Winding Drum Research Articles

RESEARCH WORKS OF METALLURGICAL EQUIPMENT USING SIMULATION METHODS

The wear and tear of the main production facilities of enterprises of the metallurgical complex requires not only renewal, but also constant modernization of morally outdated equipment in the conditions of active production. The main equipment of the flow lines of wide-scale rolling mills include winders, the quality of which depends on both the rhythm of the rolling equipment and the quality of the material shipped to the consumer. Simulation modeling of the winding process of the hot-rolled staff made it possible to establish the possibility of torsional oscillations in the winding drum drive. Further analysis of the form of the resulting oscillations will allow to create prerequisites for the study of forced oscillations occurring in the winding drum drive and to determine the most unfavorable technological mode from the point of view of dynamic component loads.

Experimental study on longitudinal vibration of mine hosting rope subjected to disturbance excitations by ADAMS

The periodic and impact excitations caused by drum winding and interface misalignment of steel guides always result in hoisting instability in mine shafts. This paper focuses on investigating the longitudinal response of the lifting system subjected to the two disturbance excitations. First, the periodic velocity and acceleration excitation from an experimental model was derived. Second, the virtual prototype model for the longitudinal vibration of the hoisting rope subjected to the two excitations was built in ADAMS, and the validity of the established virtual prototype model was verified experimentally. Eventually, the acceleration of the conveyance under the disturbance excitations were effectively reduced by applying a vibration reduction device, and the virtual simulation results confirmed the effectiveness of the proposed device. This paper can provide a good scheme for the research of vibration reduction in mine hoisting systems.

Wire Tension Coordination Control of Electro-Hydraulic Servo Driven Double-Rope Winding Hoisting Systems Using a Hybrid Controller Combining the Flatness-Based Control and a Disturbance Observer

When the double-rope winding hoisting system (DWHS) is in operation, tensions of two wire ropes of the DWHS will not be symmetrical because of some factors such as different manufacturing deviation between the twin winding drum and two wire ropes, different winding groove depths, the winding asynchronism of two wire ropes, and elastic modulus difference of two wire ropes and so on. Therefore, an electro-hydraulic servo system (EHSS) is employed to actively control two wire ropes tensions to guarantee operation security of the DWHS. Dynamic models of the hoisting system and the EHSS are introduced, of which dynamic model of the DWHS is expressed with state representation. The flatness-based controller (FBC) is designed for the hoisting system. A disturbance observer is utilized to deal with the external disturbance and unmodeled characteristics of the EHSS. Hence, a disturbance observer based integral backstepping controller (DO-BIBC) is designed for the EHSS. The stability of the overall control system is proved by de-fining an overall Lyapunov function. To investigate the property of the proposed controller, an experimental setup of the DWHS is established. As well, comparative experimental results indicate that the proposed controller exhibits a better performance on leveling control of the conveyance and tension coordination control on the two wire ropes than a conventional PI controller.

Gravity and Impedance Compensation of Body Weight Support System Driven by Two Series Elastic Actuators

Robotic devices that can support human’s motions, such as exoskeletons, have recently drawn attention. Body weight support (BWS) systems are potential robotic devices that support and assist trunk motions with elaborate force control for rehabilitation and training exercises. This article presents a BWS system with 2-D motion assistance controlled by two series elastic actuators, which can perform not only weight compensation but also impedance compensation for trunk motion assistance. As the core technology of the proposed system, a wire-driven mechanism is developed that consists of a compact planetary-geared elastic actuator (cPEA), which is a series elastic actuator. All the dynamic aspects of the cPEA output torque, the tension-generating system using a winding drum, and the dynamics interacting with the BWS system are analyzed and used to design a motion-assistive controller. The functionality and ability of the proposed system are validated through experiments performed under various conditions. The results verify that the dynamic behavior of trunk motion can be assisted by the impedance control of the proposed BWS system. In particular, the inertial force required for the trunk motion can be reduced by the proposed BWS system.

