Metal wire drawing production system

Abstract

The invention relates to the technical field of metal wire machining, in particular to a metal wire drawing production system which is characterized in that after production order information is uploaded to a central control unit through a man-machine interaction APP, the central control unit commands an intelligent pay-off module to complete wire coil placement, and the APP can be used for personnel to check the system state and remotely access; the intelligent pay-off module ensures that the pay-off tension is stable by means of a tension sensor and a PID algorithm; the wire rod preprocessing module collects images by using a high-definition camera, and defect conditions are determined through preprocessing of the central control unit and analysis of a convolutional neural network; and the intelligent control module dynamically adjusts the rotating speed of the motor by adopting a variable-frequency speed regulation technology and combining various data according to the requirements of a wire drawing process, so that the whole production process is efficient, accurate and stable. Precise placement of the wire coil is achieved through the automatic recognition device and the automatic transmission equipment, the time needed by manual operation is greatly shortened, and the working efficiency of the whole pay-off link is improved.

Description

Technical Field

[0001] The invention relates to the technical field of metal wire processing, and in particular to a metal wire drawing production system. Background Art

[0002] Metal wire plays a vital role in modern industry and is widely used in many fields such as construction, power transmission, communication, machinery manufacturing, and automobile manufacturing. With the advancement of science and technology and the growth of market demand, higher requirements are placed on the quality and production efficiency of metal wire. The traditional metal wire drawing production process has many shortcomings. The traditional wire drawing process is greatly affected by the technical level of the operator, and there may be quality differences between different batches of products. In addition, due to the lack of real-time monitoring and automated control methods, product quality is difficult to guarantee. Summary of the invention

[0003] The present invention aims at the technical problems existing in the prior art and provides a metal wire drawing production system.

[0004] The technical solution of the present invention to solve the above technical problems is as follows: A metal wire drawing production system, comprising:

[0005] Production management module: upload order information containing metal wire material, specification, quantity and quality standards to the central control unit through the human-computer interaction APP. The central control unit instructs the intelligent wire-laying module according to the order, uses the automatic transmission equipment to accurately place the wire reel to the identification area, and can allow staff to view the real-time status of the system through the human-computer interaction APP, and supports remote access to the APP;

[0006] Intelligent pay-off module: A high-precision tension sensor is set up to feed back the actual tension value to the central control unit, calculate the tension deviation, and use the discrete position PID control algorithm to calculate the control signal according to the correlation coefficient and the deviation. Based on this, the motor speed, braking torque adjustment amount and the corresponding value after adjustment are obtained to achieve stable and uniform tension and ensure the pay-off quality;

[0007] Wire pre-processing module: A high-definition camera is installed on the wire lead-out path in the wire-laying area to collect images and transmit them to the central control unit. The central control unit uses the wire pre-processing module to identify defects in the wires. After pre-processing, the convolutional neural network is used to analyze and determine the defect location and width.

[0008] Intelligent control module: It adopts variable frequency speed regulation technology, determines the target speed according to the wire drawing process requirements of the production management module, adjusts the motor speed through the inverter, communicates with the intelligent wire release module, and dynamically optimizes according to the tension deviation and production data.

[0009] In a preferred embodiment, the production management module includes a central control unit, a human-computer interaction APP, and a remote monitoring unit. The production management module uploads the production order through the human-computer interaction APP, parses the information about the material, specification, quantity and quality standard of the metal wire in the order, and uploads it to the central control unit;

[0010] The central control unit instructs the intelligent pay-off module to prepare and load the wire reels according to the order requirements. The system pre-enters the commonly used metal wire reels of various specifications and materials, including the outer diameter, inner diameter, width, weight, material type and the length of the wire that can be accommodated. A unique identification code is assigned to each wire reel, and a complete wire reel information database is established. The wire reels are accurately placed in the wire reel identification area through automated transmission equipment to ensure that the wire reels are within the effective reading range of the identification device.

[0011] Human-computer interaction APP: The staff can view the real-time operation status of the system through the APP, including the working parameters of each device and the production progress data, issue production tasks, set process parameters and query fault alarm information;

[0012] Remote monitoring unit: supports remote access through APP. Enterprise managers and technical experts can view the operation status of the production system in real time through APP in a remote location, and connect with the remote operation and maintenance platform of equipment technology to obtain professional technical support in a timely manner.

[0013] In a preferred embodiment, the intelligent wire-paying module is equipped with an automatic identification device, which automatically scans the identification code on the wire reel and sends the read information to the central control unit. The central control unit searches the database for wire reel information corresponding to the identification code, including the wire reel specification, material, target wire pay-off rack position and initial parameters required for the wire drawing process. According to the target wire pay-off rack position information obtained by the central control unit, the wire reel is placed on the corresponding wire pay-off rack through an automatic transmission device. A high-precision tension sensor is installed on the wire lead-out path in the wire-paying area to monitor the initial tension of the wire in real time, and the measured actual tension value T is used as the initial tension value. catual The data is fed back to the central control unit, which compares the actual tension value with the preset tension range [T min ,T max ] and calculate the tension deviation e(t). The specific calculation formula is:

[0014]

[0015] The tension value deviation e(t) reflects the degree to which the current tension deviates from the preset ideal range, and is the key basis for the subsequent central control unit to make adjustment decisions. The central control unit automatically adjusts the speed and braking torque of the pay-off point according to the preset tension range and algorithm to ensure that the wire is stable and uniform when it is led out from the pay-off end. The central control unit uses a discrete position PID control algorithm to determine the adjustment amount of the speed and braking torque of the pay-off motor. Suppose the sampling period is T s , at discrete time k, its calculation formula is as follows:

[0016]

[0017] Where u(k) represents the control signal calculated at discrete time k, K p Represents the proportionality coefficient, K i Indicates the integral coefficient, K d represents the differential coefficient, e(k) represents the tension deviation at discrete time k, e(k-1) represents the tension deviation at discrete time k-1, and e(i) represents the tension deviation at discrete time i. Based on the calculated control signal, the central control unit calculates the corresponding control signal u(k) according to the tension deviation data at each sampling moment;

[0018] The adjustment amount of the pay-off motor speed n is calculated based on the control signal u(k) obtained by the PID control algorithm. Assuming that there is a linear relationship between the motor speed and the control signal, the proportional coefficient is K. n / u , then the specific calculation formula of the motor speed adjustment amount Δn is as follows:

[0019] Δn=K n / u ×u(k)

[0020] According to the motor speed adjustment Δn, it is then compared with the motor's current speed n current Add together to get the adjusted motor speed n new , the specific calculation formula is as follows:

[0021] n new =n current +Δn

[0022] According to the adjusted motor speed, the speed of the pay-off motor is precisely controlled, so that it can make corresponding adjustments according to the actual tension of the wire to ensure the stable output of the wire;

[0023] Braking torque regulation of the pay-off motor assumes that there is a linear relationship between the control signal u(k) and the braking torque M, and the proportional coefficient is K M / u , then the specific calculation formula of the braking torque adjustment amount ΔM is as follows:

[0024] ΔM=KM / u×u(k)

[0025] According to the adjustment amount of the braking torque, click on the current braking torque M current Add together to get the adjusted braking torque M new , the specific calculation formula is as follows:

[0026] M new =M current +ΔM

[0027] Based on the adjusted braking torque, the central control unit can adjust the braking torque of the pay-off motor in real time according to the tension of the wire, ensuring that the wire always maintains a uniform and stable tension throughout the entire pay-off process.

