Cable automatic winding method and system

Abstract

The application discloses a cable automatic winding method and system, and belongs to the technical field of intelligent manufacturing. The technical problem to be solved by the application is how to realize real-time monitoring of the current winding state and automatically execute winding actions to reduce the labor intensity. The technical scheme is as follows: the cable is fixed to a reel, the reel size category is selected through a control panel, and a start button is pressed. A fixed type cross-shaped lifting wheel of a winding device is horizontally moved to an initial position, is vertically moved to a position just lifting the cable, and makes the cable in an approximately straight line position. The initialization rotation encoder value is 1. A PLC controller reads the data of a wire diameter instrument, and automatically sets the tension value of a take-up device according to the wire diameter. An industrial computer simultaneously collects image data of two industrial cameras. The two industrial cameras are a left industrial camera and a right industrial camera. The left industrial camera adopts an angle of shooting the right side of the reel from the top, and the right industrial camera adopts an angle of shooting the left side of the reel from the top.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of intelligent manufacturing, in particular to a cable automatic winding method and system. BACKGROUND

[0002] The traditional cable winding device needs manual observation of the winding state, processing of possible winding abnormalities such as flash gaps and overlapping lines, and manual pulling of the cable to the wall of the reel and manual execution of the reversing operation. The traditional cable winding process consumes manpower and long-time observation can easily cause visual fatigue.

[0003] Therefore, how to realize real-time monitoring of the current winding state and automatically execute the winding action to reduce the labor intensity and improve the automatic winding level of the cable is a technical problem to be solved. SUMMARY

[0004] The technical task of the present application is to provide a cable automatic winding method and system to solve the problem of how to realize real-time monitoring of the current winding state and automatically execute the winding action to reduce the labor intensity and improve the automatic winding level of the cable.

[0005] The technical task of the present application is achieved in the following manner, a cable automatic winding method, which specifically includes the following steps:

[0006] The cable is fixed to the reel, the reel size category is selected through the control panel, and the start button is pressed. The fixed cross-shaped lifting wheel of the winding device moves horizontally to the initial position, moves vertically to just lift the cable, and makes the cable in an approximate straight line. The initialization value of the rotary encoder is 1. The PLC controller reads the data of the wire diameter instrument and automatically sets the tension value of the take-up device according to the wire diameter.

[0007] The industrial computer simultaneously collects image data of two industrial cameras; wherein the two industrial cameras are a left industrial camera and a right industrial camera. The left industrial camera adopts an upward angle to shoot the right side of the reel, and the right industrial camera adopts an upward angle to shoot the left side of the reel.

[0008] The rotary encoder is used to record the number of winding turns of the current layer of the reel.

[0009] The moving direction of the current take-up device and the current count of the rotary encoder are obtained, and the image data of the left industrial camera and the right industrial camera are alternately inferred according to the current position of the cable and the threshold value of the inference start, and the inference result is obtained.

[0010] The inference result is pushed into the queue for caching. Only when the proportion of any inference result appearing in the queue is greater than the set threshold value, it is determined that the inference result is true, and then the control action is executed.

[0011] According to the inference result and the PLC controller, the wire arranging device and the wire collecting device are controlled to execute actions, specifically as follows:

[0012] In the normal state, the wire arranging device remains in the middle position and does not execute actions.

[0013] In the one-layer winding state of case one, the wire arranging device moves in the opposite direction of the movement of the wire collecting device.

[0014] In the two-layer winding state, the wire collecting device executes a reversing operation, and the wire arranging device pulls the wire in the same direction of the movement of the wire collecting device, and the count of the rotary encoder is reset to 1.

[0015] The reset state appears after the two-layer winding, and when the wire arranging device pulls the second layer of wire back to the position in line with the first layer of wire, the wire arranging device immediately executes a reset operation, moves horizontally to the middle position, and moves vertically upward by a set distance.

[0016] The abnormal cases include the one-layer winding state of case two and the flash gap state, and the corresponding actions of the wire arranging device are as follows: in the flash gap state, an audible and visual alarm is issued, the wire arranging device moves in the same direction of the movement of the wire collecting device, and the wire collecting device moves in the opposite direction of the movement of the wire arranging device until the normal state is detected, the wire arranging device returns to the original position, and the wire collecting device stops moving; in the one-layer winding state of case two, the wire arranging device moves in the opposite direction of the movement of the wire collecting device until the normal state is detected again, and the wire arranging device resets to the original position.

[0017] The industrial computer labels the inference results of the left and right image paths on the image, and converts the image into a live video stream to display on the large screen, realizing the monitoring of the real-time running state and inference result of multiple automatic wire arranging devices on one large screen.

[0018] As a preferred embodiment, the moving direction of the current wire collecting device and the current count of the rotary encoder are obtained, and the image data of the left industrial camera and the right industrial camera are alternately inferred according to the current position of the cable and the threshold value of starting inference, specifically as follows:

[0019] When the wire collecting device moves to the left and the count of the rotary encoder is less than the threshold value of the total number of layers, the inference of the left industrial camera is started.

[0020] When the wire collecting device moves to the left and the count of the rotary encoder is greater than the threshold value of the total number of layers, the inference of the right industrial camera is started.

[0021] When the wire collecting device moves to the right and the count of the rotary encoder is less than the threshold value of the total number of layers, the inference of the right industrial camera is started.

[0022] When the wire collecting device moves to the right and the count of the rotary encoder is greater than the threshold value of the total number of layers, the inference of the left industrial camera is started.

[0023] Such a back-and-forth realizes the alternating inference of the left and right images.

[0024] As preferred, the threshold value includes a first threshold value, a second threshold value, a third threshold value, a fourth threshold value, and a fifth threshold value;

[0025] The first threshold value is used to determine whether the winding is in a normal state;

[0026] The second threshold value is used to determine whether the winding is in a flash gap state;

[0027] The third threshold value is used to determine whether the winding is in a one-layer stacked wire state;

[0028] The fourth threshold value is used to determine whether the winding is in a two-layer stacked wire state;

[0029] The fifth threshold value is used to determine whether the winding is in a reset state;

[0030] The normal state indicates that the current winding is located in the middle position (third to last circle) and no abnormality occurs;

[0031] The one-layer stacked wire state includes two cases, case one is that the current winding and the last circle of winding have too small horizontal spacing, resulting in one-layer stacked wire of the cable, which is an abnormal case; case two is that the current winding is the first circle of a new layer, which is a normal case, but needs to pull the wire to make the cable close to the side wall of the reel;

[0032] The two-layer stacked wire state appears when the first circle of the new layer has been wound and the second circle of wire begins to overlap the first circle of wire;

[0033] The reset state appears after two-layer stacked wire, when the second circle of wire is pulled back to the same level as the first circle of wire by the wire arrangement device;

[0034] The flash gap state indicates that the current winding and the last circle of winding have too large horizontal spacing, resulting in loose cable arrangement;

[0035] In the case where the wire arrangement does not have any abnormality, the order of the inference result appearing is normal state, one-layer stacked wire state of case one, two-layer stacked wire state, and reset state, which circulates back and forth.

