Self-adaptive adjustment method and system for twisting tension of copper stranded wire

Abstract

The invention discloses a self-adaptive adjustment method and system for twisting tension of a copper stranded wire. According to a state analysis result, a dynamic coupling adjustment mechanism is started, rapid response adjustment of tension is achieved by adjusting the matching relation between the rotating speed of a stranding cage and the linear speed of a traction wheel and linkage with the exciting current of a magnetic powder brake, tension data are rapidly collected through a sensor, and after filtering and abnormal value processing, the tension is obtained. The fluctuation frequency and amplitude are analyzed immediately, and adjustment is started once the fluctuation frequency and amplitude exceed a set range. During adjustment, the ratio of the rotating speed of the stranding cage to the speed of the traction wheel is adjusted, the current of the magnetic powder brake is linked, mechanical adjustment and electromagnetic braking are matched, and the response speed is much faster than that of traditional single-parameter adjustment. Therefore, the stress of the copper stranded wire in the stranding process is uniform, the wire diameter is not thinned or burrs are not formed on the surface due to sudden change of tension, the stranded wire pitch is uniform, the process requirement is met, and the influence on the stranded wire quality due to sudden change of the tension is avoided as much as possible.

Description

Technical Field

[0001] This invention belongs to the field of stranded wire production technology, specifically a method and system for adaptive adjustment of stranding tension of copper stranded wire. Background Technology

[0002] Stirring tension adjustment of copper stranded wire refers to a crucial process in copper stranded wire production. This involves precisely controlling the tension of each individual wire during the stranding process to ensure a compact structure, uniform shape, and stable performance in the finished product. This adjustment process requires comprehensive consideration of material properties, equipment parameters, and process requirements. It utilizes devices such as tension sensors and closed-loop control systems to monitor and adjust the tension in real time, preventing problems such as loose strands, skipped wires, or wire breakage caused by uneven tension. Proper stranding tension adjustment not only improves the mechanical strength and conductivity of copper stranded wire but also effectively extends its service life. It is widely used in power cables, communication cables, and electrical connection wires, and is an important technical means to ensure product quality and production efficiency.

[0003] However, existing technologies are slow to adjust tension, mostly only adjusting a single parameter such as the winch speed or traction speed. This results in poor coordination with the braking system, large tension fluctuations, and inconsistent wire diameter. When changing to different wire diameters or materials, operators must manually adjust the reference values ​​and adjustment thresholds, relying entirely on experience. This process is time-consuming and prone to wire breakage or surface scratches due to improper parameter adjustments, leading to a high scrap rate. Summary of the Invention

[0004] The purpose of this invention is to provide a method and system for adaptive adjustment of the stranding tension of copper stranded wire in order to solve the problems mentioned above.

[0005] The technical solution adopted in this invention is as follows: A method for adaptive adjustment of the stranding tension of copper stranded wire, comprising the following steps:

[0006] S1: Set the target tension benchmark value and allowable fluctuation range during the copper stranding process, providing initial parameter basis for real-time tension acquisition in S2 and adjustment decision in S5.

[0007] S2: Real-time acquisition of strand tension data is achieved by a high-precision tension sensor installed at the entrance of the stranding die, and the raw signal is transmitted to the data preprocessing unit of S3 for filtering.

[0008] S3: Perform moving average filtering and outlier removal on the tension signal transmitted by S2, and synchronize the processed valid data to the tension state analysis module of S4.

[0009] S4: Based on the tension data preprocessed in S3, analyze the current tension fluctuation frequency and amplitude characteristics. If the fluctuation exceeds the allowable range set in S1, trigger the adaptive adjustment process in S5.

[0010] S5: Based on the state analysis results of S4, the dynamic coupling adjustment mechanism is activated. By adjusting the ratio between the speed of the winch and the linear speed of the traction wheel, and linking the excitation current of the magnetic powder brake in S6, the tension can be quickly adjusted in response.

[0011] S6: After receiving the adjustment command from S5, it adjusts the excitation current of the magnetic powder brake through the precision servo controller, changes the braking torque, and feeds back the real-time current value to the adjustment effect verification unit of S7.

[0012] S7: Collect the real-time tension data after adjustment in S2 and compare it with the target reference value in S1. If the deviation is still not eliminated, continue to send a secondary adjustment request to S5 until the tension stabilizes within the allowable range.

