Cable manufacturing equipment and method

Abstract

The invention provides cable manufacturing equipment and method, and the equipment comprises a cable core coating device which is used for coating a cable core, a traction device which is used for pulling the cable to move forwards, a detection device, and a traction control device. The detection device comprises the diameter measuring instrument arranged at the downstream of the cable core coating device and the rotating speed sensor arranged at the traction motor, so that the diameter of the coated cable and the rotating speed of the traction motor can be detected, and the traction speed of the traction motor to the cable can be obtained according to the rotating speed; the traction control device can control the traction speed of the traction device according to the deviation between the measured diameter and the preset standard diameter range, so that the diameter of the manufactured cable can be automatically adjusted, the diameter of the cable is controlled within the standard diameter range, manual repeated adjustment is not needed, and the production efficiency is improved. A large amount of manpower and time can be saved, and the diameter precision and the diameter uniformity of the cable can be improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of cable manufacturing equipment, and in particular relates to a cable manufacturing equipment and method. Background Art

[0002] Cables are used to transmit power and / or signals and are widely used in various fields. Cables usually include a core composed of a conductor or wire and an insulating coating coated on the outer surface of the core. The corresponding manufacturing equipment usually includes a guide wheel mechanism, an extruder, and a traction machine, wherein the extruder has a heating mechanism, a head with a coating core, and an extrusion mechanism. During the manufacturing process, the traction machine continuously pulls the core, and the core enters the coating core of the extruder head under the guidance of the guide wheel mechanism. The heating mechanism of the extruder heats the coating material in a solid particle state to make it a molten fluid state, and then the molten coating material is extruded into the coating core through the extruder's extrusion mechanism, so that the coating material is wrapped around the core in the head to form a cable.

[0003] Existing extruders usually extrude the coating material to the coating core at a constant rate. Therefore, the diameter of the manufactured cable is inversely proportional to the pulling speed. The faster the pulling speed, the smaller the cable diameter. The diameter of the manufactured cable can be adjusted by adjusting the pulling speed. At present, in order to manufacture a cable with a predetermined diameter, the operator needs to measure the diameter of the manufactured cable with tools such as calipers, and adjust the pulling speed of the pulling machine multiple times according to the measurement results until the cable diameter meets the standard. Such an operation is very time-consuming and inconvenient, and the accuracy of manual adjustment is also very limited. In addition, after the cable diameter is manually adjusted to meet the standard and formal production begins, the pulling speed may change or fluctuate due to problems such as the jamming of the pulling machine or the influence of environmental factors, resulting in the output cable diameter not meeting the standard or uneven diameter, affecting the quality of the cable.

[0004] Therefore, in order to solve the above problems, a cable manufacturing device and method are needed, which can monitor the diameter of the cable during the manufacturing process and automatically adjust the pulling speed, thereby realizing automatic adjustment of the cable diameter. Summary of the invention

[0005] The present invention is made to solve the above problems, and aims to provide a cable manufacturing device and method that can automatically adjust the pulling speed according to the current diameter of the cable, thereby automatically adjusting the cable diameter. The present invention adopts the following technical solutions:

[0006] The present invention provides a cable manufacturing device, characterized in that it includes: a wire core coating device, used to coat a coating material in a molten state onto a wire core to form a cable with a coating layer; a traction device, arranged downstream of the coating device, used to pull the cable forward; a detection device, at least including a diameter measuring unit arranged downstream of the wire core coating device, used to detect the diameter of the cable as a current diameter; and a traction control device, which controls the traction speed of the traction device according to the deviation between the measured current diameter and a predetermined standard diameter range, so that the diameter of the cable is controlled within the standard diameter range.

[0007] The cable manufacturing equipment provided by the present invention may also have such technical features, wherein the diameter measuring unit includes a diameter gauge, and the traction control device includes: a data acquisition unit, which is used to obtain the current diameter measured by the diameter gauge at every predetermined standard time interval; a traction speed adjustment determination unit, which determines that the traction speed needs to be adjusted when the current diameter exceeds the standard diameter range; an adjusted traction speed calculation unit, which calculates the adjusted traction speed that can make the diameter of the cable approach the standard diameter range based on the current diameter, the standard diameter range and the current traction speed of the traction device when the traction speed adjustment determination unit determines that the traction speed needs to be adjusted; and an adjusted traction speed output unit, which outputs the adjusted traction speed to the traction device, so that the traction device pulls the cable forward at the adjusted traction speed.

[0008] The cable manufacturing equipment provided by the present invention may also have such technical features, and further include: a current traction speed acquisition unit, which is used to acquire the current traction speed of the traction device when the traction speed adjustment determination unit determines that the traction speed needs to be adjusted, wherein the traction device includes a traction motor, and the detection device also includes a speed sensor, which is used to detect the speed of the traction motor. The current traction speed acquisition unit acquires the speed of the traction motor measured by the speed sensor, and converts the speed into a linear speed at which the cable is pulled forward as the current traction speed according to the parameters of the traction motor. The adjusted traction speed output unit converts the adjusted traction speed into an adjusted speed of the traction motor according to the parameters of the traction motor, and outputs the adjusted speed to the traction motor.

[0009] The cable manufacturing equipment provided by the present invention may also have such a technical feature, wherein the adjusted traction speed calculation unit includes: a diameter difference calculation unit, which is used to calculate the difference and percentage difference between the current diameter and the closest one of the maximum value or the minimum value in the standard diameter range; an adjustment coefficient determination unit, which determines the corresponding adjustment coefficient according to the percentage difference and the predetermined correspondence between the percentage difference and the adjustment coefficient; a target speed calculation unit, which calculates the target traction speed that can make the diameter of the cable fall within the standard diameter range according to the difference, the current traction speed and the standard diameter range; and an adjusted speed calculation unit, which calculates the adjusted traction speed that can make the diameter of the cable approach the standard diameter range according to the current traction speed, the target traction speed and the determined adjustment coefficient.

[0010] The cable manufacturing equipment provided by the present invention may also have such a technical feature, wherein the target pulling speed v1 is calculated according to the following formula: In the formula, R0 is the current diameter, r is the diameter of the wire core, v0 is the current traction speed, and the adjusted speed v2 is calculated according to the following formula: v2 = [αv1-v0], where α is the determined adjustment coefficient.

