A cable stranding process optimization method

Abstract

The present invention discloses a cable twisting process optimization method, which relates to the field of mechanical engineering. The method includes: reading the basic information of a single core and twisting requirements; training a process optimization module based on the finite element analysis principle, and setting the twisting single pitch as the control cycle; interactive initial twisting process, multi-objective optimization, and determining the optimized twisting process; performing element non-equilibrium three-dimensional modeling, and determining the cable three-dimensional model; transmitting the optimized twisting process to the twisting control system, setting a digital feedback device, and executing the cable twisting process; synchronously monitoring and mining the feedback over-limit characteristics that meet the preset frequency, and feedback adjustment and response to the optimized twisting process. The technical problem of insufficient accuracy of the cable twisting process control and optimization existing in the existing cable twisting process is solved, and the technical effect of improving the accuracy of the cable twisting process control and optimization is achieved.

Description

Technical Field

[0001] The present application relates to the field of mechanical engineering, and in particular to a method for optimizing a cable stranding process. Background Art

[0002] As a key component for power transmission and signal transmission, cables play an irreplaceable role in modern industry, energy, communications and other fields. The quality and performance of cables are directly related to the stability and safety of the entire system. In the production process of cables, especially in the twisting process, there are many factors that affect the quality of cables. In the existing cable twisting process, production is usually carried out by setting fixed twisting parameters and operating procedures. Although this method is simple and easy, it cannot adapt to changes in the basic information of different wire cores and twisting requirements, resulting in unstable product quality. At the same time, existing process optimization methods often only focus on a single goal, such as improving twisting tightness or improving electrical performance, while ignoring the balance and coordination between multiple goals. In addition, traditional cable modeling methods often only consider the physical model, ignoring the tolerance range and dynamic changes in the twisting process, resulting in a large deviation between the model and actual production.

[0003] In the current related technologies, the cable stranding process relies on experience in setting process parameters, only focuses on the optimization of a single goal, and ignores the tolerance range and dynamic changes in the stranding process, resulting in technical problems such as insufficient accuracy in cable stranding process control and optimization. Summary of the Invention

[0004] The present application provides a cable twisting process optimization method, which adopts the method of reading the basic information of the single wire core after pre-processing of the pre-twisted wire core, combining with the twisting requirements, using the finite element analysis principle to train the process optimization module, performing multi-objective optimization, determining the optimized twisting process, and performing non-balanced three-dimensional modeling of elements based on the twisting single pitch based on the optimized twisting process, including a solid model and a virtual model based on the twisting tolerance range, setting a digital feedback device and synchronously monitoring the feedback over-limit characteristics, and performing real-time adjustment and optimization of the optimized twisting process, thereby achieving the technical effect of improving the accuracy of cable twisting process control and optimization.

[0005] The present application provides a cable stranding process optimization method, comprising:

[0006] Reading basic information of the single core after pre-processing of the pre-twisted core and twisting requirements, wherein the twisting requirements include twisting tightness, electrical performance, structural stability and insulation performance;

[0007] The process optimization module is trained based on the finite element analysis principle, and the twisting single pitch is set as the control cycle;

[0008] Interactive initial stranding process, taking the basic information of the single wire core as the baseline, the stranding requirements as the optimization dimension, and the periodic control parameters of the stranding machine as the optimization target, combined with the process optimization module to perform multi-objective optimization to determine the optimized stranding process;

[0009] Based on the optimized stranding process, performing unbalanced three-dimensional modeling of elements based on a single stranding pitch to determine a three-dimensional cable model, wherein the three-dimensional cable model includes a physical model and a virtual model based on a stranding tolerance interval;

[0010] Transmitting the optimized stranding process to a stranding control system, setting a digital feedback device based on the three-dimensional cable model, and executing the cable stranding process;

[0011] The feedback exceeding limit characteristics meeting the preset frequency are monitored and mined simultaneously, and feedback adjustment and response are performed on the optimized stranding process.

[0012] In a possible implementation, before performing multi-objective optimization, the following processing is performed:

[0013] Setting a multi-threaded positioning principle based on the stranding requirement, wherein the multi-threaded positioning principle is used to constrain the position of each single-wire core under spatial coaxiality, and the coaxial dimension includes axial coaxiality and tangential coaxiality;

[0014] Setting a standard for the balance of each single core in the pre-twisted core under a single twisting pitch;

[0015] Combining the basic information of the single cores with the stranding requirements, performing stranding force analysis to determine a pressure threshold, the pressure threshold including the pressure threshold of each single core and the pressure threshold of the assembly;

[0016] Based on the multi-thread limit principle, the balance standard and the pressure threshold, optimization constraints are generated.

[0017] In a possible implementation, the multi-objective optimization is performed in combination with the process optimization module, and the following processing is performed:

[0018] Randomly select N pre-adjusted parameters from the periodic control parameters, perform an optimization iteration and select the best to determine a first optimization solution, where N is a positive integer less than or equal to the total number of parameters;

[0019] The parameter adjustment directions of the N pre-adjusted parameters are added to the taboo table, and the pre-adjusted parameters are randomly selected and iteratively optimized until the convergence conditions are met, and the optimized twisting process is determined, wherein the preset number of iterations is the taboo table release rule.

