Calculation method and system for calendering tension of wirecord fabric and electronic equipment

Abstract

The invention provides a calculation method and system for calendering main tension of wirecord fabric and electronic equipment, and the calculation method comprises the steps: presetting first tension of a single steel wire in the wirecord fabric, obtaining the width of the wirecord fabric input by a user, and obtaining a first number of the single steel wires of the wirecord fabric within a first preset length, according to the width and the first number, the number of spindles needed in the calendering process of the wirecord fabric is calculated; acquiring the thickness of the wirecord fabric input by a user, and calculating a calendaring tension coefficient of the wirecord fabric according to the thickness; the calendering main tension of the wirecord fabric is calculated according to the first tension, the number of the spindles and the calendering main tension coefficient, quantitative calculation of the calendering main tension of the wirecord fabric is achieved, process fuzzy verification is changed into precise process design, and the product quality stability is greatly improved.

Description

Technical Field

[0001] The invention relates to the technical field of calendering and manufacturing of steel cord fabrics for rubber tires, and in particular to a method and system for calculating the main force of calendering steel cord fabrics, and electronic equipment. Background Art

[0002] In the rubber tire industry, whether it is a semi-steel radial tire, a full-steel radial tire, or an engineering radial tire, steel cord must be used. This is one of the most important skeleton materials, so the steel cord calendering process technology is particularly important.

[0003] Among the technical parameters of steel cord calendering process, tension is the most important process control parameter, including steel cord pay-off tension, calendering main tension, storage tension, curling tension, etc. Among them, there are many researchers on pay-off tension, storage tension, and curling tension, and many papers and patents have been produced. However, there are few studies on calendering main tension. Although major domestic tire companies have established their own technical standards, most of them are begging for alms. They have only conducted in-depth research on tension control systems, but have not conducted in-depth research on the calculation logic of calendering main tension. In the prior art, the Northeastern University team has studied the design of steel wire calendering tension control system, but has not conducted in-depth theoretical quantitative research on the calculation logic of calendering main tension. Therefore, the current theoretical research on the calculation standard of calendering main tension is still at a relatively shallow level, mostly staying on qualitative experience sharing, lacking theoretical calculation logic support, and for a long time, there have been inconsistent and unscientific technical problems in the calculation standard of main tension in the steel cord calendering process.

[0004] Therefore, the prior art needs to be further developed. Summary of the invention

[0005] The purpose of the present invention is to overcome the above technical deficiencies and provide a method and system for calculating the main force of steel cord calendering, and electronic equipment to solve the problems existing in the prior art.

[0006] To achieve the above technical purpose, according to a first aspect of the present invention, the present invention provides a method for calculating the main force of steel cord calendering, comprising: S100, presetting a first tension of a single steel wire in a steel cord, obtaining a width of the steel cord input by a user, and a first number of single steel wires of the steel cord within a first preset length input by the user, and calculating the number of spindles required for the steel cord during a calendering process according to the width and the first number; S200, obtaining the thickness of the steel cord input by the user, and calculating the main stress coefficient of the steel cord during calendering according to the thickness; S300, calculating the calendering main tension of the steel cord according to the first tension, the number of spindles and the calendering main tension coefficient.

[0007] Specifically, the step of calculating the number of spindles required for the steel cord during the calendering process according to the width and the first number includes: The number of spindles is represented as l, the width of the steel cord is represented as W, and the first number of single steel wires in the first preset length of the steel cord is represented as a. The number of spindles is calculated according to the width and the first number. The specific calculation method is as follows: l=W*a.

[0008] Specifically, the step of obtaining the thickness of the steel cord input by the user and calculating the calendering main stress coefficient of the steel cord according to the thickness includes: The relationship between the thickness of steel cord and its main stress coefficient during calendering is analyzed by using the Six Sigma analysis method, and then the main stress coefficient during calendering is calculated according to the thickness of steel cord.

[0009] Specifically, the use of the Six Sigma analysis method to analyze the relationship between the thickness of the steel cord and the main tensile coefficient of the steel cord during calendering includes: The calendering stress of steel cords of different thicknesses under different calendering stress coefficients is tested in sequence, and the physical performance parameters of the steel cords corresponding to each calendering stress are obtained according to the calendering stress. According to the physical performance parameters of the steel cord, the optimal calendering main stress coefficient corresponding to the steel cord of different thickness is selected in turn.

[0010] Specifically, the optimal calendering main stress coefficient corresponding to steel cords of different thicknesses is selected in sequence according to the physical performance parameters of the steel cord, including: The physical performance parameters are scored using the five-finger scoring method in Six Sigma to obtain weight scores for each physical performance parameter. According to the physical performance parameters and their corresponding weight scores, a first score for the calendering main stress coefficient corresponding to steel cords of different thicknesses is obtained, and the optimal calendering main stress coefficient is selected according to the first score.

[0011] Specifically, the physical performance parameters include: Peel strength, air content, transverse stretch, transverse stretch shrinkage, and cut warping amount.

[0012] Specifically, the step of obtaining the thickness of the steel cord input by the user and calculating the main stress coefficient of the steel cord according to the thickness further includes: Using the Six Sigma analysis tool, the different thicknesses of the steel cord and the optimal calendering stress coefficient corresponding to each thickness were fitted and regressed, and the corresponding relationship between the thickness of the steel cord and the calendering stress coefficient was obtained as follows: K=x+z*d; Among them, K represents the main tensile coefficient of calendering, d represents the thickness of the steel cord, and x and z represent constant coefficients.

