Methods and devices for controlling spool speed and winding machine

Abstract

This application provides a method and apparatus for controlling the rotational speed of a bobbin and a winding machine. The bobbin rotational speed control method includes: determining the compensation winding diameter of the target bobbin for the current detection cycle based on the tension control parameters of the target bobbin for each target detection cycle; determining the adjustment winding diameter of the target bobbin for the current detection cycle based on the current winding diameter and the compensation winding diameter of the target bobbin for the current detection cycle; and determining the target rotational speed of the target bobbin for the current detection cycle based on the reference linear speed of the target bobbin, the tension control parameters of the target bobbin for the current detection cycle, and the adjustment winding diameter. Therefore, this application can achieve stable tension control during high-speed bobbin rotation to reduce abnormal bobbin breakage.

Description

Technical Field

[0001] This application relates to the field of mechanical control technology, and in particular to a method and apparatus for controlling the speed of a bobbin and a winding machine. Background Technology

[0002] A winding machine is a device used to unwind and wind large-diameter welding wire spools into small welding wire spools. Automated winding machines can efficiently replace manual labor, and the wound welding wire spools have advantages such as precise quality, tight wire arrangement, and uniform tension.

[0003] As is well known, higher winding speeds can improve the production efficiency of winding machines and increase their output per unit time. However, due to the very large inertia of large-diameter welding wire spools, it is difficult to achieve stable tension control during their high-speed rotation, which can easily lead to the risk of welding wire breakage.

[0004] In view of this, there is an urgent need for an improved spool speed control scheme to mitigate the risk of spool breakage during high-speed spool rotation. Summary of the Invention

[0005] To address the aforementioned problems, embodiments of this application provide a method and apparatus for controlling spool speed and winding machine, which at least partially solves the problems described above.

[0006] According to a first aspect of the present application, a spool speed control method is provided, comprising: determining a compensation roll diameter of the target spool for the current detection cycle in each target detection cycle based on tension control parameters of the target spool for each target detection cycle; determining an adjustment roll diameter of the target spool for the current detection cycle based on the current roll diameter of the target spool for the current detection cycle and the compensation roll diameter; and determining a target speed of the target spool for the current detection cycle based on a reference linear speed of the target spool, the tension control parameters of the target spool for the current detection cycle, and the adjustment roll diameter.

[0007] Optionally, the method further includes: determining each target detection cycle of the target spool and the current detection cycle in each target detection cycle based on the start detection time and the current detection time of the target spool.

[0008] Optionally, determining the compensation roll diameter of the target spool corresponding to the current detection cycle in each target detection cycle based on the tension control parameters of each target spool in each target detection cycle includes: determining the tension control difference of the target spool based on the two tension control parameters of any two adjacent target detection cycles in each target detection cycle; and determining the compensation roll diameter of the target spool corresponding to the current detection cycle using a given compensation roll diameter conversion formula, based on the tension control difference of the target spool and a given adjustment coefficient.

[0009] Optionally, the compensation roll diameter conversion formula is expressed as:

[0010]

[0011] Among them, the Dunwinder _a dd represents the current detection cycle of the target spool, i.e., the compensation roll diameter of the nth detection cycle, and the PID_output (n) This indicates the tension control parameters of the target spool corresponding to the nth detection cycle, and the PID_output (n-1) This indicates the tension control parameters of the target spool corresponding to the (n-1)th detection cycle, and the PID_output (n) -PID_output (n-1) The value represents the tension control difference between the nth target detection cycle and the (n-1)th target detection cycle. K represents the adjustment coefficient, which is used to characterize the adjustment range of the compensation roll diameter. The cycle duration of the target detection cycle is between 2 and 4 milliseconds. The adjustment coefficient characterizes the adjustment range of the compensation roll diameter and is between 0.0001 and 0.001.

[0012] Optionally, the method further includes: determining tension control parameters of the target spool for each target detection cycle based on the output value of the tension PID controller connected to the target spool for each target detection cycle.

[0013] Optionally, the current roll diameter of the target spool is determined by: determining the linear velocity integral of the target spool corresponding to the current detection cycle based on the linear velocities of the target spool corresponding to each target detection cycle, and determining the angular velocity integral of the target spool corresponding to the current detection cycle based on the angular velocities of the target spool corresponding to each target detection cycle; and determining the current roll diameter of the target spool based on the linear velocity integral and the angular velocity integral.

[0014] Optionally, determining the target rotational speed of the target spool corresponding to the current detection cycle based on the baseline linear speed of the target spool, the tension control parameters of the target spool corresponding to the current detection cycle, and the adjusted roll diameter includes: using a given linear speed conversion formula, determining the target rotational speed of the target spool corresponding to the current detection cycle based on the baseline linear speed, the tension control parameters of the target spool corresponding to the current detection cycle, and the adjusted roll diameter; the linear speed conversion formula is expressed as:

[0015] Nunwinder=(Vbasic+PID_output (n) ) / (Dunwinder×3.14)×60

[0016] Wherein, Nunwinder represents the target rotational speed, Vbasic represents the baseline speed, and PID_output... (n) This indicates the tension control parameters of the target spool corresponding to the nth current detection cycle, Dunwinder represents the adjustment roll diameter, the coefficient 3.14 is pi, and the coefficient 60 is the conversion unit between minutes and seconds.

[0017] According to a second aspect of the embodiments of this application, a winding machine control method is provided, comprising: obtaining a reference linear speed of the unwinding shaft of the winding machine based on a given linear speed of the main virtual shaft of the winding machine; obtaining tension control parameters of the unwinding shaft corresponding to each target detection cycle based on the output value of a tension PID controller connected to the unwinding shaft corresponding to each target detection cycle; and determining a target rotational speed of the unwinding shaft corresponding to the current detection cycle in each target detection cycle using the spool rotational speed control method described in the first aspect, based on the reference linear speed of the unwinding shaft and the tension control parameters of the unwinding shaft corresponding to each target detection cycle.