[0011] The cable manufacturing equipment provided by the present invention may also have such a technical feature, wherein the correspondence between the percentage difference and the adjustment coefficient is: when the percentage difference is greater than or equal to a predetermined threshold, the adjustment coefficient is set to a first adjustment coefficient value, and when the percentage difference is less than the predetermined threshold, the adjustment coefficient is set to a second adjustment coefficient value, and the second adjustment coefficient value is less than the first adjustment coefficient value.

[0012] The cable manufacturing equipment provided by the present invention may also have such a technical feature, wherein the predetermined threshold is 2%, the first adjustment coefficient value is 0.7, and the second adjustment coefficient value is 0.5.

[0013] The cable manufacturing equipment provided by the present invention may also have such technical features, and also includes: a traction speed feedback unit, which obtains the current speed of the traction motor measured by the speed sensor a predetermined time after the traction speed output unit outputs the adjusted speed, and determines whether the speed reaches the adjusted speed, and generates corresponding warning information when the judgment is no.

[0014] The cable manufacturing equipment provided by the present invention may also have such technical features, and also includes: a diameter median selection unit, which is used to select a median value from a plurality of current diameters as a diameter median value, wherein the diameter data acquisition unit acquires the current diameter measured by the diameter gauge at a predetermined standard time interval until a predetermined number of current diameters are acquired, and the traction speed adjustment determination unit determines that the traction speed needs to be adjusted when the diameter median value exceeds the standard diameter range; an adjusted traction speed calculation unit, which calculates the adjusted traction speed that can make the diameter of the cable approach the standard diameter range based on the diameter median value, the standard diameter range and the current traction speed of the traction device when the traction speed adjustment determination unit determines that the traction speed needs to be adjusted.

[0015] The cable manufacturing equipment provided by the present invention may also have such a technical feature, wherein the diameter median selection unit removes the maximum value and the minimum value from the multiple current diameters, and selects the median value from the remaining multiple current diameters as the diameter median.

[0016] The cable manufacturing equipment provided by the present invention may also have such technical features, and further include: a cable cooling device, arranged downstream of the wire core coating device, for cooling the cable after coating, wherein the diameter measuring unit includes a first diameter gauge and a second diameter gauge, the first diameter gauge is arranged downstream of the cable cooling device, for detecting the diameter of the cable after cooling as the current diameter, the current diameter being the current diameter after cooling, the second diameter gauge is arranged between the wire core coating device and the cable cooling device, for detecting the diameter of the cable before cooling as the current diameter before cooling, the traction control device includes: a diameter data acquisition unit after cooling, for acquiring the current diameter after cooling measured by the first diameter gauge at every predetermined standard time interval; a diameter data acquisition unit before cooling A data acquisition unit is used to acquire the current diameter before cooling measured by the second caliper at every predetermined standard time interval; a traction speed adjustment determination unit determines that it is necessary to adjust the current traction speed when the current diameter after cooling exceeds the predetermined standard diameter range after cooling or the current diameter before cooling exceeds the predetermined standard diameter range before cooling; an adjusted traction speed calculation unit calculates a first adjusted traction speed according to the current diameter after cooling, the standard diameter range after cooling and the current traction speed, and calculates a second adjusted traction speed according to the current diameter before cooling, the standard diameter range before cooling and the current traction speed, and then calculates the adjusted traction speed according to the first adjusted traction speed, the second adjusted traction speed and the corresponding weight coefficient.

[0017] The present invention provides a cable manufacturing method, characterized in that the cable manufacturing equipment mentioned above is used to manufacture the cable, and the method includes: the wire core coating device coats the molten coating material onto the wire core to form the cable, and the traction device continuously pulls the cable forward at a certain traction speed, wherein, during the advancement of the cable, the diameter gauge detects the diameter of the cable as the current diameter, and the traction control device controls the traction speed according to the measured current diameter and a predetermined standard diameter range, so that the diameter of the cable is controlled within the standard diameter range.

[0018] Function and Effect of the Invention

[0019] According to the cable manufacturing equipment and method of the present invention, the equipment includes a core coating device for coating the core of the cable, a traction device for traction the cable to make it move forward, a detection device and a traction control device. Since the detection device includes a diameter gauge arranged downstream of the core coating device, the diameter of the cable after coating can be detected. The traction control device can control the traction speed of the traction device according to the deviation between the measured diameter and the predetermined standard diameter range, so that the diameter of the manufactured cable can be automatically adjusted, so that the diameter of the cable is controlled within the standard diameter range, and no manual repeated adjustment is required, which can not only save a lot of manpower and time, but also improve the diameter accuracy and uniformity of the cable. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 is a three-dimensional diagram of a cable manufacturing device according to an embodiment of the present invention;

[0021] Figure 2 is a side view of a cable manufacturing device according to an embodiment of the present invention;

[0022] Figure 3 is a top view of a cable manufacturing device according to an embodiment of the present invention;

[0023] Figure 4 is a three-dimensional diagram of a wire core covering device in an embodiment of the present invention;

[0024] Figure 5 yes Figure 4 A magnified view of the part inside the middle circle A;

[0025] Figure 6 is a three-dimensional diagram of a wire core guide unit in an embodiment of the present invention;

[0026] Figure 7 is a three-dimensional diagram of a cable cooling device according to an embodiment of the present invention;

[0027] Figure 8 is a block diagram of a traction control device in an embodiment of the present invention;

[0028] Fig. 9 is a flow chart of a cable manufacturing method according to an embodiment of the present invention;

[0029] Fig.10 is a flow chart of step S6 of the cable manufacturing method in an embodiment of the present invention;

[0030] Fig.11 is a top view of a cable manufacturing device in an embodiment of the present invention.

