Interventional high-strength stainless steel wire intelligent self-adaptive straightening system and method

Abstract

This invention discloses an intelligent adaptive straightening system and method for high-strength stainless steel wire, comprising seven modules: a central control system, an intelligent planning system, an adaptive feed tension control system, a straightening system, a fixed-length automatic compensation system, a traction system, and a fixed-length cutting system. The intelligent straightening planning system, composed of artificial intelligence software, can obtain optimized straightening parameters through prior learning and training. Inputting the wire diameter and strength, it plans parameters such as traction speed, number of straightening modules, distance, and depth. This invention's intelligent straightening planning system can deeply learn from past experience, matching the straightening depth, spacing, and guiding speed according to the diameter / strength of the processed wire, providing a reference for process optimization, reducing straightening costs, and improving production efficiency.

Description

Technical Field

[0001] This invention belongs to the core raw material processing technology field of medical devices, specifically relating to an intelligent adaptive straightening system and method for high-strength stainless steel wire used in interventional procedures. Background Technology

[0002] With the increasing prevalence of neuro- and cardiovascular interventional surgeries, the number of guidewires used is growing daily. Guidewires play a crucial role in establishing access, providing support, and delivering tissues during surgery, significantly impacting the success of the procedure. These guidewires have a metal core, mostly made of nickel-titanium alloy or 304 stainless steel, with a diameter less than 1.0 mm. They require excellent throughput, support, tracking, and synchronization. Furthermore, during guidewire manufacturing, the first 100-400 mm of the core wire tip needs to be ground to a finer dimension before further processing; for example, some 0.35 mm diameter guidewires require grinding to 0.08-0.15 mm. These combined performance requirements place extremely stringent demands on the core wire's strength and straightness. Poor straightness significantly affects wire synchronization; when one end rotates, the other end may jump or lag severely, significantly increasing the risk of vascular puncture and dissection. In addition, these core wires are generally quite long, ranging from 150 cm to 350 cm, and ensuring both length accuracy and a smooth, undamaged surface quality presents a significant technical challenge. The high requirements for straightness and length accuracy of fine-diameter, high-strength long filaments pose challenges to straightening technology and equipment.

[0003] There are relatively many reports on conventional wire / bar straightening techniques. The literature "Research on Wire Straightening Process" (Feng Liang, Metal Products, 1987; 13(6): 9-15) studied the internal stress distribution of the wire during straightening with straightening rollers and the calculation and optimization of parameters such as the number of straightening rollers, reduction, and traction force. The wire used in the study had a diameter of 2.0 mm and a strength of 1390 N / mm². 2 This can be converted to 1390MPa. The core wire used for interventional guide wire generally has a strength higher than 2400MPa and a diameter of less than 0.5mm. Roller straightening may have problems such as insufficient reduction deformation, making it difficult to control the straightness of the steel wire. The literature "Straightening of galvanized straight steel wire" (Li Haiqing, Metal Products, 1992.18(4):42-44) reported the straightening shuttle rotation straightening. The article mentioned that the offset range of different steel wires is different. The finer the steel wire, the greater the offset. It is also affected by strength, toughness and residual stress, but there are no specific methods and performance results. In addition, the steel wire used in the article is 1520N / mm 2 The galvanized wire has low strength and its straightness is such that the chord height of a 1-meter long chord is no more than 25mm. This straightness cannot meet the requirements for the synchronization of the core wire used in intervention.

[0004] The invention patent "A Fully Automatic Intelligent Precision Straightening Machine" (application number: CN201910760085.6) discloses an intelligent straightening machine. The invention discloses a straightening machine, which includes three main parts: a feeding device, an automatic straightening device, a CNC automatic reading feeding device, and a shearing device. It realizes automatic feeding, automatic straightening without stopping the machine, accurate length calculation, automatic tracking and shearing, and can cut any length, and is suitable for wires of different specifications.

[0005] The patent "An automatic straightening device for a fully automatic intelligent precision straightening machine" (application number: CN201910760788.9) discloses the technology and structure of a straightening module that can adjust the straightening block online without stopping the machine.

[0006] The utility model patent "Metal Wire Straightening and Cutting Machine" (publication number: CN201420485062.1) discloses a metal wire straightening and cutting machine, including a frame, traction wheel, pre-straightening mechanism, straightening mechanism, cutting mechanism, power mechanism, and power transmission mechanism. However, there is no information on whether it is suitable for fine-diameter, high-strength steel wire.