[0018] Optionally, the method further includes: determining the tension control parameters of the wire feeding shaft for each target detection cycle based on the given tension parameter value and the feedback values ​​of the tension PID controller for each target detection cycle; wherein, the feedback values ​​of the tension PID controller for each target detection cycle are determined based on the actual positions of the tension arm of the tension PID controller for each target detection cycle; and the tension parameter value is set to 0.

[0019] Optionally, the winding machine further includes a take-up shaft connected to the main virtual shaft; and the method further includes: determining the current number of winding layers of the material on the take-up shaft based on the current rotation angle of the take-up shaft and a given number of unit turns; determining the current winding diameter of the take-up shaft based on the current number of winding layers, the diameter of the material, and the scaling factor of the material; and determining the current rotational speed of the take-up shaft based on the given linear speed of the main virtual shaft and the current winding diameter of the take-up shaft; wherein the number of unit turns represents the number of rotations required by the take-up shaft for each additional layer of the material on the take-up shaft.

[0020] Optionally, the wound material is welding wire, and the scaling factor of the wound material is 0.866.

[0021] According to a third aspect of the embodiments of this application, a spool speed control device is provided, comprising: a spool diameter determination module, configured to determine a compensation spool diameter for the current detection cycle of the target spool in each target detection cycle based on tension control parameters of the target spool corresponding to each target detection cycle, and to determine an adjustment spool diameter for the target spool in the current detection cycle based on the current spool diameter of the target spool in the current detection cycle and the compensation spool diameter; and a speed determination module, configured to determine a target speed for the target spool in the current detection cycle based on a reference linear speed of the target spool, tension control parameters of the target spool in the current detection cycle, and the adjustment spool diameter.

[0022] According to a fourth aspect of the embodiments of this application, a winding machine control device is provided, comprising: an acquisition module, configured to acquire a reference linear speed of the unwinding shaft of the winding machine based on a given linear speed of the main virtual shaft of the winding machine, and acquire tension control parameters of the unwinding shaft corresponding to each target detection cycle based on the output value of a tension PID controller connected to the unwinding shaft corresponding to each target detection cycle; and a control module, configured to determine the target rotational speed of the unwinding shaft corresponding to the current detection cycle in each target detection cycle using the spool rotational speed control device described in the third aspect above, based on the reference linear speed of the unwinding shaft and the tension control parameters of the unwinding shaft corresponding to each target detection cycle.

[0023] According to a fifth aspect of the present application, an electronic device is provided, comprising: a processor, a memory, a communication interface, and a communication bus, wherein the processor, the memory, and the communication interface communicate with each other through the communication bus; the memory is used to store at least one executable instruction, wherein the executable instruction causes the processor to perform an operation corresponding to the bobbin speed control method described in the first aspect above, or to perform an operation corresponding to the winding machine control method described in the second aspect above.

[0024] According to a sixth aspect of the embodiments of this application, a computer storage medium is provided, on which a computer program is stored. When the program is executed by a processor, it can implement the bobbin speed control method described in the first aspect or the winding machine control method described in the second aspect.

[0025] The spool speed control scheme provided in this application calculates the adjustment diameter of the target spool for the current detection cycle based on the tension control parameters of the spool for each target detection cycle and the current roll diameter of the target spool, and dynamically adjusts the current speed of the target spool for the current detection cycle accordingly. Therefore, this application can achieve stable tension control during high-speed spool rotation.

[0026] The spool speed control scheme provided in this application solves the problem of inaccurate spool diameter calculation and unstable tension control under high-speed spool operation caused by the uneven rolling surface of large-diameter spools. This is achieved by adding a compensation spool diameter determined based on tension control parameters to the current spool diameter of the target spool, thereby determining the adjustment spool diameter of the target spool. The scheme also optimizes the stability of tension control during spool rotation and reduces the fluctuation amplitude of the tension arm.

[0027] The spool speed control scheme provided in this application can accurately determine the compensation roll diameter of the target spool for the current detection cycle by calculating the tension control difference between any two adjacent target detection cycles.

[0028] The spool speed control scheme provided in this application uses an integral method to calculate the current roll diameter of the target spool, which can improve the accuracy of the calculation result of the current roll diameter of the spool.

[0029] The spool speed control scheme provided in this application dynamically adjusts the target speed of the target spool corresponding to the current detection cycle based on the baseline speed of the target spool, the tension control parameters of the current detection cycle, and the adjustment of the roll diameter, thereby achieving stable tension control under high-speed spool rotation.

[0030] The winding machine control method provided in this application embodiment, based on the bobbin speed control method of the above embodiment, dynamically adjusts the speed of the unwinding bobbin of the winding machine, which can achieve stable tension control during the high-speed rotation of the unwinding bobbin, effectively reduce the occurrence of wire breakage abnormalities, improve the production efficiency of the winding machine, and the stable tension control can also provide a tighter and neater winding effect, thereby improving the winding quality of the winding machine.

[0031] The winding machine control method provided in this application calculates the rotational speed of the take-up shaft based on the linear speed of the main virtual shaft and the winding diameter of the take-up shaft, thereby achieving synchronous control of the linear speed between the take-up shaft and the main virtual shaft and further improving the winding quality of the winding machine. Attached Figure Description

[0032] The accompanying drawings are intended only to illustrate and explain this application and do not limit the scope of this application.

[0033] Figure 1 This is a flowchart illustrating the spindle speed control method as an exemplary embodiment of this application.

[0034] Figure 2 This is a schematic diagram of the tension control logic of the target spool, which is an exemplary embodiment of this application.

[0035] Figure 3 This is a flowchart illustrating a winding machine control method as an exemplary embodiment of this application.

[0036] Figure 4 This is a schematic diagram of the structure of a winding machine, which is an exemplary embodiment of this application.

[0037] Figure 5 This is a schematic diagram of the control logic of each functional module in a winding machine, which is an exemplary embodiment of this application.

[0038] Figure 6 This is a flowchart illustrating a winding machine control method as another exemplary embodiment of this application.

[0039] Figure 7 This is a structural block diagram of a spool speed control device, which is an exemplary embodiment of this application.

[0040] Figure 8 This is a structural block diagram of a winding machine control device, which is an exemplary embodiment of this application.

[0041] Figure 9 This is a structural block diagram of an electronic device that is an exemplary embodiment of this application.

