Intelligent tension limiting and safety control system for calcium carbide furnace winch

Abstract

The utility model discloses an intelligent tension limit and safety control system for calcium carbide furnace winch belongs to calcium carbide furnace technical field, including base, the upper end both sides of base are provided with riser, and the side edge middle rotation of riser is connected with winding roll, and the both ends pivot of winding roll are connected with tension sensor, and the side edge lower extreme of riser is fixed with drive motor, and the pivot of drive motor is connected with drive gear, and the side edge of winding roll is provided with the transmission gear that is connected with drive gear, the utility model discloses the tension sensor collection steel wire rope and suffer the tension data of innovation high -precision sensing technique, intelligent algorithm and modularization control combination, break the traditional calcium carbide furnace winch and rely on the experience of manual judgment tension and the limitation of subsequent maintenance, through fast response's tension monitoring and grading early warning brake mechanism, reduce the safety risk that operating personnel face, accurate tension limit and overload protection, prolong the service life of equipment.

Description

Technical Field

[0001] This utility model belongs to the field of calcium carbide furnace technology, specifically relating to an intelligent tension limiting and safety control system for a calcium carbide furnace winch. Background Technology

[0002] In the calcium carbide furnace production process, the calcium carbide tapping hoist is an indispensable core piece of equipment, and its operational stability directly affects the continuity and reliability of the entire calcium carbide production system.

[0003] However, current winches suffer from the following prominent problems due to the lack of a tension limiting system: 1. Safety hazards of wire ropes: During the calcium carbide tapping process, the weight of the fully loaded calcium carbide pot is significant. If the pot gets stuck on the track or the wire rope becomes knotted, the winch's traction force will instantly exceed the wire rope's bearing capacity, easily causing wire breakage, strand breakage, or even fracture, posing a major safety hazard to production; 2. Frequent failures of transmission components: Due to the lack of a tension limiter, when the winch encounters excessive load, the motor needs to output excessive power to maintain operation, leading to motor overload, overheating, or even burnout. At the same time, the reducer will also experience rapid gear wear and shaft breakage due to excessive torque, seriously affecting the normal operation of the equipment; 3. Damage to equipment structure: The continuous excessive tension will cause the winch's frame, drum, and other key structural components to bear additional stress. Over time, these components will inevitably deform and crack, greatly weakening the overall stability and reliability of the winch and shortening its service life.

[0004] In view of this, an intelligent tension limiting and safety control system for a calcium carbide furnace winch is designed to solve the above problems. Utility Model Content

[0005] To address the problems mentioned in the background section, this invention provides an intelligent tension limiting and safety control system for a calcium carbide furnace winch, featuring intelligent monitoring, prevention of major accidents, and extension of equipment lifespan.

[0006] To achieve the above objectives, this utility model provides the following technical solution: an intelligent tension limiting and safety control system for a hoist in a calcium carbide furnace, comprising a base, uprights on both sides of the upper end of the base, a winding roller rotatably connected to the middle of the side of the uprights, tension sensors connected to the two ends of the winding roller via rotating shafts, a drive motor fixedly connected to the lower side of the uprights, a drive gear connected to the rotating shaft of the drive motor, a transmission gear connected to the drive gear on the side of the winding roller, a steel wire rope wound on the surface of the transmission gear, a cleaning assembly for cleaning the steel wire rope on the side of the base, a tension control box on the side of the base away from the drive motor, a tension sensor electrically connected to the tension control box via a control signal line, a display screen mounted on the surface of the tension control box, and an alarm device at the upper end of the tension control box.

[0007] Preferably, the alarm device includes a buzzer, which is electrically connected to the tension control box.

[0008] Preferably, the alarm device includes a warning light, which is electrically connected to the tension control box.

[0009] Preferably, the cleaning assembly includes a base plate, with columns welded to both sides of the upper end of the base plate. Two sets of rotating rollers are rotatably connected inside the columns, and flexible cleaning brushes are arranged around the surface of the rotating rollers.

[0010] Preferably, the length of the flexible cleaning brush corresponds to that of the winding roller, and the flexible cleaning brush is in close contact with the surface of the wire rope.

[0011] Compared with the prior art, the beneficial effects of this utility model are: 1. This utility model collects the tension data of the wire rope through a tension sensor, converts the analog signal into a digital signal through a control signal line, and transmits it to the tension control box. When the tension exceeds the threshold, the tension control box immediately triggers the emergency braking actuator, cuts off the control power of the drive motor, and stops the winding roller from rotating, preventing the accident from escalating. It innovatively combines high-precision sensing technology, intelligent algorithms, and modular control, breaking the limitations of traditional calcium carbide furnace winches that rely on manual experience to judge tension and subsequent maintenance. Through a rapid-response tension monitoring and graded early warning braking mechanism, warning lights provide light alarms, and buzzers provide voice alarms, effectively avoiding major safety accidents such as wire rope breakage caused by tension overload, reducing the safety risks faced by operators, effectively protecting personnel life safety, creating a safe production and operation environment, and extending the service life of equipment through precise tension limits and overload protection. 2. This utility model is equipped with a cleaning component. The wire rope moves in the middle of the rotating roller, driving the rotating roller to rotate. The flexible cleaning brush cleans the surface of the wire rope, avoiding the influence of materials on the wire rope winding, ensuring winding stability, and improving protection. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is a schematic diagram of the cleaning component structure of this utility model; In the diagram: 1. Steel wire rope; 2. Cleaning assembly; 21. Base plate; 22. Column; 23. Rotating roller; 24. Flexible cleaning brush; 3. Warning light; 4. Display screen; 5. Tension control box; 6. Buzzer; 7. Rewinding roller; 8. Base; 9. Drive gear; 10. Frame; 11. Drive motor; 12. Transmission gear; 13. Tension sensor. Detailed Implementation

