Automatic adjustment method and system for eliminating stress of steel cord

Abstract

The present invention relates to an automatic adjustment method and system for eliminating stress of steel cords, the method comprising: receiving the current torsion angle of the steel cord; calculating the torsion angle deviation based on the current torsion angle of the steel cord and the target value of the torsion angle of the steel cord; judging whether the speed that the virtual twister can reach is within the preset speed range if the virtual twister speed is adjusted based on the torsion angle deviation; in the case that the speed that the virtual twister can reach is within the preset speed range, adjusting the virtual twister speed based on the torsion angle deviation, and returning to the step of receiving the current torsion angle of the steel cord; in the case that the speed that the virtual twister can reach exceeds the preset speed range, judging whether the tension value of the tension device is within the preset tension value range if the tension value of the tension device is adjusted based on the torsion angle deviation, if yes, adjusting the tension value of the tension device based on the torsion angle deviation, and returning to the receiving step. The present invention can improve the torsion stability and torsion release stability in the startup stage, so as to reduce the steel cord bulging defect rate.

Description

Technical Field

[0001] The invention relates to the field of eliminating steel cord stress, and in particular to an automatic adjustment method and system for eliminating steel cord stress. Background Art

[0002] Steel cord is composed of two or more steel wires, or a combination of strands or a combination of strands and steel wires. The existing system to eliminate the stress of steel cord is mainly a virtual twister with a straightener. The straightener is mainly responsible for adjusting the performance of the process such as bulging and loose bow height. It is often fixed. Usually only the virtual twister is adjusted in real time according to the feedback of the ATC detection system. However, with the development of more and more structures with different strengths, the stability of the system is also more unstable.

[0003] The drumming is significantly correlated with the strength of the steel wire, the residual stress on the surface, and the speed of the virtual twister during the production process. It usually needs to be adjusted with the straightener, which often causes production interruptions and repairs due to unqualified drumming. The adjustment is controlled by manually adjusting the amount of straightener pressure, which is cumbersome and has a long downtime. The degree of automation is low, which greatly affects the production process and causes various wastes in personnel costs.

[0004] For starting torsion: During the starting process, the double-twist machine, especially the high-strength structure, uses a strong straightener process. The tension is unstable during the start-up process of the platform, and the virtual twister is in a passive start-up state, resulting in large fluctuations in torsion during the start-up phase. For the torsion release value: With the change of the torsion release value, there is a significant correlation with the virtual twister speed. Its instability will directly affect the quality stability of the product at the customer's site, and also increase the complexity of production control.

[0005] Problems and shortcomings of the existing technology: Insufficient adjustment capacity for starting torsion. Although there is a compensation plan, it cannot fundamentally solve the problem. Regular monitoring is required in actual production, which is high-risk and labor-intensive. Under the fluctuation of steel wires of different strengths, the existing solution will cause unstable torsion release due to the high and low speed adjustment of the virtual twister. Summary of the invention

[0006] The technical problem to be solved by the present invention is to overcome the defects of the prior art and provide an automatic adjustment method for eliminating the stress of steel cords, which can improve the torsional stability and torsional release stability in the startup phase to reduce the steel cord bulging defect rate.

[0007] In order to solve the above technical problems, the technical solution of the present invention is: an automatic adjustment method for eliminating the stress of a steel cord, wherein the steel cord passes through a virtual twister, a tension device and a straightener in sequence, and the method comprises:

[0008] Receive the current torsion angle of the steel cord;

[0009] Calculating the torsion angle deviation based on the current torsion angle of the steel cord and the preset target value of the torsion angle of the steel cord;

[0010] Determining whether the rotation speed of the virtual twister is within a preset rotation speed range if the rotation speed of the virtual twister is adjusted based on the torsion angle deviation;

[0011] In the case that the rotation speed that the virtual twister can reach is within the preset rotation speed range, adjusting the rotation speed of the virtual twister based on the torsion angle deviation, and returning to the step of receiving the current torsion angle of the steel cord;

[0012] When the speed that the virtual twister can reach exceeds the preset speed range, determine whether the tension value that the tension device can reach is within the preset tension value range if the tension value of the tension device is adjusted based on the torsion angle deviation. If so, adjust the tension value of the tension device based on the torsion angle deviation and return to the step of receiving the current torsion angle of the steel cord.

