Automatic winding practical training system
Through an automated winding training system, combined with PID control and machine learning algorithms, the existing winding training platform has been solved, and the problem of high maintenance and complex operation is achieved, efficient winding process control and learning experience is achieved, and students' hands-on work is improved. Ability and comprehensive quality.
Patent Information
- Application Number
- CN202411283837.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-13
- Publication Date
- 2024-12-20
AI Technical Summary
The existing winding training platform has high maintenance costs, complex operation, steep learning curve and unfriendly interface design, making it difficult to fully simulate the winding process in actual production, and lacks teaching instruments that integrate high-end process algorithms.
An automated winding training system was designed, including an automatic feeding unit, a winding driving unit, a guide unit, a real-time monitoring unit, a tension control unit, a coil diameter calculation unit and an intelligent control unit, and automatic control unit is adopted by PLC and computer. Combining PID control and machine learning algorithms, precise control of paper tape tension, speed and position.
It reduces maintenance costs, simplifies operational processes, improves learning efficiency, provides intuitive learning experience and hands-on practice opportunities, enhances students' hands-on ability and comprehensive qualities, and supports multi-disciplinary integration and project-based learning.
Smart Images
Figure CN119169898A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of winding experiments, and in particular to an automated winding training system. Background Art
[0002] With the development of industrial automation technology, automatic winding systems have been widely used in production. However, the existing teaching equipment is difficult to fully simulate the winding process in actual production, making it difficult for students and technicians to gain practical experience.
[0003] The existing winding training platform is mainly composed of the following structures: (1) Servo motor control: The servo motor is used to accurately control the movement of the winding machine, including the winding speed and position control of the material; (2) Pneumatic tension control: The tension of the wire is adjusted by a pneumatic device, and the tension is controlled by the change of air pressure; (3) Program control: The control system of the winding machine is usually automated through pre-programmed software. Operators can write or adjust the control program according to their needs to adapt to different types of coils and winding processes.
[0004] The existing winding training platform has the following problems: (1) High maintenance cost: Regular maintenance and repairs require professional technicians and special tools, which increases operating costs. (2) Complex operation: The operation and setting of the equipment requires professional knowledge, and users need to be trained to use it proficiently. (3) Steep learning curve: Users need to spend a lot of time and energy to familiarize themselves with and master the operation of the equipment. (4) Unfriendly interface design: The user interface design of some equipment is not intuitive enough, which affects operating efficiency. Therefore, there is currently no teaching instrument on the market that integrates high-end process algorithms. Summary of the invention
[0005] The present invention provides an automated winding training system, aiming to provide a teaching instrument integrating high-end process algorithms.
[0006] The present invention provides an automated winding training system comprising: The automatic feeding unit, including the unwinding end and the rewinding end, automatically loads and delivers the paper tape to simulate the actual winding operation; The winding drive unit drives the conveying of the paper tape and adjusts and controls the conveying speed of the paper tape; Guide unit, which adjusts and controls the angle of paper tape conveyance; Real-time monitoring unit, real-time monitoring of key parameters in the winding process, including tension value, paper tape offset value, color mark position value; The tension control unit uses a control algorithm to calculate the tension value of the winding process based on the monitored tension value, and controls the tension of the paper tape according to the tension value; The coil diameter calculation unit combines the paper tape conveying speed and tension value, dynamically adjusts the winding parameters through data analysis and optimization algorithms, and calculates the coil diameter in real time; Intelligent control unit, based on PLC and computer, automatically controls the entire winding process.
[0007] As a further improvement of the present invention, the automatic feeding unit includes an unwinding roller, a winding roller, an unwinding and winding frequency converter, and a winding and unwinding motor. The unwinding roller is connected to the unwinding and winding motor through the unwinding and winding frequency converter to form an unwinding end, and the winding roller is connected to the unwinding and winding motor through the unwinding and winding frequency converter to form a winding end. The two ends of the paper tape are respectively wound around the unwinding roller and the winding roller, and the computer controls the unwinding and winding motor through PLC.