[0042] Explanation of reference numerals in the attached figures:

[0043] 202. Tension parameter value; 204. Feedback value of tension PID controller; 206. Output value of tension PID controller; 208. Baseline linear speed of target spool; 210. Linear speed of target spool; 402. Pay-off spool; 403. Tension PID controller; 404. Tension arm; 406. Wire guide; 407. Encoder; 408. Take-up spool; 410. Welding wire; 700. Spool speed control device; 702. Roll diameter determination module; 704. Speed ​​determination module; 800. Winding machine control device; 802. Acquisition module; 804. Control module; 900. Electronic equipment; 902. Processor; 904. Communication interface; 906. Memory; 908. Communication bus; 910. Computer program. Detailed Implementation

[0044] To provide a clearer understanding of the technical features, objectives, and effects of the embodiments of this application, the specific implementation methods of the embodiments of this application will now be described with reference to the accompanying drawings.

[0045] Current winding machines (such as welding wire winding machines) often experience unstable tension control when the pay-off spool has a large diameter (e.g., greater than 1.2m) and an uneven surface. This can easily lead to wire breakage when the pay-off spool rotates at high speeds (e.g., linear speed greater than 30m / s). Therefore, this application proposes a spool speed control and winding machine control scheme that can effectively improve the problem of unstable tension control under high-speed spool operation.

[0046] Figure 1 The flowchart of the spool speed control method according to an exemplary embodiment of this application is shown. As shown in the figure, this embodiment mainly includes the following steps:

[0047] Step S102: Determine the compensation roll diameter of the target spool for the current detection cycle in each target detection cycle based on the tension control parameters of the target spool for each target detection cycle.

[0048] Optionally, the target bobbin may include the pay-off bobbin of a winding machine.

[0049] Optionally, the winding machine may include, but is not limited to, a welding wire winding machine.

[0050] Optionally, the target detection cycle of each target spindle and the current detection cycle in each target detection cycle can be determined based on the start detection time and the current detection time of the target spindle.

[0051] Specifically, based on the start detection time and the current detection time of the target axis, a series of consecutive target detection cycles between the start detection time and the current detection time can be determined, and the current detection cycle that includes the current detection time can be determined within each target detection cycle.

[0052] Optionally, the cycle length of each target detection cycle can be determined based on the scanning cycle of the spindle control program (e.g., PLC program).

[0053] In this embodiment, the duration of the target detection cycle can be between 2 and 4 milliseconds, but is not limited thereto. Those skilled in the art can adjust it according to actual detection needs, and this application does not impose any restrictions on it.

[0054] Optionally, the tension control difference of each target spool can be determined based on the two tension control parameters of any two adjacent target detection cycles in each target detection cycle.

[0055] Specifically, based on the detection time of each target detection cycle, two adjacent target detection cycles can be sequentially obtained from each target detection cycle to generate multiple sets of adjacent detection cycle groups. Based on the two tension control parameters of the two target detection cycles in each set of adjacent detection cycle groups, the tension control difference of each set of adjacent detection cycle groups is calculated, thereby determining the tension control difference of each target axis corresponding to each set of adjacent detection cycle groups.

[0056] Optionally, the compensation roll diameter of the target spool corresponding to the current inspection cycle can be determined based on the tension control differences of each target spool and the given adjustment coefficient.

[0057] In this embodiment, the compensation roll diameter of the target spool can be determined according to the given compensation roll diameter conversion formula, based on the tension control differences of the target spool and the given adjustment coefficient, for the current detection cycle.

[0058] The formula for converting the compensation roll diameter can be expressed as Formula 1 below:

[0059] Dunwinder _a dd=∑(PID_iutput (n) -PID_output (n-1) )×K (Formula 1)

[0060] In Formula 1 above, Dunwinder _a dd represents the compensation roll diameter of the target axis corresponding to the nth current detection cycle, and PID_output (n) This represents the tension control parameters for the target spool corresponding to the nth target detection cycle, PID_output. (n-1) This represents the tension control parameters for the target spool corresponding to the (n-1)th target detection cycle, PID_output. (n) -PID_output (n-1) This represents the tension control difference between adjacent period groups consisting of the nth target detection period and the (n-1)th target detection period. K represents the adjustment coefficient, which is used to characterize the adjustment range of the compensation roll diameter.

[0061] In this embodiment, when the unit of the tension control parameter is meters per minute (m / min) and the unit of the target spool diameter is meters (m), the adjustment coefficient K can be between 0.0001 and 0.001.

[0062] Optionally, the tension control parameters of the target spool corresponding to each target detection cycle can be determined based on the output values ​​of the tension PID controller (proportional-integral-calculus controller) connected to the target spool for each target detection cycle.

[0063] Based on the given tension parameter values, the tension PID controller can determine the output values ​​of each target detection cycle corresponding to each feedback value.

[0064] In this embodiment, the feedback values ​​of the tension PID controller corresponding to each target detection cycle can be determined based on the actual positions of the tension arm of the tension PID controller corresponding to each target detection cycle.

[0065] In this embodiment, the tension parameter value of the tension PID controller is set to 0.

[0066] Specifically, an encoder can be installed on the tension arm of the tension PID controller to detect the feedback values ​​of the tension arm corresponding to each target detection cycle, and the tension arm can be provided with tension by a cylinder.

[0067] For example, Siemens' standard motion control library provides a function module LCon_SMC_Winder with a tension control method. The control mode of the function module LCon_SMC_Winder can be set to "dancer speedadapt" to activate PID control for the position of the tension arm.

[0068] refer to Figure 2 and Figure 4 The tension parameter value 202 can be set to "0", and the actual position of the tension arm 404 can be used as the feedback value 204 of the tension PID controller 403 to determine the output value 206 of the tension PID controller 403. The output value 206 of the tension PID controller 403 can be used as an adjustment amount and superimposed with the baseline linear velocity 208 of the target spool (e.g., the pay-off spool 402) to adjust the linear velocity 210 of the target spool (e.g., the pay-off spool 402), thereby realizing the tension control of the target spool (e.g., the pay-off spool 402) by the tension PID controller 403.