[0013] S8: Records the adjustment process data of S5-S7 each time, and automatically corrects the target tension benchmark value of S1 and the fluctuation judgment threshold of S4 through the accumulated historical adjustment cases, thereby improving the system's adaptability to stranded wires of different diameters and materials.

[0014] In a preferred embodiment, in step S1, a target reference value and allowable fluctuation range for the stranding tension of the copper stranded wire are set. The reference value is set in stages according to the wire diameter and material characteristics of the copper stranded wire. For wire diameters of 0.3mm to 0.6mm, the reference value is 8N to 15N; for wire diameters of 0.6mm to 1.2mm, the reference value is 15N to 25N. The allowable fluctuation range is controlled within ±3% to ±8%, and the fluctuation range is widened proportionally for larger wire diameters. At the same time, the ideal ratio k0 between the winding speed and the linear speed of the traction wheel is preset, with a value range of 1.2 to 1.8. The specific value is calculated based on the stranding pitch requirements. For a pitch of 10mm to 30mm, the k0 value is 1.2 to 1.5; for a pitch of 30mm to 50mm, the k0 value is 1.5 to 1.8. These parameters will serve as the initial basis for subsequent tension acquisition, analysis, and adjustment.

[0015] In a preferred embodiment, in step S2, an S-shaped tension sensor is installed 10cm from the entrance of the stranding die. The sensor has a range of 0-50N, an accuracy class of 0.1%FS, and a sampling frequency set to 500Hz. It is connected to the data preprocessing unit via shielded twisted-pair cable to ensure anti-interference capability during signal transmission. The sensor must be installed perpendicular to the stranded wire direction. The contact roller is made of polytetrafluoroethylene (PTFE), with a diameter of 20mm and a surface roughness Ra of 0.8μm, to avoid damage to the copper stranded wire surface. The raw tension signal acquired in real time is transmitted to the data preprocessing unit in step S3 every 1ms.

[0016] In a preferred embodiment, in step S3, the tension signal transmitted in S2 is subjected to moving average filtering with a window size of 20 sampling points, i.e., a 40ms time window. Simultaneously, a 3x standard deviation method is used to remove outliers; when three consecutive sampling points exceed ±3x standard deviation, it is considered an outlier, and the outlier is replaced by the arithmetic mean of the first five valid sampling points. The processed valid tension data is synchronized to the tension state analysis module in S4 every 10ms. Data synchronization uses the Modbus RTU protocol with a transmission baud rate of 9600bps to ensure that the data update rate meets the real-time analysis requirements.

[0017] In a preferred embodiment, in step S4, when S4 determines that the tension fluctuation exceeds the allowable range, the system first extracts the dominant frequency f and the maximum amplitude A obtained from the analysis in S4, and calculates the current winch rotation speed ω in real time. c With the linear velocity v of the traction wheel t The actual ratio k act =ω c / v t By comparing the preset ideal ratio k0 in S1, the basic adjustment amount Δk = k0 - k is obtained. act .

[0018] To achieve dynamic coupling, a compensation factor based on wave characteristics is introduced. When f > 1.2 Hz, a high-frequency suppression mode is activated, according to Δk. h =Δk+0.03A·f correction adjustment amount; when f≤1.2Hz, the low frequency stabilization mode is adopted, and the cumulative adjustment amount is Δk1=Δk+0.05A·∫ΔTdt, where ∫ΔTdt is the tension deviation integral value after S3 preprocessing.

[0019] After being limited, the adjustment amount is applied to the winch frequency converter and the traction wheel servo controller respectively, and ω is output synchronously. c’ =ω c ·(1+Δk') and v t’ =v t The control signal of (1-Δk') is simultaneously linked to S6 according to the absolute value of Δk'. When |Δk'|>0.08, the excitation current adjustment coefficient of the magnetic powder brake is increased from the conventional value of 1.2 times to 1.5 times, realizing the coordinated response of mechanical adjustment and electromagnetic braking.

[0020] The formula for nonlinearly superimposing the basic deviation and the fluctuation characteristic parameter is as follows:

[0021] Δk'=Δk+0.02Afe -0.1|Δk| ;

[0022] In the formula:

[0023] Δk' is the final ratio correction factor;

[0024] Δk is the basic proportion deviation;

[0025] A represents the maximum amplitude of tension fluctuation detected by S4, in N.

