Fine diameter wire drawing machine and its arrangement method

Abstract

A fine diameter metal wire fine winding machine device, characterized in that, including: tension pay-off mechanism, straightening mechanism, wire passing mechanism, winding and arranging mechanism and control mechanism, the tension pay-off mechanism, straightening mechanism, wire passing mechanism and winding and arranging mechanism are arranged in sequence, the control mechanism is respectively connected with the wire passing mechanism and the winding and arranging mechanism, a fine diameter metal wire arranging method, including the following steps: S0, initial setting starting stage; S1, automatic wire arranging stage.

Description

Technical Field

[0001] This invention relates to the field of fine-diameter metal wire processing technology, and in particular to a fine-winding machine for tantalum wire used in the manufacture of tantalum capacitors and its winding method. Background Technology

[0002] Tantalum wire is an essential anode lead in the manufacture of tantalum capacitors. It serves as the anode for energizing and coating each capacitor, and its diameter typically ranges from 0.12 to 0.15 mm. As the anode material for tantalum capacitors, to meet usage requirements, the surface cleanliness, burrs, spots, and smoothness of every centimeter of tantalum wire must be inspected at the factory before shipment. The inspection method typically involves: first, using a precision winding machine to precisely arrange the tantalum wire onto a tantalum wire winding spool. During this process, there must be no wire overlap, gaps, or overlapping to achieve a near-mirror-like appearance. Second, skilled operators quickly observe the surface, judging the tantalum wire's quality based on the mirror-like reflection. If the surface cleanliness of a particular area is substandard, or if there are burrs, spots, or insufficient smoothness, the operator can observe a difference in reflection compared to the surrounding area and address the issue immediately. Therefore, the precision winding machine plays an indispensable and crucial role in the production of tantalum wire.

[0003] In existing technologies, when precision winding machines precisely arrange tantalum wires, several issues arise. First, due to variations in the concentricity and edge dimensions of the tantalum wire winding reels, as well as mechanical runout, the spacing of the tantalum wires must be manually adjusted during the winding process; otherwise, the precision winding requirement cannot be met. Second, the actual diameter of the tantalum wire has a normal error range. During winding, operators must adjust the winding speed according to the error in wire diameter; otherwise, accumulated errors will cause wire compression or gaps. Third, when reversing the direction of the reel edge, operators need to manually operate the reversing switch based on the observed winding speed and entry angle. Operating the reversing switch too early or too late can easily cause wire stacking at the reel edge. These manual operations require extremely high skill and proficiency from the operators. If operational errors occur, resulting in wire compression, gaps, or wire stacking during reversal, manual rewinding and rewinding are necessary. Therefore, in existing technologies, the precision winding of tantalum wires is technically challenging, labor-intensive, and inefficient due to manual operation. (Summary of the Invention) In view of this, it is necessary to provide a fine-winding machine for tantalum wires used in the manufacture of tantalum capacitors and a method for winding such wires.

[0004] The present invention provides a fine winding machine for small diameter metal wires, comprising: a tension unwinding mechanism, a straightening mechanism, a wire guiding mechanism, a winding and arranging mechanism, and a control mechanism; the tension unwinding mechanism, the straightening mechanism, the wire guiding mechanism, and the winding and arranging mechanism are arranged sequentially; the control mechanism is communicatively connected to the wire guiding mechanism and the winding and arranging mechanism respectively. The wire guiding mechanism includes: a base frame, a wire guiding wheel, a connecting assembly, and an angle sensor; the wire guiding wheel is movably connected to the base frame via the connecting assembly; when subjected to tension from a thin-diameter metal wire, the wire guiding wheel can rotate horizontally around the connection point between the connecting assembly and the base frame; the angle sensor is fixedly connected to the connecting assembly and is used to measure the hysteresis angle formed between the wire entry direction and the centerline direction of the thin-diameter metal wire. The winding and coiling mechanism includes: a bed, a winding reel, a spacing servo motor, and a winding servo motor; the winding reel is fixed to the top surface of the bed, and the spacing servo motor controls the bed to drive the winding reel to move laterally; the winding servo motor controls the bed to drive the winding reel to rotate along the reel shaft. The control mechanism is communicatively connected to the angle sensor, the spacing servo motor, and the winding servo motor. By controlling the matching operating speed between the spacing servo motor and the winding servo motor, the control mechanism creates a hysteresis angle between the wire entry direction and the center line direction of the fine diameter metal wire. At the same time, the control mechanism obtains the hysteresis angle based on the hysteresis angle information received from the angle sensor, and then controls the operation of the spacing servo motor through the hysteresis angle information to keep the hysteresis angle within the normal operating range, thereby achieving precise wire arrangement of the fine diameter metal wire on the winding reel.

[0005] Preferably, the connecting assembly includes: a support, a connecting bearing, and a connecting shaft; the support is cuboid in shape, with one side of the support connected to a guide wheel, and a shaft hole formed at the other end of the support; a connecting bearing is fixedly installed at the lower part of the shaft hole; the lower part of the connecting shaft is fixedly connected to the base frame, the middle part of the connecting shaft is fixedly connected to the connecting bearing, and the upper part of the connecting shaft is fixedly connected to the input shaft of the angle sensor via a coupling; the guide wheel, connected by the support, can rotate horizontally around the connecting shaft and drive the angle sensor to rotate synchronously, thereby enabling the angle sensor to measure the hysteresis angle.