[0008] As a further improvement of the present invention, the winding drive unit includes a traction wheel, a traction roller, and a traction motor. The traction wheel and the traction roller are closely connected, and the paper tape passes between the traction wheel and the traction roller. The traction motor is connected to and drives the traction wheel, and the computer controls the traction motor through PLC.
[0009] As a further improvement of the present invention, the tension control unit includes a tension adjusting roller, a rocker arm, and a rocker arm motor. The paper tape is wound on the tension adjusting roller. One end of the rocker arm is connected to the tension adjusting roller, and the other end of the rocker arm is connected to the rocker arm motor. The computer controls the rocker arm motor through PLC.
[0010] As a further improvement of the present invention, the real-time monitoring unit includes an angle sensor, the tension control unit also includes a proportional valve, the angle sensor is arranged on the rocker arm, the angle sensor sends an analog quantity to the PLC, and the PLC performs PID control of the proportional valve according to the analog quantity and the set tension value to adjust the angle of the rocker arm through the rocker arm motor.
[0011] As a further improvement of the present invention, in the tension control unit, the process of calculating the tension value of the winding process by adopting a control algorithm includes: a1. Use PID control in the initial stage: When the system is started or the parameters are initially uncertain, use the PID controller for tension control; a2. Data collection and model training: During the PID control process, the system operation data, including input, output and control signals, is collected. By generating simulated data or using the actual collected data, the error, integral, differential values and the corresponding optimal PID parameters are obtained. The data is divided into a training set and a test set. The optimal parameters are obtained based on the training set data and input into the machine learning model for training. a3. Model optimization and adjustment: The trained machine learning model is used to optimize the parameters of the PID controller. According to the system response, the three parameters of the PID controller are calculated and determined: proportional (P), integral (I), and differential (D); a4. Online switching and adaptive control: During system operation, dynamically adjust the parameters of the PID controller according to the results predicted by the machine learning model, or switch to the machine learning model for control.
[0012] As a further improvement of the present invention, the real-time monitoring unit also includes a color mark sensor, which is connected to the PLC. The color mark sensor collects a Boolean signal of the paper tape linear speed timing, captures the color mark each time before cutting the material, and uses it as a reference to determine the cutting position.
[0013] As a further improvement of the present invention, the guiding unit also includes a deflection corrector and a deflection corrector sensor. The deflection corrector is connected to the PLC, and the deflection corrector sensor is connected to the computer and feeds back the offset direction and offset amount of the paper tape. The computer controls the deflection corrector through the PLC to adjust the position of the paper tape according to the offset direction and offset amount.
[0014] As a further improvement of the present invention, in the coil diameter calculation unit, the specific process of dynamically adjusting the winding parameters and calculating the coil diameter in real time by combining the paper tape conveying speed and tension value through data analysis and optimization algorithm includes: b1. Data collection: Sensor data: Real-time monitoring units collect data on key parameters of the winding process, including tension value and speed; Historical data: Analyze historical operating data to understand the impact of different parameters on winding quality; b2. Data analysis: Preprocessing: Clean and normalize the collected data to remove noise and outliers; Feature extraction: Extract key features from the data, including winding tension changes and speed fluctuations; b3. Optimization algorithm: Modeling: Establish physical models and data-driven models to obtain the relationship between the change of coil diameter over time and winding parameters; Optimization method: Use gradient descent method to find the optimal winding parameter settings to achieve the goals of minimizing tension fluctuations and maximizing production efficiency; b4. Real-time adjustment: Control system: Design a closed-loop control system to adjust winding parameters including tension and speed in real time based on the current winding diameter and expected goals; Prediction model: Use machine learning models to predict future changes in roll diameter and adjust parameters in advance; b5. Real-time coil diameter calculation: Algorithm design: Through real-time calculation algorithm, the current coil diameter is dynamically calculated based on the properties of the winding material and the current operating parameters; Feedback mechanism: Combine real-time data and prediction model results to adjust control strategies to ensure that the roll diameter is within the expected range.
[0015] As a further improvement of the present invention, the automated winding training system is characterized in that it also includes a cutting adjustment unit, the cutting adjustment unit includes a transverse swing arm and a swing arm motor, the transverse swing arm is connected to the roller of the cutting station, the swing arm motor is connected to and drives the transverse swing arm, the computer controls the swing arm motor through PLC, and the swing speed of the transverse swing arm is synchronized with the speed of the winding drive unit.
