An electrical calculation and design system for cable process parameters

Abstract

The present invention discloses an electrical calculation design system for cable process parameters, which specifically relates to the field of electrical calculation technology, including modeling based on a complete set of process compilation and cable process calculation, building a process database, generating a temporary process compilation according to the specific needs of the cable process, taking the smallest component constituting the temporary process compilation as the basic unit of the process, determining the basic units of specific needs and non-specific needs in the temporary process compilation, collecting matching information and similarity information of the basic units in the temporary process compilation, building a temporary process compilation evaluation model, generating a derived process compilation, and determining a cable sample based on the derived process compilation, determining the electrical information and appearance information of the cable sample, building a cable evaluation model, and obtaining the optimal recommended process compilation. The present invention helps to quickly generate and screen the cable process compilation that meets customer needs, reduce manual intervention and cumbersome design processes, and accelerate the customized production of products.

Description

Technical Field

[0001] The present invention relates to the field of electrical calculation technology, and more specifically, to a cable process parameter electrical calculation design system. Background Art

[0002] Traditional process compilation methods lack intelligent support and cannot quickly and accurately generate personalized processes based on specific customer needs. In addition, the lack of real-time feedback and evaluation mechanism for process parameters leads to deviations and inconsistencies in the production process, which may affect the electrical performance and appearance quality of cable products. With the diversification of customer needs and the increasing demand for personalized product customization, existing process compilation systems mostly rely on manual intervention or fixed templates. They cannot quickly generate personalized process compilation based on specific customer needs (such as cable specifications, standard procedures and material types), and it is not easy to automatically optimize or recommend the most suitable process compilation plan based on test results, thereby affecting the decision-making efficiency and effectiveness in the production process.

[0003] In order to solve the above defects, a technical solution is now provided. Summary of the invention

[0004] In order to overcome the above-mentioned defects of the prior art, an embodiment of the present invention provides a cable process parameter electrical calculation design system to solve the problems raised in the above-mentioned background technology.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] A cable process parameter electrical calculation and design system, specifically comprising a temporary process compilation module, a data acquisition module, a derived process compilation module and a process compilation recommendation module, and signal connections between the modules;

[0007] The temporary process preparation module is used to determine the complete process preparation according to the cable specifications, standard procedures, and material types, and to build a process database based on the complete process preparation modeling and cable process calculation, and to generate temporary process preparation according to the specific needs of the cable process;

[0008] The data collection module is used to determine the basic units with specific requirements and non-specific requirements in the temporary process compilation according to the generated temporary process compilation, and collect matching information and similar information of the basic units in the temporary process compilation;

[0009] The derived process compilation module is used to comprehensively analyze the matching information and similar information of the basic units in the temporary process compilation, build a temporary process compilation evaluation model, generate derived process compilation, and determine the cable samples based on the derived process compilation, perform segmented testing on the cable samples, and determine the electrical information and appearance information of the cable samples;

[0010] The process preparation recommendation module is used to combine and analyze the electrical information and appearance information of cable samples, build a cable evaluation model, and obtain the optimal recommended process preparation;

[0011] Among them, the process database is constructed to generate temporary process preparation according to the specific needs of the cable process, including;

[0012] Determine the specific needs, including personalized materials and process parameters. Match the existing processes in the process database based on the specific needs. If the specific needs exist in the process database, automatically select the existing processes in the process database for production. If the specific needs do not exist in the process database, generate a temporary process compilation based on the specific needs.

[0013] In response to product model and specification requirements, the system will prioritize matching existing built-in process compilations in the process database based on model specifications. If there is no matching process in the database, the system will directly create a new temporary process compilation.

[0014] In a preferred embodiment, the matching information of the basic unit in the temporary process preparation is collected, including;

[0015] The matching information of basic units in the temporary process preparation is expressed by combining mature safety factors;

[0016] The logic for obtaining the combined mature safety factor is as follows: obtaining the basic units with specific requirements and non-specific requirements for temporary process preparation, determining the number of times the basic units with non-specific requirements are used in the process database, and marking the number of times the basic units with non-specific requirements are used in the process database as follows: , where n=1, 2, 3, ..., N, N is a positive integer, and n is the number of the basic unit of non-specific requirements compiled by the temporary process;

[0017] The number of times the same basic unit with no specific requirements is used in the process database is obtained, and the number of times the same basic unit with no specific requirements is used in the process database is marked as: ;

[0018] Calculate the proficiency coefficient of the basic unit without specific requirements in the temporary process preparation. The calculation formula is: ; Among them, SLD is the proficiency coefficient of the basic unit with non-specific requirements in the temporary process compilation;

[0019] Determine the number of times that the basic unit with no specific requirements in the process database and the basic unit with specific requirements for temporary process preparation are used simultaneously, and mark the number of times that the basic unit with no specific requirements in the process database and the basic unit with specific requirements for temporary process preparation are used simultaneously as: ;

[0020] Obtain the usage counts of the basic units with specific requirements for temporary process preparation and the same basic units with no specific requirements in the process database, and mark the usage counts of the basic units with specific requirements for temporary process preparation and the same basic units with no specific requirements in the process database as: ;

[0021] Calculate the credibility coefficient of the basic unit without specific requirements in the temporary process preparation, and the calculation formula is: ; Among them, KXD is the credibility coefficient of the basic unit of non-specific requirements in the temporary process compilation;

[0022] Calculate the combined mature safety factor using the following formula: ;in, is the combined mature safety factor.

