Multi-material twisted wire stress detection and twisted wire extension method and system

Abstract

The invention particularly provides a multi-material twisted wire stress detection and twisted wire extension method and system, and aims to improve the extension of twisted wires by detecting the stress of each type of twisted wires in a stranding machine for stranding the twisted wires of different materials in real time and heating the twisted wires in a targeted manner through a heating device so as to improve the extension of the twisted wires. The device has the beneficial effects that the stress borne by the twisted wire in the processing process can be adjusted in time, so that the stress level of the twisted wire in the processing process is in a safe range, the fracture possibility of the twisted wire is reduced, the quality of the twisted wire is enhanced, the size precision and the performance stability of the twisted wire are ensured, and the processing efficiency of the twisted wire is improved.

Description

Technical Field

[0001] The invention relates to the field of wire twisting machines, and in particular to a method and system for stress detection and wire extension of multi-material twisted wires. Background Art

[0002] In the production process of the wire stranding machine, it is often necessary to use a variety of different materials to twist the wires to meet the needs of different application scenarios. However, since wires of different materials have different physical properties and ductility, it is often difficult to accurately control the stress on the wires during the twisting process. When the stress on the wire exceeds its tolerance limit, it may cause the wire to break, which not only affects production efficiency, but may also cause damage to the equipment.

[0003] Traditional wire twisting machines usually lack stress detection and extension methods for multi-material twisted wires, and often can only rely on the operator's experience and manual adjustments to deal with twisted wires of different materials. This method is not only inefficient, but also difficult to ensure that the stress level of the twisted wires is within a safe range during the twisting process. In addition, due to the different sensitivities of twisted wires of different materials to environmental factors such as temperature and humidity, traditional wire twisting machines are even more difficult to stably process twisted wires of different materials under different environments.

[0004] Therefore, the present invention proposes a method and system that can detect the stress of multi-material twisted wires in real time and effectively extend it, so as to ensure that the stress to which the twisted wires are subjected during the processing can be adjusted in time, thereby reducing the possibility of twisted wire breakage, improving the quality, dimensional accuracy and performance stability of the twisted wires, and thereby improving the production efficiency and processing quality of the twisting machine. Summary of the invention

[0005] In order to solve the above problems in the prior art, a first object of the present invention is to provide a method for stress detection and extension of multi-material twisted wires.

[0006] In order to achieve the above-mentioned purpose, the solution provided by the present invention is: a method for stress detection and extension of multi-material twisted wires, including: an initial parameter setting step, setting the stress threshold of each twisted wire stress sensing module, and setting the starting temperature of the initial heating of each twisted wire heating device; by setting the starting temperature of the heating device, and heating according to the starting temperature to increase the ductility of the twisted wire, thereby dispersing the stress on the twisted wire and reducing the risk of twisted wire breakage.

[0007] A stress detection step, obtaining a wire stress value by real-time detection through the stress sensing module, and outputting a stress adjustment instruction when the wire stress value exceeds the stress threshold; In the stress adjustment step, after receiving the heat stretching instruction, the heating device heats the twisted wire according to the starting temperature, and detects the stress value of the heated twisted wire again. When the stress value of the heated twisted wire is greater than the stress threshold, a stress difference is obtained by subtraction. When the stress magnitude of the twisted wire changes, the actual stress value of the twisted wire is reduced by heating the twisted wire. At this time, the actual stress value of the twisted wire is continued to be detected. If the actual stress value still exceeds the stress threshold, the stress difference is calculated to provide effective parameters for the subsequent adjustment of the heating temperature of the heating device. The actual stress difference can improve the accuracy of the heating temperature adjustment and avoid the damage to the twisted wire stretching effect caused by improper temperature adjustment.

