Automatic fuzzy rolling diameter calculation and upper and lower limit cyclic fluctuation cross control system

Abstract

An automatic fuzzy rolling diameter calculation and upper and lower limit cyclic fluctuation cross control system relates to the technical field of intelligent rolling control, comprises an unwinding module, a rolling module, a dynamic modeling module, a calculation module and a control module, and is used for judging whether the number of turns of a rolling chuck reaches the maximum threshold value of a rope wound on each layer of the rolling chuck or not. The control module is also used for receiving the winding speed and the unwinding speed calculated by the calculation module and sending control signals to the winding frequency converter and the unwinding frequency converter in real time for execution, so that the defects that the speed change of multi-section speed control is relatively large and the stability is relatively low are greatly improved and refined, and excessive modeling and idealization of winding diameter calculation are avoided; the defects that in the prior art, in the prior art, the randomness and non-standardization of roll types in the actual application process cannot be well adapted are overcome, the advantages of two kinds of control are combined, real-time building and accurate change matching of a roll diameter model can be conducted, and the problems of oscillation and galloping caused by various errors are solved through multi-section speed adaption.

Description

Technical Field

[0001] The present invention relates to the technical field of intelligent winding control, and particularly to an automatic fuzzy coil diameter calculation and upper and lower limit cyclic fluctuation cross control system. Background Art

[0002] In the field of winding control of continuous profiles such as ropes, wires, and tapes, the speed matching control of the unwinding and winding systems has always been a core process problem. Traditional split-winding control systems mostly adopt fixed coil diameter models or manual periodic measurement and correction methods, which have problems such as significant dynamic response lag and error accumulation effects. Especially during long-period continuous operation, due to the real-time dynamic change characteristics of the coil diameters at the unwinding and winding ends, simple linear speed matching algorithms often lead to speed mismatches, causing process accidents such as rope breakage, winding, and tension fluctuations. In the prior art, although the closed-loop control method based on encoder feedback can achieve a certain degree of dynamic adjustment, when dealing with non-linear interferences such as sudden changes in the number of coil layers, elastic deformation of materials, and mechanical transmission clearances, the control accuracy significantly decreases. Some improvement schemes attempt to introduce coil diameter prediction algorithms, but due to the insufficient update frequency of static mathematical models, it is difficult to track the dynamic change process of the coil diameter in real time. Summary of the Invention

[0003] To solve the above problems, the present invention provides an automatic fuzzy coil diameter calculation and upper and lower limit cyclic fluctuation cross control system.

[0004] The technical solution of the present invention is as follows:

[0005] An automatic fuzzy coil diameter calculation and upper and lower limit cyclic fluctuation cross control system, comprising:

[0006] An unwinding module, including an unwinding chuck and an unwinding motor, the unwinding motor is electrically connected to an unwinding frequency converter, and is used to monitor the rotation speed and cumulative rotation of the unwinding chuck in real time, and adjust the rotation speed of the unwinding chuck;

[0007] A winding module, including a winding chuck and a winding motor, the winding motor is electrically connected to a winding frequency converter, and is used to monitor the rotation speed and cumulative rotation of the winding chuck in real time, and adjust the rotation speed of the winding chuck;

[0008] A dynamic modeling module, used to store the initial parameters of the unwinding chuck, winding chuck, and rope input, and store the number of turns of the winding chuck, the total unwinding volume when the unwinding chuck is full, and this module internally has a decreasing unwinding model and an increasing winding model, and is used to calculate the increasing winding volume of the winding chuck layer by layer and the remaining unwinding volume at the corresponding position of the unwinding chuck;

[0009] A calculation module calculates the winding diameter of each layer of the winding chuck and the unwinding diameter of the unwinding chuck based on the winding volume of each layer of the winding chuck and the remaining unwinding volume of the unwinding chuck, and calculates the corresponding winding speed and unwinding speed in real time based on the ratio of the winding diameter to the unwinding diameter;

[0010] A control module is used to determine whether the number of turns of the winding chuck reaches the maximum threshold of the rope wound on each layer of the winding chuck, and is also used to receive the winding speed and unwinding speed calculated by the calculation module and send control signals to the winding frequency converter and the unwinding frequency converter for execution in real time.