[0023] In a preferred embodiment, similar information of the basic unit in the temporary process compilation includes:

[0024] The similarity information of the basic units in the temporary process compilation is expressed by the difference similarity performance coefficient;

[0025] The logic for obtaining the difference similarity performance coefficient is: encode the temporary process compilation, generate a coding set of the temporary process compilation, and mark the coding set of the temporary process compilation as: , where I is a positive integer, i is the number of the basic unit in the temporary process compilation, Basic units compiled for temporary processes;

[0026] Obtain the code set of each existing process compilation in the process database, and mark the code set of each existing process compilation in the process database as: , where m=1, 2, 3, ..., M, M is a positive integer, and m is the number of the existing process compilation. Basic units compiled for each existing process;

[0027] By using Jaccard similarity, the difference performance coefficient is calculated, and the calculation formula is: ;in, is the difference similarity performance coefficient.

[0028] In a preferred embodiment, constructing a temporary process compilation assessment model includes:

[0029] Through comprehensive analysis of the matching information and similar information of the basic units in the temporary process preparation, the combined mature safety factor and the difference similarity performance coefficient are weighted analyzed to build a temporary process preparation evaluation model and generate the temporary process preparation evaluation coefficient. The calculation formula of the temporary process preparation evaluation coefficient is: ;in, Preparation of evaluation coefficients for temporary processes, , is the ratio coefficient of the combination of mature safety factor and difference similarity performance coefficient, , Both are greater than 0.

[0030] In a preferred embodiment, generating a derived process compilation includes:

[0031] Set a threshold value for the evaluation coefficient of temporary process compilation, and compare the evaluation coefficients of all generated temporary process compilations with the threshold value for the evaluation coefficient of temporary process compilation;

[0032] If the temporary process preparation evaluation coefficient of the temporary process preparation is greater than the temporary process preparation evaluation coefficient threshold, the temporary process preparation is marked as a derived process preparation;

[0033] If the temporary process preparation evaluation coefficient of the temporary process preparation is less than the temporary process preparation evaluation coefficient threshold, the temporary process preparation is marked as pending process preparation.

[0034] In a preferred embodiment, determining the electrical information of the cable sample comprises:

[0035] The electrical information of the cable sample is expressed by the insulation abnormal floating coefficient and the resistance average abnormal coefficient;

[0036] The logic for obtaining the insulation abnormal floating coefficient is: determine the nominal insulation thickness of the cable, and mark the nominal insulation thickness of the cable as: , obtain the cable sample compiled by the post-production derived process, divide the cable into sections evenly, obtain the thinnest insulation point of each section of the cable sample, and mark the thinnest insulation point of each section of the cable sample as: , where k=1, 2, 3, ..., K, K is a positive integer, and k is the number of each cable segment after the cable is evenly segmented;

[0037] Compare the thinnest insulation point of each section of the cable sample with the nominal insulation thickness of the cable, select the cable sample sections whose thinnest insulation point is greater than the nominal insulation thickness, and re-mark the thinnest insulation point of the cable sample section with the nominal insulation thickness as: , where j = 1, 2, 3, ..., J, J is a positive integer, and j is the number of the cable sample section that is greater than the nominal insulation thickness;

[0038] Calculate the insulation abnormal floating coefficient, the calculation formula is: ;in, It is the insulation abnormal floating coefficient.

[0039] In a preferred embodiment, the average abnormal coefficient of resistance includes

[0040] The logic for obtaining the average abnormal coefficient of resistance is: determine the standard conductor resistance range of the cable, and mark the standard conductor resistance range of the cable as: , obtain the average conductor resistance of each section of the cable sample, and mark the average conductor resistance of each section of the cable sample as: ,in, , where q=1, 3, 4, ..., Q, Q is a positive integer, and q is the number of the sampling point on each cable sample. is the resistance of the qth sampling point of the kth cable segment;

[0041] Calculate the difference between the standard conductor resistance range of the cable and the average conductor resistance of each section of the cable sample to obtain the average resistance anomaly coefficient. The calculation formula is: ;in, is the average abnormal coefficient of resistance.

[0042] In a preferred embodiment, determining the appearance information of the cable sample includes:

[0043] The appearance information of the cable sample is expressed by the outer diameter test fluctuation coefficient;

[0044] The logic for obtaining the outer diameter test fluctuation coefficient is: obtaining the average section diameter ratio of each section of the cable sample, and marking the average section diameter ratio of each section of the cable sample as: ,in, , is the pitch diameter ratio of the qth sampling point of the kth cable segment;

[0045] Calculate the average value and standard deviation of the average section diameter ratio of each section of the cable sample, and mark the average value and standard deviation of the average section diameter ratio of each section of the cable sample as: and ,in, , ;

[0046] Calculate the coefficient of variation of the average pitch diameter ratio of each section of the cable sample using the following formula: ;in, is the coefficient of variation of the average pitch diameter ratio of each section of the cable sample;

[0047] Calculate the outer diameter test fluctuation coefficient, the calculation formula is: ;in, The coefficient of fluctuation for outer diameter test.

[0048] In a preferred embodiment, constructing a cable evaluation model includes:

[0049] Through the electrical information and appearance information of the cable sample, the insulation abnormal floating coefficient, the average resistance abnormal coefficient and the outer diameter test fluctuation coefficient are weighted and calculated to build a cable evaluation model and generate a cable evaluation coefficient. The calculation formula of the cable evaluation coefficient is: ;in, is the cable evaluation factor, , , They are the proportional coefficients of insulation abnormality floating coefficient, resistance average abnormality coefficient, and outer diameter test fluctuation coefficient. , , They are both greater than 0;

[0050] A cable evaluation coefficient threshold is set, and the cable evaluation coefficients of the cable samples obtained from all derived process preparations are compared with the cable evaluation coefficient threshold to obtain derived process preparations that are greater than the cable evaluation coefficient threshold. The cable evaluation coefficients of the derived process preparations that are greater than the cable evaluation coefficient threshold are sorted from large to small to obtain the derived process preparation with the top sorting as the optimal recommended process preparation. If the cable evaluation coefficient of the cable sample is less than the cable evaluation coefficient threshold, a warning signal is generated.

