forward and used to connect the roller shaft. A connecting frame is symmetrically connected to the left and right sides of the rear end of the roller mounting frame. The connecting frame is symmetrically provided with hinge holes for hinged to the support. The rear ends of the two connecting frames are connected to a counterweight mounting frame, which is used to install the counterweight.
[0011] Furthermore, the limiting bracket includes a first limiting bracket and a second limiting bracket. The mechanical limiting device is detachably mounted on the second limiting bracket and located above the counterweight mounting frame. The magnetic limiting device is mounted on the first limiting bracket and is used for magnetic connection to the lower end of the counterweight mounting frame in a stationary state.
[0012] Furthermore, the mechanical limiting device is provided with mounting holes, and the mechanical limiting device is detachably fastened to the second limiting bracket by bolts passing through the mounting holes.
[0013] Furthermore, the second limiting bracket is disposed between the idler roller mounting frame and the counterweight mounting frame, and the probe of the mechanical limiting device is located above the counterweight mounting frame.
[0014] Furthermore, the magnetic limiting device and the mechanical limiting device are located at the middle of the counterweight mounting frame, and the counterweight is provided in two sets, which are respectively set on the left and right sides of the counterweight mounting frame.
[0015] Furthermore, the counterweight mounting frame has a positioning hole, and the counterweight has a vertical through hole. The counterweight is fastened to the counterweight mounting frame by bolts passing through the through hole and the positioning hole and with nuts.
[0016] Furthermore, it also includes a movable counterweight, which has a connecting hole corresponding to the through hole. The movable counterweight is used to pass through the connecting hole, the through hole, and the positioning hole with a bolt, and is installed on the counterweight with a nut.
[0017] Furthermore, the support includes two hinge seats and a support frame. The two hinge seats are respectively installed on the left and right sides of the upper end of the support frame. The left and right sides of the middle section of the frame are respectively hinged to the two hinge seats. There is a gap between the bolt shaft on the hinge seat and the bottom of the hinge seat, which allows the frame to swing back and forth or rotate.
[0018] Furthermore, the idler roller is configured as several small idler rollers, which are equally spaced on the idler roller shaft.
[0019] The beneficial effects of this utility model are:
[0020] This utility model device uses a frame hinged to the support as a lever structure, which facilitates the response of the ungrooved wire rope through the idler roller at its front end, and simultaneously drives the rear end to change displacement, thereby triggering the mechanical limit device to output a ungrooving signal; the magnetic limit device controls the overall stability of the frame by magnetic attraction, avoiding accidental activation of the mechanical limit device by shaking, and improving the accuracy of monitoring; the idler roller can rotate freely around its axis, so when the ungrooved wire rope contacts the idler roller, the idler roller is pressed down and rotates at the same time, thereby reducing wear on the wire rope.
[0021] This utility model device has a simple structure, easy-to-manufacture parts, and strong practicality; it is suitable for various working environments. It adopts a mechanical limit device to ensure monitoring accuracy and a magnetic limit device to increase overall stability, making the device less susceptible to external environmental interference and achieving a high accuracy rate for wire rope derailment alarm. Attached Figure Description
[0022] Figure 1 This is a schematic diagram illustrating the use of a wire rope derailment monitoring device proposed in this utility model;
[0023] Figure 2 This is a side view schematic diagram of a wire rope derailment monitoring device proposed in this utility model;
[0024] Figure 3 This is a top view schematic diagram of a wire rope derailment monitoring device proposed in this utility model;
[0025] Figure 4 This is a top view schematic diagram of the frame of a wire rope derailment monitoring device proposed in this utility model;
[0026] Figure 5 This is a side view of the frame of a wire rope derailment monitoring device proposed in this utility model;
[0027] Figure 6 This is a side view schematic diagram of the support for a wire rope derailment monitoring device proposed in this utility model;
[0028] Figure 7 This is a front view schematic diagram of the support for a wire rope derailment monitoring device proposed in this utility model;
[0029] Figure 8 This is a schematic diagram of the installation of the idler roller of the wire rope derailment monitoring device proposed in this utility model;
[0030] Figure 9 This is a schematic diagram showing the installation of the magnetic and mechanical limiting devices of a wire rope derailment monitoring device proposed in this utility model.
[0031] Figure 10 This is a side view of the limiting bracket of a wire rope derailment monitoring device proposed in this utility model.
