A continuous drawing and annealing production control system for oxygen-free copper wire

Abstract

This invention relates to the field of metal wire processing control, and discloses a continuous drawing and annealing production control system for oxygen-free copper wire. The system includes a data acquisition module for collecting basic operating conditions, tension reference, and environmental reference data; a feedforward control module that uses incremental enthalpy calculation to generate an annealing voltage setpoint signal to control the annealing power supply; a collaborative cooling module that combines electrical Joule heating and mechanical enthalpy increments to calculate the total heat at the nodes and generate commands to control the cooling water frequency converter and regulating valve; a bidirectional decoupling module that obtains the effective slip factor and slip deterioration rate, and generates pneumatic back pressure pulses and power intervention signals to perform bidirectional decoupling; and a winding control module that generates commands to control the end winding and wire-laying motor. This invention, by establishing an electromechanical feedforward and bidirectional decoupling mechanism, quantitatively compensates for abnormal mechanical heat and progressively suppresses micro-slippage of the conductive wheel, thus avoiding overheating and arcing / breakage defects in the oxygen-free copper wire.

Description

Technical Field

[0001] This invention relates to the field of metal wire processing control, specifically to a continuous drawing and annealing production control system for oxygen-free copper wire. Background Technology

[0002] The production process of oxygen-free copper wire typically employs a combination of continuous drawing and online annealing to ensure the wire's mechanical and electrical properties. In continuous production, the electro-thermal-dynamic and mechanical-dynamic states of the equipment are coupled, placing high demands on the real-time performance and coordination of the control system.

[0003] As production progresses, wear of the drawing die or deterioration of the lubricant can increase the mechanical resistance of the drawing process, causing additional mechanical frictional heating inside the wire. Existing annealing control systems mostly adopt a delayed temperature feedback control mode. Due to the physical delay in the response of the temperature sensor, by the time the system detects the temperature rise and lowers the annealing voltage, the mechanical frictional heating and electrical heating have often already superimposed, which can easily lead to defects such as overheating and coarse grains in oxygen-free copper wire.

[0004] Meanwhile, in the process of wire entering the cooling zone after annealing, existing equipment usually relies on non-contact infrared temperature measurement feedback or uses fixed frequency water supply. It is difficult to perform high-precision real-time surface temperature measurement on high-speed moving thin-diameter wires, and the temperature measuring element has the problem of slow response. As a result, the system cannot accurately quantify the comprehensive heat load of the wire before cooling, and the flow rate of the cooling medium cannot match the actual heat dissipation requirements, which can easily cause uneven quenching of the wire.

[0005] Furthermore, continuous drawing and annealing production lines involve multi-stage dynamic transmission, including front-end drawing, mid-stage annealing, and end-stage winding. When faced with transient tension fluctuations, the wire is prone to micro-slippage on the surface of the annealing conductive wheel. Existing control systems typically balance macroscopic tension by adjusting the speed of the end-stage winding motor, which cannot suppress localized mechanical oscillations in a timely manner. Once the micro-slippage condition worsens, arcing discharge can easily occur between the wire and the conductive wheel contact surface, leading to localized burnout of the oxygen-free copper wire or even wire breakage and shutdown. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a continuous drawing and annealing production control system for oxygen-free copper wire. This system solves the problems of existing technologies lacking a comprehensive compensation mechanism for mechanical and electrical heating, making it difficult to solve the problems of wire overheating and uneven quenching, and lacking the ability to coordinate and decouple control to suppress arcing caused by slippage of conductive wheels when facing tension fluctuations.

[0007] To achieve the above objectives, the present invention provides the following technical solution: This invention provides a continuous drawing and annealing production control system for oxygen-free copper wire, comprising: The data acquisition module is used to collect basic operating condition data, tension reference data, and environmental reference data. The feedforward control module, based on the aforementioned operating condition data and environmental reference data, uses incremental enthalpy calculation to generate an annealing voltage setpoint signal to control the annealing power supply. By calculating the additional heat energy generated by mechanical resistance and converting it into feedforward compensation demand, it actively lowers the annealing voltage to achieve energy exchange compensation between mechanical work and electrical heating.

[0008] The collaborative cooling module calculates the estimated electrical Joule heat per unit length based on the basic operating data, integrates it with the incremental mechanical enthalpy per unit length to obtain the estimated total heat of the node, and generates fluid control commands to control the cooling water frequency converter and the fluid proportional regulating valve; it combines and quantifies mechanical heat and electrical heat input to match the cooling fluid output parameters with the real-time dynamic heat load of the production line.

[0009] The bidirectional decoupling module calculates the slip factor of the conductive wheel speed using a slip factor method based on the aforementioned operating condition data. It then processes the slip factor using a low-pass filter and differential differentiation method to obtain an effective slip factor and a slip deterioration rate. Based on the effective slip factor and the slip deterioration rate, it generates a pneumatic back pressure pulse command and a power intervention signal to control the pneumatic proportional valve and the annealing power supply. By monitoring the degree of slip deterioration, it triggers pneumatic damping intervention and instantaneous electrical voltage reduction in stages to disrupt the arc discharge conditions.

[0010] The winding control module generates winding fine-tuning speed commands based on the tension reference data to control the end winding motor. It also generates wire-laying follow-up control commands based on the synchronous pulse signals fed back by the end winding motor to control the wire-laying servo motor, thereby winding the oxygen-free copper wire onto the take-up reel.

[0011] Furthermore, the data acquisition module includes: The working condition acquisition unit is used to synchronously extract dynamic operating parameters from the drawing and annealing node equipment to form the working condition basic data. The working condition basic data includes the wire drawing spindle angular velocity, wire drawing spindle torque current, wire drawing exit linear velocity, actual annealing linear velocity, annealing output voltage, and annealing output current. The reference acquisition unit is used to perform state sampling on the auxiliary reference node equipment using mechanical sensors and environmental sensors to obtain the pendulum angle deviation to form the tension reference data; the reference acquisition unit is also used to obtain the water pump output frequency, cooling pipe pressure, emulsion temperature and production workshop ambient temperature to form the environmental reference data.

[0012] Furthermore, the feedforward control module includes: The coefficient addressing unit is used to combine the wire drawing exit linear velocity in the working condition basic data, the emulsion temperature in the environmental reference data, and the production workshop ambient temperature into a multidimensional index vector, and use the multidimensional transformation matrix table to perform multidimensional interpolation algorithm operation on the multidimensional index vector to calculate the mechanical-thermal conversion coefficient. The enthalpy estimation unit is used to obtain the no-load reference current by mapping the wire drawing exit line speed based on the wire drawing exit line speed using a pre-calibrated no-load current reference curve when the wire drawing exit line speed in the working condition basic data is greater than the preset effective line speed threshold. The enthalpy estimation unit calculates the enthalpy increment based on the mechanical heat conversion coefficient, the wire drawing spindle angular velocity, the wire drawing spindle torque current, the wire drawing exit linear velocity, the spindle torque constant, and the no-load reference current in the basic operating data. It extracts the difference between the wire drawing spindle torque current and the no-load reference current for calculation to obtain the mechanical enthalpy increment per unit length. The effective threshold for linear velocity is preset based on the minimum stable operating speed of the drawing machine. By extracting the torque current difference to eliminate inherent mechanical friction, the additional heat source caused by mold abnormalities or lubrication degradation can be quantified.

[0013] Furthermore, the feedforward control module also includes: a feedforward compensation unit, which is used to map the wire drawing exit line speed in the operating condition basic data using a pre-calibrated open-loop voltage reference curve to obtain a voltage open-loop reference value; the feedforward compensation unit calculates the annealing voltage feedforward compensation amount based on the unit length mechanical enthalpy increment using a pre-calibrated enthalpy and voltage compensation mapping relationship; the feedforward compensation unit subtracts the annealing voltage feedforward compensation amount from the voltage open-loop reference value in real time using subtraction operation to generate the annealing voltage setpoint signal to control the annealing power supply.