[0036] As preferred, the inference result is pushed into the queue for caching, and only when the proportion of any inference result appearing in the queue is greater than the set threshold value, the inference result is determined to be true, and then the judgment logic of the control action is as follows:

[0037] After the inference result enters the message queue data, it is determined whether the proportion of the normal state in the message queue data is greater than or equal to the first threshold value:

[0038] If it is determined to be yes, it means that the current wire arrangement is in a normal state, and no processing action needs to be performed, and the queue data continues to be consumed;

[0039] When the proportion of the normal state is less than the first threshold value, then continue to determine whether the proportion of the flash gap is greater than the second threshold value:

[0040] If it is determined to be yes, it represents that the current wire arrangement is in the flash gap, the motor X pulls the wire in the same direction as the movement of the take-up device, the take-up device is jogged in the opposite direction to the movement of the cable, until the cable is pulled back to the normal state, the motor X is reset to the original position, and the take-up device stops jogging;

[0041] When the proportion of the flash gap is less than the second threshold value, then continue to determine whether the proportion of the one-layer winding state is greater than the third threshold value:

[0042] If it is determined to be yes, it represents that the current wire arrangement is in the one-layer winding state, the motor X pulls the wire in the opposite direction of the movement of the take-up device;

[0043] If it is determined to be no, then continue to consume the queue data;

[0044] After the current wire arrangement is in the one-layer winding state, then continue to determine whether the proportion of the two-layer winding state is greater than the fourth threshold value:

[0045] If it is determined to be no, then continue to determine whether the proportion of the normal state is greater than the first threshold value:

[0046] If the proportion of the normal state is greater than or equal to the first threshold value, it represents that the one-layer winding state is case two, after the winding is pulled back to the normal state, the motor X is reset to the original position;

[0047] When the two-layer winding state is greater than or equal to the fourth threshold value, it represents that the current wire arrangement is full, at this time the reset of the rotary encoder is 1, the direction of the take-up device motor is changed, and the motor X pulls the wire in the same direction as the movement of the take-up device;

[0048] After entering the two-layer winding state to perform the wire pulling, it is determined whether the reset state is greater than the fifth threshold value:

[0049] If it is determined to be yes, it represents that the reversing wire pulling is completed, at this time the motor Z performs the action of upward lifting movement, and the motor X is reset to the original position;

[0050] The wire arrangement action of one layer is completed, and the cycle is repeated to finally complete the automatic wire arrangement control of the entire wire reel.

[0051] More preferably, the fixed cross-shaped lifting wheel moves vertically, the lifting wire reel is in a linear state and is tangent to the wire reel, the distance of each layer of winding movement is determined by the data model corresponding to the size and installation position of the fixed cross-shaped lifting wheel, the wire arrangement device, and the take-up device; wherein the mathematical model is as follows:

[0052] The center point of the wire coil is O point, the initial wire coil winding is A1P1, the fixed cross-shaped lifting wheel lifting position of the wire arrangement device is D1 point, the cable is tangent to the wire coil at P1 point, the vertical distance from the fixed cross-shaped lifting wheel to the ground is A0A1, the vertical distance from the initial position of the wire arrangement device to the ground is B0D1, the vertical distance from the center of the wire coil of the wire collector to the ground is C0O, the horizontal distance from the fixed cross-shaped lifting wheel to the wire arrangement device is A0B0, the horizontal distance from the fixed cross-shaped lifting wheel to the center of the wire collector is A0C0, the cable diameter is d, and the winding layer number is n;

[0053] In ΔA1C1O:

[0054]

[0055]

[0056] Wherein, α0 represents the included angle between A1C1 and A1O;

[0057] In ΔA1B1D1:

[0058]

[0059]

[0060] Wherein, α1 represents the included angle between A1P1 and A1O;

[0061] In ΔA1P1O:

[0062] P1O=A1O*sinα1;

[0063] The cable after winding n layers is A1P n , the fixed cross-shaped lifting wheel lifting position of the wire arrangement device is D n point, the cable is tangent to the wire coil at P n point, and the fixed cross-shaped lifting wheel needs to be lifted vertically upward by a distance of D1D n , and the formula is as follows:

[0064] In ΔA1P n O:

[0065]

[0066]

[0067] Wherein, α n represents the included angle between A1P1 and A1P n ;

[0068] In ΔA1B1D n :

[0069] B1D n = A1B1 tan (a0 + a1 + a n );

[0070] Further lift to:

[0071] D1D n = B0D n -B0D1 = (B0B1 + B1D n )-B0D1;

[0072] The final value can be obtained by substituting the values obtained above:

[0073]

[0074] Where:

[0075]

[0076] According to the mathematical model of the fixed cross-shaped lifting wheel, the cable arranging device and the cable collecting device of the production line, the distance that the fixed cross-shaped lifting wheel needs to move vertically upward for each layer of cable winding is calculated to ensure that the cable is always lifted in a straight line.

[0077] An automatic cable arranging system, which detects the current winding state of the cable based on machine vision and controls the automatic cable arranging device to perform corresponding actions to achieve automatic cable arranging through a PLC controller.

[0078] The automatic cable arranging device includes a cable arranging device, a cable collecting device, and a control cabinet. The cable arranging device includes a bracket, a horizontal direction driving device, a vertical direction driving device, a fixed cross-shaped lifting wheel, a left industrial camera, and a right industrial camera. The left and right industrial cameras are used to collect images simultaneously, and the images of the left and right industrial cameras are alternately inferred based on the current moving direction of the cable collecting device and the current count of the rotary encoder.

[0079] A rotary encoder is added to the cable collecting device to record the number of winding turns of the current layer of the cable drum. Each time the automatic cable arranging function is started, the rotary encoder data is initialized.

[0080] The control cabinet uses a double-checking method combining algorithms and software to push the inference results to the message queue data for caching. If the proportion of any result appearing in the cache is greater than the set threshold, the corresponding action is then executed to avoid algorithmic misjudgment. The inference results are labeled on the images and the images are transcoded into live video streams to realize real-time monitoring of the running status of multiple automatic cable arranging devices and the inference results on a large screen.

[0081] As preferred, the horizontal direction driving device and the vertical direction driving device include servo motors, lead screws and slide rails; the horizontal direction driving device makes the fixed cross-shaped lifting wheel perform horizontal pulling action, and the vertical direction driving device makes the fixed cross-shaped lifting wheel perform vertical lifting action, so that the fixed cross-shaped lifting wheel achieves the purpose of arranging and lifting the cable through two degrees of freedom of horizontal and vertical movement; the left industrial camera and the right industrial camera are respectively located on the left and right sides of the upper bracket of the fixed cross-shaped lifting wheel and shoot the current winding state at an upward angle, in order to avoid the shielding of the camera by the sidewall of the reel, the left industrial camera observes the winding state of the right side of the reel, and the right industrial camera observes the winding state of the left side of the reel.

[0082] As preferred, the control cabinet includes a control panel, an industrial computer, a PLC controller and an audible and visual alarm;

[0083] The control panel is used for initializing the rotary encoder and starting and stopping the equipment.

[0084] The industrial computer is used for acquiring image data collected by the left industrial camera and the right industrial camera and performing inference, and driving the cable arranger to perform action through the PLC controller according to the inference result;

[0085] The PLC controller is used for communication with the cable arranger, the cable collector, the rotary encoder, the audible and visual alarm and a wire diameter instrument, and the wire diameter instrument is used for real-time measurement of the diameter of the current winding.

[0086] As preferred, the inference result includes a normal state, a one-layer winding state, a two-layer winding state, a reset state and a flash gap state.

[0087] The normal state indicates that the current winding is located at the middle position (the third circle to the last circle) and no abnormality occurs.

