Intelligent cable arrangement device and control method thereof

Abstract

The present invention discloses an intelligent cable arrangement device and a control method thereof. The cable arrangement device includes a cable arrangement frame and a cable arrangement control unit. The cable arrangement frame includes a horizontal moving mechanism at the upper end of the frame, a slide, and a visual detection device that moves synchronously with the slide. The slide is provided with a cable guide unit, and the detection device is connected to a PLC. The visual detection device collects cable arrangement data in real time, and by comparing the front entry point of the cable arrangement, the coordinates of the wall, and the layer height, the PLC controls the moving speed, moving direction, and start and stop of the slide in real time. The visual detection device can detect the cable arrangement status in real time, and transmit the coordinate information of the front entry point of the cable arrangement to the PLC in real time. The PLC performs closed-loop control on the entire cable arrangement process, and good mid-section cable arrangement and reversing cable arrangement can be achieved without manual intervention, thereby improving the overall automation and intelligence level of the cable arrangement device, stabilizing the cable arrangement quality, and greatly improving the cable winding efficiency. The present invention is suitable for winding various cables.

Description

Technical Field

[0001] The invention belongs to the technical field of cable winding and arranging, and relates to a cable arranging device and a control method thereof. Background Art

[0002] The last step in cable production is to roll the finished cable onto a reel. A wire winder and a wire arrangement machine are necessary equipment for completing the cable winding. Up to now, whether using an end-shaft type or a gantry type wire winding machine, manual intervention is still required throughout the cable winding process, especially in the reversing link of the cable arrangement. The wire arranger must be quick-eyed and quick-handed, accurately grasp the timing of the reversal, and push and pull the cable with appropriate force. The quality of the wire winding depends largely on the experience and responsibility of the wire arranger. Therefore, the winding quality is unstable and the efficiency is not high. It usually takes several hours to complete the winding of a cable reel. The labor intensity of the workers is high and there are many safety hazards. For this reason, people have proposed a variety of solutions, but so far, there is still no cable winding machine or related technology that can achieve flat, compact and stable quality winding of the cable without manual intervention.

[0003] Production practice has proved that the key to the cable winding technology is to find the right time to change direction during the cable winding process. Otherwise, the cables close to the wall of the reel will overlap or groove. As the cables are laid layer by layer, the irregular conditions become more and more serious, resulting in unqualified coil quality. The timing of cable winding and changing direction in the existing cable winding technology is determined by the time relay or the reversing angle setting on the cable rack. This is an open-loop control method, and the actual application effect is not good. The main reason is that there are too many variables and interference factors in the cable winding process, such as wire diameter error, cable clearance, reel width spacing and tension fluctuation. This open-loop control method cannot cope with complex working conditions and cannot achieve good results. Summary of the invention

[0004] The purpose of the present invention is to overcome the defect that the existing cable winding technology is difficult to determine and grasp the timing of cable winding reversal, resulting in low cable winding quality, and to propose an intelligent cable winding device and a control method thereof to achieve stable high-quality and high-efficiency cable winding production.

[0005] The technical solution to achieve the above purpose is:

[0006] A smart cable arrangement device comprises a cable arrangement rack and a cable arrangement control unit, wherein the cable arrangement rack comprises a frame, a first horizontal moving mechanism located at the upper end of the frame and a slide driven by the first horizontal moving mechanism, and a cable guiding unit fixedly mounted on the slide, characterized in that: a visual detection device is arranged on the frame, which is aligned with the lateral position of the slide and moves synchronously with the slide, the detection lens of the visual detection device follows the cable arrangement front entry point on the winding drum, and the detection signal is connected to the PLC in the cable arrangement control unit; the cable guiding unit is a lever-type guide roller device, comprising a connecting seat, two vertical poles, a lever and two limit guide roller groups, the connecting seat is fixedly mounted on the slide, the two vertical poles are fixed on the connecting seat at intervals, the lever is mounted between the two vertical poles through a rotating shaft, and the two limit guide roller groups are respectively mounted at both ends of the lever.

[0007] Furthermore, the visual inspection device includes a laser profiler and an electric cylinder. The laser profiler is installed on the end of the lead screw of the electric cylinder, and the electric cylinder is connected to the PLC to form a closed-loop control.

