CN-122024422-A - Intelligent monitoring and early warning method and system for pulling force of drag chain system

Abstract

A drag chain system tension intelligent monitoring and early warning method and system are provided, through collecting drag chain operation tension data in real time and comparing with a user-definable alarm threshold value, overrun alarm is realized, meanwhile, the system integrates total operation time statistics, maintenance period reminding and historical data recording and analyzing functions, and a complete full life cycle intelligent operation and maintenance scheme from real-time monitoring, early warning, maintenance management to data analysis is formed. The invention solves the problems of unpredictable maintenance and delayed fault response of the traditional drag chain system, can effectively prevent cable damage and equipment shutdown caused by abnormal tension, remarkably improves the reliability and safety of the system, can automatically turn off the driving motor when the tension is severely out of limit, and provides active safety protection.

Inventors

• XU BIZHENG
• XU SHENGZHUO

Assignees

• 麦斯特(深圳)智能有限公司

Dates

Publication Date

20260512

Application Date

20260210

Claims (10)

1. 1. The intelligent drag chain system tension monitoring and early warning method is characterized by comprising the following steps: Collecting a tension value in the running process of the drag chain in real time; comparing the real-time tension value with a preset alarm threshold value; Generating and executing an alarm action when the real-time tension value exceeds the alarm threshold value, and generating and outputting a motor power-off control signal when the real-time tension value exceeds a preset higher-level safety power-off threshold value; Accumulating the total running time of the drag chain system and generating maintenance reminding information based on a preset maintenance period; and recording and storing historical tension data, alarm events and the total running time.
2. 2. The method for intelligently monitoring and early warning pull force of a drag chain system according to claim 1, wherein a user interaction interface is provided, and at least one operation of custom setting of an alarm threshold, global switching of an alarm function, system language switching and one-key reset clearing of an alarm state is realized through the interface.
3. 3. The intelligent monitoring and early warning method for the tension of the drag chain system according to claim 1, wherein a tension change trend curve in a specific time period is generated based on recorded historical tension data and is output to a display device and/or a storage device through a data output interface.
4. 4. The method for intelligently monitoring and early warning the tension of a drag chain system according to claim 1, wherein the safety shutdown threshold is set based on the maximum allowable tension of the drag chain driving motor or the breaking tension of a cable.
5. 5. The intelligent monitoring and early warning method for the pulling force of a drag chain system according to claim 1, further comprising the step of calibrating the pulling force measuring system by receiving a weight value input by a user and collecting readings of a pulling force sensor when the weight is mounted.
6. 6. The intelligent monitoring and early warning method for drag chain system tension according to claim 1, wherein the alarm action comprises at least one of triggering a visual alarm at a user interface, triggering an on-site audible and visual alarm, and recording an alarm event including an alarm start time, an alarm end time, and a peak tension value.
7. 7. An intelligent drag chain system tension monitoring and early warning system adopting the method of any one of claims 1 to 6, characterized by comprising the following modules: the tension sensing module is used for collecting the tension value of the drag chain in real time; The data processing and control module is used for executing data comparison, logic judgment and generating a control instruction; the man-machine interaction module is used for displaying information, setting parameters and sending out reminding; The data storage module is used for storing preset parameters, historical tension data and alarm records; The safety control output module is used for outputting a control signal to turn off the power supply of the drag chain driving motor when receiving the turn-off instruction; and the tension sensing module, the safety control output module, the man-machine interaction module and the data storage module are respectively in control connection with the data processing and control module.
8. 8. The intelligent drag chain system tension monitoring and early warning system according to claim 7, wherein the man-machine interaction module comprises a local touch screen display, and the interface presented on the display comprises a real-time tension display area, an alarm state indication area, a total running time display area, a maintenance reminding information area and a parameter setting inlet.
9. 9. The intelligent drag chain system tension monitoring and early warning system of claim 7, further comprising a data export module in controlling connection with the data storage module and the data processing and control module, the data export module configured to allow a user to export stored historical data to an external storage device in a generic file format.
10. 10. The intelligent monitoring and early warning system for drag chain system tension according to claim 7, wherein the data processing and control module is configured to execute a weight calibration procedure, i.e. automatically calculate and correct the measurement coefficient of the tension sensor according to the weight of the known weight.

Description

Intelligent monitoring and early warning method and system for pulling force of drag chain system Technical Field The invention relates to the technical field of state monitoring and fault diagnosis of industrial automation equipment, in particular to an intelligent tension monitoring and early warning method for a cable drag chain system and a corresponding system. Background The drag chain system is responsible for supporting and protecting the movable cables and hoses in gantry cranes, automatic machine tools and other equipment. In actual operation, the drag chain may cause abnormal increase in tension due to track deformation, internal cable clamping stagnation, external resistance, and the like. Long-term overload or sudden tension impact can drastically shorten the service life of the cable and the drag chain itself, even leading to a cable break and sudden equipment shut down, resulting in significant economic losses. At present, most drag chain systems lack effective real-time monitoring means, maintenance work depends on regular inspection or post-maintenance, predictive maintenance cannot be realized, and fault response is seriously delayed. Therefore, a solution capable of monitoring drag chain tension in real time, intelligently pre-warning and guiding maintenance is urgently needed. Disclosure of Invention In view of the above situation, in order to solve the problems existing in the above technology, the present invention provides a drag chain system tension monitoring method and system capable of real-time monitoring, intelligent early warning, and supporting full life cycle operation and maintenance management. A drag chain system tension intelligent monitoring and early warning method comprises the following steps: Collecting a tension value in the running process of the drag chain in real time; comparing the real-time tension value with a preset alarm threshold value; Generating and executing an alarm action when the real-time tension value exceeds the alarm threshold value, and generating and outputting a motor power-off control signal when the real-time tension value exceeds a preset higher-level safety power-off threshold value; Accumulating the total running time of the drag chain system and generating maintenance reminding information based on a preset maintenance period; and recording and storing historical tension data, alarm events and the total running time. According to the intelligent monitoring and early warning method for the pulling force of the drag chain system, a user interaction interface is provided, and at least one operation of self-defining setting of an alarm threshold value, global switching of an alarm function, system language switching and one-key reset and alarm state clearing is realized through the interface. According to the intelligent monitoring and early warning method for the tension of the drag chain system, a tension change trend curve in a specific time period is generated based on recorded historical tension data, and the tension change trend curve is output to a display device and/or a storage device through a data deriving interface. According to the intelligent monitoring and early warning method for the tension of the drag chain system, the safety shutdown threshold is set based on the maximum allowable tension of the drag chain driving motor or the breaking tension of the cable. The intelligent monitoring and early warning method for the pulling force of the drag chain system further comprises the step of calibrating the pulling force measuring system by receiving the weight value input by a user and collecting the reading of a pulling force sensor when the weight is mounted. The intelligent monitoring and early warning method for the tension of the drag chain system comprises at least one of triggering visual alarm, triggering an on-site audible and visual alarm and recording alarm events including alarm starting time, ending time and peak tension value on a user interface. A drag chain system tension intelligent monitoring and early warning system comprises the following modules: the tension sensing module is used for collecting the tension value of the drag chain in real time; The data processing and control module is in communication connection with the tension sensing module and is used for executing data comparison, logic judgment and generating a control instruction; the man-machine interaction module is in communication connection with the data processing and control module and is used for displaying information, setting parameters and sending out reminding; The data storage module is used for storing preset parameters, historical tension data and alarm records; The safety control output module is used for outputting a control signal to turn off the power supply of the drag chain driving motor when receiving the turn-off instruction; and the tension sensing module, the safety control output module, the man-machine interaction module and