Wire winding parameter detection system and method of spring winding machine

Abstract

The invention relates to the technical field of automatic detection, and discloses a wire winding parameter detection system and method of a spring winding machine. According to the wire winding parameter detection system and method of the spring winding machine, key parameters such as the wire rod diameter, the wire winding speed and tension can be automatically collected, original data are filtered and calibrated through the data processing module, the accuracy of the data is ensured, the parameter calculation module calculates related performance indexes in real time according to the processed data, and the accuracy of the data is ensured. The control feedback module automatically adjusts the wire winding speed, tension and angle to form closed-loop control, and finally, the user interface module visually displays a generated wire winding parameter adjustment report to an operator, so that the influence of human factors on the production stability is reduced, the stability of the production process and the consistency of final products are improved, and the production efficiency is improved. By implementing the system, the automation level of the spring winding machine is greatly improved, potential risks caused by manual intervention are reduced, and development of intelligent manufacturing is promoted.

Description

Technical Field

[0001] The present invention relates to the technical field of automated detection, and particularly to a wire winding parameter detection system and method for a spring winding machine. Background Art

[0002] A spring winding machine is a mechanical device specifically used for manufacturing springs and other wound components. It can produce spiral springs that meet the specified requirements by precisely controlling the wire winding process. Wire winding, as the core process of the spring winding machine, involves winding the wire into the required shape at a specific angle and tension to ensure the consistency of the final product in terms of performance and quality. In modern industry, the efficiency and processing accuracy of the spring winding machine directly affect the cost and market competitiveness of the product. Therefore, it is crucial to monitor and accurately adjust various parameters during the wire winding process in real time.

[0003] Traditional methods for monitoring wire winding parameters usually rely on manual detection. Operators need to manually record and adjust various key parameters during the wire winding process. This method is not only inefficient but also easily affected by the experience and judgment of the operators, resulting in insufficient data accuracy, which in turn affects the stability of the production process and the quality of the final product. Summary of the Invention

[0004] (1) Technical Problems to be Solved

[0005] In view of the deficiencies of the prior art, the present invention provides a wire winding parameter detection system and method for a spring winding machine, which can not only automatically collect key parameters such as wire diameter, wire winding speed, tension, etc., but also filter and calibrate the original data through a data processing module to ensure data accuracy. The parameter calculation module calculates relevant performance indicators in real time based on the processed data, and automatically adjusts the wire winding speed, tension, and angle through a control feedback module to form a closed-loop control. Finally, the user interface module intuitively displays the generated wire winding parameter adjustment report to the operator, reducing the impact of human factors on production stability, thereby improving the stability of the production process and the consistency of the final product. The implementation of this system will greatly improve the automation level of the spring winding machine, reduce the potential risks brought by manual intervention, and promote the development of intelligent manufacturing.

[0006] (2) Technical Solutions

[0007] To achieve the above object, the present invention provides the following technical solution: A wire winding parameter detection system for a spring winding machine, comprising a data acquisition module, a data processing module, a parameter calculation module, a control feedback module, and a user interface module;

[0008] The data acquisition module is used to collect in real time the wire diameter, wire winding speed, tension, wire winding angle, number of wire winding turns, and temperature data during the wire winding process, and transmit them to the data processing module;

[0009] The data processing module is used to perform filtering, denoising, and calibration processing on the raw data collected by the data acquisition module, and the processed data is sent to the parameter calculation module;

[0010] The parameter calculation module is used to calculate the wire length, winding torque, winding efficiency, wire volume, and winding stress based on the data processed by the data processing module and send them to the control feedback module;

[0011] The control feedback module adjusts the winding speed, tension, and winding angle in real time according to the calculation results of the parameter calculation module, and generates a winding parameter adjustment report for transmission to the user interface module;

[0012] The user interface module is used to display the winding parameter adjustment report and receive input instructions from the operator.

[0013] Preferably, the formula for data filtering is as follows:

[0014] y(t) = α * x(t) + (1 - α) * y(t - 1)

[0015] In the formula, y(t) represents the data filtering output value at the current moment, x(t) represents the raw data input value at the current moment, y(t - 1) represents the data filtering output value at the previous moment, and α represents the filtering coefficient, with a value range of 0 - 1.