[0028] In a preferred embodiment, the wire preprocessing module installs a high-definition camera on the wire lead-out path in the wire-laying area to ensure that the camera covers the entire circumferential surface of the wire. When the wire starts to lay out, the high-definition camera continuously collects images of the wire surface, and transmits these images frame by frame in real time to the central control unit in digital image data format. The central control unit prepares for wire defect recognition through the wire preprocessing module and preprocesses the collected images, including image denoising and grayscale transformation processing. For each pixel point (x, y) in the image, its filtered pixel value I filtered (x, y) is obtained by calculating the mean of its neighborhood pixels. Assuming the selected neighborhood size is m×n, the specific calculation formula is as follows:

[0029]

[0030] Among them, I(x, y) represents the pixel value of the original image at (x, y). In order to enhance the contrast of the image and highlight the possible defect characteristics on the surface of the wire, a linear stretching grayscale transformation method is used. Suppose the grayscale range of the original image is [a, b] and it is stretched to [c, d]. For the pixel point with grayscale value I(x, y) in the original image, the transformed grayscale value I transformed (x, y) is calculated according to the following formula:

[0031]

[0032] The preprocessed image is analyzed by the convolutional neural network model through the image recognition algorithm. For a new input feature map I in , convolution operation is performed through convolution kernel K to obtain the output feature map I out , let the step size of the convolution operation be S and the padding be P, then for each position (S x , S y ), the specific calculation formula of its value is as follows:

[0033]

[0034] Among them, I out (S x , S y ) indicates that the output feature map is at the coordinate position (S x , S y ), K(i, j) represents the weight parameter at the coordinate (i, j) in the convolution kernel, I in (S x ×S+i,S y ×S+j) represents the pixel value at the position corresponding to the convolution kernel in the input feature map, S represents the step size of the convolution operation, and the size of the output feature map in the horizontal and vertical directions is determined by the convolution operation. Suppose the size of the input feature map is W in ×Hi n , the size of the convolution kernel is K×K, the step size is S, and the padding is P, then the width of the output feature map is W out and height Ho ut The calculation formulas are:

[0035]

[0036] Among them, W in Indicates the width of the input feature map, H in Represents the height of the input feature map, W out It represents the width of the output feature map after the convolution operation, which is the number of pixels in the horizontal direction of the output feature map. out It represents the height of the output feature map after the convolution operation. It is the number of pixels in the vertical direction of the output feature map. The input feature map is downsampled by the pooling operation. The pooling step is pool. Then the width of the output feature map after the pooling operation is W. out and height H out The specific calculation formula is as follows:

[0037]

[0038] Among them, CW in Represents the feature map width of the input pooling layer, which is the number of pixels in the horizontal direction of the feature map before the pooling operation. Hin represents the feature map height of the input pooling layer, M represents the pooling window size, and C Wout It represents the width of the output feature map after the pooling operation, which is the number of pixels in the horizontal direction of the output feature map. HoutRepresents the height of the output feature map after the pooling operation, which is the number of pixels in the vertical direction of the output feature map. The feature map is mapped to the original image. Suppose the coordinates are reversely mapped from the feature map of the lth layer to the feature map of the l-1th layer. For the convolution layer, if the convolution kernel size corresponding to the lth layer is k l ×k l , the step length is s l , filled with p l , then the reverse mapping is to the coordinates (x l-1 ,y l-1 ) is calculated as follows:

[0039]

[0040] Among them, l represents the layer index of the neural network, x l Indicates the number of pixels from the center of the feature area to the upper left corner in the horizontal direction, y l Indicates the number of pixels from the upper left corner in the vertical direction, x l-1 ,y l-1 Indicates that the coordinate direction in the feature map of the first layer is mapped to the coordinate in the feature map of the first layer-1. 2 is mainly used to calculate the parameters related to the center position of the convolution kernel. Here, the origin of the coordinates is the upper left corner of each layer of the feature map. Starting from the convolution layer, the coordinates are calculated in reverse according to the parameters corresponding to each layer, and then gradually reflected back to finally obtain the coordinates in the original image (x 0 ,y 0 ), this coordinate is the horizontal and vertical pixel distance of the defect from the upper left corner of the image in the original image, so as to determine the location information of the defect and calculate the width of the defect. The defect width w is obtained from the feature map of the first layer l Mapped to the defect width w in the original image 0 , let the size of a certain dimension in the original image be W 0 , the size of the corresponding dimension in the feature map of layer l is W l , from the original image to the l-th layer feature map, convolution and pooling operations are performed. Suppose the defect area detected in the l-th layer feature map occupies w in the width direction l pixels, which corresponds to a width w in the original image. 0 The specific calculation formula is as follows:

[0041]

[0042] Among them, s i , k i 、p iThey respectively represent the step size, convolution kernel size and filling status corresponding to the i-th layer of convolution. When defects are detected on the wire surface, the central control unit will notify the operator of the detection results through sound and light alarms, and display a detailed detection report on the APP interface, including the wire number, detection time and defect location information.