[0006] Preferably, the control mechanism includes: a CPU, a human-machine interface unit, an angle conversion unit, a data storage unit, a row spacing adjustment data processing unit, and a reversing data processing unit; the CPU is communicatively connected to the DIR port, PUL port, and On / Off port of the human-machine interface unit, the data storage unit, the row spacing adjustment data processing unit, the reversing data processing unit, the row spacing servo motor, and the PUL port and On / Off port of the winding servo motor; the input end of the angle conversion unit is communicatively connected to the angle sensor, and the output end of the angle conversion unit is communicatively connected to the data storage unit; the input ends of the row spacing adjustment data processing unit and the reversing data processing unit are communicatively connected to the output end of the data storage unit. The angle conversion unit receives the analog current signal from the angle sensor, converts the received analog current signal into a hysteresis angle, and then transmits it to the data storage unit for storage. The data storage unit stores the hysteresis angle for each time, the normal range of the hysteresis angle, the row spacing adjustment information, and the correlation between the hysteresis angle change rate and the composite commutation information of the winding servo motor. The spacing adjustment data processing unit acquires the hysteresis angle from the data storage unit at a set cycle, averages the acquired hysteresis angles to obtain the mean hysteresis angle, and then compares the mean hysteresis angle with the normal range of the hysteresis angle acquired from the data storage unit. If it is determined that the mean hysteresis angle exceeds the normal operating range, the spacing adjustment data processing unit determines that the spacing needs to be adjusted. Then, it compares the current mean hysteresis angle with the maximum and minimum values ​​of the normal range of hysteresis angles to determine whether the mean hysteresis angle has increased or decreased. Next, it retrieves the pre-set spacing adjustment information from the data storage unit to obtain the corresponding spacing adjustment value, and then sends the spacing adjustment signal and spacing adjustment value to the CPU. The CPU controls the spacing servo motor to adjust the spacing according to the received spacing adjustment signal and spacing adjustment value. The commutation data processing unit receives the hysteresis angle obtained from the data storage unit each time and obtains the hysteresis angle change rate. Then, based on the comparison between the hysteresis angle change rate obtained from the data storage unit and the commutation information of the winding servo motor, it determines whether commutation is required. When it is determined that commutation is required, the commutation data processing unit sends a composite commutation signal to the CPU. The CPU controls the operation of the spacing servo motor based on the received composite commutation signal.

[0007] Preferably, the composite reversing signal includes a spacing servo motor pause signal and a spacing servo motor reversing signal, which are used to control the spacing servo motor to pause operation t and then change the operating direction to ensure the tight arrangement of fine diameter metal wires during the reversing of the coil edge.

[0008] Preferably, the hysteresis angle change rate is obtained by the reversing data processing unit by subtracting the hysteresis angle obtained each time from the hysteresis angle obtained the previous time to obtain the hysteresis angle change amount, and then dividing the hysteresis angle change amount by the corresponding change time.

[0009] Preferably, the row spacing adjustment information will reduce the row spacing by a preset value when the average lag angle is greater than the maximum value of the normal lag angle range; and will increase the row spacing by a preset value when the average lag angle is less than the minimum value of the normal lag angle range.

[0010] The present invention provides a method for arranging fine-diameter metal wires, comprising the following steps: S0, Initial setup and startup phase; S1, Automatic wiring stage; The S0 includes the following steps: S00. The operator controls the CPU through the human-machine interface unit. First, the standard wire diameter of the thin-diameter metal wire is set as the initial spacing. Based on the initial spacing, the CPU sets the operating speed of the winding servo motor and the spacing servo motor. The spacing servo motor drives the winding disc to move laterally by one initial spacing, and the winding servo motor drives the winding disc to rotate one revolution. Second, the normal range of the hysteresis angle and the spacing adjustment information are set. Finally, the period for the data storage unit to send the hysteresis angle to the spacing adjustment data processing unit is set. S01. Position the guide wheel and the winding reel in their initial positions, with the right / left edge of the winding reel directly opposite the guide wheel. S02. The operator places the original wire spool on the tension wire feeding mechanism, then passes the end of the thin diameter metal wire through the straightening mechanism and the wire guide wheel, and finally winds it onto the winding spool of the winding mechanism. At this time, the wire entry direction of the thin diameter metal wire coincides with the center line. S03. The operator controls the CPU through the human-machine interface unit and sends start signals to the On / Off ports of the spacing servo motor and the winding servo motor, and the fine winding machine starts to run. S1 includes the following steps: S10. When the fine winding machine starts to operate, the angle sensor synchronously starts to measure the analog current signal representing the lag angle information and transmits the obtained analog current signal to the angle conversion unit. S11, The angle conversion unit converts the analog current signal into a hysteresis angle and transmits it to the data storage unit; S12. The row spacing adjustment data processing unit periodically receives the lag angle from the data storage unit, and takes the average value or the mean value of the lag angle for each received period; compares the mean value of the lag angle with the normal range of the lag angle obtained from the data storage unit to determine whether the lag angle exceeds the normal operating range; when it is determined that the lag angle exceeds the normal operating range, the row spacing adjustment data processing unit determines that the row spacing needs to be adjusted. When it is determined that the row spacing needs to be adjusted, the row spacing adjustment data processing unit compares the current average lag angle with the maximum and minimum values ​​of the normal lag angle range to determine whether the average lag angle has increased or decreased. Then, it retrieves the pre-set row spacing adjustment information from the data storage unit to obtain the corresponding row spacing adjustment value, and then sends the row spacing adjustment signal and row spacing adjustment value to the CPU. The CPU controls the row spacing servo motor to adjust the row spacing according to the received row spacing adjustment signal and row spacing adjustment value. The commutation data processing unit receives the hysteresis angle obtained from the data storage unit each time, subtracts it from the previous hysteresis angle to obtain the change in hysteresis angle, and divides the change in hysteresis angle by the corresponding change time to obtain the rate of change in hysteresis angle. Then, based on the comparison between the rate of change in hysteresis angle obtained from the data storage unit and the commutation information, it determines whether commutation is required. When it is determined that commutation is required, the commutation data processing unit sends a composite commutation signal to the CPU. The CPU controls the operation of the spacing servo motor according to the received composite commutation signal.