[0069] Therefore, in this embodiment of the application, the tension control difference between any two adjacent target detection cycles corresponding to the target spool is calculated to accurately determine the compensation roll diameter of the target spool corresponding to the current detection cycle.

[0070] Step S104: Determine the adjustment roll diameter of the target spool for the current detection cycle based on the current roll diameter and compensation roll diameter of the target spool for the current detection cycle.

[0071] Optionally, the adjustment roll diameter of the target spool corresponding to the current detection cycle can be determined based on the sum of the current roll diameter and the compensation roll diameter of the target spool.

[0072] In this embodiment, the adjustment roll diameter of the target spool corresponding to the current detection cycle can be calculated using the following formula 2.

[0073] Dunwinder=Dunwinder1+Dunwinder _a dd (Formula 2)

[0074] In Formula 2 above, Dunwinder represents the adjusted roll diameter of the target spool corresponding to the current detection cycle, Dunwinder1 represents the current roll diameter of the target spool, and Dunwinder... _a dd indicates the compensation roll diameter of the target spindle corresponding to the current detection cycle, where the roll diameter of the current roll diameter, compensation roll diameter, and adjustment roll diameter are all in meters (m).

[0075] Therefore, this application embodiment adds an additional compensation roll diameter based on the tension control parameters to the current roll diameter to determine the adjustment roll diameter of the target spool corresponding to the current detection cycle. This solves the problem that the uneven rolling surface of a large-diameter spool causes inaccurate spool diameter calculation and unstable tension control under high-speed spool rotation, thereby optimizing the stability of tension control during the rotation of the target spool and reducing the fluctuation amplitude of the tension arm.

[0076] Optionally, the linear velocity integral of the target line axis corresponding to the current detection cycle can be determined based on the linear velocities of the target line axis corresponding to each target detection cycle, the angular velocity integral of the target line axis corresponding to the current detection cycle can be determined based on the angular velocities of the target line axis corresponding to each target detection cycle, and the current roll diameter of the target line axis corresponding to the current detection cycle can be determined based on the linear velocity integral and the angular velocity integral.

[0077] Optionally, the current roll diameter of the target spindle can be determined using a given current roll diameter conversion formula, based on the linear velocity integral and angular velocity integral of the target spindle corresponding to the current detection cycle.

[0078] In this embodiment, the current roll diameter conversion formula can be expressed as the following formula 3:

[0079] Dunwinder1=2×S / φ (Formula 3)

[0080] In Formula 3 above, Dunwinder1 represents the current roll diameter of the target axis in the current detection cycle, S represents the linear velocity integral of the target axis in the current detection cycle, φ represents the angular velocity integral of the target axis in the current detection cycle, and coefficient 2 is the conversion unit between radius and diameter.

[0081] Therefore, by accumulating the linear velocity and angular velocity of the target spool corresponding to each target detection cycle, the current roll diameter of the target spool can be accurately determined.

[0082] Step S106: Determine the target rotation speed of the target spool for the current detection cycle based on the baseline linear speed of the target spool, the tension control parameters of the target spool corresponding to the current detection cycle, and the adjusted roll diameter.

[0083] Optionally, the target rotational speed of the target spool in the current detection cycle can be determined using a given linear speed conversion formula, based on the baseline linear speed, the tension control parameters of the target spool corresponding to the current detection cycle, and the adjusted roll diameter.

[0084] In this embodiment, the linear velocity conversion formula can be expressed as the following formula 4:

[0085] Nunwinder=(Vbasic+PID_output (n) ) / (Dunwinder×3.14)×60 (Formula 4)

[0086] In Formula 4 above, Nunwinder represents the target rotational speed of the target spool corresponding to the current detection cycle, where the unit of the target rotational speed is revolutions per minute (rpm); Vbasic represents the baseline linear velocity of the target spool, where the unit of the baseline linear velocity is m / s; PID_output (n) This indicates the tension control parameters for the target spool corresponding to the nth current detection cycle; Dunwinder indicates the adjustment roll diameter for the target spool corresponding to the current detection cycle; coefficient 3.14 is pi, and coefficient 60 is the conversion unit between seconds and minutes.

[0087] Alternatively, when the target bobbin is the pay-off bobbin of the winding machine, the reference linear speed of the target bobbin can be determined based on the given linear speed of the main virtual axis of the winding machine.

[0088] In summary, the spool speed control method provided in this application can significantly increase the target spool speed and achieve stable tension control during high-speed spool rotation, reducing the swing amplitude of the tension arm. Verification shows that the spool speed control scheme of this application can increase the target spool speed from approximately 25 m / s to over 35 m / s. Therefore, this embodiment can significantly increase the spool speed, effectively improving production efficiency.

[0089] Furthermore, without the addition of compensating roll diameter control, the fluctuation range of the tension arm of a large-diameter target spool (e.g., a target spool with a diameter greater than 1.2m) during high-speed operation is approximately between ±9°. However, after adding compensating roll diameter control, the fluctuation range of the tension arm can be reduced to within ±3°, thereby achieving stable tension control during the high-speed rotation of the spool.

[0090] Figure 3 This is a flowchart illustrating a winding machine control method as an exemplary embodiment of this application.

[0091] refer to Figure 4 The winding machine in this embodiment is, for example, a welding wire winding machine, which mainly includes a pay-off shaft 402, a tension PID controller (proportional-integral-calculus controller) 403, a wire guide 406, and a take-up shaft 408. The wire guide 406 is used to unwind the welding wire 410 on the large-diameter pay-off shaft 402 and wind it onto the small-diameter take-up shaft 408. The tension PID controller 403 is used to maintain a constant tension of the welding wire 310 during the operation of the pay-off shaft 402. The wire guide 406 can reciprocate along the axial direction of the take-up shaft 408 and dynamically adjust the winding angle of the welding wire 310 relative to the take-up shaft 408 according to the current winding diameter of the take-up shaft 408, so that the welding wire 410 can be wound evenly and neatly onto the take-up shaft 408.

