Wire rewinding machine and control method

Abstract

The invention discloses a wire rewinding machine and a control method, the wire rewinding machine comprises an unwinding shaft, a winding shaft, a wire arranging rod, a wire arranging shaft, a swing rod, a swing rod motor and a PLC module which are installed on a wire rewinding machine body, and the wire arranging shaft is installed on the wire arranging rod; the swing rod is installed on a swing rod motor, and the swing rod motor is installed on the wire rewinding machine body. The swing rod is further provided with a sensor module. According to the yarn rewinding machine and the control method thereof, the yarn rewinding precision and quality are improved, yarn tension is uniform, and winding is neat; sensitive sensing of the swing rod to tension and accurate adjustment of speed control are combined, high-precision tension control can be achieved, and the production process with strict tension requirements is met. The response speed is high, and various changes in the yarn reversing process can be adapted in real time.

Description

Technical Field

[0001] The invention relates to a wire rewinding machine, in particular to a wire rewinding machine and a control method. Background Art

[0002] A wire rewinding machine is a device used to transfer materials such as film wire and fiber wire from one reel to another. It controls the tension, speed and arrangement of the wire to ensure that the material remains neat and uniform during the winding process to avoid entanglement or breakage. A wire rewinding machine is usually composed of a reel, a reel, a wire arrangement shaft, a swing rod, a motor and a control system. It is widely used in the textile, packaging and other industries to improve production efficiency and product quality.

[0003] In the existing wire rewinding machine technology, the accuracy and stability of the swing arm control have an important impact on the quality and efficiency of the wire rewinding. However, the traditional control method often has defects such as slow response speed and low control accuracy, which leads to problems such as uneven wire tension and uneven winding during the wire rewinding process. Summary of the invention

[0004] The technical problem to be solved by the present invention is to provide a wire rewinding machine and a control method, which solves the problems of slow response speed, low control accuracy, uneven tension, uneven winding, etc. of the existing wire rewinding machine.

[0005] The technical problem to be solved by the present invention is achieved by adopting the following technical solutions:

[0006] The present invention provides a wire rewinding machine, comprising a reeling shaft, a reeling shaft, a wire rod, a wire rod shaft, a swing rod, a swing rod motor and a PLC module installed on a wire rewinding machine body, wherein:

[0007] The wire arrangement shaft is installed on the wire arrangement rod;

[0008] The swing rod is mounted on a swing rod motor, and the swing rod motor is mounted on the wire rewinding machine body;

[0009] The swing rod is also provided with a sensor module.

[0010] As a preferred technical solution of the present invention, the PLC module is used to generate control instructions.

[0011] As a preferred technical solution of the present invention, the drive motor of the unwinding shaft, the drive motor of the winding shaft, the drive motor of the wire rod connected to the wire rod shaft and the rocker motor receive control instructions from the PLC module.

[0012] The present invention also provides a control method for a wire rewinding machine, which is applied to the aforementioned wire rewinding machine and comprises the following steps:

[0013] Step S1, the sensor module of the swing arm motor collects parameters;

[0014] Step S2, the PLC module receives the aforementioned parameters;

[0015] Step S3, the PLC module calculates the expected position;

[0016] Step S4, the PLC module calculates the error between the expected position and the actual position;

[0017] Step S5, calculating the output of the proportional term, the integral term and the differential term according to the error in step S4;

[0018] Step S6, adding each item in step S5 to obtain the output of the PID controller;

[0019] Step S7, the drive motor of the unwinding shaft, the drive motor of the winding shaft, the drive motor of the wire rod connected to the wire rod shaft, and the swing arm motor are adjusted according to the PID control information in step S6;

[0020] Step S8, the PLC module adjusts the output PID control information in real time according to the monitoring value of the sensor module until the desired position is met.