[0016] The beneficial effects of the present invention are: the loading and unloading, conveying, tension adjustment, etc. of the entire paper tape are controlled by a computer and a PLC, a real-time monitoring unit is equipped to obtain the key parameters of the paper tape process in real time, and a PID control algorithm is used to achieve precise control of the paper tape tension, speed and position, thereby meeting the teaching needs of the automated winding electrical layout and teaching instrument control program. BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Figure 1 It is a control logic block diagram of the automatic winding training system of the present invention; Figure 2 It is a structural diagram of the paper tape conveying process in the automated winding training system of the present invention. DETAILED DESCRIPTION
[0018] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments.
[0019] Combination Figure 1 and Figure 2 As shown, an automated winding training system of the present invention comprises: The automatic feeding unit, including the unwinding end and the rewinding end, automatically loads and delivers the paper tape to simulate the winding in actual operation.
[0020] The winding drive unit drives the paper tape to be transported and adjusts and controls the speed of paper tape transport; it uses high-efficiency variable frequency motors and servo motors to provide stable driving force.
[0021] The guide unit adjusts and controls the angle of paper tape conveying; the guide unit is driven by a servo motor to ensure uniform winding of the paper tape.
[0022] The real-time monitoring unit monitors the key parameters in the winding process in real time, including tension value, paper tape offset value, and color mark position value; it is equipped with a tension sensor, a deviation correction sensor, a color mark sensor 7, etc., to monitor the key parameters in the winding process in real time.
[0023] The tension control unit, in combination with the monitored tension value, uses a control algorithm to calculate the tension value of the winding process, and controls the tension of the paper tape based on the tension value.
[0024] The roll diameter calculation unit combines the paper tape conveying speed and tension value, dynamically adjusts the winding parameters through data analysis and optimization algorithms, and calculates the roll diameter in real time.
[0025] Intelligent control unit, based on PLC and computer, automatically controls the entire winding process.
[0026] Each component adopts modular design, which is easy to replace and maintain. The replaceable winding module can adapt to different materials and process requirements and improve the flexibility and adaptability of the equipment.
[0027] The precise winding process is achieved through the cooperation of the automatic feeding unit, the guide unit and the winding drive unit. The automatic feeding unit realizes the automatic loading and conveying of materials, simulates the actual winding and can realize the winding and unwinding, thereby reducing manual intervention and achieving sustainable learning without the need to change the coil.
[0028] The automatic feeding unit includes an unwinding roller 1, a winding roller 2, an unwinding and winding frequency converter, and an unwinding and winding motor. The unwinding roller 1 is connected to the unwinding and winding motor through the unwinding and winding frequency converter to form an unwinding end, and the winding roller 2 is connected to the unwinding and winding motor through the unwinding and winding frequency converter to form a winding end. The two ends of the paper tape are respectively wound on the unwinding roller 1 and the winding roller 2, and the computer controls the unwinding and winding motor through the PLC.
[0029] The intelligent control system is composed of PLC, HMI, and industrial computing structure. Based on the control system of PLC (Programmable Logic Controller) and industrial computer, it realizes the automatic control of the whole winding process. The main controller of PLC control system: choose PLC with stable performance and flexible programming as the core control unit; input and output module: equipped with multi-channel I / O module, supporting the access of various sensors and actuators; analog input module: real-time detection of the angle of the tension swing arm is converted into the signal value of analog quantity.
[0030] The human-machine interface (HMI) is a user-friendly interface that facilitates users to set parameters, monitor processes and analyze results. Touch screen interface of the human-machine interface: equipped with a high-resolution touch screen, providing a friendly operation interface for easy parameter setting and monitoring; the human-machine interface also has a remote monitoring function: supports remote monitoring and operation through the network, and realizes remote experiments and fault diagnosis.
[0031] The winding drive unit includes a traction wheel 4, a traction roller, and a traction motor. The traction wheel 4 and the traction roller are closely connected, and the paper tape passes between the traction wheel 4 and the traction roller. The traction motor is connected to and drives the traction wheel 4, and the computer controls the traction motor through PLC.