[0013] Further, the calculation formula of the torsion angle deviation is:

[0014] Aavgn1=Am×a+Aavgn0×b;

[0015] Delta = Aavgn1-At;

[0016] Among them, Delta is the torsion angle deviation; Am is the current torsion angle of the steel cord; At is the target value of the torsion angle of the steel cord; a is the first weight, b is the second weight, a+b=1; Aavgn1 is the current logically stable value of the torsion angle; Aavgn0 is the previous logically stable value of the torsion angle.

[0017] Further, adjusting the rotation speed of the virtual twister based on the torsion angle deviation includes:

[0018] When the virtual twister is in the S twist direction, if the torsion angle deviation is positive, the virtual twister slows down, and if the torsion angle deviation is negative, the virtual twister speeds up;

[0019] When the virtual twister is in the Z twist direction, if the torsion angle deviation is positive, the virtual twister is accelerated, and if the torsion angle deviation is negative, the virtual twister is decelerated.

[0020] Furthermore, when the virtual twister is accelerating or decelerating, the speed adjustment amount is X×t1, where X is the adjustment capacity of the virtual twister and t1 is the preset step value of the virtual twister.

[0021] Further, adjusting the tension value of the tension device based on the torsion angle deviation includes:

[0022] When the virtual twister is in the S twist direction, if the torsion angle deviation is positive, the tension value increases, and if the torsion angle deviation is negative, the tension value decreases;

[0023] When the virtual twister is in the Z twist direction, if the torsion angle deviation is negative, the tension value decreases, and if the torsion angle deviation is positive, the tension value increases.

[0024] Furthermore, when the tension value increases or decreases, the adjustment amount of the tension value is t2, and t2 is a preset step value of the tension device.

[0025] Furthermore, the method further comprises:

[0026] When the tension value that can be achieved by the tension device exceeds the preset tension range, an alarm is issued and the vehicle stops.

[0027] The present invention also provides an automatic adjustment system for eliminating stress of a steel cord. The steel cord passes through a virtual twister, a tension device and a straightener in sequence. The system comprises:

[0028] A receiving module, used for receiving the current torsion angle of the steel cord;

[0029] A calculation module, used for calculating a torsion angle deviation based on a current torsion angle of the steel cord and a preset target value of the torsion angle of the steel cord;

[0030] A first judgment module is used to judge whether the rotation speed of the virtual twister is within a preset rotation speed range if the rotation speed of the virtual twister is adjusted based on the torsion angle deviation;

[0031] A virtual twister speed adjustment module, used for adjusting the speed of the virtual twister based on the torsion angle deviation when the speed that the virtual twister can achieve is within a preset speed range;

[0032] A second judgment module is used to judge whether the tension value that can be achieved by the tension device is within the preset tension value range if the tension value of the tension device is adjusted based on the torsion angle deviation when the rotation speed that can be achieved by the virtual twister exceeds the preset rotation speed range;

[0033] The tension value adjustment module is used to adjust the tension value of the tension device based on the torsion angle deviation when the tension value that can be achieved by the tension device is within a preset tension range.

[0034] Furthermore, the system also includes: an alarm stop module, which is used to alarm and stop when the tension value that can be achieved by the tension device exceeds a preset tension range.

[0035] After adopting the above technical scheme, the present invention limits the speed range of the virtual twister and the tension value range of the tension device, controls the torsion angle of the steel cord in a closed loop, adjusts the speed of the virtual twister first, and then adjusts the tension value. After the virtual twister reaches the adjustment limit, the tension value can also be adjusted to have the ability to continue to adjust. It also ensures the effect of the straightener after the speed of the virtual twister is too high, thereby achieving the effect of improving the bulging. During the startup phase, the present invention can ensure that the tension value is constant through the tension device, thereby achieving the effect of eliminating the startup torsion, and also controls the speed of the virtual twister so that the torsion release value is stabilized within a certain range, achieving the effect of stabilizing the release value. The present invention greatly expands the production control range, can reduce the time, labor and material waste caused by machine shutdown due to process failure, and reduces the quality risk brought to customers by the startup torsion in structural development. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 The tension device of the present invention is shown in the schematic diagram of the positions of the virtual twister and the straightener;

[0037] Figure 2 It is a flow chart of the automatic adjustment method for eliminating the stress of the steel cord of the present invention;

[0038] Figure 3 It is a principle block diagram of the automatic adjustment system for eliminating the stress of steel cord of the present invention;

[0039] Figure 4 A comparison chart of the bulging trend of steel cords produced by the traditional method and the automatic adjustment method for eliminating the stress of the steel cord in the present invention;

[0040] Figure 1 Among them, 1. virtual twister; 2. tension device; 3. straightener. DETAILED DESCRIPTION

[0041] In order to make the contents of the present invention more clearly understood, the present invention is further described in detail below based on specific embodiments in conjunction with the accompanying drawings.

