Enameled wire processing system

Abstract

The invention provides an enameled wire processing system which comprises a main frame body, a wire cylinder is arranged on the side edge of the main frame body, a cooling module is in data connection with a system control module, and the system control module is provided with a temperature sensor, a speed sensor, a tension sensor and a microprocessor. Through accurate temperature control and a PID control algorithm, it is ensured that the enameled wire is in a proper temperature condition in the machining process, and the insulation performance and quality of the enameled wire are improved. The precise linear speed and tension control can reduce the problems of stretching, deformation and the like of the enameled wire in the processing process, and ensure the dimensional precision and mechanical properties of the enameled wire. According to the method, verification and calibration are carried out according to actually collected data, potential problems and defects in the machining process can be found out, then optimization and improvement are carried out, and the machining efficiency and the resource utilization rate are improved. The optimization of the layout of the heating device and the improvement of a linear speed control system are beneficial to reducing energy consumption and equipment wear, and reducing the production cost.

Description

Technical Field

[0001] The invention relates to the technical field of enameled wire processing, and in particular to an enameled wire processing system. Background Art

[0002] Enameled wire is a conductive metal wire with an insulating layer, which is widely used in the manufacture of electrical equipment. In modern industry, the quality and performance of enameled wire plays a vital role in the reliability, safety and performance of electrical products.

[0003] With the continuous development of electronic technology, the requirements for enameled wires are getting higher and higher. There are some problems with the traditional enameled wire processing method; Chinese invention patent application number: 202210170732.X proposed a horizontal enameling machine, including a wire unwinding wheel, an annealing furnace, a painting device, a drying device and a wire taking-up device, the drying device includes a drying machine frame, a drying furnace is provided on the drying machine frame, the drying furnace includes a furnace body, and a heating channel for the enameled wire to pass through is provided below the furnace body. The heating channel is divided into a first hot flow chamber, a second hot flow chamber and a uniform flow chamber by a first partition and a second partition. A plurality of first flow holes are provided on the first partition, and a plurality of second flow holes are provided on the second partition; a heating chamber is provided in the furnace body at a position above the heating channel, and the uniform flow chamber of the heating channel is connected to the heating chamber through a reflux channel, and the heating chamber is provided with a forward circulation channel connected to the head end of the uniform flow chamber of the heating channel relative to the enameled wire transmission direction and a reverse circulation channel connected to the end of the first flow chamber of the heating channel relative to the enameled wire transmission direction. The present invention has the advantages of energy saving and emission reduction, and can reduce the processing cost of enterprises while avoiding waste of resources;

[0004] The problem to be solved by a horizontal enameling machine proposed in patent application number: 202210170732.X is that the copper wire needs to be dried in a drying furnace after painting. Traditional drying furnaces generally use electric heating, which consumes a lot of electricity, causing waste of resources while increasing the processing cost of the enterprise.

[0005] However, the existing enameled wire has some shortcomings in the process of use and still needs to be improved. The existing technology is difficult to achieve comprehensive and accurate control of the enameled wire processing process, and cannot effectively improve the product quality and production efficiency of the enameled wire. During the processing, due to the lack of effective system control, it is impossible to accurately collect various parameter information in the processing process in real time, such as the temperature, line speed, and tension of the enameled wire, and then it is impossible to transmit this information to the microprocessor in time for analysis and processing, resulting in the inability to calculate the corresponding accurate control instructions according to the preset control algorithm.

[0006] Secondly, the existing technology cannot fully verify and optimize the processing modules. This means that in actual production, there may be potential problems and deficiencies in the processing process that cannot be discovered and solved in time, thus affecting the further improvement of product quality and production efficiency.

[0007] In addition, the existing technology is not timely and accurate in collecting and analyzing parameter information during the processing, and cannot truly achieve accurate control of the enameled wire processing process. This not only leads to unstable product quality, but also may increase production costs and waste resources.

[0008] In summary, the existing technology has obvious defects in the precise control of the enameled wire processing process, the verification and optimization of the processing module, and the real-time collection and analysis of parameter information, and cannot meet the requirements of modern enameled wire production for high quality and high efficiency. Therefore, we propose an enameled wire processing system. Summary of the invention

[0009] The purpose of the present invention is to address the problems raised by the existing background technology. In order to achieve the above invention purpose, the present invention provides the following technical solutions: an enameled wire processing system, including a main frame, a pay-off wheel, the pay-off wheel is connected to the wire wheel motor through a rotating shaft, a wire wheel groove is provided on the pay-off wheel, a combing wire round roller is provided above the pay-off wheel, a round roller shaft is provided on the combing wire round roller, a wire loop rod is provided on the main frame, an enameled wire ring is provided below the wire loop rod, an enameled wire splint is provided at the upper end of the wire loop rod, a combing wire roller is provided at the upper end of the enameled wire splint, a wire material cylinder is provided on the side of the main frame, an annealing furnace is provided on the main frame, a cooling module is provided at the end of the annealing furnace, the cooling module is data-connected with a system control module, and the system control module is provided with a temperature sensor, a speed sensor, a tension sensor, and a microprocessor.

[0010] As a preferred technical solution of the present invention, the cooling module is provided with a water cooling pipe, the water cooling pipe is connected to a water cooling pump, a water cooling nozzle is provided at the end of the water cooling pipe, a cooling round roller is provided at the nozzle of the water cooling nozzle, an air cooling box is provided obliquely above the cooling round roller, an air cooling inlet pipe is provided at the upper end of the air cooling box, and an outlet pipe is provided above the air cooling inlet pipe.