[0032] Reference numerals: 1. Frame, 11. Idler roller mounting bracket, 12. Connecting bracket, 13. Hinge hole, 14. Counterweight mounting bracket, 2. Support, 21. Hinge seat, 22. Support frame, 3. Idler roller, 4. Idler roller shaft, 5. Limiting bracket, 6. Counterweight, 7. Movable counterweight, 8. Magnetic limiting device, 81. First limiting bracket, 9. Mechanical limiting device, 91. Second limiting bracket. Detailed Implementation
[0033] The present invention will now be described in detail with reference to the accompanying drawings.
[0034] As attached Figure 1 Appendix Figure 2 and attached Figure 3 As shown, an embodiment of the present invention provides a wire rope derailment monitoring device, comprising a frame 1, a support 2, an idler roller 3, an idler roller shaft 4, a counterweight 6, a limiting bracket 5, a magnetic limiting device 8, and a mechanical limiting device 9. The middle section of the frame 1 is hinged to the support 2. The front and rear ends of the frame 1 can swing or rotate around the hinge. The front end of the frame 1 is connected to an idler roller shaft 4 parallel to the axial direction of the wire rope drum. An idler roller 3 is rotatably mounted on the idler roller shaft 4. A counterweight 6 is installed at the rear end of the frame 1 to keep the frame 1 stationary. The magnetic limiting device 8 and the mechanical limiting device 9 are respectively installed below and above the rear end of the frame 1 via the limiting bracket 5. The magnetic limiting device 8 is used to magnetically connect to the lower side of the rear end of the frame 1 when it is stationary. The idler roller 3 is used to be pushed downward by the derailed wire rope. The mechanical limiting device 9 is used to be triggered by the corresponding upward movement of the rear end of the frame 1 and to send a signal.
[0035] This utility model device uses the frame 1, which is hinged to the support 2, as a lever structure. This allows the idler roller 3 at its front end to respond to the degrouted wire rope and simultaneously drive the rear end to change displacement, thereby triggering the mechanical limit device 9 to output a degrouted signal. The magnetic limit device 8 controls the overall stability of the frame 1 by magnetic attraction, preventing accidental activation of the mechanical limit device 9 due to shaking and improving the accuracy of monitoring. The idler roller 3 can rotate freely around the idler roller shaft 4. When the degrouted wire rope contacts the idler roller 3, the idler roller 3 is pressed down and rotates simultaneously, thereby reducing wear on the wire rope.
[0036] This utility model device has a simple structure, easy-to-manufacture parts, and strong practicality; it is suitable for various working environments. It adopts a mechanical limit device 9 to ensure monitoring accuracy and a magnetic limit device 8 to increase overall stability, making the device less susceptible to external environmental interference and achieving a high accuracy rate for wire rope derailment alarm.
[0037] In the above scheme, the material of the idler roller 3 can be polytetrafluoroethylene, and the main function of the counterweight 6 is to adjust the weight balance at both ends of the frame 1.
[0038] In use, the frame 1, roller 3, roller shaft 4 and counterweight 6 that can be kept stationary can be preset, and the corresponding magnetic limit device 8 can be set according to the preset size. After the mechanical limit device 9 is triggered by the corresponding upward movement of the rear end of the frame 1 and sends a signal, the PIC control unit can receive the signal and send an alarm message, or it can be directly connected to the alarm device to trigger an alarm. This method is a conventional technical method.
[0039] As attached Figure 4 and attached Figure 5 As shown, in a further specific embodiment based on the above, the frame 1 includes a roller mounting frame 11, two connecting frames 12, and a counterweight mounting frame 14. The roller mounting frame 11 is U-shaped, with its opening facing forward and used to connect the roller shaft 4. A connecting frame 12 is symmetrically connected to the left and right sides of the rear end of the roller mounting frame 11. The connecting frame 12 has symmetrically provided hinge holes 13 for hinged connection with the support 2. The rear ends of the two connecting frames 12 are connected to the counterweight mounting frame 14, which is used to install the counterweight 6. This simplifies the structure of the frame 1 while ensuring its reliability. In this design, stiffening ribs can be provided at the connections between the roller mounting frame 11, the two connecting frames 12, and the counterweight mounting frame 14 as needed to increase the structural strength.
[0040] As attached Figure 9 and attached Figure 10As shown, in a further specific embodiment based on the above, the limiting bracket 5 includes a first limiting bracket 81 and a second limiting bracket 91. The mechanical limiting device 9 is detachably installed on the second limiting bracket 91 and is located above the counterweight mounting frame 14. The magnetic limiting device 8 is installed on the first limiting bracket 81 and is used to magnetically connect to the lower end of the counterweight mounting frame 14 in a stationary state.