Investigation of Dynamic Load in Superdeep Mine Hoisting Systems Induced by Drum Winding

Blair mine hoists powered by drum winding are a key equipment in the transportation of a superdeep mine shaft. The step changes of hoisting velocity and acceleration caused by coil and layer crossover of rope winding on the LeBus drum, which will excite impact responses of hoisting systems, cannot be ignored in the hoisting system with high velocity. The paper focuses on investigating the effect of drum winding on impact responses of superdeep mine hoisting systems. Firstly, the hoisting velocity and acceleration were precisely modelled and calculated according to the structure of rope groove of the LeBus drum; secondly, impact responses of the dynamic displacement and load were obtained by applying the established model; eventually, an experiment was performed, and then, the validity of the established model and the response mechanism was verified. The paper will provide good technical support for the design and optimization of the mine hoists in superdeep mine shafts.

Magnetorheological finishing of grooved drum surface and its performance analysis in winding process

The fine level finishing of grooved drum surfaces is an essential requirement for enhancing the performance of the winding machines in today’s textile industries. The fine level of finishing is required as less as possible on the grooved surface of the textile winding drum. With the least possible roughness value over the external grooved surface of the winding drum, the breakage of the yarn and hairiness of the yarn gets reduced. To accomplish the requirement of finishing the grooved surface of the winding drum, a rectangular-rotating magnetorheological (MR) finishing process is utilized. After the MR finishing, the functional performance of the already using ground grooved winding drum in industry and the present MR finished grooved winding drum has been compared and examined their performance. The functional performance of the MR finished grooved drum is found better than the ground grooved winding drum due to the fine level of finishing. After 60 min of MR finishing, the average surface roughness value of the grooved drum surface gets reduced from 200 nm to 10 nm. Scanning electron microscopy and mirror images are also conducted. These results showed better surface characteristics with the MR finished grooved winding drum than the ground grooved winding drum. After the MR finishing operation, the grooved winding drum is taken to the textile industry. In the industry, the effect of surface roughness on the functional life of the grooved drum is investigated in the winding process. The functional performance has been found better with the MR finished grooved drum surface in the winding process than the ground grooved drum surface.

Prediction and reduction of spatial transverse vibration of hoisting catenaries induced by drum winding in super-deep mine hoists

The paper focuses on predicting and reducing the spatial transverse vibrations of hoisting catenaries, which may cause disordered rope arrangement, induced by drum winding in super-deep mine hoists. Firstly, the governing equations of spatial transverse vibrations of a hoisting catenary and the rope tension have been derived and experimentally validated; subsequently, the functions of the spatial transverse excitation displacements at the drum end and the hoisting velocity have been precisely modelled and calculated, numerical simulation indicated that large amplitude spatial vibrations will be excited by drum winding and that the quasi-static rope tension can be employed to predict the spatial transverse vibrations of the catenary. Eventually, a vibration isolated system is proposed to reduce the spatial transverse vibrations of a catenary, numerical simulation validated the feasibility. The paper will provide good technical supports for the vibration suppression of hoisting catenaries in super-deep mine hoists.

Prediction and reduction of spatial transverse vibration of hoisting catenaries induced by drum winding in super-deep mine hoists

Prediction and reduction of spatial transverse vibration of hoisting catenaries induced by drum winding in super-deep mine hoists

Design of Novel High Performance Dual Rotor Flux-Switching Drum Winding Machine

This paper proposes a novel high performance dual rotor flux-switching drum winding (DRFS-DW) machine. To achieve high torque density, the machine adopted the dual rotor topology to utilize two airgaps boosting torque, and drum winding to maximize the flux linkage. Performance of the drum winding in dual rotor machine was compared with conventional concentrated winding to show its superiority. For better description of high torque density of DRFS-DW machine, flux linkage difference of two different winding configuration for proposed machine was shown with the aid of magnetic equivalent circuit (MEC) and finite element method (FEM) analysis. Drum winding showed higher flux linkage difference, hence higher torque in same driving condition. The DRFS-DW machine was optimized for higher torque density and lower torque ripple. The optimized model was finally compared with conventional FSPMM and initial model to show the improved performance.