[0014] Furthermore, the collaborative cooling module includes: An electrothermal calculation unit is used to calculate the estimated value of electrical Joule heat per unit length based on the annealing output voltage, annealing output current and actual annealing line speed in the basic working condition data, by multiplying the annealing output voltage and the annealing output current by the electrothermal conversion algorithm to obtain the annealing electrical power, and by dividing the annealing electrical power by the actual annealing line speed. The total heat unit is used to calculate the estimated total heat value of the node by adding the estimated electrical Joule heat per unit length and the incremental mechanical enthalpy per unit length using an addition operation.

[0015] Furthermore, the collaborative cooling module also includes: A cooling intervention unit is used to compare the estimated total heat of the node with a preset upper limit of the safety range. Only when the estimated total heat of the node is determined to be greater than the upper limit of the safe range, the cooling intervention unit calculates the heat deviation between the estimated total heat of the node and the upper limit of the safe range. Combining the water pump output frequency and cooling pipeline pressure in the environmental reference data, the unit uses a closed-loop feedback algorithm to generate a fluid control command that includes a water pump frequency setpoint and a regulating valve opening setpoint. The water pump frequency setpoint is used to control the cooling water inverter, and the regulating valve opening setpoint is used to control the fluid proportional regulating valve. The upper limit of the safety range is preset based on the critical heat load tolerance of oxygen-free copper wire in the annealing process.

[0016] Furthermore, the bidirectional decoupling module includes: The slip monitoring unit is used to calculate the slip factor when both the actual annealing line speed and the wire drawing exit line speed in the basic operating data are greater than a preset effective line speed threshold. The calculation involves extracting the absolute value of the difference between the actual annealing line speed and the wire drawing exit line speed and dividing it by the wire drawing exit line speed to obtain the slip factor of the conductive wheel speed in the current control cycle. The slip monitoring unit is also used to take the effective slip factor of the previous control cycle as a historical smoothed value and, in conjunction with preset filtering weights, use the low-pass filtering formula to perform a weighted average algorithm on the conductive wheel speed slip factor and the historical smoothed value to obtain the effective slip factor for the current control cycle. The effective threshold of linear velocity is preset based on the minimum stable operating speed of the drawing machine, and the filter weight is preset based on the ratio of the discrete control period to the filter time constant.

[0017] Furthermore, the bidirectional decoupling module also includes: A pneumatic early warning unit is used to process the effective slip factor of the current control cycle and the effective slip factor of the previous control cycle, which is the historical smoothing value, using the differential formula, and extract the difference between the current control cycle and the previous control cycle and divide it by the discrete control cycle to obtain the slip deterioration rate of the current control cycle; the pneumatic early warning unit compares the slip deterioration rate with a preset early warning threshold, and when it is determined that the slip deterioration rate is greater than the early warning threshold, it generates the pneumatic back pressure pulse command to control the pneumatic proportional valve; The warning threshold is preset based on the maximum allowable slip deterioration rate tolerance during normal pulling process.

[0018] Furthermore, the bidirectional decoupling module also includes: An electrical alarm and recovery unit is used to establish a judgment boundary by combining a preset alarm threshold, a preset slip safety hysteresis threshold, and a preset deterioration rate safety hysteresis threshold. The electrical alarm and recovery unit uses a state machine control algorithm for condition monitoring. When it is in a steady-state operation without abnormal intervention and maintains the pneumatic warning state of the pneumatic back pressure pulse command, it continuously monitors the effective slip factor. If it is determined that the effective slip factor is greater than or equal to the alarm threshold, it switches to the electrical alarm state and generates the power intervention signal to control the annealing power supply. Once it is determined that the effective slip factor is less than or equal to the slip safety hysteresis threshold and the slip deterioration rate is less than or equal to the deterioration rate safety hysteresis threshold, the system switches to the hysteresis recovery state and re-switches to the steady-state operation state, simultaneously releasing the power intervention signal and the pneumatic back pressure pulse command. The alarm threshold is preset based on the physical critical slip state of arcing discharge on the conductive wheel surface; the slip safety hysteresis threshold is preset based on the anti-shake logic and the safety recovery boundary; and the degradation rate safety hysteresis threshold is preset based on the characteristics of the system acceleration returning to a stable state. Based on a state machine control algorithm with a hysteresis range, the control logic can achieve graded regulation from aerodynamic damping intervention to electrical voltage reduction, improving the stability during the state recovery period.

[0019] Furthermore, the winding control module includes: The tension closed-loop unit is used to calculate and generate the winding fine-tuning speed command based on the swing arm angle deviation in the tension reference data using a PID control algorithm, and to superimpose the winding fine-tuning speed command on the basic speed command of the end winding motor to generate a comprehensive command for controlling the end winding motor. The follow-up wiring unit is used to perform synchronous correlation calculation on the synchronous pulse signal and the preset wiring pitch using a position following algorithm, calculate the target position curve and convert it into a pulse output sequence, and generate the wiring follow-up control command based on the pulse output sequence to control the wiring servo motor to wind the oxygen-free copper wire to the take-up reel; wherein, the wiring pitch is preset based on the outer diameter specification of the oxygen-free copper wire and the wiring tightness required by the process.

[0020] This invention provides a continuous drawing and annealing production control system for oxygen-free copper wire. It has the following beneficial effects: 1. This invention extracts the difference between the drawing spindle torque current and the no-load reference current through a feedforward control module, quantifies the increase in mechanical enthalpy per unit length caused by the increase in mechanical resistance due to die wear, and converts the increased mechanical heat into a feedforward compensation amount for the annealing voltage before heat accumulation, thereby adjusting the annealing power supply output in real time and avoiding overheating defects caused by the superposition of mechanical heating and electrical heating in oxygen-free copper wire.

[0021] 2. This invention adds the estimated electrical Joule heat per unit length to the incremental mechanical enthalpy per unit length through a collaborative cooling module, and calculates the estimated total heat at the node that reflects the comprehensive heat input of the metal wire. Based on this estimated value, the system generates fluid control commands and synchronously adjusts the output frequency of the cooling water inverter and the opening of the fluid proportional control valve, overcoming the problem of slow response of the temperature sensing element and realizing real-time matching between the servo adjustment of the coolant flow rate and the dynamic heat load of the production line.

[0022] 3. This invention monitors the slip factor and slip deterioration rate of the conductive wheel through a bidirectional decoupling module, and establishes a two-level protection mechanism of mechanical pneumatic intervention and electrical voltage reduction. In the early stage of slip, the output pneumatic back pressure pulse command adjusts the tension swing arm damping to suppress mechanical oscillation. When the slip index reaches the alarm threshold, the output power intervention signal lowers the annealing voltage. Combined with the hysteresis recovery judgment, the system can quickly eliminate the arc discharge conditions at the conductive wheel and reduce the risk of wire breakage caused by electric sparks. Attached Figure Description

[0023] Figure 1 This is a diagram illustrating the architecture of a continuous drawing and annealing production control system for oxygen-free copper wire according to an embodiment of the present invention. Figure 2 This is a flowchart of a continuous drawing and annealing production control method for oxygen-free copper wire according to an embodiment of the present invention. Figure 3 This is a flowchart illustrating the workflow of the feedforward control module according to an embodiment of the present invention. Figure 4 This is a flowchart illustrating the collaborative cooling module according to an embodiment of the present invention. Figure 5 This is a flowchart illustrating the workflow of the bidirectional decoupling module according to an embodiment of the present invention. Figure 6 This is a comparison diagram of the annealing output voltage and the wire drawing spindle torque current in an application embodiment of the present invention; Figure 7 This is a comparison chart of effective slip factors in application embodiments of the present invention; Figure 8 This is a decoupling intervention command triggering state diagram for an application embodiment of the present invention. Detailed Implementation

[0024] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0025] Please see the appendix Figure 1This invention provides a continuous drawing and annealing production control system for oxygen-free copper wire, including a data acquisition module, a feedforward control module, a collaborative cooling module, a bidirectional decoupling module, and a winding control module.

[0026] The system enables cross-domain data exchange and logical decoupling with the servo drive system, annealing power supply system, and fluid control system of the annealing production line through a high-speed industrial real-time bus network.