[0013] Specifically, the calculating the calendering main tension of the steel cord according to the first tension, the number of spindles and the calendering main tension coefficient includes: The calendering main force F of the steel cord is calculated according to the calculation formula of the first tension, the number of spindles and the calculation formula of the calendering main force coefficient. The specific calculation method is as follows: F = f*W*a*k; k=x+z*d; Among them, f represents the first tension, W represents the width of the steel cord, a represents the first number of single steel wires within the first preset length, k represents the main tension coefficient of calendering, d represents the main tension coefficient of calendering, and x and z represent constant coefficients.

[0014] According to a second aspect of the present invention, there is provided a system for calculating the main force of a steel cord calendering machine, comprising: An acquisition module: used to acquire the width of the steel cord input by the user, and the first number of single steel wires within a first preset length of the steel cord input by the user; and used to acquire the thickness of the steel cord input by the user; Control module: used to store the preset first tension of a single steel wire in the steel cord, and calculate the number of spindles required for the steel cord during the calendering process according to the width and the first number; or used to calculate the calendering main tension coefficient of the steel cord according to the thickness; or used to calculate the calendering main tension of the steel cord according to the first tension, the number of spindles and the calendering main tension coefficient.

[0015] According to a third aspect of the present invention, there is provided an electronic device, comprising: a memory; and a processor, wherein the memory stores computer-readable instructions, and when the computer-readable instructions are executed by the processor, the above-mentioned method for calculating the main force of steel cord calendering is implemented.

[0016] Beneficial effects: The present invention pre-sets a first tension of a single steel wire in a steel cord, and calculates the number of spindles required for the steel cord in a calendering process according to the width of the steel cord and the first number of single steel wires in the steel cord within a first preset length; calculates the calendering main tension coefficient of the steel cord according to the thickness of the steel cord; and calculates the calendering main tension of the steel cord according to the first tension, the number of spindles and the calendering main tension coefficient, thereby achieving quantitative calculation of the calendering main tension of the steel cord, changing process fuzzy verification into precise process design, and greatly improving product quality stability. The calendering main tension calculation formula in the present invention is more scientific and meets the essential requirements of the calendering process, thereby further reducing the defective rate of the steel cord and greatly reducing the quality cost. The present invention can also be applied to the test evaluation of new skeleton materials to improve the evaluation efficiency, thereby greatly expanding the application scenarios of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a flow chart of a method for calculating the main force of steel cord calendering provided in a specific embodiment of the present invention; Figure 2 Schematic diagram of the system composition of the calculation system of the steel cord calendering main force provided in a specific embodiment of the present invention; Figure 3 is a comparative trend diagram of the peeling strength of steel cord fabrics when the main force coefficients are different in a specific embodiment of the present invention; Figure 4 It is a comparative trend diagram of the amount of warping cut when the main force coefficient is different provided in a specific embodiment of the present invention; Figure 5 is a comparative trend diagram of air content when the main force coefficient is different provided in a specific embodiment of the present invention; Figure 6 is a comparative trend diagram of transverse stretching when the main force coefficients are different provided in a specific embodiment of the present invention; Figure 7 is a fitted regression curve diagram of the calendering main tension coefficient and the steel cord thickness provided in a specific embodiment of the present invention; Figure 8 It is a schematic diagram of the main force setting principle of the steel wire calendering provided in a specific embodiment of the present invention; Wherein, the reference numerals of the above-mentioned drawings are as follows: 1. Calendering main roller; 2. Sizing roller; 3. Pressure roller; 4. Single steel wire; 5. Rubber cord fabric; 6. Cooling roller. DETAILED DESCRIPTION In order to enable those skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention is clearly and completely described below in conjunction with the accompanying drawings of the present invention. Based on the embodiments in this application, other similar embodiments obtained by ordinary technicians in this field without making creative work should all fall within the scope of protection of this application. In addition, the directional words mentioned in the following embodiments, such as "up", "down", "left", "right", etc., are only reference to the directions of the accompanying drawings. Therefore, the directional words used are used to illustrate rather than limit the invention.

[0018] The present invention will be further described below in conjunction with the accompanying drawings and preferred embodiments.

[0019] See also Figure 1 This embodiment provides a method for calculating the main force of steel cord calendering, including: S100, presetting a first tension of a single steel wire in a steel cord, obtaining a width of the steel cord input by a user, and a first number of single steel wires of the steel cord within a first preset length input by the user, and calculating the number of spindles required for the steel cord during a calendering process according to the width and the first number; It is understandable that the first tension of a single steel wire of the steel cord is not fixed, which is mainly related to the structure and size of the steel cord. For semi-steel steel cord, the first tension of a single steel wire can be set to 10N. This has been verified by a large number of tests. The setting basis of the steel cord pay-off tension, that is, the first tension, is to ensure lower tension calendering under the premise of ensuring the passability of the process. The main reason is that if the tension is too large during production, the structural degree of the cord will be excessively damaged, especially for high elongation structures, which will affect the penetration of rubber into the steel cords; in addition, if the tension is too large, the cord will shrink in a free state after cutting, resulting in the cord to appear warped or a large head and small tail after cutting.