[0088] The one-layer winding state includes two cases, case one is that the current winding and the winding of the last circle have too small horizontal spacing, resulting in one-layer winding of the cable, which is an abnormal case; case two is that the current winding is the first circle of a new layer, which is a normal case, but the cable needs to be pulled to be close to the sidewall of the reel;

[0089] The two-layer winding state appears when the first circle of the new layer has been wound and the second circle of the line begins to be stacked on the first circle of the line.

[0090] The reset state appears after two-layer winding, and appears when the cable arranger pulls the second circle of the line back to the position where the first circle of the line is flush.

[0091] The flash gap state indicates that the current winding and the winding of the last circle have too large horizontal spacing, resulting in loose arrangement of the cable.

[0092] In the case of no abnormality of the cable, the order of the inference result appearing is normal state, one-layer winding state of case one, two-layer winding state, reset state, and so on, and the cycle is repeated.

[0093] More preferably, the action of driving the cable winder by the PLC controller according to the inference result is as follows:

[0094] In the normal state, the cable winder remains in the middle position and does not perform the action.

[0095] In the one-layer winding state of case one, the cable winder moves in the opposite direction of the movement of the cable winder.

[0096] In the two-layer winding state, the cable winder performs the reversing operation, and the cable winder pulls the cable in the same direction of the movement of the cable winder, and the count of the rotary encoder is reset to 1.

[0097] The reset state appears after the two-layer winding, and when the cable winder pulls the second layer of cable to the position of being flush with the first layer of cable, the cable winder immediately performs the reset operation, moves horizontally to the middle position, and moves vertically upward by a certain distance.

[0098] The abnormal cases include the one-layer winding state of case two and the flash gap state, and the corresponding actions of the cable winder are as follows:

[0099] In the flash gap state, the cable winder moves in the same direction of the movement of the cable winder, and the cable winder points in the opposite direction of the movement of the cable, until the cable is pulled back to the normal position, until the normal state is detected again, the cable winder returns to the original position, and the cable winder stops pointing.

[0100] In the one-layer winding state of case two, the cable winder moves in the opposite direction of the movement of the cable winder, until the normal state is detected again, and the cable winder returns to the original position.

[0101] The cable automatic winding method and system have the following advantages:

[0102] (1) The cable automatic winding method and system can automatically perform the winding action, reduce the work burden of manual work, and significantly improve the automatic winding level of the cable.

[0103] (2) The cable automatic winding method and system realizes the detection of the current winding state of the cable based on machine vision, and controls the cable winder and the cable winder to perform corresponding actions to realize the automatic winding of the cable. Compared with the traditional method, the cable automatic winding method and system can realize the real-time monitoring of the current winding state and automatically perform the winding action, reduce the work burden of manual work, and improve the automatic winding level of the cable.

[0104] (III) In order to ensure the real-time control effect, the length of the cache queue should not be too large. The present invention adopts a dual verification method combining algorithm and software to prevent misoperation caused by misjudgment of the inference model and significantly improve the detection accuracy. The dual verification method pushes the inference results to the queue for caching. The normal state, flash gap state, one layer overlapping line state, two layer overlapping line state, and reset state correspond to the first threshold, the second threshold, the third threshold, the fourth threshold, and the fifth threshold, respectively. Only when the proportion of a certain inference result appearing in the queue is greater than the threshold can it be considered as that result, and then the control action is executed, thereby improving the detection accuracy.

[0105] (iv) The industrial control computer of the present invention annotates the inference results on the image and displays the continuous images as a live video stream on the large screen. It supports the function of simultaneously monitoring the real-time operating status and inference results of multiple automatic cable laying devices on one large screen, and is not limited to monitoring the cable laying status of a single cable reel.

[0106] (v) Based on a mathematical model, this invention can calculate the distance that the fixed grid lifting wheel needs to move vertically upward for each layer of cable wound, thereby ensuring that the cable is always lifted in a straight line. Attached Figure Description

[0107] The invention will be further described below with reference to the accompanying drawings.

[0108] Appendix Figure 1 This is a schematic diagram of automatic wiring.

[0109] Appendix Figure 2 This is a diagram illustrating the normal state of the cable.

[0110] Appendix Figure 3 This is a schematic diagram of the cable flashover state;

[0111] Appendix Figure 4 This is a schematic diagram of the single-layer cable configuration in case one.

[0112] Appendix Figure 5 This is a schematic diagram of the single-layer cable stacking state in case two of the cable configuration;

[0113] Appendix Figure 6 This is a schematic diagram showing the double-layered state of the cable.

[0114] Appendix Figure 7 This is a schematic diagram showing the cable in reset state.

[0115] Appendix Figure 8 The inference result loop diagram for normal winding;

[0116] Appendix Figure 9 A schematic diagram of the mathematical model of the automatic wiring structure;

[0117] AppendixFigure 10 A flow chart of the automatic cable arranging method;

[0118] Figure 1 is a schematic diagram of the automatic cable arranging method of the present application. Figure 11 Figure 2 is a coordinate diagram with the horizontal axis representing the number of winding layers and the vertical axis representing the distance to be lifted. DETAILED DESCRIPTION

[0119] The automatic cable arranging method and system of the present application will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0120] Embodiment 1:

[0121] The present embodiment provides an automatic cable arranging method, which is specifically as follows:

[0122] S1, fix the cable to the reel, select the reel size category through the control panel and press the start button, move the fixed cross-shaped lifting wheel of the cable arranger horizontally to the initial position, move it vertically to the position where it just lifts the cable to make the cable in an approximate straight line, initialize the rotary encoder value to 1, read the data of the wire diameter instrument by the PLC controller, and automatically set the tension value of the take-up device according to the wire diameter;

[0123] S2, the industrial computer simultaneously collects image data of two industrial cameras; wherein the two industrial cameras are a left industrial camera and a right industrial camera, the left industrial camera adopts an upward angle to shoot the right side of the reel, and the right industrial camera adopts an upward angle to shoot the left side of the reel;

[0124] S3, record the number of winding turns of the current layer of the reel by using the rotary encoder;

[0125] S4, obtain the moving direction of the current take-up device and the current count of the rotary encoder, and alternately infer the image data of the left industrial camera and the right industrial camera according to the current position of the cable and the threshold value of the inference, and obtain the inference result;

[0126] S5, push the inference result to the queue for caching, and only when the proportion of any inference result appearing in the queue is greater than the set threshold value, it is determined that the inference result is true, and then the control action is executed;

[0127] S6, communicate with the PLC controller according to the inference result to control the actions of the cable arranger and the take-up device, specifically:

[0128] ① in the normal state, the cable arranger remains in the middle position and does not execute the action;

[0129] ② in the case of one layer of winding state, the cable arranger moves in the opposite direction of the take-up device that is moving;

[0130] ③Two layers of wire stacking state, the winding device performs a reversing operation, and the wire arranging device pulls the wire in the same direction as the movement of the winding device, and the count of the rotary encoder is reset to 1;

[0131] ④The reset state appears after two layers of wire stacking, and when the wire arranging device pulls the second layer of wire to the same level as the first layer of wire, the wire arranging device immediately performs a reset operation, moves horizontally to the middle position, and moves vertically upward by a set distance;

[0132] ⑤Abnormal situations include the one-layer wire stacking state of case two and the flash gap state, and the corresponding actions of the wire arranging device are as follows: in the flash gap state, sound and light alarms are issued, the wire arranging device moves in the same direction as the movement of the winding device, the winding device points in the opposite direction of the movement of the wire arranging device, until the normal state is detected, the wire arranging device returns to the original position, and the winding device stops pointing; in the one-layer wire stacking state of case two, the wire arranging device moves in the opposite direction of the movement of the winding device, until the normal state is detected again, and the wire arranging device resets to the original position;

[0133] S7, the industrial computer labels the inference results of the left and right image on the image, and converts the image into a live video stream to display on the large screen, realizing the monitoring of the real-time running state and inference result of multiple automatic wire arranging devices on one large screen.