[0026] f is the dominant frequency of tension fluctuation in S4 analysis, in units of Hz, and e is the natural constant.

[0027] In a preferred embodiment, in step S5, the dynamic coupling adjustment mechanism is activated based on the state analysis results of S4. First, the encoder collects the winch rotation speed ωc and the traction wheel linear speed vt in real time with a sampling period of 100ms. The actual ratio kact = ωc / vt is calculated and compared with the ideal ratio k0 preset in S1 to obtain the basic adjustment amount Δk = k0 - kact.

[0028] When the main frequency f detected by S4 is greater than 1.2Hz, the high-frequency suppression mode is activated, and the adjustment amount is corrected according to Δkh=Δk+0.03A·f;

[0029] When f≤1.2Hz, the low-frequency stabilization mode is activated, and the cumulative adjustment is set to Δkl=Δk+0.05A·∫ΔTdt, where ∫ΔTdt is the integral value of the tension deviation after S3 preprocessing, and the integration time constant is 0.5s.

[0030] The adjustment amount is output after being limited, with a limiting range of ±0.1. It acts synchronously on the winch frequency converter and the traction wheel servo controller, outputting control signals ωc'=ωc·(1+Δk') and vt'=vt·(1-Δk'). When |Δk'|>0.08, the excitation current adjustment coefficient of the magnetic powder brake of S6 is increased from 1.2 times to 1.5 times.

[0031] In a preferred embodiment, in step S6, after receiving the adjustment command from S5, the excitation current of the magnetic powder brake is adjusted by a precision servo controller. The controller output signal is a standard current of 4–20 mA, corresponding to an excitation current adjustment range of 0–2 A, with an adjustment accuracy of ±0.5% and a response time ≤50 ms. The braking torque of the magnetic powder brake is linearly related to the excitation current, with a linearity error ≤2% and a rated torque range of 0.5–10 N·m. The real-time current value is converted into a 0–5 V voltage signal through a sampling resistor and fed back to the adjustment effect verification unit in S7 at a feedback frequency of 1 kHz to ensure closed-loop monitoring of the adjustment process.

[0032] In a preferred embodiment, in step S7, real-time tension data after adjustment in S2 is collected, with a sampling period of 50ms. The tension values ​​at 5 sampling points are continuously monitored and compared with the target reference value set in S1 to calculate the percentage deviation. If the percentage deviation exceeds the allowable fluctuation range for 3 consecutive sampling periods, a secondary adjustment request is sent to S5, with an adjustment interval of 200ms. The correction amount for each secondary adjustment is 60% of the initial adjustment amount. A maximum of 5 secondary adjustment requests are sent consecutively. If a stable state is still not reached, a system alarm is triggered, and the alarm signal is output through an audible and visual alarm. At the same time, the twisting process is paused.

[0033] In a preferred embodiment, step S8 records the adjustment process data for each of S5-S7, including adjustment timestamps, initial tension values, dominant fluctuation frequency f, maximum amplitude A, basic adjustment amount Δk, final correction coefficient Δk', and stable tension values ​​after adjustment. The data storage capacity is no less than 100,000 records, with a storage period of 3 months. The system automatically executes a parameter correction program at 2:00 AM daily. Based on adjustment cases from the past 24 hours, a weighted average method is used to correct the target tension benchmark value of S1, with a correction range not exceeding ±5%. Simultaneously, based on the historical statistical characteristics of tension fluctuations, the fluctuation judgment threshold of S4 is adjusted. When the proportion of high-frequency fluctuations (f>1.2Hz) exceeds 30%, the activation threshold of the high-frequency suppression mode is lowered from 1.2Hz to 1.0Hz, improving the system's adaptability to complex operating conditions.

[0034] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0035] 1. In this invention, tension data is rapidly acquired through sensors. After filtering and outlier processing, the frequency and amplitude of fluctuations are immediately analyzed. Once the fluctuations exceed the set range, adjustment is initiated. The adjustment not only modifies the ratio of the winch speed and the traction wheel speed but also links the current of the magnetic powder brake. This combination of mechanical adjustment and electromagnetic braking results in a significantly faster response speed than traditional single-parameter adjustment. Consequently, the copper stranded wire experiences uniform stress during stranding, preventing thinning of the wire diameter or surface burrs due to sudden tension changes. The resulting stranded wire has a uniform pitch, meeting process requirements and minimizing the impact of fluctuating tension on wire quality.