[0020] Furthermore, the types of semi-steel steel wire include 2*2*0.35HT, 3*0.25ST, 3*0.28ST, 3*0.20+6*0.35HT and other specifications. The first tension of a single steel wire of these specifications is uniformly set to 10N. First of all, based on the theoretical mechanism analysis, the purpose of ensuring the pay-off tension (first tension) is to ensure that the cord has a certain tension and improve the penetration effect of the rubber. On the other hand, excessive tension will lead to severe stretching and a tight structure, which will affect the penetration effect of the rubber.

[0021] The first tension is set to 10N and is mainly verified through experiments. The main verification process includes: setting different factor levels of wire pay-off tension (8 / 9 / 10 / 11 / 12N), testing the peel strength of the steel cord respectively, performing one-way analysis of variance, and then performing polynomial regression to predict the optimal value. Finally, the set value of the first tension is verified and determined through field tests.

[0022] Specifically, the step of calculating the number of spindles required for the steel cord during the calendering process according to the width and the first number includes: The number of spindles is represented as l, the width of the steel cord is represented as W, and the first number of single steel wires in the first preset length of the steel cord is represented as a. The number of spindles is calculated according to the width and the first number. The specific calculation method is as follows: l=W*a.

[0023] It should be further explained that in the production process of steel cord, spindles are an important part of the calender. They are usually composed of multiple rows of cylinders, which are used to guide and support the steel cord. When the steel cord passes through the spindle, the spindle can control the tension of the steel cord to ensure the uniform distribution and appropriate tension of the steel cord during the calendering process. In some designs, the spindle can also automatically adjust the tension to adapt to different production requirements. The correct setting and maintenance of the spindle is essential for the production of high-quality steel cord. The number of spindles depends on the width and density of the steel cord. For example, the width of the steel cord is W mm, and the density is the first number of single steel wires in the first preset length of the steel cord. The first preset length here can be set to 1 inch, and the first number is set to a, that is, the number of single steel wires per inch of the steel cord is a. Since 1 inch is equal to 25.4 mm, the number of spindles can be expressed as W*a / 25.4, in mm.

[0024] S200, obtaining the thickness of the steel cord input by the user, and calculating the main stress coefficient of the steel cord during calendering according to the thickness.

[0025] See also Figure 8When the steel cord is calendered, the main force is to straighten the multiple evenly arranged steel cords that have passed through the sizing roller 2 and the pressure roller 3. When the steel cord is calendered, ensure that the upper and lower films can penetrate into the gaps in the steel cord structure well, and ensure that the steel wire cannot be displaced or jump during the calendering process, and the surface of the cord should be as smooth as possible, without appearance defects such as cold glue spots and cooked glue delamination. Therefore, the calendering main force should be large enough, at least greater than the pay-off tension of all steel wires, that is, the algebraic sum of the first tension, otherwise the calendering main force will not be able to carry the steel cord during calendering, the steel cord will be loose, and the jump will be serious, resulting in unqualified density and unqualified glue penetration. Therefore, it is necessary to establish the relationship between the calendering main force and the number of single steel wires of the steel cord. The calendering main force should be at least greater than the algebraic sum of the pay-off tension of all steel cords.

[0026] In actual tests, for steel cords of different thicknesses, the relationship between the calendering force and the algebraic sum of the tensions of all individual steel wires presents different proportions; at the same time, for the same steel cord, when the proportional relationship between the calendering force and the algebraic sum of the tensions of all individual steel wires is different, the performance of the steel cord also has certain differences. Through the double-sample t-test of the hypothesis test, it can be obtained that the value of the calendering force is strongly correlated with the cord thickness.

[0027] Specifically, the step of obtaining the thickness of the steel cord input by the user and calculating the calendering main stress coefficient of the steel cord according to the thickness includes: The relationship between the thickness of steel cord and its main stress coefficient during calendering is analyzed by using the Six Sigma analysis method, and then the main stress coefficient during calendering is calculated according to the thickness of steel cord.

[0028] Specifically, the use of the Six Sigma analysis method to analyze the relationship between the thickness of the steel cord and the main tensile coefficient of the steel cord during calendering includes: The calendering stress of steel cords of different thicknesses under different calendering stress coefficients is tested in sequence, and the physical performance parameters of the steel cords corresponding to each calendering stress are obtained according to the calendering stress. According to the physical performance parameters of the steel cord, the optimal calendering main stress coefficient corresponding to the steel cord of different thickness is selected in turn.

[0029] Specifically, the optimal calendering main stress coefficient corresponding to steel cords of different thicknesses is selected in sequence according to the physical performance parameters of the steel cord, including: The physical performance parameters are scored using the five-finger scoring method in Six Sigma to obtain weight scores for each physical performance parameter. According to the physical performance parameters and their corresponding weight scores, a first score for the calendering main stress coefficient corresponding to steel cords of different thicknesses is obtained, and the optimal calendering main stress coefficient is selected according to the first score.

[0030] Specifically, the physical performance parameters include: Peel strength, air content, transverse stretch, transverse stretch shrinkage, and cut warping amount.