[0011] In order to be able to guide the rope during unwinding, a guide wheel is provided on one side of the unwinding module, and the rope is unwound from the unwinding chuck, bypasses the guide wheel and reaches the winding chuck.

[0012] In order to facilitate the installation of the unwinding chuck and the winding chuck, and to facilitate the control of the rotation speeds of the two, the axis of the unwinding chuck is arranged vertically, the axis of the winding chuck is arranged horizontally, and the plane where the axis of the unwinding chuck is located passes through the central plane of the winding chuck.

[0013] The calculation method of the total unwinding volume is that the initial parameters of the unwinding chuck, the winding chuck and the rope include:

[0014] The length L of the unwinding chuck, the empty coil diameter D min , the full coil diameter D max ;

[0015] The length l of the winding chuck, the empty coil diameter d min , the full coil diameter d max ;

[0016] The diameter d of the rope;

[0017] Then the total unwinding volume V of the full unwinding chuck 满 =π*L*(D 2 max -D 2 min ) / 4.

[0018] The signal for the calculation module to execute the calculation instruction is that the preset maximum threshold for each layer of the winding chuck is N, and when each layer of the winding chuck winds N turns, the calculation module executes the calculation instruction.

[0019] In order to be able to repair the error in the system's control of the rope winding speed and make the speeds of the rope winding end and the rope unwinding end more accurate, the system further includes a correction module, and the correction module is located between the unwinding module and the winding module;

[0020] The correction module includes a pulley block with a fixed height. A counterweight module is arranged below the pulley block, and the rope sequentially bypasses the pulley block and the counterweight from the unwinding chuck to the winding chuck. During the rope winding process, the counterweight module can be driven to move up and down.

[0021] To facilitate the monitoring of the displacement of the counterweight module, multiple displacement sensors are arranged on one side of the counterweight module and are arranged vertically at intervals, which can detect the vertical displacement change of the counterweight module and send the displacement signal to the control module.

[0022] To facilitate the winding of the rope, reduce the resistance of the rope winding, and ensure the accuracy of the vertical displacement of the counterweight module, the fixed height of the pulley block is higher than that of the unwinding chuck, and the counterweight module is a movable pulley block, and its axis is parallel to the axis of the pulley block and is located in the same vertical plane.

[0023] An automatic fuzzy coil diameter calculation and upper and lower limit cyclic fluctuation cross-control method includes the following steps:

[0024] S1: Input the initial parameters of the unwinding chuck and the winding chuck, including the diameter d of the winding rope, the length L of the unwinding chuck, the empty coil diameter D min , the full coil diameter D max , the length l of the winding chuck, the empty coil diameter d min , the full coil diameter d max ;

[0025] S2: Establish a coil diameter model, establish a winding model with the volume of the rope increasing layer by layer for the winding chuck, and correspondingly establish a winding model with the volume of the rope decreasing layer by layer for the unwinding chuck;

[0026] S3: Perform real-time coil diameter calculation;

[0027] S31: Judge whether the number of winding turns of the winding chuck reaches N. If it does not reach, continue to perform the winding action. If it reaches N, then execute S32;

[0028] S32: Trigger the layer increment and calculate the winding volume of the winding chuck and the winding diameter of the winding chuck;

[0029] S33: Reverse-infer the remaining rope volume of the unwinding chuck according to the cumulative volume of the winding chuck, and calculate the real-time remaining unwinding diameter of the current unwinding chuck;

[0030] S4: Correspondingly adjust the output speeds of the winding frequency converter and the unwinding frequency converter according to the coil diameter ratio of the real-time winding diameter and the remaining unwinding diameter;

[0031] S5: Stop winding until the winding diameter of the winding chuck calculated in real time reaches the full coil diameter, and replace the next winding chuck.

