Permanent magnet variable frequency tensioning device

Abstract

The utility model relates to conveyor supporting equipment technical field especially relates to a kind of permanent magnet variable frequency tensioning device, including permanent magnet variable frequency winch unit, variable frequency control unit, tension detection unit, movable trolley unit and wireless remote control unit;The variable frequency control unit includes variable frequency cabinet body and built-in three-level four-quadrant frequency converter, cloud platform communication module, copper base water cooling system and the PLC control module of tension detection unit electric connection;The tension detection unit includes tension sensor installed in series in the end of steel wire rope, and the tension sensor is used for real-time detection steel wire rope tension;The movable trolley unit includes movable trolley body, multiple rope pulley and pulley mechanism fixedly installed on the surface of movable trolley body, and the pulley mechanism includes fixed support, redirection sheave group and steel wire rope fixed position.Tension regulation is accurate, ensures conveyor stability, integration and remote control, saves space and is safe, intelligent monitoring reduces operation and maintenance cost, and has strong compatibility.

Description

Technical Field

[0001] This utility model relates to the technical field of conveyor equipment, and in particular to a permanent magnet frequency conversion tensioning device. Background Technology

[0002] As the core equipment for continuous material transport in industrial production, the stability of belt conveyors directly determines production efficiency and operational safety. To prevent belt slippage or deviation due to insufficient tension, or belt breakage or overload damage to drive components due to excessive tension, belt conveyors need to be equipped with a dedicated tensioning device to dynamically adjust belt tension to meet the needs of different working conditions.

[0003] Existing belt conveyor tensioning devices are mainly divided into two categories: one is a hydraulic tensioning device, which adopts a configuration mode of "hydraulic pump station + hydraulic winch + hydraulic cylinder". The tension is changed by adjusting the pressure of the hydraulic pump station to drive the cylinder to extend and retract and the winch to rotate. The other is a conventional frequency conversion tensioning device, which uses a three-phase asynchronous motor as the power source, connects to an external reducer through a coupling to drive the winch, and uses a conventional frequency converter to realize motor start-stop and speed control.

[0004] Among the existing belt conveyor tensioning devices, hydraulic tensioning devices have problems such as slow response, complex maintenance, and safety and pollution risks from hydraulic oil leakage. Ordinary frequency conversion tensioning devices have problems such as loose structure, large space occupation, low transmission efficiency, high energy consumption, and poor control accuracy and safety. Moreover, both types of devices have low intelligence and rely heavily on manual inspection, making it difficult to automatically adjust and monitor. Utility Model Content

[0005] The purpose of this utility model is to solve the following shortcomings in the existing technology. In the existing belt conveyor tensioning devices, the hydraulic tensioning device has problems such as slow response, complicated maintenance, and safety and pollution risks due to hydraulic oil leakage. The ordinary frequency conversion tensioning device has problems such as loose structure, large space occupation, low transmission efficiency, high energy consumption, and poor control accuracy and safety. Moreover, both types of devices have low level of intelligence, rely more on manual inspection, and are difficult to automatically adjust and monitor. Therefore, a permanent magnet frequency conversion tensioning device is proposed.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: A permanent magnet variable frequency tensioning device includes a permanent magnet variable frequency winch unit, a variable frequency control unit, a tension detection unit, a traveling trolley unit, and a wireless remote control unit. A steel wire rope is wound on the permanent magnet variable frequency winch unit, with one end of the steel wire rope fixed to the permanent magnet variable frequency winch unit and the other end extending to the traveling trolley unit. The frequency conversion control unit includes a frequency conversion cabinet and a built-in three-level four-quadrant frequency converter, a cloud platform communication module, a copper-based water cooling system, and a PLC control module electrically connected to the tension detection unit. The tension detection unit includes a tension sensor installed in series at the end of the wire rope, and the tension sensor is used to detect the tension of the wire rope in real time. The mobile trolley unit includes a mobile trolley body, multiple rope wheels and pulley mechanisms fixedly installed on the surface of the mobile trolley body, the pulley mechanism being fixed on the foundation, and the pulley mechanism including a fixed support, a redirecting pulley group and a wire rope fixing position. The wire rope passes through multiple rope wheels, the redirecting pulley group and the tension sensor in sequence, and is then fixed at the wire rope fixing position. The wireless remote control unit includes a wireless remote control transmitter for operating the device from a location away from the danger zone of the tensioning device and a wireless receiver integrated into the frequency conversion control unit.