[0042] like Figure 1 , 2 As shown, an automatic adjustment method for eliminating stress of a steel cord is provided, wherein the steel cord passes through a virtual twister 1, a tension device 2 and a straightener 3 in sequence, and the method comprises:

[0043] S1, receiving the current torsion angle of the steel cord;

[0044] S2, calculating the torsion angle deviation based on the current torsion angle of the steel cord and a preset target value of the torsion angle of the steel cord;

[0045] S3, determining whether the rotation speed of the virtual twister 1 is within a preset rotation speed range if the rotation speed of the virtual twister 1 is adjusted based on the torsion angle deviation;

[0046] When the rotation speed that the virtual twister 1 can reach is within the preset rotation speed range, the rotation speed of the virtual twister 1 is adjusted based on the torsion angle deviation, and the process returns to step S1;

[0047] When the rotation speed that the virtual twister 1 can reach exceeds the preset rotation speed range, it is determined whether the tension value that the tension device 2 can reach is within the preset tension value range if the tension value of the tension device 2 is adjusted based on the torsion angle deviation. If so, the tension value of the tension device 2 is adjusted based on the torsion angle deviation, and the process returns to step S1.

[0048] The present embodiment limits the speed range of the virtual twister 1 and the tension value range of the tension device 2, and controls the torsion angle of the steel cord in a closed loop. The speed of the virtual twister 1 is adjusted first, and the tension value is adjusted secondly. After the virtual twister 1 reaches the adjustment limit, the tension value can also be adjusted to have the ability to continue to adjust. The effect of the straightener 3 is also ensured after the speed of the virtual twister 1 is too high, thereby achieving the effect of improving the drum. In the startup phase of the present invention, the tension device does not participate in the torsion adjustment. Therefore, the tension value can be guaranteed to be constant by the tension device 2, thereby achieving the effect of eliminating the startup torsion. The speed of the virtual twister 1 is also controlled, so that the torsion release value is stabilized within a certain range, achieving the effect of stabilizing the release value. The present embodiment of the present invention greatly expands the production control range, can reduce the time, labor and material waste caused by machine shutdown due to process failure, and at the same time reduces the quality risk brought to customers by the startup torsion in structural development.

[0049] In this embodiment, the calculation formula of the torsion angle deviation is:

[0050] Aavgn1=Am×a+Aavgn0×b;

[0051] Delta = Aavgn1-At;

[0052] Among them, Delta is the torsion angle deviation; Am is the current torsion angle of the steel cord; At is the target value of the torsion angle of the steel cord; a is the first weight, b is the second weight, a+b=1; Aavgn1 is the current logically stable value of the torsion angle; Aavgn0 is the previous logically stable value of the torsion angle. The initial value of the torsion angle logically stable value Aavgn can be the average of the torsion angles of several steel cords in the initial period, or it can be set manually. In this embodiment, the current torsion angle of the steel cord refers to the current torsion angle of the steel cord after passing through the straightener, generally refers to the calculated moving average Aavgn. The physical meaning of the moving average Aavgn represents the relative measurement angle of torsion under a time period, that is, a certain length. When the torsion of the equipment is calibrated, it also represents the torsion value under the current certain length.

[0053] In this embodiment, a is 5% and b is 95%. a and b may also adopt other values.

[0054] Due to the existence of signal lag and response delay, as well as the possible error in the current torsion angle of the collected steel cord, in order to reduce the signal fluctuation caused by the inertial oscillation brought by the mechanical system during the sampling process, signal noise reduction calculation processing should be used. Calculating the torsion angle deviation in this way can reduce noise and fluctuations.

[0055] In this embodiment, adjusting the rotation speed of the virtual twister 1 based on the torsion angle deviation includes:

[0056] When the virtual twister 1 is in the S twist direction, if the torsion angle deviation is positive, the virtual twister 1 decelerates, and if the torsion angle deviation is negative, the virtual twister 1 accelerates;

[0057] When the virtual twister 1 is in the Z twist direction, if the torsion angle deviation is positive, the virtual twister 1 is accelerated, and if the torsion angle deviation is negative, the virtual twister 1 is decelerated.