[0008] The step of heat extension correction is to calculate the temperature adjustment factor according to the stress difference and the twisting speed of the stranded wire, and to calculate the re-extension temperature according to the temperature adjustment factor and the starting temperature, and to adjust the heating temperature of the heating device according to the re-extension temperature, and repeat the stress adjustment step again until the stress value of the heated stranded wire is lower than the stress threshold. Since the stress on the stranded wire is related to the speed at which the stranded wire is twisted and advanced in the stranding machine, when the stranding speed is fast, the stranded wire stress it is subjected to increases. Therefore, by adjusting the heating temperature of the heating device according to the stress difference and the twisting speed of the stranded wire, generating the temperature adjustment factor, and adjusting the temperature of the heating device according to the temperature adjustment factor and the starting temperature of the heating device, the accuracy of the temperature adjustment of the heating device can be improved.

[0009] As a further improvement of the present invention, the stress threshold setting in the initial parameter setting step includes determining the stress threshold of each strand and the starting temperature of each heating device according to the physical properties of the strand material and the strand twisting speed. The maximum stress that strands of different materials can withstand and the ductility of the materials are different. Therefore, by setting a threshold value related to the maximum stress that the material can withstand for each strand, it is used to determine whether the strand has a risk of local twisting.

[0010] As a further improvement of the present invention, the stress adjustment step includes calculating the stabilization time for the thermal ductility of the twisted wire to reach a stable state according to the material of the twisted wire, the starting temperature and the current ambient temperature, and detecting the stress value of the heated twisted wire again when the heating time of the heating device reaches the stabilization time. Since there is a time difference between the heat conduction of the twisted wire and the actual heating process, by calculating the time when the thermal ductility of the twisted wire reaches a stable state and detecting the stress value of the heated twisted wire again after the time, it is possible to avoid the repetition of the stress adjustment step caused by repeated sampling, thereby destroying the effect of the twisted wire stress monitoring and the twisted wire ductility enhancement.

[0011] As a further improvement of the present invention, the temperature adjustment factor is calculated as follows: ; in, represents the temperature adjustment factor function, T 0 The starting temperature is the initial setting of the twisted wire heating temperature. The setting of the starting temperature is related to the twisted wire material. It is set to the temperature at which the twisted wire can reach the maximum ductility to enhance the ductility of the twisted wire. t is the detected real-time wire stress value, S d is the stress threshold, β is the thermal ductility parameter of the twisted wire, which is related to the material of the twisted wire and is used to indicate the influence of temperature on the ductility of different twisted wire materials, that is, to indicate the thermal ductility of twisted wires of different materials, e is an exponential constant, is the standard deviation of the stress differences, It represents the enhancement index of the temperature adjustment factor with the stress difference, that is, the larger the temperature difference is, the smaller the standard deviation of the stress difference is, which means that the stress of the twisted wire exceeds the threshold at the current heating temperature, and the greater the adjustment range of the heating temperature is.

[0012] As a further improvement of the present invention, the calculation of the re-extension temperature is provided with: ; Among them, T r represents the re-extension temperature, e is an exponential constant, λ is the enhancement coefficient related to the twisting speed of the twisted wire, and v i is the twisting speed of the ith strand, It indicates the enhancement coefficient of the re-extension temperature with the twisting speed. The re-extension temperature is the working temperature of the heating device adjusted by the temperature adjustment factor. Since the stress on the stranded wire is related to the speed at which the stranded wire is twisted by the stranding machine, and the purpose of enhancing the ductility of the stranded wire by heating the stranded wire is to reduce the stress value of the stranded wire, an influence factor affecting the re-extension temperature is generated by the twisting speed of the stranded wire, which is used to improve the effect of stress detection and strand extension.

[0013] As a further improvement of the present invention, the multi-material wire stress detection and wire extension method further includes: setting a threshold value for the number of executions of the thermal extension correction step. When the number of executions of the thermal extension correction step during a single stress detection and wire extension process exceeds the threshold value, the heating device is stopped and the wire twisting parameters are adjusted. When the stress detection and wire extension method is executed a certain number of times in a cycle, the wire ductility is affected by the temperature and reaches the maximum value. At this time, continuing to adjust the temperature of the heating device will cause the wire material to be damaged by excessive temperature. Therefore, by setting the threshold value for the number of executions, the risk of wire damage and breakage caused by overheating can be reduced.