[0007] Preferably, the three-level four-quadrant frequency converter has multiple control modes such as V / F control, S / LVECTORCONTROL, and CLVECTORCONTROL, and can output 2.5 times the rated torque in low-frequency state.

[0008] Preferably, the three-level four-quadrant frequency converter is equipped with multiple communication interfaces, including CAN, RS485, RJ45 and RS232, to meet the requirements of digital connection.

[0009] Preferably, the three-level four-quadrant frequency converter adopts three-level technology and realizes four-quadrant operation, and the output voltage and current waveforms are approximately sinusoidal waveforms, with high-order harmonic components reduced by 40%.

[0010] Preferably, the three-level four-quadrant frequency converter adopts vector control technology to realize master-slave control, which can realize automatic power balance of multiple machines.

[0011] Preferably, the permanent magnet variable frequency winch unit includes an explosion-proof housing, a permanent magnet motor, an electromagnetic brake, and a winding mechanism. The permanent magnet motor is directly connected to the winding mechanism. The electromagnetic brake and the permanent magnet motor are integrated and enclosed together in the explosion-proof housing. The wire rope is wound on the winding mechanism, with one end of the wire rope fixed to the winding mechanism and the other end extending to the trolley unit. The electromagnetic brake is installed at the tail end of the permanent magnet motor opposite to the output shaft and achieves braking through magnetic force.

[0012] Compared with the prior art, the beneficial effects of this utility model are: 1. The permanent magnet variable frequency winch unit is designed with a permanent magnet motor directly connected to the winding mechanism and an electromagnetic brake integrated with the permanent magnet motor in an explosion-proof housing. This eliminates redundant components such as external reducers. Combined with the optimized layout of the rope wheel and pulley mechanism of the traveling trolley unit, the overall size is greatly reduced. It can be flexibly adapted to space-constrained scenarios such as underground mines and small workshops. At the same time, the explosion-proof housing design can meet the safety requirements of high-risk scenarios such as coal mines, thus broadening the application range of the device. 2. The tension sensor of the tension detection unit is connected in series with the end of the wire rope. It can capture tension changes in real time and feed them back to the frequency conversion control unit. The three-level four-quadrant frequency converter supports multiple modes such as V / F and vector control. It can output 2.5 times the rated torque in low frequency state. It can quickly respond to the sudden tension change when the belt conveyor starts and stops under heavy load, avoid belt slippage or breakage, and output a near sine waveform to reduce high-order harmonics by 40%, reduce signal interference, and improve tension adjustment accuracy. 3. Compared with traditional asynchronous motors, permanent magnet motors have higher torque and lower energy consumption. With the energy feedback function of a three-level four-quadrant frequency converter, the electrical energy generated by the motor can be recovered to the power supply side, reducing energy waste. At the same time, the core components of the device have low maintenance requirements, eliminating the need for frequent hydraulic oil replacement and seal repair, significantly reducing long-term operation and maintenance costs. 4. The wireless remote control unit allows staff to operate the device away from dangerous areas, avoiding the risk of close contact. The explosion-proof housing and the multi-machine power balancing function of vector control further improve the stability of equipment operation. When the tension sensor detects a deviation exceeding the threshold, the motor overheats, or the frequency converter malfunctions, the frequency converter control unit can stop the machine and alarm in time, reducing the probability of safety accidents. 5. The built-in cloud platform communication module of the frequency converter control unit supports WIFI / 5G data transmission and remote fault diagnosis. It can upload and automatically store operating data such as tension value and motor temperature in real time, eliminating the need for frequent manual inspections. Multiple communication interfaces can be adapted to different digital systems, achieving seamless integration with industrial control networks and meeting the needs of modern industrial intelligent management. Attached Figure Description

[0013] Figure 1 This is a top view of the permanent magnet frequency conversion tensioning device proposed in this utility model; Figure 2 This is a front structural diagram of the mobile trolley unit in this utility model; Figure 3 This is a structural schematic diagram of the permanent magnet variable frequency winch unit in this utility model; Figure 4 This is a partial cross-sectional structural diagram of the frequency conversion control unit in this utility model; Figure 5 This is a three-dimensional structural diagram of the wireless remote control transmitter in this utility model.