[0008] Furthermore, a second horizontal moving mechanism is installed on the upper end of the frame. The second horizontal moving mechanism is parallel to the first horizontal moving mechanism where the slide is located and is connected to the PLC to form a closed-loop control. The visual inspection device is installed on a slide driven by the second horizontal moving mechanism.

[0009] Furthermore, a magnetic switch is installed at the bottom of the visual inspection device, and a magnetic metal sheet is installed on the slide. The magnetic metal sheet and the magnetic switch have the same height and corresponding positions.

[0010] Furthermore, an electrical cabinet is fixed on one side of the rack, and an audible and visual alarm is arranged on the electrical cabinet.

[0011] The control method of the intelligent cable arrangement device is characterized in that: the laser profiler collects the cable arrangement data, the data is the coordinate information (X, Z) of the cutting point at the front of the cable arrangement, X is the horizontal coordinate, and Z is the height coordinate. The laser profiler communicates with the PLC, processes the coordinate data (X, Z), extracts the cutting point at the front of the cable arrangement (X1, Z1), the wall coordinates (X2, Z2), and the layer height (X3, Z3), and then executes the following steps in sequence:

[0012] 1) Initialization, that is, the cable arrangement device is started, and the PLC compares the horizontal coordinate difference δ between the cable outlet of the cable arrangement rack and the front entry point of the cable arrangement. When δ>0, it is judged as the leading state, when δ=0, it is judged as the alignment state, and when δ<0, it is judged as the lagging state. In the leading state, the slide moves in the reverse direction until it is aligned. In the alignment state, no adjustment is made. In the lagging state, the slide moves forward until it is aligned;

[0013] 2) Start, that is, the operator starts the winding machine, the cable is wound on the reel, and the front edge of the cable arrangement is steadily pushed forward in the direction of the cable arrangement;

[0014] 3) PLC controls the moving speed of the slide in real time according to the three types of cable arrangement, that is, controls the moving speed of the cable outlet of the cable arrangement rack driven by the slide, ensuring that the middle section of the cable arrangement is neat and dense, laying a good foundation for subsequent cable arrangement;

[0015] 4) When the X1 coordinate of the front edge of the wiring coincides with the X2 coordinate of the disk wall, the PLC controls the slide to stop moving and enter the reversing process;

[0016] 5) The cable continues to be wound on the reel. When the layer height coordinate Z3 is detected to increase by one wire diameter, the PLC controls the slide to move in the opposite direction. The moving distance is one wire diameter. The outlet of the wire rack is facing the second wire arrangement position, and the reversal is completed.

[0017] 6) Continue to arrange the wire according to steps 3) to 5) until the set meter length is reached and then stop the machine.

[0018] During the entire wiring process, machine vision technology completely replaces the human eye, wiring features are extracted through image processing, and PLC and servo systems are used to achieve position control of the wiring rack outlet.

[0019] The visual inspection device in the present invention can detect the cable arrangement status in real time, and transmit the coordinate information of the cable arrangement front cutting point to the PLC in real time. The PLC performs closed-loop control on the whole process of cable arrangement, and can achieve good middle section cable arrangement and reversing cable arrangement without manual intervention, thereby improving the overall automation and intelligence level of the cable arrangement device, stabilizing the cable arrangement quality, and greatly improving the cable winding efficiency. The present invention is suitable for winding various cables. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a front perspective schematic diagram of an embodiment of the present invention.

[0021] Figure 2 yes Figure 1 A schematic rear perspective view of the illustrated embodiment.

[0022] Figure 3 It is a schematic diagram of the positional relationship between the visual inspection device and the slide in the present invention.

[0023] Figure 4 It is a related block diagram of each component in the present invention.

[0024] In the figure: 1. frame, 2. horizontal lead screw device A, 2-1. lead screw, 2-2. guide rod, 3. slide, 4. cable guide unit, 4-1. front upright guide roller, 4-2. front horizontal guide roller, 4-3. rear upright guide roller, 4-4. rear horizontal guide roller, 4-5. lever, 4-6. vertical rod, 4-7. connecting seat, 4-8. rotating shaft, 5. cable control unit, 5-1. PLC, 5-2. display, 5-3. power supply, 5-4. left and right moving servo drive, 5-5. electric cylinder servo drive, 5-6. cable servo drive, 6. horizontal lead screw device B, 6-1. slide, 7. magnetic switch, 8. magnetic metal sheet, 9. visual inspection device, 9-1. laser profiler, 10. electric cylinder, 10-1. lead screw, 11. electrical cabinet, 12. sound and light alarm, 13. bracket. DETAILED DESCRIPTION

[0025] The present invention will be further described below in conjunction with the accompanying drawings.