[0032] The tension control unit includes a tension adjustment roller 52, a swing rod 51, and a swing rod motor. The paper tape is wound on the tension adjustment roller 52. One end of the swing rod 51 is connected to the tension adjustment roller 52, and the other end of the swing rod 51 is connected to the swing rod motor. The computer controls the swing rod motor through the PLC. A tension sensor is configured at the tension control unit to monitor the tension of the material in real time and ensure stability during the winding process.
[0033] The real-time monitoring unit includes an angle sensor 53, and the tension control unit also includes a proportional valve. The angle sensor 53 is arranged on the rocker arm 51. The angle sensor 53 sends an analog quantity to the PLC. The PLC performs PID control of the proportional valve according to the analog quantity and the set tension value to adjust the angle of the rocker arm 51 through the rocker arm motor.
[0034] In the tension control unit, advanced control algorithms (such as PID control, machine learning (neural network)) are used to achieve precise control of the tension of the winding process. The specific control algorithm process includes: a1. Use PID control in the initial stage: When the system is started or the parameters are initially uncertain, the PID controller is first used for tension control. When the equipment is just started, the paper tape is pre-tensioned. First, the inverter of the swing arm motor is started to slowly tighten the paper tape, and then the proportional valve begins to adjust the angle of the swing arm 51 to the horizontal (270°). Finally, the angle sensor 53 obtains the real-time angle value of the swing arm 51, and the swing angle of the swing arm 51 is adjusted by continuously adjusting the rewinding and unwinding motor speed and the proportional valve signal through PID.
[0035] a2. Data collection and model training: During the PID control process, the system operation data, including input, output and control signals, is collected. By generating simulated data or using the actual collected data, the error, integral, differential values and the corresponding optimal PID parameters are obtained. The data is divided into a training set and a test set. The optimal parameters are obtained based on the training set data and input into the machine learning model for training.
[0036] The process of obtaining the error, integral, differential values and the corresponding optimal PID parameters by generating simulated data or using the actual collected data is as follows: a21.Model selection: Select appropriate deep learning models in machine learning to predict and optimize PID parameters.
[0037] a22.Model training: Using the collected training data to train the machine learning model, the model will learn the dynamic characteristics of the system and predict the optimal PID parameters.
[0038] a23.Model Validation: The performance of the model is evaluated using a validation data set to verify whether the model can accurately predict and optimize PID parameters, thereby improving the control performance of the system.
[0039] a24.Online adjustment: The trained model is deployed to the actual system to implement online adjustment. The model dynamically adjusts the PID parameters according to real-time data to ensure that the system is always in the best state.
[0040] a3. Model optimization and adjustment: The trained machine learning model is used to optimize the parameters of the PID controller to adapt it to the nonlinear and time-varying characteristics of the system. According to the response of the system, the three parameters of the PID controller are calculated and determined: proportional (P), integral (I), and differential (D), to ensure that the system can maintain good control effects under different working conditions; after the machine learning model obtains the PID parameters, the PLC self-tuning function can automatically calculate and adjust the PID parameters according to the real-time response data of the system.
[0041] a4. Online switching and adaptive control: During system operation, dynamically adjust the parameters of the PID controller according to the results predicted by the machine learning model, or switch to the machine learning model for control.
[0042] The real-time monitoring unit also includes a color mark sensor 7, which is connected to the PLC. The color mark sensor 7 collects Boolean signals of the paper tape linear speed timing, and captures the color mark before cutting the material each time and uses it as a reference to determine the cutting position.
[0043] The guide unit also includes a deflection corrector 3 and a deflection corrector sensor. The deflection corrector 3 is connected to the PLC. The deflection corrector sensor is connected to the computer and feeds back the offset direction and offset of the paper tape. The computer controls the deflection corrector 3 through the PLC to adjust the position of the paper tape according to the offset direction and offset. The deflection corrector sensor is configured on the deflection corrector 3 to detect the position of the paper tape and the angles of the unwinding roller 1 and the winding roller 2 to achieve precise positioning control.