[0043] In a preferred embodiment, the intelligent control module accurately controls the speed of the wire drawing motor through variable frequency speed regulation technology, receives the current wire drawing process requirements from the production management module, and determines the target wire drawing speed v according to the process requirements. target , send speed instructions through the control interface of the frequency converter, adjust the motor speed to the corresponding value, establish telecommunication connection with the intelligent wire-paying module, receive the tension deviation signal e(t), and when the tension deviation exceeds the allowable range, adjust the motor speed according to the algorithm of the intelligent wire-paying module. During the wire drawing process, dynamically optimize the motor speed according to the real-time collected production data, including changes in wire diameter and die wear;

[0044] The relationship between the wire diameter and the drawing force is established. According to the basic mechanical principles of the wire drawing process, the drawing force F is related to the degree of deformation of the wire. Assuming that the wire drawing process conforms to the simple principle of constant cylindrical volume, that is:

[0045]

[0046] Among them, D 1 , L 1 Indicates the diameter and length of the wire before drawing, D 2 , L 2 It indicates the diameter and length of the wire after drawing. The drawing force is obtained according to the plastic deformation formula of the metal. The specific calculation formula is as follows:

[0047]

[0048] Among them, SC represents the strength coefficient of the material, ∈ represents the true strain, and hc represents the strain hardening exponent. For the wire drawing process, the specific calculation formula of the strain is as follows:

[0049]

[0050] Among them, A 1 , A 2 It represents the cross-sectional area of ​​the wire before and after drawing. The specific calculation formula of drawing force is as follows:

[0051] F=σA 2

[0052] The relationship between the drawing force and the wire diameter change is as follows:

[0053]

[0054] The motor drives the wire drawing wheel through the transmission device. Assuming the transmission efficiency is trans and the wire drawing wheel radius is r, the relationship between the motor torque T and the wire drawing force L is: Substituting the formula of wire drawing force and wire material command change into the formula, the relationship between wire drawing force and motor torque can be obtained. The specific calculation formula is as follows:

[0055]

[0056] Adjust the motor speed according to the motor torque-speed characteristics. The motor usually has its own torque-speed characteristic curve, which is represented by a polynomial function, T = a 0 +a 1 z+a 2 z 2 +…+a m z m , where z represents the motor speed, a 0 , a 1 , ..., a m It represents the coefficient obtained by fitting the motor experimental data. After the required motor torque T is calculated according to the change of wire diameter, it is substituted into the motor torque-speed characteristic equation. The motor speed is adjusted by solving the equation. When the motor torque-speed characteristic curve is expressed by a quadratic polynomial, T = a 0 +a 1 z+a 2 z 2 , substitute the calculated required motor torque T into the equation to obtain:

[0057] a 0 +a 1 z+a 2 z 2 -T=0

[0058] Use the root-finding formula to calculate the motor speed z. The specific calculation formula is as follows:

[0059]

[0060] Based on the above content, the specific calculation formula for adjusting the speed considering the motor power is as follows:

[0061]

[0062] Among them, 2π means converting the motor speed z into the corresponding angular velocity. When the motor shaft rotates one circle, the corresponding angle change is 2π radians. min means converting the unit of the speed n from revolutions per minute to radians per second.

[0063] Establish the relationship model between die wear and wire drawing resistance, and set the die wear amount ΔM SThere is a linear relationship between the increase in wire drawing resistance ΔF and the increase in wire drawing resistance ΔF: ΔF = G 1 ΔM S , where G 1 The coefficient is determined according to the process requirements. According to the mechanical transmission efficiency η of the wire drawing machine and the torque characteristic curve of the motor, the relationship between the motor torque increment ΔT and the wire drawing resistance increment is determined. The specific calculation formula is as follows:

[0064]

[0065] Among them, r represents the radius of the drawing wheel. According to the torque-speed characteristic curve of the motor, the motor speed adjustment Δn is obtained. z The relationship with the torque increment is as follows:

[0066] Δn z =G 2 ΔT

[0067] Among them, G 2 It represents the coefficient obtained by fitting the electric shock characteristic curve. Based on the above content, the specific calculation formula for the new motor speed is as follows:

[0068] n new =n original +Δn

[0069] Among them, n original Indicates the original speed of the motor.

[0070] The beneficial effects of the present invention are as follows: the present invention realizes accurate placement of the wire reel through an automatic identification device and an automated transmission device, thus avoiding possible errors in manual identification and handling of the wire reel, greatly reducing the time required for manual operation, and improving the work efficiency of the entire wire-paying link, so that the production process can be started more quickly and smoothly. The high-precision tension sensor is used to feedback data in real time, and the parameters of the wire-paying motor are automatically adjusted, which can quickly adapt to the tension requirements of wires of different specifications and materials, and ensure that the tension of the wire led out from the wire-paying end is always stable and uniform, which not only lays a good foundation for subsequent wire drawing work, but also avoids wire quality problems and interruptions in the wire drawing process caused by unstable tension, reduces time loss caused by production failures, and improves overall production efficiency. Advanced detection devices are used to perform preliminary inspections on the appearance of the wire in the wire-paying stage, so that defective wires can be discovered as early as possible to avoid them entering the subsequent more costly wire drawing process, saving time, materials, manpower and other resources wasted in the subsequent processes due to the processing of defective products, and helping to improve the yield rate and overall production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0071] Figure 1 is a flow chart of the present invention;

[0072] Figure 2 It is a system block diagram of the present invention. DETAILED DESCRIPTION

[0073] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of this application.

[0074] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of this application, "plurality" means two or more, unless otherwise clearly and specifically defined.

[0075] In the description of the present application, the term "for example" is used to mean "used as an example, illustration or description". Any embodiment described as "for example" in the present application is not necessarily to be construed as being more preferred or advantageous than other embodiments. The following description is given to enable any technician in the field to implement and use the present invention. In the following description, details are listed for the purpose of explanation. It should be understood that a person of ordinary skill in the art can recognize that the present invention can be implemented without using these specific details. In other examples, well-known structures and processes will not be elaborated in detail to avoid unnecessary details to obscure the description of the present invention. Therefore, the present invention is not intended to be limited to the embodiments shown, but is consistent with the widest scope consistent with the principles and features disclosed in the present application.

[0076] like Figure 1-2 This embodiment provides: a metal wire drawing production system, comprising:

[0077] Production management module: upload order information containing metal wire material, specification, quantity and quality standards to the central control unit through the human-computer interaction APP. The central control unit instructs the intelligent wire-laying module according to the order, uses the automatic transmission equipment to accurately place the wire reel to the identification area, and can allow staff to view the real-time status of the system through the human-computer interaction APP, and supports remote access to the APP;

[0078] In this embodiment, it is necessary to specifically explain the production management module, which includes a central control unit, a human-computer interaction APP, and a remote monitoring unit. The production management module uploads the production order through the human-computer interaction APP, parses the information about the material, specification, quantity and quality standard of the metal wire in the order, and uploads it to the central control unit;

[0079] The central control unit instructs the intelligent pay-off module to prepare and load the wire reels according to the order requirements. The system pre-enters the commonly used metal wire reels of various specifications and materials, including the outer diameter, inner diameter, width, weight, material type and the length of the wire that can be accommodated. A unique identification code is assigned to each wire reel, and a complete wire reel information database is established. The wire reels are accurately placed in the wire reel identification area through automated transmission equipment to ensure that the wire reels are within the effective reading range of the identification device.