[0027] The data acquisition module is used to synchronously acquire basic operating condition data, tension reference data, and environmental reference data within each discrete control cycle. This data is then provided to other control modules within the system as a source of foundational data.

[0028] The feedforward control module calculates the mechanical enthalpy increment per unit length using incremental enthalpy calculation based on operating condition data and environmental baseline data. The feedforward control module generates an annealing voltage setpoint signal based on this mechanical enthalpy increment per unit length. This annealing voltage setpoint signal is used to control the annealing power supply to perform feedforward compensation, thereby suppressing the accumulation of additional heat energy caused by mechanical friction variations in the oxygen-free copper wire.

[0029] The collaborative cooling module calculates the estimated electrical Joule heat per unit length based on the operating condition data. It integrates this estimated electrical Joule heat per unit length with the increase in mechanical enthalpy per unit length to calculate the estimated total heat at the node. Based on this total heat estimate, the module generates fluid control commands and uses these commands to control the cooling water inverter and the proportional fluid control valve to maintain the total heat balance before the oxygen-free copper wire enters the cooling zone.

[0030] The bidirectional decoupling module calculates the slip factor of the conductive wheel speed based on the operating condition data using a slip factor formula. It then combines low-pass filtering to process the slip factor and obtain the effective slip factor, further processing the effective slip factor using differential differentiation to obtain the slip degradation rate. The module monitors the effective slip factor and slip degradation rate, generating a pneumatic back pressure pulse command and a power intervention signal to execute bidirectional decoupling control.

[0031] The winding control module generates winding fine-tuning speed commands based on tension reference data, and uses these commands to control the end winding motor. The module also combines the winding fine-tuning speed commands with the synchronous pulse signals fed back from the end winding motor to generate wire-laying follow-up control commands. These commands control the wire-laying servo motor to maintain the overall macroscopic process balance of the drawing and annealing production line.

[0032] See appendix Figure 2 This invention also provides a method for controlling the continuous drawing and annealing production of oxygen-free copper wire, comprising the following steps: S1, within each discrete control cycle, the data acquisition module synchronously acquires basic operating condition data, tension reference data, and environmental reference data; the basic operating condition data, tension reference data, and environmental reference data serve as the real-time operating status characteristics of the annealing production line, providing a data foundation for subsequent logic calculations.

[0033] S2, the feedforward control module calculates the mechanical enthalpy increment per unit length using incremental enthalpy based on the drawing conditions and environmental reference data; the feedforward control module generates an annealing voltage setpoint signal based on the mechanical enthalpy increment per unit length, and the annealing power supply performs feedforward compensation according to the annealing voltage setpoint signal to suppress abnormal heat accumulation in oxygen-free copper wire.

[0034] S3, the collaborative cooling module calculates the estimated total heat of the node based on the estimated electrical Joule heat per unit length and the incremental mechanical enthalpy per unit length; the collaborative cooling module generates fluid control commands based on the estimated total heat of the node. The fluid control commands control the cooling water frequency converter and the fluid proportional regulating valve to maintain the equivalent thermal state balance of the oxygen-free copper wire before the cooling zone.

[0035] S4, the bidirectional decoupling module calculates the slip factor of the conductive wheel speed using a slip factor formula, filters the slip factor using a low-pass filter to obtain an effective slip factor, and processes the effective slip factor using a differential formula to obtain the slip deterioration rate. Based on the effective slip factor and the slip deterioration rate, the bidirectional decoupling module generates a pneumatic back pressure pulse command and a power intervention signal and executes bidirectional decoupling control to block the transmission of abnormal states.

[0036] S5, the winding control module generates a winding fine-tuning speed command based on the swing arm angle deviation in the tension reference data. The winding fine-tuning speed command is used to control the end winding motor; the winding control module synchronously generates a cable servo control command to control the cable servo motor.

[0037] The end-rewinding motor and the wire-laying servo motor work together based on the winding fine-tuning speed command and the wire-laying follow-up control command to ensure that the oxygen-free copper wire is evenly wound into the take-up reel.

[0038] In this embodiment, step S1 is executed, whereby the data acquisition module performs synchronous data acquisition within each discrete control cycle, providing a foundation for subsequent logic calculations. The data acquisition module specifically includes a working condition acquisition unit and a reference acquisition unit, and its synchronous acquisition process includes the following sub-steps: S101, the working condition acquisition unit uses the drawing and annealing node equipment as the acquisition node for physical layer state acquisition. The drawing and annealing node equipment includes the final stage drawing spindle motor, the annealing conductive wheel motor encoder, and the annealing power supply.

[0039] The operating condition acquisition unit synchronously extracts dynamic operating parameters from each equipment node, namely, the angular velocity of the wire drawing spindle motor, the torque current of the wire drawing spindle motor, the wire drawing exit linear velocity, the actual annealing linear velocity fed back by the encoder of the annealing conductive wheel motor, the annealing output voltage of the annealing power supply, and the annealing output current of the annealing power supply.

[0040] In specific engineering implementation, the parameters of the final stage wire drawing spindle motor can be obtained through the high-speed current loop and speed loop observer built into its matching servo driver; the actual annealing line speed can be directly calculated by the incremental or absolute photoelectric encoder installed on the end of the annealing conductive wheel shaft; the annealing output voltage and annealing output current are sampled at high frequency through the isolation voltage sampling circuit and Hall current sensor inside the annealing power supply.

[0041] The above data, as core dynamic and electromagnetic state parameters characterizing oxygen-free copper wire during the drawing and electrical heating stages, are compiled into basic operating condition data after being processed by timestamp alignment using the fieldbus protocol.

[0042] S102, the reference acquisition unit uses auxiliary reference node equipment as the acquisition node for physical layer state acquisition. The auxiliary reference node equipment includes tension swing arm, cooling water frequency converter, cooling pipeline, wire drawing box and production workshop.

[0043] The reference acquisition unit uses mechanical and environmental sensors to perform state sampling on the auxiliary reference node equipment, obtains the pendulum angle deviation of the tension pendulum, and thus forms tension reference data.

[0044] The deviation of the pendulum angle can be measured by a precision potentiometer or a non-contact magnetic encoder installed at the pendulum shaft.

[0045] Meanwhile, the reference acquisition unit acquires the water pump output frequency of the cooling water inverter, the cooling pipe pressure of the cooling pipe, the emulsion temperature inside the wire drawing box, and the ambient temperature of the production workshop, thereby forming environmental reference data.

[0046] The temperature of the emulsion can be acquired using a PT100 thermal resistor inserted into the liquid tank of the drawing box, while the ambient temperature of the production workshop is obtained through standardized temperature and humidity sensors arranged around the drawing machine. The pressure of the cooling pipeline can be obtained through a diffused silicon pressure transmitter.

[0047] The collected environmental and fluid parameters will serve as the basic reference for subsequent thermodynamic model correction and fluid closed-loop control.

[0048] For the hardware selection and communication configuration of underlying data acquisition components such as servo drive systems, photoelectric encoders, Hall sensors, PT100 RTDs and pressure transmitters, those skilled in the art can set them according to the standard specifications of fieldbus protocols (such as EtherCAT, PROFINET, etc.). Their communication networking and data reading mechanisms are well-known technologies in this field and will not be elaborated here.

[0049] See appendix Figure 3 In this embodiment, step S2 is executed. The feedforward control module calculates the mechanical enthalpy increment per unit length based on the drawing conditions and environmental reference data, and corrects the annealing voltage setpoint signal of the annealing power supply according to the mechanical enthalpy increment per unit length, so that the annealing power supply performs feedforward compensation according to the corrected annealing voltage setpoint signal. The feedforward control module specifically includes a coefficient addressing unit, an enthalpy estimation unit, and a feedforward compensation unit. Its feedforward compensation calculation process specifically includes the following sub-steps: S201, the coefficient addressing unit combines the wire drawing exit linear speed in the working condition base data, the emulsion temperature in the environmental reference data, and the production workshop ambient temperature into a multi-dimensional index vector.