[0011] As a preferred technical solution of the present invention, a wire passing plate is provided at the front section of the wire outlet pipe, an oblique wheel is provided at the side of the wire passing plate, a painting module is provided at the front side of the oblique wheel, the painting module is provided with a main painting wheel, auxiliary painting wheels are provided above and below the main painting wheel, wheel grooves are provided in the main painting wheel and the auxiliary painting wheel, the painting module is provided with a painting mold, and a paint nozzle is provided at the side of the painting mold.

[0012] As a preferred technical solution of the present invention, a drying module is provided at the front side of the painting module, the drying module is provided with a drying box, and a drying heating plate is provided in the drying box.

[0013] As a preferred technical solution of the present invention, the front section of the drying module is provided with an enameled wire conveying module, the enameled wire conveying module is provided with an enameled wire conveying rack, the enameled wire conveying rack is provided with an enameled wire conveying auxiliary wheel, and the front side of the enameled wire conveying auxiliary wheel is provided with an enameled wire conveying wire wheel.

[0014] As a preferred technical solution of the present invention, a wire taking-up module is arranged on the front side of the enameled wire conveying module, the wire taking-up module is provided with a wire taking-up box, a wire taking-up and dividing wheel is arranged on the side of the wire taking-up and dividing wheel, a wire taking-up wheel is arranged on the side of the wire taking-up and dividing wheel, and the wire taking-up wheel is rotatably mounted on the wire taking-up box through a wire wheel adjusting shaft.

[0015] As a preferred technical solution of the present invention, the painting module and the enameled wire conveying module as well as the enameled wire conveying module and the wire taking-up module are all connected to the system control module by wires.

[0016] As a preferred technical solution of the present invention, the annealing furnace; temperature sensors are arranged in the cooling module and the drying module, speed sensors and tension sensors are arranged on the wire wheel motor, the main wire wheel for painting, the enameled wire conveying wheel and the wire take-up wheel, the temperature sensor, the speed sensor and the tension sensor are connected to the microprocessor by wires, and the microprocessor is arranged in a control box.

[0017] As a preferred technical solution of the present invention, the temperature control formula of the system control module is: the ideal temperature of the drying module is T ideal The actual measured temperature is T actual , the temperature error is e(t) = T ideal -T actual

[0018] The output U(t) of the PID controller can be expressed as:

[0019]

[0020] where K P Proportional coefficient, K i is the integration coefficient, K d is the differential coefficient.

[0021] The linear speed adjustment formula of the system control module is: Use PID controller to adjust the linear speed V(t), introduce friction coefficient μ and load torque T load , the differential equation of linear velocity is expressed as:

[0022]

[0023]

[0024] F is the driving force, N is the normal pressure, m is the mass, a is the acceleration, I is the moment of inertia, T motor is the motor output torque, ω is the linear speed; T load is the load torque.

[0025] A control method for an enameled wire processing system, characterized in that it comprises the following steps:

[0026] Step 1: Parameter information collection: Install temperature sensors, linear speed sensors and tension sensors at key locations of the enameled wire processing equipment; the temperature sensor has a measuring range of 0-500°C, an accuracy of ±1°C, and a sampling frequency of 10Hz; the linear speed sensor has a measuring range of 0-50m / min, an accuracy of ±0.1m / min, and a sampling frequency of 20Hz; the tension sensor has a measuring range of 0-50N, an accuracy of ±0.5N, and a sampling frequency of 15Hz; the sensor sends the collected parameter information to the data acquisition module at a set frequency;

[0027] Step 2: Data transmission and processing: The data acquisition module organizes and formats the received parameter information and transmits it to the microprocessor through a high-speed Ethernet communication link; after receiving the parameter information, the microprocessor uses an advanced filtering algorithm to remove noise, using a median filtering algorithm with a window size of 5;

[0028] Step 3: Calculation of control instructions: The microprocessor performs analysis and processing according to the preset control algorithm; for example, for temperature control, the PID control algorithm is adopted, the target temperature is set to 200°C, the proportional coefficient Kp=2, the integral coefficient Ki=0.5, and the differential coefficient Kd=0.2; according to the analysis results, the corresponding precise control instructions are calculated, including adjusting the heating temperature, changing the line speed, and adjusting the tension; when the temperature is higher than 200°C, the heating power is reduced; when the temperature is lower than 200°C, the heating power is increased; when the line speed deviates from the set value, the motor speed is adjusted accordingly; when the tension is not within the set range, the tension of the tension device is adjusted;

[0029] Step 4: Processing module verification and optimization: Establish a mathematical model of the processing module, taking into account the material properties of the enameled wire and the processing parameters; use the actual collected parameter information to verify and calibrate the mathematical model; adjust the model parameters by comparing the model prediction values ​​with the actual measured values;

[0030] Through the analysis of mathematical models, potential problems and deficiencies in the processing process can be found and optimized and improved; for example, the layout of the heating device can be optimized to improve temperature uniformity; the line speed control system can be improved to reduce speed fluctuations;

[0031] Step 5: Parameter information monitoring and feedback: Real-time monitoring of parameter information collection and analysis process to ensure the timeliness and accuracy of data; set the data update interval to 1 second; promptly issue an alarm if abnormal or inaccurate data is found; when the temperature exceeds the set upper limit or falls below the set lower limit, an audible and visual alarm is issued, error correction measures are initiated, and processing is suspended for inspection; adjust the parameters of the PID control algorithm based on product quality feedback.