[0032] Since the coil diameter of the pay-off chuck coming out of the rope making machine is not an ideal coil diameter model, and the diameter of the rope has a slight fluctuation, it is not entirely possible for the take-up chuck to wind up an ideal coil diameter in real time. Therefore, in the actual speed regulation process, there is a certain error in the speed ratio of the rope pay-off end and the rope take-up end depending on the coil diameter. Therefore, to correct the winding speed, step S4 further includes

[0033] Collect the position signal of the counterweight module in real time. When the displacement sensors at the uppermost and lowermost positions collect the displacement signal of the counterweight module, the control module receives the displacement signal and adjusts the output speeds of the take-up frequency converter and the pay-off frequency converter.

[0034] The beneficial effects of the present invention are as follows: The present invention is an automatic fuzzy coil diameter calculation and upper and lower limit cyclic fluctuation cross control system. Different from the prior art, this control system calculates the pay-off volume and the take-up volume layer by layer in real time, and then calculates the coil diameter. The rotation speeds of the take-up chuck and the pay-off chuck are adjusted layer by layer in real time through the coil diameter ratio. By combining the control logic of multi-stage speed with the complex model of coil diameter calculation, it not only greatly improves and refines the disadvantages of large speed changes and low stability in multi-stage speed control, but also avoids the over-modeling and idealization of coil diameter calculation, which cannot well adapt to the randomness and non-standardization of the coil type in the actual application process. Instead, it combines the advantages of the two controls, that is, it can build and change the coil diameter model in real time and accurately match it, and also adapts to the oscillation and runaway problems caused by various errors through multi-stage speed;

[0035] By automatically adjusting the rotation speed compared with manual operation, it can reduce the input of time and manpower, improve the stability and speed of speed regulation, reduce the repeated start and stop of the equipment, and improve the service life of the motor and related transmission equipment;

[0036] Moreover, this solution also designs a correction module. By using displacement sensors, it realizes the monitoring of the position of the counterweight module. Then, at the upper and lower limit positions, it can reflect the magnitude relationship between the rope take-up speed and the rope pay-off speed, and then can accurately adjust the corresponding frequency converter in real time, solving the problems of lag in dynamic response and error accumulation in the traditional method, and having the advantages of real-time dynamic adjustment, avoiding the problems of rope breakage or winding caused by speed mismatch, and improving the tension control accuracy. Description of the Drawings

[0037] By reading the detailed description of the preferred embodiments below, the solutions and advantages of this application will become clear to those of ordinary skill in the art. The drawings are only for the purpose of showing the preferred embodiments and are not considered to be a limitation of the present invention.

[0038] In the drawings:

[0039] Figure 1 is the connection schematic diagram of this system;

[0040] Figure 2 It is the connection diagram of the control module system;

[0041] Figure 3 It is the schematic diagram of the dynamic correction module;

[0042] Figure 4 It is the flowchart of the control method;

[0043] The components represented by each reference numeral in the figure are as follows:

[0044] 1. Unwinding module; 11. Unwinding chuck; 12. Unwinding motor; 13. Unwinding frequency converter; 2. Rewinding module; 21. Rewinding chuck; 22. Rewinding motor; 23. Rewinding frequency converter; 3. Dynamic modeling module; 4. Rope; 5. Calculation module; 6. Control module; 7. Guide pulley; 8. Correction module; 81. Pulley block; 82. Counterweight module; 83. Displacement sensor. Detailed implementation manners

[0045] Embodiment

[0046] In the prior art, the field of winding control has long faced the problem of matching the unwinding and rewinding speeds. Traditional methods rely on fixed coil diameter models or manual periodic corrections, resulting in problems such as lag in dynamic response and error accumulation. Especially during continuous operation, the real-time change of the coil diameter at the unwinding and rewinding ends leads to speed mismatch, easily causing rope breakage, winding, and tension fluctuations. Although the closed-loop control method realizes dynamic adjustment through encoder feedback, the control accuracy decreases under non-linear interferences such as the jump of the number of coil layers and material deformation. Existing coil diameter prediction algorithms are difficult to track the dynamic change process in real time due to insufficient update frequency.

[0047] To solve the above problems, it is necessary to design a system that can dynamically track the change of the coil diameter and adjust the control parameters in real time. By establishing an increasing and decreasing model of the unwinding and rewinding volumes, combined with the rotation speed data collected in real time, the current coil diameter is accurately calculated. On this basis, the output of the frequency converter is dynamically adjusted according to the coil diameter ratio to eliminate speed mismatch. At the same time, a layer number threshold trigger mechanism is introduced to ensure that the model update frequency is synchronized with the process beat.