[0014] As a further improvement of the present invention, when the execution times exceed the execution times threshold, the initial speed of twisting the strands and the tension applied to the ends of the strands are reduced. Since the adjustment of the strands by thermal ductility has reached the maximum limit at this time, if the stress value still does not reach the standard of being lower than the stress threshold, the stranding speed of the stranding machine is reduced and the tension on the strands is reduced to prevent the strands from breaking.

[0015] As a further improvement of the present invention, the heating device is controlled by PLC, and the re-extension temperature is dynamically calculated by PID algorithm. By controlling the heating device by PLC and calculating the re-extension temperature by PID algorithm, the accuracy of heating temperature control is improved.

[0016] The second purpose of the present invention is to provide a system for detecting and extending the stress of multi-material twisted wires, including: a stress sensing module for real-time acquisition of the wire stress value data of each twisted wire; a data processing module for receiving and processing the wire stress value data, judging whether the preset stress threshold is reached, and issuing a control instruction when it is reached; a heating adjustment module, including a temperature sensor and a heating device, for detecting the temperature of the twisted wire, and adjusting the heating device at the corresponding wire inlet position in the twisting machine to heat the twisted wire according to the received control instruction; a control module for executing the control instruction, adjusting the temperature of the heating device, adjusting the twisting speed, and the tension exerted on the ends of the twisted wires. By using the system for detecting and extending the stress of multi-material twisted wires, the stress value of the twisted wires is detected in real time, and the heating temperature of the heating device is adjusted as needed to achieve precise control and extension of the wire stress. The system can ensure that the wires maintain an appropriate stress level during the processing, thereby improving product quality and processing efficiency.

[0017] As a further improvement of the present invention, the stress sensing module and the heating adjustment module include a plurality of independently controlled sensing elements, and respectively perform data collection and heating on one strand of wire. By independently controlling and collecting data and heating different strands of wire, the ductility and stress of the strands of wire of different materials can be changed by heating in a targeted manner, thereby improving the control accuracy.

[0018] The beneficial effects of the present invention are: By real-time detection of the stress exerted on each strand of wire in a stranding machine using strands of different materials for stranding, and targeted heating of the strands through a heating device to improve their ductility, it is ensured that the stress exerted on the strands during processing can be adjusted in time, thereby ensuring that the stress level of the strands during processing is within a safe range, reducing the possibility of strand breakage, enhancing the quality of the strands, ensuring the dimensional accuracy and performance stability of the strands, and improving the processing efficiency of the strands. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a flow chart of a method for stress detection and wire extension of multi-material twisted wires according to an embodiment of the present invention; Figure 2 It is a system block diagram of a method system for stress detection and extension of twisted wires of multiple materials according to an embodiment of the present invention. DETAILED DESCRIPTION

[0020] The specific embodiments of the present invention will be described in detail below. It should be noted that the embodiments described here are only part of the embodiments of the present invention, not all of the embodiments. Based on the following embodiments, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0021] The first embodiment of the present invention proposes a method for stress detection and extension of multi-material twisted wires, including: an initial parameter setting step, setting the stress threshold of each twisted wire stress sensing module, and setting the starting temperature of the initial heating of each twisted wire heating device; by setting the starting temperature of the heating device, and heating according to the starting temperature to increase the ductility of the twisted wire, thereby dispersing the stress on the twisted wire and reducing the risk of twisted wire breakage.