[0051] Technical effects and advantages of the present invention:

[0052] The present invention builds a complete process database, generates personalized temporary process compilations for cables based on specific customer needs, and screens process compilations that are more in line with actual usage. Through further testing of the process compilations, the cable process compilation that ultimately meets the specific needs and performs better is determined. The present invention helps to quickly generate and screen cable process compilations that meet customer needs, reduce manual intervention and cumbersome design processes, and accelerate customized production of products. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] In order to facilitate understanding by those skilled in the art, the present invention is further described below in conjunction with the accompanying drawings;

[0054] Figure 1 The present invention is a schematic diagram of the structure of a cable process parameter electrical calculation design system. DETAILED DESCRIPTION

[0055] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention. Example 1

[0056] like Figure 1 A schematic diagram of the structure of a cable process parameter electrical calculation design system of the present invention is given, which specifically includes a temporary process compilation module, a data acquisition module, a derived process compilation module and a process compilation recommendation module, and the signal connections between the modules;

[0057] The temporary process preparation module is used to determine the complete process preparation according to the cable specifications, standard procedures, and material types, and to build a process database based on the complete process preparation modeling and cable process calculation, and to generate temporary process preparation according to the specific needs of the cable process;

[0058] The data collection module is used to determine the basic units with specific requirements and non-specific requirements in the temporary process compilation according to the generated temporary process compilation, and collect matching information and similar information of the basic units in the temporary process compilation;

[0059] The derived process compilation module is used to comprehensively analyze the matching information and similar information of the basic units in the temporary process compilation, build a temporary process compilation evaluation model, generate derived process compilation, and determine the cable samples based on the derived process compilation, perform segmented testing on the cable samples, and determine the electrical information and appearance information of the cable samples;

[0060] The process preparation recommendation module is used to combine and analyze the electrical information and appearance information of cable samples, build a cable evaluation model, and obtain the optimal recommended process preparation.

[0061] A cable process parameter electrical calculation and design system connects the production processes of various cables in series with materials, process parameters, algorithms, and standard procedures. It has built-in various execution standards and keeps them updated continuously, supports the adjustment of customized production processes, and finally calculates and outputs process data of complete sets of wire and cable structures and customized structures that meet various standards in the system.

[0062] Based on the calculated structural process data, the automatic derivation of finished product and semi-finished product material codes, BOM and process routes are completed according to the structural model of wires and cables and the material coding rules, greatly improving work efficiency.

[0063] For different types of cables, there are built-in production processes applicable to various execution standards, including the processing steps of the standard process, the input materials and output products, and the calculation methods of various parameters under each standard process. By selecting the cable model, voltage level, corresponding implementation standard and the built-in production process of the system, the calculation of the structural process of the included model specifications can be completed.

[0064] The modeling of complete process compilation is to model various processes, materials, calculation rules, equipment requirements, etc. involved in the entire production process in a systematic and modular way to support automated production design, process optimization and dynamic adjustment, including determining the core information of the cable, such as specification parameters, implementation standards and functional types, defining all the processes required for product production, such as the order of each processing step, equipment requirements, etc., the material types and characteristics involved in each process link, such as raw materials (copper conductors, insulating materials, sheath materials, etc.), attribute information (physical and chemical properties such as specific gravity, conductivity, tensile strength, etc.), specification selection (material parameter ranges of different specifications and models), etc., combining processes and materials, establishing various formulas and rules, such as size calculation, weight calculation and performance calculation, etc., defining the association and constraints between data, such as the matching rules between materials and processes, parameter range restrictions (the minimum insulation thickness cannot be lower than the standard requirements, etc.), and the limitations of product performance by implementation standards.

[0065] Cable process calculation is a calculation method used to design, evaluate and optimize the process during the cable production process. It covers multiple aspects such as cable structure design, material usage, performance indicators, weight and cost. It is based on cable specifications, production process, material characteristics and industry standards. It includes determining the size and parameters of each layer of the cable structure, such as conductor design, insulation thickness calculation, sheath thickness calculation, etc., estimating the amount of materials required for production, controlling costs, such as conductor weight, insulation material weight, sheath material weight, etc., ensuring that the cable meets electrical requirements, such as resistance calculation, voltage resistance, voltage drop, etc. By building in a large number of process parameters used in the cable industry, combined with industry data such as process procedures and cable materials, it provides applicable rules for process parameters, process procedures and cable materials, and quickly completes the generation of process parameters.

[0066] Based on the complete set of process modeling and cable process calculation, a process database is constructed. The functions of the process database include:

[0067] Through the meticulous management of production process versions, the process of process optimization and adjustment can be recorded and traced to ensure that the process always meets the production needs of the enterprise and improves production efficiency;

[0068] Supports calculation of complete process data and temporary process data for different orders and product requirements, and flexibly responds to market changes, customer needs and special production tasks. For example, the system has built-in standard complete process templates, which are suitable for common cable models and specifications. These templates cover all necessary process steps and parameters, such as material selection, processing steps, equipment requirements, etc. According to the input cable specifications and production requirements, the system automatically calculates the corresponding complete process data, including the required materials, processing time, equipment requirements, etc. for each process;

[0069] By collecting, managing and analyzing all production process data and establishing a big data center, we can help companies achieve data-driven decision-making and refined management. For example, all process-related historical data, current version data, temporary order data, etc. are gathered in the data center to form a unified database. During the production process, various process data are collected in real time, including equipment operating parameters, material usage, processing time, etc.

[0070] In the case of customized production, special orders or customer-specific needs, the specific needs are determined, including personalized materials, process parameters, etc. Based on the specific needs, they are matched with the existing processes in the process database. If the specific needs exist in the process database, the existing processes in the process database are automatically selected for production. If the specific needs do not exist in the process database, a temporary process compilation is generated based on the specific needs.