[0026] like Figures 1 to 3 As shown, the present invention includes a wire arranging rack and a wire arranging control unit 5. The wire arranging rack includes a frame 1, a first horizontal moving mechanism located at the upper end of the frame 1, namely a horizontal lead screw device A2 and a slide 3 driven by the horizontal lead screw device, and a cable guiding unit 4 fixedly mounted on the slide 3. The difference from the existing wire arranging device is that: a visual inspection device 9 is arranged on the frame 1, which is aligned with the horizontal position of the slide 3 and moves synchronously with the slide 3. The inspection lens of the visual inspection device 9 follows the entry point of the cable at the front of the arranging on the winding drum, and the inspection signal is connected to the PLC in the wire arranging control unit 5.

[0027] The horizontal screw device A2 includes a screw 2-1, a guide rod 2-2 and a servo motor.

[0028] In 1 to Figure 3 In the embodiment shown,

[0029] The visual inspection device 9 includes a laser profiler 9-1 and an electric cylinder 10. The laser profiler 9-1 is installed at the end of the lead screw 10-1 of the electric cylinder 10 and can be telescopically displaced. The electric cylinder 10 is connected to the PLC in the cable arrangement control unit 5 to form a closed-loop control. The electric cylinder 10 is used to adjust the object distance detected by the laser profiler 9-1 to ensure that the required cable arrangement position information is collected. The horizontal lead screw device B 6 is used to keep the laser profiler 9-1 in an aligned position with the cable led out of the cable guide unit 4 during the cable arrangement process to ensure that the position information of the required cable arrangement front entry point is collected and the images of different cable arrangement layers are clearly collected;

[0030] A second horizontal moving mechanism, namely, a horizontal screw device B6, is also installed at the upper end of the frame 1. The structure of the horizontal screw device B6 is similar to that of the horizontal screw device A2, and it also has a screw, a set of guide rods and a servo motor. The horizontal screw device B6 is parallel to the horizontal screw device A2 and is connected to the PLC in the cable control unit 5 to form a closed-loop control. The electric cylinder 10 is fixedly installed on the slide 6-1 driven by the horizontal screw device B6 through the bracket 13, and the screw 10-1 is perpendicular to the screw in the screw device B6;

[0031] A magnetic switch 7 is installed at the bottom of the visual detection device 9, and a magnetic metal sheet 8 is installed on the slide 3. The magnetic metal sheet 8 and the magnetic switch 7 have the same height and corresponding positions.

[0032] In this embodiment, an electrical cabinet 11 is fixed to one side of the frame 1, and the cable control unit 5 is installed in the electrical cabinet 11. The electrical cabinet 11 is provided with an audible and visual alarm 12. The audible and visual alarm 12 has both a four-color indicator light and a buzzer alarm function. In the industrial field, the four-color indicator light includes four colors: red, green, yellow, and white, which can indicate the four operating states of the current equipment, namely, standby state, normal operating state, fault state, and full winding state. Specifically, when the winding equipment is powered on and the cable arrangement device passes the self-test, the white light is on; after startup, the cable arrangement device operates normally and the green light is on; when it is detected that the current length is about to reach the set cable length, the yellow light flashes, prompting to replace the new reel, and when the reel reaches the predetermined length, the yellow light is always on; during operation, if a fault occurs, the red light is on, reminding that the equipment fault needs to be promptly troubleshooted. In the fault state, a rapid buzzer alarm is sounded.