[0032] Compared with the prior art, the invention has the following beneficial effects: through precise temperature control (PID control algorithm), the enameled wire is ensured to be under suitable temperature conditions during processing, which helps to improve the adhesion and uniformity of the paint, thereby improving the insulation performance and quality of the enameled wire. Accurate line speed and tension control can reduce the problems of stretching and deformation of the enameled wire during processing, and ensure the dimensional accuracy and mechanical properties of the enameled wire.

[0033] The present invention verifies and calibrates based on the actual collected data, can identify potential problems and deficiencies in the processing process, and then optimize and improve them, thereby improving processing efficiency and resource utilization. The optimization of the heating device layout and the improvement of the line speed control system help reduce energy consumption and equipment wear, and reduce production costs.

[0034] The present invention monitors the collection and analysis process of parameter information in real time, discovers data anomalies in time, and issues alarms and error corrections, which can effectively avoid production accidents caused by equipment failure or process parameter deviations, and improve the stability and reliability of the system. The control algorithm is continuously adjusted and optimized, so that the system can better adapt to different production conditions and product requirements, and enhance the flexibility and adaptability of the system.

[0035] The automated parameter collection, transmission, processing and control instruction calculation of the present invention can reduce manual intervention, improve production efficiency and shorten the production cycle. The precise control and optimization of the system over the processing process can reduce the scrap rate and rework rate, improve the product qualification rate, and thus further improve production efficiency. The system has a high degree of automation, which can reduce the labor intensity of workers, freeing them from cumbersome operations and allowing them to engage in more valuable work. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 A schematic diagram of the structure provided by the present invention;

[0037] Figure 2 A schematic diagram of the overall structure provided by the present invention;

[0038] Figure 3 A schematic diagram of a local structure provided by the present invention;

[0039] Figure 4 A schematic diagram of the structure of the wire take-up module provided by the present invention;

[0040] Figure 5 A schematic diagram of the structure of the pay-off wheel provided by the present invention;

[0041] Figure 6 A schematic diagram of the main structure provided by the present invention;

[0042] Figure 7 A left-side structural schematic diagram provided by the present invention;

[0043] Figure 8 This is a system logic block diagram provided by the present invention.

[0044] Indicated in the figure:

[0045] 1. Main frame; 2. Pay-off wheel; 3. Wire wheel motor; 4. Wire wheel groove; 5. Combing line roller; 51. Roller shaft; 6. Wire ring rod; 61. Enameled wire ring; 7. Enameled wire clamp; 8. Combing roller; 9. Wire cylinder; 10. Annealing furnace; 11. Cooling module; 111. Water cooling pipe; 112. Water cooling nozzle; 113. Water cooling pump; 12. Cooling roller; 13. Air cooling box; 131. Air cooling inlet pipe; 14. Wire outlet pipe; 15. Wire plate; 16. Oblique wheel; 17. Painting module; 18. Painting main wire wheel; 19. Painting auxiliary wire wheel; 20. Wire wheel groove ; 21. Painting mold; 211. Painting nozzle; 22. Drying module; 23. Drying box; 231. Drying heating plate; 24. Enameled wire conveying module; 25. Enameled wire conveying rack; 26. Enameled wire conveying auxiliary wheel; 27. Enameled wire conveying wheel; 28. Take-up module; 29. ​​Take-up box; 30. Take-up and dividing wheel; 31. Take-up wheel; 311. Wire wheel adjustment shaft, 312. Wire wheel adjustment knob; 32. System control module; 321. Temperature sensor, 322. Speed ​​sensor, 323. Tension sensor; 324. Microprocessor; 33. Control box. DETAILED DESCRIPTION

[0046] To make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be described clearly and completely in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them.

[0047] Therefore, the following detailed description of the embodiments of the present invention is not intended to limit the scope of the claimed invention, but merely represents some embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention. It should be noted that the embodiments of the present invention and the features and technical solutions in the embodiments can be combined with each other without conflict. It should be noted that similar numbers and letters represent similar items in the following drawings. Therefore, once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings.

[0048] Example 1: Please refer to Figure 1-Figure 8 A enameled wire processing system comprises a main frame 1 and a pay-off wheel 2, the pay-off wheel 2 is connected to a wire wheel motor 3 through a rotating shaft, a wire wheel groove 4 is provided on the pay-off wheel 2, a combing wire round roller 5 is provided above the pay-off wheel 2, a round roller shaft 51 is provided on the combing wire round roller 5, a wire loop rod 6 is provided on the main frame 1, an enameled wire loop 61 is provided below the wire loop rod 6, an enameled wire clamping plate 7 is provided at the upper end of the wire loop rod 6, a wire combing roller 8 is provided at the upper end of the enameled wire clamping plate 7, a wire material cylinder 9 is provided on the side of the main frame 1, an annealing furnace 10 is provided inside the main frame 1, and a cooling module 11 is provided at the end of the annealing furnace 10.