[0134] In the embodiment, the current movement direction of the winding device and the current count of the rotary encoder are obtained, and the image data of the left industrial camera and the right industrial camera are alternately inferred according to the current position of the cable and the threshold value of starting inference, as follows:

[0135] When the winding device moves to the left and the count of the rotary encoder is less than the threshold value of the total number of turns of the current layer, the inference of the left industrial camera is started;

[0136] When the winding device moves to the left and the count of the rotary encoder is greater than the threshold value of the total number of turns of the current layer, the inference of the right industrial camera is started;

[0137] When the winding device moves to the right and the count of the rotary encoder is less than the threshold value of the total number of turns of the current layer, the inference of the right industrial camera is started;

[0138] When the winding device moves to the right and the count of the rotary encoder is greater than the threshold value of the total number of turns of the current layer, the inference of the left industrial camera is started;

[0139] In this way, the inference of the images on the left and right sides is alternated.

[0140] The threshold values in the embodiment include a first threshold value, a second threshold value, a third threshold value, a fourth threshold value, and a fifth threshold value;

[0141] The first threshold value is used to determine whether the winding is in a normal state;

[0142] The second threshold is used to determine whether the winding is in a flash gap state;

[0143] The third threshold is used to determine whether the winding is in a one-layer winding state;

[0144] The fourth threshold is used to determine whether the winding is in a two-layer winding state;

[0145] The fifth threshold is used to determine whether the winding is in a reset state;

[0146] As shown in the accompanying Figure 2 , the normal state indicates that the current winding is located in the middle position (the third circle to the last circle) and no abnormality occurs;

[0147] As shown in the accompanying Figure 4 and 5 , the one-layer winding state includes two cases. Case one is that the current winding and the winding of the last circle have too small horizontal spacing, resulting in one-layer winding of the cable, which is an abnormal case. Case two is that the current winding is the first circle of a new layer, which is a normal case, but needs to pull the line to make the cable close to the side wall of the reel;

[0148] As shown in the accompanying Figure 6 , the two-layer winding state appears when the first circle of a new layer has been wound and the second circle of the line begins to overlap the first circle of the line;

[0149] As shown in the accompanying Figure 7 , the reset state appears after two-layer winding, when the line dispenser pulls the second circle of the line back to the position where it is flush with the first circle of the line;

[0150] As shown in the accompanying Figure 3 , the flash gap state indicates that the current winding and the winding of the last circle have too large horizontal spacing, resulting in loose cable arrangement;

[0151] As shown in the accompanying Figure 8 , in the case where the line arrangement has no abnormality, the order of the inference results appearing is normal state, one-layer winding state of case one, two-layer winding state, reset state, and so on.

[0152] As shown in the accompanying Figure 10 , in this embodiment, the inference results are pushed into the queue for caching. Only when the proportion of any inference result appearing in the queue is greater than a set threshold, it is determined that the inference result is true, and then the judgment logic of the control action is as follows:

[0153] After the inference result enters the message queue data, it is determined whether the proportion of the normal state in the message queue data is greater than or equal to the first threshold:

[0154] If it is determined to be yes, it means that the current line arrangement is in a normal state, and no processing action needs to be performed, and the queue data continues to be consumed;

[0155] When the proportion of the normal state is less than the first threshold value, then continue to determine whether the proportion of the flash gap is greater than the second threshold value:

[0156] If the determination is yes, it means that the current wire is in the flash gap state, the motor X pulls the wire in the same direction as the movement of the take-up device, and the take-up device is jogged in the opposite direction to the movement of the cable. After the cable is pulled back to the normal state, the motor X is reset to the original position, and the take-up device stops jogging.

[0157] When the proportion of the flash gap state is less than the second threshold value, then continue to determine whether the proportion of the one-layer winding state is greater than the third threshold value:

[0158] If the determination is yes, it means that the current wire is in the one-layer winding state, and the motor X pulls the wire in the opposite direction of the movement of the take-up device.

[0159] If the determination is no, then continue to consume the queue data.

[0160] After the current wire is in the one-layer winding state, continue to determine whether the proportion of the two-layer winding state is greater than the fourth threshold value:

[0161] If the determination is no, then continue to determine whether the proportion of the normal state is greater than the first threshold value:

[0162] If the proportion of the normal state is greater than or equal to the first threshold value, it means that the one-layer winding state is case two, and after the winding is pulled back to the normal state, the motor X is reset to the original position.

[0163] When the two-layer winding state is greater than or equal to the fourth threshold value, it means that the current wire has been fully wound, at which point the rotary encoder count is reset to 1, the direction of the take-up device motor is changed, and the motor X pulls the wire in the same direction as the movement of the take-up device.

[0164] After entering the two-layer winding state and performing the wire pulling, determine whether the reset state is greater than the fifth threshold value:

[0165] If the determination is yes, it means that the reversing wire pulling is complete, at which point the motor Z performs an upward lifting movement, and the motor X is reset to the original position.

[0166] The one-layer wire winding action is completed, and the cycle is repeated to ultimately complete the automatic wire winding control of the entire wire reel.

[0167] The fixed cross-shaped lifting wheel in this embodiment moves vertically, and the lifting wire reel is in a linear state and is tangent to the wire reel. The distance of each layer of winding movement is determined by the data model corresponding to the size and installation position of the fixed cross-shaped lifting wheel, the wire winder, and the take-up device. As shown in FIG. 8, the mathematical model is as follows: Figure 9

[0168] ​The center point of the wire coil is O point, the initial wire coil winding is A1P1, the fixed cross-shaped lifting wheel lifting position of the wire arrangement device is D1 point, the cable is tangent to P1 point of the wire coil, the vertical distance of the fixed cross-shaped lifting wheel to the ground is A0A1, the vertical distance of the initial position of the wire arrangement device to the ground is B0D1, the vertical distance of the center of the wire coil of the wire collector to the ground is C0O, the horizontal distance of the fixed cross-shaped lifting wheel to the wire arrangement device is A0B0, the horizontal distance of the fixed cross-shaped lifting wheel to the center of the wire collector is A0C0, the diameter of the cable is d, and the winding layer number is n;

[0169] In ΔA1C1O:

[0170]

[0171]

[0172] Wherein, α0 represents the included angle between A1C1 and A1O;

[0173] In ΔA1B1D1:

[0174]

[0175]

[0176] Wherein, α1 represents the included angle between A1P1 and A1O;

[0177] In ΔA1P1O:

[0178] P1O=A1O*sinα1;

[0179] The cable after winding n layers is A1P n , the fixed cross-shaped lifting wheel lifting position of the wire arrangement device is D n point, the cable is tangent to P n point, and the fixed cross-shaped lifting wheel needs to be lifted vertically upward by a distance of D1D n , and the formula is as follows:

[0180] In ΔA1P n O:

[0181]

[0182]

[0183] Wherein, α n represents the included angle between A1P1 and A1P n ;

[0184] In ΔA1B1D n :

[0185] B1D n = A1B1 tan (a0+ a1+ a n );

[0186] Further lift to:

[0187] D1D n = B0D n -B0D1 = (B0B1 + B1D n )-B0D1;

[0188] The final value can be obtained by substituting the values obtained in the foregoing:

[0189]

[0190] Wherein:

[0191]

[0192] According to the mathematical model of the fixed cross-shaped lifting wheel, the cable arranging device and the cable collecting device of the production line, the distance that the fixed cross-shaped lifting wheel needs to move vertically upward for each layer of cable winding is calculated to ensure that the cable is always lifted in a straight line.