[0048] Therefore, this application proposes a system including an unwinding module 1, a rewinding module 2, a dynamic modeling module 3, a calculation module 5, and a control module 6. The unwinding module 1 monitors the rotation speed and cumulative rotation speed of the unwinding chuck 11 through the unwinding frequency converter 13 and adjusts the rotation speed. The rewinding module 2 monitors the rotation speed and cumulative rotation speed of the rewinding chuck 21 through the rewinding frequency converter 23 and adjusts the rotation speed. The dynamic modeling module 3 stores the initial parameters and operation data, and calculates the volume change by means of a decreasing unwinding model and an increasing rewinding model built-in. The calculation module 5 calculates the real-time coil diameter based on the volume data and deduces the speed ratio. The control module 6 triggers a control signal according to the layer number threshold and sends an execution instruction to the frequency converter.

[0049] The unwinding module 1 includes an unwinding chuck 11 and an unwinding motor 12. Combining Figure 1 , the unwinding motor 12 is electrically connected to an unwinding frequency converter 13, which is used to monitor the rotation speed and cumulative rotation count of the unwinding chuck 11 in real time and adjust the rotation speed of the unwinding chuck 11. The winding motor 22 and the unwinding motor 12 applied in this system can be, but are not limited to, driving devices such as DC, AC, or servo motors. In this solution, a servo motor and a rotary encoder can be combined to achieve rotation speed monitoring, and stepless speed regulation can be achieved through a frequency converter. The winding module 2 includes a winding chuck 21 and a winding motor 22. It should be noted that the winding motor 22 is electrically connected to a winding frequency converter 23, which is used to monitor the rotation speed and cumulative rotation count of the winding chuck 21 in real time and adjust the rotation speed of the winding chuck 21. Specifically, an AC motor with an absolute encoder can be used to achieve rotation count accumulation.

[0050] In this solution, the system further includes a dynamic modeling module 3. Combining Figure 2 and Figure 3 , it is used to store the initial parameters of the unwinding chuck 11, the winding chuck 21, and the rope 4 input, and store the number of turns of the winding chuck 21 and the total unwinding volume when the unwinding chuck 11 is full. Among them, the initial parameters of the unwinding chuck 11, the winding chuck 21, and the rope 4 include: the length L of the unwinding chuck 11, the empty coil diameter D min , the full coil diameter D max ; the length l of the winding chuck 21, the empty coil diameter d min , the full coil diameter d max ; the diameter d of the rope 4; the total unwinding volume V 满 = π * L * (D 2 max - D 2 min ) / 4. The length L refers to the axial dimension of the effective winding area of the unwinding chuck 11. Specifically, a laser rangefinder can be used for calibration to ensure the accuracy of the reference parameters for volume calculation. The empty coil diameter D min is defined as the minimum coil diameter of the unwinding chuck 11 when the rope 4 is not loaded, and the full coil diameter D max refers to the coil diameter when the maximum loading capacity of the unwinding chuck 11 is reached, which can be obtained through an optoelectronic encoder combined with an edge detection algorithm. The diameter d of the rope 4 is calibrated in real time using a non-contact optical measuring device.

[0051] In addition, the dynamic modeling module 3 is built-in with a decreasing unwinding model and an increasing winding model, which are used to calculate the increasing winding volume of the winding chuck 21 layer by layer and the remaining unwinding volume at the corresponding position of the unwinding chuck 11. Among them, the winding volume of the winding chuck 21 is calculated first, and the preset maximum threshold for each layer of the winding chuck 21 is N, that is, the rope 4 of this layer is fully wound. When the winding chuck 21 winds N turns per layer, the calculation module 5 executes a calculation instruction, that is, during the operation of the system, the number of rotation turns of the winding chuck 21 is monitored in real time. When the single-layer winding reaches the preset N turns, the calculation module 5 is triggered to immediately start the winding volume calculation process, and at the same time automatically jump to the next layer of winding rope, and the count for each layer is n. At this time, the volume of the rope 4 on the winding chuck 21 is V 收 = π * l * (n 2 d 2 + d min * n * d). Synchronously, the remaining volume V 剩 = V 满 - V 收 is deduced through the principle of volume conservation to form a closed-loop parameter update.