[0011] S13. As the fine-diameter metal wires are precisely arranged, the operators observe the surface condition of the fine-diameter metal wires. S14. If the operator finds defects on the surface of the thin-diameter metal wire, he can use the human-machine interface unit to control the CPU of the control mechanism to pause the operation of the spacing servo motor and the winding servo motor, and cut off the defective thin-diameter metal wire. S15. The operator manually places the thin-diameter metal wire joint after removing the defects back to the original break point on the winding spool. The operator then uses the CPU of the human-machine interface unit to control the spacing servo motor and the winding servo motor to continue until the current spacing is completed.

[0012] Preferably, in step S12, the composite reversing signal includes a spacing servo motor pause signal and a spacing servo motor reversing signal, which are used to control the spacing servo motor to pause operation t and then change the operating direction, so as to achieve the tight arrangement of fine diameter metal wires during the reversing of the coil edge. When the fine winding machine reverses direction, the data storage unit resets the previously stored lag angle to zero and starts storing the lag angle again; the row spacing adjustment data processing unit also starts receiving and processing data from the new cycle.

[0013] Preferably, the row spacing adjustment information will reduce the row spacing by a preset value when the average lag angle is greater than the maximum value of the normal lag angle range; and will increase the row spacing by a preset value when the average lag angle is less than the minimum value of the normal lag angle range.

[0014] The aforementioned fine-winding machine for small-diameter metal wires and its winding method, on the one hand, control the matching operating speeds between the winding spacing servo motor and the take-up servo motor to create a hysteresis angle between the wire's entry direction relative to the winding reel and the center line. By setting up an angle sensor and control mechanism, the analog current signal representing the hysteresis angle is measured in real time during the winding process. The control mechanism provides feedback control to the winding spacing servo motor based on the acquired hysteresis angle information, ensuring that the hysteresis angle remains within a normal range during winding. When the hysteresis angle is within a normal range, it ensures that the portion of small-diameter metal wire about to enter the winding reel is always close to, yet not excessively so, the small-diameter metal wire already wound on the winding reel. This invention improves the tightness of the wire stacking, ensuring the close arrangement of fine-diameter metal wires and creating a mirror-like effect, making it easier for operators to observe surface defects in the fine-diameter metal wires. On the other hand, during the reversal of the coil edge, the hysteresis angle undergoes a significant abrupt change. Therefore, the control mechanism obtains the reversal signal by acquiring the rate of change of the hysteresis angle. Compared with the existing technology where operators manually adjust the spacing to control the operation of the spacing servo motor, and where operators need to manually operate the reversing switch based on the observed wire laying speed and entry angle during reversal of the coil edge, this invention achieves automatic spacing control and automatic coil edge reversal control, reducing the technical difficulty of the operation, reducing the labor intensity of the operators, and improving the operation efficiency. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall structure of the fine-diameter metal wire winding machine equipment in this invention.

[0016] Figure 2 This is a side view of the wire-passing mechanism in this invention.

[0017] Figure 3 This is a top view of the wire-passing mechanism in this invention.

[0018] Figure 4 This is a schematic diagram showing the hysteresis angle formed between the tantalum wire entry direction and the center line in this invention.

[0019] Figure 5 This is a schematic diagram of the control mechanism structure in this invention.

[0020] In the diagram: 1. Tension wire feeding mechanism; 2. Straightening mechanism; 3. Wire guiding mechanism; 30. Base frame; 31. Wire guiding wheel; 320. Shaft hole; 321. Connecting bearing; 322. Connecting shaft; 323. Angle sensor; 33. Center line; 34. Lag angle; 35. Winding and wire laying mechanism; 4. Bed; 40. Winding reel; 41. Servo motor for spacing; 42. Servo motor for winding; 43. Control mechanism; 5. CPU; 50. Human-machine interaction unit; 51. Angle conversion unit; 52. Data storage unit; 53. Serving spacing adjustment data processing unit; 54. Reversing data processing unit; 55. Operator; 6. Tantalum wire; 7. Detailed Implementation

[0021] The technical solutions and effects of the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings.

[0022] In this embodiment, tantalum wire for tantalum capacitor leads is used as an example for illustration. The center line is referred to... Figure 1 and Figure 4 As shown, when the guide wheel 31 does not rotate around the connection between the connecting assembly and the base frame 30, the wheel body of the guide wheel 31 is directly opposite the vertical line formed by the winding disc 41; the hysteresis angle 35 refers to the angle formed between the tantalum wire and the winding disc 41 and the center line 34 after the tantalum wire passes through the guide wheel 31 when the fine winding machine is running.