[0031] Furthermore, peel strength is a key parameter for evaluating the quality of steel cord fabric. Theoretically, the main force of steel cord calendering determines the quality of peel strength. Too large or too small calendering force of steel cord fabric will affect the quality of peel strength. The unit of peel strength is N / m. Air content is a key parameter for quantitatively characterizing the tightness of steel cord fabric glue application. In theory, if the main force of calendering is too small, the steel wire is relatively loose and not easy to compact, which will affect the quality of steel cord fabric and the performance of the final tire. The unit of air content is mm 3 / cord*cm, indicates how many mm are contained in 1cm long steel cord 3 Air, usually the smaller the air volume, the better; transverse stretch is another parameter that quantitatively characterizes the tightness of the cord glue application. When the main force increases during the calendering process, theoretically, the tensile force on the steel cord in the transverse direction increases, which will cause the cord to be stretched more in the transverse direction, making the internal structure of the cord more compact, and the bond between the steel wire and the rubber more tightly, thereby characterizing the increase in the tightness of the glue application. The unit of transverse stretch is N; the transverse stretch shrinkage rate has a strong linear correlation with the transverse stretch. When the transverse stretch is large, the fiber and rubber molecular chains inside the cord are stretched and are in a high-energy state. Once the external force is removed, the cord will shrink due to the elastic recovery of the molecular chains. The greater the transverse stretch, the longer the molecular chains are stretched, and the more obvious the shrinkage trend is. Therefore, the transverse stretch shrinkage rate will increase with the transverse stretch. It increases with the increase of lateral stretch, showing a strong linear correlation. This strong correlation is very important for the quality control of the cord gluing process. In the production process, the lateral stretch can be measured to indirectly predict the lateral stretch shrinkage rate, so as to adjust the production process parameters (such as tension, temperature, etc.) in advance to ensure the tightness of the cord gluing and the dimensional stability of the final product; the cutting warp amount is a key parameter for quantitatively characterizing the processability of the cord, and the unit can be mm. In theory, the greater the calendering main force, the greater the cutting warp amount. This is because the larger calendering main force will cause greater stress inside the cord. During cutting, this stress release will cause the edge of the cord to warp more easily. However, among the factors affecting the cutting warp amount, the calendering main force only accounts for about 20%. The more critical factors are the residual torsion and bow height of the steel cord.

[0032] Specifically, the step of obtaining the thickness of the steel cord input by the user and calculating the main stress coefficient of the steel cord according to the thickness further includes: Using the Six Sigma analysis tool, the different thicknesses of the steel cord and the optimal calendering stress coefficient corresponding to each thickness were fitted and regressed, and the corresponding relationship between the thickness of the steel cord and the calendering stress coefficient was obtained as follows: k=x+z*d; Among them, k represents the main tensile coefficient of calendering, d represents the thickness of the steel cord, and x and z represent constant coefficients.

[0033] It is understandable that the main tension coefficient k of the cord specifications with different thicknesses can be studied one by one using the statistical experimental method, and then statistical induction can be performed.

[0034] The following is an analysis of the relationship between the thickness of the steel cord and the main tensile coefficient k of the calendering by taking the steel cord with a thickness of 1.70 mm as an example: 1. Please refer to Table 1 and conduct tests on 5 different levels of the main tensile coefficient k of the calendering; Table 1 Test results of calendering main stress coefficient k at 5 different levels In Table 1, the experimental principle of the main tension coefficient is: according to the calendering tension gradient theory, that is, in the calendering process of the material, by controlling the distribution of tension, the material is stretched to different degrees at different positions, thereby realizing the regulation of the material microstructure and performance, and by controlling the cord tension at different stages of calendering, the tightness of the skeleton material and the rubber is realized, thereby realizing the regulation of the material microstructure and performance, mainly the influence of tension on the fixed load elongation rate of the skeleton material and the influence of tension on the penetration of the rubber. Considering that when the main tension coefficient k is less than 1.0, that is, the main tension is less than the tension of a single steel wire When and, the steel cord fabric will not be able to be produced and pulled normally, and the cord fabric will be in a relaxed state when it comes out of the calender; and when the calendering main force is greater than the single steel wire tension and * 1.4, that is, k>1.4, the excessive main force will cause severe stretching of the skeleton material, and the gaps between the steel wires will be significantly reduced. The rubber material cannot effectively penetrate into the gaps between the steel wires, which is prone to poor glue application. Therefore, the main force coefficient of this embodiment selects a value greater than 1.0 and less than 1.4, that is, a test scheme is selected between 1.0 and 1.4, and then the main force is calculated according to the calculation formula of main force = coefficient * single steel wire tension 10N * total number of steel wires.