[0049] The cooling module 11 is provided with a water cooling pipe 111, and the water cooling pipe 111 is connected to a water cooling pump 113. A water cooling nozzle 112 is provided at the end of the water cooling pipe 111. A cooling round roller 12 is provided at the nozzle of the water cooling nozzle 112. An air cooling box 13 is provided obliquely above the cooling round roller 12. An air cooling inlet pipe 131 is provided at the upper end of the air cooling box 13, and an outlet pipe 14 is provided above the air cooling inlet pipe 131.

[0050] A wire passing plate 15 is provided at the front section of the wire outlet pipe 14, an oblique wheel 16 is provided on the side of the wire passing plate 15, a painting module 17 is provided on the front side of the oblique wheel 16, the painting module 17 is provided with a main painting wheel 18, and auxiliary painting wheels 19 are provided above and below the main painting wheel 18. Wheel grooves 20 are provided in the main painting wheel 18 and the auxiliary painting wheel 19, the painting module 17 is provided with a painting mold 21, and a paint nozzle 211 is provided on the side of the painting mold 21.

[0051] A drying module 22 is disposed at the front side of the painting module 17 . The drying module 22 is provided with a drying box 23 . A drying heating plate 231 is disposed in the drying box 23 .

[0052] The front section of the drying module 22 is provided with an enameled wire conveying module 24 , which is provided with an enameled wire conveying frame 25 , on which an enameled wire conveying auxiliary wheel 26 is provided, and in front of which an enameled wire conveying wheel 27 is provided.

[0053] A wire taking-up module 28 is provided on the front side of the enameled wire conveying module 24, and a wire taking-up box 29 is provided on the wire taking-up box 29. A wire taking-up dividing wheel 30 is provided on the side of the wire taking-up dividing wheel 30. A wire taking-up wheel 31 is provided on the side of the wire taking-up dividing wheel 30. The wire taking-up wheel 31 is rotatably mounted on the wire taking-up box 29 through a wire wheel adjusting shaft 311, and a wire wheel adjusting knob 312 is provided on the upper end of the wire taking-up wheel 31.

[0054] The painting module 17 and the enameled wire conveying module 24 as well as the enameled wire conveying module 24 and the wire taking-up module 28 are all connected to the system control module 32 by wires.

[0055] Annealing furnace 10; temperature sensor 321 is arranged in cooling module 11 and drying module 22, speed sensor 322 and tension sensor 323 are arranged on wire wheel motor 3, painting main wire wheel 18, enameled wire conveying wire wheel 27 and take-up wire wheel 31, temperature sensor 321, speed sensor 322 and tension sensor 323 are connected with microprocessor 324 by wires, and microprocessor 324 is arranged in control box 33.

[0056] Working principle of enameled wire processing system: Pay-off process: The wire wheel motor 3 drives the pay-off wheel 2 to rotate through the rotating shaft, and the enameled wire raw material to be processed is placed in the wire wheel groove 4 on the pay-off wheel 2. After the enameled wire is paid out from the pay-off wheel 2, it is preliminarily combed by the combing wire roller 5 to make it more neat.

[0057] Wire loop guidance: The combed enameled wire passes through the enameled wire loop 61 below the wire loop rod 6, which plays a role in guiding and stabilizing the direction of the enameled wire.

[0058] Clamp and roller combing: The enameled wire passes through the enameled wire clamp 7, and the combing roller 8 at the upper end further combs and adjusts the enameled wire to ensure the flatness and straightness of the enameled wire.

[0059] Supply of wire drum 9: The wire drum 9 on the side of the main frame 1 provides necessary materials or auxiliary agents for subsequent processing.

[0060] Annealing treatment: The enameled wire enters the annealing furnace 10 in the main frame 1 for annealing treatment to change its physical properties and improve the quality of subsequent processing.

[0061] Cooling treatment: The annealed enameled wire enters the cooling module 11. The water cooling pump 113 delivers cooling water to the water cooling nozzle 112 through the water cooling pipe 111. The cooling water is sprayed from the nozzle to the enameled wire on the cooling roller 12 for water cooling. At the same time, the air cooling box 13 blows air to the enameled wire through the air cooling inlet pipe 131 to further cool the enameled wire.

[0062] Painting process: The cooled enameled wire passes through the outlet pipe 14 and enters the painting module 17. The main painting wheel 18 drives the enameled wire to move, and the upper and lower auxiliary painting wheels 19 assist in maintaining the position of the enameled wire. The painting nozzle 211 sprays the paint onto the enameled wire to coat the surface with a paint layer, and the painting mold 21 ensures the uniformity and thickness of the paint layer.

[0063] Drying treatment: the enameled wire after painting enters the drying box 23 of the drying module 22, and the drying heating plate 231 heats the enameled wire to make the paint dry quickly and form a firm enameled layer.

[0064] Conveying process: The dried enameled wire is conveyed by the enameled wire conveying auxiliary wheel 26 and the enameled wire conveying wheel 27 on the enameled wire conveying frame 25 of the enameled wire conveying module 24, ensuring that the enameled wire smoothly enters the next processing link.

[0065] Wire-receiving process: The enameled wire finally enters the wire-receiving box 29 of the wire-receiving module 28. The wire-receiving wire-splitting wheel 30 separates the enameled wire, and the wire-receiving wheel 31 rotates through the wire wheel adjusting shaft 311 to neatly reel up the enameled wire.