[0007] Although there are many publicly available steel wire straightening technologies, the steel wires used in interventional guidewires are characterized by high strength, small diameter, and long length. Their high aspect ratio results in insufficient rigidity and stringent straightness requirements, making them extremely prone to breakage, twisting, or localized minor bends during straightening, thus failing to meet usage requirements. Furthermore, the thin diameter and large aspect ratio also lead to significant length deviations during fixed-length cutting. In short, existing straightening methods, equipment, and processes for stainless steel core wires used in interventional medicine have significant problems and need improvement to meet the performance requirements of interventional core wires. For example, the fixed-length portion in publicly available straightening technologies generally uses encoders. For interventional steel wires with strength exceeding 2500MPa, the high strength makes it easy for the initially drawn wire to form small bends and slippage, ultimately resulting in large errors in encoder length measurement. Moreover, many devices rely on manual length compensation, which cannot adapt to changes in wire material in real time, leading to substantial length errors. For example, a wire with a specified length of 850mm may have an actual cutting length error as high as ±3mm, failing to meet usage requirements.

[0008] In addition, there are many diameter specifications for the interventional steel wires, and the wires are twisted by the high-speed rotating straightening blocks when passing through the straightening module, which adds small bends and seriously affects the straightness and makes them easy to break. All of these are difficulties in straightening high-strength interventional fine wires. Summary of the Invention

[0009] This invention addresses the problems encountered in straightening high-strength steel wire using existing technologies. It provides a novel intelligent adaptive straightening system and method. This system achieves high straightness, accurate length setting, and high production efficiency when straightening high-strength stainless steel wire.

[0010] To achieve the above objectives, the present invention provides the following technical solution: an intelligent adaptive straightening system for high-strength stainless steel wire, comprising seven modules: a central control system, an intelligent planning system, an adaptive feed tension control system, a straightening system, a fixed-length automatic compensation system, a traction system, and a fixed-length cutting system;

[0011] Intelligent straightening planning system: Composed of artificial intelligence software, it can obtain optimized straightening parameters through prior learning and training. By inputting the diameter and strength of the steel wire, it can plan parameters such as traction speed, number of straightening modules, distance, and depth.

[0012] The feed tension adaptive control system consists of two parts: a real-time tension detection module and a tension adjustment module, ensuring stable and controllable feed tension.

[0013] The fixed-length automatic compensation system consists of an encoder and a compensation device. The compensation device is composed of an accelerometer and a new signal transmission line. The encoder is equipped with a guide wheel, and the accelerometer is located on the edge of the guide wheel. The wire passes around the guide wheel to drive the encoder to rotate. The compensation data obtained by the accelerometer is transmitted to the central processing unit. After deducting the length error caused by slippage, it is transmitted to the fixed-length cutting module.

[0014] The traction system consists of two parts: a first guide wheel and a second guide wheel. The second guide wheel is equipped with a tension detection device, which can detect the tension of the steel wire in real time.

[0015] The fixed-length cutting system is connected to the central processing unit and communicates with the fixed-length automatic compensation system.

[0016] Furthermore, the number of straightening modules is 3-20, the depth is 0.5mm-20mm, the spacing is 0.5mm-100mm, and the traction speed is 0.1m / min-100m / min.

[0017] Furthermore, the aforementioned artificial intelligence software: expresses straightness in mm / mm (meaning that the arching of a circle within a certain length must not exceed a certain number of millimeters), establishes a functional relationship between straightness and diameter, strength, traction speed, number of straightening modules, spacing between straightening modules, and depth of straightening modules, and performs deep learning to match the diameter and strength of each steel wire with the equipment's traction speed, number of straightening modules, spacing, and depth, ultimately fitting a mathematical model. When straightening a specific steel wire, after inputting specific strength, diameter, and other data, the software automatically simulates and calculates data for traction speed, number of straightening modules, spacing between straightening modules, and depth of straightening modules.

[0018] A method for intelligent adaptive straightening of high-strength stainless steel wire, characterized by the following steps:

[0019] S1. Intelligent Straightening Planning: Input the required straightening diameter and strength into the planning system, and the system will provide suggested straightening module parameters, traction speed, and other straightening parameters.

[0020] S2. Straightening Module Adjustment: The wire passes through the straightening module. Based on the straightening plan, the modulation system is activated to automatically adjust the number, depth, and spacing of the straightening modules.

[0021] S3, Feeding Tension Setting: Pass the steel wire through the feeding tension adjustment module and set a certain feeding tension, then pass it out into the next module.

[0022] S4. Set the cutting length, bypass the encoder and compensation system, the fixed-length cutting system, and after passing through the first guide wheel and the second guide wheel of the traction system, assemble the tension monitoring system on the second guide wheel, and pull it out by traction.

[0023] Beneficial technical effects of the present invention:

[0024] The intelligent straightening planning system can learn deeply from past experience and match the straightening depth, spacing and guiding speed according to the diameter / strength of the wire being processed, providing a reference for process optimization, reducing straightening costs and improving production efficiency.

[0025] The feed tension adaptive control system can monitor the tension of the feed filament in real time, ensuring that the tension is controlled within a certain range, which can effectively reduce filament twisting and reduce the probability of filament breakage.

