Intelligent tension control system of high-precision six-head arched stranding machine

Abstract

The invention relates to the technical field of stranding machines, and discloses a high-precision six-head arch stranding machine tension intelligent control system which comprises a passive pay-off rack, a main machine, a wire concentration seat, a single-head center taping machine, a tape storage rack, a leading machine and a shaft row type take-up machine. The wire outlet end of the driven pay-off rack, the wire stranding wheel set of the main machine and the wire inlet end of the shaft row type take-up machine are respectively installed on the wire outlet end of the driven pay-off rack and the wire stranding wheel set of the main machine; the controller is electrically connected with the tension sensor group, and a tension control algorithm is built in the controller; and the executing mechanism is electrically connected with the controller and comprises a pay-off driving motor arranged on the passive pay-off rack. In the invention, the tension sensor groups are respectively arranged at the wire outlet end of the passive pay-off rack, so that the problems that the traditional stranding machine depends on a manually adjusted or fixed gravity structure, so that the tension control precision is low, and the slight change of the tension in the stranding process is difficult to cope with are solved.

Description

Technical Field

[0001] The present invention relates to the technical field of stranding machines, and particularly to an intelligent tension control system for a high-precision six-head bow-shaped stranding machine. Background Art

[0002] A stranding machine is a mechanical device that twists multiple single wires together according to specified models and pitches to form a bundled or stranded conductor, and is widely used in industries such as wire and cable, electronics, and electrical appliances. Its working principle is based on the stranding motion. Single wires are released from a pay-off stand, the tension of each single wire is controlled evenly by a tension regulating device, and then rotating components (such as a stranding bow, a stranding cage, etc.) drive the single wires to perform a spiral stranding motion around the central axis, finally forming a stranded wire that meets the requirements.

[0003] Most traditional stranding machines adopt tension control methods such as mechanical friction type and gravity type. Due to relying on manual adjustment or fixed gravity structures, lacking real-time dynamic monitoring and precise regulation mechanisms, it is easy to have problems such as low tension control accuracy and difficulty in coping with subtle changes in tension during the stranding process. Summary of the Invention

[0004] In view of the deficiencies of the prior art, the present invention provides an intelligent tension control system for a high-precision six-head bow-shaped stranding machine, which solves the problems that most traditional stranding machines adopt tension control methods such as mechanical friction type and gravity type. Due to relying on manual adjustment or fixed gravity structures, lacking real-time dynamic monitoring and precise regulation mechanisms, it is easy to have problems such as low tension control accuracy and difficulty in coping with subtle changes in tension during the stranding process.

[0005] To achieve the above objectives, the present invention is realized through the following technical solutions: An intelligent tension control system for a high-precision six-head bow-shaped stranding machine, including a passive pay-off stand, a main machine, a wire collecting base, a single-head center taping machine, a tape storage rack, a take-up machine, and an axial row type take-up machine. A tension intelligent control module is provided inside the main machine. The tension intelligent control module includes:

[0006] A group of tension sensors, which are respectively installed at the wire outlet end of the passive pay-off stand, the stranding wheel group of the main machine, and the wire inlet end of the axial row type take-up machine;

[0007] A controller, electrically connected to the group of tension sensors, and built-in with a tension control algorithm;

[0008] An actuator, electrically connected to the controller, including a pay-off drive motor arranged on the passive pay-off stand, a stranding wheel drive motor of the main machine, and a take-up drive motor of the axial row type take-up machine;

[0009] The controller collects the wire tension data of each working station through the group of tension sensors, and adjusts the rotation speed and torque of each drive motor through the actuator.