[0044] In the coil diameter calculation unit, the specific process of dynamically adjusting the winding parameters and calculating the coil diameter in real time by combining the paper tape conveying speed and tension value through data analysis and optimization algorithm includes: b1. Data collection: Sensor data: The sensor real-time monitoring unit is installed to collect data on key parameters of the winding process, including tension value and speed; Historical Data: Analyze historical operating data to understand the impact of different parameters on winding quality.
[0045] b2. Data analysis: Preprocessing: Clean and normalize the collected data to remove noise and outliers; Feature extraction: Extract key features from the data, including winding tension changes and speed fluctuations.
[0046] b3. Optimization algorithm: Modeling: Establish physical models and data-driven models to describe the relationship between the roll diameter and the change of winding parameters over time.
[0047] Specifically, the process of establishing a physical model to describe the relationship between the change of coil diameter over time and the change of winding parameters includes: b31. Define the roll diameter and winding parameters: roll diameter (d): the radius or diameter of the roll; winding speed (v): the speed at which the roll is wound; tension (T): the tension of the roll; thickness (h): the thickness of the roll.
[0048] b32. Establish physical relationship: The change of coil diameter over time is mainly determined by the winding speed and coil thickness. Assuming the coil is uniform, the change of coil diameter can be described by the following formula: d(t)=d0+(2vt / π)×h, where d0 represents the initial coil diameter.
[0049] The process of establishing a data-driven model to describe the relationship between coil diameter and winding parameters over time includes: b33. Collect the following data: time (t), coil diameter (d), winding speed (v), coil tension (T), coil thickness (h); b34. Perform pre-processing steps such as cleaning and normalization on the data to ensure data quality; b35. Use machine learning algorithms to train data to obtain model parameters.
[0050] Optimization method: Use optimization algorithms (gradient descent method) to find the best winding parameter settings to achieve goals, such as minimizing tension fluctuations and maximizing production efficiency.
[0051] b4. Real-time adjustment: Control system: Design a closed-loop control system to adjust winding parameters including tension and speed in real time based on the current winding diameter and expected goals; Predictive model: Use machine learning models (neural networks) to predict future roll diameter changes and adjust parameters in advance to deal with potential problems.
[0052] b5. Real-time coil diameter calculation: Algorithm design: Through real-time calculation algorithm, the current coil diameter is dynamically calculated based on the properties of the winding material and the current operating parameters; The specific coil diameter calculation process is: Calculate the coil diameter by linear velocity and angular velocity: Angular velocity = (2 × π × rotation speed); Linear velocity = radius × angular velocity; Unwinding radius = traction roller linear speed, unwinding angular velocity.
[0053] Rewinding and unwinding speed control formula: The relationship between the inverter frequency and speed: (set speed / set frequency) = (rated speed / rated frequency); Relationship between set speed, linear speed and shaft radius: set speed (r / min) = (linear speed (mm / s) × 60) / (2 × π × radius (mm)); Relationship between set frequency and set speed: Set frequency = set speed × (rated frequency / rated speed) = (linear speed (mm / s) × 60) / (2 × π × radius (mm) × (rated frequency / rated speed); The motor shaft end of the equipment is equipped with a 7:1 reducer. After the reducer is installed, the motor rotates faster and the load rotates slower. In order to control the load end to maintain the same linear speed, the motor speed needs to be increased by 7 times, and its frequency also needs to be increased by 7 times accordingly.
[0054] That is, set frequency = set rotation speed × (rated frequency / rated rotation speed) × 7 = (linear speed (mm / s) × 60) / (2 × π × radius (mm) × (rated frequency / rated rotation speed) × 7.
[0055] Feedback mechanism: Combine real-time data and prediction model results to adjust control strategies to ensure that the roll diameter is within the expected range.
[0056] The optimization algorithm automatically adjusts control parameters through real-time data analysis to achieve dynamic optimization of the process. With the help of machine learning algorithms, historical data and experimental results are used to train machine learning models to predict and optimize the winding process.