[0052] It also includes a calculation module 5, which calculates the winding diameter of the winding chuck 21 and the unwinding diameter of the unwinding chuck 11 for each layer based on the winding volume of each layer of the winding chuck 21 and the remaining unwinding volume of the unwinding chuck 11. At this time, based on the current cumulative number of turns and combined with the volume increasing model for each layer, the winding diameter d 收 = d min + 2 * n * d can be accurately obtained. Therefore, V 剩 = π * L * (M 2 * d 2 + M * d * D min ), where M is the remaining number of layers of the unwinding chuck 11. Since V 剩 can be calculated, the remaining number of layers M can be deduced, and thus D 剩 = 2 * (M * d)+ D min is obtained. The remaining winding diameter D of the winding chuck 21 is calculated through the remaining winding volume of the winding chuck 21. 剩 . And the corresponding winding speed and unwinding speed are calculated in real time based on the ratio of the winding diameter to the unwinding diameter to ensure real-time matching of the two.

[0053] The above modules all need to respond to the following control module 6. The control module 6 is used to judge whether the number of turns of the winding chuck 21 reaches the maximum threshold of the rope 4 wound on each layer of the winding chuck 21. When the maximum threshold is reached, it transmits a signal to the calculation module 5 for calculation. It is also used to receive the winding speed and unwinding speed calculated by the calculation module 5 and send control signals to the winding frequency converter 23 and the unwinding frequency converter 13 in real time for execution. Specifically, when the system runs, the dynamic modeling module 3 stores initial parameters such as the length of the unwinding chuck 11 and the full-winding diameter. When the winding chuck 21 completes each set number of turns N, the calculation module 5 performs winding volume calculation, calculates the winding diameter, and inversely deduces the remaining unwinding volume. By substituting the remaining unwinding volume into the geometric model, the diameter data of the real-time unwinding chuck 11 is obtained. The control module 6 calculates the speed ratio according to the current winding diameter ratio and sends a pulse width modulation signal to the frequency converter to adjust the motor speed. When the winding diameter reaches the full-winding set value, the system automatically stops and prompts to replace the winding chuck 21.

[0054] In addition, the winding diameter of the unwinding chuck 11 of the large reel coming out of the rope making machine is not an ideal winding diameter model, and the diameter of the rope 4 has a slight fluctuation. It is not completely possible to wind an ideal winding diameter when the winding chuck 21 winds in real time. Therefore, this solution also designs a correction module 8, which is used to correct the problem of speed mismatch caused by errors generated during the winding process. The correction module 8 is located between the unwinding module 1 and the winding module 2. The correction module 8 includes a pulley group 81 with a fixed height. The fixed height of the pulley group 81 is higher than that of the unwinding chuck 11. A counterweight module 82 is arranged below the pulley group 81. The rope 4 bypasses the pulley group 81 and the counterweight block in sequence from the unwinding chuck 11 to the winding chuck 21, and can drive the counterweight module 82 to move up and down during the winding process.

[0055] Among them, the fixed height setting of the pulley group 81 means that the installation position of the pulley group 81 remains constant in the vertical direction. For example, it is fixed on the equipment frame through a rigid bracket, and its function is to form a stable turning support point. The counterweight module 82 adopts a movable pulley group 81 structure, such as being composed of two parallel pulleys. Its axis is parallel to the axis of the pulley group 81 and is located in the same vertical plane, and forms a linkage relationship with the main rope through a steel wire rope, which is used to balance the tension fluctuation during the operation of the rope 4. A plurality of displacement sensors 83 are arranged on one side of the counterweight module 82 and are arranged at vertical intervals. They can detect the vertical displacement change of the counterweight module 82 and send displacement signals to the control module 6. The displacement sensors 83 can be optoelectronic or magnetic grating sensors, and are arranged at intervals along the movement track of the counterweight module 82. Moreover, at least two groups of displacement sensors 83 are arranged at the upper and lower limit positions of the movement of the counterweight module 82, which are used to capture the vertical displacement amount of the counterweight module 82 and convert it into an electrical signal for output. Optionally, the displacement sensors 83 can also be fixed interval analog or communication sensors such as pull cord switches, as long as they can completely monitor and feedback the position of the counterweight module 82.