[0092] refer to Figure 5 The pay-off shaft 402 and take-up shaft 408 of the winding machine can be connected to the main virtual shaft 400 respectively. Based on the given linear speed of the main virtual shaft 400 and the current winding diameter of the pay-off shaft 402 or take-up shaft 408, the current rotational speed of the pay-off shaft 402 or take-up shaft 408 can be adjusted, thereby achieving synchronous control of the linear speed between the pay-off shaft 402 and the main virtual shaft 400 and between the take-up shaft 408 and the main virtual shaft 400.

[0093] like Figure 3 As shown, the method in this embodiment mainly includes the following steps:

[0094] Step S302: Determine the reference linear speed of the unwinding shaft of the winding machine based on the given linear speed of the main virtual shaft of the winding machine.

[0095] refer to Figure 5 The baseline speed of the pay-off axis 402 can be determined based on the given linear speed of the main virtual axis 400.

[0096] Step S304: Based on the output value of the tension PID controller connected to the wire feeding shaft corresponding to each target detection cycle, obtain the tension control parameters of the wire feeding shaft corresponding to each target detection cycle.

[0097] Optionally, the tension control parameters of the wire feeding shaft corresponding to each target detection cycle can be determined based on the given tension parameter values ​​and the feedback values ​​of the tension PID controller corresponding to each target detection cycle.

[0098] In this embodiment, the given tension parameter value can be set to "0".

[0099] In this embodiment, the feedback value of the tension PID controller corresponding to each target detection cycle is determined based on the actual position of the tension arm of the tension PID controller corresponding to each target detection cycle.

[0100] Optionally, the duration of each target detection cycle can be determined based on the scanning cycle of the winding machine's control program (e.g., a PLC program). For example, the duration of the target detection cycle can be between 2 and 4 milliseconds.

[0101] refer to Figure 2 , Figure 4 , Figure 5 Based on the given tension parameter value 202, the tension PID controller 403 can determine the output value 206 of each target detection cycle corresponding to each feedback value 204 of each target detection cycle.

[0102] In this embodiment, an encoder (not shown) installed on the tension arm 404 of the tension PID controller 403 can be used to detect the actual position of the tension arm 404 corresponding to each target detection cycle, thereby determining the feedback value 204 of the tension PID controller 403 corresponding to each target detection cycle.

[0103] Step S306: Based on the baseline linear speed of the wire feeding shaft and the tension control parameters of the wire feeding shaft corresponding to each target detection cycle, determine the target rotation speed of the wire feeding shaft for the current detection cycle in each target detection cycle.

[0104] In this embodiment, the above-mentioned Figure 1 The bobbin speed control method described in the embodiment determines the target speed of the bobbin for the current detection cycle based on the baseline bobbin speed and the tension control parameters of the bobbin for each target detection cycle.

[0105] Specifically, the compensation roll diameter of the pay-off shaft 402 in the current detection cycle can be determined based on the tension control parameters of the pay-off shaft 402 in each target detection cycle. The adjustment roll diameter of the pay-off shaft 402 in the current detection cycle can be determined based on the current roll diameter and compensation roll diameter of the pay-off shaft 402 in the current detection cycle. Finally, the target rotational speed of the pay-off shaft 402 in the current detection cycle can be determined based on the baseline line speed of the pay-off shaft 402, the tension control parameters of the pay-off shaft 402 in the current detection cycle, and the adjustment roll diameter.

[0106] In this embodiment, the encoder 407 can be used to detect the linear velocity and angular velocity of the pay-off shaft 402 for each detection cycle, and the integral algorithm can be used to calculate the current roll diameter of the pay-off shaft 402 for the current detection cycle based on the linear velocity and angular velocity of the pay-off shaft 402 for each detection cycle.

[0107] In summary, the winding machine control method of this application adds a compensation winding diameter determined based on the tension control difference to the current winding diameter of the pay-off shaft, thereby dynamically adjusting the rotational speed of the pay-off shaft. This achieves stable tension control during the high-speed rotation of the pay-off shaft, reduces the swing amplitude of the tension arm, and reduces abnormal wire breakage during the winding process, effectively improving the production efficiency of the winding machine.

[0108] Figure 6 This application illustrates a processing flow diagram of a winding machine control method according to another embodiment of the present application. The winding machine control method of this embodiment includes, in addition to... Figure 3 In addition to the processing steps shown in the embodiments, the following steps may be further included:

[0109] Step S602: Determine the current number of winding layers of the material on the take-up shaft based on the current rotation angle of the take-up shaft and the given number of unit turns.

[0110] Optionally, the current number of winding layers on the take-up spool can be determined using a given winding layer conversion formula, based on the current rotation angle of the take-up spool and the given number of unit turns.

[0111] In this embodiment, the formula for converting the number of winding layers can be expressed as the following formula 5:

[0112] Layrewinder=INT(Total_Angle / 360 / Turn_Number) (Formula 5)

[0113] Where INT represents rounding, Layrewinder represents the current number of layers of the winding on the take-up spool, Total_Angle represents the current rotation angle of the take-up spool, Turn_Number represents the number of turns per unit, and the coefficient 360 represents the rotation angle corresponding to each rotation.

[0114] In this embodiment, the number of turns (Turn_Number) represents the number of turns the take-up spool needs to make for each additional layer of winding on the take-up spool.

[0115] In this embodiment, when the winding machine is a welding wire winding machine, the winding material of the winding machine is welding wire.

[0116] Step S604: Determine the current winding diameter of the take-up spool based on the current number of winding layers, the diameter of the winding, and the scaling factor of the winding.

[0117] Optionally, the current diameter of the take-up spool can be determined using a given take-up spool diameter conversion formula, based on the current number of winding layers, the diameter of the wound material, and the scaling factor of the wound material.

[0118] In this embodiment, the formula for converting the take-up spool diameter is expressed as the following formula 6:

[0119] Drewinder=Layerrewinder×Wire_Diam×N×2 (Formula 6)

[0120] In Formula 6 above, Drewinder represents the current winding diameter of the take-up spool, with the current winding diameter in meters (m), Layerrewinder represents the current number of winding layers on the take-up spool, Wire_Diam represents the diameter of the wound object, with the diameter in meters (m), N represents the scaling factor of the wound object, and coefficient 2 is the conversion unit between radius and diameter.