[0057] The automated winding training system also includes a cutting adjustment unit, which includes a horizontal swing arm 6 and a swing arm motor. The horizontal swing arm 6 is connected to the roller of the cutting station, and the swing arm motor is connected to and drives the horizontal swing arm 6. The computer controls the swing arm motor through the PLC, and the swing speed of the horizontal swing arm 6 is synchronized with the speed of the winding drive unit. A camera 8 and a laser 9 are also provided at the position of the cutting adjustment unit. The camera 8 is used to capture the position of the color mark on the paper tape, and the laser 9 is used to irradiate the paper tape to simulate the effect of the cutting knife action.
[0058] The entire system equipment adopts a solid and stable frame structure to ensure the stability and durability of the equipment during operation. The design of an open equipment structure and the use of a transparent acrylic plate as the shell are convenient for teaching and scientific research personnel to observe and operate. The entire system is also equipped with safety protection devices such as emergency stop buttons and safety light curtains to ensure the safety of operators. The equipment is equipped with multiple emergency stop buttons to ensure that the equipment can be quickly stopped in an emergency; safety light curtains are installed in dangerous areas to prevent people from entering the operating area by mistake. It is also equipped with real-time monitoring of the equipment status, and timely alarms and corresponding measures are taken when faults are found to prevent equipment damage and accidents.
[0059] This system can record the experimental process and results in detail through the computer, which is convenient for students and researchers to analyze and summarize, and provide detailed experimental guidance and operating instructions to assist students in experimental operations; the built-in data recording system records the experimental data in detail, supports subsequent analysis and research, and supports the access to a variety of sensors and external devices, which is convenient for diversified experimental research. Through the connection between the computer and the PLC, users are allowed to write and modify the control program to conduct experiments and research on different processes.
[0060] The implementation process of this automated winding training system is as follows: S1. HMI sets the device to working state. After starting the system, select the device to work. Click the device start button and manually reach out to test whether the grating alarm is normal. After the test is completed, clear the alarm and put the device into standby state.
[0061] S2. Set the winding direction of the reel on the HMI and adjust the linear speed of the reel. After clicking the start button again, the device will first reset the horizontal swing arm 6.
[0062] S3, at this time, the reeling motor is running forward and the reeling shaft is ventilated and expanded to lock the reel core. The unwinding motor also starts to work, the paper tape will be wound in one direction, and the paper tape will be quickly tightened at this time.
[0063] S4, the synchronous traction wheel 4 quickly pulls the paper tape at this time, and winds the loose paper tape into the winding core as soon as possible.
[0064] S5, the deviation corrector 3 starts to work, and corrects the axial position of the paper tape in real time, so as to ensure that the paper tape does not deviate under the winding motor and the end surface of the winding paper tape is neat.
[0065] S6. According to the analog value given to the PLC by the angle sensor 53 and the set tension value, the PLC performs PID control on the proportional valve to push the swing rod 51 to adjust the tension.
[0066] S7, the tension of the paper tape between the left and right traction wheels 4 is controlled by the displacement difference of the left and right traction wheels 4 per unit time. That is, a certain tension is provided to the paper tape through the slight speed difference of the left and right traction wheels 4, so as to ensure the flatness of the paper tape.
[0067] S8, using the color mark sensor 7 to collect the Boolean signal of the color mark sensor 7 according to the paper tape linear speed. Before cutting (or other processing) the material each time, the color mark is captured and used as a reference to determine the cutting (or other processing) position.
[0068] S9, using electronic cam to synchronize the traction wheel 4 and the horizontal swing arm 6, because the swing arm is in the same speed as the paper tape line speed, the roller corresponding to the horizontal swing arm 6 and the traction wheel 4 reciprocate in a shearing model, and when the speeds of the two are synchronized, the paper tape below them will remain stationary to facilitate the cutting action.
[0069] S10, the cutter in the teaching equipment is replaced by laser 9 and camera 8, and the relative position of the laser 9 and the color mark can be observed, or the camera 8 takes a picture of the color mark below it, and the distance value obtained each time is compared, and the deviation should be as small as possible.
[0070] S11. The above actions are repeated to achieve the continuity of the entire winding.