[0031] Reference numerals:

[0032] Cable manufacturing equipment 1000; wire core coating device 100; coating device housing 110; feeding mechanism 120; wire core coating mechanism 130; coating core 131; center hole 131a; wire core guiding mechanism 140; base 141; base bracket 1411; base plate 1412; guide wheel mechanism 142; first guide wheel 1421; guide groove 1421a; second guide wheel 1422; third guide wheel 1423; fourth guide wheel 1424; guide wheel bracket 1425; upper bracket 1426; lower bracket 1427; wire core guide wheel moving mechanism 143; first moving assembly 1431; second moving assembly 1432; third moving assembly 1433; fourth moving assembly 1434; alignment driving mechanism 144; first driving assembly 1441; second driving assembly 1442; third driving assembly 1443; fourth driving assembly 1444; 43; cable cooling device 200; cooling device shell 210; cooling groove 220; notch 220a; cooling cable guiding mechanism 230; cooling guide wheel bracket 231; cooling guide wheel 232; cooling groove moving mechanism 240; traction device 300; detection device 400; first diameter gauge 410; second diameter gauge 420; traction control device 500; data storage unit 510; diameter data acquisition unit 520; diameter median value selection unit 530; traction speed adjustment determination unit 540; current traction speed acquisition unit 550; traction speed calculation unit 560; diameter difference calculation unit 561; adjustment coefficient determination unit 562; target speed calculation unit 563; adjusted speed calculation unit 564; traction speed output unit 570; traction speed feedback unit 580; traction control unit 590. DETAILED DESCRIPTION

[0033] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the cable manufacturing equipment and method of the present invention are specifically described below in conjunction with embodiments and drawings.

[0034] <Example 1>

[0035] This embodiment provides a cable manufacturing device and a corresponding cable manufacturing method.

[0036] Figure 1 to Figure 3They are respectively a stereoscopic view, a side view and a top view of the cable manufacturing equipment in this embodiment.

[0037] like Figure 1 to Figure 3 As shown, the cable manufacturing equipment 1000 includes a wire core coating device 100, a cable cooling device 200, a traction device 300, a detection device 400 and a traction control device 500. The wire core coating device 100 is used to coat the coating material on the outer surface of the wire core to form a cable, the cable cooling device 200 is arranged downstream of the wire core coating device 100, and its input end is close to the output end of the wire core coating device 100. The cable cooling device 200 is used to cool the cable coated by the wire core coating device 100. The traction device 300 is arranged downstream of the cable cooling device 200, and is used to pull the cable / wire core and pull the cable / wire core to move along the forward direction (the D1 direction in the figure), so as to continuously manufacture the cable. The detection device 400 is used to detect the diameter of the manufactured cable, and the traction control device 500 is used to control the traction speed of the traction device 300 according to the measured diameter, so as to control the diameter of the manufactured cable.

[0038] Figure 4 It is a three-dimensional diagram of the wire core covering device in this embodiment.

[0039] like Figure 4 As shown, the core coating device 100 includes a coating device housing 110, a feeding mechanism 120, an extrusion mechanism (not shown in the figure), a coating mechanism 130 and a core guiding unit 140. The feeding mechanism 120 is used to receive a granular coating material and heat the coating material into a molten state. The extrusion mechanism is used to extrude the molten coating material into the coating mechanism 130. The coating mechanism 130 is used to coat the molten coating material onto the outer surface of the core, thereby forming a cable. The core guiding unit 140 is used to guide the core to be coated to the core coating unit 130.

[0040] Figure 5 yes Figure 4 Enlarged view of the part within the middle circle A.

[0041] like Figure 5 As shown, the core coating mechanism 130 includes a coating core 131, and the coating core 131 has a center hole 131a for the core to pass through at the axial center position. The coating core 131 has a cavity connected to the center hole 131a inside, and the cavity is connected to the pipeline of the extrusion mechanism. After the core passes through the center hole 131a, the extrusion mechanism extrude the molten coating material into the cavity of the coating core 131 through the pipeline, and the coating material is coated on the portion of the core that passes through the coating core 141. In order to make the coating material uniformly coat the core circumferentially, it is necessary to align the center of the core with the center of the center hole 131a at the center position of the coating core 131 as much as possible.

[0042] Figure 6 3D is a perspective view of the wire core guide unit in this embodiment.

[0043] like Figure 6 As shown, the wire core guiding unit 140 includes a base 141, a guide wheel mechanism 142, a moving mechanism 143, a driving mechanism 144, and a control mechanism (not shown in the figure). The guide wheel mechanism 142 is used to guide the wire core, under which the wire core continuously enters the covering mold core 131. The moving mechanism 143 is used to move the guide wheel mechanism 142 so that the center of the wire core to be covered is aligned with the center hole 131a at the center position of the covering mold core 131. The driving mechanism 144 is used to drive the moving mechanism 143 to move. The control mechanism is used to control the driving mechanism 144 so that the driving mechanism 144 drives the moving mechanism 143 to move the guide wheel mechanism 142 to a position where the center of the wire core can be aligned with the center hole 131a at the center position of the covering mold core 131.

[0044] The base 141 includes a base support 1411 and a base plate 1412. The base support 1411 is fixedly connected to the side of the device housing 110, and the base plate 1412 is fixedly connected to the end extending from the base support 1411, and the base plate 1412 is horizontally arranged.

[0045] The guide wheel mechanism 142 includes a guide wheel bracket 1425, a first guide wheel 1421, a second guide wheel 1422, and a third guide wheel 1423. The guide wheel bracket 1425 is a rectangular plate, and the first guide wheel 1421, the second guide wheel 1422, and the third guide wheel 1423 are mounted on the same surface of the guide wheel mounting plate 1421, and are arranged in series at equal intervals along the length direction of the guide wheel bracket 1425. In this embodiment, the first guide wheel 1421, the second guide wheel 142, and the third guide wheel 1423 have the same shape and size.

[0046] Along the advancing direction of the wire core, the wire core can be wound around the lower end of the third guide wheel 1423, the upper end of the second guide wheel 1422, and the upper end of the first guide wheel 1421 in sequence, and horizontally extend from the upper end of the first guide wheel 1421 to the center hole 131a at the center of the covering mold core 131. Other winding methods can also be used.