[0071] Among them, in order to efficiently find and match existing processes in the process database, it is necessary to uniformly encode the process parameters and convert complex process information (such as material specifications, process flow, equipment requirements, etc.) into a unified code for easy computer recognition and processing. The coding can quickly locate the corresponding process records in the process database. That is, if all the parameter codes required by the customer can match the records in the process database, the corresponding process is directly selected. If some of the parameter codes required by the customer match, but there are no corresponding records for other parameters, the unmatched parts need to be supplemented.

[0072] It should be noted that specific parameters can be specified through the system input interface according to product model and specification requirements, and the existing built-in process compilation in the process database will be matched first according to the model specifications. If there is no matching process in the database, the system supports the direct creation of a new temporary process compilation. The system allows users to make adjustments to the existing process based on the customer's personalized needs, such as supporting process adjustments, including adjusting colors, inserting standard processes, deleting standard processes, adjusting input materials, modifying parameter calculation formulas, etc., and for special needs, the system supports creating a new process plan from scratch.

[0073] According to the generated temporary process preparation, the smallest component that constitutes the temporary process preparation is taken as the basic unit of the process, the basic units of specific requirements and non-specific requirements in the temporary process preparation are determined, the matching information and similarity information of the basic units in the temporary process preparation are collected, the matching information of the basic units in the temporary process preparation is represented by a combined mature safety factor, and the similarity information of the basic units in the temporary process preparation is represented by a difference similarity performance coefficient.

[0074] It should be noted that a new process compilation is generated by replacing, adjusting or combining the minimum basic units. The minimum basic units include material units, process units, parameter units and configuration units. The basic units of specific needs and non-specific needs are the core components for building temporary process compilation. The basic units of specific needs refer to clear customer requirements with quantitative or qualitative descriptions. The basic units of non-specific needs are parameters or requirements that are not clearly defined and are part of the process compilation.

[0075] The logic for obtaining the combined mature safety factor is as follows: obtaining the basic units with specific requirements and non-specific requirements for temporary process preparation, determining the number of times the basic units with non-specific requirements are used in the process database, and marking the number of times the basic units with non-specific requirements are used in the process database as follows: , where n=1, 2, 3, ..., N, N is a positive integer, and n is the number of the basic unit of non-specific requirements compiled by the temporary process;

[0076] The number of times the same basic unit with no specific requirements is used in the process database is obtained, and the number of times the same basic unit with no specific requirements is used in the process database is marked as: ;

[0077] It should be noted that similar basic units with non-specific requirements refer to the parts in the process preparation that involve flexible, adjustable, or not completely fixed requirements. A basic unit may contain multiple options. For example, the type of material for cable packaging. A process preparation is composed of multiple similar basic units, and the same basic units contain multiple basic units to choose from.

[0078] Calculate the proficiency coefficient of the basic unit without specific requirements in the temporary process preparation. The calculation formula is: ; Among them, SLD is the proficiency coefficient of the basic unit with non-specific requirements in the temporary process compilation;

[0079] It should be noted that the higher the proficiency coefficient is, the more times the non-specific demand basic units in temporary process preparation are used in other existing process preparations, which means that the technology is more mature and this type of basic units should be given priority.

[0080] Determine the number of times that the basic unit with no specific requirements in the process database and the basic unit with specific requirements for temporary process preparation are used simultaneously, and mark the number of times that the basic unit with no specific requirements in the process database and the basic unit with specific requirements for temporary process preparation are used simultaneously as: ;

[0081] It should be noted that the simultaneous use of basic units of non-specific requirements and basic units of specific requirements for temporary process preparation in the process database indicates that the basic units of non-specific requirements and specific requirements are used in combination in the historical process preparation records. Therefore, the more times the basic units of non-specific requirements and basic units of specific requirements for temporary process preparation are used simultaneously in the process database, the higher the credibility of the basic units of non-specific requirements and the more likely it is that the basic units will be used.

[0082] Obtain the usage counts of the basic units with specific requirements for temporary process preparation and the same basic units with no specific requirements in the process database, and mark the usage counts of the basic units with specific requirements for temporary process preparation and the same basic units with no specific requirements in the process database as: ;

[0083] Calculate the credibility coefficient of the basic unit without specific requirements in the temporary process preparation, and the calculation formula is: ; Among them, KXD is the credibility coefficient of the basic unit of non-specific requirements in the temporary process compilation;

[0084] It should be noted that the higher the credibility coefficient, the higher the proportion of the number of times the non-specific demand basic units and specific demand basic units are used in the historical usage records in the temporary process preparation.

[0085] Calculate the combined mature safety factor using the following formula: ;in, is the combined mature safety factor.

[0086] It can be seen from the formula that the higher the combination maturity safety factor, the better the combination of temporary process preparation, and it is more likely to be used as the actual process preparation for production.

[0087] The logic for obtaining the difference similarity performance coefficient is: encode the temporary process compilation, generate a coding set of the temporary process compilation, and mark the coding set of the temporary process compilation as: , where I is a positive integer, i is the number of the basic unit in the temporary process compilation, Basic units compiled for temporary processes;

[0088] Obtain the code set of each existing process compilation in the process database, and mark the code set of each existing process compilation in the process database as: , where m=1, 2, 3, ..., M, M is a positive integer, and m is the number of the existing process compilation. Basic units compiled for each existing process;

[0089] By using Jaccard similarity, the difference performance coefficient is calculated, and the calculation formula is: ;in, is the difference similarity performance coefficient.

[0090] It can be seen from the formula that the larger the difference similarity performance coefficient, the closer or more consistent the temporary process compilation is with the existing process compilation in the process database, indicating that the degree of overlap between the process compilation requirements and the company's existing process resources is large, which may be more in line with production reality and experience accumulation, reducing the risk of trial and error.