[0050] The coefficient addressing unit uses a multidimensional interpolation algorithm to perform multidimensional interpolation operations on a pre-built multidimensional transformation matrix table within the system to calculate the mechanical heat conversion coefficient, which characterizes the mapping relationship between mechanical friction work and effective heat energy.

[0051] Among them, the frictional heat generated by machining is affected by the combined effects of operating speed and the heat dissipation capacity of the system environment; the multidimensional conversion matrix table is formed through calibration experiments at different wire drawing exit line speeds, different emulsion temperatures, and different production workshop ambient temperatures. The data in the table is used to record the mapping relationship between mechanical friction work and the effective heat energy increment of oxygen-free copper wire; the multidimensional conversion matrix table is set based on temperature measurement experiments and thermodynamic energy conservation calibration data in historical production processes (for example, a three-dimensional data lookup table is made by recording the corresponding frictional heat generation ratio coefficients for different line speed segments and different ambient temperature points).

[0052] The specific operation logic of the multidimensional interpolation algorithm is as follows: Based on the current wire drawing exit linear velocity, current emulsion temperature, and current production workshop ambient temperature in the multidimensional index vector, locate the eight adjacent calibration grid points surrounding the current operating point in the multidimensional transformation matrix table; sequentially perform four one-dimensional linear interpolation calculations on the adjacent grid points along the wire drawing exit linear velocity dimension, then perform two one-dimensional linear interpolation calculations on the calculation results of the previous step along the emulsion temperature dimension, and finally perform one one-dimensional linear interpolation calculation on the results generated in the previous step along the production workshop ambient temperature dimension. The mechanical-thermal conversion coefficient with smooth transition is obtained by weighting by spatial distance.

[0053] S202, the enthalpy estimation unit triggers thermodynamic estimation logic when the wire drawing exit linear velocity in the operating condition baseline data exceeds a preset effective linear velocity threshold; when the wire drawing exit linear velocity in the operating condition baseline data is less than or equal to the preset effective linear velocity threshold (i.e., the drawing machine is in a very low-speed crawling or threading state), the enthalpy calculation remains in standby limiting state, that is, the mechanical enthalpy increment per unit length is forcibly set to zero to prevent output runaway. The enthalpy estimation unit uses a pre-calibrated no-load current reference curve to map the wire drawing exit linear velocity to obtain the no-load reference current.

[0054] After obtaining the no-load reference current, the enthalpy estimation unit, based on the mechanical-thermal conversion coefficient generated by the aforementioned unit, the wire drawing spindle angular velocity, wire drawing spindle torque current, and wire drawing exit linear velocity in the basic operating data, and combining the pre-stored spindle torque constant and no-load reference current, uses the enthalpy increment formula to calculate the mechanical enthalpy increment per unit length caused by the variation in mechanical work done. The enthalpy increment formula is as follows: ; In the formula: The increment of mechanical enthalpy per unit length; The mechanical-thermal conversion coefficient; The wire drawing exit line speed; The temperature of the emulsion; The ambient temperature of the production workshop; The main spindle torque constant; This refers to the torque current of the wire drawing spindle. This is the no-load reference current; This is the angular velocity of the wire drawing spindle.

[0055] The effective threshold for linear speed is set based on the minimum stable operating speed of the drawing machine to avoid drastic fluctuations in parameters during the startup phase and to prevent abnormalities in subsequent division-to-zero calculations (e.g., 2.0 m / s to 5.0 m / s).

[0056] The no-load current reference curve is set based on the calibration test results of the current required to overcome the inherent friction of the mechanical transmission system under no-load conditions of the final stage wire drawing spindle motor as a function of speed (e.g., scanning and recording the steady-state current curve of the final stage wire drawing spindle motor at each speed point under no metal wire inserted).

[0057] The spindle torque constant is set based on the inherent electromagnetic parameters of the selected final stage wire drawing spindle motor (e.g., 1.2 N·m / A to 2.5 N·m / A).

[0058] The above calculation process reduces the impact of the inherent resistance of the final stage drawing spindle motor on enthalpy estimation by extracting the difference between the drawing spindle torque current and the no-load reference current, and is used to estimate the additional heat energy accumulation caused by the wear of the drawing die or the deterioration of the lubrication condition.

[0059] S203, the feedforward compensation unit uses a pre-calibrated open-loop voltage reference curve to map the wire drawing exit line speed in the basic operating data to obtain the open-loop voltage reference value; the open-loop voltage reference curve is set according to the relationship between the theoretical voltage and line speed required for oxygen-free copper wire to reach the target softening temperature under standard annealing process (e.g., a voltage and speed proportional mapping comparison table measured under ideal wear-free operating conditions).

[0060] The feedforward compensation unit calculates the annealing voltage feedforward compensation amount based on the unit length mechanical enthalpy increment generated by the aforementioned unit using a pre-calibrated mapping relationship between enthalpy and voltage compensation. The mapping relationship between enthalpy and voltage compensation is set according to the energy equivalent substitution criterion between the enthalpy generated by the equivalent Joule heat of annealing and mechanical energy (e.g., the linear compensation coefficient between mechanical thermal energy and voltage drop value derived using Joule's law and the energy conservation equation). The conversion process converts the unit length energy in the spatial dimension into the voltage compensation requirement in the electrical dimension.

[0061] The feedforward compensation unit subtracts the annealing voltage feedforward compensation amount from the open-loop voltage reference value in real time using subtraction operation to generate the annealing voltage setpoint signal. The annealing voltage setpoint signal is used to control the annealing power supply, thereby completing the feedforward compensation for abnormal heat accumulation.

[0062] By establishing the aforementioned feedforward compensation mechanism, the control system can directly reduce the electrical energy input of the annealing power supply when it detects the initial stage of increased mechanical resistance leading to increased frictional heat. This effectively prevents the uncontrollable superposition of mechanical and electrical heat energy and avoids the phenomenon of overheating and coarse grains in oxygen-free copper wires due to excessive overall heat.

[0063] See appendix Figure 4 In this embodiment, step S3 is executed. The collaborative cooling module calculates the total heat estimate of the node based on the estimated electrical Joule heat per unit length and the mechanical enthalpy increment per unit length, and generates fluid control commands to control the cooling water frequency converter and the fluid proportional regulating valve. The collaborative cooling module specifically includes an electrothermal calculation unit, a total heat unit, and a cooling intervention unit. Its heat management and cooling regulation process specifically includes the following sub-steps: S301, when the actual annealing line speed in the operating condition basic data is greater than the preset effective line speed threshold, the electrothermal calculation unit triggers the logic of the electrothermal conversion algorithm; when the actual annealing line speed is less than or equal to the preset effective line speed threshold, the electrothermal calculation unit enters the standby protection state.

[0064] Based on the annealing output voltage, annealing output current, and actual annealing line speed in the basic operating data, the electrothermal calculation unit uses an electrothermal conversion algorithm to multiply the annealing output voltage and annealing output current to obtain the annealing electrical power. Subsequently, the electrothermal calculation unit divides the annealing electrical power by the actual annealing line speed to calculate the estimated value of electrical Joule heat per unit length.

[0065] In this process, the electrothermal conversion algorithm converts the electrical heating power in the time dimension into the energy distribution state in the spatial dimension. This is used to reflect the estimated electrical Joule heat per unit length corresponding to each unit distance traveled by the oxygen-free copper wire at the current operating speed, providing a unified dimensional basis for subsequent overall heat calculation.

[0066] The effective threshold for linear speed is set based on the minimum stable operating speed of the drawing machine to avoid drastic fluctuations in parameters during the start-up phase and to prevent abnormal division-to-zero calculations (e.g., 2.0 m / s to 5.0 m / s).

[0067] S302, the total heat unit calculates the total heat estimate of the node, which is used to characterize the equivalent thermal state of the oxygen-free copper wire before entering the cooling zone, by adding the estimated value of electrical Joule heat per unit length and the increase of mechanical enthalpy per unit length generated by the aforementioned unit using an addition operation.