[0016] Preferably, the formula for data denoising is as follows:

[0017]

[0018] In the formula, k(t) represents the denoising output value at the current moment, N represents the window size of the moving average, and y(t - i) represents the filtered data input values at the current moment and the previous N - 1 moments.

[0019] Preferably, the formula for data calibration is as follows:

[0020] p = m * k + b

[0021] In the formula, p represents the calibrated data output value, m represents the calibration coefficient, k represents the denoised data input value, and b represents the calibration offset.

[0022] Preferably, the formula for calculating the wire length is as follows:

[0023]

[0024] In the formula, L represents the total length of the wire, n represents the number of winding turns, π represents the pi, taking 3.1416, D represents the diameter of the wire, Denotes the angle correction factor, used to correct the deviation caused by non-vertical winding.

[0025] Preferably, the formula for calculating the wire winding torque is as follows:

[0026] T = F * r * sin(θ + α) * e -βt

[0027] In the formula, T represents the wire winding torque, F represents the tension of the wire, r represents the distance from the wire winding point to the rotation center, θ represents the wire winding angle, sn() represents the sine function, α represents the additional angle for correction of the external force or error during the instruction, e represents the base of the natural logarithm, β represents the attenuation factor describing the influence of friction or resistance changing with time, and t represents the time variable.

[0028] Preferably, the formula for calculating the wire winding efficiency is as follows:

[0029]

[0030] In the formula, η represents the wire winding efficiency, L represents the total length of the wire, f(v) represents the speed correction function, t proc represents the time consumed during the wire blowing process, and p represents the output power maintained by the machine under specific conditions.

[0031] Preferably, the formula for calculating the volume of the wire is as follows:

[0032]

[0033] In the formula, V represents the volume of the wire, D represents the diameter of the wire, L represents the total length of the wire, π represents the pi, taking 3.1416, represents the correction of the coil working angle for volume calculation, E represents the Young's modulus of the material, and G represents the shear modulus of the material.

[0034] Preferably, the formula for calculating the wire winding stress is as follows:

[0035]

[0036] In the formula, σ represents the wire winding stress, F represents the tension of the wire, A represents the cross-sectional area of the wire, and the calculation formula is k(θ) represents the angle correction factor, and δt represents the time correction factor.

[0037] A method for detecting wire winding parameters of a spring winding machine, comprising the following steps:

[0038] S1. Real-time collect data of the wire diameter, wire winding speed, tension, wire winding angle, number of wire winding turns, and temperature during the wire winding process;

[0039] S2. Filter, denoise, and calibrate the raw data collected in S1;

[0040] S3. Calculate the wire length, winding torque, winding efficiency, wire volume, and winding stress based on the processed data;

[0041] S4. Adjust the winding speed, tension, and winding angle in real time according to the calculation results of S3, and generate a winding parameter adjustment report;

[0042] S5. Display the winding parameter adjustment report through the user interface and receive input instructions from the operator.

[0043] Compared with the prior art, the present invention provides a winding parameter detection system and method for a spring winding machine, having the following beneficial effects:

[0044] The present invention can not only automatically collect key parameters such as wire diameter, winding speed, and tension, but also filter and calibrate the raw data through a data processing module to ensure the accuracy of the data. The parameter calculation module calculates relevant performance indicators in real time based on the processed data, and automatically adjusts the winding speed, tension, and angle through a control feedback module to form a closed-loop control. Finally, the user interface module intuitively displays the generated winding parameter adjustment report to the operator, reducing the influence of human factors on production stability, thereby improving the stability of the production process and the consistency of the final product. The implementation of this system will greatly improve the automation level of the spring winding machine, reduce the potential risks brought by manual intervention, and promote the development of intelligent manufacturing. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 It is a schematic diagram of the system flow of the present invention;