[0021] As a preferred technical solution of the present invention, in step S5, calculating the output of the proportional term, the integral term and the differential term specifically includes the following sub-steps:

[0022] S5.1 calculates the proportional term and generates a control output proportional to the error based on the current error;

[0023] S5.2 calculates the integral term and generates a control output for eliminating the long-term error based on the accumulated amount of the error;

[0024] S5.3 calculates the differential term and generates a control output for predicting the error change trend based on the error change rate;

[0025] S5.4 adds the output values ​​of the proportional term, the integral term, and the differential term to generate a comprehensive output of the PID controller.

[0026] Preferably, the calculation formula of the PID control algorithm in step S5 is as follows:

[0027]

[0028] Further preferably, in the step S1, the sensor module detects the position of the swing rod and the wire tension in real time, and continuously collects tension change parameters related to the wire rewinding process;

[0029] In step S3, the PLC module calculates the required adjustment position of the swing rod in real time based on the collected tension change parameters to ensure the stability of the tension during the rewinding process.

[0030] The beneficial effects of the present invention are as follows: the wire rewinding machine and its control method of the present invention improve the precision and quality of wire rewinding, and the wire tension is uniform and the winding is neat; the combination of the sensitive sensing of the swing rod to the tension and the precise adjustment of the speed control can realize high-precision tension control and meet the production process with strict tension requirements; the response speed is fast and can adapt to various changes in the wire rewinding process in real time. The swing rod can quickly sense the tension change, and the speed control can quickly adjust the motor speed, so that the system responds to the tension change very quickly; the stability and reliability of the system are enhanced, and the probability of failure is reduced; the control swing rod system has high reliability and stability, and reduces the maintenance cost and the risk of production interruption. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is one of the structural schematic diagrams of the present invention;

[0032] Figure 2 This is the second structural schematic diagram of the present invention;

[0033] Figure 3 This is the third structural schematic diagram of the present invention;

[0034] In the figure: 000, wire rewinding machine body; 1, unwinding shaft; 2, rewinding shaft; 3, wire arrangement rod; 4, wire arrangement shaft; 5, rocker arm; 51, rocker arm motor; 6, PLC module. DETAILED DESCRIPTION

[0035] The preferred embodiments of the present invention are described below in conjunction with the accompanying drawings. It should be understood that the preferred embodiments described herein are only used to illustrate and explain the present invention, and are not used to limit the present invention.

[0036] Example 1

[0037] like Figure 1-2 As shown, this embodiment provides a wire rewinding machine, including a reel 1, a reel 2, a wire rod 3, a wire rod 4, a swing rod 5, a swing rod motor 51 and a PLC module 6, wherein the wire rod 4 is mounted on the wire rod 3; the swing rod 5 is mounted on the swing rod motor 51, and the swing rod motor 51 is mounted on the wire rewinding machine body 000; the swing rod 5 also has a sensor module. The PLC module 6 is used to generate control instructions. In this embodiment, the PLC module 6 can be set in the wire rewinding machine housing or on the back of the wire rewinding machine housing.

[0038] The actuator includes a high-performance unwinding shaft, a reeling shaft, a wire arrangement shaft and a motor device thereof. Its working principle is to sense the tension change of the material through the swing rod, and at the same time, the control system adjusts the speed of the driving motor of the unwinding shaft and the reeling shaft according to the position feedback signal of the swing rod, thereby realizing the control of the wire drawing tension; specifically, the driving motor of the unwinding shaft 1, the driving motor of the reeling shaft 2, the driving motor of the wire arrangement rod 3 connected to the wire arrangement shaft 4 and the swing rod motor 51 receive control instructions from the PLC module 6.

[0039] Firstly, the high-precision rocker and sensor module can realize real-time monitoring and adjustment of the wire tension to ensure the stability and uniformity of the tension; secondly, the advanced PLC control module combined with the PID control algorithm can quickly respond to changes in wire tension and ensure efficient and precise control during high-speed rewinding; finally, the overall structural design of the rewinding machine is simple, the system is stable and reliable, the maintenance cost is low, and it is suitable for various production environments and process requirements, which improves the working efficiency and product quality of the rewinding machine.