[0035] 2. Please refer to Table 2 for the test results of the physical properties of steel cord fabrics, including peel strength, air content, transverse stretch, transverse stretch shrinkage. The above physical performance parameters are all obtained by sampling and sending to the laboratory for testing. There are standard test methods. The amount of cutting warping is measured in the workshop, and the measuring tool is a steel ruler with an accuracy of 0.5mm. Table 2 Physical properties test results of steel cord fabric 3. If Figure 3-Figure 6 As shown in the figure, when the calendering main stress coefficient k is different, the comparative trend chart of the peeling strength, cutting head amount, air content and transverse stretch of the cord fabric can be seen from the trend chart. The optimal calendering main stress coefficient corresponding to each physical performance parameter can be seen, that is, for the steel cord fabric with a thickness of 1.70mm, when the calendering main stress coefficient is 1.25, the corresponding peeling strength and air content are optimal, when the calendering main stress coefficient is 1.30, the corresponding transverse stretch and transverse stretch shrinkage are optimal, and when the calendering main stress coefficient is 1.10, the corresponding cutting head amount is optimal; 4. Through the PCS20117B cord main tension test, the comparative analysis is as follows: (the > sign indicates superiority) (1) Peel strength: calendering main stress coefficient 1.25> calendering main stress coefficient 1.30> calendering main stress coefficient 1.15> calendering main stress coefficient 1.20> calendering main stress coefficient 1.10; (2) Air content: calender main stress coefficient 1.25 = calender main stress coefficient 1.30 > calender main stress coefficient 1.20 > calender main stress coefficient 1.15 > calender main stress coefficient 1.10; (3) Transverse stretching: calendering main stress coefficient 1.30> calendering main stress coefficient 1.25> calendering main stress coefficient 1.20> calendering main stress coefficient 1.10> calendering main stress coefficient 1.15; (4) Transverse tensile shrinkage: calendering main tensile coefficient 1.30> calendering main tensile coefficient 1.25> calendering main tensile coefficient 1.15> calendering main tensile coefficient 1.20> calendering main tensile coefficient 1.10; (5) Cutting warping amount: calender main stress coefficient 1.10> calender main stress coefficient 1.15> calender main stress coefficient 1.20> calender main stress coefficient 1.25> calender main stress coefficient 1.30; 5. According to the five-finger scoring method of Six Sigma, professional personnel are organized to determine the scoring standards as shown in Table 3. It is understandable that when evaluating the quality of steel cord fabrics, multiple physical performance parameters will inevitably be involved. Different weight levels are assigned to each parameter according to its importance. Among them, peel strength and air content are the highest level of 5 points, cutting head volume is 4 points, transverse stretch is 3 points, and transverse stretch shrinkage is 2 points; Table 3 The weight scores of various physical performance parameters confirmed by the five-finger scoring method; According to the above experiments, the optimal calendering stress coefficient corresponding to each physical performance parameter and the score weight corresponding to each physical performance parameter in Table 3 were obtained, and the first score of each calendering stress coefficient was obtained as shown in Table 4. The four members of the research team scored the cord fabrics of different schemes respectively. The scoring was based on five dimensions. The score of each dimension was the average of the scores of each expert, and then the weight score * average was used to get the score of a single dimension. Finally, the scores of the five dimensions were added up to get the final score: Table 4 The first score of the main stress coefficient of each rolling mill 6. According to the first scores corresponding to the above calendering stress coefficients, it can be concluded that for the cord specification with a thickness of 1.70 mm, when the calendering stress coefficient is 1.25, the comprehensive performance of the steel cord is optimal; 7. According to the above method, it can be obtained that for the cord specification with a thickness of 1.20 mm, when the main stress coefficient of calendering is 1.20, the comprehensive performance of the steel cord is optimal; for the cord specification with a thickness of 1.90 mm, when the main stress coefficient of calendering is 1.30, the comprehensive performance is optimal; for the cord specification with a thickness of 2.10 mm, when the main stress coefficient of calendering is 1.40, the comprehensive performance is optimal; for the cord specification with a thickness of 2.40 mm, when the main stress coefficient of calendering is 1.50, the comprehensive performance is optimal.

[0036] 8. Please refer to Figure 7 , establish a fitting regression curve of the main stress coefficient of each calender in the above steps and its corresponding steel cord thickness; Through the Six Sigma analysis tool, the four-in-one graph shows that the regression analysis equation is reliably fitted and the residual is acceptable. The specific evaluation parameters are shown in Table 5.

[0037] Table 5 Quality evaluation table of fitted regression model In Table 5, S is the standard deviation, which indicates the degree of dispersion of a set of data; P is the probability value, which reflects the probability of an event; F is the statistic value of the F test, which is used to determine whether the parameters in the statistical model are suitable for estimating the population; T is the statistic value of the T test, which is used to measure the degree of difference between the means of two sets of data. The larger the T value, the more obvious the difference; SS is the mean square sum of deviations, which is the sum of the squares of the differences of the expected mean of each data point, and measures the degree of deviation of the data point from its mean; MS refers to the mean of the sum of squares of a set of numbers, which indicates the ratio of the square of the deviation to the degree of freedom; R-Sq and R-Sq (adjusted) are both related decision coefficients, indicating the quality of model regression. The larger the value, the more reliable the regression model is. It is required that R-Sq and R-Sq (adjusted) are not less than 80%. R-Sq (adjusted) indicates the decision coefficient of the model after residual deletion, which is more accurate than R-Sq. The percentage of regression model error (R-Sq (adjusted)) in the total error is between 0-100%. The larger the value, the better the regression model fits the data.

[0038] Through fitting regression, the fitting equation between the main tensile coefficient of calendering and the thickness of steel cord fabric can be obtained as follows: Calendering main tension coefficient k = 0.858 + 0.254 * cord thickness (d ≤ 2.40mm); Conclusion: P=0.014<0.05, the null hypothesis is rejected, and the equation has no lack of fit.

[0039] It can be understood that the P value is used to measure the statistical significance of the observed results. When conducting a hypothesis test, the significance level is usually set at 0.05. When P < 0.05, the observed difference is considered significant, and the null hypothesis is rejected. 0.003 is the hypothesis test result of the constant term, and 0.014 is the test result of the independent variable X. Both are less than 0.05. Therefore, the null hypothesis can be fully rejected and the fitting equation has no loss of fit.

[0040] S300, calculating the calendering main tension of the steel cord according to the first tension, the number of spindles and the calendering main tension coefficient.