[0056] Specifically, when the counterweight module 82 continuously moves upward to the upper limit position, it means that the rope winding speed is faster than the rope unwinding speed at this time. The displacement sensor 83 at the uppermost end collects the signal and transmits it to the control module 6. At this time, the control module 6 needs to control the frequency converter to reduce the rotation speed of the winding chuck 21 or increase the rotation speed of the unwinding chuck 11. When the counterweight module 82 continuously moves downward to the lower limit position, it means that the rope winding speed is slower than the rope unwinding speed at this time. The displacement sensor 83 at the lowermost end collects the signal and transmits it to the control module 6. At this time, it is necessary to increase the rotation speed of the winding chuck 21 or reduce the rotation speed of the unwinding chuck 11.

[0057] Through the combined design of the pulley block 81 and the movable pulley block 81 in this solution, the displacement of the counterweight module 82 directly reflects the change range of the tension. Combined with the distributed detection of multiple displacement sensors 83, real-time monitoring with a millimeter-level displacement resolution can be achieved. Compared with the control method that solely relies on the feedback of the motor encoder, this mechanical-electrical composite detection mechanism significantly improves the sensitivity of the system to capture transient tension fluctuations. Through the above technical solution, this application effectively solves the problem of sudden tension caused by speed mismatch during the long-distance winding and unwinding process. The inertial mass of the counterweight module 82 and the lever effect of the pulley block 81 work together to quickly absorb instantaneous impact energy. The multi-point detection mode of the displacement sensor 83 can accurately identify the abnormal tension area and prevent the rope breakage accident caused by local stress concentration. The introduction of the correction module 8 enables the system to have an adaptive tension compensation ability and maintain a stable linear velocity synchronization under the condition of dynamic change of the coil diameter.

[0058] In addition, for the correction module 8, the dynamic coefficients of the upper and lower limits can also be dynamically adjusted according to the time when the upper and lower limits are alternately reached, so as to match the coil diameter mismatch result caused by the actual error or the cumulative error. When the time from the upper speed limit back to the lower limit is significantly longer than the time from the lower limit back to the upper limit, that is, the time for the counterweight module 82 to move from the displacement sensor 83 at the uppermost end to the displacement sensor 83 at the lowermost end is significantly longer than the return time, it means that the dynamic reference coefficient of the rope unwinding is greater than the dynamic reference coefficient of the rope winding at this time. At this time, the control system controls the rope unwinding reference coefficient to gradually decrease and the rope winding reference coefficient to gradually increase, and finally makes the time from the upper limit back to the lower limit gradually approach the time from the lower limit back to the upper limit. Vice versa. This logic is a two-dimensional speed change on the basis of the one-dimensional speed change of the pure position of the upper and lower limits. It is more like taking the derivative on the basis of the speed to obtain the acceleration. It is a deeper upper and lower limit control logic and can better achieve real-time correction under the comparison of the ideal coil diameter calculation model and the actual coil diameter.

[0059] It should be noted that when the structure of this solution is designed, the details of some structures are designed. Among them, a guide wheel 7 is arranged on one side of the unwinding module 1, and the rope 4 is released from the unwinding chuck 11, bypasses the guide wheel 7 and reaches the winding chuck 21. By setting the guide wheel 7, the rope release end can be limited, improving the stability of the rope 4. Secondly, optionally, the axis of the unwinding chuck 11 is arranged vertically, the axis of the winding chuck 21 is arranged horizontally, and the plane where the axis of the unwinding chuck 11 is located passes through the central plane of the winding chuck 21. And Figure 1 the axial directions of the two chucks will not be a limitation to this solution, but only for the convenience of understanding as the schematic diagram of this solution. On the one hand, it facilitates the installation of the winding chuck 21 and the unwinding chuck 11, and on the other hand, it ensures that the rope 4 will not tilt too much during winding.