[0058] In this embodiment, when the virtual twister 1 is accelerated or decelerated, the speed adjustment amount is X×t1, where X is the adjustment capacity of the virtual twister 1 and t1 is the preset step value of the virtual twister 1. X is determined by the virtual twister 1 itself, and t1 can be preset. This adjustment method can minimize the fluctuation of the speed of the virtual twister 1 to achieve the purpose of gentle adjustment.

[0059] In this embodiment, adjusting the tension value of the tension device 2 based on the torsion angle deviation includes:

[0060] When the virtual twister 1 is in the S twist direction, if the torsion angle deviation is positive, the tension value increases, and if the torsion angle deviation is negative, the tension value decreases;

[0061] When the virtual twister 1 is in the Z twist direction, if the torsion angle deviation is negative, the tension value decreases, and if the torsion angle deviation is positive, the tension value increases.

[0062] In this embodiment, when the tension value increases or decreases, the adjustment amount of the tension value is t2, and t2 is a preset step value of the tension device 2. The value of t2 can be preset, and this adjustment method can prevent the tension value from fluctuating too much to achieve the purpose of gentle adjustment.

[0063] In this embodiment, the automatic adjustment method for eliminating the stress of the steel cord further includes:

[0064] When the tension value that can be achieved by the tension device 2 exceeds the preset tension range, an alarm is triggered and the vehicle stops.

[0065] When the tension value is adjusted to the limit value, but the target value of the steel cord torsion angle has not been adjusted in place, the alarm will be sounded and the machine will be stopped. This can quickly confirm abnormal problems with the raw materials and discover the problems in time to reduce losses.

[0066] like Figure 3 As shown, an automatic adjustment system for eliminating stress of a steel cord comprises:

[0067] A receiving module, used for receiving the current torsion angle of the steel cord;

[0068] A calculation module, used for calculating a torsion angle deviation based on a current torsion angle of the steel cord and a preset target value of the torsion angle of the steel cord;

[0069] A first judgment module is used to judge whether the rotation speed of the virtual twister 1 is within a preset rotation speed range if the rotation speed of the virtual twister 1 is adjusted based on the torsion angle deviation;

[0070] A rotation speed adjustment module for the virtual twister 1, used for adjusting the rotation speed of the virtual twister 1 based on the torsion angle deviation when the rotation speed that the virtual twister 1 can reach is within a preset rotation speed range;

[0071] The second judgment module is used to judge whether the tension value that can be achieved by the tension device 2 is within the preset tension value range if the tension value of the tension device 2 is adjusted based on the torsion angle deviation when the rotation speed that can be achieved by the virtual twister 1 exceeds the preset rotation speed range;

[0072] The tension value adjustment module is used to adjust the tension value of the tension device 2 based on the torsion angle deviation when the tension value that can be achieved by the tension device 2 is within a preset tension range.

[0073] like Figure 3 As shown, the automatic adjustment system for eliminating steel cord stress also includes: an alarm stop module, which is used to alarm and stop when the tension value that can be achieved by the tension device 2 exceeds a preset tension range.

[0074] The advantages of the technical solutions involved in the above embodiments are described in detail below in conjunction with specific embodiments.

[0075] Embodiment 1

[0076] For a certain steel cord structure, its bulging trend is as follows Figure 4 As shown, Figure 4 In the figure, the trend line on the left side adopts the existing control method, and the two trend lines on the right side adopt the control method in the above embodiment. The difference between the two trend lines on the right side is that the pressing amount of the straightener 3 is different.

[0077] Embodiment 2

[0078] By controlling the constant tension of the starting section, various structural samples were used, and each group of experimental data was tested 10 times, and the range of each group of data was averaged. After adopting the control method of the present invention, the starting torsion fluctuation value was as follows, which was significantly reduced.

[0079]

[0080] Embodiment 3

[0081] The cord samples were produced from steel wires of different strengths of a 3 / 9 structure and their 5-minute and 24-hour torsion release values ​​were tested.

[0082]

[0083] Conclusion: After adopting the adjustment method of the present invention, the difference in release values ​​caused by raw materials is significantly reduced.

[0084] Based on the above ideal embodiments of the present invention, the relevant staff can make various changes and modifications without departing from the technical concept of the present invention through the above description. The technical scope of the present invention is not limited to the contents of the specification, and its technical scope must be determined according to the scope of the claims.