[0023] In this embodiment, the initial wiring direction of the tantalum wire on the winding reel 41 is from right to left; In this embodiment, the normal operating range of the hysteresis angle 35° is 2 to 3 degrees; The angle sensor 33 measures the frequency of the analog current signal, that is, the angle conversion unit 52 receives the frequency of the analog current signal. The angle sensor 33 measures once and the angle conversion unit 52 receives once for every one revolution of the winding servo motor 43 driving the winding reel. The row spacing adjustment data processing unit 54 obtains the lag angle 35 from the data storage unit 53 according to a set period, and performs average processing on the obtained lag angle 35 to obtain the average value of the lag angle. The set period is that the row spacing adjustment data processing unit 54 obtains information once every 8 lag angle information received by the data storage unit 53, and performs average calculation on these 8 lag angles. The row spacing adjustment information is as follows: when the average lag angle is greater than the maximum value of the normal lag angle range, the row spacing will be reduced by 0.08mm; when the average lag angle is less than the minimum value of the normal lag angle range, the row spacing will be increased by 0.08mm. The correlation between the rate of change of hysteresis angle and the composite commutation information of the winding servo motor 43 is as follows: when the rate of change of hysteresis angle is greater than or equal to 0.3 degrees / s, commutation is required; when the rate of change of hysteresis angle is less than 0.3 degrees / s, commutation is not required.

[0024] The composite reversing signal includes a pause signal and a reversing signal for the spacing servo motor, which are used to control the spacing servo motor 42 to stop running for t and then change its running direction to achieve tight stacking of fine-diameter metal wires during the reversing of the coil edge; t is the time taken for the spacing servo motor 42 to control the winding coil to move one spacing.

[0025] Please refer to Figure 1-5 As shown in the figure, the fine-diameter metal wire winding machine provided in this specific embodiment includes: a tension unwinding mechanism 1, a straightening mechanism 2, a wire guiding mechanism 3, a winding and arranging mechanism 4, and a control mechanism 5; the tension unwinding mechanism 1, the straightening mechanism 2, the wire guiding mechanism 3, and the winding and arranging mechanism 4 are arranged in sequence; the control mechanism 5 is communicatively connected to the wire guiding mechanism 3 and the winding and arranging mechanism 4 respectively. The wire guiding mechanism 3 includes: a base frame 30, a wire guiding wheel 31, a connecting assembly, and an angle sensor 33; the wire guiding wheel 31 is movably connected to the base frame 30 via the connecting assembly; when subjected to tension from the tantalum wire 7, the wire guiding wheel 31 can rotate horizontally around the connection between the connecting assembly and the base frame; the angle sensor is fixedly connected to the connecting assembly and is used to measure the hysteresis angle formed between the wire entry direction and the centerline direction of the tantalum wire 7. The winding and laying mechanism 4 includes: a bed 40, a winding reel 41, a laying spacing servo motor 42, and a winding servo motor 43; the winding reel 41 is fixed on the top surface of the bed 40, the laying spacing servo motor 42 controls the bed 40 to drive the winding reel 41 to move laterally; the winding servo motor 43 controls the bed 40 to drive the winding reel 41 to rotate along the reel shaft; The control mechanism 5 is communicatively connected to the angle sensor 33, the spacing servo motor 42, and the winding servo motor 43. The control mechanism 5 controls the matching operating speed between the spacing servo motor 42 and the winding servo motor 43 to form a hysteresis angle 35 between the wire entry direction and the center line direction of the tantalum wire 7. At the same time, the control mechanism 5 obtains the hysteresis angle 35 based on the hysteresis angle information received from the angle sensor 33, and then controls the operation of the spacing servo motor 42 through the hysteresis angle information to keep the hysteresis angle 35 within the normal operating range, thereby achieving precise wire arrangement of the tantalum wire 7 on the winding reel 41.

[0026] In this embodiment, when the hysteresis angle 35 is within the normal range, it ensures that the tantalum wires that are about to enter the winding spool 41 and the tantalum wires that have already been arranged on the winding spool are always close together without overlapping, thus ensuring the tight arrangement of the tantalum wires. If the hysteresis angle 35 is greater than the normal range, the tantalum wires that are about to enter the winding spool 41 and the tantalum wires 7 that have already been arranged on the winding spool 41 are too crowded, which can easily lead to overlapping. If the hysteresis angle 35 is less than the normal range, the tantalum wires 7 that are about to enter the winding spool 41 and the tantalum wires 7 that have already been arranged on the winding spool 41 are too loose, which can easily lead to gaps. Both overlapping and gaps will affect the formation of the mirror effect, and thus affect the operator's observation of the surface condition of the tantalum wires 7. Further, see Figure 2-4 As shown, in order to enable the wire guide wheel 31 to rotate horizontally around the connection between the connecting assembly and the base frame 30, and to enable the angle sensor 33 to measure the hysteresis angle 35 formed between the wire entry direction of the tantalum wire 7 and the center line 34, the connecting assembly includes: a support 320, a connecting bearing 322, and a connecting shaft 323; the support 320 is cuboid in shape, with one side of the support 320 connected to the wire guide wheel 31, and the other end of the support 320 having a shaft hole 321; the connecting bearing 322 is fixedly installed at the lower part of the shaft hole 321; the lower part of the connecting shaft 323 is fixedly connected to the base frame 30, the middle part of the connecting shaft 323 is fixedly connected to the connecting bearing 322, and the upper part of the connecting shaft 323 is fixedly connected to the input shaft of the angle sensor 33 through a coupling; with the support 320 connected, the wire guide wheel 31 can rotate horizontally around the connecting shaft 323, and drive the angle sensor 33 to rotate synchronously, so as to realize the measurement of the hysteresis angle 35 by the angle sensor 33.