[0060] This solution also provides an automatic fuzzy coil diameter calculation and upper and lower limit cyclic fluctuation cross-control method for the above system. Combining Figure 4 , it includes the following steps:

[0061] S1: Input the initial parameters of the unwinding chuck 11 and the winding chuck 21, including the diameter d of the winding rope, the length L of the unwinding chuck 11, the empty coil diameter D min , the full coil diameter D max , the length l of the winding chuck 21, the empty coil diameter d min , the full coil diameter d max ;

[0062] S2: Establish a coil diameter model. For the winding chuck 21, establish a winding model with the volume of the rope 4 increasing layer by layer, and correspondingly establish a winding model with the volume of the rope 4 decreasing layer by layer for the unwinding chuck 11;

[0063] S3: Execute real-time coil diameter calculation;

[0064] S31: Judge whether the number of winding turns of the winding chuck 21 reaches N. If it does not reach, continue to execute the winding action. If it reaches N, then execute S32;

[0065] S32: Trigger the layer increment and calculate the winding volume V of the winding chuck 21 收 =π*l(n 2 *d 2 +d min *n*d) and the winding diameter d of the winding chuck 21 收 =d min +2*n*d;

[0066] S33: Reverse-deduce the remaining rope 4 volume V of the unwinding chuck 11 according to the accumulated volume of the winding chuck 21 剩 =V 满 -V 收 , and calculate the real-time remaining unwinding diameter D of the current unwinding chuck 11剩 = 2 * (M * d) + D min ;

[0067] S4: Adjust the output speeds of the rewinding frequency converter 23 and the unwinding frequency converter 13 according to the winding diameter ratio of the real-time rewinding diameter and the remaining unwinding diameter;

[0068] Collect the position signal of the counterweight module 82 in real time. When the displacement sensors 83 at the uppermost and lowermost positions collect the displacement signal of the counterweight module 82, the control module 6 receives the displacement signal and adjusts the output speeds of the rewinding frequency converter 23 and the unwinding frequency converter 13;

[0069] S5: Stop winding until the rewinding diameter of the rewinding chuck 21 calculated in real time reaches the full-winding diameter, and replace the next rewinding chuck 21.

Claims

1. An automatic fuzzy coil diameter calculation and upper and lower limit cyclic fluctuation cross control system, characterized in that, Including: An unwinding module, including an unwinding chuck and an unwinding motor, the unwinding motor is electrically connected to an unwinding frequency converter, which is used to monitor the rotation speed and cumulative rotation of the unwinding chuck in real time, and adjust the rotation speed of the unwinding chuck; A winding module, including a winding chuck and a winding motor, the winding motor is electrically connected to a winding frequency converter, which is used to monitor the rotation speed and cumulative rotation of the winding chuck in real time, and adjust the rotation speed of the winding chuck; A dynamic modeling module, which is used to store the initial parameters of the unwinding chuck, winding chuck and rope input, and store the number of turns of the winding chuck and the total unwinding volume when the unwinding chuck is full. This module is built-in with a decreasing unwinding model and an increasing winding model, which are used to calculate the increasing winding volume of each layer of the winding chuck and the remaining unwinding volume at the corresponding position of the unwinding chuck; A calculation module, which calculates the winding diameter of each layer of the winding chuck and the unwinding diameter of the unwinding chuck based on the winding volume of each layer of the winding chuck and the remaining unwinding volume of the unwinding chuck, and calculates the corresponding winding speed and unwinding speed in real time based on the ratio of the winding diameter to the unwinding diameter; A control module, which is used to judge whether the number of turns of the winding chuck reaches the maximum threshold of the rope wound on each layer of the winding chuck, and is also used to receive the winding speed and unwinding speed calculated by the calculation module and send control signals to the winding frequency converter and unwinding frequency converter for execution in real time.

2. The automatic fuzzy coil diameter calculation and upper and lower limit cyclic fluctuation cross control system according to claim 1, characterized in that A guide wheel is arranged on one side of the unwinding module, and the rope is released from the unwinding chuck, bypasses the guide wheel and reaches the winding chuck.