[0091] Through comprehensive analysis of the matching information and similar information of the basic units in the temporary process preparation, the combined mature safety factor and the difference similarity performance coefficient are weighted analyzed to build a temporary process preparation evaluation model and generate the temporary process preparation evaluation coefficient. The calculation formula of the temporary process preparation evaluation coefficient is: ;in, Preparation of evaluation coefficients for temporary processes, , is the ratio coefficient of the combination of mature safety factor and difference similarity performance coefficient, , Both are greater than 0.

[0092] It can be seen from the formula that the larger the combined mature safety factor and the difference similarity performance coefficient, the larger the temporary process preparation evaluation coefficient, which means that the temporary process preparation may be more in line with production practice and accumulated experience; conversely, the smaller the combined mature safety factor and the difference similarity performance coefficient, the smaller the temporary process preparation evaluation coefficient, which means that the temporary process preparation may be less in line with production practice and accumulated experience.

[0093] Set a threshold for the assessment coefficient of temporary process preparation, and compare the assessment coefficients of all generated temporary process preparations with the threshold for the assessment coefficient of temporary process preparation. If the assessment coefficient of a temporary process preparation is greater than the threshold for the assessment coefficient of temporary process preparation, the temporary process preparation will be marked as a derived process preparation, indicating that the temporary process preparation is preliminarily recognized as being able to be used, but specific inspection is still required. If the assessment coefficient of a temporary process preparation is less than the threshold for the assessment coefficient of temporary process preparation, the temporary process preparation will be marked as a pending process preparation, indicating that the temporary process preparation may not be able to be used, and the staff needs to actually generate it through trial and error to determine whether the pending process preparation can be used.

[0094] According to the obtained derived process preparation, inspection is carried out according to the cable inspection standard. First, the theoretical simulation values ​​of each process parameter in the derived process preparation are obtained through cable process calculation. Then, each process parameter in the derived process preparation is actually produced to obtain cable samples obtained from the derived process preparation after production. The cable samples are tested in sections to determine the electrical information and appearance information of the cable samples. The electrical information of the cable samples is represented by the insulation abnormal floating coefficient and the resistance average abnormal coefficient. The appearance information of the cable samples is represented by the outer diameter test fluctuation coefficient.

[0095] By measuring the electrical information and appearance information of the cable samples obtained by the derived process, it is tested whether the cable samples obtained by the derived process do not meet the standards. The specific test parameters include the thinnest point of insulation, conductor resistance and pitch ratio;

[0096] Derived process compilation is a new process that is personalized or adjusted based on the existing process, which may involve different materials, process parameters or equipment settings. By detecting the thinnest point of insulation, it can be ensured that the insulation performance of the product after the derived process is implemented meets the requirements;

[0097] The detection of the thinnest point of insulation helps to find the impact of process changes on product quality, especially when adjusting process parameters such as materials, temperature, pressure, etc., to ensure that the thickness of the insulation layer of the final product is not unqualified;

[0098] Conductor resistance is a key parameter to measure the electrical conductivity of the cable, which is directly related to the transmission capacity and energy efficiency of the cable. If the conductor resistance is too large, the power transmission efficiency of the cable will be reduced, and it may cause overheating, increased losses, and even electrical failures;

[0099] During the process of developing the derived process, adjustments may be made to the conductor material, manufacturing process, processing, etc. Conductor resistance detection can verify whether these adjustments affect the electrical performance of the cable. By detecting the resistance value, it can be ensured that the new process does not lead to unqualified electrical properties;

[0100] Conductor materials (such as copper, aluminum, etc.) have a direct impact on the resistance of the cable. The purity of the material, processing technology, etc. will affect its resistance value. Testing the conductor resistance helps to evaluate whether the quality of the material and the processing process meet the design requirements;

[0101] If the derivative process involves new conductor materials or different material combinations, testing the conductor resistance can ensure that the material selection and processing quality meet the standard requirements and avoid high resistance problems caused by low-quality materials;

[0102] The pitch ratio is the ratio of the cross-sectional shape of a single conductor in a cable conductor to its length, and is often used to describe the structural characteristics of cable conductors. The pitch ratio has an important influence on the mechanical properties of the cable, such as tensile strength and wear resistance;

[0103] Testing the pitch-to-diameter ratio of cable samples produced by the derivative process can ensure that the new process does not affect the mechanical strength of the conductor while maintaining electrical performance. If the pitch-to-diameter ratio is too large or too small, it may cause the cable conductor to break or be damaged under conditions of use such as stretching and bending, reducing the reliability of the cable.

[0104] The logic for obtaining the insulation abnormal floating coefficient is: determine the nominal insulation thickness of the cable, and mark the nominal insulation thickness of the cable as: , obtain the cable sample compiled by the post-production derived process, divide the cable into sections evenly, obtain the thinnest insulation point of each section of the cable sample, and mark the thinnest insulation point of each section of the cable sample as: , where k=1, 2, 3, ..., K, K is a positive integer, and k is the number of each cable segment after the cable is evenly segmented;

[0105] It should be noted that the nominal insulation thickness of the cable is set by professional staff and is usually determined according to industry standards or international standards. Cable average segmentation refers to dividing the cable into several uniform small segments according to certain standards, intervals or parameters, and conducting segment-by-segment inspection, analysis or control.

[0106] Compare the thinnest insulation point of each section of the cable sample with the nominal insulation thickness of the cable, select the cable sample sections whose thinnest insulation point is greater than the nominal insulation thickness, and re-mark the thinnest insulation point of the cable sample section with the nominal insulation thickness as: , where j = 1, 2, 3, ..., J, J is a positive integer, and j is the number of the cable sample section that is greater than the nominal insulation thickness;

[0107] Calculate the insulation abnormal floating coefficient, the calculation formula is: ;in, It is the insulation abnormal floating coefficient.