[0193] Example 2:

[0194] The embodiment provides a cable automatic arranging system, which realizes detection of the current winding state of the cable based on machine vision, and controls the automatic arranging device to perform corresponding actions to realize automatic arranging through a PLC controller;

[0195] The automatic arranging device includes a cable arranging device, a cable collecting device and a control cabinet. Figure 1 As shown in the accompanying drawings, 1 is a fixed cross-shaped lifting wheel on the production line, 2 is a cable arranging device, and 3 is a sectional view of a cable collecting device. The cable arranging device includes a support, a horizontal direction driving device, a vertical direction driving device, a fixed cross-shaped lifting wheel, a left industrial camera and a right industrial camera; the left industrial camera and the right industrial camera are used to collect images alternately according to the current moving direction of the cable collecting device and the current count of the rotary encoder; the horizontal direction driving device and the vertical direction driving device include a servo motor, a lead screw and a sliding rail; the horizontal direction driving device makes the fixed cross-shaped lifting wheel perform a horizontal cable pulling action, and the vertical direction driving device makes the fixed cross-shaped lifting wheel perform a vertical lifting action, so that the fixed cross-shaped lifting wheel can achieve the purpose of arranging and lifting the cable through two degrees of freedom of horizontal and vertical movement; the left industrial camera and the right industrial camera are located on the left and right sides of the support above the fixed cross-shaped lifting wheel, and are used to take the current winding state at an upward angle; in order to avoid the obstruction of the camera by the sidewall of the cable reel, the left industrial camera is used to observe the winding state of the right side of the cable reel, and the right industrial camera is used to observe the winding state of the left side of the cable reel;

[0196] A rotary encoder is added to the take-up device, and the rotary encoder is used to record the number of winding turns of the current layer of the wire reel. Each time the automatic wire arranging function is started, the rotary encoder data is initialized.

[0197] The control cabinet uses a double-checking method combining algorithms and software. The inference result is pushed to the message queue data for caching. According to whether the proportion of any result appearing in the cache is greater than the set threshold, the corresponding action is executed, avoiding the misjudgment of the algorithm. The inference result is labeled on the image, and the image is transcoded into a live video stream, realizing real-time monitoring of the running state of multiple automatic wire arranging devices and the inference result on a large screen.

[0198] The control cabinet in this embodiment includes a control panel, an industrial computer, a PLC controller, and an audible and visual alarm;

[0199] The control panel is used to initialize the rotary encoder and start and stop the device.

[0200] The industrial computer is used to obtain image data collected by the left and right industrial cameras and perform inference. According to the inference result, the PLC controller drives the wire arranging device to perform an action.

[0201] The PLC controller is used to communicate with the wire arranging device, the take-up device, the rotary encoder, the audible and visual alarm, and the wire diameter instrument. The wire diameter instrument measures the diameter of the current winding in real time.

[0202] The inference result in this embodiment includes a normal state, a one-layer overlapping state, a two-layer overlapping state, a reset state, and a flash gap state.

[0203] As shown in the accompanying Figure 2 , the normal state indicates that the current winding is located in the middle position (the third turn to the last turn) and no abnormality occurs.

[0204] As shown in the accompanying Figure 4 and 5 , the one-layer overlapping state includes two cases. Case one is that the current winding and the previous winding have too small horizontal spacing, causing one-layer overlapping of the cable, which is an abnormal case. Case two is that the current winding is the first turn of a new layer, which is a normal case, but the cable needs to be pulled to adhere to the side wall of the wire reel.

[0205] As shown in the accompanying Figure 6 , the two-layer overlapping state appears when the first turn of a new layer has been wound and the second turn of the wire begins to overlap the first turn.

[0206] As shown in the accompanying Figure 7 , the reset state appears after two-layer overlapping, and appears when the wire arranging device pulls the second turn of the wire back to the same level as the first turn of the wire.

[0207] As shown in the accompanying Figure 3As shown, the flash gap state indicates that the current winding is too far apart from the last winding, resulting in loose cable arrangement;

[0208] As shown in the accompanying Figure 8 As shown, in the case of no abnormality of the arrangement, the order of the inference results is normal state, one-layer overlapping state of case one, two-layer overlapping state, reset state, and so on.

[0209] In this embodiment, the action of the arrangement is driven by the PLC controller according to the inference results, which is as follows:

[0210] In the normal state, the arrangement keeps the intermediate position and does not perform the action;

[0211] In the one-layer overlapping state of case one, the arrangement moves in the opposite direction of the movement of the take-up reel;

[0212] In the two-layer overlapping state, the take-up reel performs the reversing operation, and the arrangement pulls the cable in the same direction of the movement of the take-up reel, and the count of the rotary encoder is reset to 1;

[0213] The reset state appears after the two-layer overlapping, and when the arrangement pulls the second layer of cable to the position of the first layer of cable, the arrangement immediately performs the reset operation, moves horizontally to the intermediate position, and moves vertically upward by a certain distance;

[0214] The abnormal cases include the one-layer overlapping state of case two and the flash gap state, and the corresponding actions of the arrangement are as follows:

[0215] In the flash gap state, the arrangement moves in the same direction of the movement of the take-up reel, and the take-up reel moves in the opposite direction of the movement of the cable, until the cable is pulled back to the normal position, and until the normal state is detected again, the arrangement returns to the original position, and the take-up reel stops;

[0216] In the one-layer overlapping state of case two, the arrangement moves in the opposite direction of the movement of the take-up reel, and until the normal state is detected again, the arrangement returns to the original position.

[0217] The horizontal motor of the arrangement in this embodiment is referred to as motor X, and the vertical motor is referred to as motor Z, so that the two-degree-of-freedom linear motion pair can complete the horizontal pulling action and the lifting action of the cross-shaped wheel. The control system process is as follows:

[0218] (1) After the user fixes the cable to the reel, selects the reel size category through the control panel, and presses the start button, the arrangement cross-shaped wheel moves horizontally to the initial position, moves vertically to the position of just lifting the cable to make it approximately straight, initializes the rotary encoder value to 1, the PLC reads the data of the wire diameter instrument, and automatically sets the tension value of the take-up reel according to the wire diameter.

[0219] (2) The industrial computer simultaneously acquires image data of two industrial cameras. The left camera adopts an upward angle to shoot the right side of the reel, and the right camera adopts an upward angle to shoot the left side of the reel. When the winding position is on the right side of the reel, the artificial intelligence reasoning service deployed on the industrial computer reasons the picture shot by the left camera; when the winding position is on the left side of the reel, the reasoning service reasons the picture shot by the right camera. The left and right cameras take pictures simultaneously, and the pictures are reasoned alternately, which can ensure that the complete cable state is shot, and can reduce the pressure of the reasoning service and reduce redundant calculation.