[0066] System control module 32 temperature control formula: The ideal temperature of the drying module 22 is T ideal The actual measured temperature is T actual , the temperature error is e(t) = T ideal -T actual ;

[0067] The output U(t) of the PID controller can be expressed as:

[0068]

[0069] where K P Proportional coefficient, K i is the integration coefficient, K d is the differential coefficient.

[0070] System control module 32 Line speed adjustment formula: Use PID controller to adjust the line speed V(t), introduce friction coefficient μ and load torque T load , the differential equation of linear velocity is expressed as:

[0071]

[0072]

[0073] F is the driving force, N is the normal pressure, m is the mass, a is the acceleration, I is the moment of inertia, T motor is the motor output torque, ω is the linear speed; T load is the load torque.

[0074] Working process of enameled wire processing system: Pay-off: The wire wheel motor 3 drives the pay-off wheel 2 to rotate through the rotating shaft, and the enameled wire raw material in the wire groove of the pay-off wheel 2 is paid out. The enameled wire passes through the combing wire round roller 5 above for preliminary combing.

[0075] Guiding and combing: The combed enameled wire passes through the enameled wire ring 61 below the wire ring rod 6, then passes through the enameled wire clamping plate 7, and is further combed by the combing roller 8 at the upper end to ensure that the enameled wire is neat.

[0076] Annealing: The enameled wire enters the annealing furnace 10 in the main frame 1 for annealing treatment to improve its performance.

[0077] Cooling: The annealed enameled wire enters the cooling module 11. The water cooling pump 113 delivers cooling water to the water cooling nozzle 112 through the water cooling pipe 111 to cool the enameled wire on the cooling roller 12. At the same time, the air cooling box 13 blows air to the enameled wire through the air cooling inlet pipe 131 to enhance the cooling effect.

[0078] Painting: The cooled enameled wire passes through the wire plate 15 and the inclined wheel 16 at the front of the outlet tube 14 and enters the painting module 17. The main painting wheel 18 drives the enameled wire to move, the secondary painting wheel 19 assists in maintaining the position of the enameled wire, the painting nozzle 211 sprays the paint onto the enameled wire, and the painting mold 21 ensures a uniform paint layer.

[0079] Drying: The enameled wire after painting enters the drying box 23 of the drying module 22, and is heated by the drying heating plate 231 to dry the paint and form a firm enameled layer.

[0080] Conveying: The dried enameled wire is conveyed by the enameled wire conveying auxiliary wheel 26 and the enameled wire conveying wheel 27 on the enameled wire conveying frame 25 of the enameled wire conveying module 24 .

[0081] Wire collection: The enameled wire finally enters the wire collection box 29 of the wire collection module 28. The wire collection and separation wheel 30 separates the enameled wires, and the wire collection wheel 31 rotates through the wire wheel adjustment shaft 311 to neatly reel the enameled wires.

[0082] In the whole working process, the temperature sensors 321 in the annealing furnace 10, the cooling module 11 and the drying module 22 monitor the temperature in real time, and the speed sensors 322 and the tension sensors 323 on the wire wheel motor 3, the main wire wheel 18 for painting, the enameled wire conveying wire wheel 27 and the wire take-up wheel 31 monitor the running speed and tension in real time. These sensors transmit the data to the microprocessor 324, which analyzes and processes according to the preset parameters.

[0083] System control module 32 temperature control formula: The ideal temperature of the drying module 22 is T ideal The actual measured temperature is T actual , the temperature error is e(t) = T ideal -T actual ;

[0084] The output U(t) of the PID controller can be expressed as:

[0085]

[0086] where K P Proportional coefficient, K i is the integration coefficient, K d is the differential coefficient.

[0087] System control module 32 Line speed adjustment formula: Use PID controller to adjust the line speed V(t), introduce friction coefficient μ and load torque T load , the differential equation of linear velocity is expressed as:

[0088]

[0089]

[0090] F is the driving force, N is the normal pressure, m is the mass, a is the acceleration, I is the moment of inertia, T motor is the motor output torque, ω is the linear speed; T load The system control module 32 adjusts and controls each module to ensure the quality and efficiency of enameled wire processing.

[0091] The specific steps of system control of an enameled wire processing system are as follows: Step 1: Parameter information collection

[0092] A temperature sensor 321, a line speed sensor 322 and a tension sensor 323 are installed at key positions of the enameled wire processing equipment.

[0093] The measurement range of the temperature sensor 321 is 0-500°C, the accuracy is ±1°C, and the sampling frequency is 10Hz.

[0094] The measurement range of the linear velocity sensor 322 is 0-50 m / min, the accuracy is ±0.1 m / min, and the sampling frequency is 20 Hz.

[0095] The measurement range of the tension sensor 323 is 0-50N, the accuracy is ±0.5N, and the sampling frequency is 15Hz.

[0096] The sensor sends the collected parameter information to the data acquisition module at a set frequency.

[0097] Step 2: Data transmission and processing

[0098] The data acquisition module organizes and formats the received parameter information and transmits it to the microprocessor 324 via a high-speed Ethernet communication link.

[0099] After receiving the parameter information, the microprocessor 324 uses an advanced filtering algorithm to remove noise and improve the accuracy of the data. For example, a median filtering algorithm is used with a window size of 5.

[0100] Step 3: Control instruction calculation

[0101] The microprocessor 324 performs analysis and processing according to a preset control algorithm. For example, for temperature control, a PID control algorithm is used, and the target temperature is set to 200° C., the proportional coefficient Kp=2, the integral coefficient Ki=0.5, and the differential coefficient Kd=0.2.