[0080] Human-computer interaction APP: The staff can view the real-time operation status of the system through the APP, including the working parameters of each device and the production progress data, issue production tasks, set process parameters and query fault alarm information;

[0081] Remote monitoring unit: supports remote access through APP. Enterprise managers and technical experts can view the operation status of the production system in real time through APP in a remote location, and connect with the remote operation and maintenance platform of equipment technology to obtain professional technical support in a timely manner.

[0082] Intelligent pay-off module: A high-precision tension sensor is set up to feed back the actual tension value to the central control unit, calculate the tension deviation, and use the discrete position PID control algorithm to calculate the control signal according to the correlation coefficient and the deviation. Based on this, the motor speed, braking torque adjustment amount and the corresponding value after adjustment are obtained to achieve stable and uniform tension and ensure the pay-off quality;

[0083] In this embodiment, it is necessary to specifically explain the intelligent wire-paying module, which is equipped with an automatic identification device. The wire drum identification device automatically scans the identification code on the wire drum and sends the read information to the central control unit. The central control unit searches the database for wire drum information corresponding to the identification code, including wire drum specifications, materials, target wire-paying frame positions, and initial parameters required for the wire drawing process. According to the target wire-paying frame position information obtained by the central control unit, the wire drum is placed on the corresponding wire-paying frame through an automatic transmission device. A high-precision tension sensor is installed on the wire lead-out path in the wire-paying area to monitor the initial tension of the wire in real time, and the measured actual tension value T is used. catual The data is fed back to the central control unit, which compares the actual tension value with the preset tension range [T min , T max] and calculate the tension deviation e(t). The specific calculation formula is:

[0084]

[0085] The tension value deviation e(t) reflects the degree to which the current tension deviates from the preset ideal range, and is the key basis for the subsequent central control unit to make adjustment decisions. The central control unit automatically adjusts the speed and braking torque of the pay-off point according to the preset tension range and algorithm to ensure that the wire is stable and uniform when it is led out from the pay-off end. The central control unit uses a discrete position PID control algorithm to determine the adjustment amount of the speed and braking torque of the pay-off motor. Suppose the sampling period is T s , at discrete time k, its calculation formula is as follows:

[0086]

[0087] Where u(k) represents the control signal calculated at discrete time k, K p Represents the proportionality coefficient, K i Indicates the integral coefficient, K d represents the differential coefficient, e(k) represents the tension deviation at discrete time k, e(k-1) represents the tension deviation at discrete time k-1, and e(i) represents the tension deviation at discrete time i. Based on the calculated control signal, the central control unit calculates the corresponding control signal u(k) according to the tension deviation data at each sampling moment;

[0088] The adjustment amount of the pay-off motor speed n is calculated based on the control signal u(k) obtained by the PID control algorithm. Assuming that there is a linear relationship between the motor speed and the control signal, the proportional coefficient is K. n / u , then the specific calculation formula of the motor speed adjustment amount Δn is as follows:

[0089] Δn=K n / u ×u(k)

[0090] According to the motor speed adjustment Δn, it is then compared with the motor's current speed n current Add together to get the adjusted motor speed n new , the specific calculation formula is as follows:

[0091] n new =n current +Δn

[0092] According to the adjusted motor speed, the speed of the pay-off motor is precisely controlled, so that it can make corresponding adjustments according to the actual tension of the wire to ensure the stable output of the wire;

[0093] Braking torque regulation of the pay-off motor assumes that there is a linear relationship between the control signal u(k) and the braking torque M, and the proportional coefficient is K M / u , then the specific calculation formula of the braking torque adjustment amount ΔM is as follows:

[0094] ΔM=K M / u ×u(k)

[0095] According to the adjustment amount of the braking torque, click on the current braking torque M current Add together to get the adjusted braking torque M new , the specific calculation formula is as follows:

[0096] M new =M current +ΔM

[0097] Based on the adjusted braking torque, the central control unit can adjust the braking torque of the pay-off motor in real time according to the tension of the wire, ensuring that the wire always maintains a uniform and stable tension throughout the entire pay-off process.

[0098] It should be noted that when the actual measured wire tension value T catual Greater than the preset tension range upper limit T max When the tension deviation e(t) is equal to the actual tension value T catual Subtract the preset tension range upper limit T max , indicating that the wire tension exceeds the expected upper limit at this time. The central control unit needs to take corresponding measures according to this positive deviation value to reduce the tension and return it to the preset reasonable range. When the actual tension value is within the preset tension range T min ≤T catual ≤T max When the actual tension value T is within the range of 0, the value of the tension deviation e(t) is 0, which means that the current wire tension is within the expected reasonable range. The central control unit does not need to adjust the speed and braking torque parameters of the pay-off motor. catual Less than the preset tension range lower limit T min When the tension deviation e(t) is equal to the actual tension value T catual Subtract the preset tension range lower limit T min At this time, a negative deviation value is obtained, indicating that the wire tension is lower than the expected lower limit. The central control unit should increase the tension accordingly to make it meet the preset process requirements.

[0099] Wire pre-processing module: A high-definition camera is installed on the wire lead-out path in the wire-laying area to collect images and transmit them to the central control unit. The central control unit uses the wire pre-processing module to identify defects in the wires. After pre-processing, the convolutional neural network is used to analyze and determine the defect location and width.

[0100] In this embodiment, it is necessary to specifically explain the wire preprocessing module. The wire preprocessing module is installed with a high-definition camera on the wire lead-out path in the wire-laying area to ensure that the camera covers the entire circumferential surface of the wire. When the wire starts to lay out, the high-definition camera continuously collects images of the wire surface, and transmits these images frame by frame in real time to the central control unit in digital image data format. The central control unit prepares for wire defect recognition through the wire preprocessing module and preprocesses the collected images, including image denoising and grayscale transformation processing. For each pixel point (x, y) in the image, its filtered pixel value I filtered (x, y) is obtained by calculating the mean of its neighborhood pixels. Assuming the selected neighborhood size is m×n, the specific calculation formula is as follows:

[0101]

[0102] Among them, I(x, y) represents the pixel value of the original image at (x, y). In order to enhance the contrast of the image and highlight the possible defect characteristics on the surface of the wire, a linear stretching grayscale transformation method is used. Suppose the grayscale range of the original image is [a, b] and it is stretched to [c, d]. For the pixel point with grayscale value I(x, y) in the original image, the transformed grayscale value I transformed (x, y) is calculated according to the following formula:

[0103]

