Cable Reel Guide Feedback Control for EV Cable Wear
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Solution Overview
Problem
Electrically driven vehicles, such as mine machines, face excessive cable wear due to high and varying tension during cable winding and unwinding, which shortens the cable's lifespan and risks the cable being run over by the vehicle.
Innovation Solution
A cable unwinding and winding arrangement featuring a triangle-shaped cable guiding system with three contacting surfaces, a control arm, and a controlling arrangement that includes a force measuring system and sensors to calculate and manage cable forces, providing force feedback to maintain optimal tension and prevent cable damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high and varying tension is applied to the cable during winding and unwinding, then the cable can be effectively controlled and guided, but excessive wearing of the cable occurs
Solution Approach 1:
The patent implements a feedback control system using force measuring systems (load cells) in the cable guide arrangement to continuously monitor cable tension. The controlling arrangement receives force measurements and calculates estimated forces on the cable, then adjusts the reel motor torque accordingly to maintain optimal tension levels, preventing both excessive tension that causes wear and insufficient tension that loses control
Solution Approach 2:
The cable guide arrangement is designed to be dynamically adjustable through the control arm mechanism that can pivot to different positions. This allows the guide arrangement to adapt its position and orientation based on cable tension conditions and vehicle movement, maintaining effective cable control while distributing mechanical stresses more evenly to reduce wear
2Duration of action of stationary object
If the cable is allowed to run loose during vehicle movement, then cable wear is reduced, but the cable may be run over by the vehicle
Solution Approach 1:
The force measuring systems continuously monitor cable tension and provide feedback to the controlling arrangement. When the vehicle moves or changes position, the system detects tension changes and automatically adjusts the reel motor to maintain appropriate cable tightness, preventing the cable from becoming loose enough to be run over while avoiding excessive tension that would cause wear
Solution Approach 2:
The control system automatically adjusts cable tension based on real-time conditions without requiring manual intervention. The controlling arrangement uses force measurements and angle sensor data to self-regulate the reel motor, maintaining optimal cable tension adaptively as the vehicle operates in different positions and conditions
3Measurement precision
If a complex force measurement and control system is implemented, then cable force control precision is improved, but device complexity increases
Solution Approach 1:
The patent uses the control arm and triangle arrangement as mechanical intermediaries that translate cable tension forces into measurable angular positions. Force measuring systems positioned in the control arm indirectly measure cable forces through lever arm mechanics, and angle sensors measure the control arm position, which is then used to calculate cable forces. This intermediary approach enables precise measurement while keeping the direct measurement system relatively simple
Data Source
Figure 1
Figure 2a~3b
Figure 4a~4c
AI summary
An arrangement (100), a vehicle (12) and method for cable unwinding and winding in an electrically driven vehicle. The arrangement comprises a cable reel (1) and a cable guiding arrangement (3) comprising three contacting surfaces (4a, 4b, 4c) arranged parallel and in a triangle arrangement (5). The contacting surfaces (4a, 4b, 4c) are arranged and dimensioned such that the cable (2) arranged between one of the contacting surfaces on its first side and two of the contacting surfaces on its second side bends on a surface of at least one of the contacting surfaces (4a, 4b, 4c). The arrangement further comprises a control arm (6) and a controlling arrangement (7). The controlling arrangement (7) comprises a force measuring system (8) provided in at least one of the contacting surfaces (4a, 4b, 4c) and arranged to measure force caused by the cable against said contacting surface(s), the force measuring system (8) providing a force (F), a control arm sensor arrangement (9) arranged to detect the direction in which the control arm (6) is pointing in relation to the longitudinal axis (L) of the electrically driven vehicle, and for providing a control arm angle information (CA). The controlling arrangement (7) is arranged to calculate an estimate of forces focusing on the cable (2) based on the force (F) and the control arm angle information (CA).