[0108] It can be seen from the formula that the larger the insulation abnormal floating coefficient is, the more cable segments there are with insulation thickness greater than the nominal thickness after the cable sample is segmented, and the larger the value of the insulation nominal thickness that may be exceeded is, indicating that the cable sample compiled by the derived process performs poorly.

[0109] The logic for obtaining the average abnormal coefficient of resistance is: determine the standard conductor resistance range of the cable, and mark the standard conductor resistance range of the cable as: , obtain the average conductor resistance of each section of the cable sample, and mark the average conductor resistance of each section of the cable sample as: ,in, , where q=1, 3, 4, ..., Q, Q is a positive integer, and q is the number of the sampling point on each cable sample. is the resistance of the qth sampling point of the kth cable segment;

[0110] It should be noted that the sampling points are usually selected based on the physical properties of the cable and the test requirements, and are set by professional staff to ensure that they can represent the overall resistance characteristics of the cable. By measuring at multiple sampling points, sufficient resistance data can be obtained to obtain the average conductor resistance value of the cable section.

[0111] Calculate the difference between the standard conductor resistance range of the cable and the average conductor resistance of each section of the cable sample to obtain the average resistance anomaly coefficient. The calculation formula is: ;in, is the average abnormal coefficient of resistance.

[0112] It can be seen from the formula that the larger the average resistance abnormality coefficient is, the greater the difference in resistance values ​​of different sections may be due to uneven materials, inconsistent processes or improper operations during the cable production process, indicating that the cable samples compiled by the derived process perform poorly.

[0113] The logic for obtaining the outer diameter test fluctuation coefficient is: obtaining the average section diameter ratio of each section of the cable sample, and marking the average section diameter ratio of each section of the cable sample as: ,in, , is the pitch diameter ratio of the qth sampling point of the kth cable segment;

[0114] It should be noted that the pitch ratio of the cable is the ratio of the conductor to the insulation layer in the cable. It represents the proportional relationship between the diameter of the cable conductor and the total outer diameter of the cable (including the conductor and the insulation layer). This ratio is usually used to measure the compactness of the cable structure and the electrical performance of the cable.

[0115] Calculate the average value and standard deviation of the average section diameter ratio of each section of the cable sample, and mark the average value and standard deviation of the average section diameter ratio of each section of the cable sample as: and ,in, , ;

[0116] Calculate the coefficient of variation of the average pitch diameter ratio of each section of the cable sample using the following formula: ;in, is the coefficient of variation of the average pitch diameter ratio of each section of the cable sample;

[0117] Calculate the outer diameter test fluctuation coefficient, the calculation formula is: ;in, The coefficient of fluctuation for outer diameter test.

[0118] It can be seen from the formula that the larger the outer diameter test fluctuation coefficient is, the greater the fluctuation or unevenness of the ratio between the conductor diameter and the total outer diameter of the cable is during the production process, indicating that the cable sample obtained by the derived process performs poorly.

[0119] Through the electrical information and appearance information of the cable sample, the insulation abnormal floating coefficient, the average resistance abnormal coefficient and the outer diameter test fluctuation coefficient are weighted and calculated to build a cable evaluation model and generate a cable evaluation coefficient. The calculation formula of the cable evaluation coefficient is: ;in, is the cable evaluation factor, , , They are the proportional coefficients of insulation abnormality floating coefficient, resistance average abnormality coefficient, and outer diameter test fluctuation coefficient. , , Both are greater than 0.

[0120] It can be seen from the formula that the larger the insulation abnormal floating coefficient, the average resistance abnormal coefficient and the outer diameter test fluctuation coefficient, the larger the cable evaluation coefficient, which means that the cable sample obtained by the derived process performs poorly and is less likely to be used as a qualified production standard. Conversely, the smaller the insulation abnormal floating coefficient, the average resistance abnormal coefficient and the outer diameter test fluctuation coefficient, the smaller the cable evaluation coefficient, which means that the cable sample obtained by the derived process performs better and is more likely to be used as a qualified production standard.

[0121] A cable evaluation coefficient threshold is set, and the cable evaluation coefficients of the cable samples obtained from all derived process preparations are compared with the cable evaluation coefficient threshold to obtain a derived process preparation that is greater than the cable evaluation coefficient threshold. The cable evaluation coefficients of the derived process preparations that are greater than the cable evaluation coefficient threshold are sorted from large to small to obtain the derived process preparation with the top sorting as the optimal recommended process preparation. If the cable evaluation coefficient of the cable sample is less than the cable evaluation coefficient threshold, a warning signal is generated to mark the basic unit combination in the derived process preparation to avoid reusing the same combination in the next generated temporary process preparation, thereby reducing the system calculation burden.

[0122] The present invention builds a complete process database, generates personalized temporary process compilations for cables based on specific customer needs, and screens process compilations that are more in line with actual usage. Through further testing of the process compilations, the cable process compilation that ultimately meets the specific needs and performs better is determined. The present invention helps to quickly generate and screen cable process compilations that meet customer needs, reduce manual intervention and cumbersome design processes, and accelerate customized production of products.

[0123] The above formulas are all dimensionless and numerical calculations. The formula is a formula for the most recent real situation obtained by collecting a large amount of data and performing software simulation. The preset parameters in the formula are set by technicians in this field according to actual conditions.