[0104] The preprocessed image is analyzed by the convolutional neural network model through the image recognition algorithm. For a new input feature map I in , convolution operation is performed through convolution kernel K to obtain the output feature map I out , let the step size of the convolution operation be S and the padding be P, then for each position (S x , S y ), the specific calculation formula of its value is as follows:

[0105]

[0106] Among them, I out (S x , S y ) indicates that the output feature map is at the coordinate position (S x , S y ), K(i, j) represents the weight parameter at the coordinate (i, j) in the convolution kernel, I in (S x ×S+i,S y×S+j) represents the pixel value at the position corresponding to the convolution kernel in the input feature map, S represents the step size of the convolution operation, and the size of the output feature map in the horizontal and vertical directions is determined by the convolution operation. Suppose the size of the input feature map is W in ×H in , the size of the convolution kernel is K×K, the step size is S, and the padding is P, then the width of the output feature map is W out and height H out The calculation formulas are:

[0107]

[0108] Among them, W in Indicates the width of the input feature map, H in Represents the height of the input feature map, W out It represents the width of the output feature map after the convolution operation, which is the number of pixels in the horizontal direction of the output feature map. out It represents the height of the output feature map after the convolution operation. It is the number of pixels in the vertical direction of the output feature map. The input feature map is downsampled by the pooling operation. The pooling step is pool. Then the width of the output feature map after the pooling operation is W. out and height H out The specific calculation formula is as follows:

[0109]

[0110] Among them, C Win Represents the feature map width of the input pooling layer, which is the number of pixels in the horizontal direction of the feature map before the pooling operation. Hin represents the feature map height of the input pooling layer, M represents the pooling window size, and C Wout It represents the width of the output feature map after the pooling operation, which is the number of pixels in the horizontal direction of the output feature map. Hout Represents the height of the output feature map after the pooling operation, which is the number of pixels in the vertical direction of the output feature map. The feature map is mapped to the original image. Suppose the coordinates are reversely mapped from the feature map of the lth layer to the feature map of the l-1th layer. For the convolution layer, if the convolution kernel size corresponding to the lth layer is k l ×k l , the step length is s l , filled with p l , then the reverse mapping is to the coordinates (x l-1 ,y l-1 ) is calculated as follows:

[0111]

[0112]

[0113] Among them, l represents the layer index of the neural network, x l Indicates the number of pixels from the center of the feature area to the upper left corner in the horizontal direction, y l Indicates the number of pixels from the upper left corner in the vertical direction, x l-1 ,y l-1 Indicates that the coordinate direction in the feature map of the first layer is mapped to the coordinate in the feature map of the first layer-1. 2 is mainly used to calculate the parameters related to the center position of the convolution kernel. Here, the origin of the coordinates is the upper left corner of each layer of the feature map. Starting from the convolution layer, the coordinates are calculated in reverse according to the parameters corresponding to each layer, and then gradually reflected back to finally obtain the coordinates in the original image (x 0 ,y 0 ), this coordinate is the horizontal and vertical pixel distance of the defect from the upper left corner of the image in the original image, so as to determine the location information of the defect and calculate the width of the defect. The defect width w is obtained from the feature map of the first layer l Mapped to the defect width w in the original image 0 , let the size of a certain dimension in the original image be W 0 , the size of the corresponding dimension in the feature map of layer l is W l , from the original image to the l-th layer feature map, convolution and pooling operations are performed. Suppose the defect area detected in the l-th layer feature map occupies w in the width direction l pixels, which corresponds to a width w in the original image. 0 The specific calculation formula is as follows:

[0114]

[0115] Among them, s i , k i 、p i They respectively represent the step size, convolution kernel size and filling status corresponding to the i-th layer of convolution. When defects are detected on the wire surface, the central control unit will notify the operator of the detection results through sound and light alarms, and display a detailed detection report on the APP interface, including the wire number, detection time and defect location information.

[0116] It should be noted that the specific steps of wire surface defect detection using convolutional neural network are as follows:

[0117] S1, obtaining the surface image data of the wire to be detected, and inputting it into the convolutional neural network model as the original image;

[0118] S2, convolution operation: For the input original image, it is regarded as a two-dimensional pixel matrix plus the number of channels as the input feature map of the convolution layer, which has a certain width and height. According to the preset convolution kernel size, step size and padding, the convolution kernel is allowed to slide on the feature map according to the step size;

[0119] S3, pooling operation: the feature map output by the convolution layer is used as the input of the pooling layer. According to the set pooling window size and pooling offset, the width and height of the output feature map after pooling are calculated, and the feature map is downsampled by taking the maximum value in the pooling window.

[0120] S4, repeat the convolution and pooling layer operations. According to the network structure design, repeat the above convolution and pooling layer operations many times to gradually extract more advanced and abstract features, so that the size of the feature map becomes smaller and the feature representation becomes more and more concentrated. The parameters of each layer can be adjusted according to actual needs and network architecture;

[0121] S5. In the last layer of feature maps obtained after multi-layer convolution and pooling, when a feature area indicating a possible defect is detected, its coordinates in the feature map are obtained, and the upper left corner of the feature map is used as the coordinate origin. Starting from this layer, according to the convolution layer parameters corresponding to each layer, the coordinate reverse mapping formula is used to reversely calculate the coordinates layer by layer from the back to the front, and gradually trace back to the original image coordinates. This coordinate is the horizontal and vertical pixel distance of the defect from the upper left corner in the original image, so as to determine the location information of the defect;

[0122] S6. Determine the number of pixels occupied by the defective area in a certain dimension, such as the width direction, and perform reverse conversion based on the size of the original image in this dimension, as well as the compensation, convolution kernel size, and padding parameters corresponding to each layer from the original image to the feature map of this layer, to obtain the actual width size corresponding to the defect in the original image, thereby determining the actual size information of the defect.

[0123] Intelligent control module: It adopts variable frequency speed regulation technology, determines the target speed according to the wire drawing process requirements of the production management module, adjusts the motor speed through the inverter, communicates with the intelligent wire release module, and dynamically optimizes according to the tension deviation and production data.