[0046] Figure 2 It is a schematic diagram of the method steps of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0047] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0048] Aiming at the problem that the traditional monitoring method of winding parameters usually relies on manual detection. Operators need to manually record and adjust various key parameters during the wire winding process. This method is not only inefficient but also easily affected by the experience and judgment of operators, resulting in insufficient data accuracy, which in turn affects the stability of the production process and the quality of the final product. Therefore, a wire winding parameter detection system for a spring winding machine is proposed. Please refer to Figure 1 , the system includes a data acquisition module, a data processing module, a parameter calculation module, a control feedback module, and a user interface module;

[0049] The data acquisition module is the core front-end module of the wire winding parameter detection system for the spring winding machine, responsible for real-time acquisition of key parameters during the wire winding process, including wire diameter, winding speed, tension, winding angle, number of winding turns, and temperature data. The wire diameter is obtained through a high-precision laser sensor or a mechanical measuring device, which can accurately measure the cross-sectional size of the wire to ensure consistency during the wire winding process. The winding speed is monitored in real time through an encoder or a speed sensor, reflecting the operating state of the spring winding machine and providing basic data for subsequent calculation of the winding efficiency. The tension data is collected by a tension sensor, used to monitor the force on the wire during the wire winding process to avoid quality problems caused by excessive or too little tension. The winding angle is measured by an angle sensor to ensure the angle accuracy during the wire winding process and guarantee the accuracy of the winding shape. The number of winding turns is recorded in real time by a counter, providing an important basis for calculating the wire length and winding efficiency. The temperature data is collected by a temperature sensor, used to monitor the temperature change of the wire or the environment during the wire winding process to prevent the wire winding quality from being affected by too high or too low temperature. These raw data are transmitted to the data processing module in real time through a high-speed data transmission channel (such as RS485, CAN bus, or Ethernet) to ensure the timeliness and integrity of the data. The high precision, high reliability, and real-time performance of the data acquisition module lay a solid foundation for subsequent data processing and parameter calculation, and are the key link to realize intelligent monitoring and adjustment of the wire winding process. Through the accurate acquisition and transmission of this module, the system can comprehensively master various parameters during the wire winding process and provide strong support for the efficient operation of the spring winding machine and product quality control;

[0050] The data processing module is the core intermediate link of the wire winding parameter detection system for the spring winding machine, responsible for filtering, denoising, and calibration processing of the raw data transmitted by the data acquisition module to ensure the accuracy, stability, and reliability of the data. First, data filtering uses the low-pass filtering formula y(t) = α * x(t) + (1 - α) * y(t - 1), where y(t) is the filtered output value at the current moment, x(t) is the raw input value at the current moment, y(t - 1) is the filtered output value at the previous moment, and α is the filtering coefficient (the value range is 0 - 1), used to smooth high-frequency noise and eliminate random fluctuations in the data to ensure the smoothness and continuity of the data. Secondly, data denoising is carried out through the moving average filtering formula Implementation, where k(t) is the denoised output value, y(t - i) are the original input values at the current and the previous N - 1 moments, N is the moving average window size, which is used to further eliminate short-term fluctuations and outliers in the data and improve data stability. Finally, data calibration uses the linear calibration formula p = m * k + b, where p is the calibrated output value, m is the original input value, k is the calibration coefficient, and b is the calibration offset, which is used to correct the systematic error of the sensor and ensure data accuracy and consistency. The data processed through filtering, denoising, and calibration is sent to the parameter calculation module for further calculation of the key parameters during the wire winding process. This series of data processing operations can not only significantly improve the quality of the data but also provide a reliable basis for subsequent parameter calculation, thus ensuring the precise control and efficient operation of the wire winding process. Through the optimization of the data processing module, the system can effectively reduce noise interference and eliminate data errors;

[0051] The parameter calculation module is a bridge connecting the data processing module and the control feedback module, responsible for calculating the wire length, winding torque, winding efficiency, wire volume, and winding stress based on the processed data. These calculations are crucial for ensuring the high efficiency, precision, and safety of the wire winding process;

[0052] First, the formula for calculating the wire length Provides a quantitative assessment of material usage, helps optimize production plans, and avoids waste of raw materials. By accurately knowing the wire length, production personnel can effectively control material costs and improve production efficiency;