[0220] (3) In order to reduce the misjudgment of the reasoning model and ensure the accuracy of the reasoning result, the control software pushes the reasoning result to the queue for caching. Only when the proportion of a certain reasoning result in the queue is greater than a certain threshold value, it can be considered as true, and then the control action is executed. In addition, in order to ensure the real-time performance of the control effect, the length of the cache queue should not be too large. Through the double check of algorithm and software, the accuracy of detection can be significantly improved. The above threshold values include five threshold values: the first threshold value is used to judge whether the winding is in a normal state, the second threshold value is used to judge whether the winding is in a flash gap state, the third threshold value is used to judge whether the winding is in a one-layer winding state, the fourth threshold value is used to judge whether the winding is in a two-layer winding state, and the fifth threshold value is used to judge whether the winding is in a reset state.

[0221] (4) The control software communicates with the PLC controller according to the reasoning result, and controls the wire arranging device and the wire collecting device to execute actions. In the normal state, the wire arranging device remains in the middle position and does not execute actions. In the one-layer winding state (case one), the wire arranging device needs to move in the opposite direction of the movement of the wire collecting device. In the two-layer winding state, the wire collecting device needs to execute a reversing operation, and the wire arranging device pulls the wire in the same direction of the movement of the wire collecting device, and the count of the rotary encoder is reset to 1. The reset state appears after the two-layer winding, and when the wire arranging device pulls the second coil of wire to the position where the first coil of wire is flush, the wire arranging device immediately executes a reset operation, moves horizontally to the middle position, and moves vertically upward by a certain distance.

[0222] (5) During the operation, the one-layer winding state (case two) and the flash gap state are continuously judged. In the flash gap state, an audible and visual alarm is issued, the wire arranging device moves in the same direction of the movement of the wire collecting device, and the wire collecting device moves in the opposite direction of its movement until the normal state is detected, and the wire arranging device returns to the original position and the wire collecting device stops. In the one-layer winding state (case two), the wire arranging device moves in the opposite direction of the movement of the wire collecting device until the normal state is detected again, and the wire arranging device resets to the original position.

[0223] (6) The inference software of the industrial control computer annotates the inference results of the left and right images on the images and transcodes them into a live video stream for display on the large screen. Thus, the function of simultaneously monitoring the real-time operating status and inference results of multiple automatic wire arranging devices on one large screen can be achieved.

[0224] In step (4) above, the motor Z moves vertically upward by a certain distance, which is determined by the mathematical models of the fixed cross-shaped pulley, wire arranging device, and wire take-up device on this production line. As shown in the appendix Figure 9 The specific mathematical models are as follows:

[0225] The center point of the wire reel is point O, the initial winding of the wire reel is A1P1, the lifting position of the fixed cross-shaped supporting pulley of the wire arranging device is point D1, the wire is tangent to the wire reel at point P1, the vertical distance from the fixed cross-shaped supporting pulley to the ground is A0A1, the vertical distance from the initial position of the wire arranging device to the ground is B0D1, the vertical distance from the center of the wire take-up device's wire reel to the ground is C0O, the horizontal distance from the fixed cross-shaped supporting pulley to the wire arranging device is A0B0, the horizontal distance from the fixed cross-shaped supporting pulley to the center of the wire take-up device is A0C0, the wire diameter is d, and the number of winding layers is n;

[0226] In ΔA1C1O:

[0227]

[0228]

[0229] Among them, α0 represents the angle between A1C1 and A1O;

[0230] In ΔA1B1D1:

[0231]

[0232]

[0233] Among them, α1 represents the angle between A1P1 and A1O;

[0234] In ΔA1P1O:

[0235] P1O = A1O·sinα1;

[0236] After winding n layers, the wire is A1P n , the lifting position of the fixed cross-shaped supporting pulley of the wire arranging device is D n point, the wire is tangent to the wire reel at P n point, the vertical distance that the fixed cross-shaped supporting pulley needs to be lifted upward is D1D n , and the calculation formula is as follows:

[0237] In ΔA1P n O:

[0238]

[0239]

[0240] wherein, α n represents the angle between A1P1 and A1P n ;

[0241] In ΔA1B1D n :

[0242] B1D n = A1B1·tan(α0+α1+α n );

[0243] Further lifting to:

[0244] D1D n = B0D n -B0D1 = (B0B1+B1D n )-B0D1;

[0245] Substituting the values obtained in the foregoing, finally we can get:

[0246]

[0247] wherein:

[0248]

[0249] According to the mathematical model of the fixed cross-shaped lifting wheel, the line arranging device and the line collector of the production line, the distance that the fixed cross-shaped lifting wheel needs to move vertically upward for each layer of cable winding is calculated to ensure that the cable is always lifted in a straight line.

[0250] Example 3

[0251] This embodiment provides a specific implementation process of automatic cable arranging, as follows:

[0252] (I) Workers fix the automatic arranging device on the cable after passing through the line arranging device cross-shaped wheel, and the cable is lifted in a straight line position by the cross-shaped wheel of the line arranging device. The rotary encoder is initialized to 1 turn, the start button on the control panel is pressed, and the automatic arranging software on the industrial computer starts running. The industrial computer reads the current cable diameter on the line diameter instrument through the Modbus TCP protocol, automatically matches the corresponding line collector tension value according to the line diameter, and starts to execute the line collecting action.

[0253] (ii) The automatic wire arranging software obtains the moving direction of the current take-up device and the current count of the rotary encoder, obtains the image data of the two industrial cameras, and alternately infers according to the current position of the cable; when the take-up device moves to the left, if the count of the rotary encoder is less than 50% of the total number of turns of the current layer, the inference of the left camera is started, and if the count of the rotary encoder is greater than 50% of the total number of turns of the current layer, the inference of the right camera is started; when the take-up device moves to the right, if the count of the rotary encoder is less than 50% of the total number of turns of the current layer, the inference of the right camera is started, and if the count of the rotary encoder is greater than 50% of the total number of turns of the current layer, the inference of the left camera is started; thus, the inference of the images on both sides is alternated.

[0254] (iii) The image frame rate is collected at a speed of 10 frames per second, and the result after inference is pushed to the queue for caching. The length of the queue is set to 10, and the first threshold, the second threshold, the third threshold, the fourth threshold and the fifth threshold are all set to 80%. As shown in FIG. 8, the judgment logic is as follows: Figure 10

[0255] ① After the inference result enters the queue, it is first judged whether the proportion of the normal state in the queue is greater than or equal to the first threshold. If the judgment is true, it means that the current wire arranging is in a normal state, and no processing action needs to be performed, and the queue data continues to be consumed.

[0256] ② When the proportion of the normal state is less than the first threshold, it is further judged whether the proportion of the flash gap is greater than the second threshold. If the judgment is true, it means that the current wire arranging is in a flash gap, and the motor X pulls the wire in the same direction as the movement of the take-up device, and the take-up device is jogged in the opposite direction to the movement of the take-up device until the wire is pulled back to the normal state, and then the motor X is reset to the original position and the take-up device stops jogging.

[0257] ③ When the proportion of the flash gap is less than the second threshold, it is further judged whether the proportion of the one-layer stacking is greater than the third threshold. If the judgment is true, it means that the current wire arranging is in a one-layer stacking, and the motor X pulls the wire in the opposite direction to the movement of the take-up device. If the judgment is false, the queue data continues to be consumed.

[0258] ④ After the current wire arranging is in a one-layer stacking, it is further judged whether the proportion of the two-layer stacking is greater than the fourth threshold. If the judgment is false, it is further judged whether the proportion of the normal state is greater than or equal to the first threshold. If the proportion of the normal state is greater than or equal to the first threshold, it means that the one-layer stacking is case 2, and after the stacked wire is pulled back to the normal state, the motor X is reset to the original position.