[0020] In a possible implementation, the following processing is performed:

[0021] The priority of the global optimization direction is higher than that of the single-dimensional indicator optimization direction. The optimization principle is iteration of the optimization direction and retreat of the inferior direction. The single optimization parameter is at least one of the cycle control parameters.

[0022] In a possible implementation, the non-balanced three-dimensional modeling of elements based on twisted single pitch is performed by performing the following processing:

[0023] Guided by quality visualization requirements, determine effective modeling elements and the refinement of element features;

[0024] Mapping the effective modeling elements and the feature refinement of the elements to determine the non-equilibrium modeling rules;

[0025] Based on the non-equilibrium modeling rule and taking the expected quality of the optimized stranding process as a standard, stranding single pitch three-dimensional modeling is performed to determine the solid model.

[0026] In a possible implementation, the three-dimensional cable model includes a virtual model based on the twist tolerance interval, and performs the following processing:

[0027] Determining the twist tolerance range based on cable quality accuracy and damage threshold;

[0028] Based on the twisting tolerance range, a controllable amplitude variation based on the physical model is determined, and visual three-dimensional modeling is performed to determine the virtual model, wherein the physical model and the virtual model have different display features;

[0029] The solid model and the virtual model are fitted to determine the three-dimensional model of the cable.

[0030] In a possible implementation, the following processing is performed:

[0031] Establishing a communication connection between the digital feedback device and the stranding control system;

[0032] Monitor real-time process data, and based on the digital feedback device, perform mapping and deviation measurement between the three-dimensional cable model and the real-time characteristics to determine deviation information, wherein the deviation information is defined by virtual body edges;

[0033] Based on the deviation information, control parameter mapping and deviation-based amplitude modulation analysis are performed to determine feedback control information;

[0034] Based on the feedback control information, strangulation control management is performed.

[0035] In a possible implementation, the following processing is performed:

[0036] Performing a quality inspection on a twisted cable of a preset pitch to determine a first deviation characteristic, wherein the first deviation characteristic satisfies the twisting tolerance interval;

[0037] The accuracy of mapping control parameters is enhanced based on the first deviation feature, and the optimized stranding process is regulated.

[0038] The present application proposes a cable stranding process optimization method. First, the basic information of the pre-twisted cores after pre-processing is read, along with the stranding requirements, which include stranding density, electrical performance, structural stability, and insulation performance. A process optimization module is then trained based on the finite element analysis principle, and the stranding pitch is set as the control cycle. The initial stranding process is then interactively determined. Using the basic information of the single core as a baseline, the stranding requirements as the optimization dimension, and the stranding machine's cycle control parameters as the optimization target, the process optimization module is combined to perform multi-objective optimization to determine the optimized stranding process. Based on the optimized stranding process, non-balanced three-dimensional modeling of elements based on the stranding pitch is then performed to determine a three-dimensional cable model. The three-dimensional cable model includes a physical model and a virtual model based on the stranding tolerance range. The optimized stranding process is then transmitted to the stranding control system. A digital feedback device is set based on the three-dimensional cable model, and the cable stranding process is executed. Finally, feedback overrun characteristics that meet a preset frequency are simultaneously monitored and mined, and feedback adjustments and responses are made to the optimized stranding process, achieving the technical effect of improving the accuracy of cable stranding process control and optimization. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings of the embodiments of the present invention are briefly introduced below. Flowcharts are used in this application to illustrate the operations performed by the methods according to the embodiments of the present application. It should be understood that the preceding or following operations are not necessarily performed in precise order. Instead, the various steps may be processed in reverse order or simultaneously as needed. Furthermore, other operations may be added to these processes, or one or more operations may be removed from these processes.

[0040] Figure 1 A schematic diagram of a process flow of a cable stranding process optimization method provided in an embodiment of the present application;

[0041] Figure 2 A schematic diagram of a process for generating optimization constraints in a cable twisting process optimization method provided in an embodiment of the present application. DETAILED DESCRIPTION

[0042] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below.

[0043] In order to make the purpose, technical solutions and advantages of this application clearer, the application will be further described in detail below with reference to the accompanying drawings. The described embodiments should not be regarded as limiting this application. All other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0044] In the following description, reference is made to “some embodiments”, which describes a subset of all possible embodiments, but it will be understood that “some embodiments” may be the same subset or different subsets of all possible embodiments and may be combined with each other without conflict, and the terms “first\second” involved are merely used to distinguish similar objects and do not represent a specific ordering of the objects. The terms “including” and “having” and any variations thereof are intended to cover non-exclusive inclusions. For example, a process, method, product, or server that includes a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or modules that are not clearly listed or inherent to these processes, methods, products, or devices. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this application belongs. The terms used herein are for the purpose of describing the embodiments of this application only.