[0014] In the diagram: 1 Permanent magnet variable frequency winch unit, 11 Permanent magnet motor, 12 Electromagnetic brake, 13 Winding mechanism, 14 Explosion-proof housing, 2 Variable frequency control unit, 21 Variable frequency cabinet, 3 Tension detection unit, 31 Tension sensor, 4 Traveling trolley unit, 41 Traveling trolley body, 42 Rope pulley, 43 Pulley mechanism, 431 Fixed support, 432 Pulley block, 433 Wire rope fixing position, 5 Wireless remote control unit, 51 Wireless remote control transmitter, 52 Wireless receiver, 6 Wire rope. Detailed Implementation

[0015] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0016] The terms used in this utility model, such as "upper", "lower", "left", "right", "middle" and "one", 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.

[0017] Reference Figures 1-2 A permanent magnet variable frequency tensioning device includes a permanent magnet variable frequency winch unit 1, a variable frequency control unit 2, a tension detection unit 3, a traveling trolley unit 4, and a wireless remote control unit 5. A steel wire rope 6 is wound around the permanent magnet variable frequency winch unit 1, with one end fixed to the winch unit 1 and the other end extending to the traveling trolley unit 4. The permanent magnet variable frequency winch unit 1 includes an explosion-proof housing 14, a permanent magnet motor 11, an electromagnetic brake 12, and a winding mechanism 13. The permanent magnet motor 11 is directly connected to the winding mechanism 13, and the electromagnetic brake 12 is connected to the permanent magnet motor 14. The motor 11 is integrated and enclosed within the explosion-proof housing 14. The wire rope 6 is wound around the winding mechanism 13, with one end of the wire rope 6 fixed to the winding mechanism 13 and the other end extending to the traveling trolley unit 4. The electromagnetic brake 12 is installed at the tail end opposite the output shaft of the permanent magnet motor 11 and brakes by magnetic force. The response time is no more than 0.1S. The transmission efficiency of the direct connection between the permanent magnet motor 11 and the winding mechanism 13 is no less than 95%. The rope winding speed of the winding mechanism 13 is three times that of a traditional frequency conversion winch.

[0018] Reference Figures 3-4The frequency converter control unit 2 includes a frequency converter cabinet 21 and a built-in three-level four-quadrant frequency converter, a cloud platform communication module, a copper-based water cooling system, and a PLC control module electrically connected to the tension detection unit 3. The frequency converter cabinet 21 adopts an explosion-proof structure with a protection level of IP54. The three-level four-quadrant frequency converter has a feedback unit and a braking unit. The three-level four-quadrant frequency converter has multiple control modes such as V / F control, S / LVECTORCONTROL, and CLVECTORCONTROL, and can output 2.5 times the rated torque in low-frequency state. The three-level four-quadrant frequency converter is equipped with multiple communication interfaces, including CAN, RS485, RJ45, and RS232, to meet the requirements of digital connection. Employing three-level technology and achieving four-quadrant operation, the output voltage and current waveforms are approximately sinusoidal, with a 40% reduction in high-order harmonic components. The three-level four-quadrant frequency converter uses vector control technology to achieve master-slave control, enabling automatic power balance among multiple machines. The three-level four-quadrant frequency converter feeds back the electrical energy generated by the permanent magnet motor 11 to the power supply side through a feedback unit, achieving an energy saving rate of no less than 15%. The cloud platform communication module supports WIFI / 5G data transmission and can upload equipment operation data in real time, including tension value, motor temperature, and frequency converter status, and has remote fault diagnosis function. The copper-based water cooling system has intelligent temperature control function, automatically enhancing heat dissipation when the frequency converter temperature exceeds 60℃. The surface of the frequency converter cabinet 21 is equipped with an audible and visual alarm.

[0019] The tension detection unit 3 includes a tension sensor 31 installed in series at the end of the wire rope 6. The tension sensor 31 is used to detect the tension of the wire rope 6 in real time and outputs a 4-20mA dynamic current signal. When the deviation of the detection value of the tension sensor 31 exceeds 5%, the frequency conversion control unit 2 automatically issues an alarm signal.

[0020] The mobile trolley unit 4 includes a mobile trolley body 41, multiple rope wheels 42 fixedly installed on the surface of the mobile trolley body 41, and a pulley mechanism 43. The pulley mechanism 43 is fixed on the foundation and includes a fixed support 431, a redirecting pulley group 432, and a wire rope fixing position 433. The wire rope 6 passes through multiple rope wheels 42, the redirecting pulley group 432, and the tension sensor 31 in sequence, and is then fixed at the wire rope fixing position 433.