[0022] A stress detection step, obtaining a wire stress value by real-time detection through the stress sensing module, and outputting a stress adjustment instruction when the wire stress value exceeds the stress threshold; In the stress adjustment step, after receiving the heat stretching instruction, the heating device heats the twisted wire according to the starting temperature, and detects the stress value of the heated twisted wire again. When the stress value of the heated twisted wire is greater than the stress threshold, a stress difference is obtained by subtraction. When the stress magnitude of the twisted wire changes, the actual stress value of the twisted wire is reduced by heating the twisted wire. At this time, the actual stress value of the twisted wire is continued to be detected. If the actual stress value still exceeds the stress threshold, the stress difference is calculated to provide effective parameters for the subsequent adjustment of the heating temperature of the heating device. The actual stress difference can improve the accuracy of the heating temperature adjustment and avoid the damage to the twisted wire stretching effect caused by improper temperature adjustment.

[0023] The step of heat extension correction is to calculate the temperature adjustment factor according to the stress difference and the twisting speed of the stranded wire, and to calculate the re-extension temperature according to the temperature adjustment factor and the starting temperature, and to adjust the heating temperature of the heating device according to the re-extension temperature, and repeat the stress adjustment step again until the stress value of the heated stranded wire is lower than the stress threshold. Since the stress on the stranded wire is related to the speed at which the stranded wire is twisted and advanced in the stranding machine, when the stranding speed is fast, the stranded wire stress it is subjected to increases. Therefore, by adjusting the heating temperature of the heating device according to the stress difference and the twisting speed of the stranded wire, generating the temperature adjustment factor, and adjusting the temperature of the heating device according to the temperature adjustment factor and the starting temperature of the heating device, the accuracy of the temperature adjustment of the heating device can be improved.

[0024] In this embodiment, refer to Figures 1 to 2 As shown, the stress threshold setting in the initial parameter setting step includes determining the stress threshold of each strand and the starting temperature of each heating device according to the physical properties of the strand material and the strand twisting speed. The maximum stress that strands of different materials can withstand and the ductility of the materials are different. Therefore, by setting a threshold value related to the maximum stress that the material can withstand for each strand, it is used to determine whether the strand has a risk of local twisting.

[0025] In this embodiment, refer to Figures 1 to 2 As shown, the stress adjustment step includes calculating the stabilization time for the thermal ductility of the twisted wire to reach a stable state according to the material of the twisted wire, the starting temperature and the current ambient temperature, and detecting the stress value of the heated twisted wire again when the heating time of the heating device reaches the stabilization time. Since there is a time difference between the heat conduction of the twisted wire and the actual heating process, by calculating the time when the thermal ductility of the twisted wire reaches a stable state and detecting the stress value of the heated twisted wire again after the time, it is possible to avoid the repetition of the stress adjustment step caused by repeated sampling, thereby destroying the effect of the twisted wire stress monitoring and the twisted wire ductility enhancement.

[0026] In this embodiment, refer to Figures 1 to 2 As shown, the temperature adjustment factor is calculated as: ; in, represents the temperature adjustment factor function, T 0 The starting temperature is the initial setting of the twisted wire heating temperature. The setting of the starting temperature is related to the twisted wire material. It is set to the temperature at which the twisted wire can reach the maximum ductility to enhance the ductility of the twisted wire. t is the detected real-time wire stress value, S d is the stress threshold, β is the thermal ductility parameter of the twisted wire, which is related to the material of the twisted wire and is used to indicate the influence of temperature on the ductility of different twisted wire materials, that is, to indicate the thermal ductility of twisted wires of different materials, e is an exponential constant, is the standard deviation of the stress differences, It represents the enhancement index of the temperature adjustment factor with the stress difference, that is, the larger the temperature difference is, the smaller the standard deviation of the stress difference is, which means that the stress of the twisted wire exceeds the threshold at the current heating temperature, and the greater the adjustment range of the heating temperature is.

[0027] In this embodiment, refer to Figures 1 to 2 As shown, the calculation of the re-extension temperature is provided by: ; Among them, T r represents the re-extension temperature, e is an exponential constant, λ is the enhancement coefficient related to the twisting speed of the twisted wire, and v i is the twisting speed of the ith strand, It indicates the enhancement coefficient of the re-extension temperature with the twisting speed. The re-extension temperature is the working temperature of the heating device adjusted by the temperature adjustment factor. Since the stress on the stranded wire is related to the speed at which the stranded wire is twisted by the stranding machine, and the purpose of enhancing the ductility of the stranded wire by heating the stranded wire is to reduce the stress value of the stranded wire, an influence factor affecting the re-extension temperature is generated by the twisting speed of the stranded wire, which is used to improve the effect of stress detection and strand extension.