[0041] The aforementioned mechanical limiting device 9 is provided with mounting holes, and the mechanical limiting device 9 is detachably fastened to the second limiting bracket 91 by bolts passing through the mounting holes. In this solution, bolt holes can also be correspondingly provided on the second limiting bracket 91 for installing mechanical limiting devices 9 at different operating heights as needed.
[0042] The second limiting bracket 91 is positioned between the idler roller mounting frame 11 and the counterweight mounting frame 14, with the probe of the mechanical limiting device 9 located above the counterweight mounting frame 14. This improves the space utilization of the device structure during use, and the position of the probe of the mechanical limiting device 9 above the counterweight mounting frame 14 ensures its normal operation.
[0043] The magnetic limiting device 8 and mechanical limiting device 9 are located at the middle of the counterweight mounting frame 14. Two sets of counterweights 6 are provided, one on the left and one on the right. Therefore, during use, the magnetic limiting device 8 and mechanical limiting device 9 can directly monitor the middle section of the counterweight mounting frame 14 and respond to changes in its displacement, unaffected by the size of the counterweights 6 located on either side.
[0044] The counterweight mounting bracket 14 has positioning holes, and the counterweight 6 has vertical through holes. The counterweight 6 is bolted through the through holes and positioning holes and then fastened to the counterweight mounting bracket 14 with nuts. This facilitates the assembly and disassembly of the counterweight 6.
[0045] This includes a movable counterweight 7, which has a connecting hole corresponding to the through hole. The movable counterweight 7 is used to pass bolts through the connecting hole, through hole, and positioning hole, and is then fitted onto the counterweight 6 with a nut. Thus, movable counterweights 7 can be added as needed. In use, movable counterweights 7 and counterweight 6 with the same density but different thicknesses can be used as required, for example, movable counterweight 7 with a thickness of 4mm and counterweight 6 with a thickness of 80mm. The movable counterweight 7 is lightweight and serves a fine-tuning function; multiple pieces can be set as needed.
[0046] As attached Figure 6 and attached Figure 7As shown, in a further specific embodiment based on the above, the support 2 includes two hinge seats 21 and a support frame 22. The two hinge seats 21 are respectively installed on the left and right sides of the upper end of the support frame 22. The left and right sides of the middle section of the frame 1 are respectively hinged to the two hinge seats 21. There is a gap between the bolt shaft on the hinge seat 21 and the bottom of the hinge seat 21, allowing the frame 1 to swing back and forth or rotate. In the specific embodiment based on the above, the two hinge seats 21 can be respectively connected to the hinge holes 13 on the connecting frames 12 on both sides.
[0047] As attached Figure 8 As shown, in a further specific embodiment based on the above, the idler roller 3 is configured as several small idler rollers, which are evenly spaced on the idler roller shaft 4. This arrangement of small idler rollers facilitates manufacturing and installation, and at the same time, more effectively reduces friction and responds to situations where the wire rope in the rope groove at different positions derails.
[0048] In the above scheme, the magnetic limit device 8 can be a stainless steel cabinet door magnetic closure, and the mechanical limit device 9 can be a Schmersal Z4V7H-335-11Z limit device, or other devices that are suitable for this scheme.
[0049] One specific embodiment of the device of this utility model is as follows:
[0050] This device is installed below the wire rope drum. Adjustable counterweights 7 and 6 are installed as needed to ensure that the weights at both ends of the frame 1, which acts as a lever, are nearly balanced. The idler roller 3 is positioned less than 5mm from the bottom of the wire rope drum and will not interfere with the wire rope. The magnetic limit device 8 provides a small attraction force to ensure that the frame 1 will not shake on its own when the magnetic limit device 8 is in effect, and the magnetic attraction will immediately release when the idler roller 3 is lightly touched.
[0051] When the wire rope slackens or comes off the groove, it touches the idler roller 3. The front side of the frame 1, where the idler roller 3 is located, is pressed down by the wire rope. Under the action of the lever principle, the frame 1 rotates around the hinge point with the support 2. The rear side of the frame 1, where the counterweight 6 is located, tilts up to trigger the mechanical limit device 9, thereby cooperating with the PIC control unit to issue warning information and stop signal.
[0052] It should be noted that the terms such as "upper", "lower", "left", "right", "front", and "back" used in this utility model are only for clarity of description and are not intended to limit the scope of implementation of this utility model. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered as within the scope of implementation of this utility model.