[0036] 2. In this invention, the effect is verified after each adjustment. If the adjustment is not satisfactory, it continues until the tension stabilizes. Furthermore, all adjustment data is recorded, gradually refining the initial baseline value and fluctuation judgment criteria. For example, if a thicker copper wire is used, the system automatically increases the baseline tension, widening the fluctuation range; in cases of high-frequency vibration, a suppression mode is activated in advance. This eliminates the need for operators to manually adjust parameters based on experience, reducing human error, improving production efficiency, and lowering the scrap rate. Attached Figure Description

[0037] Figure 1 This is a schematic diagram illustrating the process principle of the present invention. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0039] Example:

[0040] Reference Figure 1 An adaptive adjustment method for the stranding tension of copper stranded wire, the method comprising the following steps:

[0041] S1: Set the target tension benchmark value and allowable fluctuation range during the copper stranding process, providing initial parameter basis for real-time tension acquisition in S2 and adjustment decision in S5.

[0042] S2: Real-time acquisition of strand tension data is achieved by a high-precision tension sensor installed at the entrance of the stranding die, and the raw signal is transmitted to the data preprocessing unit of S3 for filtering.

[0043] S3: Perform moving average filtering and outlier removal on the tension signal transmitted by S2, and synchronize the processed valid data to the tension state analysis module of S4.

[0044] S4: Based on the tension data preprocessed in S3, analyze the current tension fluctuation frequency and amplitude characteristics. If the fluctuation exceeds the allowable range set in S1, trigger the adaptive adjustment process in S5.

[0045] S5: Based on the state analysis results of S4, the dynamic coupling adjustment mechanism is activated. By adjusting the ratio between the speed of the winch and the linear speed of the traction wheel, and linking the excitation current of the magnetic powder brake in S6, the tension can be quickly adjusted in response.

[0046] S6: After receiving the adjustment command from S5, it adjusts the excitation current of the magnetic powder brake through the precision servo controller, changes the braking torque, and feeds back the real-time current value to the adjustment effect verification unit of S7.

[0047] S7: Collect the real-time tension data after adjustment in S2 and compare it with the target reference value in S1. If the deviation is still not eliminated, continue to send a secondary adjustment request to S5 until the tension stabilizes within the allowable range.

[0048] S8: Records the adjustment process data of S5-S7 each time, and automatically corrects the target tension benchmark value of S1 and the fluctuation judgment threshold of S4 through the accumulated historical adjustment cases, thereby improving the system's adaptability to stranded wires of different diameters and materials.

[0049] In step S1, the target reference value and allowable fluctuation range of the copper stranded wire tension are set. The reference value is set according to the wire diameter and material characteristics of the copper stranded wire. The reference value is 8N to 15N for a wire diameter of 0.3mm to 0.6mm, and 15N to 25N for a wire diameter of 0.6mm to 1.2mm. The allowable fluctuation range is controlled within ±3% to ±8%. The fluctuation range is widened proportionally for larger wire diameters. At the same time, the ideal ratio k0 between the winch speed and the traction wheel linear speed is preset, with a value range of 1.2 to 1.8. The specific value is calculated based on the stranding pitch requirements. The k0 value is 1.2 to 1.5 for a pitch of 10mm to 30mm, and 1.5 to 1.8 for a pitch of 30mm to 50mm. These parameters will serve as the initial basis for subsequent tension acquisition, analysis, and adjustment.

[0050] In step S2, an S-shaped tension sensor is installed 10cm from the entrance of the stranding die. The sensor has a range of 0-50N, an accuracy class of 0.1%FS, and a sampling frequency of 500Hz. It is connected to the data preprocessing unit via shielded twisted-pair cable to ensure anti-interference capability during signal transmission. The sensor must be installed perpendicular to the stranded wire direction. The contact roller is made of polytetrafluoroethylene (PTFE), with a diameter of 20mm and a surface roughness of Ra0.8μm to avoid damaging the surface of the copper stranded wire. The raw tension signal acquired in real time is transmitted to the data preprocessing unit in step S3 every 1ms.