[0028] In this embodiment, refer to Figures 1 to 2 As shown, the multi-material wire stress detection and wire extension method also includes: setting a threshold value for the number of executions of the thermal extension correction step. When the number of executions of the thermal extension correction step in a single stress detection and wire extension process exceeds the threshold value, the heating device is stopped and the wire twisting parameters are adjusted. When the stress detection and wire extension method is executed a certain number of times in a cycle, the ductility of the wire reaches the maximum value under the influence of temperature. At this time, continuing to adjust the temperature of the heating device will cause the wire material to be damaged by excessive temperature. Therefore, by setting the threshold value for the number of executions, the risk of wire damage and breakage caused by overheating can be reduced.

[0029] In this embodiment, refer to Figures 1 to 2 As shown, when the execution times exceed the execution times threshold, the initial speed of the twisted wire and the tension applied to the ends of the twisted wire are reduced. Since the adjustment of the twisted wire by thermal ductility has reached the maximum limit at this time, if the stress value is still not lower than the stress threshold, the twisting speed of the twisting machine is reduced and the tension on the twisted wire is reduced to prevent the twisted wire from breaking.

[0030] In this embodiment, refer to Figures 1 to 2As shown, the heating device is controlled by PLC, and the re-extension temperature is dynamically calculated by PID algorithm. By using PLC to control the heating device and calculating the re-extension temperature by PID algorithm, the accuracy of heating temperature control is improved.

[0031] The second embodiment of the present invention proposes a system for stress detection and extension of multi-material twisted wires, including: a stress sensing module, used to collect the twisted wire stress value data of each twisted wire in real time; a data processing module, used to receive and process the twisted wire stress value data, determine whether a preset stress threshold is reached, and issue a control instruction when it is reached; a heating adjustment module, including a temperature sensor and a heating device, used to detect the temperature of the twisted wire, and adjust the heating device at the corresponding twisted wire inlet position in the twisting machine to heat the twisted wire according to the received control instruction; a control module, used to execute the control instruction, adjust the temperature of the heating device, adjust the twisting speed and the tension exerted on the ends of the twisted wire.

[0032] In this embodiment, refer to Figures 1 to 2 As shown, the stress sensing module and the heating adjustment module include multiple independently controlled sensing elements, and perform data collection and heating on one strand of wire respectively. By independently controlling and collecting data and heating different strands of wire respectively, the ductility and stress of the strands of wire of different materials can be changed by heating in a targeted manner, thereby improving the control accuracy.

[0033] The embodiment of the present invention detects in real time the stress exerted on each strand of wire in a stranding machine that uses strands of wires of different materials for stranding, and performs targeted heating on the strands through a heating device to improve their ductility, thereby ensuring that the stress exerted on the strands during processing can be adjusted in time, thereby ensuring that the stress level of the strands during processing is within a safe range, reducing the possibility of strand breakage, enhancing the quality of the strands, ensuring the dimensional accuracy and performance stability of the strands, and improving the processing efficiency of the strands.

[0034] The above shows and describes the basic features, principles and advantages of the present invention. It should be noted that the present invention is not limited to the above embodiments, which are only partial embodiments. Under the premise of not departing from the spirit and scope of the present invention, several improvements and supplements made are considered as the protection scope of the present invention.