[0045] The embodiment of the present application provides a method for optimizing the cable stranding process, such as Figure 1 As shown, the method includes:

[0046] Step S100, read the basic information of the single core after pre-processing of the pre-twisted core and the twisting requirements, the twisting requirements include twisting tightness, electrical performance, structural stability and insulation performance. Among them, the pre-twisted core refers to a single core or wire bundle that has not yet been twisted, and is the original material in the cable manufacturing process. Specifically, in order to ensure the smooth progress of the twisting process, the pre-twisted core is pre-processed, including cleaning, stretching, annealing, etc., to improve the physical and chemical properties of the pre-twisted core. After the pre-twisted core is pre-processed, the basic information of the single core is read using measuring instruments, chemical composition analysis, automated detection and other methods. The basic information of the single core includes parameters such as the diameter, material, tensile strength, elongation, conductivity and the like of the core. The basic information of the single core determines the basic performance of the core. Set or read the twisting requirements, which are the various performance indicators and requirements that need to be met during the cable manufacturing process. They are the goals and directions of process optimization, including twisting tightness, electrical performance, structural stability and insulation performance. Among them, the twisting tightness refers to the tightness of the wire core during the twisting process, which affects the appearance, structure and performance of the cable. Twisting too tightly will cause damage to the wire core, and twisting too loosely will affect the structural stability of the cable. The electrical performance includes the conductivity, resistivity, insulation resistance, etc. of the cable. The structural stability refers to the performance that the cable structure should remain stable after twisting is completed, and it is not easy to deform or loosen. The insulation performance refers to the insulation performance that the cable should have to ensure that safety problems such as leakage or short circuit will not occur during use.

[0047] Step S200, training the process optimization module based on the finite element analysis principle, and setting the twisting single pitch as the control period. The finite element analysis is a numerical analysis method that approximates the behavior of a continuous system by dividing a continuous object into a finite number of small units. Each unit is interconnected through nodes to form a grid structure. Within each unit, the value of the unknown variable at the node is solved by mathematical models and physical equations, and finally the behavior of the entire system is obtained. Specifically, a mathematical model of cable twisting is established using finite element analysis software or tools, and different twisting parameters such as twisting angle, pitch, tension, etc. are set in the mathematical model. Simulation is performed using historical data or experimental data to simulate the twisting process under different parameters, and the corresponding cable performance is calculated. The simulation results are analyzed to find the twisting parameter combination with the best performance. Machine learning or optimization algorithms are used to train the process optimization module. The process optimization module is a module or system that can automatically find the optimal process parameters. Through training, the process optimization module can automatically recommend the best twisting parameters based on given twisting requirements. The twist pitch refers to the distance a single core (or strand) travels during one rotation along the cable's axis during the twisting process. It reflects the tightness of the cable's twist, the arrangement of the strands, and the overall structural characteristics of the cable. The twist pitch range is determined based on the cable's performance requirements and material properties. The control cycle refers to the time interval between data acquisition, control calculations, and signal output. By setting the twist pitch as the control cycle, each optimization and adjustment is performed within this control cycle.

[0048] Step S300 involves interactively determining the initial stranding process. Using the basic single-core information as a baseline, the stranding requirements as optimization dimensions, and the stranding machine's cyclic control parameters as optimization targets, the process optimization module performs multi-objective optimization to determine the optimal stranding process. The stranding machine's cyclic control parameters refer to the periodic parameters that require control during stranding machine operation, such as stranding pitch and rotational speed. Specifically, the module interacts with the stranding machine operator or expert system to obtain an initial stranding process based on experience and conventional practices, namely, initial stranding process parameters, such as initial stranding angle, tension, and speed. The initial stranding process, basic single-core information, and stranding requirements are input into the process optimization module. Based on the basic single-core information and in combination with the stranding requirements, the process optimization module utilizes machine learning or optimization algorithms to perform multi-objective optimization of the stranding machine's cyclic control parameters within the set optimization dimensions. The module evaluates cable performance under different parameter combinations. After multiple iterations and calculations, the module finds the optimal parameter combination that meets all stranding requirements. The module then outputs the optimized stranding process parameters, i.e., the optimized stranding process.