[0071] The automated winding training system of the present invention has the following advantages: (1) Hands-on practice opportunities Enhance hands-on ability: Students can operate the equipment by themselves, conduct various winding experiments, and cultivate practical skills and problem-solving abilities.
[0072] Experimental verification of theory: Through practical operations, students can verify the theoretical knowledge learned in class and deepen their understanding and memory.
[0073] (2) Intuitive learning experience Visualization process: The open structure of the equipment and the real-time monitoring system make the winding process intuitive and visible, helping students better understand each step and principle.
[0074] Strong interactivity: Students can directly observe changes in results by adjusting parameters and settings, which enhances the interactivity and fun of learning.
[0075] (3) Improve learning efficiency Automated operation: The automated system reduces tedious manual operation steps, allowing students to focus on understanding and analyzing experimental results and improving learning efficiency.
[0076] Quick feedback: Real-time data acquisition and analysis systems can quickly feedback experimental results, helping students identify problems and make adjustments in a timely manner.
[0077] Industry-education integration: Students can practice simulated programming in school without having to go to companies for practical training. Students can start working after graduation without further training.
[0078] (4) Multidisciplinary integration Interdisciplinary application: Winding scientific and educational instruments involve multiple disciplines such as mechanical engineering, electrical engineering, and control engineering. Students can comprehensively apply knowledge from different disciplines in practical applications.
[0079] Project-based learning: The equipment supports complex experiments and project design, allowing students to conduct interdisciplinary project research and develop comprehensive qualities and teamwork skills.
[0080] Exploratory learning: It is possible to learn different algorithms in the same system. It can also conduct real-time testing, which is convenient for quickly mastering algorithms including but not limited to PID and visual correction. During the operation of the equipment, it will automatically detect the speed of the drive motor and automatically adjust the winding line speed to achieve a constant winding speed.
[0081] (5) Cultivate innovation capabilities Free programming and design: Students can write and modify control programs, conduct different experimental designs and innovations, and stimulate creativity and innovative thinking.
[0082] Experimental Exploration: The equipment supports a variety of experimental schemes, and students can explore different processes and methods to cultivate their spirit of exploration and scientific research ability.
[0083] The above contents are further detailed descriptions of the present invention in combination with specific preferred embodiments, and it cannot be determined that the specific implementation of the present invention is limited to these descriptions. For ordinary technicians in the technical field to which the present invention belongs, several simple deductions or substitutions can be made without departing from the concept of the present invention, which should be regarded as falling within the protection scope of the present invention.
Claims
1. An automated winding training system, characterized in that: include: The automatic feeding unit, including the unwinding end and the rewinding end, automatically loads and delivers the paper tape to simulate the actual winding operation; The winding drive unit drives the conveying of the paper tape and adjusts and controls the conveying speed of the paper tape; Guide unit, which adjusts and controls the angle of paper tape conveyance; Real-time monitoring unit, real-time monitoring of key parameters in the winding process, including tension value, paper tape offset value, color mark position value; The tension control unit uses a control algorithm to calculate the tension value of the winding process based on the monitored tension value, and controls the tension of the paper tape according to the tension value; The coil diameter calculation unit combines the paper tape conveying speed and tension value, dynamically adjusts the winding parameters through data analysis and optimization algorithms, and calculates the coil diameter in real time; Intelligent control unit, based on PLC and computer, automatically controls the entire winding process.
2. The automated winding training system according to claim 1, characterized in that: The automatic feeding unit includes an unwinding roller, a winding roller, an unwinding and winding frequency converter, and an unwinding and winding motor. The unwinding roller is connected to the unwinding and winding motor through the unwinding and winding frequency converter to form an unwinding end, and the winding roller is connected to the unwinding and winding motor through the unwinding and winding frequency converter to form a winding end. The two ends of the paper tape are respectively wound on the unwinding roller and the winding roller, and the computer controls the unwinding and winding motor through PLC.
3. The automated winding training system according to claim 1, characterized in that: The winding drive unit includes a traction wheel, a traction roller, and a traction motor. The traction wheel and the traction roller are closely connected, and the paper tape passes between the traction wheel and the traction roller. The traction motor is connected to and drives the traction wheel, and the computer controls the traction motor through PLC.