[0051] In step S3, the tension signal transmitted in S2 is processed by a moving average filter with a window size of 20 sampling points (40ms). Outlier removal is performed using a 3x standard deviation method; if three consecutive sampling points exceed ±3x standard deviation, it is considered an outlier, and the outlier is replaced by the arithmetic mean of the first five valid sampling points. The processed valid tension data is synchronized to the tension state analysis module in S4 every 10ms. Data synchronization uses the Modbus RTU protocol with a transmission baud rate of 9600bps to ensure the data update rate meets the real-time analysis requirements.

[0052] In step S4, when S4 determines that the tension fluctuation exceeds the allowable range, the system first extracts the dominant frequency f and the maximum amplitude A obtained from the analysis in S4, and then calculates the current winch rotation speed ω in real time. c With the linear velocity v of the traction wheel t The actual ratio k act =ω c / v t By comparing the preset ideal ratio k0 in S1, the basic adjustment amount Δk = k0 - k is obtained. act .

[0053] To achieve dynamic coupling, a compensation factor based on wave characteristics is introduced. When f > 1.2 Hz, a high-frequency suppression mode is activated, according to Δk. h=Δk+0.03A·f correction adjustment amount; when f≤1.2Hz, the low frequency stabilization mode is adopted, and the cumulative adjustment amount is Δk1=Δk+0.05A·∫ΔTdt, where ∫ΔTdt is the tension deviation integral value after S3 preprocessing.

[0054] After being limited, the adjustment amount is applied to the winch frequency converter and the traction wheel servo controller respectively, and ω is output synchronously. c’ =ω c ·(1+Δk') and v t’ =v t The control signal of (1-Δk') is simultaneously linked to S6 according to the absolute value of Δk'. When |Δk'|>0.08, the excitation current adjustment coefficient of the magnetic powder brake is increased from the conventional value of 1.2 times to 1.5 times, realizing the coordinated response of mechanical adjustment and electromagnetic braking.

[0055] The formula for nonlinearly superimposing the basic deviation and the fluctuation characteristic parameter is as follows:

[0056] Δk'=Δk+0.02Afe -0.1|Δk| ;

[0057] In the formula:

[0058] Δk' is the final ratio correction factor;

[0059] Δk is the basic proportion deviation;

[0060] A represents the maximum amplitude of tension fluctuation detected by S4, in N.

[0061] f is the dominant frequency of tension fluctuation in S4 analysis, in units of Hz, and e is the natural constant.

[0062] In step S5, the dynamic coupling adjustment mechanism is activated based on the state analysis results of S4. First, the encoder collects the winch speed ωc and the traction wheel linear speed vt in real time with a sampling period of 100ms. The actual ratio kact = ωc / vt is calculated and compared with the ideal ratio k0 preset in S1 to obtain the basic adjustment amount Δk = k0 - kact.

[0063] When the main frequency f detected by S4 is greater than 1.2Hz, the high-frequency suppression mode is activated, and the adjustment amount is corrected according to Δkh=Δk+0.03A·f;

[0064] When f≤1.2Hz, the low-frequency stabilization mode is activated, and the cumulative adjustment is Δk1=Δk+0.05A·∫ΔTdt, where ∫ΔTdt is the integral value of the tension deviation after S3 preprocessing, and the integration time constant is 0.5s.

[0065] The adjustment amount is output after being limited, with a limiting range of ±0.1. It acts synchronously on the winch frequency converter and the traction wheel servo controller, outputting control signals ωc'=ωc·(1+Δk') and vt'=vt·(1-Δk'). When |Δk'|>0.08, the excitation current adjustment coefficient of the magnetic powder brake of S6 is increased from 1.2 times to 1.5 times.

[0066] In step S6, after receiving the adjustment command from S5, the excitation current of the magnetic powder brake is adjusted through a precision servo controller. The controller output signal is a standard current of 4–20mA, corresponding to an excitation current adjustment range of 0–2A, with an adjustment accuracy of ±0.5% and a response time of ≤50ms. The braking torque of the magnetic powder brake is linearly related to the excitation current, with a linearity error of ≤2% and a rated torque range of 0.5–10 N·m. The real-time current value is converted into a 0–5V voltage signal through a sampling resistor and fed back to the adjustment effect verification unit in S7 at a feedback frequency of 1kHz to ensure closed-loop monitoring of the adjustment process.