[0047] In order to adjust the position of the first guide wheel 1421 relative to the covering core 131, and thus adjust the position of the wire core relative to the covering core 131, a moving mechanism 143 capable of moving the guide wheel bracket 1425 is provided. The moving mechanism 143 includes a first moving component 1431, a second moving component 1432, a third moving component 1433, and a fourth moving component 1434. The first moving component 1431 is used to drive the guide wheel bracket 1425 to move along the forward direction of the wire core; the second moving component 1432 is used to drive the guide wheel bracket 1425 to move in the left-right direction; the third moving component 1433 is used to drive the guide wheel bracket 1425 to move in the up-and-down direction; the fourth moving component 1434 is used to drive the guide wheel bracket 1425 and the first to third moving components to move as a whole in the forward direction or the opposite direction of the forward direction. Figure 5 As shown, the fourth moving assembly 1434 includes two equal guide rails, four sliders and a support plate. The first to third moving assemblies are all arranged on the support plate, and each includes a linear guide rail and a slider, wherein the linear guide rail of the second moving assembly 1432 is mounted on the support plate, the linear guide rail of the third moving assembly 1433 is mounted on the slider of the second moving assembly 1432, and the linear guide rail of the first moving assembly 1431 is mounted on the slider of the third moving assembly 1433.

[0048] The driving mechanism 144 includes a first driving assembly 1441, a second driving assembly 1442, and a third driving assembly 1443, which are respectively used to drive the sliders of the first to third moving assemblies to move, thereby driving the first guide wheel 1421 to move in three axial directions. The first to third driving assemblies all include servo motors, screw rods, and connectors, which are structures in the prior art and are not described in detail.

[0049] The wire core guiding control mechanism controls the driving mechanism 144 to drive the moving mechanism 143 to move the guide wheel bracket 1425 according to the specifications of the wire core and the shape and size of the guide groove 1421a of the first guide wheel 1421, so that the first guide wheel 1421 moves from the initial position to an alignment position corresponding to the wire core to be carried and aligning the wire core with the center position of the covering mold core 131. Specifically, the wire core guiding control mechanism first resets the first guide wheel 1421 to a predetermined starting position, and then obtains the movement information between the starting position and the alignment position according to the pre-input wire core diameter and the size of the guide groove 1421a, and then controls the corresponding servo motor in the driving mechanism 144 according to the movement information, so that the first guide wheel 1421 is moved to the alignment position so that the center of the wire core is aligned with the center of the covering mold core. For example, the diameter of the wire core is a. When the wire core is carried on the first guide wheel 1421, the distance between the outer surface of the wire core and the lowest point at the bottom of the guide groove 1421a is b. The position at a distance c directly below the position where the lowest point of the guide groove 1421a is aligned with the center of the covering mold core is taken as the starting position. The wire core guiding control mechanism controls the corresponding servo motor to reset the first guide wheel 1421 to the starting position, and then moves the first guide wheel 1421 upward by a distance (cab) to align the center of the wire core with the center of the covering mold core.

[0050] Figure 6 is a three-dimensional diagram of the cable cooling device in this embodiment.

[0051] like Figure 6 As shown, the cable cooling device 200 includes a cooling device housing 210 , a cooling tank 220 , a cooling cable guide mechanism 230 , and a cooling tank moving mechanism 240 .

[0052] The cooling groove 220 is a rectangular groove, and its two ends in the length direction are in the form of double-layer plywood, and the double-layer plywood is provided with notches 220a aligned along the length direction, and a guide plate groove is formed between the double-layer plywood. The cooling groove 220 contains a coolant for cooling the high-temperature cable after coating.

[0053] The cooling cable guide mechanism 230 includes two guide plates (not shown), a cooling guide wheel 231 and a cooling guide wheel bracket 232 .

[0054] The middle of the guide plate has a guide hole for the cable to pass through. The diameter of the guide hole is slightly larger than the diameter of the cable before cooling, and is used to guide the cable. The two guide plates are respectively embedded in the two guide plate embedding grooves at both ends of the length direction of the cooling groove 220, and the guide hole in the middle of the guide plate is exposed from the notch 220a. In addition, the guide plate is also used to block the coolant in the cooling groove 220, so that the coolant in the groove can have a higher liquid level.

[0055] The cooling guide wheel bracket 232 includes a U-shaped buckle plate and a guide wheel shaft connected to the buckle plate. The buckle plate is buckled on the two side walls of the cooling groove 220 in the width direction, and the cooling guide wheel 231 is connected to the guide wheel shaft. The structure of the cooling guide wheel 231 is the same as that of the first guide wheel 1421, and also has a V-shaped guide groove. The cable output from the overmolding core 131 passes through the guide hole in the middle of the guide plate at one end of the cooling groove 220, is carried on the cooling guide wheel 231, passes through the guide hole in the middle of the guide plate at the other end of the cooling groove 220, and is then connected to the traction device 300.

[0056] The cooling trough moving mechanism 240 includes a chain installed at the bottom of the cooling trough 220, a plurality of pulley assemblies and gears installed on the cooling device housing 210. The extension direction of the chain at the bottom of the cooling trough 220 is consistent with the length direction of the cooling trough 220. The lower parts of both sides in the width direction of the cooling trough 220 are respectively placed on a plurality of pulley assemblies. The gears are engaged with the chain at the bottom of the cooling trough 220. In this way, the cooling trough 220 can be moved along its length direction. By moving the cooling trough 220, the guide hole in the middle of the guide plate at one end of the cooling trough 220 can be aligned with the center of the covering core.

[0057] The traction device 300 includes a traction guiding mechanism for carrying and guiding the cable, a winding mechanism for winding the cable, and a traction motor for driving the winding mechanism to wind the cable so that the downstream part of the cable is pulled and moved. The specific structure can adopt the structure in the prior art and will not be elaborated herein.

[0058] The detection device 400 is used to detect the diameter of the cable and the current traction speed of the traction device 300. In this embodiment, the detection device 400 includes a first diameter gauge 410 disposed downstream of the cable cooling device 200 and a speed sensor disposed at the traction motor of the traction device 300. The first diameter gauge 410 is used to detect the diameter of the cooled cable at the position as the current diameter. The speed sensor is used to detect the current speed of the traction motor.

[0059] The traction control device 500 adjusts the traction speed of the traction device 300 according to the current diameter measured by the detection device 400 and the predetermined standard diameter range, so that the diameter of the manufactured cable can be maintained within the standard diameter range.

[0060] Figure 8 is a block diagram of the traction control device in this embodiment.

[0061] like Figure 8As shown, the traction control device 500 includes a data storage unit 510, a diameter data acquisition unit 520, a diameter median value selection unit 530, a traction speed adjustment determination unit 540, a current traction speed acquisition unit 550, an adjusted traction speed calculation unit 560, an adjusted traction speed output unit 570, an adjusted traction speed feedback unit 580 and a traction control unit 590.