4. The automated winding training system according to claim 1, characterized in that: The tension control unit includes a tension adjustment roller, a swing rod, and a swing rod motor. The paper tape is wound on the tension adjustment roller. One end of the swing rod is connected to the tension adjustment roller, and the other end of the swing rod is connected to the swing rod motor. The computer controls the swing rod motor through a PLC.
5. The automated winding training system according to claim 4, characterized in that: The real-time monitoring unit includes an angle sensor, and the tension control unit also includes a proportional valve. The angle sensor is arranged on the rocker arm. The angle sensor sends an analog quantity to the PLC. The PLC performs PID control of the proportional valve according to the analog quantity and the set tension value to adjust the angle of the rocker arm through the rocker arm motor.
6. The automated winding training system according to claim 4, characterized in that: In the tension control unit, the process of calculating the tension value of the winding process by using a control algorithm includes: a1. Use PID control in the initial stage: When the system is started or the parameters are initially uncertain, use the PID controller for tension control; a2. Data collection and model training: During the PID control process, the system operation data, including input, output and control signals, is collected. By generating simulated data or using the actual collected data, the error, integral, differential values and the corresponding optimal PID parameters are obtained. The data is divided into a training set and a test set. The optimal parameters are obtained based on the training set data and input into the machine learning model for training. a3. Model optimization and adjustment: The trained machine learning model is used to optimize the parameters of the PID controller. According to the system response, the three parameters of the PID controller are calculated and determined: proportional (P), integral (I), and differential (D); a4. Online switching and adaptive control: During system operation, dynamically adjust the parameters of the PID controller according to the results predicted by the machine learning model, or switch to the machine learning model for control.
7. The automated winding training system according to claim 1, characterized in that: The real-time monitoring unit also includes a color mark sensor, which is connected to the PLC. The color mark sensor collects Boolean signals of the paper tape linear speed timing, and captures the color mark before cutting the material each time and uses it as a reference to determine the cutting position.
8. The automated winding training system according to claim 1, characterized in that: The guide unit also includes a deflection corrector and a deflection corrector sensor. The deflection corrector is connected to the PLC, and the deflection corrector sensor is connected to the computer and feeds back the offset direction and offset amount of the paper tape. The computer controls the deflection corrector through the PLC to adjust the position of the paper tape according to the offset direction and offset amount.
9. The automated winding training system according to claim 1, characterized in that: In the coil diameter calculation unit, the specific process of dynamically adjusting the winding parameters and calculating the coil diameter in real time by combining the paper tape conveying speed and tension value through data analysis and optimization algorithm includes: b1. Data collection: Sensor data: Real-time monitoring units collect data on key parameters of the winding process, including tension value and speed; Historical data: Analyze historical operating data to understand the impact of different parameters on winding quality; b2. Data analysis: Preprocessing: Clean and normalize the collected data to remove noise and outliers; Feature extraction: Extract key features from the data, including winding tension changes and speed fluctuations; b3. Optimization algorithm: Modeling: Establish physical models and data-driven models to obtain the relationship between the change of coil diameter over time and winding parameters; Optimization method: Use gradient descent method to find the optimal winding parameter settings to achieve the goals of minimizing tension fluctuations and maximizing production efficiency; b4. Real-time adjustment: Control system: Design a closed-loop control system to adjust winding parameters including tension and speed in real time based on the current winding diameter and expected goals; Prediction model: Use machine learning models to predict future changes in roll diameter and adjust parameters in advance; b5. Real-time coil diameter calculation: Algorithm design: Through real-time calculation algorithm, the current coil diameter is dynamically calculated based on the properties of the winding material and the current operating parameters; Feedback mechanism: Combine real-time data and prediction model results to adjust control strategies to ensure that the roll diameter is within the expected range.
10. The automated winding training system according to claim 1, characterized in that: It also includes a cutting adjustment unit, which includes a transverse swing arm and a swing arm motor. The transverse swing arm is connected to the roller of the cutting station, and the swing arm motor is connected to and drives the transverse swing arm. The computer controls the swing arm motor through PLC, and the swing speed of the transverse swing arm is synchronized with the speed of the winding drive unit.