[0068] In high-speed continuous production sites, it is difficult to directly measure the real-time temperature distribution inside the metal using physical sensors in a non-contact and moving state. Therefore, the total heat unit performs an addition operation to directly combine the unit length mechanical enthalpy increment representing heat generated by mechanical resistance with the unit length electrical Joule heat estimate representing electrical heat generation. The calculated total heat estimate of the node is used to equivalently represent the heat load accumulation of oxygen-free copper wire before quenching and cooling.

[0069] S303, the cooling intervention unit uses a numerical comparison algorithm to monitor and compare the estimated total heat of the node in real time based on the node's total heat estimated value generated by the aforementioned unit and the preset safety range upper limit.

[0070] When the estimated total heat of the judgment node is greater than the upper limit of the safe range, it indicates that the total heat energy currently existing in the annealing production line has exceeded the adjustment limit of the conventional physical heat dissipation capacity. At this time, the cooling intervention unit combines the water pump output frequency and cooling pipeline pressure in the environmental reference data, uses the closed-loop feedback algorithm to perform closed-loop calculation, and actively generates fluid control commands.

[0071] The upper limit of the safe range is set based on the critical heat load tolerance required for maintaining grain refinement and preventing overheating of oxygen-free copper wire during the annealing process, and is calibrated and adjusted according to the wire diameter, target annealing softening degree and annealing process speed (e.g., 12000J / m~18000J / m).

[0072] The fluid control commands include the water pump frequency setting value and the regulating valve opening setting value, and participate in the regulation process of the cooling water frequency converter and the fluid proportional regulating valve.

[0073] In the specific adjustment process, the cooling intervention unit first calculates the heat deviation between the estimated total heat of the node and the upper limit of the safe range, and uses this heat deviation as an input variable to calculate the target value of the cooling flow rate to be compensated using proportional-integral logic. Subsequently, the cooling intervention unit reads the current water pump output frequency and cooling pipeline pressure to determine the current actual hydraulic load status of the pipeline, and generates a fluid control command that includes the water pump frequency setting value and the regulating valve opening setting value in combination with the target value of cooling flow rate.

[0074] Specifically, the fluid control command, on the one hand, increases the water pump frequency setpoint proportionally to the target cooling flow rate using a preset conversion coefficient, thereby controlling the cooling water inverter to increase the total water supply. On the other hand, it uses the current cooling pipeline pressure as a feedforward reference to compensate for the regulating valve opening setpoint. Furthermore, when the water pump accelerates and causes a sudden change in cooling pipeline pressure, the fluid proportional regulating valve synchronously increases its opening according to the regulating valve opening setpoint to counteract the hydraulic shock effect. The system achieves this combined regulation through the fluid control command, realizing a stable servo match between the cooling medium flow rate and pressure, and promptly removing excess accumulated heat.

[0075] See appendix Figure 5 In this embodiment, step S4 is executed, whereby the bidirectional decoupling module monitors the slip factor of the conductive wheel speed and obtains the effective slip factor and slip deterioration rate to generate a pneumatic back pressure pulse command and a power intervention signal for bidirectional decoupling control. The bidirectional decoupling module specifically includes a slip monitoring unit, a pneumatic early warning unit, and an electrical alarm and recovery unit. Its bidirectional monitoring and state machine control process specifically includes the following sub-steps: S401, when the actual annealing line speed and wire drawing exit line speed in the working condition basic data are both greater than the effective line speed threshold, the slip monitoring unit calculates the slip factor of the conductive wheel speed for the current control cycle using the slip factor formula.

[0076] In continuous drawing and annealing production, the wire exit linear velocity represents the given mechanical motion reference of the metal wire, while the actual annealing linear velocity reflects the annealing linear velocity of the metal wire on the surface of the annealing conductive wheel. The conductive wheel speed slip factor characterizes the degree of relative slippage between the wire and the wheel due to slight tension imbalances. The slip factor formula is as follows: ; In the formula: The slip factor of the conductive wheel speed in the current control cycle; This is the current control cycle; This is the absolute value operator; This refers to the actual annealing line speed; This refers to the wire drawing exit line speed.

[0077] To eliminate data abrupt changes caused by high-frequency white noise generated by the electrical system in the industrial field, the slip monitoring unit directly sets the slip factor of the conductive wheel speed calculated in the current control cycle as the effective slip factor for the initial control cycle in the initial control cycle, thereby establishing a benchmark.

[0078] In non-initial control cycles, the slip monitoring unit extracts the slip factor of the conductive wheel speed calculated in the current control cycle as the input signal, uses the effective slip factor of the previous control cycle as the historical smoothed value, and combines it with the filter weights determined according to the preset filter time constant. A first-order low-pass filter algorithm is then used to perform a weighted average calculation to obtain the effective slip factor for the current control cycle. The low-pass filter formula is as follows: ; In the formula: The effective slip factor for the current control cycle; These are the filter weights; The slip factor of the conductive wheel speed in the current control cycle; This is the effective slip factor for the previous control cycle. The filter time constant is set based on the system sampling frequency and the natural frequency of the mechanical oscillation (e.g., 0.05s to 0.2s), and the filter weight is determined based on the ratio of the discrete control cycle to the filter time constant.

[0079] S402, the aerodynamic warning unit sets the slip deterioration rate to zero during the initial control cycle. In subsequent control cycles, the aerodynamic warning unit, based on the effective slip factor of the current control cycle and the effective slip factor of the previous control cycle (which serves as a historical smoothing value), and in conjunction with a preset discrete control cycle, uses a first-order difference algorithm to process the slip deterioration rate through a differential expression to obtain the current control cycle's slip deterioration rate. The differential expression is specifically as follows: ; In the formula: The slippage deterioration rate for the current control cycle; The effective slip factor for the current control cycle; The effective slip factor of the previous control cycle; For discrete control cycles.

[0080] The pneumatic early warning unit combines a preset early warning threshold with a numerical comparison algorithm to compare the slip deterioration rate with the early warning threshold. When the slip deterioration rate is determined to be greater than the early warning threshold, it indicates that the slippage of the oxygen-free copper wire on the surface of the conductive wheel is accelerating, at which point the pneumatic early warning unit generates a pneumatic back pressure pulse command.

[0081] The warning threshold is set based on the maximum allowable slip deterioration rate tolerance during normal pulling process (e.g., 0.08 / s to 0.25 / s).

[0082] The pneumatic back pressure pulse command is used to control the pneumatic proportional valve. The rapid inflation and deflation of the pneumatic proportional valve applies a pneumatic back pressure pulse to the cylinder of the tension swing arm. The transient damping change of the pneumatic circuit changes the equivalent stiffness and natural frequency of the swing arm cylinder, thereby interfering with and suppressing the mechanical oscillation of the tension swing arm, and blocking it mechanically in the initial stage of slippage.

[0083] S403, the electrical alarm and recovery unit performs electrical protection intervention based on the effective slip factor, slip deterioration rate and pneumatic back pressure pulse command generated by the aforementioned unit.

[0084] The electrical alarm and recovery unit establishes a judgment boundary by combining preset alarm thresholds, early warning thresholds, slippage safety hysteresis thresholds, and deterioration rate safety hysteresis thresholds.

[0085] Among them, the alarm threshold is set based on the physical critical slip state of arc discharge on the surface of the conductive wheel (e.g., 0.02 to 0.05); the slip safety hysteresis threshold is set based on the anti-shake logic and the safety recovery boundary (e.g., 0.005 to 0.015); the degradation rate safety hysteresis threshold is set based on the characteristics of the system acceleration returning to a stable state (e.g., 0.01 / s to 0.03 / s); the system sets the alarm threshold to be greater than the slip safety hysteresis threshold and the warning threshold to be greater than the degradation rate safety hysteresis threshold.

[0086] The electrical alarm and recovery unit uses a state machine control algorithm for condition monitoring. This state machine control algorithm includes at least the steady-state operation state when there is no abnormal intervention, the pneumatic warning state when the pneumatic back pressure pulse command is in the holding process, the electrical alarm state after the power intervention signal is generated, and the hysteresis recovery state during the intervention release process.