[0027] Further, see Figure 5 As shown, the control mechanism 5 includes: a CPU 50, a human-machine interaction unit 51, an angle conversion unit 52, a data storage unit 53, a row spacing adjustment data processing unit 54, and a reversing data processing unit 55. The CPU 50 is communicatively connected to the DIR port, PUL port, and On / Off port of the human-machine interaction unit 51, the data storage unit 53, the row spacing adjustment data processing unit 54, the reversing data processing unit 55, the row spacing servo motor 42, and the PUL port and On / Off port of the winding servo motor 43. The input end of the angle conversion unit 52 is communicatively connected to the angle sensor 33, and the output end of the angle conversion unit 52 is communicatively connected to the data storage unit 53. The input ends of the row spacing adjustment data processing unit 54 and the reversing data processing unit 55 are communicatively connected to the output ends of the data storage unit 53. The angle conversion unit 52 receives the analog current signal from the angle sensor 33, converts the received analog current signal into a hysteresis angle 35, and then transmits it to the data storage unit 53 for storage. The data storage unit 53 stores the hysteresis angle 35 for each time, the normal range of the hysteresis angle 35, the row spacing adjustment information, and the correlation between the hysteresis angle change rate and the composite commutation information of the winding servo motor. The spacing adjustment data processing unit 54 acquires the hysteresis angle 35 from the data storage unit 53 at a set period, averages the acquired hysteresis angle 35 to obtain the average hysteresis angle, and then compares the average hysteresis angle with the normal range of the hysteresis angle 35 acquired from the data storage unit 53. If it is determined that the average hysteresis angle exceeds the normal operating range, the spacing adjustment data processing unit 54 determines that the spacing needs to be adjusted. Then, it compares the current average hysteresis angle with the maximum and minimum values ​​of the normal range of hysteresis angle 35 to determine whether the average hysteresis angle has increased or decreased. Next, it retrieves the pre-set spacing adjustment information from the data storage unit 53 to obtain the corresponding spacing adjustment value, and then sends the spacing adjustment signal and spacing adjustment value to the CPU 50. The CPU controls the spacing servo motor 42 to adjust the spacing according to the received spacing adjustment signal and spacing adjustment value. The commutation data processing unit 55 receives the hysteresis angle 35 obtained from the data storage unit each time and obtains the hysteresis angle change rate. Then, based on the comparison relationship between the hysteresis angle change rate obtained from the data storage unit 53 and the commutation information of the winding servo motor, it determines whether commutation is required. When it is determined that commutation is required, the commutation data processing unit sends a composite commutation signal to the CPU 50. The CPU 50 controls the operation of the spacing servo motor according to the received composite commutation signal.

[0028] In this invention, the operator can set the spacing according to the different types of fine diameter metal wires, thereby controlling the operation of the spacing servo motor 42 and the winding servo motor 43.

[0029] In this embodiment, the row spacing adjustment data processing unit 54 obtains the lag angle from the data storage unit 53 at a set period, and performs average processing on the obtained lag angle 35 to obtain the average value of the lag angle. The set period is that the row spacing adjustment data processing unit 54 obtains information once for every 8 lag angles received by the data processing unit 53, and performs average calculation on these 8 lag angles. In this embodiment, the correlation between the hysteresis angle change rate and the composite commutation information of the take-up servo motor is as follows: when the hysteresis angle change rate is greater than or equal to 0.3 degrees / s, commutation is required; when the hysteresis angle change rate is less than 0.3 degrees / s, commutation is not required.

[0030] Furthermore, during the reversal of the disc edge, in order to avoid the influence of the R angle and prevent screws or gaps from appearing in the tantalum wire cabling, the composite reversal signal includes a pause signal and a reversal signal for the spacing servo motor. This signal is used to control the spacing servo motor 42 to pause operation for t and then change its operating direction to ensure the tight arrangement of the tantalum wires during the reversal of the disc edge.

[0031] In this embodiment, t is the time taken for the spacing servo motor 42 to control the winding reel 41 to move one spacing. During the period when the spacing servo motor 42 is temporarily stopped, the winding servo motor 43 runs one revolution.

[0032] Furthermore, the hysteresis angle change rate is obtained by the reversing data processing unit 55 by subtracting the hysteresis angle 35 obtained each time from the hysteresis angle 35 obtained previously, and then dividing the hysteresis angle change by the corresponding change time.

[0033] Furthermore, the row spacing adjustment information will reduce the row spacing by a preset value when the average lag angle is greater than the maximum value of the normal lag angle range; and will increase the row spacing by a preset value when the average lag angle is less than the minimum value of the normal lag angle range.

[0034] In this embodiment, when the average hysteresis angle is greater than the maximum value of 3 degrees in the normal range of hysteresis angle, the spacing is reduced by 0.08 mm, which reduces the speed at which the spacing servo motor 42 drives the winding reel 41 to move laterally, while the operating speed of the winding servo motor 42 remains unchanged, thereby reducing the hysteresis angle 35. When the average hysteresis angle is less than the minimum value of 2 degrees in the normal range of hysteresis angle 35, the spacing is increased by 0.08 mm, which increases the speed at which the spacing servo motor 42 drives the winding reel 41 to move laterally, while the operating speed of the winding servo motor 43 remains unchanged, thereby increasing the hysteresis angle 35.