[0041] Specifically, the calculating the calendering main tension of the steel cord according to the first tension, the number of spindles and the calendering main tension coefficient includes: The calendering main force F of the steel cord is calculated according to the calculation formula of the first tension, the number of spindles and the calculation formula of the calendering main force coefficient. The specific calculation method is as follows: F = f*W*a*k; k=x+z*d; Among them, f represents the first tension, W represents the width of the steel cord, a represents the first number of single steel wires within the first preset length, k represents the main tension coefficient of calendering, d represents the main tension coefficient of calendering, and x and z represent constant coefficients.

[0042] Further, if the width of the steel cord is W mm, the first number of single steel wires in the first preset length of the steel cord is a, and the first preset length here can be set to 1 inch, that is, the number of single steel wires per inch of the steel cord is a. Since 1 inch is equal to 25.4 mm, the number of spindles can be expressed as W*a / 25.4, in mm. Therefore, the quantitative calculation formula for the main force of the steel cord calender can be further summarized as follows: F=f*W*a*k / 25.4; k=0.858+0.254*d; Wherein, F is the main calendering force, f is the single steel wire tension (first tension), W is the width of the steel cord, a is the first quantity; k is the main tension coefficient.

[0043] The working principle of the present invention is described below by means of specific examples: The purpose of the present invention is to solve the long-standing problem of inconsistent and unscientific main force calculation standards in the steel cord calendering process. For the first time, regression analysis is performed through scientific Six Sigma analysis tools, and the main force calculation formula is fitted. Through a large number of DOE experimental studies, the correctness and practicality of the calculation formula are proved, thereby effectively improving the warping problem in the cutting process and the wire jumper and thin wire problem of the steel cord. In fact, in practical applications, the warping problem and the wire jumper problem of the steel cord can be improved and enhanced to a certain extent.

[0044] With the calculation formula for the main tension of calendering, the standard main tension setting value can be calculated according to the information such as wire structure type, cord width, density, number of spindles, cord thickness, etc. during process setting, so as to guide the calendering process production well. More importantly, for a new wire structure, the standard tension value can also be predicted according to this calculation formula, thereby reducing the number of tests and improving the test pass rate. From a theoretical perspective, it solves a problem that has long plagued the industry, changing passive tests into active tests, and changing fuzzy process tests into precise process designs, thereby ultimately improving the stability of product quality and the core competitiveness of the product.

[0045] According to the thickness of each steel cord and its corresponding optimal main tension coefficient in Table 6, the calculation formula of the main tension of calendering corresponding to each steel cord thickness can be obtained as follows: (1) When the thickness of the steel cord is less than 1.50 mm: Main tension of calendered cord: F = single steel wire tension f * number of spindles * main tension coefficient 1.20; (2) When the thickness of the steel cord is between 1.5-1.8 mm: Main tension of calendered cord: F = single steel wire tension f * number of spindles * main tension coefficient 1.25; (3) When the thickness of the steel cord is between 1.8-2.0 mm: Main tension of calendered cord: F = single steel wire tension f * number of spindles * main tension coefficient 1.30; (4) When the thickness of the steel cord is between 2.0-2.2 mm: Main tension of calendered cord: F = single wire tension f * number of spindles * main tension coefficient 1.40; (5) When the thickness of the steel cord is between 2.2-2.5 mm: Main tension of calendered cord: F = single steel wire tension f * number of spindles * main tension coefficient 1.50; Among them, the single steel wire tension f is the first tension. According to the law, it can be predicted that when the thickness of the cord is greater than 2.5 mm, the main tension coefficient of the cord calendering will continue to increase. The corresponding calculation formula can be obtained by conducting experiments according to the calculation logic and experimental scheme of the main tension of the calendering in the present invention.

[0046] Table 6 Optimal main load coefficient corresponding to different steel cord thicknesses The specific implementation steps are as follows: Step 1: First, establish a test plan to determine the specifications, width, density standard, and tension value of a single steel wire of the steel cord, and then calculate the number of steel cords and the algebraic sum of the tension of a single steel wire. The main tension of the calender should not be less than the algebraic sum of the tension of a single steel wire; Step 2: Select different steel cord fabric specifications for testing, and gradually test the cord fabric thickness from small to large. The test span is relatively long. Other process technologies on site should be recorded to keep them stable and avoid the influence of other parameters. Step 3: For each thickness of steel cord, set 5 different levels of main tension coefficients, and produce 500 meters of test cord for each scheme; Step 4: Take samples from each solution and send them to the test center for physical performance tests, including but not limited to the following tests: fabric peel strength, transverse stretch, transverse stretch shrinkage, air content, etc.; Step 5: Track and measure the warping amount of the experimental cord fabric of each scheme during the cutting process, record the warping amount data in detail, and calculate the average value and standard deviation; Step 6: Use the five-finger evaluation method to design weights for different properties, and the professional team will score them. The plan with the highest score is the best plan; Step 7: Carry out cyclic experiments until all steel cord specifications are covered; Step 8: Conduct mathematical statistical analysis on steel cords of different thicknesses and their corresponding optimal values ​​of the main tension coefficients of calendering, and establish a regression fitting equation; Step 9: Apply Six Sigma analysis tools to conduct hypothesis testing to determine whether the solution is lack of fit, and conduct experimental verification again to verify the effectiveness of the fitting method in practice; Step 10: Combined with the fitting equation of the main tension coefficient k and the cord thickness d, the quantitative calculation formula of the main tension of the steel cord calendering is summarized.