[0026] The fixed-length automatic compensation device can automatically deduct the sliding angle based on the compensation data, thereby calculating a more accurate length value and greatly improving the fixed-length accuracy.

[0027] The second guide wheel can detect the tension of the wire at the discharge port in real time. When the tension suddenly decreases or increases, it automatically controls the downward pressure of the guide wheel to play a compensating role, greatly reducing the probability of wire breakage and significantly improving production efficiency. Attached Figure Description

[0028] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof.

[0029] Figure 1 This is a schematic diagram of the structure of the device of the present invention. Detailed Implementation

[0030] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] Please see Figure 1 This invention provides a technical solution for an intelligent adaptive straightening system for high-strength stainless steel wire used in interventional procedures, comprising seven modules: a central control system, an intelligent planning system, an adaptive feed tension control system, a straightening system, a fixed-length automatic compensation system, a traction system, and a fixed-length cutting system.

[0032] Intelligent straightening planning system: Composed of artificial intelligence software, it can obtain optimized straightening parameters through prior learning and training. By inputting the diameter and strength of the steel wire, it can plan parameters such as traction speed, number of straightening modules, distance, and depth.

[0033] The feed tension adaptive control system consists of two parts: a real-time tension detection module and a tension adjustment module, ensuring stable and controllable feed tension.

[0034] The fixed-length automatic compensation system consists of an encoder and a compensation device. The compensation device is composed of an accelerometer and a new signal transmission line. The encoder is equipped with a guide wheel, and the accelerometer is located on the edge of the guide wheel. The wire passes around the guide wheel to drive the encoder to rotate. The compensation data obtained by the accelerometer is transmitted to the central processing unit. After deducting the length error caused by slippage, it is transmitted to the fixed-length cutting module.

[0035] The traction system consists of two parts: a first guide wheel and a second guide wheel. The second guide wheel is equipped with a tension detection device, which can detect the tension of the steel wire in real time.

[0036] The fixed-length cutting system is connected to the central processing unit and communicates with the fixed-length automatic compensation system.

[0037] In this embodiment, the number of straightening modules is 3-20, with a depth of 0.5mm-20mm and a spacing of 0.5mm-100mm, and a traction speed of 0.1m / min-100m / min. The combined effect is that the depth of the pressure blocks determines the deformation of the steel wire during the straightening process, while the spacing determines the distance the steel wire travels. Because the pressure blocks are arranged in a crisscross pattern, when a point on the steel wire is compressed at a pressure block, some of the original residual stress can be eliminated, but new residual stress is inevitably introduced. Therefore, when the steel wire moves forward and rotates to the next pressure block, that point should be under tension to eliminate the additional residual stress generated by the previous pressure block. Thus, the traveling speed of the steel wire, i.e., the traction speed, and the rotational angular velocity of the straightening modules should be matched. This embodiment takes into account this comprehensive effect and proposes specific combination parameters that can match within a certain range, thereby further improving the straightening effect.

[0038] In this embodiment, the artificial intelligence software, based on accumulated process experience, expresses straightness in mm / mm (meaning that the arc bulge within a certain length must not exceed a certain number of millimeters). It establishes a functional relationship between straightness and diameter, strength, traction speed, number of straightening modules, spacing between straightening modules, and depth of straightening modules, and performs deep learning to match the diameter and strength of each steel wire with the equipment's traction speed, number of straightening modules, spacing, and depth, ultimately fitting a mathematical model. When straightening a specific steel wire, after inputting specific strength, diameter, and other data, the software automatically simulates and calculates data for traction speed, number of straightening modules, spacing between straightening modules, and depth of straightening modules.

[0039] A method for intelligent adaptive straightening of high-strength stainless steel wire, characterized by the following steps:

[0040] S1. Intelligent Straightening Planning: Input the required straightening diameter and strength into the planning system, and the system will provide suggested straightening module parameters, traction speed, and other straightening parameters.

[0041] S2. Straightening Module Adjustment: The wire passes through the straightening module. Based on the straightening plan, the modulation system is activated to automatically adjust the number, depth, and spacing of the straightening modules.

[0042] S3, Feeding Tension Setting: Pass the steel wire through the feeding tension adjustment module and set a certain feeding tension, then pass it out into the next module.

[0043] S4. Set the cutting length, bypass the encoder and compensation system, the fixed-length cutting system, and after passing through the first guide wheel and the second guide wheel of the traction system, assemble the tension monitoring system on the second guide wheel, and pull it out by traction.