[0049] like Figure 2As shown, in one possible implementation, before performing multi-objective optimization, step S300 further includes step S310, setting a multi-threaded positioning principle based on the twisting requirements, wherein the multi-threaded positioning principle is used to constrain the position of each single core under spatial coaxiality, and the coaxial dimensions include axial coaxiality and tangential coaxiality. Specifically, during the twisting process, since multiple single cores are twisted simultaneously, it is necessary to ensure that the multiple single cores maintain the correct relative position in space. Therefore, the multi-threaded positioning principle is set, that is, the multi-threaded positioning principle is used to constrain the position of each single core during the twisting process. The axial coaxiality refers to the centerline of each single core remaining consistent in the longitudinal direction without offset; the tangential coaxiality refers to the distribution of each single core around the same center point in the cross section, maintaining relative position stability. The coaxiality requirements in the twisting requirements are analyzed, the axial and tangential coaxial accuracy are determined, and according to the accuracy requirements, the position constraint conditions for each single core during the twisting process are set. Step S320, the balance standard of each single core in the pre-twisted wire core under the twisting single pitch is set. Specifically, during the twisting process, each single core should be evenly distributed to avoid localized dense or sparse conditions. The impact of the twisting pitch on the arrangement of the single cores is analyzed, and a balance standard is determined, that is, an indicator used to measure the uniformity of the distribution of each single core. Based on the indicator, a balance requirement is set for each single core under the twisting pitch. Step S330: Combine the basic information of the single cores with the twisting requirements to perform a twisting force analysis and determine a pressure threshold. The pressure threshold includes the pressure threshold of each single core and the pressure threshold of the assembly. Specifically, the mechanical performance data of the single cores, such as tensile strength and elastic modulus, is extracted from the basic information of the single cores. According to the twisting requirements, the forces that each single core may be subjected to during the twisting process are analyzed. Combined with the mechanical performance data of the single cores, the pressure threshold of each single core during the twisting process is calculated, that is, the maximum pressure or tension that the single core can withstand during the twisting process. At the same time, the stability of the overall structure is analyzed to determine the pressure threshold of the assembly. Step S340, based on the multi-threaded limiting principle, the balance standard and the pressure threshold, generate optimization constraints. Specifically, the multi-threaded limiting principle is converted into a mathematical expression or logical condition, the balance standard is quantified into a specific numerical range or proportion requirement, and the pressure threshold is used as one of the constraints in the optimization process. Combining the above three points, a complete set of optimization constraints is generated to guide the multi-objective optimization process. This implementation method ensures that each single-wire core maintains the correct relative position during the twisting process by setting the multi-threaded limiting principle; by setting the balance standard, it ensures that each single-wire core is evenly distributed under a single twisting pitch to avoid local defects; by performing twisting force analysis and determining the pressure threshold, it ensures that the mechanical properties of each single-wire core are not damaged during the twisting process. By setting these constraints, it ensures that the twisting process can meet multiple key requirements at the same time, achieving the technical effect of ensuring that the optimized twisting process can meet the cable performance requirements.

[0050] In one possible implementation, the process optimization module is combined with multi-objective optimization, and step S300 further includes step S350, randomly selecting N pre-adjustment parameters from the cycle control parameters, performing an optimization iteration, and determining the first optimization solution by optimization, wherein N is a positive integer less than or equal to the total number of parameters. Specifically, N pre-adjustment parameters are randomly selected from the cycle control parameters of the stranding machine, and the N pre-adjustment parameters are used as the adjustment objects of this iterative optimization. The process optimization module is used to perform an optimization iteration on these N pre-adjustment parameters, that is, the values ​​of the N pre-adjustment parameters are adjusted to observe the changing trend of the cable performance. After the completion of this iteration, the best performance group is selected from all possible parameter combinations based on the evaluation index of the cable performance as the first optimization solution. Step S360, the parameter adjustment direction of the N pre-adjustment parameters is added to the taboo table, and the random selection and iterative optimization of the pre-adjustment parameters are continued until the convergence condition is met to determine the optimized stranding process, wherein the preset number of iterations is the taboo table release rule. Specifically, the parameter adjustment directions (i.e., whether the parameters are increasing or decreasing) of the N randomly selected pre-tuned parameters in step S350 are added to a taboo table. The taboo table records previously attempted parameter adjustment directions, preventing repeated selection of the same parameter adjustment direction in subsequent iterations and thus increasing search diversity. The random selection of pre-tuned parameters and iterative optimization are continued. During each iteration, the selected parameter adjustment direction is checked to see if it is in the taboo table. If so, a new random selection is made; if not, optimization iterations are performed. This process is repeated until convergence conditions are met. These conditions may include reaching a preset number of iterations or the performance improvement being less than a certain threshold. When convergence conditions are met, iterations are terminated, and the parameter combination with the best performance is determined as the optimized stranding process. During the process optimization process, the preset number of iterations serves as a rule for removing the taboo table. That is, when the number of iterations reaches the preset value, the previously tabooed parameter adjustment direction is removed and can be selected again. This rule is used to balance local and global search during the search process. This implementation method combines random search and taboo search. By randomly selecting pre-adjusted parameters, it increases the diversity of the search and avoids falling into the local optimum. The use of the taboo table avoids repeatedly trying the same parameter adjustment direction, and is used to jump out of the local optimal solution. Through iterative optimization and selection, it gradually approaches the optimal solution, thereby obtaining an optimized twisting process. This method takes into account both the breadth and depth of the search, and achieves the technical effect of improving the accuracy and efficiency of optimization.