[0053] The above are merely preferred embodiments of this utility model. The protection scope of this utility model is not limited to the above embodiments. All technical solutions falling within the scope of this utility model's concept are within its protection scope. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of this utility model should be considered within its protection scope.
Claims
1. A wire rope off track monitoring device characterized by: The system includes a frame (1), a support (2), an idler roller (3), an idler roller shaft (4), a counterweight (6), a limiting bracket (5), a magnetic limiting device (8), and a mechanical limiting device (9). The middle section of the frame (1) is hinged to the support (2). The front and rear ends of the frame (1) can swing or rotate around the hinge. The front end of the frame (1) is connected to an idler roller shaft (4) parallel to the axial direction of the wire rope drum. An idler roller (3) is rotatably mounted on the idler roller shaft (4). The rear end of the frame (1)... The end is equipped with a counterweight (6) to keep the frame (1) stationary. The magnetic limiting device (8) and the mechanical limiting device (9) are respectively installed below and above the rear end of the frame (1) through the limiting bracket (5). The magnetic limiting device (8) is used to magnetically connect the lower rear end of the frame (1) in a stationary state. The roller (3) is used to be pushed down by the degrouted wire rope. The mechanical limiting device (9) is used to be triggered by the corresponding upward movement of the rear end of the frame (1) and send a signal.
2. A steel wire rope off groove monitoring device according to claim 1, characterized in that: The frame (1) includes a roller mounting frame (11), two connecting frames (12) and a counterweight mounting frame (14). The roller mounting frame (11) is shaped like a "U". The opening of the "U" shaped roller mounting frame (11) faces forward and is used to connect the roller shaft (4). A connecting frame (12) is symmetrically connected to the left and right sides of the rear end of the roller mounting frame (11). The connecting frame (12) is symmetrically provided with hinge holes (13) for hinged to the support (2). The rear ends of the two connecting frames (12) are connected to the counterweight mounting frame (14). The counterweight mounting frame (14) is used to install the counterweight (6).
3. The wire rope derailment monitoring device according to claim 2, characterized in that: The limiting bracket (5) includes a first limiting bracket (81) and a second limiting bracket (91). The mechanical limiting device (9) is detachably installed on the second limiting bracket (91) and located above the counterweight mounting frame (14). The magnetic limiting device (8) is installed on the first limiting bracket (81) and is used to magnetically connect to the lower end of the counterweight mounting frame (14) in a stationary state.
4. The wire rope derailment monitoring device according to claim 3, characterized in that: The mechanical limiting device (9) is provided with a mounting hole, and the mechanical limiting device (9) is detachably fastened to the second limiting bracket (91) by bolts passing through the mounting hole.
5. The steel wire rope off-tracking monitoring device of claim 3, wherein: The second limiting bracket (91) is disposed between the idler roller mounting frame (11) and the counterweight mounting frame (14), and the probe of the mechanical limiting device (9) is located above the counterweight mounting frame (14).
6. The wire rope derailment monitoring device according to claim 3, characterized in that: The magnetic limiting device (8) and the mechanical limiting device (9) are located at the middle of the counterweight mounting frame (14). The counterweight (6) is provided in two sets, and the two sets of counterweight (6) are respectively set on the left and right sides of the counterweight mounting frame (14).
7. A steel wire rope off-tracking monitoring device according to claim 6, characterized in that: The counterweight mounting bracket (14) has a positioning hole, and the counterweight (6) has a vertical through hole. The counterweight (6) passes through the through hole and the positioning hole with bolts and is fastened to the counterweight mounting bracket (14) with nuts.
8. A steel wire rope off-tracking monitoring device according to claim 7, characterized in that: It also includes a movable counterweight (7), which has a connecting hole corresponding to the through hole. The movable counterweight (7) is used to pass through the connecting hole, the through hole and the positioning hole with bolts, and is installed on the counterweight (6) with nuts.
9. The steel wire rope off-tracking monitoring device of claim 1, wherein: The support (2) includes two hinge seats (21) and a support frame (22). The two hinge seats (21) are respectively installed on the left and right sides of the upper end of the support frame (22). The left and right sides of the middle section of the frame (1) are respectively hinged to the two hinge seats (21). There is a gap between the bolt shaft on the hinge seat (21) and the bottom of the hinge seat (21) that allows the frame (1) to swing back and forth or rotate.
10. The steel wire rope off-tracking monitoring device of claim 1, wherein: The idler roller (3) is configured as several small idler rollers, which are equally spaced on the idler roller shaft (4).