[0124] In this embodiment, it is necessary to specifically explain the intelligent control module, which uses variable frequency speed regulation technology to accurately control the speed of the wire drawing motor, receives the current wire drawing process requirements from the production management module, and determines the target wire drawing speed v according to the process requirements. target, send speed instructions through the control interface of the frequency converter, adjust the click speed to the corresponding value, make telecommunication connection with the intelligent wire-paying module, receive the tension deviation signal e(t), and when the tension deviation exceeds the allowable range, adjust the motor speed according to the algorithm of the intelligent wire-paying module. During the wire drawing process, according to the real-time collected production data, including the change of wire diameter and the wear of the die, the motor speed is dynamically optimized;

[0125] The relationship between the wire diameter and the drawing force is established. According to the basic mechanical principles of the wire drawing process, the drawing force F is related to the degree of deformation of the wire. Assuming that the wire drawing process conforms to the simple principle of constant cylindrical volume, that is:

[0126]

[0127] Among them, D 1 , L 1 Indicates the diameter and length of the wire before drawing, D 2 , L 2 It indicates the diameter and length of the wire after drawing. The drawing force is obtained according to the plastic deformation formula of the metal. The specific calculation formula is as follows:

[0128]

[0129] Among them, SC represents the strength coefficient of the material, ∈ represents the true strain, and hc represents the strain hardening exponent. For the wire drawing process, the specific calculation formula of the strain is as follows:

[0130]

[0131] Among them, A 1 , A 2 It represents the cross-sectional area of ​​the wire before and after drawing. The specific calculation formula of drawing force is as follows:

[0132] F=σA 2

[0133] The relationship between the drawing force and the wire diameter change is as follows:

[0134]

[0135] The motor drives the wire drawing wheel through the transmission device. Assuming the transmission efficiency is trans and the wire drawing wheel radius is r, the relationship between the motor torque T and the wire drawing force L is: Substituting the formula of wire drawing force and wire material command change into the formula, the relationship between wire drawing force and motor torque can be obtained. The specific calculation formula is as follows:

[0136]

[0137] Adjust the motor speed according to the motor torque-speed characteristics. The motor usually has its own torque-speed characteristic curve, which is represented by a polynomial function, T = a 0 +a 1 z+a 2 z 2 +…+a m z m , where z represents the motor speed, a 0 , a 1 , ..., a m It represents the coefficient obtained by fitting the motor experimental data. After the required motor torque T is calculated according to the change of wire diameter, it is substituted into the motor torque-speed characteristic equation. The motor speed is adjusted by solving the equation. When the motor torque-speed characteristic curve is expressed by a quadratic polynomial, T = a 0 +a 1 z+a 2 z 2 , substitute the calculated required motor torque T into the equation to obtain:

[0138] a 0 +a 1 z+a 2 z 2 -T=0

[0139] Use the root-finding formula to calculate the motor speed z. The specific calculation formula is as follows:

[0140]

[0141] Based on the above content, the specific calculation formula for adjusting the speed considering the motor power is as follows:

[0142]

[0143] Among them, 2π means converting the motor speed z into the corresponding angular velocity. When the motor shaft rotates one circle, the corresponding angle change is 2π radians. min means converting the unit of the speed n from revolutions per minute to radians per second.

[0144] It should be noted that the angle corresponding to 1 revolution is 2π radians, and 1 minute is equal to 60 seconds, so when converting the speed from revolutions per minute to radians per second, you need to multiply it by This coefficient, in the power formula In the motor power formula, 2π is used to convert revolutions to radians, and min is used to convert minutes to seconds, so that the entire formula is consistent in units. In the equation, 2π is used to convert the motor speed n into the corresponding angular velocity, because when the motor shaft rotates one circle, the corresponding angle change is 2π radians. Therefore, if the motor speed is n revolutions per minute, then the angular velocity w is When calculating the motor power, the product of torque T and angular velocity w is involved, that is, power P = Tw. Substituting into the power formula, we get This allows the motor power to be calculated based on its torque and speed.

[0145] Establish the relationship model between die wear and wire drawing resistance, and set the die wear amount ΔM S There is a linear relationship between the increase in wire drawing resistance ΔF and the increase in wire drawing resistance ΔF: ΔF = G 1 ΔM S , where G 1 The coefficient is determined according to the process requirements. According to the mechanical transmission efficiency η of the wire drawing machine and the torque characteristic curve of the motor, the relationship between the motor torque increment ΔT and the wire drawing resistance increment is determined. The specific calculation formula is as follows:

[0146]

[0147] Among them, r represents the radius of the drawing wheel. According to the torque-speed characteristic curve of the motor, the motor speed adjustment Δn is obtained. z The relationship with the torque increment is as follows:

[0148] Δn z =G 2 ΔT

[0149] Among them, G 2 It represents the coefficient obtained by fitting the electric shock characteristic curve. Based on the above content, the specific calculation formula for the new motor speed is as follows:

[0150] n new =n original +Δn

[0151] Among them, n original Indicates the original speed of the motor.

[0152] It should be noted that in the above embodiments, the description of each embodiment has its own emphasis, and for parts that are not described in detail in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

[0153] Those skilled in the art will appreciate that embodiments of the present invention may be provided as methods, systems, or computer program products. Therefore, the present invention may take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Moreover, the present invention may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0154] The present invention is described with reference to flowcharts and / or block diagrams of methods, devices (systems), and computer program products according to embodiments of the present invention. It should be understood that each process and / or block in the flowchart and / or block diagram, as well as the combination of processes and / or blocks in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded computer, or other programmable data processing device to generate a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0155] These computer program instructions may also be stored in a computer-readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer-readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 A process or multiple processes and / or boxes Figure 1 A function specified in one or more boxes.

[0156] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process. Figure 1 A process or multiple processes and / or boxes Figure 1 The steps for the functions specified in one or more boxes.

[0157] Although the preferred embodiments of the present invention have been described, those skilled in the art may make other changes and modifications to these embodiments once they have learned the basic creative concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications that fall within the scope of the present invention.

[0158] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include these modifications and variations.

Claims

1. A metal wire drawing production system, characterized in that: include: Production management module: upload order information containing metal wire material, specification, quantity and quality standards to the central control unit through the human-computer interaction APP. The central control unit instructs the intelligent wire-laying module according to the order, uses the automatic transmission equipment to accurately place the wire reel to the identification area, and can allow staff to view the real-time status of the system through the human-computer interaction APP, and supports remote access to the APP; Intelligent pay-off module: A high-precision tension sensor is set up to feed back the actual tension value to the central control unit, calculate the tension deviation, and use the discrete position PID control algorithm to calculate the control signal according to the correlation coefficient and the deviation. Based on this, the motor speed, braking torque adjustment amount and the corresponding value after adjustment are obtained to achieve stable and uniform tension and ensure the pay-off quality; Wire pre-processing module: A high-definition camera is installed on the wire lead-out path in the wire-laying area to collect images and transmit them to the central control unit. The central control unit uses the wire pre-processing module to identify defects in the wires. After pre-processing, the convolutional neural network is used to analyze and determine the defect location and width. Intelligent control module: It adopts variable frequency speed regulation technology, determines the target speed according to the wire drawing process requirements of the production management module, adjusts the motor speed through the inverter, communicates with the intelligent wire release module, and dynamically optimizes according to the tension deviation and production data.