[0051] In one possible implementation, step S350 further includes step S351, the priority of the global optimal direction is higher than the single-dimensional indicator optimal direction, the optimization principle is the iteration of the optimal direction and the retreat of the inferior direction, and the single optimization parameter is at least one of the periodic control parameters. Among them, the global optimal direction refers to the parameter adjustment direction that can significantly improve the overall performance of the line core; the single-dimensional indicator optimal direction refers to the parameter adjustment direction that only has a positive impact on a specific performance indicator of the line core (such as coaxiality). Specifically, when adjusting the parameters, first evaluate the global performance indicators (such as the comprehensive score of the overall performance of the line core), and then analyze the indicators of a single dimension (such as coaxiality, balance, etc.). If there is a conflict between the global performance indicators and the single-dimensional indicators (that is, adjusting a parameter will improve the global performance but reduce a single-dimensional indicator), the adjustment will be mainly based on the global optimal direction. The preferred iteration direction is to continue iterating in the direction that results in improved performance when parameter adjustment results in that direction, attempting to find a more optimal parameter combination. The inferior backward direction is to immediately stop adjusting in that direction if parameter adjustment results in performance degradation, and try other directions or revert to the previous parameter combination. This optimization principle is used to find the optimal parameter combination that improves core performance through continuous trial and adjustment, while avoiding wasting time and resources in the direction of performance degradation. During each iterative optimization process, at least one cycle control parameter (such as core speed, tension, etc.) is adjusted. Based on the principle of preferred iteration and inferior backward direction, these cycle control parameters are gradually adjusted to observe changes in core performance. At least one cycle control parameter is adjusted in a single optimization process to quickly find the direction of performance improvement. This implementation method ensures that the algorithm always focuses on improving the overall performance of the cable core during the optimization process by giving higher priority to the global optimal direction; through the optimization principle of iterating in the optimal direction and retreating in the inferior direction, it ensures that the algorithm stops adjusting the direction that may lead to performance degradation in a timely manner when exploring new parameter combinations, avoiding falling into local optimal solutions; by adjusting at least one cycle control parameter in a single optimization, it ensures that the algorithm gains something in each iteration, avoiding ineffective attempts and waste of resources. By adopting this optimization strategy, a technical effect is achieved that helps find the best parameter combination.

[0052] Step S400, based on the optimized twisting process, perform element non-balanced three-dimensional modeling based on the twisting single pitch to determine the cable three-dimensional model, wherein the cable three-dimensional model includes a physical model and a virtual model based on the twisting tolerance range. The element non-balance refers to the state in which the cores are non-uniformly distributed in position, angle and shape due to the differences in physical properties and twisting process parameters between the cores during the cable twisting process. Specifically, key parameters such as the number of cores, core diameter, twisting pitch, etc. are extracted from the optimized twisting process. According to the extracted key parameters, a geometric model of the twisting single pitch is constructed through computer modeling. The geometric model reflects a basic unit or cycle of the cable in the twisting process, and analyzes the non-balance of the cores in the twisting process, including the relative position, angle and shape changes between the cores. Based on the results of the stranding single-pitch model and element non-balanced analysis, a three-dimensional solid model of the cable is constructed. This solid model reflects the structure and shape of the cable, including the overall shape of the cable, the core layout, etc.; according to the process requirements and cable performance standards, the tolerance range in the stranding process is determined. The stranding tolerance range refers to the range of allowable changes in the position and shape of the core during the cable stranding process. On the basis of the solid model, a three-dimensional virtual model of the cable is established by adding or modifying specific elements according to the stranding tolerance range. This virtual model shows the possible position and shape changes of the core within the stranding tolerance range.

[0053] In a possible implementation, non-balanced three-dimensional modeling of elements based on twisting single pitch is performed, and step S400 further includes step S410, which determines the effective modeling elements and the element feature precision based on the quality visualization requirements. The quality visualization requirements refer to the specific requirements for the visual presentation and data analysis of the cable three-dimensional model. Specifically, the purpose and requirements of the modeling are determined, and based on the requirements, the effective modeling elements are determined. The effective modeling elements refer to the key parameters or features that have an important impact on the construction and performance analysis of the cable three-dimensional model, such as the number of cores, core diameter, twisting pitch, core material properties, etc. For each effective modeling element, the element feature precision is determined. The element feature precision refers to the degree of detail and accuracy of the expression of each element feature during the modeling process. For example, the core diameter needs to be accurate to several decimal places, and the core material properties need to be roughly classified. Step S420 maps the effective modeling elements and the element feature precision to determine the non-balanced modeling rules. Specifically, imbalance refers to the differences and mutual influences of different modeling elements during the twisting process. The mutual influences and differences of each effective modeling element during the twisting process are analyzed to identify the manifestation of imbalance. Based on the requirements of element characteristics and precision, a mapping relationship between effective modeling elements and element feature precision is established. Based on the mapping relationship, specific rules for imbalanced modeling are formulated, that is, specific principles and methods for guiding how to handle each effective modeling element during the three-dimensional modeling process, such as which effective modeling elements require high-precision modeling and which can be simplified. Step S430, based on the imbalanced modeling rules, and taking the expected quality of the optimized twisting process as the standard, single-pitch three-dimensional modeling of the twisting is performed to determine the solid model. Specifically, according to the requirements of the optimized twisting process, the quality standards that the model needs to meet are set. During the modeling process, different effective modeling elements are processed with different precisions according to the imbalanced modeling rules determined in step S420. Based on the optimized twisting process parameters and the imbalanced modeling rules, a single-pitch three-dimensional model of the twisting is constructed using modeling software. The single-pitch three-dimensional model of the twisting is a three-dimensional solid model of the cable constructed based on the single-pitch twisting parameters, reflecting the structure and performance characteristics of the cable. This implementation method can process different elements in a targeted manner by determining the effective modeling elements and the refinement of element features, achieving the technical effect of reducing modeling complexity and computational costs while maintaining model accuracy.