[0067] In step S7, real-time tension data after adjustment in S2 is collected, with a sampling period of 50ms. The tension values ​​at 5 sampling points are continuously monitored and compared with the target reference value set in S1 to calculate the percentage deviation. If the percentage deviation exceeds the allowable fluctuation range for 3 consecutive sampling periods, a secondary adjustment request is sent to S5, with an adjustment interval of 200ms. The correction amount for each secondary adjustment is 60% of the initial adjustment amount. A maximum of 5 secondary adjustment requests are sent consecutively. If a stable state is still not reached, a system alarm is triggered, and the alarm signal is output through an audible and visual alarm. At the same time, the twisting process is paused.

[0068] In step S8, data from each adjustment process in S5-S7 is recorded, including adjustment timestamp, initial tension value, dominant fluctuation frequency f, maximum amplitude A, basic adjustment amount Δk, final correction coefficient Δk', and stable tension value after adjustment. The data storage capacity is no less than 100,000 records, with a storage period of 3 months. The system automatically executes a parameter correction program at 2:00 AM daily. Based on adjustment cases from the past 24 hours, a weighted average method is used to correct the target tension benchmark value of S1, with a correction range not exceeding ±5%. Simultaneously, based on the historical statistical characteristics of tension fluctuations, the fluctuation judgment threshold of S4 is adjusted. When high-frequency fluctuations (f>1.2Hz) account for more than 30%, the activation threshold of the high-frequency suppression mode is lowered from 1.2Hz to 1.0Hz to improve the system's adaptability to complex operating conditions.

[0069] An adaptive tension adjustment system for copper stranded wire is provided, which is applied to the aforementioned adaptive tension adjustment method for copper stranded wire.

[0070] From the above, we can conclude that:

[0071] In this invention, tension data is rapidly acquired via sensors. After filtering and outlier processing, the frequency and amplitude of fluctuations are immediately analyzed. Adjustment is initiated if the data exceeds a set range. The adjustment not only modifies the ratio of the winch speed and the traction wheel speed but also links the current of the magnetic powder brake. This combination of mechanical adjustment and electromagnetic braking results in a significantly faster response time than traditional single-parameter adjustment. Consequently, the copper stranded wire experiences uniform stress during stranding, preventing thinning or surface burrs caused by sudden tension changes. The resulting stranded wire has a uniform pitch, meeting process requirements and minimizing the impact of fluctuating tension on wire quality.

[0072] In this invention, the effect is verified after each adjustment; if not properly adjusted, adjustments continue until the tension stabilizes. Furthermore, data from all adjustments is recorded, gradually refining the initial baseline value and fluctuation judgment criteria. For example, if a thicker copper wire is used, the system automatically increases the baseline tension, widening the fluctuation range; in cases of high-frequency vibration, a suppression mode is activated in advance. This eliminates the need for operators to manually adjust parameters based on experience, reducing human error, improving production efficiency, and lowering the scrap rate.

[0073] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0074] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for adaptive adjustment of stranding tension of copper stranded wire, characterized in that: The method includes the following steps: S1: Set the target tension benchmark value and allowable fluctuation range during the copper stranding process to provide initial parameter basis for real-time tension acquisition in S2 and adjustment decision in S5; S2: Real-time acquisition of strand tension data is achieved by a high-precision tension sensor installed at the entrance of the stranding die, and the raw signal is transmitted to the data preprocessing unit of S3 for filtering. S3: Perform moving average filtering and outlier removal on the tension signal transmitted by S2, and synchronize the processed valid data to the tension state analysis module of S4. S4: Based on the tension data preprocessed in S3, analyze the current tension fluctuation frequency and amplitude characteristics. If the fluctuation exceeds the allowable range set in S1, trigger the adaptive adjustment process in S5. S5: Based on the state analysis results of S4, the dynamic coupling adjustment mechanism is activated. By adjusting the ratio between the speed of the winch and the linear speed of the traction wheel, and linking the excitation current of the magnetic powder brake in S6, the tension can be quickly adjusted in response. S6: After receiving the adjustment command from S5, it adjusts the excitation current of the magnetic powder brake through the precision servo controller, changes the braking torque, and feeds back the real-time current value to the adjustment effect verification unit of S7. S7: Collect the real-time tension data after S2 adjustment and compare it with the target reference value of S1. If the deviation is still not eliminated, continue to send a second adjustment request to S5 until the tension stabilizes within the allowable range. S8: Records the adjustment process data of S5-S7 each time, and automatically corrects the target tension benchmark value of S1 and the fluctuation judgment threshold of S4 through the accumulated historical adjustment cases, thereby improving the system's adaptability to stranded wires of different diameters and materials.