[0087] When in steady-state operation or pneumatic warning state, the electrical alarm and recovery unit continuously monitors the effective slip factor. If the effective slip factor is determined to be greater than or equal to the alarm threshold, it indicates that there is still a risk of slip abnormality after pneumatic compensation and that there is a risk of arc discharge in the metal wire. At this time, the system switches to electrical alarm state and generates a power intervention signal. The power intervention signal controls the annealing power supply to instantaneously reduce the voltage value of the annealing voltage setpoint signal generated by the aforementioned unit according to the preset voltage reduction amplitude.

[0088] The preset voltage drop is set based on the safe voltage drop required for instantaneous arc extinguishing (e.g., 15% to 25% of the target reference voltage).

[0089] During continuous monitoring following the generation of pneumatic back pressure pulse commands and power intervention signals, the system switches to hysteresis recovery mode.

[0090] The electrical alarm and recovery unit performs a dual recovery judgment with a hysteresis range. After the effective slip factor is determined to be less than or equal to the slip safety hysteresis threshold and the slip deterioration rate is less than or equal to the deterioration rate safety hysteresis threshold, it is confirmed that the dynamic tension has become stable and no longer has the conditions for arcing. At this time, the system re-enters the steady-state operation state and simultaneously releases the power intervention signal and the pneumatic back pressure pulse command to release the intervention state of the annealing power supply and the pneumatic back pressure pulse holding state of the control pneumatic proportional valve, and restore the stable output state of the annealing power supply.

[0091] State machine logic with hysteresis threshold effectively avoids power oscillations caused by frequent command triggering in the critical state of the system.

[0092] In this embodiment, step S5 is executed, whereby the winding control module generates a winding fine-tuning speed command to control the end winding motor, and generates a wire-laying follow-up control command to control the wire-laying servo motor. The winding control module specifically includes a tension closed-loop unit and a follow-up wire-laying unit, and its macroscopic process balance maintenance process specifically includes the following sub-steps: S501, the tension closed-loop unit executes constant tension control logic based on the pendulum angle deviation in the tension reference data.

[0093] At the end of the continuous drawing and annealing production line, the winding speed of the end take-up motor needs to match the speed of the preceding drawing and annealing line. The deviation of the swing arm angle directly reflects the real-time tension fluctuation caused by the speed mismatch at both ends. The tension closed-loop unit uses a PID control algorithm to calculate the swing arm angle deviation and obtain the take-up fine-tuning speed command.

[0094] Specifically, the tension closed-loop unit extracts the current deviation value of the pendulum angle deviation and multiplies it by a preset proportional coefficient to obtain the proportional adjustment term; it performs a time-series summation operation on the pendulum angle deviations acquired sequentially from the initial control cycle of the equipment start-up to the current control cycle to calculate the cumulative integral, and performs integral limiting processing on the cumulative integral, multiplying the limited cumulative integral by a preset integral coefficient to obtain the integral adjustment term; it calculates the rate of change of the difference between the current deviation value and the pendulum angle deviation of the previous control cycle, multiplies it by a preset differential coefficient to obtain the differential adjustment term; finally, it adds the proportional adjustment term, the integral adjustment term, and the differential adjustment term to comprehensively calculate a continuous and smooth winding fine-tuning speed command.

[0095] The preset proportional coefficient, preset integral coefficient, and preset differential coefficient are set based on the inertia and tension response speed requirements of the winding machine system.

[0096] The tension closed-loop unit first superimposes the winding fine-tuning speed command onto the basic speed command of the end winding motor, and the superimposed comprehensive command is then used to control the end winding motor.

[0097] The basic speed command is set based on the main control line speed of the drawing and annealing production line combined with the current take-up reel diameter, which is the feedforward synchronous speed (e.g., a basic synchronous reference of 500r / min to 1500r / min calculated in real time based on the current reel diameter).

[0098] The system adopts a composite control mode that superimposes the basic speed command and the winding fine-tuning speed command. It can maintain macroscopic linear speed tracking while using fine-tuning commands to quickly absorb and resolve local tension disturbances.

[0099] S502, the follow-up cable laying unit establishes a linkage relationship between winding and cable laying based on the synchronous pulse signal generated by the feedback after the end winding motor executes the aforementioned winding fine-tuning speed command.

[0100] The synchronization pulse signal originates from the real-time position pulse sequence output by the encoder at the tail of the end-rewinding motor, reflecting the actual angular displacement and transient speed of the take-up reel. The follow-up cable laying unit uses a position following algorithm to perform synchronous correlation calculations between the synchronization pulse signal and the preset cable laying pitch.

[0101] In the synchronous correlation calculation, the position following algorithm uses the synchronous pulse signal as the main spindle phase reference and, combined with the preset wiring pitch, calculates the target position curve that the wiring mechanism needs to follow. The preset wiring pitch is set according to the outer diameter specifications of the oxygen-free copper wire currently being produced and the wiring density required by the process (e.g., 1.2mm to 3.5mm).

[0102] To achieve precise driving of the underlying servo hardware, the follow-up wiring unit combines the hardware encoder resolution of the wiring servo motor and the physical lead of the wiring mechanical screw to calculate the pulse equivalent conversion coefficient. Then, it uses this pulse equivalent conversion coefficient to perform a dimension conversion operation on the calculated target position curve, multiplying the displacement data in physical length units by this pulse equivalent conversion coefficient, thereby converting it into a continuous pulse output sequence, thus forming the wiring follow-up control command.

[0103] The servo motor control command includes the target position, running speed, and commutation boundary parameters, which are used to control the servo motor. Based on the servo motor control command, the servo motor drives the mechanical screw mechanism to move the guide wheel in a reciprocating linear motion, ensuring that the oxygen-free copper wire is wound evenly and smoothly into the take-up reel.

[0104] To further aid in understanding the technical solution of this invention, an application embodiment based on a real engineering environment is provided below, along with logical deduction and verification comparison using real data. This application embodiment assumes the drawing and annealing production line is in a stable operating phase.

[0105] In the basic operating data acquired by the operating condition acquisition unit, the wire drawing exit linear velocity is 10.0 m / s, and the wire drawing spindle angular velocity of the final stage wire drawing spindle motor is 150.0 rad / s. Under no-load conditions with no metal wire inserted, the no-load reference current obtained by the enthalpy estimation unit based on the no-load current reference curve is 5.0 A. The spindle torque constant pre-stored by the system is 1.5 N·m / A.

[0106] As production progresses into the mid-to-late stages, the mechanical resistance of the wire drawing die increases due to microscopic wear. At a control cycle time of 15, the operating condition acquisition unit synchronously acquires the real-time reading of the wire drawing spindle torque current, which rises to 18.0A. The emulsion temperature inside the wire drawing box and the ambient temperature of the production workshop, acquired by the reference acquisition unit, serve as input parameters for the multidimensional index vector. The coefficient addressing unit uses a multidimensional interpolation algorithm to address and calculate the current mechanical-thermal conversion coefficient as 0.85 in the multidimensional transformation matrix table.

[0107] At this point, the wire drawing exit linear velocity of 10.0 m / s is greater than the preset effective threshold for linear velocity (set to 2.0 m / s). The enthalpy estimation unit uses the incremental enthalpy formula for calculation. Substituting the above specific values ​​into the formula, it extracts the difference between the wire drawing spindle torque current and the no-load reference current for calculation. The specific calculation process is as follows: ; Calculations show that the mechanical enthalpy increment per unit length is 248.6 J / m. The feedforward compensation unit converts this mechanical enthalpy increment per unit length into an annealing voltage feedforward compensation amount using the enthalpy-voltage compensation mapping relationship. This annealing voltage feedforward compensation amount is then subtracted in real-time from the current open-loop voltage reference value of 40.0V to generate a corrected annealing voltage setpoint signal. The annealing power supply performs reverse voltage sag compensation according to this signal, smoothly reducing its output voltage from 40.0V to 32.5V and stabilizing it, thus reducing electrical heat input.

[0108] In the heat calculation stage, the electrothermal calculation unit uses the current annealing power supply's annealing output voltage of 40.0V and annealing output current of 3000.0A to multiply the two using an electrothermal conversion algorithm to obtain an annealing power of 120000.0W. This power is then divided by the actual annealing line speed of 10.0m / s to calculate an estimated electrical Joule heat per unit length of 12000.0J / m.