[0062] The data storage unit 510 is used to temporarily store multiple current diameters and corresponding timing information measured by the detection device 400. In this embodiment, the first diameter gauge 410 detects the diameter of the cooled cable once every 0.5 seconds to obtain a current diameter value and a corresponding measurement time, and temporarily stores the current diameter value and the corresponding measurement time in the data storage unit 510.

[0063] The diameter data acquisition unit 520 acquires N consecutive current diameters from the data storage unit 510 at predetermined standard intervals for further calculation and analysis. In this embodiment, the detection data acquisition unit 520 acquires a latest measured current diameter value from the data storage unit 510 every 0.5 seconds according to the corresponding measurement time, and continuously acquires 5 current diameter values.

[0064] The diameter median value selection unit 530 discards the maximum value and the minimum value among the N current diameter values ​​obtained by the detection data acquisition unit 520, and selects the median value from the remaining N-2 current diameter values ​​as the diameter median value. In this embodiment, the maximum value and the minimum value are discarded among the 5 current diameter values ​​obtained, and the median value is selected from the remaining 3 current diameter values.

[0065] When the median diameter value exceeds the predetermined standard diameter range, the traction speed adjustment determination unit 540 determines that the traction speed of the traction device 400 needs to be adjusted, thereby adjusting the diameter of the manufactured cable. In this embodiment, the standard diameter range is set to 1.6 cm ± 0.004 cm, where 1.6 cm is the standard diameter value. When the measured median diameter value exceeds the range, it is determined that the current traction speed needs to be adjusted.

[0066] When the traction speed adjustment determination unit 540 determines that the current traction speed needs to be adjusted, the current traction speed acquisition unit 550 acquires the current rotation speed of the traction motor from the rotation speed sensor, and converts the rotation speed into the linear speed of the traction cable as the current traction speed according to the parameters of the traction motor.

[0067] After the current traction speed acquisition unit 550 acquires the current traction speed, the adjusted traction speed calculation unit 560 calculates the adjusted traction speed (hereinafter referred to as the adjusted speed) of the traction device 400 according to the median diameter value selected by the median diameter selection unit 530, the predetermined standard diameter range, and the current traction speed acquired by the traction speed acquisition unit 550. The traction speed calculation unit 560 includes a diameter difference calculation unit 561, an adjustment coefficient determination unit 562, a target speed calculation unit 563, and an adjusted speed calculation unit 564.

[0068] The diameter difference calculation unit 561 is used to calculate the difference between the median diameter and the standard diameter value in the standard diameter range and the percentage difference. For example, if the measured median diameter is 1 cm and the predetermined standard diameter value is 1.6 cm, the percentage difference is calculated to be (1.6-1) / 1.6=37.5%.

[0069] The adjustment coefficient determination unit 562 determines the adjustment coefficient to be used according to the percentage difference calculated by the diameter difference calculation unit 551 and the correspondence between the predetermined difference percentage and the multiple adjustment coefficients. In this embodiment, when the percentage difference is greater than 2%, the adjustment coefficient is 0.7; when the percentage difference is less than 2%, the adjustment coefficient is 0.5, that is, when the measured diameter differs greatly from the standard diameter range, a relatively large adjustment amplitude is applied, and when the measured diameter is closer to the standard diameter range, a relatively small adjustment amplitude is applied, so that the actual diameter of the cable can be well close to the set standard diameter range. In an alternative solution, more levels of adjustment coefficients can also be used.

[0070] The target speed calculation unit 563 calculates a target traction speed that can keep the cable diameter within the standard diameter range according to the difference between the median diameter value calculated by the diameter difference calculation unit 561 and the standard diameter range, the acquired current traction speed and the standard diameter range.

[0071] Specifically, assuming that the measured current radius of the cable is R0, the radius of the inner core of the cable is r, the current traction speed is v0, the target traction speed is v1, and the cable radius at the target traction speed is R1. Since the extrusion mechanism of the core coating device 100 extrude the coating material at a constant speed, the volume of the extruded coating material within a period of time t is constant. Since the cross-section of the coating layer is annular, we have:

[0072]

[0073] By rearranging the above formula, we can get the calculation formula for the target traction speed v1:

[0074]

[0075] For example, if the current median diameter is 1 cm, the set standard diameter is 1.6 cm, and the measured current traction speed is 120 mm / s, the target traction speed that can make the cable diameter 1.6 cm can be calculated as 73.125 mm / s through the above formula.

[0076] The adjusted speed calculation unit 564 calculates an adjusted speed that can make the cable diameter approach the set standard diameter range according to the acquired current pulling speed, the calculated target pulling speed and the adjustment coefficient determined by the adjustment coefficient determination unit 562 .

[0077] Specifically, assuming the adjustment coefficient is α, the adjusted speed v2 is calculated according to the following formula:

[0078] v2=[αv1-v0]

[0079] For example, if the current traction speed is 120 mm / s, the target traction speed is 73.125 mm / s, and the adjustment coefficient is 0.7, the adjusted speed can be calculated by the above formula to be 68.8125 mm / s.

[0080] The adjusted traction speed output unit 570 converts the adjusted traction speed calculated by the traction speed calculation unit 560 into an adjusted rotation speed of the traction motor according to the parameters of the traction motor, and outputs the adjusted rotation speed to the traction motor.

[0081] The adjusted traction speed feedback unit 580 obtains the current speed of the traction motor from the speed sensor a predetermined time after the traction speed output unit 570 outputs the adjusted speed, and determines whether the current speed of the traction motor reaches the adjusted speed, and generates corresponding warning information when the judgment is no.

[0082] The traction control unit 590 is used to control the operation of the above-mentioned functional units.

[0083] Before starting to manufacture cables using the cable manufacturing device 1000, the operator first needs to move the guide wheel bracket 1425 to a position away from the covering core 131 through the fourth moving assembly 1434, wind the wire core around the guide wheel mechanism 14, and sequentially pass the wire core through the center hole 131a of the covering core 131, the guide hole in the middle of the guide plate at one end of the cooling groove 220, the guide hole in the middle of the guide plate carried on the cooling guide wheel 231 and passed through the other end of the cooling groove 220, and then connect the wire core to the traction device 300. The operator measures the diameter of the wire core by using a tool such as a caliper, finds the shape and size of the guide groove 1421a according to the model of the first guide wheel 1421, and inputs it into the wire core guide control mechanism, so that the wire core guide control can align the center of the wire core carried on the first guide wheel 1421 with the center of the covering core 131 according to the diameter of the wire core and the shape and size of the guide groove 1421.