2. A metal wire drawing production system according to claim 1, characterized in that: The production management module includes a central control unit, a human-computer interaction APP, and a remote monitoring unit. The production management module uploads the production order through the human-computer interaction APP, analyzes the information about the material, specification, quantity and quality standard of the metal wire in the order, and uploads it to the central control unit; The central control unit instructs the intelligent pay-off module to prepare and load the wire reels according to the order requirements. The system pre-enters the commonly used metal wire reels of various specifications and materials, including the outer diameter, inner diameter, width, weight, material type and the length of the wire that can be accommodated. A unique identification code is assigned to each wire reel, and a complete wire reel information database is established. The wire reels are accurately placed in the wire reel identification area through automated transmission equipment to ensure that the wire reels are within the effective reading range of the identification device. Human-computer interaction APP: The staff can view the real-time operation status of the system through the APP, including the working parameters of each device and the production progress data, issue production tasks, set process parameters and query fault alarm information; Remote monitoring unit: supports remote access through APP. Enterprise managers and technical experts can view the operation status of the production system in real time through APP in a remote location, and connect with the remote operation and maintenance platform of equipment technology to obtain professional technical support in a timely manner.

3. A metal wire drawing production system according to claim 1, characterized in that: The intelligent pay-off module is equipped with an automatic identification device. The wire drum identification device automatically scans the identification code on the wire drum and sends the read information to the central control unit. The central control unit searches the database for wire drum information corresponding to the identification code, including the wire drum specification, material, target pay-off rack position and initial parameters required for the wire drawing process. According to the target pay-off rack position information obtained by the central control unit, the wire drum is placed on the corresponding pay-off rack through the automatic transmission equipment. A high-precision tension sensor is installed on the wire lead-out path in the pay-off area to monitor the initial tension of the wire in real time and measure the actual tension value T catukal The data is fed back to the central control unit, which compares the actual tension value with the preset tension range [T min ,T max ] and calculate the tension deviation e(t). The specific calculation formula is: The tension value deviation e(t) reflects the degree to which the current tension deviates from the preset ideal range, and is the key basis for the subsequent central control unit to make adjustment decisions. The central control unit automatically adjusts the speed and braking torque of the pay-off point according to the preset tension range and algorithm to ensure that the wire is stable and uniform when it is led out from the pay-off end. The central control unit uses a discrete position PID control algorithm to determine the adjustment amount of the speed and braking torque of the pay-off motor. Suppose the sampling period is T s , at discrete time k, its calculation formula is as follows: Where u(k) represents the control signal calculated at discrete time k, K p Represents the proportionality coefficient, K i Indicates the integral coefficient, K d represents the differential coefficient, e(k) represents the tension deviation at discrete moment k, e(k-1) represents the tension deviation at discrete moment k-1, and e(i) represents the tension deviation at discrete moment i. Based on the calculated control signal, the central control unit calculates the corresponding control signal u(k) according to the tension deviation data at each sampling moment.

4. A metal wire drawing production system according to claim 3, characterized in that: The adjustment amount of the pay-off motor speed is calculated according to the control signal u(k) obtained by the PID control algorithm to calculate the adjustment amount of the pay-off motor speed n. Assuming that there is a linear relationship between the motor speed and the control signal, the proportional coefficient is K. n / u , then the specific calculation formula of the motor speed adjustment amount Δn is as follows: Δn=K n / u ×u(k) According to the motor speed adjustment Δn, it is then compared with the motor's current speed n current Add together to get the adjusted motor speed n new , the specific calculation formula is as follows: n new =n current +Δn According to the adjusted motor speed, the speed of the pay-off motor is precisely controlled, so that it can make corresponding adjustments according to the actual tension of the wire and ensure the stable output of the wire.

5. A metal wire drawing production system according to claim 3, characterized in that: The braking torque adjustment of the pay-off motor assumes that there is a linear relationship between the control signal u(k) and the braking torque M, and the proportional coefficient is K M / u , then the specific calculation formula of the braking torque adjustment amount ΔM is as follows: ΔM=K M / u ×u(k) According to the adjustment amount of the braking torque, click on the current braking torque M current Add together to get the adjusted braking torque M new , the specific calculation formula is as follows: M new =M current +ΔM Based on the adjusted braking torque, the central control unit can adjust the braking torque of the pay-off motor in real time according to the tension of the wire, ensuring that the wire always maintains a uniform and stable tension throughout the entire pay-off process.