[0109] The total heat unit performs an addition operation, directly combining the estimated electrical Joule heat per unit length of 12000.0 J / m with the mechanical enthalpy increment per unit length of 248.6 J / m, to calculate the estimated total heat of the node as 12248.6 J / m. The system's preset upper limit of the safety range is 12100.0 J / m. After numerical comparison algorithm, it is determined that the estimated total heat of the node of 12248.6 J / m is greater than the upper limit of the safety range.

[0110] The cooling intervention unit calculates a heat deviation of 148.6 J / m and uses proportional-integral logic to calculate the target cooling flow rate that needs to be compensated. Then, the cooling intervention unit combines the water pump output frequency and cooling pipe pressure in the environmental reference data to generate a fluid control command that includes the water pump frequency setting value and the regulating valve opening setting value. The command instructs the cooling water frequency converter to increase the frequency to increase the total water supply, and at the same time instructs the fluid proportional regulating valve to increase the opening to remove excess heat energy in time.

[0111] In the bidirectional decoupling control loop, the preset discrete control cycle is set to 0.1s, the effective slip factor of the previous control cycle is 0.01, and the filter weight is 0.2. When the annealing conductive wheel slips due to transient tension fluctuations, the actual annealing linear velocity fed back by the encoder of the annealing conductive wheel motor suddenly changes to 10.6m / s at time 1.0s.

[0112] The slip monitoring unit calculates the slip factor of the conductive wheel speed in the current control cycle using the slip factor formula. The specific calculation process is as follows: ; Subsequently, the slip monitoring unit uses a first-order low-pass filtering algorithm to calculate the effective slip factor for the current control cycle. The specific calculation process is as follows: ; The aerodynamic early warning unit uses a first-order difference algorithm to process the data through differential equations to calculate the slip deterioration rate for the current control cycle. The specific calculation process is as follows: ; The preset warning threshold is 0.05 / s, and the alarm threshold is 0.02. The pneumatic warning unit determines that the slip deterioration rate of the current control cycle (0.1 / s) is greater than the warning threshold (0.05 / s). At 1.05s, it generates a pneumatic back pressure pulse command to control the pneumatic proportional valve to apply a reverse air pressure pulse to the cylinder of the tension swing arm, thereby changing the equivalent stiffness and natural frequency of the swing arm cylinder and suppressing the mechanical oscillation of the tension swing arm.

[0113] Meanwhile, the electrical alarm and recovery unit determines that the effective slip factor of the current control cycle, 0.02, has reached the alarm threshold of 0.02. The system switches to the electrical alarm state at 1.15s and generates a power intervention signal. It controls the annealing power supply to instantaneously reduce the voltage value of the annealing voltage setpoint signal by the preset voltage reduction amplitude, and performs instantaneous electrical voltage reduction to eliminate the risk of arc discharge.

[0114] During continuous monitoring, the system switched to hysteresis recovery state. The power intervention signal and the pneumatic back pressure pulse command were released synchronously at 1.7s and 2.2s respectively because the recovery conditions were met, and the system switched back to steady-state operation.

[0115] The end winding motor and the wire servo motor always execute winding fine-tuning speed commands and wire servo control commands based on the cumulative amount of the swing arm angle deviation extracted by the tension closed-loop unit over time and the synchronous pulse signal fed back by the encoder, so as to maintain the overall macroscopic process balance of the drawing and annealing production line.

[0116] To verify the effectiveness of the above control system and method in continuous drawing and annealing production, a comparative test environment was set up, and a comparative experiment was conducted between the control system based on the traditional control system and the control system of the present invention. The experimental results are as follows: Figure 6 , Figure 7 and Figure 8 .

[0117] See appendix Figure 6 ,exist Figure 6 The solid line represents the annealing output voltage curve of the present invention group, the dashed line represents the annealing output voltage curve of the conventional group, and the dotted line represents the torque current curve of the wire drawing spindle. A resistance disturbance was injected during the experiment at a control cycle time of 15.

[0118] Figure 6 The dotted line indicates that the drawing spindle torque current exhibits a significant step increase after a control cycle time of 15. Traditional methods, lacking a feedforward compensation mechanism, maintain a constant 40.0V output voltage after the disturbance, leading to the accumulation of additional mechanical enthalpy inside the oxygen-free copper wire and posing a risk of overheating. In contrast, this invention utilizes a feedforward control module for immediate response, exhibiting synchronous reverse voltage drop compensation corresponding to the increase in the drawing spindle torque current after a control cycle time of 15, stabilizing at 32.5V, thus capturing and offsetting the additional heat accumulation caused by die wear.

[0119] See appendix Figure 7 ,exist Figure 7 In the diagram, the solid blue line represents the effective slip factor curve of the present invention group, and the dashed red-orange line represents the effective slip factor curve of the conventional group.

[0120] The experiment induced tension fluctuation disturbances at a time of 1.0 s. Figure 7The effective slip factor of the traditional group rapidly increases to 0.07 and generates continuous low-frequency oscillations, which easily induces arcing discharge on the surface of the conductive wheel; when faced with the same disturbance, the effective slip factor of the present invention only increases slightly due to the timely intervention of the bidirectional decoupling module, and then quickly falls back to the safe hysteresis range.

[0121] See appendix Figure 8 ,exist Figure 8 In the diagram, a high level indicates triggering, a low level indicates no triggering, a solid blue square wave represents the pneumatic back pressure pulse command status curve, and a dashed red square wave represents the power intervention signal status curve.

[0122] Figure 8 The timing sequence clearly shows that at 1.05s, the pneumatic back pressure pulse command state first jumps to a high level, executing advanced mechanical intervention through the pneumatic proportional valve; at 1.15s, the power intervention signal state subsequently jumps to a high level, executing instantaneous electrical voltage reduction. As the effective slip factor and slip degradation rate return to within the slip safety hysteresis threshold and degradation rate safety hysteresis threshold, respectively, the red dashed square wave and the blue solid square wave reset to low level at 1.7s and 2.2s, respectively, completing the electromechanical decoupling and smooth recovery.

[0123] Metallographic structure and tensile mechanical properties tests were conducted on samples of oxygen-free copper wire produced by the two systems. The average grain size deviation of the traditional group sample in the disturbed section reached 18.5%, and the range of tensile strength fluctuation was 12.3 MPa. The average grain size deviation of the sample in the present invention group was controlled within 4.2%, and the range of tensile strength fluctuation was reduced to 3.1 MPa.

[0124] Data comparison confirms that the technical solution of the present invention has the ability to decouple and balance processes when facing complex thermodynamic and mechanical coupling conditions.

Claims

1. A continuous drawing and annealing production control system for oxygen-free copper wire, characterized in that, include: The data acquisition module is used to acquire basic operating condition data, tension reference data, and environmental reference data within the discrete control cycle. The feedforward control module, based on the aforementioned operating condition data and environmental reference data, uses incremental enthalpy calculation to determine the mechanical enthalpy increment per unit length, thereby generating an annealing voltage setpoint signal to control the annealing power supply. The collaborative cooling module calculates the estimated electrical Joule heat per unit length based on the aforementioned operating condition data, integrates it with the incremental mechanical enthalpy per unit length to obtain the estimated total heat at the node, and generates fluid control commands to control the cooling water frequency converter and the fluid proportional regulating valve. The bidirectional decoupling module calculates the slip factor of the conductive wheel speed using the slip factor method based on the working condition data, and processes the slip factor of the conductive wheel speed using a combination of low-pass filtering and differential differentiation to obtain an effective slip factor and slip deterioration rate. Based on the effective slip factor and the slip deterioration rate, it generates a pneumatic back pressure pulse command and a power intervention signal to control the pneumatic proportional valve and the annealing power supply. The winding control module generates winding fine-tuning speed commands based on the tension reference data to control the end winding motor. It also generates wire-laying follow-up control commands based on the synchronous pulse signals fed back by the end winding motor to control the wire-laying servo motor, thereby winding the oxygen-free copper wire onto the take-up reel.