[0102] Based on the analysis results, the corresponding precise control instructions are calculated, including adjusting the heating temperature, changing the line speed, and adjusting the tension.

[0103] When the temperature is higher than 200°C, reduce the heating power; when the temperature is lower than 200°C, increase the heating power.

[0104] When the line speed deviates from the set value such as 30m / min, the motor speed is adjusted accordingly.

[0105] When the tension is not within the set range such as 10-20N, adjust the tension of the tension device.

[0106] Step 4: Processing module verification and optimization

[0107] A mathematical model of the processing module is established, taking into account the material properties of the enameled wire and the processing parameters.

[0108] The mathematical model is verified and calibrated using the actual parameter information collected. For example, by comparing the model predictions with the actual measured values, the model parameters are adjusted to keep the model error within the acceptable range of ±5%.

[0109] By analyzing the mathematical model, we can find out the potential problems and deficiencies in the processing process and make optimization and improvement. For example, we can optimize the layout of the heating device to improve the temperature uniformity and improve the line speed control system to reduce speed fluctuation.

[0110] Step 5: Parameter information monitoring and feedback

[0111] Real-time monitoring of parameter information collection and analysis process to ensure the timeliness and accuracy of data. Set the data update interval to 1 second.

[0112] If the data is found to be abnormal or inaccurate, an alarm will be issued in time. For example, when the temperature exceeds the set upper limit such as 250°C or falls below the set lower limit such as 150°C, an audible and visual alarm will be issued, and corresponding error correction measures will be taken, such as suspending processing for inspection.

[0113] According to the actual production situation, the control algorithm is constantly adjusted and optimized. For example, according to the feedback of product quality, the parameters of the PID control algorithm are adjusted to improve the control effect.

[0114] Enameled wire processing system control algorithm framework:

[0115] Python

[0116] import time

[0117] #Define the sensor class to collect various parameter information of enameled wire

[0118] class Sensor:

[0119] def __init__(self):

[0120] self.temperature = enameled wire temperature

[0121] self.line_speed = Line speed

[0122] self.tension = tension

[0123] def collect_data(self):

[0124] #Simulate the collection of temperature, line speed and tension data of enameled wire

[0125] self.temperature=200#In actual application, real data should be obtained through sensors

[0126] self.line_speed = 10#In actual application, real data should be obtained through sensors

[0127] self.tension=5#In actual application, real data should be obtained through sensors

[0128] #Define the microprocessor 324 class, which is used to analyze and process the data collected by the sensor and calculate the control instructions

[0129] class Microprocessor:

[0130] def __init__(self):

[0131] self.target_temperature=220#Preset target temperature

[0132] self.target_line_speed = 12 # preset target line speed

[0133] self.target_tension = 6 # preset target tension

[0134] def analyze_data(self,sensor_data):

[0135] #Compare the actual collected data with the preset target value and calculate the control instructions

[0136] temperature_error=self.target_temperature-sensor_data.temperature

[0137] line_speed_error=self.target_line_speed-sensor_data.line_speed

[0138] tension_error=self.target_tension-sensor_data.tension

[0139] control_instructions={"temperature_control":temperature_error,

[0140] "line_speed_control":line_speed_error,

[0141] "tension_control":tension_error}

[0142] return control_instructions

[0143] #Main program

[0144] def main():

[0145] sensor=Sensor()

[0146] microprocessor=Microprocessor()

[0147] while True:

[0148] sensor.collect_data()#Collect parameter information of enameled wire

[0149] sensor_data=sensor# passes the collected data to the microprocessor 324

[0150] control_instructions = microprocessor.analyze_data(sensor_data) #microprocessor 324 analyzes data and calculates control instructions

[0151] #Perform corresponding control operations on the enameled wire processing system according to the control instructions

[0152] print("Temperature error:",control_instructions["temperature_control"])

[0153] print("Line speed error:",control_instructions["line_speed_control"])

[0154] print("Tension error:",control_instructions["tension_control"])

[0155] time.sleep(1)#Collect data every 1 second and process it

[0156] if__name__=="__main__":

[0157] Enameled wire processing system control algorithm First, a sensor class Sensor is defined to collect the temperature, line speed and tension parameter information of the enameled wire. In the initialization method of the Sensor class, the temperature, line speed and tension are initialized to 0. The collect_data method is used to simulate the collection of the temperature of the enameled wire as 200, the line speed as 10, and the tension as 5. In actual applications, real data should be obtained through sensors.

[0158] Then, a microprocessor 324 class Microprocessor is defined to analyze and process the data collected by the sensor and calculate the control instructions. In the initialization method of the Microprocessor class, the target temperature is preset to 220, the target line speed is 12, and the target tension is 6. The analyze_data method is used to compare the actual collected data with the preset target values, calculate the temperature error, line speed error, and tension error, and store them in a dictionary as control instructions and return them.

[0159] In the main program, instances of Sensor and Microprocessor are created. Through an infinite loop, the following operations are performed every 1 second:

[0160] The sensor collects parameter information of the enameled wire.

[0161] The collected data is transmitted to the microprocessor 324Microprocessor.

[0162] Microprocessor 324 analyzes the data and calculates control instructions.

[0163] Print out temperature error, line speed error and tension error.