[0054] In one possible implementation, the three-dimensional cable model includes a virtual model based on a twist tolerance range. Step S400 further includes step S440, determining the twist tolerance range based on cable quality accuracy and damage threshold. The cable quality accuracy refers to the degree of accuracy in dimensions, performance, and other aspects required for the cable during manufacturing and use; the damage threshold refers to the maximum acceptable performance loss or damage to the cable during twisting. Specifically, the quality accuracy required for the cable during manufacturing and use is determined, including requirements for dimensional accuracy and performance stability. The acceptable degree of damage to the cable during twisting is determined based on the cable's material properties and application scenarios. Based on the cable quality accuracy requirements and the damage threshold, the allowable range of position and shape changes of the core during twisting, i.e., the twist tolerance range, is determined through theoretical calculation or experimental verification. Step S450, based on the twist tolerance range, determines a controllable amplitude variation based on the physical model, performs visual three-dimensional modeling, and determines the virtual model. The physical model and the virtual model have distinguishing display features. Specifically, based on the twist tolerance range, a controllable range of variation in position and shape of the virtual model relative to the physical model is set, including the range of variation of parameters such as the core position and shape. Using 3D modeling software, a virtual model is constructed based on the physical model and based on the set controllable range. The virtual model reflects the possible variations of the core within the twist tolerance range. During the modeling process, methods such as adjusting the model's color, using a wireframe display, and applying different textures are employed to ensure that the physical and virtual models are visually distinct, allowing for easy distinction and comparison. Step S460 involves fitting the physical and virtual models to determine the cable's three-dimensional model. Specifically, the physical and virtual models are coordinated and adjusted to ensure structural compatibility and visual integration. The accuracy and completeness of the three-dimensional model are verified by comparison with actual cable samples. Based on the verification results, necessary corrections and adjustments are made to the model. After fitting and verification, a final three-dimensional cable model is determined, which reflects both the accuracy of the physical model and the possible variations within the twist tolerance range represented by the virtual model. This implementation method determines the twisting tolerance range based on the cable quality accuracy and damage threshold, accurately reflecting the range of changes in the core position and shape that may occur in the cable during the manufacturing process, achieving the technical effect of making the virtual model closer to the actual manufacturing situation.

[0055] Step S500, the optimized twisting process is transmitted to the twisting control system, and the digital feedback device is set based on the three-dimensional model of the cable to execute the cable twisting process. Specifically, the twisting process parameters determined by the optimization algorithm are transmitted to the twisting control system through a data interface or a communication protocol. The twisting control system is a computer system or device for controlling the operation of the cable twisting equipment, which can receive the twisting process parameters and control the action of the twisting equipment. Based on the physical model and the virtual model in the three-dimensional model of the cable, the digital feedback device is set. The digital feedback device is a device for real-time monitoring and control of the state of the cable during the twisting process. It can accurately monitor whether the position, shape and other parameters of the cable during the twisting process are within the allowable range of variation. The digital feedback device interacts with the twisting control system to provide real-time feedback on the actual twisting condition of the cable, so that the twisting control system can be adjusted in time. The stranding control system controls the operation of the stranding equipment and executes the stranding process of the cable based on the received optimized stranding process parameters and real-time feedback from the digital feedback device. During the stranding process, the digital feedback device continuously monitors the status of the cable and transmits real-time data back to the stranding control system. The stranding control system adjusts the stranding process based on the real-time data to ensure that the stranding quality of the cable meets the expected requirements.

[0056] Step S600 simultaneously monitors and discovers feedback overrun characteristics that meet a preset frequency, and responds by providing feedback adjustments to the optimized twisting process. These overrun characteristics are abnormal or overrun characteristics in the feedback data that exceed a preset frequency, manifesting as dimensional deviations, shape changes, and other variations during the cable twisting process. Specifically, during the twisting process, the digital feedback device monitors and provides real-time feedback on the cable's twisting status, including parameters such as cable size, shape, and core position. The twisting control system synchronously receives feedback data and performs real-time processing and analysis. Specifically, the twisting control system presets a set of frequency thresholds to identify abnormal or out-of-limit features in the feedback data. The frequency threshold is determined based on the twisting tolerance range represented by the virtual model in the three-dimensional cable model. The feedback data is analyzed to find out-of-limit features that exceed the preset frequency threshold. Once an out-of-limit feature that meets the preset frequency is found, the feedback adjustment mechanism is immediately triggered. According to the type and degree of the out-of-limit feature, the twisting process is adjusted accordingly, including adjusting the wire core speed, changing the twisting pitch, optimizing the wire core tension, etc. The adjusted twisting process parameters are transmitted to the twisting equipment in real time to achieve instant optimization of the twisting process. The embodiment of the present application adopts the method of reading the basic information of the single wire core after pre-processing of the pre-twisted wire core, combining it with the twisting requirements, using the finite element analysis principle to train the process optimization module, performing multi-objective optimization, determining the optimized twisting process, and performing non-balanced three-dimensional modeling of elements based on the twisting single pitch based on the optimized twisting process, including a solid model and a virtual model based on the twisting tolerance range, setting a digital feedback device and synchronously monitoring and feedback over-limit characteristics, and performing real-time adjustment and optimization of the optimized twisting process, etc., to achieve the technical effect of improving the accuracy of cable twisting process control and optimization.