Claims

1. A method for stress detection and extension of twisted wires of multiple materials, characterized in that: include: An initial parameter setting step, setting a stress threshold of each strand stress sensing module, and setting a starting temperature for initial heating of each strand heating device; A stress detection step, obtaining a wire stress value by real-time detection through the stress sensing module, and outputting a stress adjustment instruction when the wire stress value exceeds the stress threshold; A stress adjustment step, wherein the heating device heats the strand according to the start temperature after receiving the heat extension instruction, and detects the stress value of the heated strand again, and when the stress value of the heated strand is greater than the stress threshold, a stress difference value is obtained by subtraction; A thermal stretch correction step is performed, wherein a temperature adjustment factor is calculated according to the stress difference and the twisting speed of the twisted wire, and a re-stretching temperature is calculated according to the temperature adjustment factor and the starting temperature. The heating temperature of the heating device is adjusted according to the re-stretching temperature, and the stress adjustment step is repeated again until the stress value of the heated twisted wire is lower than the stress threshold.

2. A method for stress detection and wire extension of multi-material twisted wires according to claim 1, characterized in that: The stress threshold setting in the initial parameter setting step includes determining the stress threshold of each strand and the starting temperature of each heating device according to the physical properties of the strand material and the strand twisting speed.

3. The method for stress detection and wire extension of multi-material twisted wires according to claim 1, characterized in that: The stress adjustment step includes calculating the stabilization time for the thermal extension of the strand to reach stability according to the strand material, the starting temperature and the current ambient temperature, and detecting the stress value of the heated strand again when the heating time of the heating device reaches the stabilization time.

4. The method for stress detection and wire extension of multi-material twisted wires according to claim 1, characterized in that: The temperature adjustment factor is calculated as: ； in, represents the temperature adjustment factor function, T0 is the starting temperature, S t is the detected real-time wire stress value, S d is the stress threshold, β is the thermal expansion parameter of the twisted wire, which indicates the thermal expansion performance of the twisted wire of different materials, e is the exponential constant, is the standard deviation of the stress differences, It represents the enhancement index of the temperature adjustment factor with the stress difference.

5. The method for stress detection and wire extension of multi-material twisted wires according to claim 1, characterized in that: The calculation of the re-extension temperature is as follows: ； Among them, T r represents the re-extension temperature, e is an exponential constant, λ is the enhancement coefficient related to the twisting speed of the twisted wire, and v i is the twisting speed of the ith strand, It represents the enhancement factor of the re-extension temperature with the twisting speed.

6. The method for stress detection and wire extension of multi-material twisted wires according to claim 1, characterized in that: The multi-material twisted wire stress detection and twisted wire extension method also includes: setting an execution times threshold of the thermal extension correction step, and when the execution times threshold of the thermal extension correction step during a single stress detection and twisted wire extension process exceeds the execution times threshold, stopping the heating device and adjusting the twisted wire twisting parameters.

7. A method for stress detection and wire extension of multi-material twisted wires according to claim 6, characterized in that: Also includes: When the execution times exceed the execution times threshold, the initial speed of twisting the strands and the tension applied to the ends of the strands are reduced.

8. The method for stress detection and wire extension of multi-material twisted wires according to claim 1, characterized in that: The heating device is controlled by PLC, and the re-extension temperature is dynamically calculated by PID algorithm.

9. A system for detecting stress of twisted wires of multiple materials and extending the twisted wires, applicable to the method for detecting stress of twisted wires of multiple materials and extending the twisted wires as claimed in any one of claims 1 to 8, characterized in that: include: A stress sensing module is used to collect the wire stress value data of each wire in real time; The data processing module is used to receive and process the wire stress value data, determine whether the preset stress threshold is reached, and issue a control instruction when the threshold is reached; The heating adjustment module includes a temperature sensor and a heating device, which is used to detect the temperature of the twisted wire and adjust the heating device at the corresponding position of the twisted wire inlet in the twisting machine to heat the twisted wire according to the received control command; The control module is used to execute control instructions, adjust the temperature of the heating device, adjust the twisting speed and the tension on the ends of the twisted wires.

10. A system for detecting stress of twisted wires of multiple materials and extending twisted wires according to claim 9, characterized in that: The stress sensing module and the heating regulating module include a plurality of independently controlled sensing elements, and respectively perform data collection and wire heating on one strand of twisted wire.

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