[0044] Example 1:

[0045] For straightening 0.35mm diameter stainless steel wire, the tensile strength was tested at 2720MPa. After inputting the data into the intelligent straightening planning system, the basic parameters were determined: four straightening blocks are needed, with a straightening depth of 2cm and a spacing of 11mm. The feed tension was set to 0.2 kgf, and the traction speed was 1.8m / min. After activating the tension adjustment module, the wire was assembled and pulled out. The cutting length was set to 800mm, and straightening and cutting to that length began. The results showed a length tolerance of ±1mm and a straightness of 0.10mm / 300mm. The entire system is managed by a central control system.

[0046] Example 2:

[0047] For straightening 0.86mm diameter stainless steel wire, the tensile strength was tested at 2200MPa. After inputting the data into the intelligent planning system, it was determined that four straightening blocks were needed, with a straightening depth of 1cm and a spacing of 50mm. The feed tension was set to 1 kgf, and the traction speed was 0.5m / min. After activating the tension adjustment module, the wire was assembled and pulled out. The cutting length was set to 1500mm. After straightening and cutting to the specified length, the length tolerance was ±0.8mm, and the straightness was 0.15mm / 300mm.

[0048] Example 3:

[0049] For straightening 0.45mm diameter stainless steel wire, the tensile strength was tested at 2510MPa. After inputting the data into the intelligent straightening planning system, it was determined that 6 straightening blocks were needed, with a straightening depth of 3cm and a spacing of 30mm. The feed tension was set to 0.2 kgf, and the traction speed was 2m / min. After activating the tension adjustment module, the wire was assembled and pulled out. The cutting length was set to 3100mm. After straightening and cutting to the specified length, the length tolerance was ±0.9mm, and the straightness was 0.10mm / 300mm.

[0050] The above are preferred embodiments of the present invention. Those skilled in the art can make changes and modifications to the above embodiments. Therefore, the present invention is not limited to the specific embodiments described above. Any obvious improvements, substitutions or modifications made by those skilled in the art based on the present invention are within the protection scope of the present invention.

Claims

1. An intelligent adaptive straightening system for high-strength stainless steel wire, characterized in that, include: The system consists of seven modules: a central control system, an intelligent planning system, an adaptive feed tension control system, a straightening system, a fixed-length automatic compensation system, a traction system, and a fixed-length cutting system. Artificial intelligence software: Expresses straightness in mm / mm (meaning that the arch of a circle within a certain length must not exceed a certain number of millimeters), establishes a functional relationship between straightness and diameter, strength, traction speed, number of straightening modules, spacing between straightening modules, and depth of straightening modules, and performs deep learning to match the diameter and strength of each steel wire with the equipment traction speed, number of straightening modules, spacing, and depth, and finally fits a mathematical model. When straightening a specific steel wire, after inputting specific strength, diameter, and other data, it automatically simulates and calculates to provide data on traction speed, number of straightening modules, spacing between straightening modules, and depth of straightening modules. The number of straightening modules is 3-20, the depth is 0.5mm-20mm, the spacing is 0.5mm-100mm, and the traction speed is 0.1m / min-100m / min; Intelligent straightening planning system: Composed of the aforementioned artificial intelligence software, it can obtain optimized straightening parameters through prior learning and training. By inputting the diameter and strength of the steel wire, it can plan parameters such as traction speed, number of straightening modules, spacing, and depth. The feed tension adaptive control system consists of two parts: a real-time tension detection module and a tension adjustment module, ensuring stable and controllable feed tension. The fixed-length automatic compensation system consists of an encoder and a compensation device. The compensation device is composed of an accelerometer and a new signal transmission line. The encoder is equipped with a guide wheel, and the accelerometer is located on the edge of the guide wheel. The wire passes around the guide wheel to drive the encoder to rotate. The compensation data obtained by the accelerometer is transmitted to the central processing unit. After deducting the length error caused by slippage, it is transmitted to the fixed-length cutting module. The traction system consists of two parts: a first guide wheel and a second guide wheel. The second guide wheel is equipped with a tension detection device, which can detect the tension of the steel wire in real time. The fixed-length cutting system is connected to the central processing unit and communicates with the fixed-length automatic compensation system.

2. The intelligent adaptive straightening method for high-strength stainless steel wire used in interventional procedures according to claim 1, characterized in that: Includes the following steps: S1. Intelligent Straightening Planning: Input the required straightening diameter and intensity into the planning system, and the planning system will provide suggested straightening module parameters, traction speed, and other straightening parameters. S2. Straightening Module Adjustment: As the wire passes through the straightening module, the modulation system is activated based on the straightening plan results, automatically adjusting the number, depth, and spacing of the straightening modules. S3, Feed tension setting: Pass the steel wire through the feed tension adjustment module and set a certain feed tension, then pass it out into the next module; S4. Set the cutting length, bypass the encoder and compensation system, the fixed-length cutting system, and after passing through the first guide wheel and the second guide wheel of the traction system, assemble the tension monitoring system on the second guide wheel, and pull it out by traction.

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