[0057] In one possible implementation, step S600 further includes step S610, establishing a communication connection between the digital feedback device and the twisting control system. Specifically, the communication interface between the digital feedback device and the twisting control system is configured, and the communication protocol and data transmission format are set to ensure smooth data exchange between the two. Step S620, monitoring real-time process data, based on the digital feedback device, performing mapping and deviation measurement between the three-dimensional cable model and real-time features, and determining deviation information, wherein the deviation information is defined by virtual edges. Specifically, the real-time process data during the twisting process of the cable, such as the position and size of the core, is monitored by the digital feedback device, and these real-time process data are mapped and analyzed with the three-dimensional cable model. The deviation between the real-time features and the three-dimensional model is calculated using a deviation measurement algorithm to determine the degree and range of the deviation, wherein the deviation information is defined by virtual edges, that is, when the real-time features exceed the twisting tolerance range represented by the virtual model, it is considered a deviation. Step S630, based on the deviation information, control parameter mapping and amplitude modulation analysis based on the degree of deviation are performed to determine feedback control information. Specifically, the deviation information is mapped to the control parameters, which control parameters cause the deviation, the influence of the deviation on the control parameters is analyzed, the adjustment amplitude and direction are determined, and the feedback control information that needs to be adjusted is determined based on the amplitude modulation analysis results. Step S640, based on the feedback control information, the twisting control management is performed. Specifically, according to the feedback control information, the relevant parameters of the twisting control system, such as the wire core speed, tension, etc., are adjusted, and the real-time data is continuously monitored through the digital feedback device. According to the monitoring results, necessary fine-tuning is performed until the expected twisting effect and quality requirements are achieved. This implementation method measures the deviation by mapping the three-dimensional cable model with the real-time characteristics, accurately determines the deviation information, provides an accurate basis for twisting control management, and achieves the technical effect of improving the control accuracy during the cable twisting process.

[0058] In one possible implementation, step S600 further includes step S650, performing a quality inspection on a stranded cable with a preset pitch to determine a first deviation characteristic, where the first deviation characteristic satisfies the stranding tolerance range. Specifically, samples with a preset pitch are selected from the stranded cables for quality inspection, where the preset pitch is determined based on the cable's design requirements and performance standards. Using inspection equipment and methods, the sample cables are subjected to a comprehensive quality inspection, including but not limited to inspections of the cable's size, shape, and core uniformity. Based on the inspection results, the cable samples are analyzed for characteristics that deviate from design requirements. These deviation characteristics are then identified as first deviation characteristics. First deviation characteristics satisfy the stranding tolerance range, meaning that, while deviating from the ideal state, they are still within an acceptable range. Step S660, based on the first deviation characteristics, enhances the accuracy of mapping control parameters to control the optimized stranding process. Specifically, the first deviation characteristics are mapped to corresponding control parameters. Based on the analysis results of the first deviation characteristics, the accuracy of the control parameters is enhanced, including by optimizing the control algorithm, improving equipment accuracy, or adjusting operating specifications. Based on the enhanced control parameter accuracy, the stranding process is optimized and regulated, for example, by adjusting core speed to improve core uniformity, tension to optimize cable shape, or pitch to match design requirements. The regulated stranding process is verified to ensure significant improvements in cable quality. Verification results are fed back to the stranding control system for further optimization. This approach, through quality inspection and analysis of cables that meet the stranding tolerance range, identifies subtle deviations and enables precise regulation, further improving cable quality and performance stability.

[0059] The above specific embodiments do not constitute a limitation to the scope of protection of this application. It should be understood by those skilled in the art that various modifications, combinations and substitutions can be made according to design requirements and other factors. Any modifications, equivalent replacements and improvements made within the spirit and principles of this application should be included in the scope of protection of this application. In some cases, the actions or steps recorded in this application can be performed in an order different from that in the embodiments and can still achieve the desired results. In addition, the processes depicted in the accompanying drawings do not necessarily require the specific order or continuous order shown to achieve the desired results. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