3. The automatic fuzzy coil diameter calculation and upper and lower limit cyclic fluctuation cross control system according to claim 1, characterized in that, The axis of the unwinding chuck is arranged vertically, the axis of the winding chuck is arranged horizontally, and the plane where the axis of the unwinding chuck is located passes through the central plane of the winding chuck.

4. The automatic fuzzy coil diameter calculation and upper and lower limit cyclic fluctuation cross control system according to claim 1, characterized in that, The initial parameters of the unwinding chuck, winding chuck and rope include: The length L of the unwinding chuck, the empty roll diameter D min , the full roll diameter D max ; The length l of the rewinding chuck, the diameter d of the empty roll min , the diameter d of the full roll max ; The diameter d of the rope; Then the total unwinding volume V of the full unwinding chuck 满 = π * L * (D 2 max - D 2 min ) / 4.

5. The automatic fuzzy coil diameter calculation and upper and lower limit cyclic fluctuation cross control system according to claim 1, characterized in that The preset maximum threshold for each layer of the winding chuck to wind is N, and when each layer of the winding chuck winds N turns, the calculation module executes the calculation instruction.

6. The automatic fuzzy coil diameter calculation and upper and lower limit cyclic fluctuation cross control system according to claim 1, characterized in that The system further includes a correction module, and the correction module is located between the unwinding module and the winding module; The correction module includes a pulley group with a fixed height, a counterweight module is arranged below the pulley group, and the rope bypasses the pulley group and the counterweight block in sequence from the unwinding chuck to the winding chuck. During the rope winding process, it can drive the counterweight module to move up and down.

7. The automatic fuzzy coil diameter calculation and upper and lower limit cyclic fluctuation cross control system according to claim 6, characterized in that, A plurality of displacement sensors are arranged on one side of the counterweight module, and are arranged vertically at intervals, which can detect the vertical displacement change of the counterweight module and send the displacement signal to the control module.

8. The automatic fuzzy roll diameter calculation and upper and lower limit cyclic fluctuation cross control system according to claim 6, characterized in that The fixed height of the pulley group is higher than that of the unwinding chuck, and the counterweight module is a movable pulley group, and its axis is parallel to the axis of the pulley group and is located in the same vertical plane.

9. An automatic fuzzy coil diameter calculation and upper and lower limit cyclic fluctuation cross-control method, characterized in that, Including the following steps: S1: Input the initial parameters of the unwinding chuck and the winding chuck, including the diameter d of the winding rope, the length L of the unwinding chuck, and the empty coil diameter D min , and the full coil diameter D max , the length l of the winding chuck, and the empty coil diameter d min , and the full coil diameter d max ; S2: Establish a coil diameter model, establish a winding model with the rope volume increasing layer by layer for the winding chuck, and establish a winding model with the rope volume decreasing layer by layer for the unwinding chuck correspondingly; S3: Execute real-time coil diameter calculation; S31: Judge whether the number of winding turns of the winding chuck reaches N. If it does not reach, continue to execute the winding action. If it reaches N, then execute S32; S32: Trigger the layer increment and calculate the winding volume of the winding chuck and the winding diameter of the winding chuck; S33: Reverse-infer the remaining rope volume of the unwinding chuck according to the cumulative volume of the winding chuck, and calculate the real-time remaining unwinding diameter of the current unwinding chuck; S4: Corresponding adjust the output speeds of the rewinding frequency converter and the unwinding frequency converter according to the winding diameter ratio of the real-time rewinding diameter and the remaining unwinding diameter; S5: Until the rewinding diameter of the real-time calculated rewinding chuck reaches the full-winding diameter, stop winding and replace the next rewinding chuck.

10. The automatic fuzzy coil diameter calculation and upper and lower limit cyclic fluctuation cross control method according to claim 9, characterized in that, The step S4 further includes, Real-time collect the position signal of the counterweight module. When the displacement sensors located at the uppermost and lowermost ends collect the displacement signal of the counterweight module, the control module receives the displacement signal and adjusts the output speeds of the rewinding frequency converter and the unwinding frequency converter.

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