[0121] In this embodiment, when the winding material is welding wire, the scaling factor N of the winding material can be set to 0.866.

[0122] Step S606: Determine the current rotation speed of the take-up spool based on the given linear speed of the main virtual shaft and the current winding diameter of the take-up spool.

[0123] Optionally, the current rotational speed of the take-up spool can be determined using a given formula for converting the take-up spool speed, based on the given linear speed of the main virtual shaft and the current winding diameter of the take-up spool.

[0124] In this embodiment, the formula for converting the take-up spool speed can be expressed as the following formula 7:

[0125] Nrewinder=VvirtualAxis / (Drewinder×3.14)×60 (Formula 7)

[0126] In Formula 7 above, Nrewinder represents the current rotational speed of the take-up spool, where the unit of the current rotational speed is rpm; VvirtualAxix represents the given linear speed of the main virtual axis, where the unit of the given linear speed is m / s; Drewinder represents the current winding diameter of the take-up spool, where the winding diameter is in meters; the coefficient 3.14 is pi, and the coefficient 60 is the conversion unit between seconds and minutes.

[0127] In summary, the winding machine control method provided in this application embodiment can achieve synchronous rotational speed between the take-up shaft and the main virtual shaft, so that the welding wire can be tightly and neatly wound on the take-up shaft, thereby improving the winding quality of the winding machine.

[0128] Figure 7 A structural block diagram of a spool speed control device according to an exemplary embodiment of this application is shown. As shown, the spool speed control device 700 of this embodiment mainly includes: a roll diameter determination module 702 and a speed determination module 704.

[0129] The roll diameter determination module 702 is used to determine the compensation roll diameter of the target spool in the current detection cycle of each target detection cycle according to the tension control parameters of the target spool in each target detection cycle, and to determine the adjustment roll diameter of the target spool in the current detection cycle according to the current roll diameter of the target spool in the current detection cycle and the compensation roll diameter.

[0130] The rotational speed determination module 704 is used to determine the target rotational speed of the target spool corresponding to the current detection cycle based on the baseline linear speed of the target spool, the tension control parameters of the target spool corresponding to the current detection cycle, and the adjusted roll diameter.

[0131] Optionally, the roll diameter determination module 702 is further configured to: determine each target detection cycle of the target spool and the current detection cycle in each target detection cycle based on the start detection time and the current detection time of the target spool.

[0132] Optionally, the roll diameter determination module 702 is further configured to: determine each tension control difference of the target spool based on two tension control parameters of any two adjacent target detection cycles in each target detection cycle; and determine the compensation roll diameter of the target spool corresponding to the current detection cycle based on each tension control difference of the target spool and a given adjustment coefficient using a given compensation roll diameter conversion formula.

[0133] Optionally, the compensation roll diameter conversion formula is expressed as:

[0134] Dunwinder _a dd = Σ(PID_output) (n) -PID_output (n-1) )×K

[0135] Among them, the Dunwinder _a dd represents the current detection cycle of the target spool, i.e., the compensation roll diameter of the nth detection cycle, and the PID_output (n) This indicates the tension control parameters of the target spool corresponding to the nth target detection cycle, and the PID_output... (n-1) This indicates the tension control parameters of the target spool corresponding to the (n-1)th target detection cycle, and the PID_output... (n) -PID_output (n-1) This represents the tension control difference between the nth target detection cycle and the (n-1)th target detection cycle, where K represents the adjustment coefficient, used to characterize the adjustment range of the compensation roll diameter.

[0136] Optionally, the duration of the target detection period is between 2 and 4 milliseconds, and the adjustment coefficient represents the adjustment range of the compensation roll diameter, with the adjustment coefficient being between 0.0001 and 0.001.

[0137] Optionally, the tension control parameters of the target spool corresponding to each target detection cycle can be determined based on the output value of the tension PID controller connected to the target spool corresponding to each target detection cycle.

[0138] Optionally, the roll diameter determination module 702 is further configured to: determine the linear velocity integral of the target spindle corresponding to the current detection cycle based on the linear velocities of the target spindle corresponding to each target detection cycle, and determine the angular velocity integral of the target spindle corresponding to the current detection cycle based on the angular velocities of the target spindle corresponding to each target detection cycle; and determine the current roll diameter of the target spindle based on the linear velocity integral and the angular velocity integral.

[0139] Optionally, the rotational speed determination module 704 is further configured to: determine the target rotational speed of the target spool corresponding to the current detection cycle using a given linear speed conversion formula, based on the baseline linear speed, the tension control parameters of the target spool corresponding to the current detection cycle, and the adjusted roll diameter.

[0140] The linear velocity conversion formula is expressed as follows:

[0141] Nunwinder=(Vbasic+PID_output (n) ) / (Dunwinder×3.14)×60

[0142] Wherein, Nunwinder represents the target rotational speed, Vbasic represents the baseline speed, and PID_output... (n) This indicates the tension control parameters of the target spool corresponding to the nth current detection cycle, Dunwinder represents the adjustment roll diameter, the coefficient 3.14 is pi, and the coefficient 60 is the conversion unit between minutes and seconds.

[0143] The spool speed control device provided in this embodiment of the invention corresponds to the spool speed control method provided in this embodiment of the invention. Other descriptions can refer to the description of the spool speed control method provided in this embodiment of the invention, and will not be repeated here.

[0144] Figure 8 A structural block diagram of a winding machine control device according to an exemplary embodiment of this application is shown. The winding machine control device 800 of this embodiment includes an acquisition module 802 and a control module 804.

[0145] The acquisition module 802 is used to acquire the reference linear speed of the pay-off shaft of the winding machine based on the given linear speed of the main virtual shaft of the winding machine, and to acquire the tension control parameters of the pay-off shaft corresponding to each target detection cycle based on the output value of the tension PID controller connected to the pay-off shaft corresponding to each target detection cycle.

[0146] Control module 804, used for Figure 7 The bobbin speed control device 700 described in the embodiment determines the target speed of the bobbin in the current detection cycle corresponding to each target detection cycle based on the reference bobbin speed and the tension control parameters of the bobbin corresponding to each target detection cycle.