[0164] During the operation of the enameled wire processing system: temperature sensors 321, linear speed sensors 322 and tension sensors 323 are installed at key locations of the enameled wire processing equipment. These sensors have specific measurement ranges and accuracies, as well as different sampling frequencies. The temperature sensor 321 can measure temperatures of 0-500°C with an accuracy of ±1°C and a sampling frequency of 10Hz; the linear speed sensor 322 can measure linear speeds of 0-50m / min with an accuracy of ±0.1m / min and a sampling frequency of 20Hz; the tension sensor 323 can measure tensions of 0-50N with an accuracy of ±0.5N and a sampling frequency of 15Hz. The sensor will send the collected parameter information to the data acquisition module at a set frequency.

[0165] Next, the data acquisition module organizes and formats the received parameter information and transmits it to the microprocessor 324 via a high-speed Ethernet communication link. The microprocessor 324 uses advanced filtering algorithms, such as a median filtering algorithm with a window size of 5, to remove noise and improve the accuracy of the data.

[0166] Then, the microprocessor 324 performs analysis and processing according to the preset control algorithm. For example, in terms of temperature control, the PID control algorithm is used, the target temperature is set to 200°C, and the corresponding precise control instructions are calculated according to the proportional coefficient Kp=2, the integral coefficient Ki=0.5, and the differential coefficient Kd=0.2. When the temperature is higher than 200°C, the heating power is reduced; when the temperature is lower than 200°C, the heating power is increased. For line speed control, when the line speed deviates from the set value such as 30m / min, the motor speed is adjusted accordingly. In terms of tension control, when the tension is not within the set range such as 10-20N, the tension of the tension device is adjusted.

[0167] After that, the mathematical model of the processing module is established, taking into account factors such as the material properties of the enameled wire and the processing parameters. The mathematical model is verified and calibrated using the actual parameter information collected. By comparing the model prediction value with the actual measurement value, the model parameters are adjusted to make the model error within the acceptable range of ±5%. Through the analysis of the mathematical model, potential problems and deficiencies that may exist in the processing process are identified and optimized, such as optimizing the layout of the heating device to improve temperature uniformity and improving the line speed control system to reduce speed fluctuations.

[0168] Finally, the collection and analysis process of parameter information is monitored in real time to ensure the timeliness and accuracy of the data, and the data update interval is set to 1 second. If the data is found to be abnormal or inaccurate, an alarm is issued in time. For example, when the temperature exceeds the set upper limit such as 250°C or is lower than the set lower limit such as 150°C, an audible and visual alarm is issued, and corresponding error correction measures are taken, such as suspending processing for inspection. At the same time, according to the actual production situation, the control algorithm is continuously adjusted and optimized, such as adjusting the parameters of the PID control algorithm according to the feedback of product quality to improve the control effect.

[0169] The above embodiments are only used to illustrate the present invention and are not intended to limit the technical solutions described in the present invention. Although the present invention has been described in detail with reference to the above embodiments, the present invention is not limited to the above specific implementation methods. Therefore, any modification or replacement of the present invention; and all technical solutions and improvements thereof that do not depart from the spirit and scope of the invention are included in the scope of the claims of the present invention.

Claims

1. An enameled wire processing system, characterized in that: The invention comprises a main frame (1) and a wire-releasing wheel (2), wherein the wire-releasing wheel (2) is connected to a wire-releasing wheel motor (3) via a rotating shaft, a wire-releasing wheel (2) is provided with a wire-releasing wheel groove (4), a combing wire round roller (5) is provided above the wire-releasing wheel (2), a round roller shaft (51) is provided on the combing wire round roller (5), a wire ring rod (6) is provided on the main frame (1), an enameled wire ring (61) is provided below the wire ring rod (6), an enameled wire clamping plate (7) is provided at the upper end of the wire ring rod (6), and the wire ring rod (6) is provided with a wire-releasing wheel (6). A wire combing roller (8) is arranged at the upper end of the enameled wire clamping plate (7), a wire material cylinder (9) is arranged on the side of the main frame (1), an annealing furnace (10) is arranged on the main frame (1), a cooling module (11) is arranged at the end of the annealing furnace (10), the cooling module (11) is data-connected with a system control module (32), and the system control module (32) is provided with a temperature sensor (321), a speed sensor (322), a tension sensor (323) and a microprocessor (324).

2. The enameled wire processing system according to claim 1, characterized in that: The cooling module (11) is provided with a water cooling pipe (111), the water cooling pipe (111) is connected to a water cooling pump (113), a water cooling nozzle (112) is provided at the end of the water cooling pipe (111), a cooling round roller (12) is provided at the nozzle of the water cooling nozzle (112), an air cooling box (13) is provided obliquely above the cooling round roller (12), an air cooling inlet pipe (131) is provided at the upper end of the air cooling box (13), and an outlet pipe (14) is provided above the air cooling inlet pipe (131).

3. The enameled wire processing system according to claim 2, characterized in that: The front section of the outlet pipe (14) is provided with a wire passing plate (15), the side of the wire passing plate (15) is provided with an inclined wheel (16), the front side of the inclined wheel (16) is provided with a painting module (17), the painting module (17) is provided with a main painting wheel (18), and the upper and lower parts of the main painting wheel (18) are provided with auxiliary painting wheels (19), and the main painting wheel (18) and the auxiliary painting wheel (19) are provided with wheel grooves (20), the painting module (17) is provided with a painting mold (21), and the side of the painting mold (21) is provided with a paint nozzle (211).