Claims

1. An automatic adjustment method for eliminating steel cord stress, characterized in that: The steel cord passes through a virtual twister, a tension device and a straightener in sequence, and the method includes: Receive the current torsion angle of the steel cord, where the current torsion angle of the steel cord refers to the current torsion angle of the steel cord after passing through the straightener; Calculating the torsion angle deviation based on the current torsion angle of the steel cord and the preset target value of the torsion angle of the steel cord; Determining whether the rotation speed of the virtual twister is within a preset rotation speed range if the rotation speed of the virtual twister is adjusted based on the torsion angle deviation; In the case that the rotation speed that the virtual twister can reach is within the preset rotation speed range, adjusting the rotation speed of the virtual twister based on the torsion angle deviation, and returning to the step of receiving the current torsion angle of the steel cord; In the case that the speed that the virtual twister can reach exceeds the preset speed range, it is determined whether the tension value that the tension device can reach is within the preset tension value range if the tension value of the tension device is adjusted based on the torsion angle deviation. If so, the tension value of the tension device is adjusted based on the torsion angle deviation, and the step of receiving the current torsion angle of the steel cord is returned; wherein, The calculation formula of the torsion angle deviation is: Aavgn1=Am×a+Aavgn0×b; Delta=Aavgn1-At; Among them, Delta is the torsion angle deviation; Am is the current torsion angle of the steel cord; At is the target value of the torsion angle of the steel cord; a is the first weight, b is the second weight, a+b=1; Aavgn1 is the current logical stable value of the torsion angle; Aavgn0 is the previous logical stable value of the torsion angle; the initial value of the logical stable value of the torsion angle Aavgn is the average of the torsion angles of several steel cords in the initial period; The adjusting the rotation speed of the virtual twister based on the torsion angle deviation comprises: When the virtual twister is in the S twist direction, if the torsion angle deviation is positive, the virtual twister slows down, and if the torsion angle deviation is negative, the virtual twister speeds up; When the virtual twister is in the Z twist direction, if the torsion angle deviation is positive, the virtual twister is accelerated, and if the torsion angle deviation is negative, the virtual twister is decelerated; The adjusting the tension value of the tension device based on the torsion angle deviation comprises: When the virtual twister is in the S twist direction, if the torsion angle deviation is positive, the tension value increases, and if the torsion angle deviation is negative, the tension value decreases; When the virtual twister is in the Z twist direction, if the torsion angle deviation is negative, the tension value decreases, and if the torsion angle deviation is positive, the tension value increases.

2. The automatic adjustment method for eliminating steel cord stress according to claim 1, characterized in that: When the virtual twister is accelerating or decelerating, the speed adjustment amount is X×t1, where X is the adjustment capacity of the virtual twister and t1 is the preset step value of the virtual twister.

3. The automatic adjustment method for eliminating steel cord stress according to claim 1, characterized in that: When the tension value increases or decreases, the adjustment amount of the tension value is t2, and t2 is a preset step value of the tension device.

4. The automatic adjustment method for eliminating steel cord stress according to claim 1, characterized in that: Also includes: When the tension value that can be achieved by the tension device exceeds the preset tension value range, an alarm is issued to stop the vehicle.

5. An automatic adjustment system for eliminating steel cord stress for implementing the automatic adjustment method for eliminating steel cord stress according to any one of claims 1 to 4, characterized in that: The steel cord passes through the virtual twister, tension device and straightener in sequence. The system includes: A receiving module, used for receiving a current torsion angle of the steel cord, where the current torsion angle of the steel cord refers to the current torsion angle of the steel cord after passing through the straightener; A calculation module, used for calculating a torsion angle deviation based on a current torsion angle of the steel cord and a preset target value of the torsion angle of the steel cord; A first judgment module is used to judge whether the rotation speed of the virtual twister is within a preset rotation speed range if the rotation speed of the virtual twister is adjusted based on the torsion angle deviation; A virtual twister speed adjustment module, used for adjusting the speed of the virtual twister based on the torsion angle deviation when the speed that the virtual twister can achieve is within a preset speed range; A second judgment module is used to judge whether the tension value that can be achieved by the tension device is within the preset tension value range if the tension value of the tension device is adjusted based on the torsion angle deviation when the rotation speed that can be achieved by the virtual twister exceeds the preset rotation speed range; The tension value adjustment module is used to adjust the tension value of the tension device based on the torsion angle deviation when the tension value that can be achieved by the tension device is within a preset tension value range.

6. The automatic adjustment system for eliminating steel cord stress according to claim 5, characterized in that: Also includes: The alarm stop module is used to alarm and stop the vehicle when the tension value that can be achieved by the tension device exceeds the preset tension value range.

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