[0147] Optionally, the acquisition module 802 is further configured to: determine the tension control parameters of the wire feeding shaft corresponding to each target detection cycle based on the given tension parameter value and the feedback values ​​of the tension PID controller corresponding to each target detection cycle; wherein, the feedback values ​​of the tension PID controller corresponding to each target detection cycle can be determined based on the actual positions of the tension arm of the tension PID controller corresponding to each target detection cycle; the tension parameter value is set to 0.

[0148] Optionally, the winding machine further includes a take-up shaft connected to the main virtual shaft.

[0149] Optionally, the control module 804 is further configured to: determine the current number of winding layers of the material on the take-up shaft based on the current rotation angle of the take-up shaft and a given number of unit turns; determine the current winding diameter of the take-up shaft based on the current number of winding layers, the diameter of the material, and the scaling factor of the material; and determine the current rotational speed of the take-up shaft based on the given linear speed of the main virtual axis and the current winding diameter of the take-up shaft; wherein the number of unit turns represents the number of rotations required by the take-up shaft for each additional layer of the material on the take-up shaft.

[0150] Optionally, the wound material is welding wire, and the scaling factor of the wound material is 0.866.

[0151] The winding machine control device provided in this embodiment of the invention corresponds to the winding machine control method provided in this embodiment of the invention. Other descriptions can be referred to the description of the winding machine control method provided in this embodiment of the invention, and will not be repeated here.

[0152] Another embodiment of the present invention provides an electronic device, including: a processor, a memory, a communication interface and a communication bus, wherein the processor, the memory and the communication interface communicate with each other through the communication bus.

[0153] Figure 9 A structural block diagram of an electronic device according to an exemplary embodiment of the present invention, such as... Figure 9 As shown, the electronic device 900 of this embodiment may include a processor 902, a communication interface 904, and a memory 906.

[0154] The processor 902, communication interface 904, and memory 906 can communicate with each other via communication bus 908.

[0155] The communication interface 904 is used to communicate with other electronic devices such as terminal devices or servers.

[0156] The processor 902 is used to execute the computer program 910, specifically to execute the relevant steps in the above-described method embodiments, that is, to execute the steps in the bobbin speed control method as described in the above-described embodiments or to execute the steps in the winding machine control method as described in the above-described embodiments.

[0157] Specifically, computer program 910 may include program code that includes computer operation instructions.

[0158] Processor 902 may be a central processing unit (CPU), an application-specific integrated circuit (ASIC), or one or more integrated circuits configured to implement embodiments of the present invention. The electronic device may include one or more processors of the same type, such as one or more CPUs; or it may include processors of different types, such as one or more CPUs and one or more ASICs.

[0159] Memory 906 is used to store computer program 910. Memory 906 may include high-speed RAM memory, and may also include non-volatile memory, such as at least one disk storage device.

[0160] Another embodiment of the present invention provides a computer storage medium storing a computer program thereon. When the program is executed by a processor, it can implement the bobbin speed control method or the winding machine control method described in the above embodiments.

[0161] It should be noted that, depending on the implementation needs, the various components / steps described in the embodiments of the present invention can be broken down into more components / steps, or two or more components / steps or parts of the operation of components / steps can be combined into new components / steps to achieve the purpose of the embodiments of the present invention.

[0162] The methods described above according to embodiments of the present invention can be implemented in hardware, firmware, or as software or computer code that can be stored in a recording medium (such as a CD-ROM, RAM, floppy disk, hard disk, or magneto-optical disk), or as computer code originally stored on a remote recording medium or a non-transitory machine-readable medium and subsequently stored on a local recording medium, downloaded via a network. Thus, the methods described herein can be stored on a recording medium using a general-purpose computer, a dedicated processor, or programmable or dedicated hardware (such as an ASIC or FPGA) for such software processing. It is understood that the computer, processor, microprocessor controller, or programmable hardware includes storage components (e.g., RAM, ROM, flash memory, etc.) capable of storing or receiving software or computer code. When said software or computer code is accessed and executed by the computer, processor, or hardware, the spool speed control method or winding machine control method described herein is implemented. Furthermore, when a general-purpose computer accesses code for implementing the spool speed control method or winding machine control method shown herein, the execution of the code transforms the general-purpose computer into a dedicated computer for executing the spool speed control method or winding machine control method shown herein.

[0163] Those skilled in the art will recognize that the units and method steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of the embodiments of the present invention.

[0164] The above embodiments are only used to illustrate the embodiments of the present invention, and are not intended to limit the embodiments of the present invention. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the embodiments of the present invention. Therefore, all equivalent technical solutions also fall within the scope of the embodiments of the present invention, and the patent protection scope of the embodiments of the present invention should be defined by the claims.

Claims

1. A method of controlling the rotational speed of a spool, characterized by, The method comprises the following steps: According to the tension control parameters of the target spool corresponding to each target detection period, the compensation winding diameter of the target spool corresponding to the current detection period in each target detection period is determined; According to the current winding diameter of the target spool corresponding to the current detection period and the compensation winding diameter, the adjustment winding diameter of the target spool corresponding to the current detection period is determined; According to the reference line speed of the target spool, the tension control parameter of the target spool corresponding to the current detection period, and the adjustment winding diameter, the target rotating speed of the target spool corresponding to the current detection period is determined; The method comprises the following steps: According to the two tension control parameters of any two adjacent target detection periods in each target detection period, the tension control difference value of the target spool is determined; According to the tension control difference value of the target spool, the given adjustment coefficient, and the given compensation winding diameter conversion formula, the compensation winding diameter of the target spool corresponding to the current detection period is determined; The compensation winding diameter conversion formula is as follows: Wherein, the compensation winding diameter of the target spool in the current detection cycle, i.e., the first compensation winding diameter of the target spool in the current detection cycle, i.e., the first target detection cycle, the target spool corresponds to the tension control parameter of the first target detection cycle, the target spool corresponds to the tension control parameter of the first target detection cycle, the target spool corresponds to the tension control parameter of the first target detection cycle, the target spool corresponds to the tension control parameter of the first target detection cycle, the target spool corresponds to the tension control parameter of the first target detection cycle and the first target detection cycle, the target spool corresponds to the tension control difference value of the first target detection cycle and the first target detection cycle, the target spool corresponds to the tension control difference value of the first target detection cycle and the first target detection cycle, the target spool corresponds to the tension control difference value of the first target detection cycle and the first target detection cycle, the target spool corresponds to the tension control difference value of the first 2. The method of claim 1, wherein, The method further comprises the following steps: According to the starting detection time and the current detection time of the target spool, the target detection period of the target spool and the current detection period in each target detection period are determined.