Claims

1. A cable stranding process optimization method, characterized in that: The method comprises: Read the basic information of the single wire core after pre-processing of the pre-twisted wire core and the twisting requirements, wherein the twisting requirements include twisting tightness, electrical performance, structural stability and insulation performance; The process optimization module is trained based on the finite element analysis principle, and the twisting single pitch is set as the control cycle; Interactively obtain the initial twisting process, based on the basic information of the single wire core, taking the twisting requirements as the optimization dimension, taking the periodic control parameters of the twisting machine as the optimization target, and combining the process optimization module to perform multi-objective optimization to determine the optimized twisting process; Based on the optimized twisting process, non-balanced three-dimensional modeling of elements based on twisting single pitch is performed to determine a three-dimensional cable model, wherein the three-dimensional cable model includes a physical model and a virtual model based on a twisting tolerance interval, wherein the non-balanced elements refer to the state in which the cores are non-uniformly distributed in position, angle and shape due to differences in physical properties and twisting process parameters between the cores during the twisting process of the cable, the twisting tolerance interval refers to the range in which the core position and shape are allowed to change during the twisting process of the cable, and the virtual model shows the position and shape changes of the cores within the twisting tolerance interval; The optimized twisting process is transmitted to a twisting control system, a digital feedback device is set based on the three-dimensional model of the cable, and a cable twisting process is performed; The feedback over-limit characteristics exceeding the preset frequency are monitored and mined simultaneously, and feedback adjustment and response are made to the optimized stranding process.

2. A cable twisting process optimization method as claimed in claim 1, characterized in that: Before multi-objective optimization, include: A multi-threaded positioning principle based on the twisting requirement is set, wherein the multi-threaded positioning principle is used to constrain the position of each single-wire core under spatial coaxiality, and the coaxial dimension includes axial coaxiality and tangential coaxiality; Setting the balance standard of each single wire core in the pre-twisted wire core under the twisting single pitch; Combining the basic information of the single wire core with the twisting requirement, performing twisting force analysis to determine a pressure threshold, wherein the pressure threshold includes a pressure threshold of each single wire core and an assembly pressure threshold; Based on the multi-thread limit principle, the balance standard and the pressure threshold, optimization constraints are generated.

3. A cable twisting process optimization method as claimed in claim 1, characterized in that: The multi-objective optimization is performed in combination with the process optimization module, including: Randomly select N pre-adjustment parameters from the periodic control parameters, perform an optimization iteration and select the first optimization scheme, where N is a positive integer less than or equal to the total number of parameters; The parameter adjustment directions of the N pre-adjustment parameters are added to the taboo table, and the pre-adjustment parameters are randomly selected and iteratively optimized until the convergence conditions are met, and the optimized twisting process is determined, wherein the preset number of iterations is the taboo table release rule.

4. A cable stranding process optimization method as claimed in claim 3, characterized in that: The priority of the global optimization direction is higher than that of the single-dimensional indicator optimization direction. The optimization principle is iteration in the optimization direction and retreat in the inferior direction. The single optimization parameter is at least one of the periodic control parameters. The global optimization direction refers to the parameter adjustment direction that can significantly improve the overall performance of the line core. The single-dimensional indicator optimization direction refers to the parameter adjustment direction that only has a positive impact on a specific performance indicator of the line core. The iteration in the optimization direction means that when the parameter adjustment direction brings performance improvement, continue to iterate along this direction to find a better parameter combination. The retreat in the inferior direction means that if the parameter adjustment direction causes performance degradation, the adjustment in this direction will be stopped immediately, and other directions will be adopted or the previous parameter combination will be rolled back.

5. A cable twisting process optimization method as claimed in claim 1, characterized in that: The non-balanced three-dimensional modeling of elements based on twisted single pitch comprises: Guided by the quality visualization requirements, determine the effective modeling elements and the refinement of element features; Mapping the effective modeling elements and the feature refinement of the elements to determine the non-equilibrium modeling rules; Based on the non-equilibrium modeling rule and taking the expected quality of the optimized twisting process as a standard, three-dimensional modeling of single-pitch twisting is performed to determine the solid model.

6. A cable stranding process optimization method as claimed in claim 5, characterized in that: The cable three-dimensional model includes a virtual model based on a twisting tolerance interval, including: Determining the twisting tolerance interval based on the cable quality accuracy and damage threshold; Based on the twisting tolerance interval, a controllable amplitude variation based on the physical model is determined, and visual three-dimensional modeling is performed to determine the virtual model, wherein the physical model and the virtual model have different display features; The solid model and the virtual model are fitted to determine the three-dimensional model of the cable.

7. A cable stranding process optimization method as claimed in claim 1, characterized in that: include: Establishing a communication connection between the digital feedback device and the stranding control system; Monitor the real-time process data, and based on the digital feedback device, perform mapping and deviation measurement between the three-dimensional cable model and the real-time features to determine deviation information, wherein the deviation information is defined by virtual body edges; Based on the deviation information, control parameter mapping and deviation-based amplitude modulation analysis are performed to determine feedback control information; Based on the feedback control information, control management is performed.

8. A cable stranding process optimization method as claimed in claim 1, characterized in that: The method further comprises: Performing quality inspection on a twisted cable of a preset pitch to determine a first deviation characteristic, wherein the first deviation characteristic satisfies the twisting tolerance interval; The accuracy of mapping control parameters is enhanced based on the first deviation characteristics, and the optimized stranding process is regulated.

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