[0021] When the permanent magnet motor 11 overheats, the frequency converter malfunctions, or the tension sensor 31 detects an abnormality, the frequency conversion control unit 2 immediately controls the equipment to stop and issues an audible and visual alarm. At the same time, it pushes the fault information to the management personnel terminal through the cloud platform communication module.

[0022] Reference Figure 5The wireless remote control unit 5 includes a wireless remote control transmitter 51 for operating the device in a location far from the danger zone of the tensioning device and a wireless receiver 52 integrated in the frequency conversion control unit 2. The effective control distance of the wireless remote control transmitter 51 is not less than 50m, and it can realize motor start-stop and tension fine adjustment operations.

[0023] Through the human-machine interface of the frequency converter cabinet 21, the target tension value of the belt conveyor is preset. The PLC control module stores the value in the internal register. Pressing the "start" button of the wireless remote control transmitter 51, the frequency converter control unit 2 first controls the electromagnetic brake 12 to be energized and engaged, releasing the braking state. Then, the three-level four-quadrant frequency converter starts the permanent magnet motor 11 in V / F control mode. The permanent magnet motor 11 drives the winding mechanism 13 to rotate through the direct connection structure. The drum winds up the steel wire rope 6, pulling the traveling trolley body 41 to move along the guide rail, thereby driving the conveyor belt to be tensioned.

[0024] Tension sensor 31 detects the tension of wire rope 6 in real time and transmits a 4-20mA dynamic current signal to PLC control module. PLC control module converts the current signal into actual tension value through internal algorithm and compares it with preset target value.

[0025] When the actual tension is less than the preset target tension value, the PLC control module issues a command, the three-level four-quadrant frequency converter switches to S / LVECTORCONTROL mode, increases the output torque of the permanent magnet motor 11, and the winding mechanism 13 accelerates the winding of the rope until the actual tension reaches the preset target, the permanent magnet motor 11 stops running, and the electromagnetic brake 12 de-energizes and holds the brake.

[0026] When the actual tension exceeds the preset target tension value, the PLC control module controls the three-level four-quadrant frequency converter to switch to the power generation state, the permanent magnet motor 11 rotates in reverse, the winding mechanism 13 slowly releases the rope, and at the same time the frequency converter's feedback unit feeds back the electrical energy generated by the motor to the power supply side, the braking unit consumes excess electrical energy to avoid voltage fluctuations, until the actual tension returns to 20kN, and the equipment returns to a stable state.

[0027] During stable operation, the three-level four-quadrant frequency converter outputs voltage and current with an approximate sine wave, reducing interference to other electrical control equipment underground. The copper-based water cooling system monitors the frequency converter temperature in real time, and automatically increases the cooling water flow when the temperature exceeds 60°C to enhance heat dissipation and ensure long-term stable operation of the frequency converter.

[0028] During operation, if the deviation of the detection value of the tension sensor 31 exceeds 5%, or the temperature of the permanent magnet motor 11 exceeds 120℃, or the three-level four-quadrant frequency converter experiences an overcurrent / overvoltage fault, the PLC control module will immediately trigger the protection mechanism, control the permanent magnet motor 11 to stop, the electromagnetic brake 12 to engage, and the audible and visual alarm of the frequency converter cabinet 21 to issue a red alarm signal. At the same time, the cloud platform communication module will push the fault information to the management personnel terminal via 5G signal and automatically store it in the system database for easy fault analysis and maintenance in the future.

[0029] For heavy-load start-up conditions of belt conveyors in underground coal mines, the three-level four-quadrant frequency converter switches to CLVECTORCONTROL mode, outputting 2.5 times the rated torque at low frequency to ensure that the permanent magnet motor 11 can drive the winding mechanism 13 to quickly respond to tension requirements and avoid belt slippage. If multiple tensioning devices need to work together, the three-level four-quadrant frequency converter realizes master-slave control through vector control technology. The PLC control module of the master device sends synchronization commands to the slave device to realize automatic power balance of multiple machines, ensuring that the tension output of each device is consistent and avoiding damage caused by uneven local stress on the belt.