Research on The Influence of Rope Jumping on The Tension of Multi-layer Winding Wire Ropes in Super Deep Mine Hoisting Machine

Aimed at the process of rope arrangement in double-rope winding drum of super-deep mine hoist, the tension change during rope jumping fault is studied. By analyzing the relationship between the length difference of two ropes caused by rope jumping and tension, the tension simulation model of multi-layer winding drum rope jumping is established in MATLAB, and the results of simulation and experiment are analyzed and compared. The results show that the rope jumping fault will lead to the tension change of the two ropes, and under different rope jumping faults, the tension change law of the rope is different. The simulation model can well reflect the relationship between rope jumping and tension change, and can quantitatively simulate the tension change during rope jumping. These results have important reference value for fault diagnosis research of hoisting system jump in ultra-deep mine.

Capability study of dry gravity energy storage

Abstract The increasing penetration of intermittent renewable energy sources has renewed interest in energy storage methods and technologies. This paper describes a gravitational potential energy storage method. A review of current storage methods that make use of the principle of gravitational potential energy is done, with a comparison given in terms of power, energy rating and round trip efficiency. One of these gravitational energy storage methods, involving moving a solid mass vertically up and down, is further analysed in terms of energy storage capacity, energy and power density and the levelised cost of storage. Two different hoisting methods are discussed, the first of which is the traditional drum winder hoist and the second is a proposed, multi-piston hoist based on the use of linear electric machines. The two hoist methods produce storage systems with distinctly different properties and storage applications.

Regulating the Coil Stress by Adjusting the Rigidity of the Winding Drum

The sources of defects associated with stability loss of cold-rolled strip coils are established. The influence of the winding-drum structure in cold-rolling mills on the stress–strain state of the coils, both before and after removal from the winding system, is analyzed in detail. The possibility of modifying the stress–strain state of the coils by regulating the rigidity of the winding drum is considered. Recommendations are made regarding the selection of the winding technology for rolled strip.

New processing method to fabricate high-performance carbon-nanotube/polyvinyl alcohol composite films

Bad dispersion, low volume fraction, and poor alignment of long carbon nanotubes (CNTs) in a polymer matrix are the main reasons for the disappointing performance of CNT reinforced polymer composites. Here, we report a novel technique for the preparation of high performance CNT/Polyvinyl alcohol (PVA) composite films, involving continuous production of a hollow cylindrical CNT assembly from a tubular reactor and its in-situ deposition on a paper substrate wrapped on a winding drum under the spray of a PVA solution. The distribution, alignment and loading of CNTs in the composite film are easily tailored by changing the winding rate and the PVA concentration in the spray solution. It is found that the properties of the prepared film are strongly dependent upon the CNT loading in the film. At the optimal high CNT loading of 56.8 wt%, the tensile strength has reached 3.16 GPa, and electrical conductivity 1322 S cm−1. This combination of mechanical and electrical properties is superior to any other CNT/polymer composites developed to date. In terms of its versatility and simplicity, the reported process paves a new way for continuous production of high-performance CNT reinforced composites.

High-Strength Carbon Nanotube Film from Improving Alignment and Densification.

A new method is reported for preparing carbon nanotube (CNT) films. This method involves the continuous production of a hollow cylindrical CNT assembly and its condensation on a winding drum. The alignment and densification of CNTs in the film are improved by controlling the winding rate and imposition of mechanical rolling, respectively. The prepared film has a strength of 9.6 GPa, which is well above those for all other man-made films and fibers.

Application in Composite Machine Using RBF Neural Network Based on PID Control

In the absence of solvent composite machine, because the radius of drum winding and rewinding roller in the transmission process is changing. With the coiled material rolls diameter more and more large, and put the curly size getting smaller and smaller, this has the certain difficulty for the tension control. Therefore, good tension control is non solvent composite is very important. Analyzed the reason and the tension control mathematical model generation composite machine tension in the BOPP production line, for the constant tension control of composite machine, put forward a kind of improved PID control method based on RBF neural network. By the method of Jacobian information identification of RBF neural network, combined with the incremental PID algorithm to realize the self-tuning tension control parameters, control simulation and implementation of the model using Matlab software programming. The simulation results show that, the improved algorithm has better control effect than the general PID.