[0010] By adopting the above technical solution, by installing the tension sensor groups at the wire outlet end of the passive pay-off reel, the main machine stranding wheel group and the wire inlet end of the shaft-type take-up machine respectively, the wire tension data of each working station can be comprehensively and accurately collected. After the controller receives these data, it can perform precise calculations according to the built-in tension control algorithm, and then precisely adjust the rotation speed and torque of each driving motor through the actuator, so as to achieve high-precision control of the tension, thereby improving the problem that most traditional stranding machines adopt tension control methods such as mechanical friction type and gravity type. Due to relying on manual adjustment or fixed gravity structure, it is easy to generate errors, so it is easy to have low tension control accuracy and difficulty in coping with the subtle changes in tension during the stranding process.

[0011] Preferably, the tension sensor group includes six groups of non-contact tension sensors, and the six groups of non-contact tension sensors respectively correspond to each wire path of the six-strand stranding. The sampling frequency of each group of sensors ≥ 100Hz.

[0012] Preferably, the tension control algorithm of the controller includes a fuzzy PID control model, and the fuzzy PID control model is used to adjust parameters according to the change of wire diameter and the fluctuation of stranding speed.

[0013] Preferably, a tension buffer roller group is arranged in the tape storage rack, and the tension buffer roller group includes at least two groups of parallel guide rollers. The roller spacing between the guide rollers is adjusted by a servo motor driving a screw nut mechanism in the actuator.

[0014] Preferably, the wire collecting seat is provided with a tension equalizer, and the tension equalizer includes six elastic guide wheels arranged in a circumferential array. Each elastic guide wheel is connected to the mounting frame of the wire collecting seat through a return spring.

[0015] Preferably, a pressure sensor is arranged on the surface of the take-up wheel of the take-up machine, and the pressure sensors are evenly distributed along the circumferential direction of the take-up wheel. The pressure sensors are electrically connected to the controller.

[0016] Preferably, a torque sensor is arranged on the take-up shaft of the shaft-type take-up machine. The torque sensor is nested in the bearing seat of the take-up shaft, and the torque sensor is electrically connected to the controller.

[0017] Preferably, the pay-off reel of the passive pay-off reel is provided with a damping adjustment device, and the damping adjustment device includes a magnetic powder brake coaxially arranged with the pay-off reel. The excitation current input end of the magnetic powder brake is electrically connected to the actuator.

[0018] Preferably, the operation panel of the main machine is integrated with a human-machine interaction interface. The human-machine interaction interface is communicatively connected to the controller through an RS485 bus. The human-machine interaction interface is provided with a tension setting input module, a real-time data display module and a fault alarm module.

[0019] The control method of the intelligent tension control system for a high-precision six-head bow-type stranding machine includes the following steps:

[0020] S1. Data acquisition trigger: The controller sends acquisition instructions to the tension sensor groups at the wire outlet end of the passive pay-off stand, the main machine stranding wheel group, and the wire inlet end of the shaft-type take-up machine to obtain the real-time tension data of the wire at each station.

[0021] S2. Signal processing and algorithm operation: The controller performs filtering, noise reduction, and normalization processing on the collected tension data, and generates tension adjustment parameters based on the built-in fuzzy PID control model in combination with the wire diameter and stranding speed parameters.

[0022] S3. Execution instruction generation: The controller generates speed and torque control instructions for the pay-off drive motor of the passive pay-off stand, the stranding wheel drive motor of the main machine, and the take-up drive motor of the shaft-type take-up machine according to the tension adjustment parameters, and sends them to the actuator.

[0023] S4. Closed-loop feedback adjustment: The controller receives the motor adjustment status feedback from the actuator, compares it with the preset tension threshold value. If there is a deviation, repeat steps S1 - S3 until the wire tension at each station is stable.

[0024] The present invention provides an intelligent tension control system for a high-precision six-head bow-type stranding machine, having the following beneficial effects:

[0025] 1. In the present invention, by installing the tension sensor groups at the wire outlet end of the passive pay-off stand, the main machine stranding wheel group, and the wire inlet end of the shaft-type take-up machine respectively, the wire tension data at each station can be comprehensively and accurately collected. After receiving these data, the controller can perform precise calculations based on the built-in tension control algorithm, and then precisely adjust the speed and torque of each drive motor through the actuator, thereby realizing high-precision control of the tension, and improving the problem that most traditional stranding machines adopt tension control methods such as mechanical friction type and gravity type. Due to relying on manual adjustment or fixed gravity structures, it is easy to generate errors, so it is easy to have low tension control accuracy and difficulty in coping with the subtle changes in tension during the stranding process.