[0084] Fig. 9 4 is a flow chart of the cable manufacturing method in this embodiment.

[0085] Fig.10 4 is a flow chart of step S6 of the cable manufacturing method in this embodiment.

[0086] like Fig. 9 and Fig.10 As shown, the method for manufacturing a cable using the cable manufacturing device 1000 specifically includes the following steps:

[0087] In step S1 , the wire core coating device 100 continuously coats the molten coating material onto the wire core to form a cable, and at the same time, the pulling device 400 continuously pulls the cable forward at a predetermined pulling speed.

[0088] In step S2, the diameter data acquisition unit 520 acquires a measured cable diameter from the first diameter measuring instrument 410 as a current diameter at every predetermined standard time interval until N current diameters are acquired.

[0089] Step S3: the diameter median selection unit 530 removes the maximum value and the minimum value from the N current diameters, and selects the diameter median from the remaining N-2 current diameters.

[0090] In step S4, the pulling speed adjustment determination unit 540 determines whether the current pulling speed needs to be adjusted according to the median diameter value and the predetermined standard diameter range. If the determination is no, the process returns to step S2, i.e., the cable is continued to be pulled at the current pulling speed and the diameter detection is continued.

[0091] Step S5: When it is determined in step S4 that the current traction speed needs to be adjusted, the current traction speed acquisition unit 550 acquires the current traction speed of the traction device 300 from the speed sensor.

[0092] In step S6, the pulling speed calculation unit 560 calculates an adjusted pulling speed that can make the cable diameter approach the standard diameter range according to the current pulling speed, the measured diameter median value, and the predetermined standard diameter range.

[0093] like Fig.10 As shown, step S6 specifically includes the following sub-steps:

[0094] Step S6-1, the diameter difference calculation unit 561 calculates the difference between the median diameter and the standard diameter range and the percentage difference.

[0095] In step S6-2, the adjustment coefficient determination unit 562 determines the corresponding adjustment coefficient according to the percentage difference and the correspondence between the predetermined percentage difference and the adjustment coefficient.

[0096] Step S6-3: The target speed calculation unit 563 calculates a target pulling speed that can make the cable diameter fall within the standard diameter range according to the current pulling speed and the difference between the median diameter value and the standard diameter range.

[0097] Step S6-4: the adjusted speed calculation unit 564 calculates an adjusted pulling speed that can make the cable diameter approach the standard diameter range according to the current pulling speed, the target pulling speed and the adjustment coefficient.

[0098] In step S7 , the traction speed output unit 570 converts the adjusted traction speed into an adjusted rotational speed of the traction motor, and outputs the adjusted rotational speed to the traction motor.

[0099] Step S8: After a predetermined time has passed since the traction speed output unit 570 outputted the adjusted speed, the traction speed feedback unit 580 obtains the current speed of the traction motor from the speed sensor.

[0100] In step S9, the traction speed feedback unit 580 determines whether the acquired rotation speed reaches the adjusted rotation speed, and returns to step S2 when the determination is yes.

[0101] Step S10: When the result of step S9 is negative, the traction speed feedback unit 580 generates a corresponding warning message. After the operator observes the warning message, he can perform corresponding inspection and manual adjustment.

[0102] Through the above steps, the diameter of the cable can be continuously monitored during the cable manufacturing process, and the linear speed of the cable (that is, the traction speed of the traction device 500) can be adjusted according to the measured diameter, so that the cable diameter gradually approaches the set standard diameter. As an example, the following Table 1 shows the traction speed and the corresponding cable diameter after each automatic adjustment during the manufacturing process of a certain type of cable with a set diameter of 1.6 cm.

[0103] Table 1 Traction speed adjustment and cable diameter change table

[0104]

[0105] From the data in Table 1, we can see that after the first 5 rounds of adjustment of about 10 seconds, the cable diameter has been very close to the set standard diameter value, and the deviation between the actual cable diameter and the set diameter value is only -0.3125%; and after 10 rounds of adjustment of about 20 seconds, the deviation between the actual cable diameter and the set diameter value is further reduced to -0.0125%, and the accuracy of the cable diameter is very high. At the same time, it can be seen from the time consumption of adjustment that the efficiency is greatly improved compared with the manual adjustment method.

[0106] Functions and Effects of Embodiment 1

[0107] According to the cable manufacturing equipment and method provided in this embodiment, the equipment includes a core coating device for coating the core of the cable, a traction device for traction the cable to make it move forward, a detection device and a traction control device. Since the detection device includes a diameter gauge arranged downstream of the core coating device and a speed sensor arranged at the traction motor, it is capable of detecting the diameter of the coated cable and the speed of the traction motor, and obtaining the traction speed of the traction motor for the cable according to the speed. The traction control device can control the traction speed of the traction device according to the deviation between the measured diameter and the predetermined standard diameter range, thereby automatically adjusting the diameter of the manufactured cable so that the diameter of the cable is controlled within the standard diameter range, and no manual repeated adjustment is required, which can not only save a lot of manpower and time, but also improve the diameter accuracy and uniformity of the cable.

[0108] In an embodiment, the traction control device includes a diameter data acquisition unit, a diameter median value selection unit, a traction speed adjustment determination unit, a current traction speed acquisition unit, a traction speed calculation unit and a traction speed output unit. The diameter median value selection unit can obtain the median value of multiple cable diameters measured within a period of time, and the traction speed calculation unit can calculate the adjusted traction speed according to the diameter median value, the standard diameter range and the current traction speed. In this way, the adjusted traction speed calculated based on the diameter median value can stably make the cable diameter approach the standard diameter range, thereby avoiding the fluctuation of the adjusted diameter caused by the fluctuation of the measured diameter value.