4. The enameled wire processing system according to claim 3, characterized in that: A drying module (22) is arranged at the front side of the painting module (17), the drying module (22) is provided with a drying box (23), and a drying heating plate (231) is arranged inside the drying box (23).

5. The enameled wire processing system according to claim 4, characterized in that: The front section of the drying module (22) is provided with an enameled wire conveying module (24), the enameled wire conveying module (24) is provided with an enameled wire conveying frame (25), the enameled wire conveying frame (25) is provided with an enameled wire conveying auxiliary wheel (26), and the front side of the enameled wire conveying auxiliary wheel (26) is provided with an enameled wire conveying wire wheel (27).

6. The enameled wire processing system according to claim 5, characterized in that: A wire take-up module (28) is arranged at the front side of the enameled wire conveying module (24), and the wire take-up module (28) is provided with a wire take-up box (29). A wire take-up and wire dividing wheel (30) is arranged at the side of the wire take-up and wire dividing wheel (30), and a wire take-up wheel (31) is arranged at the side of the wire take-up and wire dividing wheel (30). The wire take-up wheel (31) is rotatably mounted on the wire take-up box (29) via a wire wheel adjustment shaft (311), and a wire wheel adjustment knob (312) is arranged at the upper end of the wire take-up wheel (31).

7. The enameled wire processing system according to claim 6, characterized in that: The painting module (17) and the enameled wire conveying module (24) as well as the enameled wire conveying module (24) and the wire taking-up module (28) are all connected to the system control module (32) by electric wires.

8. The enameled wire processing system according to claim 7, characterized in that: The annealing furnace (10); a temperature sensor (321) is arranged in the cooling module (11) and the drying module (22); a speed sensor (322) and a tension sensor (323) are arranged on the wire wheel motor (3), the main wire wheel for painting (18), the enameled wire conveying wheel (27) and the wire take-up wheel (31); the temperature sensor (321), the speed sensor (322) and the tension sensor (323) are connected to a microprocessor (324) by wires; and the microprocessor (324) is arranged in a control box (33).

9. The enameled wire processing system according to claim 8, characterized in that: The temperature control formula of the system control module (32) is: The ideal temperature of the drying module (22) is T ideal The actual measured temperature is T actual , the temperature error is e(t) = T ideal- T actual The output U(t) of the PID controller can be expressed as: where K P Proportional coefficient, K i is the integration coefficient, K d is the differential coefficient; The linear speed adjustment formula of the system control module (32) uses a PID controller to adjust the linear speed V(t), introducing the friction coefficient μ and the load torque T load , the differential equation of linear velocity is expressed as: F is the driving force, N is the normal pressure, m is the mass, a is the acceleration, I is the moment of inertia, T motor is the motor output torque, ω is the linear speed; T load is the load torque.

10. A control method for an enameled wire processing system, characterized in that: The following steps are involved: Step 1: Parameter information collection: temperature sensors (321), linear speed sensors (322) and tension sensors (323) are installed at key positions of the enameled wire processing equipment; the measuring range of the temperature sensor (321) is 0-500°C, the accuracy is ±1°C, and the sampling frequency is 10Hz; the measuring range of the linear speed sensor (322) is 0-50m / min, the accuracy is ±0.1m / min, and the sampling frequency is 20Hz; the measuring range of the tension sensor (323) is 0-50N, the accuracy is ±0.5N, and the sampling frequency is 15Hz; the sensor sends the collected parameter information to the data acquisition module at a set frequency; Step 2: Data transmission and processing: The data acquisition module organizes and formats the received parameter information and transmits it to the microprocessor (324) via a high-speed Ethernet communication link; after receiving the parameter information, the microprocessor (324) uses an advanced filtering algorithm to remove noise, using a median filtering algorithm with a window size of 5; Step 3: Calculation of control instructions: The microprocessor (324) performs analysis and processing according to a preset control algorithm; for example, for temperature control, a PID control algorithm is used, the target temperature is set to 200° C., the proportional coefficient Kp=2, the integral coefficient Ki=0.5, and the differential coefficient Kd=0.2; according to the analysis results, the corresponding precise control instructions are calculated, including adjusting the heating temperature, changing the line speed, and adjusting the tension; when the temperature is higher than 200° C., the heating power is reduced; when the temperature is lower than 200° C., the heating power is increased; when the line speed deviates from the set value, the motor speed is adjusted accordingly; when the tension is not within the set range, the tension of the tension device is adjusted; Step 4: Processing module verification and optimization: Establish a mathematical model of the processing module, taking into account the material properties of the enameled wire and the processing parameters; Use the actual collected parameter information to verify and calibrate the mathematical model; adjust the model parameters by comparing the model prediction values ​​with the actual measured values; Optimize and improve through analysis of mathematical models; optimize the layout of heating devices to improve temperature uniformity; improve line speed control system to reduce speed fluctuations; Step 5: Parameter information monitoring and feedback: Real-time monitoring of parameter information collection and analysis process to ensure the timeliness and accuracy of data; set the data update interval to 1 second; promptly issue an alarm if abnormal or inaccurate data is found; when the temperature exceeds the set upper limit or falls below the set lower limit, an audible and visual alarm is issued, error correction measures are initiated, and processing is suspended for inspection; adjust the parameters of the PID control algorithm based on product quality feedback.

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