[0033] like Figure 1 As shown, in this embodiment, the cable guide unit 4 is a lever-type guide roller device, which includes a connecting seat 4-7, two vertical poles 4-6, a lever 4-5 and two limit guide roller groups, and the two limit guide roller groups are respectively installed at both ends of the lever 4-5. The connecting seat 4-7 is fixedly installed on the slide 3, the two poles 4-6 are fixed on the connecting seat 4-7 at intervals, and the lever 4-5 is installed between the two poles 4-6 through the rotating shaft 4-8. The two limit guide roller groups are divided into a front guide roller group and a rear guide roller group. The front guide roller group is composed of two front vertical guide rollers 4-1 and a front horizontal guide roller 4-2; the rear guide roller group is composed of two rear vertical guide rollers 4-3 and a rear horizontal guide roller 4-4. The front and rear limit guide roller groups play a role in supporting and limiting the cables. When arranging the cables, as the arranging speed and other factors change, the lever 4-5 can rotate freely around the rotating shaft 4-8, which can improve the stability of the arranging cables. The cable guide unit 4 drives the servo motor and the lead screw 2-1 in the horizontal lead screw device A2 through the cable arrangement servo driver 5-6 to achieve left-right overall displacement, thereby completing horizontal cable arrangement in the left-right direction.

[0034] like Figure 2 and Figure 4 As shown, the cable arrangement control unit 5 in the present invention includes PLC5-1, display 5-2, power supply 5-3, left and right moving servo driver 5-4, electric cylinder servo driver 5-5 and cable arrangement servo driver 5-6. Among them, the left and right moving servo driver 5-4 is used to drive the screw in the screw device B 6 to rotate, so as to drive the visual inspection device 9 to move left and right; the electric cylinder servo driver 5-5 is used to drive the visual inspection device 9 to extend and retract forward and backward; the cable arrangement servo driver 5-6 is used to drive the screw 2-1 in the horizontal screw device A 2 to rotate, so as to drive the slide 3 to move left and right, so that the cable arrangement mechanism can arrange the cables left and right; the power supply 5-3 provides power for the device of the present invention; PLC5-1 is the core of the cable arrangement control unit 5. When PLC5-1 receives the feedback signal of the laser profiler 9-1 and the detection signal of the magnetic switch 7, it can implement the drive control and logic control of the left and right moving servo driver 5-4, the electric cylinder servo driver 5-5 and the cable arrangement servo driver 5-6, and realize parameter setting and cable arrangement information display in combination with the display 5-2. The cable control unit 5 is mainly responsible for completing the logic control, cable detection, control parameter setting and detection data information display of the entire system.

[0035] In the present invention, the magnetic metal sheet 8 is used for induction detection by the magnetic switch 7 to achieve the position alignment of the cable guide unit 4 and the visual detection device 9. The magnetic switch 7 further realizes the synchronous movement of the slide 3 and the visual detection device 9 in the middle section of the cable arrangement by PLC5-1 according to whether the magnetic metal sheet 8 is detected, so as to detect the position information of the cable during the cable arrangement process.

[0036] The control method of the intelligent cable arrangement device is:

[0037] The laser profiler 9-1 collects the line arrangement data, which is the coordinate information (X, Z) of the line arrangement front entry point, where X is the horizontal coordinate and Z is the height coordinate. The laser profiler 9-1 communicates with PLC5-1, processes the coordinate data (X, Z), extracts the line arrangement front entry point (X1, Z1), the disk wall coordinates (X2, Z2), and the layer height (X3, Z3), and then executes the following steps in sequence:

[0038] 1) Initialization, i.e., the cable arrangement device is started, PLC5-1 compares the horizontal coordinate difference δ between the cable outlet of the cable arrangement rack, i.e., the cable outlet of the cable guide unit 4, and the front entry point of the cable arrangement. When δ>0, it is determined to be in the advanced state, when δ=0, it is determined to be in the aligned state, and when δ<0, it is determined to be in the lagging state. In the advanced state, the slide 3 moves in the reverse direction until it is aligned. In the aligned state, no adjustment is made. In the lagging state, the slide 3 moves forward until it is aligned.

[0039] 2) Start, that is, the operator starts the winding machine, the cable is wound on the reel, and the front edge of the cable arrangement is steadily pushed forward in the direction of the cable arrangement;

[0040] 3) PLC5-1 controls the moving speed of slide 3 in real time according to the three types of cable arrangement, that is, controls the moving speed of the cable outlet of the cable arrangement rack driven by slide 3, ensuring that the middle section of the cable arrangement is neat and dense, laying a good foundation for subsequent cable arrangement;

[0041] 4) When the X1 coordinate of the front edge of the wiring coincides with the X2 coordinate of the disk wall, PLC5-1 controls the slide to stop moving and enter the reversing process;

[0042] 5) The cable continues to be wound on the reel. When it detects that the layer height coordinate Z3 increases by one wire diameter, PLC5-1 controls the slide 3 to move in the opposite direction. The moving distance is one wire diameter. The outlet of the wire rack is facing the second wire arrangement position, and the reversal is completed.