[0124] The above embodiments can be implemented in whole or in part by software, hardware, firmware or any other combination. When implemented by software, the above embodiments can be implemented in whole or in part in the form of a computer program product. The computer program product includes one or more computer instructions or computer programs. When the computer instructions or computer programs are loaded or executed on a computer, the process or function described in the embodiment of the present application is generated in whole or in part. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions can be stored in a computer-readable storage medium, or transmitted from one computer-readable storage medium to another computer-readable storage medium. For example, the computer instructions can be transmitted from one website site, computer, server or data center to another website site, computer, server or data center by wired or wireless (e.g., infrared, wireless, microwave, etc.). The computer-readable storage medium can be any available medium that a computer can access or a data storage device such as a server or data center that contains one or more available media sets. The available medium can be a magnetic medium (e.g., a floppy disk, a hard disk, a tape), an optical medium (e.g., a DVD), or a semiconductor medium. The semiconductor medium can be a solid-state hard disk.

[0125] It should be understood that in the various embodiments of the present application, the size of the serial numbers of the above-mentioned processes does not mean the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present application.

[0126] Those of ordinary skill in the art will appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professional and technical personnel can use different methods to implement the described functions for each specific application, but such implementation should not be considered to be beyond the scope of this application.

[0127] Those skilled in the art can clearly understand that, for the convenience and brevity of description, the specific working processes of the systems, devices and units described above can refer to the corresponding processes in the aforementioned method embodiments and will not be repeated here.

[0128] In the several embodiments provided in the present application, it should be understood that the disclosed systems, devices and methods can be implemented in other ways. For example, the device embodiments described above are only schematic. For example, the division of the units is only a logical function division. There may be other division methods in actual implementation, such as multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be through some interfaces, indirect coupling or communication connection of devices or units, which can be electrical, mechanical or other forms.

[0129] If the functions are implemented in the form of software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present application can be essentially or partly embodied in the form of a software product that contributes to the prior art. The computer software product is stored in a storage medium and includes several instructions for a computer device (which can be a personal computer, a server, or a network device, etc.) to perform all or part of the steps of the methods described in the various embodiments of the present application. The aforementioned storage media include: various media that can store program codes, such as USB flash drives, mobile hard disks, read-only memories (ROM), random access memories (RAM), magnetic disks or optical disks.

[0130] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art who is familiar with the present technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

Claims

1. A cable process parameter electrical calculation design system, characterized in that: Specifically, it includes temporary process preparation module, data acquisition module, derived process preparation module and process preparation recommendation module, and the signal connections between the modules; The temporary process preparation module is used to determine the complete process preparation according to the cable specifications, standard procedures, and material types, and to build a process database based on the complete process preparation modeling and cable process calculation, and to generate temporary process preparation according to the specific needs of the cable process; The data collection module is used to determine the basic units with specific requirements and non-specific requirements in the temporary process compilation according to the generated temporary process compilation, and collect matching information and similar information of the basic units in the temporary process compilation; The derived process compilation module is used to comprehensively analyze the matching information and similar information of the basic units in the temporary process compilation, build a temporary process compilation evaluation model, generate derived process compilation, and determine the cable samples based on the derived process compilation, perform segmented testing on the cable samples, and determine the electrical information and appearance information of the cable samples; The process preparation recommendation module is used to combine and analyze the electrical information and appearance information of cable samples, build a cable evaluation model, and obtain the optimal recommended process preparation; Among them, the process database is constructed to generate temporary process preparation according to the specific needs of the cable process, including; Determine the specific needs, including personalized materials and process parameters. Match the existing processes in the process database based on the specific needs. If the specific needs exist in the process database, automatically select the existing processes in the process database for production. If the specific needs do not exist in the process database, generate a temporary process compilation based on the specific needs. In response to product model and specification requirements, the system will prioritize matching existing built-in process compilations in the process database based on model specifications. If there is no matching process in the database, the system will directly create a new temporary process compilation.

2. A cable process parameter electrical calculation design system according to claim 1, characterized in that: Collect matching information of basic units in temporary process preparation, including; The matching information of basic units in the temporary process preparation is expressed by combining mature safety factors; The logic for obtaining the combined mature safety factor is as follows: obtaining the basic units with specific requirements and non-specific requirements for temporary process preparation, determining the number of times the basic units with non-specific requirements are used in the process database, and marking the number of times the basic units with non-specific requirements are used in the process database as follows: , where n=1, 2, 3, ..., N, N is a positive integer, and n is the number of the basic unit of non-specific requirements compiled by the temporary process; The number of times the same basic unit with no specific requirements is used in the process database is obtained, and the number of times the same basic unit with no specific requirements is used in the process database is marked as: ; Calculate the proficiency coefficient of the basic unit without specific requirements in the temporary process preparation. The calculation formula is: ; Among them, SLD is the proficiency coefficient of the basic unit with non-specific requirements in the temporary process compilation; Determine the number of times that the basic unit with no specific requirements in the process database and the basic unit with specific requirements for temporary process preparation are used simultaneously, and mark the number of times that the basic unit with no specific requirements in the process database and the basic unit with specific requirements for temporary process preparation are used simultaneously as: ; Obtain the usage counts of the basic units with specific requirements for temporary process preparation and the similar basic units with no specific requirements in the process database, and mark the usage counts of the basic units with specific requirements for temporary process preparation and the similar basic units with no specific requirements in the process database as: ; Calculate the credibility coefficient of the basic unit without specific requirements in the temporary process preparation, and the calculation formula is: ; Among them, KXD is the credibility coefficient of the basic unit of non-specific requirements in the temporary process compilation; Calculate the combined mature safety factor using the following formula: ;in, is the combined mature safety factor.