[0030] In this utility model, through optimized structural layout, the permanent magnet variable frequency winch unit 1 forms a reasonable rope path with multiple rope wheels 42 and redirecting pulley blocks 432 of the traveling trolley unit 4 via the wire rope 6, adapting to different spaces. The integrated design of the variable frequency control unit 2 and the remote control of the wireless remote control unit 5 reduce space occupation and ensure safe operation. The tension adjustment is precise, and the tension sensor 31 of the tension detection unit 3 provides real-time feedback of tension to the PLC control module of the variable frequency control unit 2. Combined with the three-level four-quadrant frequency converter, the permanent magnet variable frequency winch unit 1 is controlled to avoid conveyor slippage or breakage. It has a high degree of intelligence, and the cloud platform communication module of the variable frequency control unit 2 enables remote monitoring. The copper-based water cooling system ensures the stability of the frequency converter. The wireless remote control simplifies operation and reduces maintenance costs. It has strong compatibility and expandability, and the frequency converter has diverse functions. The pulley mechanism 43 can be adjusted in installation position, and the modular design facilitates future upgrades and component replacement.

[0031] In this utility model, unless otherwise explicitly specified and limited, the terms "installation", "connection", "linking", "fixing", etc., should be interpreted broadly.

[0032] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A permanent magnet variable frequency tensioning device, comprising a permanent magnet variable frequency winch unit (1), a variable frequency control unit (2), a tension detection unit (3), a travelling trolley unit (4) and a wireless remote control unit (5), characterized in that, A steel wire rope (6) is wound around the permanent magnet frequency conversion winch unit (1). One end of the steel wire rope (6) is fixed to the permanent magnet frequency conversion winch unit (1), and the other end extends to the mobile trolley unit (4). The frequency conversion control unit (2) includes a frequency conversion cabinet (21) and a built-in three-level four-quadrant frequency converter, a cloud platform communication module, a copper-based water cooling system, and a PLC control module electrically connected to the tension detection unit (3). The tension detection unit (3) includes a tension sensor (31) installed in series at the end of the wire rope (6), and the tension sensor (31) is used to detect the tension of the wire rope (6) in real time. The mobile trolley unit (4) includes a mobile trolley body (41), multiple rope wheels (42) fixedly installed on the surface of the mobile trolley body (41), and a pulley mechanism (43). The pulley mechanism (43) is fixed on the foundation. The pulley mechanism (43) includes a fixed support (431), a redirecting pulley group (432), and a wire rope fixing position (433). The wire rope (6) passes through multiple rope wheels (42), the redirecting pulley group (432), and the tension sensor (31) in sequence, and is then fixed at the wire rope fixing position (433). The wireless remote control unit (5) includes a wireless remote control transmitter (51) for operating the device at a location away from the danger zone of the tensioning device and a wireless receiver (52) integrated into the frequency conversion control unit (2).

2. A permanent magnet variable frequency tensioning device according to claim 1, characterized in that, The three-level four-quadrant frequency converter has multiple control modes, including V / F control, S / LVECTORCONTROL, and CLVECTORCONTROL, and can output 2.5 times the rated torque in low-frequency conditions.

3. A permanent magnet variable frequency tensioning device according to claim 1, characterized in that, The three-level four-quadrant frequency converter is equipped with multiple communication interfaces, including CAN, RS485, RJ45 and RS232, to meet the requirements of digital connection.

4. The permanent magnet variable frequency tensioning device according to claim 1, characterized in that, The three-level four-quadrant frequency converter adopts three-level technology and realizes four-quadrant operation. The output voltage and current waveforms are approximately sinusoidal waveforms, and the high-order harmonic components are reduced by 40%.

5. A permanent magnet variable frequency tensioning device according to claim 1, characterized in that, The three-level four-quadrant frequency converter uses vector control technology to achieve master-slave control and realize automatic power balance among multiple machines.

6. A permanent magnet variable frequency tensioning device according to claim 1, characterized in that, The permanent magnet variable frequency winch unit (1) includes an explosion-proof housing (14), a permanent magnet motor (11), an electromagnetic brake (12), and a winding mechanism (13). The permanent magnet motor (11) is directly connected to the winding mechanism (13). The electromagnetic brake (12) is integrated with the permanent magnet motor (11) and is enclosed in the explosion-proof housing (14). The wire rope (6) is wound on the winding mechanism (13), and one end of the wire rope (6) is fixed to the winding mechanism (13), while the other end extends to the trolley unit (4). The electromagnetic brake (12) is installed on the tail shaft end opposite to the output shaft of the permanent magnet motor (11) and brakes by magnetic force.

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