2. The continuous drawing and annealing production control system for oxygen-free copper wire according to claim 1, characterized in that, The data acquisition module includes: The working condition acquisition unit is used to synchronously acquire dynamic operating parameters from the drawing and annealing node equipment to form the working condition basic data. The working condition basic data includes the wire drawing spindle angular velocity, wire drawing spindle torque current, wire drawing exit linear velocity, actual annealing linear velocity, annealing output voltage, and annealing output current. The reference acquisition unit is used to perform state sampling on the auxiliary reference node device using mechanical sensors and environmental sensors, and to obtain the pendulum angle deviation to form the tension reference data. The reference acquisition unit is also used to acquire the water pump output frequency, cooling pipe pressure, emulsion temperature, and production workshop ambient temperature to form the environmental reference data.

3. The continuous drawing and annealing production control system for oxygen-free copper wire according to claim 1, characterized in that, The feedforward control module includes: The coefficient addressing unit is used to combine the wire drawing exit linear velocity in the working condition basic data, the emulsion temperature in the environmental reference data, and the production workshop ambient temperature into a multidimensional index vector, and use the multidimensional transformation matrix table to perform multidimensional interpolation algorithm operation on the multidimensional index vector to calculate the mechanical-thermal conversion coefficient. The enthalpy estimation unit is used to obtain the no-load reference current by mapping the wire drawing exit line speed based on the wire drawing exit line speed using a pre-calibrated no-load current reference curve when the wire drawing exit line speed in the working condition basic data is greater than the preset effective line speed threshold. The enthalpy estimation unit calculates the enthalpy increment based on the mechanical heat conversion coefficient, the wire drawing spindle angular velocity, the wire drawing spindle torque current, the wire drawing exit linear velocity, the spindle torque constant, and the no-load reference current in the basic operating data. It extracts the difference between the wire drawing spindle torque current and the no-load reference current for calculation to obtain the mechanical enthalpy increment per unit length. The effective threshold for linear velocity is preset based on the minimum stable operating speed of the drawing machine.

4. The continuous drawing and annealing production control system for oxygen-free copper wire according to claim 3, characterized in that, The feedforward control module also includes: The feedforward compensation unit is used to map the wire drawing exit line speed in the aforementioned working condition data using a pre-calibrated open-loop voltage reference curve to obtain the open-loop voltage reference value. The feedforward compensation unit calculates the annealing voltage feedforward compensation amount based on the unit length mechanical enthalpy increment using a pre-calibrated enthalpy-voltage compensation mapping relationship. The feedforward compensation unit subtracts the annealing voltage feedforward compensation amount from the open-loop voltage reference value in real time using a subtraction operation to generate the annealing voltage setpoint signal to control the annealing power supply.

5. The continuous drawing and annealing production control system for oxygen-free copper wire according to claim 1, characterized in that, The collaborative cooling module includes: An electrothermal calculation unit is used to calculate the estimated value of electrical Joule heat per unit length based on the annealing output voltage, annealing output current and actual annealing line speed in the basic working condition data, by multiplying the annealing output voltage and the annealing output current by the electrothermal conversion algorithm to obtain the annealing electrical power, and by dividing the annealing electrical power by the actual annealing line speed. The total heat unit is used to calculate the estimated total heat value of the node by adding the estimated electrical Joule heat per unit length and the incremental mechanical enthalpy per unit length using an addition operation.

6. The continuous drawing and annealing production control system for oxygen-free copper wire according to claim 5, characterized in that, The synergistic cooling module also includes: A cooling intervention unit is used to compare the estimated total heat of the node with a preset upper limit of the safety range. Only when the estimated total heat of the node is determined to be greater than the upper limit of the safe range, the cooling intervention unit calculates the heat deviation between the estimated total heat of the node and the upper limit of the safe range. Combining the water pump output frequency and cooling pipeline pressure in the environmental reference data, the unit uses a closed-loop feedback algorithm to generate a fluid control command that includes a water pump frequency setpoint and a regulating valve opening setpoint. The water pump frequency setpoint is used to control the cooling water inverter, and the regulating valve opening setpoint is used to control the fluid proportional regulating valve. The upper limit of the safety range is preset based on the critical heat load tolerance of oxygen-free copper wire in the annealing process.

7. The continuous drawing and annealing production control system for oxygen-free copper wire according to claim 1, characterized in that, The bidirectional decoupling module includes: The slip monitoring unit is used to calculate the slip factor formula when the actual annealing line speed and the wire drawing exit line speed in the working condition basic data are both greater than the preset effective line speed threshold. The absolute value of the difference between the actual annealing line speed and the wire drawing exit line speed is extracted and divided by the wire drawing exit line speed to obtain the slip factor of the conductive wheel speed in the current control cycle. The slip monitoring unit is also used to take the effective slip factor of the previous control cycle as the historical smooth value, and combine it with the preset filter weights, and use the low-pass filter to perform a weighted average algorithm on the slip factor of the conductive wheel speed and the historical smooth value to obtain the effective slip factor of the current control cycle. The effective threshold of linear velocity is preset based on the minimum stable operating speed of the drawing machine, and the filter weight is preset based on the ratio of the discrete control cycle to the filter time constant.

8. A continuous drawing and annealing production control system for oxygen-free copper wire according to claim 7, characterized in that, The bidirectional decoupling module further includes: The aerodynamic early warning unit is used to process the effective slip factor and the historical smoothing value based on the current control cycle using the differential formula, and extract the difference between the current control cycle and the previous control cycle and divide it by the discrete control cycle to obtain the slip deterioration rate of the current control cycle. The pneumatic early warning unit compares the slip deterioration rate with a preset early warning threshold. When it is determined that the slip deterioration rate is greater than the early warning threshold, it generates the pneumatic back pressure pulse command to control the pneumatic proportional valve. The warning threshold is preset based on the maximum allowable slip deterioration rate tolerance during normal pulling process.

9. A continuous drawing and annealing production control system for oxygen-free copper wire according to claim 8, characterized in that, The bidirectional decoupling module further includes: The electrical alarm and recovery unit is used to establish a judgment boundary by combining preset alarm thresholds, preset slip safety hysteresis thresholds, and preset deterioration rate safety hysteresis thresholds. The electrical alarm and recovery unit uses a state machine control algorithm for condition monitoring. When it is in a steady-state operation without abnormal intervention and maintains the pneumatic warning state of the pneumatic back pressure pulse command, it continuously monitors the effective slip factor. If it is determined that the effective slip factor is greater than or equal to the alarm threshold, it switches to the electrical alarm state and generates the power intervention signal to control the annealing power supply. Once it is determined that the effective slip factor is less than or equal to the slip safety hysteresis threshold and the slip deterioration rate is less than or equal to the deterioration rate safety hysteresis threshold, the system switches to the hysteresis recovery state and re-switches to the steady-state operation state, simultaneously releasing the power intervention signal and the pneumatic back pressure pulse command. The alarm threshold is preset based on the physical critical slip state of arc discharge on the surface of the conductive wheel, the slip safety hysteresis threshold is preset based on the anti-shake logic and the safety recovery boundary, and the degradation rate safety hysteresis threshold is preset based on the characteristics of the system acceleration returning to a stable state.

10. A continuous drawing and annealing production control system for oxygen-free copper wire according to claim 1, characterized in that, The winding control module includes: The tension closed-loop unit is used to calculate and generate the winding fine-tuning speed command based on the swing arm angle deviation in the tension reference data using a PID control algorithm, and to superimpose the winding fine-tuning speed command on the basic speed command of the end winding motor to generate a comprehensive command for controlling the end winding motor. The follow-up wiring unit is used to perform synchronous correlation calculation on the synchronous pulse signal and the preset wiring pitch using a position following algorithm, calculate the target position curve and convert it into a pulse output sequence, and form the wiring follow-up control command based on the pulse output sequence to control the wiring servo motor to wind the oxygen-free copper wire to the take-up reel. The cable pitch is preset based on the outer diameter of the oxygen-free copper wire and the required wiring density according to the process.

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