[0040] Example 2

[0041] This embodiment provides a control method for a wire rewinding machine, which is applied to the wire rewinding machine in Embodiment 1 and includes the following steps:

[0042] Step S1, the sensor module of the swing arm motor 51 collects parameters;

[0043] Step S2, the PLC module 6 receives the aforementioned parameters;

[0044] Step S3, the PLC module 6 calculates the expected position;

[0045] Step S4, the PLC module 6 calculates the error between the expected position and the actual position;

[0046] Step S5, calculating the output of the proportional term, the integral term and the differential term according to the error in step S4;

[0047] Step S6, adding each item in step S5 to obtain the output of the PID controller;

[0048] Step S7, the drive motor of the unwinding shaft 1, the drive motor of the winding shaft 2, the drive motor of the wire rod 3 connected to the wire rod 4 and the rocker motor 51 are adjusted according to the PID control information in step S6;

[0049] Step S8, the PLC module 6 adjusts the output PID control information in real time according to the monitoring value of the sensor module until the desired position is met.

[0050] Furthermore, in step S5, the outputs of the proportional term, the integral term and the differential term are calculated, which specifically includes the following sub-steps:

[0051] S5.1 calculates the proportional term and generates a control output proportional to the error based on the current error;

[0052] S5.2 calculates the integral term and generates a control output for eliminating the long-term error based on the accumulated amount of the error;

[0053] S5.3 calculates the differential term and generates a control output for predicting the error change trend based on the error change rate;

[0054] S5.4 adds the output values ​​of the proportional term, the integral term, and the differential term to generate a comprehensive output of the PID controller.

[0055] The calculation formula of the PID control algorithm in step S5 is as follows:

[0056]

[0057] Specific:

[0058] u(t) is the output of the PID controller;

[0059] e(t) is the error between the set value and the actual value, that is, e(t) = r(t)-y(t), r(t) is the set value.

[0060] Fixed value, y(t) is the actual measured value;

[0061] K p is the proportionality factor, which determines the degree of immediate response to the error;

[0062] K i is the integral coefficient, which is used to eliminate steady-state errors and the integral of the accumulated errors over time;

[0063] K d is the differential coefficient, which responds to the rate of change of the error and plays a role in predicting and stabilizing the system;

[0064] In the PID control algorithm, the function of the formula is to dynamically adjust the system output through the three parts of proportion, integration and differentiation, so that it approaches the set value r(t) faster and more accurately. The parameters in the formula are derived from the specific needs of the system and the experimental debugging results.

[0065] About the proportionality factor K p : It comes from the control system's requirement for error sensitivity. It directly determines the system's immediate response strength to the error e(t). In the calculation, K p The role of e(t) is to quickly reduce instantaneous errors, but too high a proportionality factor may cause system oscillation.

[0066] About the integral coefficient K i : It comes from the requirement for long-term stability of the system. The integral part is calculated by adding up the accumulated value of the error over time. Gradually eliminate the residual error, so that the system output and the set value tend to be completely consistent. This parameter is suitable for compensating the system steady-state error.

[0067] About the differential coefficient K d :It comes from the need to optimize the dynamic performance of the system. The differential part calculates the error change rate Predict the trend of system error changes, thereby suppressing the error change rate and improving system stability. Especially when the demand for rapid response is high, the differential effect is particularly important. In the calculation, these three parts work together to build a closed-loop control system. Proportional control is responsible for real-time adjustment of the current error, integral control compensates for the accumulated error, and differential control suppresses the rapid fluctuation of the error. By reasonably adjusting K p , K i and K d The value of can achieve a balance between response speed, control accuracy and system stability, providing reliable guarantee for tension control.