[0013] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0014] Example 1 Please see Figure 1-2 This utility model provides the following technical solution: an intelligent tension limiting and safety control system for a hoist in a calcium carbide furnace, comprising a base 8, uprights 10 on both sides of the upper end of the base 8, a winding roller 7 rotatably connected to the middle of the side of the uprights 10, tension sensors 13 connected to the two ends of the winding roller 7, a drive motor 11 fixedly connected to the lower side of the uprights 10, a drive gear 9 connected to the shaft of the drive motor 11, a transmission gear 12 connected to the drive gear 9 on the side of the winding roller 7, a steel wire rope 1 wound on the surface of the transmission gear 12, a cleaning assembly 2 for cleaning the steel wire rope 1 on the side of the base 8, a tension control box 5 on the side of the base 8 away from the drive motor 11, the tension sensor 13 electrically connected to the tension control box 5 through a control signal line, a display screen 4 mounted on the surface of the tension control box 5, and an alarm device on the upper end of the tension control box 5.

[0015] Specifically, the alarm device includes a buzzer 6, which is electrically connected to the tension control box 5.

[0016] By adopting the above technical solution, the buzzer 6 provides a voice alarm.

[0017] Specifically, the alarm device includes a warning light 3, which is electrically connected to the tension control box 5.

[0018] By adopting the above technical solution, the warning light 3 provides a light alarm.

[0019] In this embodiment, the tension data of the wire rope 1 is collected by the tension sensor 13. The analog signal is converted into a digital signal and transmitted to the tension control box 5 through the control signal line. When the tension exceeds the threshold, the tension control box 5 immediately triggers the emergency braking actuator, cuts off the control power of the drive motor 11, and stops the winding roller 7 from rotating, preventing the accident from escalating. It innovatively combines high-precision sensing technology, intelligent algorithms and modular control, breaking the limitations of traditional calcium carbide furnace winches that rely on manual experience to judge the tension and subsequent maintenance. Through the fast-response tension monitoring and graded early warning braking mechanism, the warning light 3 provides light alarm and the buzzer 6 provides voice alarm, effectively avoiding major safety accidents such as wire rope 1 breakage caused by tension overload, reducing the safety risks faced by operators, effectively protecting personnel life safety, creating a safe production and operation environment, and extending the service life of equipment through precise tension limit and overload protection. Example 2 The difference between this embodiment and embodiment 1 is that the cleaning component 2 includes a base plate 21, and columns 22 are welded to both sides of the upper end of the base plate 21. Two sets of rotating rollers 23 are rotatably connected inside the columns 22, and flexible cleaning brushes 24 are arranged around the surface of the rotating rollers 23.

[0020] By adopting the above technical solution, the wire rope 1 moves in the middle of the rotating roller 23, driving the rotating roller 23 to rotate. The flexible cleaning brush 24 cleans the surface of the wire rope 1, avoiding the influence of materials on the winding of the wire rope 1, ensuring the winding stability, and improving the protection.

[0021] Specifically, the length of the flexible cleaning brush 24 corresponds to that of the winding roller 7, and the flexible cleaning brush 24 is in close contact with the surface of the wire rope 1.

[0022] By adopting the above technical solution, it is ensured that the flexible cleaning brush 24 cleans the surface of the wire rope 1.

[0023] In this embodiment, the wire rope 1 moves in the middle of the rotating roller 23, causing the rotating roller 23 to rotate. The flexible cleaning brush 24 cleans the surface of the wire rope 1, preventing materials from affecting the winding of the wire rope 1, ensuring stable winding, and improving protection.

[0024] The working principle and usage process of this utility model are as follows: When in use, the tension sensor 13 collects the tension data of the wire rope 1. The analog signal is converted into a digital signal via a control signal line and transmitted to the tension control box 5. When the tension exceeds a threshold, the tension control box 5 immediately triggers the emergency braking actuator, cutting off the control power to the drive motor 11, causing the winding roller 7 to stop rotating and preventing the accident from escalating. This innovatively combines high-precision sensing technology, intelligent algorithms, and modular control, breaking the limitations of traditional calcium carbide furnace winches that rely on manual experience to judge tension and perform post-accident maintenance. Through rapid response… The corresponding tension monitoring and graded early warning braking mechanism, the warning light 3 provides light alarm and the buzzer 6 provides voice alarm, effectively avoids major safety accidents such as wire rope 1 breakage caused by tension overload, reduces the safety risks faced by operators, effectively protects personnel life safety, creates a safe production and operation environment, and the precise tension limit and overload protection extend the service life of the equipment; the wire rope 1 moves in the middle of the rotating roller 23, driving the rotating roller 23 to rotate, and the flexible cleaning brush 24 cleans the surface of the wire rope 1 to prevent materials from affecting the winding of the wire rope 1, ensuring winding stability and improving protection.

[0025] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

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