[0047] See also Figure 8 The following introduces the setting principle of the main force of steel cord calendering, among which the steel cord calendering process mainly involves 6 equipment parts.

[0048] (1) Calendering main machine roller 1, there are 4 calendering rollers in total, showing an S-shaped distribution. The top two rollers are used for calendering the upper rubber sheet, the bottom two rollers are used for calendering the lower rubber sheet, and the middle two rollers are used for glue application. Through the lateral pressure of the two rollers and the rubbing action, the rubber material can be better adhered to the surface of the steel wire; (2) Sizing roller 2 is used for arranging the steel wires to ensure that the steel wires coming out of the threading plate in the spindle room can be evenly arranged in the groove of the sizing roller 2; (3) Pressure roller 3, whose function is to keep a certain tension on the steel wire before it enters the gap between the calender rollers, so as to better adhere to the rubber material; (4) Single steel wire 4, which is the steel wire before applying glue. Each steel wire has a certain tension. If the tension of each steel wire is f, and there are n steel wires in total, then the algebraic sum of the tensions of all single steel wires is f*n; (5) Rubber-attached curtain fabric 5, the upper and lower rubber materials have been attached to the steel wires, and a certain amount of rubber materials are attached to the gaps between the steel wires and the gaps inside the steel wires; (6) The cooling roller 6 plays a cooling role and also plays a role in controlling the calendering force. The source of the calendering force is determined by the speed ratio (speed ratio) between the cooling roller 6 and the calendering main roller 1. The larger the speed ratio, the greater the calendering force, and vice versa. The calendering force area is all the areas between the cooling roller 6 and the calendering main roller 1. The calendering force not only pulls all the steel cords, but also allows the rubber in the gaps between the steel cords and the rubber on the upper and lower surfaces to adhere to the steel wires evenly and stably, so it is necessary to provide some additional tension. Therefore, when the cord thickness is greater, the ratio of the calendering force to the algebraic sum of the tension of a single steel cord will also be greater, that is, the greater the force coefficient, which is the core theoretical basis for setting the calendering force.

[0049] It should be noted here that the present invention pre-sets the first tension of a single steel wire in the steel cord, and calculates the number of spindles required for the steel cord in the calendering process according to the width of the steel cord and the first number of single steel wires in the steel cord within the first preset length; calculates the calendering main stress coefficient of the steel cord according to the thickness of the steel cord; calculates the calendering main stress of the steel cord according to the first tension, the number of spindles and the calendering main stress coefficient, thereby realizing the quantitative calculation of the calendering main stress of the steel cord, changing the process fuzzy verification into precise process design, and greatly improving the product quality stability. The calendering main stress calculation formula in the present invention is more scientific and meets the essential requirements of the calendering process, thereby further reducing the defective incidence of the steel cord and greatly reducing the quality cost. The present invention can also be applied to the test evaluation of new skeleton materials to improve the evaluation efficiency, which greatly expands the application scenarios of the present invention.

[0050] See also Figure 2 This embodiment provides a system for calculating the main force of steel cord calendering, the system comprising: The acquisition module 100 is used to acquire the width of the steel cord input by the user, and the first number of single steel wires within a first preset length of the steel cord input by the user; and to acquire the thickness of the steel cord input by the user; Control module 200: used to store a preset first tension of a single steel wire in a steel cord, and calculate the number of spindles required for the steel cord during the calendering process according to the width and the first number; or used to calculate the calendering main tension coefficient of the steel cord according to the thickness; or used to calculate the calendering main tension of the steel cord according to the first tension, the number of spindles and the calendering main tension coefficient.

[0051] It should be noted here that the present invention pre-sets the first tension of a single steel wire in the steel cord, and calculates the number of spindles required for the steel cord in the calendering process according to the width of the steel cord and the first number of single steel wires in the steel cord within the first preset length; calculates the calendering main stress coefficient of the steel cord according to the thickness of the steel cord; calculates the calendering main stress of the steel cord according to the first tension, the number of spindles and the calendering main stress coefficient, thereby realizing the quantitative calculation of the calendering main stress of the steel cord, changing the process fuzzy verification into precise process design, and greatly improving the product quality stability. The calendering main stress calculation formula in the present invention is more scientific and meets the essential requirements of the calendering process, thereby further reducing the defective incidence of the steel cord and greatly reducing the quality cost. The present invention can also be applied to the test evaluation of new skeleton materials to improve the evaluation efficiency, which greatly expands the application scenarios of the present invention.

[0052] In a preferred embodiment, the present application further provides an electronic device, the electronic device comprising: A memory; and a processor, wherein the memory stores computer-readable instructions, and when the computer-readable instructions are executed by the processor, the method for calculating the main force of the steel cord calendering is implemented.

[0053] It should be noted here that the present invention pre-sets the first tension of a single steel wire in the steel cord, and calculates the number of spindles required for the steel cord in the calendering process according to the width of the steel cord and the first number of single steel wires in the steel cord within the first preset length; calculates the calendering main stress coefficient of the steel cord according to the thickness of the steel cord; calculates the calendering main stress of the steel cord according to the first tension, the number of spindles and the calendering main stress coefficient, thereby realizing the quantitative calculation of the calendering main stress of the steel cord, changing the process fuzzy verification into precise process design, and greatly improving the product quality stability. The calendering main stress calculation formula in the present invention is more scientific and meets the essential requirements of the calendering process, thereby further reducing the defective incidence of the steel cord and greatly reducing the quality cost. The present invention can also be applied to the test evaluation of new skeleton materials to improve the evaluation efficiency, which greatly expands the application scenarios of the present invention.