[0109] Furthermore, the traction speed calculation unit includes a diameter difference calculation unit, an adjustment coefficient determination unit, a target speed calculation unit and an adjusted speed calculation unit. The target speed calculation unit can calculate a target traction speed that makes the cable diameter fall within the standard diameter range. The adjusted speed calculation unit can calculate an adjusted traction speed that makes the cable diameter approach the standard diameter range based on the current traction speed, the target traction speed and the adjustment coefficient, thereby enabling the cable diameter to gradually and stably approach the standard diameter range, and ultimately the cable diameter can achieve a very high accuracy.

[0110] Furthermore, the adjustment coefficient is set according to the percentage difference between the current median diameter of the cable and the standard diameter range. When the percentage difference is large, the adjustment coefficient is set to be larger, and when the percentage difference is small, the adjustment coefficient is set to be smaller. In this way, the cable diameter can be adjusted with a larger amplitude when the difference between the cable diameter and the set standard diameter range is large, and can be adjusted with a smaller amplitude when the difference is small, so that the cable diameter can achieve a very high accuracy.

[0111] In an embodiment, the traction control device also includes a traction speed feedback unit, which can detect whether the speed of the traction motor reaches the adjusted speed after a period of time after the traction speed output unit outputs the adjusted speed, and generate corresponding warning information when it is judged that it has not reached the adjusted speed, thereby facilitating the operator to promptly discover problems in the traction speed adjustment process.

[0112] <Example 2>

[0113] This embodiment provides a cable manufacturing device and a corresponding cable manufacturing method. In this embodiment, the same symbols are given to the same components as those in the first embodiment and the corresponding descriptions are omitted.

[0114] Fig.11 is a top view of the cable manufacturing equipment in this embodiment.

[0115] like Fig.11 As shown, compared with the first embodiment, the difference is that the detection device 400 of this embodiment further includes a second diameter gauge 420, which is arranged between the coating mold core 131 of the wire core coating device 100 and the cooling groove 220 of the cable cooling device 200, and is used to detect the diameter of the cable at this position after coating and before cooling, as the current diameter before cooling. The diameter of the cable after cooling measured by the first diameter gauge 410 is used as the current diameter after cooling.

[0116] In this embodiment, the diameter data acquisition unit 520 also acquires the current diameter after cooling measured by the first caliper 410 and the current diameter before cooling measured by the second caliper 420 at every predetermined standard time interval until N consecutive current diameters after cooling and N current diameters before cooling are acquired.

[0117] The diameter median value selection unit 530 selects a median value from the N current diameters before cooling as the median value of the diameter before cooling, and selects a median value from the N current diameters after cooling as the median value of the diameter after cooling.

[0118] The traction speed adjustment determination unit 540 determines that the current traction speed of the traction device 300 needs to be adjusted when the median diameter value after cooling exceeds the standard diameter range after cooling or the median diameter value before cooling exceeds the standard diameter range before cooling.

[0119] In the pulling speed calculation part 560, the diameter difference calculation unit 561 calculates the difference and percentage difference between the median diameter before cooling and the standard diameter range before cooling, and calculates the difference and percentage difference between the median diameter after cooling and the standard diameter range after cooling.

[0120] The adjustment coefficient determination unit 562 determines the corresponding pre-cooling adjustment coefficient based on the percentage difference between the median value of the diameter before cooling and the standard pre-cooling diameter range, and the predetermined corresponding relationship between the percentage difference and the pre-cooling adjustment coefficient, and determines the corresponding post-cooling adjustment coefficient based on the percentage difference between the median value of the diameter after cooling and the standard post-cooling diameter range, and the predetermined corresponding relationship between the percentage difference and the post-cooling adjustment coefficient.

[0121] The target speed calculation unit 563 calculates a first target traction speed that can make the cable diameter after cooling fall within the standard diameter range after cooling according to the measured current traction speed, the median value of the diameter after cooling and the standard diameter range after cooling, and calculates a second target traction speed that can make the cable diameter before cooling fall within the standard diameter range before cooling according to the measured current traction speed, the median value of the diameter before cooling and the standard diameter range before cooling.

[0122] The adjusted speed calculation unit 564 calculates a first adjusted traction speed according to the current traction speed, the first target traction speed and the adjustment coefficient, and calculates a second adjusted traction speed according to the current traction speed, the second target traction speed and the adjustment coefficient before cooling, and then multiplies the first adjusted speed and the second adjusted traction speed by the predetermined corresponding weight coefficients respectively and then adds them together to obtain the final adjusted traction speed.

[0123] In this embodiment, other structures and cable manufacturing methods are the same as those in the first embodiment, and thus will not be described again.

[0124] Functions and Effects of Embodiment 2

[0125] According to the cable manufacturing equipment and method provided by this embodiment, on the basis of the functions and effects of the first embodiment, the diameter of the cable before cooling is measured by a second diameter gauge, and similarly, whether to adjust the current traction speed is determined based on the median value of the cable diameter before cooling. When it is determined to be yes, the first adjusted traction speed and the second adjusted traction speed are calculated based on the median value of the diameter before cooling and the median value of the diameter after cooling, respectively, and the two speeds are weighted averaged to obtain the final adjusted traction speed. That is, in the second embodiment, the diameter of the cable before cooling is further considered on the basis of the first embodiment. Since the cable shrinks at a predetermined ratio after cooling, the diameter of the cable before cooling is further considered, which can reduce the poor adjustment effect caused by the floating of the measured cable diameter after cooling, thereby further improving the accuracy of cable diameter adjustment.

[0126] The above embodiments are only used to illustrate specific implementation modes of the present invention, and the present invention is not limited to the description scope of the above embodiments.

Claims

1. A cable manufacturing device, characterized in that: include: A wire core coating device, used for coating the molten coating material onto the wire core to form a cable with a coating layer; A traction device, disposed downstream of the covering device, for traction of the cable forward; A detection device, comprising at least a diameter measuring unit disposed downstream of the wire core covering device, for detecting a diameter of the cable as a current diameter; as well as The traction control device controls the traction speed of the traction device according to the measured deviation between the current diameter and a predetermined standard diameter range, so that the diameter of the cable is controlled within the standard diameter range.