[0053] The formula for the winding torque T = F * r * sin(θ + α) * e -βt By evaluating the rotational force required by the machine during the winding process, it can effectively monitor the operating load of the equipment. Excessive torque may cause equipment damage or safety hazards. Therefore, by real-time monitoring of torque changes, production parameters can be adjusted in a timely manner to ensure the safe and stable operation of the equipment;

[0054] The formula for calculating the winding efficiency Quantifies the effectiveness of the production process, which provides an important basis for production decisions. The real-time feedback of production efficiency enables managers to quickly identify bottlenecks and take necessary improvement measures to optimize the overall production process;

[0055] The formula for calculating the wire volume By evaluating the volume change of the material, it can help enterprises better manage inventory and logistics and avoid production delays caused by material surplus or shortage. In addition, accurate volume calculation also ensures product consistency and quality stability;

[0056] Finally, the formula for calculating the winding stress It is used to evaluate the internal stress of wire materials under specific working conditions, which helps to ensure the safety standards and durability of products. By precisely monitoring stress changes, potential material fatigue and damage problems can be detected in a timely manner, thus effectively avoiding product failures and related financial losses;

[0057] The parameter calculation module, through a series of precise calculation formulas, not only provides a reliable data basis for the control feedback module, but also enhances the intelligence and automation level of the production process, ensuring the efficiency, stability and safety of the wire winding process;

[0058] The control feedback module, through advanced algorithms and real-time data processing technologies, can monitor and dynamically adjust the wire winding speed, tension and winding angle in real time to ensure the efficiency and stability of the wire winding process. For realizing automatic control, high-performance sensors and actuators are equipped inside the module. These devices can quickly respond and adjust parameters to ensure the best wire winding quality under different operating environments. At the same time, after the calculation is completed, the control feedback module generates a detailed wire winding parameter adjustment report. This report not only includes the current wire winding speed, tension and angle, but also provides optimization suggestions and historical data analysis. These data and suggestions will be transmitted to the user interface module in real time through wireless communication technologies to ensure that operators can obtain the latest information in a timely manner;

[0059] The user interface module adopts a friendly graphical user interface (GUI), which can intuitively display the wire winding parameter adjustment report, enabling operators to clearly understand the current wire winding status and historical changes at a glance. This module is designed with a variety of interactive functions, supporting operators to input instructions according to actual needs to manually adjust the wire winding parameters or set new operation modes. Operators can quickly adjust the settings through a touch screen or other input devices, and the system will provide real-time feedback on the adjustment results, further improving production efficiency and product quality. Generally speaking, this system integrates advanced automatic control technologies and human-machine interaction designs to form a set of efficient and flexible wire winding control solutions.

[0060] Please refer to Figure 2 , a method for detecting wire winding parameters of a spring winding machine, comprising the following steps:

[0061] S1. Real-time collect data of wire diameter, wire winding speed, tension, wire winding angle, number of wire winding turns and temperature during the wire winding process;

[0062] S2. Perform filtering, denoising and calibration processing on the original data collected in S1;

[0063] S3. Calculate the wire length, wire winding torque, wire winding efficiency, wire volume and wire winding stress according to the processed data;

[0064] S4. According to the calculation result of S3, adjust the wire winding speed, tension and wire winding angle in real time, and generate a wire winding parameter adjustment report;

[0065] S5. Display the wire winding parameter adjustment report through the user interface and receive the input instructions of the operator.

[0066] Through the comprehensive application of the above system and method, the automation level of the spring winding machine will be greatly improved, the potential risks brought by manual intervention will be reduced, and the development of intelligent manufacturing will be promoted.