[0054] The various technical features described above can be combined arbitrarily. Although all possible combinations of these technical features are not described, any combination of these technical features should be considered to be covered by this specification as long as there is no contradiction in such combination.

[0055] The specific implementation of the present invention described above does not constitute a limitation on the protection scope of the present invention. Any other corresponding changes and modifications made based on the technical concept of the present invention should be included in the protection scope of the claims of the present invention.

Claims

1. A method for calculating the main force of steel cord calendering, characterized in that: include: S100, presetting a first tension of a single steel wire in a steel cord, obtaining a width of the steel cord input by a user, and a first number of single steel wires of the steel cord within a first preset length input by the user, and calculating the number of spindles required for the steel cord during a calendering process according to the width and the first number; S200, obtaining the thickness of the steel cord input by the user, and calculating the main stress coefficient of the steel cord during calendering according to the thickness; S300, calculating the calendering main tension of the steel cord according to the first tension, the number of spindles and the calendering main tension coefficient.

2. The method for calculating the main force of steel cord calendering according to claim 1, characterized in that: The step of calculating the number of spindles required for the steel cord during the calendering process according to the width and the first number includes: The number of spindles is represented as l, the width of the steel cord is represented as W, and the first number of single steel wires in the first preset length of the steel cord is represented as a. The number of spindles is calculated according to the width and the first number. The specific calculation method is as follows: l=W*a.

3. The method for calculating the main force of steel cord calendering according to claim 1, characterized in that: The step of obtaining the thickness of the steel cord input by the user and calculating the main stress coefficient of the steel cord according to the thickness comprises: The relationship between the thickness of steel cord and its main stress coefficient during calendering is analyzed by using the Six Sigma analysis method, and then the main stress coefficient during calendering is calculated according to the thickness of steel cord.

4. The method for calculating the main force of steel cord calendering according to claim 3, characterized in that: The six sigma analysis method is used to analyze the relationship between the thickness of the steel cord and the main tensile coefficient of the steel cord during calendering, including: The calendering stress of steel cords of different thicknesses under different calendering stress coefficients is tested in sequence, and the physical performance parameters of the steel cords corresponding to each calendering stress are obtained according to the calendering stress. According to the physical performance parameters of the steel cord, the optimal calendering main stress coefficient corresponding to the steel cord of different thickness is selected in turn.

5. The method for calculating the main force of steel cord calendering according to claim 4, characterized in that: The optimal calendering main stress coefficient corresponding to steel cords of different thicknesses is selected in sequence according to the physical performance parameters of the steel cord, including: The physical performance parameters are scored using the five-finger scoring method in Six Sigma to obtain weight scores for each physical performance parameter. According to the physical performance parameters and their corresponding weight scores, a first score for the calendering main stress coefficient corresponding to steel cords of different thicknesses is obtained, and the optimal calendering main stress coefficient is selected according to the first score.

6. The method for calculating the main force of steel cord calendering according to claim 5, characterized in that: The physical performance parameters include: Peel strength, air content, transverse stretch, transverse stretch shrinkage, and cut warping amount.

7. The method for calculating the main force of steel cord calendering according to claim 5, characterized in that: The step of obtaining the thickness of the steel cord input by the user and calculating the main stress coefficient of the steel cord according to the thickness further includes: Using the Six Sigma analysis tool, the different thicknesses of the steel cord and the optimal calendering stress coefficient corresponding to each thickness were fitted and regressed, and the corresponding relationship between the thickness of the steel cord and the calendering stress coefficient was obtained as follows: K=x+z*d; Among them, K represents the main tensile coefficient of calendering, d represents the thickness of the steel cord, and x and z represent constant coefficients.

8. The method for calculating the main force of steel cord calendering according to claim 7, characterized in that: The step of calculating the calendering main tension of the steel cord according to the first tension, the number of spindles and the calendering main tension coefficient comprises: The calendering main force F of the steel cord is calculated according to the calculation formula of the first tension, the number of spindles and the calculation formula of the calendering main force coefficient. The specific calculation method is as follows: F = f*W*a*k; k=x+z*d; Among them, f represents the first tension, W represents the width of the steel cord, a represents the first number of single steel wires within the first preset length, k represents the main tension coefficient of calendering, d represents the main tension coefficient of calendering, and x and z represent constant coefficients.

9. A calculation system for the main force of steel cord calendering, characterized in that: include: An acquisition module (100): used to acquire the width of the steel cord input by a user, and the first number of single steel wires within a first preset length of the steel cord input by the user; and used to acquire the thickness of the steel cord input by the user; A control module (200): used to store a pre-set first tension of a single steel wire in a steel cord, and to calculate the number of spindles required for the steel cord during a calendering process according to the width and the first number; or to calculate the calendering main tension coefficient of the steel cord according to the thickness; or to calculate the calendering main tension of the steel cord according to the first tension, the number of spindles and the calendering main tension coefficient.

10. An electronic device, characterized in that: include: Memory; and a processor, wherein the memory stores computer-readable instructions, and when the computer-readable instructions are executed by the processor, the method for calculating the main force of the steel cord calendering according to any one of claims 1 to 8 is implemented.

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