2. The adaptive adjustment method for stranding tension of copper stranded wire as described in claim 1, characterized in that: In step S1, the target reference value and allowable fluctuation range of the copper stranded wire tension are set. The reference value is set according to the wire diameter and material characteristics of the copper stranded wire. The reference value is 8N to 15N for a wire diameter of 0.3mm to 0.6mm, and 15N to 25N for a wire diameter of 0.6mm to 1.2mm. The allowable fluctuation range is controlled within ±3% to ±8%. The fluctuation range is widened proportionally for larger wire diameters. At the same time, the ideal ratio k0 between the winding speed and the linear speed of the traction wheel is preset, with a value range of 1.2 to 1.

8. The specific value is calculated according to the stranding pitch requirements. The k0 value is 1.2 to 1.5 for a pitch of 10mm to 30mm, and 1.5 to 1.8 for a pitch of 30mm to 50mm. These parameters will serve as the initial basis for subsequent tension acquisition, analysis and adjustment.

3. The adaptive adjustment method for stranding tension of copper stranded wire as described in claim 1, characterized in that: In step S2, an S-shaped tension sensor is installed 10cm from the entrance of the stranding die. The sensor has a range of 0-50N, an accuracy class of 0.1%FS, and a sampling frequency of 500Hz. It is connected to the data preprocessing unit via a shielded twisted pair cable to ensure anti-interference capability during signal transmission. When installing the sensor, it is necessary to ensure that it is perpendicular to the direction of the stranded wire. The contact roller is made of polytetrafluoroethylene with a diameter of 20mm and a surface roughness of Ra0.8μm to avoid damaging the surface of the copper stranded wire. The raw tension signal collected in real time is transmitted to the data preprocessing unit in S3 every 1ms.

4. The adaptive adjustment method for stranding tension of copper stranded wire as described in claim 1, characterized in that: In step S3, the tension signal transmitted in S2 is subjected to moving average filtering with a window size of 20 sampling points, i.e., a 40ms time window. At the same time, outlier removal is performed using the 3x standard deviation method. When three consecutive sampling points exceed the range of ±3x standard deviation, it is judged as an outlier. Outliers are replaced by the arithmetic mean of the first five valid sampling points. The processed valid tension data is synchronized to the tension state analysis module in S4 every 10ms. Data synchronization adopts the Modbus RTU protocol with a transmission baud rate of 9600bps to ensure that the data update rate meets the real-time analysis requirements.

5. The adaptive adjustment method for stranding tension of copper stranded wire as described in claim 1, characterized in that: In step S4, when S4 determines that the tension fluctuation exceeds the allowable range, the system first extracts the dominant frequency f and the maximum amplitude A obtained from the analysis in S4, and then calculates the current winch rotation speed ω in real time. c With the linear velocity v of the traction wheel t The actual ratio k act =ω c / v t By comparing the preset ideal ratio k0 in S1, the basic adjustment amount Δk = k0 - k is obtained. act ; To achieve dynamic coupling, a compensation factor based on wave characteristics is introduced. When f > 1.2 Hz, a high-frequency suppression mode is activated, according to Δk. h =Δk+0.03A·f correction adjustment amount; when f≤1.2Hz, the low frequency stabilization mode is adopted, and the cumulative adjustment amount is Δk1=Δk+0.05A·∫ΔTdt, where ∫ΔTdt is the tension deviation integral value after S3 preprocessing; After being limited, the adjustment amount is applied to the winch frequency converter and the traction wheel servo controller respectively, and ω is output synchronously. c’ =ω c ·(1+Δk') and v t’ =v t The control signal of (1-Δk') is simultaneously linked to S6 according to the absolute value of Δk'. When Δk'|>0.08, the excitation current adjustment coefficient of the magnetic powder brake is increased from the conventional value of 1.2 times to 1.5 times, realizing the coordinated response of mechanical adjustment and electromagnetic braking. The formula for nonlinearly superimposing the basic deviation and the fluctuation characteristic parameter is as follows: Δk′=Δk+0.02Afe -0.1|Δk| ; In the formula: Δk' is the final ratio correction factor; Δk is the basic proportion deviation; A represents the maximum amplitude of tension fluctuation detected by S4, in N; f is the dominant frequency of tension fluctuation in the S4 analysis, in Hz; e is a natural constant.