6. A metal wire drawing production system according to claim 1, characterized in that: The wire preprocessing module is equipped with a high-definition camera on the wire lead-out path in the wire-laying area to ensure that the camera covers the entire circumferential surface of the wire. When the wire starts to lay out, the high-definition camera continuously collects images of the wire surface, and transmits these images frame by frame in real time to the central control unit in digital image data format. The central control unit prepares for wire defect recognition through the wire preprocessing module and preprocesses the collected images, including image denoising and grayscale transformation processing. For each pixel point (x, y) in the image, its filtered pixel value I filtered (x, y) is obtained by calculating the mean of its neighborhood pixels. Assuming the selected neighborhood size is m×n, the specific calculation formula is as follows: Among them, I(x,y) represents the pixel value of the original image at (x,y). In order to enhance the contrast of the image and highlight the possible defect characteristics on the surface of the wire, a linear stretching grayscale transformation method is used. Suppose the grayscale range of the original image is [a,b] and it is stretched to [c,d]. For the pixel point with grayscale value I(x,y) in the original image, the transformed grayscale value I transformed (x,y) is calculated according to the following formula: The preprocessed image is analyzed by the convolutional neural network model through the image recognition algorithm. For a new input feature map I in , convolution operation is performed through convolution kernel K to obtain the output feature map I out , let the step size of the convolution operation be S and the padding be P, then for each position (S x ,S y ), the specific calculation formula of its value is as follows: Among them, I out (S x ,S y ) indicates that the output feature map is at the coordinate position (S x ,S y ), K(i,j) represents the weight parameter at the coordinate (i,j) in the convolution kernel, I in (S x ×i+i,S y ×S+j) represents the pixel value at the position corresponding to the convolution kernel in the input feature map, S represents the step size of the convolution operation, and the size of the output feature map in the horizontal and vertical directions is determined by the convolution operation. Suppose the size of the input feature map is W in ×H in , the size of the convolution kernel is K×K, the step size is S, and the padding is P, then the width of the output feature map is W out and height H out The calculation formulas are: Among them, W in Indicates the width of the input feature map, H in Represents the height of the input feature map, W out It represents the width of the output feature map after the convolution operation, which is the number of pixels in the horizontal direction of the output feature map. out It represents the height of the output feature map after the convolution operation. It is the number of pixels in the vertical direction of the output feature map. The input feature map is downsampled by the pooling operation. The pooling step is pool. Then the width of the output feature map after the pooling operation is W. out and height H out The specific calculation formula is as follows: Among them, C Win Represents the feature map width of the input pooling layer, which is the number of pixels in the horizontal direction of the feature map before the pooling operation. Hin represents the feature map height of the input pooling layer, M represents the pooling window size, and C Wout It represents the width of the output feature map after the pooling operation, which is the number of pixels in the horizontal direction of the output feature map. Hout Represents the height of the output feature map after the pooling operation, which is the number of pixels in the vertical direction of the output feature map. The feature map is mapped to the original image. Suppose the coordinates are reversely mapped from the feature map of the lth layer to the feature map of the l-1th layer. For the convolution layer, if the convolution kernel size corresponding to the lth layer is k l ×k l , the step length is s l , filled with p l , then the reverse mapping is to the coordinates (x l-1 ,y l-1 ) is calculated as follows: Among them, l represents the layer index of the neural network, x l Indicates the number of pixels from the center of the feature area to the upper left corner in the horizontal direction, y l Indicates the number of pixels from the upper left corner in the vertical direction, x l-1 ,y l-1 Indicates that the coordinate direction in the feature map of the lth layer is mapped to the coordinate in the feature map of the l-1th layer. 2 is mainly used to calculate the parameters related to the center position of the convolution kernel. Here, the origin of the coordinates is the upper left corner of each layer of the feature map. Starting from the convolution layer, the coordinates are calculated in reverse according to the parameters corresponding to each layer, and then gradually reflected back to finally obtain the coordinates (x0, y0) in the original image. This coordinate is the horizontal and vertical pixel distance of the defect from the upper left corner of the image in the original image. In this way, the position information of the defect is determined and the width of the defect is calculated. The defect width w is obtained from the feature map of the lth layer. l Mapped to the defect width w0 in the original image, let the size of a certain dimension in the original image be W0, and the size of the corresponding dimension in the feature map of layer l be W l , from the original image to the l-th layer feature map, convolution and pooling operations are performed. Suppose the defect area detected in the l-th layer feature map occupies w in the width direction l pixels, and the specific calculation formula for the corresponding width w0 in the original image is as follows: Among them, s i , k i 、p i They respectively represent the step size, convolution kernel size and filling status corresponding to the i-th layer of convolution. When defects are detected on the wire surface, the central control unit will notify the operator of the detection results through sound and light alarms, and display a detailed detection report on the APP interface, including the wire number, detection time and defect location information.

7. A metal wire drawing production system according to claim 1, characterized in that: The intelligent control module uses variable frequency speed regulation technology to accurately control the speed of the wire drawing motor, receives the current wire drawing process requirements from the production management module, and determines the target wire drawing speed v according to the process requirements. target , send speed instructions through the control interface of the frequency converter, adjust the click speed to the corresponding value, establish telecommunication connection with the intelligent wire-paying module, receive the tension deviation signal e(t), and when the tension deviation exceeds the allowable range, adjust the motor speed according to the algorithm of the intelligent wire-paying module. During the wire drawing process, the motor speed is dynamically optimized based on the real-time collected production data, including changes in wire diameter and die wear.

8. A metal wire drawing production system according to claim 7, characterized in that: The relationship between the wire diameter and the drawing force is established. According to the basic mechanical principles of the wire drawing process, the drawing force F is related to the degree of deformation of the wire. Assuming that the wire drawing process conforms to the simple principle of constant cylindrical volume, that is: Among them, D1 and L1 represent the diameter and length of the wire before drawing, D2 and L2 represent the diameter and length of the wire after drawing, and the drawing force is obtained according to the plastic deformation formula of the metal. The specific calculation formula is as follows: σ=SC ∈hc Among them, SC represents the strength coefficient of the material, ∈ represents the true strain, and hc represents the strain hardening exponent. For the wire drawing process, the specific calculation formula of the strain is as follows: Among them, A1 and A2 represent the cross-sectional area of ​​the wire before and after drawing, and the specific calculation formula of the drawing force is as follows: F=σA2 The relationship between the drawing force and the wire diameter change is as follows: The motor drives the wire drawing wheel through the transmission device. Assuming the transmission efficiency is trans and the wire drawing wheel radius is r, the relationship between the motor torque T and the wire drawing force L is: Substituting the formula of wire drawing force and wire material command change into the formula, the relationship between wire drawing force and motor torque can be obtained. The specific calculation formula is as follows: The motor speed is adjusted according to the motor torque-speed characteristics. The motor usually has its own torque-speed characteristic curve, which is represented by a polynomial function, T = a0 + a1z + a2z 2 +...+a m z m , where z represents the motor speed, a0, a1, ..., a m It represents the coefficient obtained by fitting the motor experimental data. After the required motor torque T is calculated according to the change of wire diameter, it is substituted into the motor torque-speed characteristic equation. The motor speed is adjusted by solving the equation. When the motor torque-speed characteristic curve is expressed by a quadratic polynomial, T=a0+a1z+a2z 2 , substitute the calculated required motor torque T into the equation to obtain: a0+a1z+a2z 2 -T=0 Use the root-finding formula to calculate the motor speed z. The specific calculation formula is as follows: Based on the above content, the specific calculation formula for adjusting the speed considering the motor power is as follows: Among them, 2π means converting the motor's rotational speed z into the corresponding angular velocity. When the motor shaft rotates one circle, the corresponding angle change is 2π radians. min means converting the unit of the rotational speed n from revolutions per minute to radians per second.

9. A metal wire drawing production system according to claim 7, characterized in that: Establish the relationship model between die wear and wire drawing resistance, and set the die wear amount ΔM S There is a linear relationship between the increase in wire drawing resistance ΔF and the increase in wire drawing resistance ΔF: ΔF = G1ΔM S , where G1 is a coefficient determined according to the process requirements. According to the mechanical transmission efficiency η of the wire drawing machine and the torque characteristic curve of the motor, the relationship between the motor torque increment ΔT and the wire drawing resistance increment is determined. The specific calculation formula is as follows: Among them, r represents the radius of the drawing wheel. According to the torque-speed characteristic curve of the motor, the motor speed adjustment Δn is obtained. z The relationship with the torque increment is as follows: Δn z =G2ΔT Among them, G2 represents the coefficient obtained by fitting the electric shock characteristic curve. Based on the above content, the specific calculation formula for the new motor speed is as follows: n new =n original +Δn Among them, n original Indicates the original speed of the motor.

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