3. A cable process parameter electrical calculation design system according to claim 2, characterized in that ,Similar information of basic units in temporary process preparation includes: The similarity information of the basic units in the temporary process compilation is expressed by the difference similarity performance coefficient; The logic for obtaining the difference similarity performance coefficient is: encode the temporary process compilation, generate a coding set of the temporary process compilation, and mark the coding set of the temporary process compilation as: , where I is a positive integer, i is the number of the basic unit in the temporary process compilation, Basic units compiled for temporary processes; Obtain the code set of each existing process compilation in the process database, and mark the code set of each existing process compilation in the process database as: , where m=1, 2, 3, ..., M, M is a positive integer, and m is the number of the existing process compilation. Basic units compiled for each existing process; By using Jaccard similarity, the difference performance coefficient is calculated, and the calculation formula is: ;in, is the difference similarity performance coefficient.

4. A cable process parameter electrical calculation design system according to claim 3, characterized in that: Construct a temporary process preparation assessment model, including: Through comprehensive analysis of the matching information and similar information of the basic units in the temporary process preparation, the combined mature safety factor and the difference similarity performance coefficient are weighted analyzed to build a temporary process preparation evaluation model and generate the temporary process preparation evaluation coefficient. The calculation formula of the temporary process preparation evaluation coefficient is: ;in, Preparation of evaluation coefficients for temporary processes, , is the ratio coefficient of the combination of mature safety factor and difference similarity performance coefficient, , Both are greater than 0.

5. A cable process parameter electrical calculation design system according to claim 4, characterized in that: Generate derived process compilation, including: Set a threshold value for the evaluation coefficient of temporary process compilation, and compare the evaluation coefficients of all generated temporary process compilations with the threshold value for the evaluation coefficient of temporary process compilation; If the temporary process preparation evaluation coefficient of the temporary process preparation is greater than the temporary process preparation evaluation coefficient threshold, the temporary process preparation is marked as a derived process preparation; If the temporary process preparation evaluation coefficient of the temporary process preparation is less than the temporary process preparation evaluation coefficient threshold, the temporary process preparation is marked as pending process preparation.

6. A cable process parameter electrical calculation design system according to claim 5, characterized in that: Determine the electrical information of the cable sample, including; The electrical information of the cable sample is expressed by the insulation abnormal floating coefficient and the resistance average abnormal coefficient; The logic for obtaining the insulation abnormal floating coefficient is: determine the nominal insulation thickness of the cable, and mark the nominal insulation thickness of the cable as: , obtain the cable sample compiled by the post-production derived process, divide the cable into sections evenly, obtain the thinnest insulation point of each section of the cable sample, and mark the thinnest insulation point of each section of the cable sample as: , where k=1, 2, 3, ..., K, K is a positive integer, and k is the number of each cable segment after the cable is evenly segmented; Compare the thinnest insulation point of each section of the cable sample with the nominal insulation thickness of the cable, select the cable sample sections whose thinnest insulation point is greater than the nominal insulation thickness, and re-mark the thinnest insulation point of the cable sample section with the nominal insulation thickness as: , where j = 1, 2, 3, ..., J, J is a positive integer, and j is the number of the cable sample section that is greater than the nominal insulation thickness; Calculate the insulation abnormal floating coefficient, the calculation formula is: ;in, It is the insulation abnormal floating coefficient.

7. A cable process parameter electrical calculation design system according to claim 6, characterized in that: Average resistance anomaly coefficient, including The logic for obtaining the average abnormal coefficient of resistance is: determine the standard conductor resistance range of the cable, and mark the standard conductor resistance range of the cable as: , obtain the average conductor resistance of each section of the cable sample, and mark the average conductor resistance of each section of the cable sample as: ,in, , where q=1, 3, 4, ..., Q, Q is a positive integer, and q is the number of the sampling point on each cable sample. is the resistance of the qth sampling point of the kth cable segment; Calculate the difference between the standard conductor resistance range of the cable and the average conductor resistance of each section of the cable sample to obtain the average resistance anomaly coefficient. The calculation formula is: ;in, is the average abnormal coefficient of resistance.

8. A cable process parameter electrical calculation design system according to claim 7, characterized in that: Determine the appearance information of the cable sample, including; The appearance information of the cable sample is expressed by the outer diameter test fluctuation coefficient; The logic for obtaining the outer diameter test fluctuation coefficient is: obtaining the average section diameter ratio of each section of the cable sample, and marking the average section diameter ratio of each section of the cable sample as: ,in, , is the pitch diameter ratio of the qth sampling point of the kth cable segment; Calculate the average value and standard deviation of the average section diameter ratio of each section of the cable sample, and mark the average value and standard deviation of the average section diameter ratio of each section of the cable sample as: and ,in, , ; Calculate the coefficient of variation of the average pitch diameter ratio of each section of the cable sample using the following formula: ;in, is the coefficient of variation of the average pitch diameter ratio of each section of the cable sample; Calculate the outer diameter test fluctuation coefficient, the calculation formula is: ;in, The coefficient of fluctuation for outer diameter test.

9. A cable process parameter electrical calculation design system according to claim 8, characterized in that: Build a cable assessment model including: Through the electrical information and appearance information of the cable sample, the insulation abnormal floating coefficient, the average resistance abnormal coefficient and the outer diameter test fluctuation coefficient are weighted and calculated to build a cable evaluation model and generate a cable evaluation coefficient. The calculation formula of the cable evaluation coefficient is: ;in, is the cable evaluation factor, , , They are the proportional coefficients of insulation abnormality floating coefficient, resistance average abnormality coefficient, and outer diameter test fluctuation coefficient. , , They are both greater than 0; A cable evaluation coefficient threshold is set, and the cable evaluation coefficients of the cable samples obtained from all derived process preparations are compared with the cable evaluation coefficient threshold to obtain derived process preparations that are greater than the cable evaluation coefficient threshold. The cable evaluation coefficients of the derived process preparations that are greater than the cable evaluation coefficient threshold are sorted from large to small to obtain the derived process preparation with the top sorting as the optimal recommended process preparation. If the cable evaluation coefficient of the cable sample is less than the cable evaluation coefficient threshold, a warning signal is generated.

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