[0035] This specific embodiment provides a method for arranging fine-diameter metal wires, including the following steps: S0, Initial setup and startup phase; S1, Automatic wiring stage; The S0 includes the following steps: S00, the operator 6 controls the CPU 50 through the human-machine interface unit 51. First, the standard wire diameter of tantalum wire, 0.1mm, is set as the initial spacing. According to the initial spacing, the CPU 50 sets the operating speed of the winding servo motor 43 and the spacing servo motor 42. The spacing servo motor 42 drives the winding disc 41 to move laterally by one initial spacing, and the winding servo motor 43 drives the winding disc 41 to rotate one revolution. Second, the normal range of the hysteresis angle 35 and the spacing adjustment information are set. Finally, the data storage unit 53 is set to send the period of the hysteresis angle 35 to the spacing adjustment data processing unit 54. S01. Position the guide wheel 31 and the winding reel 41 in their initial positions, with the right edge of the winding reel 41 facing the guide wheel. S02, Operator 6 places the original wire spool on the tension wire feeding mechanism 1, and then passes the end of the tantalum wire 7 through the straightening mechanism 2 and the wire guide wheel 31, and finally winds it onto the winding spool 41 of the winding and wire feeding mechanism 4. At this time, the wire entry direction of the tantalum wire 7 coincides with the center line 34. S03, the operator 6 controls the CPU 50 through the human-machine interaction unit 51, and at the same time sends a start signal to the On / Off port of the spacing servo motor 42 and the winding servo motor 43, and the fine winding machine starts to run; S1 includes the following steps: S10. When the fine winding machine starts to operate, the angle sensor 33 synchronously starts to measure the analog current signal representing the lag angle information and transmits the obtained analog current signal to the angle conversion unit 52. S11, Angle conversion unit 52 converts the analog current signal into a hysteresis angle 35 and transmits it to data storage unit 53; S12. The row spacing adjustment data processing unit 54 periodically receives the lag angle 35 from the data storage unit 53, and takes the average value of the lag angle received in each cycle, or the average value of the lag angle; compares the average value of the lag angle with the normal range of 2 to 3 degrees of the lag angle 35 obtained from the data storage unit 53, and determines whether the lag angle 35 exceeds the normal operating range; when it is determined that the lag angle 35 exceeds the normal operating range of 2 to 3 degrees, the row spacing adjustment data processing unit 54 determines that the row spacing needs to be adjusted. When it is determined that the row spacing needs to be adjusted, the row spacing adjustment data processing unit 54 compares the current average lag angle with the maximum value of 3 degrees and the minimum value of 2 degrees within the normal range of lag angle 35. It determines whether the average lag angle has increased or decreased. Then, it retrieves the pre-set row spacing adjustment information from the data storage unit 53 to obtain the corresponding row spacing adjustment value. It then sends the row spacing adjustment signal and the row spacing adjustment value to the CPU 50. The CPU 50 controls the row spacing servo motor 42 to adjust the row spacing according to the received row spacing adjustment signal and row spacing adjustment value. When the average lag angle is greater than the maximum value of 3 degrees within the normal range of lag angle, the row spacing is reduced by 0.08 mm; when the average lag angle is less than the minimum value of 2 degrees within the normal range of lag angle, the row spacing is increased by 0.08 mm. The commutation data processing unit 55 receives the hysteresis angle obtained from the data storage unit 53 each time, subtracts it from the previous hysteresis angle to obtain the change in hysteresis angle, and divides the change in hysteresis angle by the corresponding change time to obtain the rate of change in hysteresis angle. Then, based on the comparison between the rate of change in hysteresis angle obtained from the data storage unit and the commutation information of the winding servo motor, it determines whether commutation is required. When it is determined that commutation is required, the commutation data processing unit 55 sends a composite commutation signal to the CPU 50. The CPU 50 controls the operation of the spacing servo motor 42 according to the received composite commutation signal.

[0036] S13. As the tantalum wire 7 is precisely arranged, the operator observes the surface condition of the tantalum wire 7. S14. If the operator finds a defect on the surface of the tantalum wire 7, the operator can control the CPU 50 of the control mechanism through the human-machine interaction unit 51 to stop the operation of the spacing servo motor 42 and the winding servo motor 43 and cut off the defective tantalum wire 7. S15. The operator manually places the tantalum wire 7 connector after the defect has been removed back onto the original break point of the winding reel 41. The operator then controls the CPU 50 of the control mechanism through the human-machine interface unit 51 to continue starting the spacing servo motor 42 and the winding servo motor 43 until the current spacing is completed.

[0037] Furthermore, the composite reversing signal includes a spacing servo motor pause signal and a spacing servo motor reversing signal, which are used to control the spacing servo motor 42 to pause operation t and then change its operating direction, so as to achieve tight arrangement of tantalum wires 7 during disc edge reversal. After the fine winding machine reverses direction, the data storage unit 53 resets the previously stored hysteresis angle to zero and starts storing the hysteresis angle again; the row spacing adjustment data processing unit 54 also starts receiving and processing data from the new cycle; t is the time taken for the row spacing servo motor 42 to control the winding disk 41 to move one row spacing. During the period when the row spacing servo motor 42 is temporarily stopped, the winding servo motor 43 runs one more revolution.

[0038] The aforementioned fine-winding machine for thin-diameter metal wire and its winding method, on the one hand, control the matching operating speeds between the winding spacing servo motor 42 and the winding servo motor 43 to create a hysteresis angle 35 between the wire entry direction of the thin-diameter metal wire relative to the winding reel 41 and the center line 34. By setting an angle sensor 33 and a control mechanism 5, the analog current signal representing the hysteresis angle information is measured in real time during the winding process. The control mechanism 5 provides feedback control to the winding spacing servo motor 42 based on the acquired hysteresis angle information, ensuring that the hysteresis angle 35 remains within a normal range during the winding process. When the hysteresis angle 35 is within a normal range, it ensures that the portion of thin-diameter metal wire about to enter the winding reel 41 is aligned with the thin-diameter metal wire already wound on the winding reel 41. The wires are always kept close together without overlapping, ensuring a tight arrangement of fine-diameter metal wires and creating a mirror-like effect, making it easier for operators to observe surface defects. On the other hand, during the reversal of the coil edge, the hysteresis angle 35 undergoes a significant abrupt change. Therefore, the control mechanism 5 obtains the reversal signal by acquiring the rate of change of the hysteresis angle. Compared with the prior art where operators manually adjust the spacing to control the operation of the spacing servo motor, and where operators need to manually operate the reversing switch based on the observed wire speed and entry angle during reversal, this invention achieves automatic spacing control and automatic coil edge reversal control, reducing the technical difficulty of the operation, reducing the labor intensity of the operators, and improving the operation efficiency.