3. The method according to claim 1, wherein: The period length of the target detection period is between 2 and 4 milliseconds, the adjustment coefficient represents the adjustment range of the compensation winding diameter, and the adjustment coefficient is between 0.0001 and 0.

001.

4. The method according to claim 1 or 3, characterized in that, The method further comprises the following steps: Based on the output value of the tension PID controller corresponding to each target detection period connected to the target spool, the tension control parameter of the target spool corresponding to each target detection period is determined.

5. The method of claim 1, wherein, The current winding diameter of the target spool is determined in the following manner: According to the line speed of the target spool corresponding to each target detection period, the line speed integral of the target spool corresponding to the current detection period is determined, and according to the angular speed of the target spool corresponding to each target detection period, the angular speed integral of the target spool corresponding to the current detection period is determined; According to the line speed integral and the angular speed integral, the current winding diameter of the target spool is determined.

6. The method according to any one of claims 1 to 3, 5, characterized in that, The method comprises the following steps: According to the reference line speed of the target spool, the tension control parameter of the target spool corresponding to the current detection period, and the adjustment winding diameter, the target rotating speed of the target spool corresponding to the current detection period is determined; According to the reference line speed, the tension control parameter of the target spool corresponding to the current detection period, and the adjustment winding diameter, the target rotating speed of the target spool corresponding to the current detection period is determined by using a given line speed conversion formula; Wherein, the represents the target speed, the represents the reference linear speed, the represents the target linear speed corresponding to the tension control parameter of the first current detection period, the represents the adjusted diameter, the coefficient 3.14 is the circular constant, and the coefficient 60 is the conversion unit of minutes and seconds.

7. A winding machine control method characterized by, The line speed conversion formula is as follows: The method comprises the following steps: According to the given line speed of the main virtual axis of the winding machine, the reference line speed of the pay-off spool of the winding machine is obtained; According to the output value of the tension PID controller corresponding to each target detection period, the tension control parameter of the pay-off shaft corresponding to each target detection period is obtained; According to the reference linear velocity of the pay-off shaft, the tension control parameter of the pay-off shaft corresponding to each target detection period, the target rotational velocity of the pay-off shaft corresponding to the current detection period in each target detection period is determined.

8. The method of claim 7, wherein, The method further comprises: According to the given tension parameter value and the feedback value of the tension PID controller corresponding to each target detection period, the tension control parameter of the pay-off shaft corresponding to each target detection period is determined; The feedback value of the tension PID controller corresponding to each target detection period is determined based on the actual position of the tension arm of the tension PID controller corresponding to each target detection period. The tension parameter value is set to 0.

9. The method of claim 7, wherein, The winding machine further comprises a take-up shaft connected to the main virtual shaft; And wherein the method further comprises: According to the current rotation angle of the take-up shaft and the given unit number of turns, the current number of turns of the winding material on the take-up shaft is determined; According to the current number of turns, the diameter of the winding material and the scaling coefficient of the winding material, the current winding diameter of the take-up shaft is determined; According to the given linear velocity of the main virtual shaft and the current winding diameter of the take-up shaft, the current rotational velocity of the take-up shaft is determined; The unit number of turns represents the number of turns required for the take-up shaft to rotate when the winding material on the take-up shaft increases by one layer.

10. The method of claim 9, wherein, The winding material is a welding wire, and the scaling coefficient of the winding material is 0.

866.

11. A spool speed control device characterized by comprising: It comprises: A winding diameter determination module is configured to determine a compensation winding diameter of a target spool corresponding to a current detection period in each target detection period according to the tension control parameter of the target spool corresponding to each target detection period, and determine an adjusted winding diameter of the target spool corresponding to the current detection period according to the current winding diameter of the target spool corresponding to the current detection period and the compensation winding diameter; wherein the compensation winding diameter of the target spool corresponding to the current detection period is determined according to the tension control parameter of the target spool corresponding to each target detection period, which comprises determining a tension control difference value of the target spool according to two tension control parameters of any two adjacent target detection periods in each target detection period, and determining the compensation winding diameter of the target spool corresponding to the current detection period according to the tension control difference value of the target spool and an adjusted coefficient according to a given compensation winding diameter conversion formula; The compensation winding diameter conversion formula is expressed as: Among them, the This indicates the current detection cycle of the target spool, i.e., the [number]th [time period]. The compensation roll diameter for each detection cycle, the This indicates that the target axis corresponds to the first... The tension control parameters for each target detection cycle, the This indicates that the target axis corresponds to the first... The tension control parameters for each target detection cycle, the Indicates the adjacent first The target detection cycle and the first The tension control difference of each target detection cycle, the This represents the adjustment coefficient, used to characterize the adjustment range of the compensation roll diameter; A rotational velocity determination module is configured to determine a target rotational velocity of the target spool corresponding to the current detection period according to the reference linear velocity of the target spool, the tension control parameter of the target spool corresponding to the current detection period and the adjusted winding diameter.

12. A winding machine control device, characterized by, It comprises: The acquisition module is used for acquiring the reference line speed of the unwinding shaft of the winding machine according to the given line speed of the main virtual shaft of the winding machine, and acquiring each tension control parameter corresponding to each target detection period of the unwinding shaft according to the output value of the tension PID controller corresponding to each target detection period connected with the unwinding shaft. The control module is used for determining the target rotating speed of the unwinding shaft corresponding to the current detection period in each target detection period according to the reference line speed of the unwinding shaft and each tension control parameter corresponding to each target detection period of the unwinding shaft by using the spool rotating speed control device in claim 11.

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