[0259] ⑤ When the proportion of the two-layer stacking is greater than or equal to the fourth threshold, it means that the current wire arranging is full, and at this time the count of the rotary encoder is reset to 1, the direction of the take-up device motor is changed, and the motor X pulls the wire in the same direction as the movement of the take-up device.

[0260] ​⑥When entering the two-layer stacking wire state and performing the pulling wire, it is needed to judge whether the reset state is greater than the fifth threshold value, if true, it represents that the reversing pulling wire is completed, at this time, the motor Z performs the action of upward lifting movement, and the motor X resets to the original point;

[0261] After the above process completes the wire arranging action of one layer, the whole wire coil automatic wire arranging control is finally completed through the above-mentioned circulation.

[0262] Wherein, the motor Z moves vertically upward by a certain distance for each winding layer, and the distance can be determined by the mathematical model of the fixed cross-shaped wheel, the wire arranging device and the wire collecting device. For the wire coil with a diameter of 3150mm, the vertical distance A0A1 between the fixed cross-shaped wheel and the ground is 1100mm, the vertical distance B0D1 between the wire arranging device cross-shaped wheel and the ground is 1900mm, the vertical distance C0O between the wire collecting device wire coil center and the ground is 1675mm, the horizontal distance A0B0 between the fixed cross-shaped wheel and the wire arranging device is 4300mm, the horizontal distance A0C0 between the fixed cross-shaped wheel and the wire collecting device center is 7875mm, and the cable diameter d is 34mm. According to the mathematical model, the corresponding relationship between the upward lifting movement distance of the motor Z and the winding layer number n can be calculated, as shown in the attached figure, wherein the horizontal coordinate is the winding layer number, and the vertical coordinate is the distance to be lifted. Figure 11

[0263] Finally, it should be noted that: the above embodiments are only used to illustrate the technical solutions of the present application, but not to limit them; although the present application has been described in detail with reference to the above embodiments, those skilled in the art should understand that: it can still modify the technical solutions recorded in the above embodiments, or make equivalent replacement for part or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application.​

Claims

1. A method of automatic cable routing, characterized by, The method is as follows: The cable is fixed to the wire reel, the wire reel size category is selected through the control panel, and the start button is pressed, the fixed type cross-shaped lifting wheel of the wire arranging device is horizontally moved to the middle position, is vertically moved to the position of just lifting the cable, the cable is in the position of approximate straight line, the initialization value of the rotary encoder is 1, the PLC controller reads the data of the wire diameter instrument, and the tension value of the wire collecting device is automatically set according to the wire diameter; The industrial computer simultaneously collects image data of two industrial cameras; wherein the two industrial cameras are a left industrial camera and a right industrial camera, and the left industrial camera shoots the right side of the wire reel at an upward angle, and the right industrial camera shoots the left side of the wire reel at an upward angle; The rotary encoder is used to record the number of winding turns of the current layer of the wire reel; The moving direction of the current wire collecting device and the current count of the rotary encoder are obtained, and the image data of the left industrial camera and the right industrial camera are alternately inferred according to the current position of the cable and the threshold value of starting inference, and the inference result is obtained; The inference result is pushed into the queue for caching, and only when the proportion of any inference result appearing in the queue is greater than the set threshold value, the inference result is determined to be true, and then the control action is executed; According to the inference result, the PLC controller communicates to control the actions of the wire arranging device and the wire collecting device, specifically: In the normal state, the wire arranging device remains in the middle position and does not execute the action; In the one-layer winding state of case one, the wire arranging device moves in the opposite direction of the movement of the wire collecting device; In the two-layer winding state, the wire collecting device performs a reversing operation, and the wire arranging device pulls the wire in the same direction as the movement of the wire collecting device, and the count of the rotary encoder is reset to 1; The reset state appears after the two-layer winding, and when the wire arranging device pulls the second winding back to the position of being flush with the first winding, the wire arranging device immediately performs a reset operation, moves horizontally to the middle position, and moves vertically upward by a set distance; The abnormal conditions include the one-layer winding state of case two and the flash gap state, and the corresponding actions of the wire arranging device are: in the flash gap state, sound and light alarms are issued, the wire arranging device moves in the same direction as the movement of the wire collecting device, and the wire collecting device moves in the opposite direction of the movement of the wire arranging device until the normal state is detected, the wire arranging device returns to the middle position, and the wire collecting device stops; The industrial computer labels the inference results of the left and right image on the image, and displays the image on the large screen in the form of live video stream, realizing the monitoring of the real-time running state and inference result of multiple automatic wire arranging devices on one large screen.

2. The cable automatic arranging method according to claim 1, characterized by, The moving direction of the current wire collecting device and the current count of the rotary encoder are obtained, and the image data of the left industrial camera and the right industrial camera are alternately inferred according to the current position of the cable and the threshold value of starting inference, and the inference result is obtained as follows: When the wire collecting device moves to the left and the count of the rotary encoder is less than the threshold value of the total number of turns of the current layer, the inference of the left industrial camera is started; When the wire collecting device moves to the left and the count of the rotary encoder is greater than the threshold value of the total number of turns of the current layer, the inference of the right industrial camera is started; When the take-up moves to the right and the count of the rotary encoder is less than the threshold of the total number of turns of the current layer, the inference of the right industrial camera is started; When the take-up moves to the right and the count of the rotary encoder is greater than the threshold of the total number of turns of the current layer, the inference of the left industrial camera is started; In this way, the left and right images are alternately inferred.

3. The cable automatic arranging method according to claim 1, characterized by, The threshold values include a first threshold value, a second threshold value, a third threshold value, a fourth threshold value, and a fifth threshold value; The first threshold value is used to determine whether the winding is in a normal state; The second threshold value is used to determine whether the winding is in a flash gap state; The third threshold value is used to determine whether the winding is in a one-layer winding state; The fourth threshold value is used to determine whether the winding is in a two-layer winding state; The fifth threshold value is used to determine whether the winding is in a reset state; The normal state indicates that the current winding is located at the middle position and no abnormality occurs; The one-layer winding state includes two cases. Case one is that the current winding and the last winding have a small horizontal distance, causing a one-layer winding of the cable, which is an abnormal case. Case two is that the current winding is the first winding of a new layer, which is a normal case, but the cable needs to be pulled to be close to the side wall of the reel. The two-layer winding state appears when the first winding of a new layer is completed and the second winding starts to overlap the first winding. The reset state appears after the two-layer winding, when the second winding is pulled back to the same level as the first winding by the cable arrangement device. The flash gap state indicates that the current winding and the last winding have a large horizontal distance, causing the cable to be loose. In the case where the cable arrangement is normal, the inference results appear in the following order: normal state, one-layer winding state of case one, two-layer winding state, and reset state, which are repeated in a loop.