[0068] In the step S1, the sensor module detects the position of the swing rod and the wire tension in real time, and continuously collects tension change parameters related to the wire rewinding process;

[0069] In step S3, the PLC module calculates the required adjustment position of the swing rod in real time based on the collected tension change parameters to ensure the stability of the tension during the rewinding process.

[0070] Specifically, firstly, the control method introduces a high-precision sensor module in step S1 to monitor the position of the swing rod and the wire tension in real time, and can continuously obtain accurate tension change data, providing an accurate basis for subsequent control; secondly, in step S3, the PLC module calculates the required adjustment position of the swing rod in real time based on the collected tension change parameters, effectively maintains the stability of the tension during the rewinding process, and avoids the influence of tension fluctuations on product quality; in step S5, by calculating the proportional term, integral term and differential term in detail, and using the PID control algorithm for comprehensive adjustment, it can achieve efficient and accurate tension control to meet the production process requirements with strict tension requirements; finally, in step S8, the PLC module adjusts the PID control information in real time to ensure the system's rapid response and adaptation to tension changes, further improving the working efficiency and stability of the rewinding machine. These features jointly improve the control accuracy and production reliability of the rewinding machine, while reducing the failure rate and maintenance cost.

[0071] The wire rewinding machine control method in this embodiment has the following significant features and advantages:

[0072] High-precision real-time monitoring: In step S1, the sensor module is used to detect the position of the swing rod and the wire tension in real time, and continuously collect relevant tension change parameters. This real-time monitoring ensures that the system can accurately perceive every subtle change in the wire rewinding process, providing high-quality data support for subsequent control.

[0073] Precise tension adjustment: In step S3, the PLC module calculates the required adjustment position of the swing rod based on the real-time collected tension change parameters, ensuring the continuous stability of the tension during the rewinding process. This precise adjustment capability effectively avoids the negative impact of tension fluctuations on the quality of the wire, ensuring high rewinding precision and product consistency.

[0074] Advanced PID control algorithm: In step S5, the proportional term, integral term, and differential term are calculated in detail, and their output values ​​are added to generate the comprehensive output of the PID controller. This algorithm combines the immediate response of proportional control, the long-term error elimination of integral control, and the error change prediction of differential control to achieve precise control of the yarn tension. This efficient PID control strategy significantly improves the system's adaptability to complex process requirements.

[0075] Quick response and dynamic adjustment: In step S8, the PLC module dynamically adjusts the PID control information according to the real-time monitoring value of the sensor module to ensure that the system can quickly respond to tension changes. This dynamic adjustment function enables the wire rewinding machine to adapt to various changing conditions in real time during the production process, improving the flexibility and reliability of the system.

[0076] Enhanced stability and reliability: This method not only improves the control accuracy of the wire rewinding machine through precise real-time monitoring and PID control, but also enhances the overall stability of the system. The use of mature motor drive and sensor technology reduces the probability of failure, reduces equipment maintenance costs and the risk of production interruptions, and improves the reliability and economy of the production line.

[0077] Adaptable control strategy: By comprehensively analyzing the tension change trend, adjusting the control parameters in real time, and adaptively adjusting the control output, this method can handle the wire rewinding tasks under various material and process conditions. This adaptable control strategy enables the wire rewinding machine to cope with different production environments and process requirements, improving product quality and production efficiency.

[0078] The working principle is to sense the tension change of the material through the pendulum, and the control system adjusts the speed of the drive motor of the unwinding shaft and the reel according to the position feedback signal of the pendulum, so as to realize the control of the wire drawing tension. Specifically, the pendulum is the core component of tension sensing, and its position is slightly adjusted with the change of tension. The sensor module monitors the position of the pendulum in real time and transmits the signal to the PLC module. The PLC module accurately identifies the dynamic changes of tension by calculating the feedback signal and generates corresponding control instructions. Subsequently, the control instructions are transmitted to the drive motors of the unwinding shaft and the reel, and the speed is adjusted to compensate for the tension change to ensure that the wire tension is always maintained within the target range. This dynamic adjustment method based on pendulum feedback can effectively avoid the problems of uneven winding or broken wires caused by tension fluctuations, while improving the stability and production efficiency of the rewinding process.