[0039] The above-disclosed embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of the invention. Those skilled in the art will understand that implementing all or part of the above-described embodiments and making equivalent changes in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A fine-diameter metal wire winding machine, characterized in that, include: The system includes a tension pay-off mechanism, a straightening mechanism, a wire guiding mechanism, a winding and arranging mechanism, and a control mechanism; the tension pay-off mechanism, the straightening mechanism, the wire guiding mechanism, and the winding and arranging mechanism are arranged in sequence; the control mechanism is communicatively connected to the wire guiding mechanism and the winding and arranging mechanism respectively. The wire guiding mechanism includes: a base frame, a wire guiding wheel, a connecting assembly, and an angle sensor; the wire guiding wheel is movably connected to the base frame via the connecting assembly; when subjected to tension from a thin-diameter metal wire, the wire guiding wheel can rotate horizontally around the connection point between the connecting assembly and the base frame; the angle sensor is fixedly connected to the connecting assembly and is used to measure the hysteresis angle formed between the wire entry direction and the centerline direction of the thin-diameter metal wire. The winding and coiling mechanism includes: a bed, a winding reel, a spacing servo motor, and a winding servo motor; the winding reel is fixed to the top surface of the bed, and the spacing servo motor controls the bed to drive the winding reel to move laterally; the winding servo motor controls the bed to drive the winding reel to rotate along the reel shaft. The control mechanism is communicatively connected to the angle sensor, the spacing servo motor, and the winding servo motor. The control mechanism controls the matching operating speed between the spacing servo motor and the winding servo motor to create a hysteresis angle between the wire entry direction and the center line direction of the fine diameter metal wire. At the same time, the control mechanism obtains the hysteresis angle based on the hysteresis angle information received from the angle sensor, and then controls the operation of the spacing servo motor through the hysteresis angle information to keep the hysteresis angle within the normal operating range, thereby achieving precise wire laying of the fine diameter metal wire on the winding spool. The control mechanism includes: a CPU, a data storage unit, and a commutation data processing unit; the CPU is communicatively connected to both the data storage unit and the commutation data processing unit; the input of the commutation data processing unit is communicatively connected to the output of the data storage unit; the data storage unit stores the hysteresis angle for each cycle, and the correlation between the hysteresis angle change rate and the composite commutation information of the take-up servo motor; the commutation data processing unit receives the hysteresis angle obtained from the data storage unit for each cycle, obtains the hysteresis angle change rate, and then determines whether commutation is required based on the correlation between the hysteresis angle change rate obtained from the data storage unit and the commutation information of the take-up servo motor; when commutation is determined to be required, the commutation data processing unit sends a composite commutation signal to the CPU, and the CPU controls the operation of the spacing servo motor according to the received composite commutation signal.

2. The fine-diameter metal wire winding machine as described in claim 1, characterized in that, The connecting assembly includes: a support, a connecting bearing, and a connecting shaft; the support is rectangular, with one side of the support connected to a guide wheel, and a shaft hole at the other end; a connecting bearing is fixedly installed at the lower part of the shaft hole; the lower part of the connecting shaft is fixedly connected to the base frame, the middle part of the connecting shaft is fixedly connected to the connecting bearing, and the upper part of the connecting shaft is fixedly connected to the input shaft of the angle sensor via a coupling; the guide wheel, connected by the support, can rotate horizontally around the connecting shaft, and drive the angle sensor to rotate synchronously, thereby enabling the angle sensor to measure the lag angle.

3. The fine-diameter metal wire winding machine as described in claim 1, characterized in that, The control mechanism further includes: a human-machine interaction unit, an angle conversion unit, and a row spacing adjustment data processing unit; the CPU is communicatively connected to the human-machine interaction unit, the row spacing adjustment data processing unit, the DIR port, the PUL port, and the On / Off port of the row spacing servo motor, and the PUL port and the On / Off port of the winding servo motor, respectively; the input end of the angle conversion unit is communicatively connected to the angle sensor, and the output end of the angle conversion unit is communicatively connected to the data storage unit; the input end of the row spacing adjustment data processing unit is communicatively connected to the output end of the data storage unit. The angle conversion unit receives the analog current signal from the angle sensor, converts the received analog current signal into a hysteresis angle, and then transmits it to the data storage unit for storage. The data storage unit stores the lag angle for each time, the normal range of the lag angle, and the row spacing adjustment information. The spacing adjustment data processing unit acquires the hysteresis angle from the data storage unit at a set cycle, averages the acquired hysteresis angles to obtain the mean hysteresis angle, and then compares the mean hysteresis angle with the normal range of the hysteresis angle acquired from the data storage unit. If it is determined that the mean hysteresis angle exceeds the normal operating range, the spacing adjustment data processing unit determines that the spacing needs to be adjusted. Then, it compares the current mean hysteresis angle with the maximum and minimum values ​​of the normal range of hysteresis angles to determine whether the mean hysteresis angle has increased or decreased. Next, it retrieves the pre-set spacing adjustment information from the data storage unit to obtain the corresponding spacing adjustment value, and then sends the spacing adjustment signal and spacing adjustment value to the CPU. The CPU controls the spacing servo motor to adjust the spacing according to the received spacing adjustment signal and spacing adjustment value.