4. The cable automatic arranging method according to claim 1, characterized by, The inference results are pushed into a queue for caching. Only when the proportion of any inference result in the queue is greater than a set threshold value, the inference result is determined to be true, and then the judgment logic of the control action is as follows: After the inference result enters the message queue data, it is determined whether the proportion of the normal state in the message queue data is greater than or equal to the first threshold value: If the determination is yes, it indicates that the current cable arrangement is in a normal state, and no processing action needs to be performed, and the queue data continues to be consumed. When the proportion of the normal state is less than the first threshold value, it is determined whether the proportion of the flash gap is greater than the second threshold value: If the determination is yes, it indicates that the current cable arrangement is in a flash gap, and the motor X pulls the cable in the same direction as the movement of the take-up, and the take-up moves in the opposite direction of the cable until the cable is pulled back to the normal state, and then the motor X is reset to the original position and the take-up stops. When the proportion of the flash gap is less than the second threshold value, it is determined whether the one-layer winding state is greater than the third threshold value: If the determination is yes, it indicates that the current cable arrangement is in a one-layer winding state, and the motor X pulls the cable in the opposite direction of the movement of the take-up. If the determination is no, the queue data continues to be consumed. After the current cable arrangement is in a one-layer winding state, it is determined whether the two-layer winding state is greater than the fourth threshold value: If the determination is no, it is determined whether the proportion of the normal state is greater than the first threshold value: If the proportion of the normal state is greater than or equal to the first threshold value, it indicates that the one-layer winding state is case two, and after the winding is pulled back to the normal state, the motor X is reset to the original position. When the two-layer winding state is greater than or equal to the fourth threshold value, it represents that the current winding is full, at this time, the rotating encoder count is reset to 1, the motor direction of the take-up device is changed, and the motor X moves in the same direction as the take-up device to pull the wire; After entering the two-layer winding state to perform wire pulling, it is judged whether the reset state is greater than the fifth threshold value: If it is judged to be yes, it represents that the reversing wire pulling is completed, at this time, the motor Z performs the action of upward lifting movement, and the motor X is reset to the original position; The winding action of one layer is completed, and the cycle is repeated to finally complete the automatic winding control of the entire wire reel.

5. The cable automatic arranging method according to any one of claims 1 to 4, characterized by, The fixed cross-shaped lifting wheel moves vertically, and the lifted cable is in a straight line state tangent to the wire reel. The distance of each layer of winding movement is determined by the mathematical model corresponding to the size and installation position of the fixed cross-shaped lifting wheel, the winding device, and the take-up device. The mathematical model is as follows: The center point of the wire coil is O point, and the initial winding of the wire coil is , the fixed cross-shaped lifting wheel lifting position is point, the cable is tangent to the wire coil at , the vertical distance from the fixed cross-shaped lifting wheel to the ground is , the vertical distance from the initial position of the cable arrangement device to the ground is , the vertical distance from the center of the wire coil of the cable arrangement device to the ground is , the horizontal distance from the fixed cross-shaped lifting wheel to the cable arrangement device is , the horizontal distance from the fixed cross-shaped lifting wheel to the center of the cable arrangement device is , the cable diameter is , and the winding layer is n. In which: ； ； wherein denotes between the angle between In which: ； Then it is lifted to: ； By bringing in the value obtained in the foregoing, the final value can be obtained: ； Wherein: ； According to the mathematical model of the fixed cross-shaped lifting wheel, the winding device, and the take-up device, the distance that the fixed cross-shaped lifting wheel needs to move vertically upward for each layer of cable winding is calculated, which ensures that the cable is always lifted in a straight line state.

6. An automatic cable routing system, characterized by The system realizes the detection of the current winding state of the cable based on machine vision, and controls the automatic winding device to perform corresponding actions to realize automatic winding through the PLC controller; Wherein, the automatic winding device includes a winding device, a take-up device, and a control cabinet; the winding device includes a support, a horizontal direction driving device, a vertical direction driving device, a fixed cross-shaped lifting wheel, a left industrial camera, and a right industrial camera; the left industrial camera and the right industrial camera are used for simultaneous collection, and the images of the left industrial camera and the right industrial camera are alternately inferred according to the current movement direction of the take-up device and the current count of the rotating encoder; A rotating encoder is added to the take-up device, which is used to record the current winding turns of the wire reel. Each time the automatic winding function is started, the rotating encoder data is initialized; The control cabinet adopts a double verification method combining algorithm and software, pushes the inference result to the message queue data for caching, and according to whether the proportion of any result appearing in the cache is greater than a set threshold value, the corresponding action is then performed; and the inference result is marked on the image and the image is transcoded into a live video stream, realizing real-time monitoring of the running state and inference result of multiple automatic winding devices on a large screen; Wherein, the inference result includes a normal state, a one-layer winding state, a two-layer winding state, a reset state, and a flash gap state; Wherein, the normal state indicates that the current winding is located in the middle position and no abnormality occurs; The one-layer winding state includes two cases. Case one is that the current winding and the last winding have too small horizontal spacing, resulting in one-layer winding of the cable, which is an abnormal case. Case two is that the current winding is the first turn of a new layer, which is a normal case, but needs to be pulled to make the cable close to the wire reel side wall; The two-layer winding state appears when the first turn of the new layer has been wound and the second turn of the line begins to overlap on the first turn of the line. The reset state appears after two-layer winding, when the winding device pulls the second turn of the line back to the position where it is flush with the first turn of the line. The flash gap state indicates that the current winding and the last winding have too large horizontal spacing, resulting in loose winding of the cable. In the case of no abnormality of the wire arrangement, the order of the inference result appearing is normal state, one-layer winding state of case one, two-layer winding state, reset state, and so on, which circulates repeatedly.

7. The cable auto-routing system of claim 6, wherein, The horizontal direction driving device and the vertical direction driving device include servo motors, lead screws and slide rails; the horizontal direction driving device makes the fixed cross-shaped lifting wheel perform horizontal pulling action, and the vertical direction driving device makes the fixed cross-shaped lifting wheel perform vertical lifting action, so that the fixed cross-shaped lifting wheel achieves the purpose of arranging and lifting the wire through two degrees of freedom of horizontal and vertical movement; the left and right industrial cameras are respectively located on the left and right sides of the upper bracket of the fixed cross-shaped lifting wheel and shoot the current winding state at an upward angle; the left industrial camera observes the winding state on the right side of the wire reel, and the right industrial camera observes the winding state on the left side of the wire reel.

8. The cable auto-routing system of claim 6, wherein, The control cabinet includes a control panel, an industrial computer, a PLC controller and an audible and visual alarm; The control panel is used for initializing the rotary encoder and starting and stopping the equipment; The industrial computer is used for acquiring image data collected by the left and right industrial cameras and performing inference, and driving the wire arranger to perform action through the PLC controller according to the inference result; The PLC controller is used for communicating with the wire arranger, the wire collector, the rotary encoder, the audible and visual alarm and a wire diameter instrument, and the wire diameter instrument measures the diameter of the current winding in real time.

9. The cable automatic routing system according to any one of claims 6 to 8, wherein, The driving of the wire arranger by the PLC controller according to the inference result is as follows: In the normal state, the wire arranger remains in the middle position and does not perform action; In the one-layer winding state of case one, the wire arranger moves in the opposite direction of the movement of the wire collector; In the two-layer winding state, the wire collector performs reversing operation, and the wire arranger pulls the wire in the same direction of the movement of the wire collector, and the count of the rotary encoder is reset to 1; The reset state appears after the two-layer winding, and when the wire arranger pulls the second layer of wire back to the position flush with the first layer of wire, the wire arranger immediately performs reset operation, moves horizontally to the middle position and moves vertically upward by a certain distance; The abnormal conditions include the one-layer winding state of case two and the flash gap state, and the corresponding actions of the wire arranger are as follows: In the flash gap state, the wire arranger moves in the same direction of the movement of the wire collector, and the wire collector moves in the opposite direction of the movement of the wire, until the wire is pulled back to the normal position, and until the normal state is detected again, the wire arranger returns to the middle position and the wire collector stops; In the one-layer winding state of case two, the wire arranger moves in the opposite direction of the movement of the wire collector, and until the normal state is detected again, the wire arranger returns to the middle position.

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