6. The adaptive adjustment method for stranding tension of copper stranded wire as described in claim 1, characterized in that: In step S5, the dynamic coupling adjustment mechanism is activated based on the state analysis results of S4. First, the encoder collects the winch speed ωc and the traction wheel linear speed vt in real time with a sampling period of 100ms. The actual ratio kact = ωc / vt is calculated and compared with the ideal ratio k0 preset in S1 to obtain the basic adjustment amount Δk = k0-kact. When the main frequency f detected by S4 is greater than 1.2Hz, the high-frequency suppression mode is activated, and the adjustment amount is corrected according to Δkh=Δk+0.03A·f; When f≤1.2Hz, the low-frequency stabilization mode is activated, and the cumulative adjustment is Δkl=Δk+0.05A·∫ΔTdt, where ∫ΔTdt is the integral value of the tension deviation after S3 preprocessing, and the integration time constant is 0.5s; The adjustment amount is output after being limited, with a limiting range of ±0.

1. It acts synchronously on the winch frequency converter and the traction wheel servo controller, outputting control signals ωc'=ωc·(1+Δk') and vt'=vt·(1-Δk'). When |Δk'|>0.08, the excitation current adjustment coefficient of the magnetic powder brake of S6 is increased from 1.2 times to 1.5 times.

7. The adaptive adjustment method for stranding tension of copper stranded wire as described in claim 1, characterized in that: In step S6, after receiving the adjustment command from S5, the excitation current of the magnetic powder brake is adjusted by a precision servo controller. The controller output signal is a standard current of 4-20mA, corresponding to an excitation current adjustment range of 0-2A, with an adjustment accuracy of ±0.5% and a response time of ≤50ms. The braking torque of the magnetic powder brake is linearly related to the excitation current, with a linearity error of ≤2% and a rated torque range of 0.5-10N·m. The real-time current value is converted into a 0-5V voltage signal through a sampling resistor and fed back to the adjustment effect verification unit in S7 at a feedback frequency of 1kHz to ensure closed-loop monitoring of the adjustment process.

8. The adaptive adjustment method for stranding tension of copper stranded wire as described in claim 1, characterized in that: In step S7, real-time tension data after adjustment in S2 is collected with a sampling period of 50ms. The tension values ​​of 5 sampling points are continuously monitored and compared with the target reference value set in S1 to calculate the deviation percentage. If the deviation percentage exceeds the allowable fluctuation range for 3 consecutive sampling periods, a secondary adjustment request is sent to S5 with an adjustment interval of 200ms. The correction amount of each secondary adjustment is 60% of the amount of the first adjustment. A maximum of 5 secondary adjustment requests are sent continuously. If a stable state is still not reached, a system alarm is triggered, and the alarm signal is output through an audible and visual alarm. At the same time, the twisting process is paused.

9. The adaptive adjustment method for stranding tension of copper stranded wire as described in claim 1, characterized in that: In step S8, the adjustment process data of each S5-S7 is recorded, including adjustment timestamp, initial tension value, main fluctuation frequency f, maximum amplitude A, basic adjustment amount Δk, final correction coefficient Δk', and stable tension value after adjustment. The data storage capacity is no less than 100,000 records, and the storage period is 3 months. The system automatically executes the parameter correction program at 2:00 AM every day. Based on the adjustment cases of the past 24 hours, the target tension benchmark value of S1 is corrected using a weighted average method, with the correction range not exceeding ±5%. At the same time, according to the historical statistical characteristics of tension fluctuation, the fluctuation judgment threshold of S4 is adjusted. When the proportion of high-frequency fluctuation (f>1.2Hz) exceeds 30%, the activation threshold of high-frequency suppression mode is lowered from 1.2Hz to 1.0Hz to improve the system's adaptability to complex working conditions.

10. A copper stranded wire stranding tension adaptive adjustment system, characterized in that: The system is applied to the adaptive adjustment method for stranding tension of copper stranded wire as described in any one of claims 1 to 9.

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