4. The fine-diameter metal wire winding machine as described in claim 3, characterized in that, The composite reversing signal includes a spacing servo motor pause signal and a spacing servo motor reversing signal, which are used to control the spacing servo motor to pause operation for t and then change its operating direction to ensure the tight arrangement of fine diameter metal wires during the reversing of the coil edge; t is the time taken for the spacing servo motor to control the winding coil to move one spacing.

5. The fine-diameter metal wire winding machine as described in claim 3, characterized in that, The hysteresis angle change rate is obtained by subtracting the hysteresis angle obtained each time from the hysteresis angle obtained the previous time by the commutation data processing unit, and then dividing the hysteresis angle change by the corresponding change time.

6. The fine-diameter metal wire winding machine as described in claim 3, characterized in that, The row spacing adjustment information states that when the average lag angle is greater than the maximum value of the normal lag angle range, the row spacing will be reduced by a preset value; when the average lag angle is less than the minimum value of the normal lag angle range, the row spacing will be increased by a preset value.

7. A method for arranging fine-diameter metal wires, characterized in that, The fine winding machine for small diameter metal wires as described in any one of claims 1-6 includes the following steps: S0, Initial setup and startup phase; S1, Automatic wiring stage; The S0 includes the following steps: S00. The operator controls the CPU through the human-machine interface unit. First, the standard wire diameter of the thin-diameter metal wire is set as the initial spacing. Based on the initial spacing, the CPU sets the operating speed of the winding servo motor and the spacing servo motor. The spacing servo motor drives the winding disc to move laterally by one initial spacing, and the winding servo motor drives the winding disc to rotate one revolution. Second, the normal range of the hysteresis angle and the spacing adjustment information are set. Finally, the period for the data storage unit to send the hysteresis angle to the spacing adjustment data processing unit is set. S01. Position the guide wheel and the winding reel in their initial positions, with the right / left edge of the winding reel directly opposite the guide wheel. S02. The operator places the original wire spool on the tension wire feeding mechanism, then passes the end of the thin diameter metal wire through the straightening mechanism and the wire guide wheel, and finally winds it onto the winding spool of the winding mechanism. At this time, the wire entry direction of the thin diameter metal wire coincides with the center line. S03. The operator controls the CPU through the human-machine interface unit and sends start signals to the On / Off ports of the spacing servo motor and the winding servo motor, and the fine winding machine starts to run. S1 includes the following steps: S10. When the fine winding machine starts to operate, the angle sensor synchronously starts to measure the analog current signal representing the lag angle information and transmits the obtained analog current signal to the angle conversion unit. S11, The angle conversion unit converts the analog current signal into a hysteresis angle and transmits it to the data storage unit; S12. The row spacing adjustment data processing unit periodically receives lag angles from the data storage unit, averages the lag angles received in each period, and obtains the average lag angle value. The average lag angle value is compared with the normal range of lag angles obtained from the data storage unit to determine whether the lag angle exceeds the normal operating range. When it is determined that the lag angle exceeds the normal operating range, the row spacing adjustment data processing unit determines that the row spacing needs to be adjusted. When it is determined that the row spacing needs to be adjusted, the row spacing adjustment data processing unit compares the current average lag angle with the maximum and minimum values ​​of the normal lag angle range to determine whether the average lag angle has increased or decreased. Then, it retrieves the pre-set row spacing adjustment information from the data storage unit to obtain the corresponding row spacing adjustment value, and then sends the row spacing adjustment signal and row spacing adjustment value to the CPU. The CPU controls the row spacing servo motor to adjust the row spacing according to the received row spacing adjustment signal and row spacing adjustment value. The commutation data processing unit receives the hysteresis angle obtained from the data storage unit each time, subtracts it from the previous hysteresis angle to obtain the change in hysteresis angle, and divides the change in hysteresis angle by the corresponding change time to obtain the rate of change in hysteresis angle. Then, based on the comparison between the rate of change in hysteresis angle obtained from the data storage unit and the commutation information of the winding servo motor, it determines whether commutation is required. When it is determined that commutation is required, the commutation data processing unit sends a composite commutation signal to the CPU. The CPU controls the operation of the spacing servo motor according to the received composite commutation signal. S13. As the fine-diameter metal wires are precisely arranged, the operators observe the surface condition of the fine-diameter metal wires. S14. If the operator finds defects on the surface of the thin-diameter metal wire, he can use the human-machine interface unit to control the CPU of the control mechanism to pause the operation of the spacing servo motor and the winding servo motor, and cut off the defective thin-diameter metal wire. S15. The operator manually places the thin-diameter metal wire joint after removing the defects back to the original break point on the winding spool. The operator then uses the CPU of the human-machine interface unit to control the spacing servo motor and the winding servo motor to continue until the current spacing is completed.

8. The method for arranging fine-diameter metal wires as described in claim 7, characterized in that, In step S12, the composite reversing signal includes a spacing servo motor pause signal and a spacing servo motor reversing signal, which are used to control the spacing servo motor to pause operation for t and then change the operating direction to achieve tight stacking of fine diameter metal wires when the coil edge is reversed; t is the time taken for the spacing servo motor to control the winding coil to move one spacing. When the fine winding machine reverses direction, the data storage unit resets the previously stored lag angle to zero and starts storing the lag angle again; the row spacing adjustment data processing unit also starts receiving and processing data from the new cycle.

9. The method for arranging fine-diameter metal wires as described in claim 7, wherein the spacing adjustment information is such that when the average hysteresis angle is greater than the maximum value of the normal hysteresis angle range, the spacing is reduced by a preset value; and when the average hysteresis angle is less than the minimum value of the normal hysteresis angle range, the spacing is increased by a preset value.

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