The Study of Winding Performance in Key Stage on a Parallel Grooved Drum

The parallel grooved multi-layer winding drum can wind rapidly and reliably compared to traditional multi-layer winding drum, because of the special groove which is generated by circular and helical motion. The present paper represented the key winding stage for parallel grooved drum was the helical motion in first circle on the second layer, and the stage was simulated in ADAMS under several factors as fleet angle, winding linear velocity and rope tension. Taguchi method was adopted to estimate the winding performance through two simulation outputs, including the time delay compared to ideal time and the sum of amplitude error during the delayed time. Experiment was applied by considering more factors than that in ADAMS, and the experiment results could verify the validity of simulation in ADAMS. The simulation and experiment results showed that the optimal winding performance could be obtained with certain combination of factors.

Full Hydraulic and Control Systems Application in Open-Cut Mine Drill

The LWD-200B full hydraulic open cut mine drill's hydraulic system uses a variable displacement pump with load sensing constant power, load sensitive electromagnetic proportional multi-way directional valve, high torque hydraulic motor overhead direct drive rotary head, a long stroke hydraulic cylinder and steel wire rope and pulley speed lifting system, hydraulic cylinder to drive the unloading rod mechanism, hydraulic motor driving crawler, double hydraulic cylinder lifting the drill frame mechanism, a hydraulic motor driven cable winding drum, hydraulic legs leveling method. Control system adopts the control handle and the PLC control mode, with real-time data acquisition, computer automatic recognition of lithology and closed loop feedback control and GPS precise positioning function, to achieving the automatic or manual drilling, specified depth or level drilling. Through the test of practice, it is a multifunctional, fully hydraulic, which is intelligent and efficient perforation equipment.

Design of the Low Gravity Simulation System for Planetary Rovers

A large scale gravity compensation system for planetary rovers is designed. The compensation system comprises a tension system and a position system: the tension system generates the constant tension of the string; the position system carries the tension system to follow the horizontal motion of the rover so as to keep the string vertical. To acquire rapidity and dynamic precision without resonating the position system, a macro-micro and open-closed loop design is brought forward: the coaxial macro and micro motors drive the winding drum to adjust the length of the cable; a constant-force mechanism is used to strain the string. The macro motor generates the majority of the tension and suppresses the low-frequency disturbance; the micro motor precisely adjusts the tension of the string to suppress intermediate-frequency disturbance; the constant-force mechanism suppresses high-frequency disturbance with its open loop performance. To precisely follow the rover over a large scale, a double position servo system is used: the girder-trolley system carries the two-dimensional platform; the girder-trolley system covers a large area but is sluggish and imprecise, and therefore is used to imprecisely follow the rover over a large area; the platform is precise and fast but covers a small area, and therefore is used to precisely follow the rover. The system covers a 30 m×30 m area. Experiments show that the position error does not exceed 0.01 m and the force compensation error does not exceed ±0.5% under normal working condition. When step interference emerges, the force compensation error does not exceed 1.5%.

Experimental Investigation of Mechanical Characteristics of Parallel Polygonal Line Groove Multilayer Winding Drum

The characteristics and mechanism of parallel polygonal line groove multilayer winding drum were investigated by an experimental approach. Strain-electricity method was used to test the stress of the cylinder body and the end plates of the drum. Experimental results show that the distribution of the axial bending stress on cylinder body is symmetric in the radial symmetry section. The largest axial bending stress appears in the symmetry plane; however the minimum stress is in the sections close to the end plates on both sides. The axial bending stress of the cylinder body is found to grow with the number of layers wrapped around the drum increasing, while the increment of the stress decreases. When the layer number of the wire rope increases from 4 to 5, the increment of the stress is less than 3 [MPa].

Winder control using a Ward-Leonard system

An electrically driven winder for a deep shaft mine is considered. The system comprises a two stage Ward-Leonard motor-generator set, a winding drum, head and reduction gear and a braking unit, for which a linear model is derived. A minimum control effort regulation strategy is proposed enabling the simultaneous regulation of the motor speed and armature current. The computed responses for the system are presented for open and closed loop conditions. The effectiveness of the system when following particular, demanded speed requirements is investigated. The control energy dissipation and regenerative braking performance of the system are commented upon.