[0067] Although the embodiments of the present invention have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principle and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A wire winding parameter detection system for a spring winding machine, characterized in that: It includes a data acquisition module, a data processing module, a parameter calculation module, a control feedback module, and a user interface module; The data acquisition module is used to collect in real time the wire diameter, winding speed, tension, winding angle, number of winding turns, and temperature data during the wire winding process, and transmit them to the data processing module; The data processing module is used to perform filtering, denoising, and calibration processing on the raw data collected by the data acquisition module, and the processed data is sent to the parameter calculation module; The parameter calculation module is used to calculate the wire length, winding torque, winding efficiency, wire volume, and winding stress based on the data processed by the data processing module, and send them to the control feedback module; The control feedback module adjusts the winding speed, tension, and winding angle in real time according to the calculation results of the parameter calculation module, and generates a winding parameter adjustment report and transmits it to the user interface module; The user interface module is used to display the winding parameter adjustment report and receive input instructions from the operator.

2. The wire winding parameter detection system of a spring winding machine according to claim 1, characterized in that: The formula for the data filtering is as follows: y(t) = α * x(t) + (1 - α) * y(t - 1) In the formula, y(t) represents the data filtering output value at the current moment, x(t) represents the raw data input value at the current moment, y(t - 1) represents the data filtering output value at the previous moment, and α represents the filtering coefficient, with a value range of 0 - 1.

3. The wire winding parameter detection system of a spring winding machine according to claim 2, wherein: The formula for the data denoising is as follows: In the formula, k(t) represents the denoising output value at the current moment, N represents the window size of the moving average, and y(t - i) represents the filtered data input values at the current moment and the previous N - 1 moments.

4. The wire winding parameter detection system of a spring winding machine according to claim 3, characterized in that: The formula for the data calibration is as follows: p = m * k + b In the formula, p represents the calibrated data output value, m represents the calibration coefficient, k represents the denoised data input value, and b represents the calibration offset.

5. The wire winding parameter detection system of a spring winding machine according to claim 4, characterized in that: The formula for calculating the wire length is as follows: In the formula, L represents the total length of the wire, n represents the number of turns of the wire winding, π represents pi, taking 3.1416, D represents the diameter of the wire, represents the angle correction factor, which is used to correct the deviation caused by non-vertical winding.

6. The wire winding parameter detection system of a spring winding machine according to claim 5, characterized in that: The formula for calculating the winding torque is as follows: T = F * r * sin(θ + α) * e -βt In the formula, T represents the winding torque, F represents the tension of the wire, r represents the distance from the winding point to the rotation center, θ represents the winding angle, sin() represents the sine function, α represents the additional angle for correcting the external force or error during the instruction, e represents the base of the natural logarithm, β represents the attenuation factor describing the influence of friction or resistance changing with time, and t represents the time variable.

7. The wire winding parameter detection system of a spring winding machine according to claim 6, characterized in that: The formula for calculating the winding efficiency is as follows: In the formula, η represents the winding efficiency, L represents the total length of the wire, f(v) represents the speed correction function, and t proc represents the time consumed in the wire blowing process, and p represents the output power maintained by the machine under specific conditions.

8. The wire winding parameter detection system of a spring winding machine according to claim 7, characterized in that: The formula for calculating the wire volume is as follows: In the formula, V represents the volume of the wire, D represents the diameter of the wire, L represents the total length of the wire, π represents the pi, taking 3.1416, represents the correction of the coil working angle to the volume calculation, E represents the Young's modulus of the material, and G represents the shear modulus of the material.

9. The wire winding parameter detection system of a spring winding machine according to claim 8, characterized in that: The formula for calculating the winding stress is as follows: In the formula, σ represents the winding stress, F represents the tension of the wire, and A represents the cross-sectional area of the wire. The calculation formula is k(θ) represents the angle correction factor, and δt represents the time correction factor.

10. A method for detecting wire winding parameters of a spring winding machine, characterized in that, It includes the following steps: S1. Collect in real time the wire diameter, winding speed, tension, winding angle, number of winding turns, and temperature data during the wire winding process; S2. Perform filtering, denoising, and calibration processing on the raw data collected in S1; S3. Calculate the wire length, winding torque, winding efficiency, wire volume, and winding stress based on the processed data; S4. Adjust the winding speed, tension, and winding angle in real time according to the calculation results of S3, and generate a winding parameter adjustment report; S5. Display the winding parameter adjustment report through the user interface and receive input instructions from the operator.

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