[0043] 6) Continue to arrange the wire according to steps 3) to 5) until the set meter length is reached and then stop the machine.

Claims

1. An intelligent cable arrangement device, comprising a cable arrangement rack and a cable arrangement control unit, wherein the cable arrangement rack comprises a frame, a first horizontal moving mechanism located at the upper end of the frame and a slide table driven by the first horizontal moving mechanism, and a cable guide unit fixedly mounted on the slide table, characterized in that: The frame is provided with a visual inspection device which is aligned with the lateral position of the slide and moves synchronously with the slide. The inspection lens of the visual inspection device follows the front entry point of the cable on the cable reel, and the inspection signal is connected to the PLC in the cable arrangement control unit; the visual inspection device includes a laser profiler and an electric cylinder, the laser profiler is installed at the lead screw end of the electric cylinder, and the electric cylinder is connected to the PLC to form a closed-loop control; the cable guiding unit is a lever-type guide roller device, including a connecting seat, two vertical poles, a lever and two limit guide roller groups, the connecting seat is fixedly installed on the slide, the two vertical poles are fixed on the connecting seat at intervals, the lever is installed between the two vertical poles through a rotating shaft, and the two limit guide roller groups are respectively installed at both ends of the lever.

2. The intelligent cable arrangement device according to claim 1, characterized in that: A second horizontal moving mechanism is also installed on the upper end of the frame. The second horizontal moving mechanism is parallel to the first horizontal moving mechanism where the slide is located and is connected to the PLC to form a closed-loop control. The visual inspection device is installed on a slide driven by the second horizontal moving mechanism.

3. The intelligent cable arrangement device according to claim 1, characterized in that: A magnetic switch is installed at the bottom of the visual detection device, and a magnetic conductive metal sheet is installed on the slide. The height of the magnetic conductive metal sheet and the magnetic switch are equal and the position is corresponding.

4. The intelligent cable arrangement device according to claim 1, wherein: An electrical cabinet is fixed on one side of the frame, and an audible and visual alarm is arranged on the electrical cabinet.

5. A control method for an intelligent cable arrangement device, characterized in that: The laser profiler collects the data of the line arrangement. The data is the coordinates (X, Z) of the line arrangement front entry point. X is the horizontal coordinate and Z is the height coordinate. The laser profiler communicates with the PLC, processes the coordinates (X, Z), and extracts the line arrangement front entry point coordinates (X1, Z1), the disk wall coordinates (X2, Z2), and the layer height coordinates (X3, Z3). Then, the following steps are executed in sequence. 1) Initialization, that is, the cable arrangement device is started, and the PLC compares the horizontal coordinate difference δ between the cable outlet of the cable arrangement rack and the cutting point at the front of the cable arrangement. When δ>0, it is judged as the leading state, when δ=0, it is judged as the alignment state, and when δ<0, it is judged as the lagging state. In the leading state, the slide moves in the reverse direction until it is aligned. In the alignment state, no adjustment is made. In the lagging state, the slide moves forward until it is aligned; 2) Start, that is, the operator starts the winding machine, the cable is wound on the reel, and the front edge of the cable arrangement is steadily pushed forward in the direction of the cable arrangement; 3) PLC controls the moving speed of the slide in real time according to the three types of cable arrangement, that is, controls the moving speed of the cable outlet of the cable arrangement rack driven by the slide, ensuring that the middle section of the cable arrangement is neat and dense, laying a good foundation for subsequent cable arrangement; 4) When the cutting point coordinate X1 of the front of the wiring coincides with the wall coordinate X2, the PLC controls the slide to stop moving and enter the reversing process; 5) The cable continues to be wound on the reel. When the layer height coordinate Z3 is detected to increase by one wire diameter, the PLC controls the slide to move in the opposite direction. The moving distance is one wire diameter. The outlet of the cable rack is facing the second wire arrangement position, and the reversal is completed. 6) Continue to arrange the wire according to steps 3) to 5) until the set meter length is reached and then stop the machine.

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