[0079] The wire rewinding machine and its control method of the present invention improve the precision and quality of wire rewinding in actual operation, and the wire tension is uniform and the winding is neat; it combines the sensitive response of the swing rod to the tension and the precise adjustment of the speed control, and can achieve high-precision tension control to meet the production process with strict tension requirements; it has a fast response speed and can adapt to various changes in the wire rewinding process in real time. The swing rod can quickly sense the tension change, and the speed control can quickly adjust the motor speed, so that the system responds to the tension change very quickly; it enhances the stability and reliability of the system and reduces the probability of failure; the control swing rod system has high reliability and stability, and reduces the maintenance cost and the risk of production interruption.

[0080] The basic principles, main features and advantages of the present invention are shown and described above. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention. The scope of the present invention is defined by the attached claims and their equivalents.

Claims

1. Wire rewinding machine, characterized in that: The invention comprises an unwinding shaft (1), a rewinding shaft (2), a wire arrangement rod (3), a wire arrangement shaft (4), a swing rod (5), a swing rod motor (51) and a PLC module (6) which are installed on a wire rewinding machine body (000), wherein: The wire arrangement shaft (4) is mounted on the wire arrangement rod (3); The swing rod (5) is mounted on a swing rod motor (51), and the swing rod motor (51) is mounted on the wire rewinding machine body (000); The swing rod (5) is also provided with a sensor module.

2. The wire rewinding machine according to claim 1, characterized in that: The PLC module (6) is used to generate control instructions.

3. The wire rewinding machine according to claim 1, characterized in that: The drive motor of the unwinding shaft (1), the drive motor of the winding shaft (2), the drive motor of the wire rod (3) connected to the wire rod shaft (4), and the rocker motor (51) receive control instructions from the PLC module (6).

4. A control method for a wire rewinding machine, applied to the wire rewinding machine according to any one of claims 1 to 4, characterized in that: The steps include: Step S1, the sensor module of the rocker motor (51) collects parameters; Step S2, the PLC module (6) receives the aforementioned parameters; Step S3, the PLC module (6) calculates the desired position; Step S4, the PLC module (6) calculates the error between the expected position and the actual position; Step S5, calculating the output of the proportional term, the integral term and the differential term according to the error in step S4; Step S6, adding each item in step S5 to obtain the output of the PID controller; Step S7, the drive motor of the unwinding shaft (1), the drive motor of the winding shaft (2), and the drive motor of the wire rod (3) connected to the wire rod (4) are adjusted according to the PID control information in step S6; Step S8, the PLC module (6) adjusts the output PID control information in real time according to the monitoring value of the sensor module until the desired position is met.

5. The control method of the wire rewinding machine according to claim 4, characterized in that: In step S5, the outputs of the proportional term, the integral term and the differential term are calculated, which specifically includes the following sub-steps: S5.1 calculates the proportional term and generates a control output proportional to the error based on the current error; S5.2 calculates the integral term and generates a control output for eliminating the long-term error based on the accumulated amount of the error; S5.3 calculates the differential term and generates a control output for predicting the error change trend based on the error change rate; S5.4 adds the output values ​​of the proportional term, the integral term, and the differential term to generate a comprehensive output of the PID controller.

6. The control method of the wire rewinding machine according to claim 4, characterized in that: The calculation formula of the PID control algorithm in step S5 is as follows:

7. The control method of the wire rewinding machine according to claim 4, characterized in that: In the step S1, the sensor module detects the position of the swing rod and the wire tension in real time, and continuously collects tension change parameters related to the wire rewinding process; In step S3, the PLC module calculates the required adjustment position of the swing rod in real time based on the collected tension change parameters to ensure the stability of the tension during the rewinding process.

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