2. The cable manufacturing device according to claim 1, Features: in, The diameter measuring unit comprises a diameter gauge, The traction control device comprises: A diameter data acquisition unit, used for acquiring the current diameter measured by the caliper at every predetermined standard time interval; a traction speed adjustment determination unit, which determines that the traction speed needs to be adjusted when the current diameter exceeds the standard diameter range; an adjusted traction speed calculation unit, which, when the traction speed adjustment determination unit determines that the traction speed needs to be adjusted, calculates an adjusted traction speed that enables the diameter of the cable to be within the standard diameter range according to the current diameter, the standard diameter range, and the current traction speed of the traction device; and The adjusted traction speed output unit outputs the adjusted traction speed to the traction device, so that the traction device pulls the cable forward at the adjusted traction speed.

3. The cable manufacturing equipment according to claim 2, characterized in that: Also includes: a current traction speed acquisition unit, configured to acquire the current traction speed of the traction device when the traction speed adjustment determination unit determines that the traction speed needs to be adjusted, Wherein, the traction device comprises a traction motor, The detection device also includes a rotation speed sensor for detecting the rotation speed of the traction motor. The current traction speed acquisition unit acquires the rotation speed of the traction motor measured by the rotation speed sensor, and converts the rotation speed into a linear speed of the cable being pulled forward as the current traction speed according to the parameters of the traction motor. The adjusted traction speed output unit converts the adjusted traction speed into an adjusted rotational speed of the traction motor according to the parameters of the traction motor, and outputs the adjusted rotational speed to the traction motor.

4. The cable manufacturing device according to claim 3, Features: in, The adjusted traction speed calculation unit includes: A diameter difference calculation unit, used for calculating the difference and percentage difference between the current diameter and a standard diameter value in the standard diameter range; an adjustment coefficient determination unit, for determining the corresponding adjustment coefficient according to the percentage difference and a predetermined correspondence between the percentage difference and the adjustment coefficient; a target speed calculation unit, which calculates a target pulling speed that can make the diameter of the cable fall within the standard diameter range according to the difference, the current pulling speed and the standard diameter range; and The adjusted speed calculation unit calculates an adjusted traction speed that can make the diameter of the cable approach the standard diameter range according to the current traction speed, the target traction speed, and the determined adjustment coefficient.

5. The cable manufacturing equipment according to claim 4, characterized in that: in, The target traction speed v1 is calculated according to the following formula: Wherein, R0 is the radius corresponding to the current diameter, r is the radius of the wire core, v0 is the current pulling speed, The adjusted speed v2 is calculated according to the following formula: v2=[αv1-v0] In the formula, α is the determined adjustment coefficient.

6. The cable manufacturing equipment according to claim 4, characterized in that: in, The corresponding relationship between the percentage difference and the adjustment coefficient is: When the percentage difference is greater than or equal to a predetermined threshold, the adjustment coefficient is set to a first adjustment coefficient value. When the percentage difference is less than the predetermined threshold, the adjustment coefficient is set to a second adjustment coefficient value, The second adjustment coefficient value is smaller than the first adjustment coefficient value.

7. The cable manufacturing equipment according to claim 6, characterized in that: in, The predetermined threshold is 2%. The first adjustment coefficient value is 0.7, and the second adjustment coefficient value is 0.

5.

8. The cable manufacturing equipment according to claim 4, characterized in that: Also includes: The traction speed feedback unit obtains the current speed of the traction motor measured by the speed sensor a predetermined time after the traction speed output unit outputs the adjusted speed, and determines whether the speed reaches the adjusted speed, and generates corresponding warning information when the determination is no.

9. The cable manufacturing equipment according to any one of claims 2 to 8, characterized in that: Also includes: a diameter median value selection unit, used to select a median value from the multiple current diameters as the diameter median value, The diameter data acquisition unit acquires the current diameter measured by the caliper at predetermined standard time intervals until a predetermined number of current diameters are acquired. The pulling speed adjustment determination unit determines that the pulling speed needs to be adjusted when the median diameter value exceeds the standard diameter range; The adjusted traction speed calculation unit calculates the adjusted traction speed that can make the diameter of the cable approach the standard diameter range according to the median diameter, the standard diameter range and the current traction speed of the traction device when the traction speed adjustment determination unit determines that the traction speed needs to be adjusted.

10. The cable manufacturing equipment according to claim 9, characterized in that: in, The diameter median value selection unit removes the maximum value and the minimum value from the multiple current diameters, and selects the median value from the remaining multiple current diameters as the diameter median value.

11. The cable manufacturing equipment according to claim 1, characterized in that: Also includes: A cable cooling device is arranged downstream of the wire core coating device and is used to cool the coated cable. Wherein, the caliper measuring unit comprises a first caliper and a second caliper, The first diameter gauge is arranged downstream of the cable cooling device, and is used to detect the diameter of the cable after cooling as the current diameter, and the current diameter is the current diameter after cooling. The second diameter gauge is disposed between the wire core covering device and the cable cooling device, and is used to detect the diameter of the cable before cooling as the current diameter before cooling. The traction control device comprises: a diameter data acquisition unit, configured to acquire the current diameter after cooling measured by the first caliper at each predetermined standard time interval, and to acquire the current diameter before cooling measured by the second caliper at each predetermined standard time interval; a traction speed adjustment determination unit, which determines that the traction speed needs to be adjusted when the current diameter after cooling exceeds a predetermined standard diameter range after cooling or the current diameter before cooling exceeds a predetermined standard diameter range before cooling; an adjusted traction speed calculation unit, which calculates a first adjusted traction speed according to the current diameter after cooling, the standard diameter range after cooling, and the current traction speed of the traction device, and calculates a second adjusted traction speed according to the current diameter before cooling, the standard diameter range before cooling, and the current traction speed, and then calculates an adjusted traction speed according to the first adjusted traction speed, the second adjusted traction speed, and corresponding weight coefficients; and The adjusted traction speed output unit outputs the adjusted traction speed to the traction device, so that the traction device pulls the cable forward at the adjusted traction speed.

12. A cable manufacturing method, characterized in that: A cable is manufactured using the cable manufacturing device according to any one of claims 1 to 11, the method comprising: The wire core coating device coats the molten coating material onto the wire core to form the cable, and the traction device continuously pulls the cable forward at a certain traction speed. Wherein, during the progress of the cable, the diameter measuring unit detects the diameter of the cable as the current diameter, The traction control device controls the traction speed according to the measured current diameter and a predetermined standard diameter range, so that the diameter of the cable is controlled within the standard diameter range.

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