[0026] 2. In the present invention, the tension sensor group adopts six non-contact tension sensors, corresponding to each wire path of the six-head stranding respectively, and the sampling frequency ≥ 100Hz, so as to independently and accurately measure the tension of each wire, avoid interference between wires and damage to the wires caused by measurement. High-frequency sampling can monitor the tension change in real time and provide data support for precise control.

[0027] 3. In the present invention, the controller continuously collects tension data, processes and calculates it, generates control instructions and receives feedback, and compares it with the preset tension threshold. If there is a deviation, it is continuously adjusted until the wire tension at each station is stable. This closed-loop control method can effectively ensure the consistency and stability of the tension during the stranding process, thereby improving the quality of the stranded wire, reducing the defective rate, and meeting the requirements of high-quality production. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a schematic diagram of the elevation structure of the present invention;

[0029] Figure 2 It is a schematic diagram of the top view of the structure of the present invention;

[0030] Figure 3 It is a schematic diagram of the method steps of the present invention.

[0031] Among them, 1. Passive pay-off rack; 2. Main machine; 3. Wire collection seat; 4. Single-head center tape wrapping machine; 5. Tape storage rack; 6. Take-up machine; 7. Shaft-type wire take-up machine. DETAILED DESCRIPTION

[0032] The technical solution of the present invention will be described clearly and completely below in conjunction with the accompanying drawings of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. 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.

[0033] Please refer to the attached Figure 1 -Attached Figure 3 The embodiment of the present invention provides a high-precision six-head bow-shaped stranding machine tension intelligent control system, including a passive pay-off frame 1, a main machine 2, a wire collection seat 3, a single-head center tape wrapping machine 4, a tape storage rack 5, a take-up machine 6 and a shaft-type take-up machine 7. The main machine 2 is provided with a tension intelligent control module, and the tension intelligent control module includes:

[0034] The tension sensor group is respectively installed at the outlet end of the passive pay-off frame 1, the stranding wheel group of the main machine 2 and the inlet end of the shaft-type take-up machine 7;

[0035] A controller, electrically connected to the tension sensor group, with a built-in tension control algorithm;

[0036] The actuator is electrically connected to the controller, and includes a pay-off drive motor arranged on the passive pay-off frame 1, a stranding wheel drive motor of the main machine 2, and a take-up drive motor of the shaft-type take-up machine 7;

[0037] The controller collects the wire tension data of each workstation through the tension sensor group, and adjusts the speed and torque of each drive motor through the actuator.

[0038] Specifically, the main machine 2 is fixedly arranged behind the passive pay-off stand 1, the wire collecting base 3 is fixedly arranged behind the main machine 2, the single-head center taping machine 4 is fixedly arranged behind the wire collecting base 3, the tape storage rack 5 is fixedly arranged behind the single-head center taping machine 4, the take-up machine 6 is fixedly arranged behind the tape storage rack 5, and the shaft row type wire drawing machine 7 is fixedly arranged behind the take-up machine 6. The passive pay-off stand 1 provides an initial placement position for the wire materials of the stranding machine, carrying the wire materials to be stranded. It is the starting end of the wire material supply in the entire stranding process, ensuring continuous wire material supply during the stranding process and being the basic condition for the stranding operation to proceed. The main machine 2 is equipped with a stranding wheel set and a stranding wheel driving motor. The stranding wheel driving motor drives the stranding wheel set to operate, providing power for the stranding operation, enabling multiple strands of wire materials to complete the stranding operation under the action of the stranding wheel set, which is the key execution action in the stranding process. The wire collecting base 3 is responsible for converging multiple wire materials from different directions, arranging the wire materials in an orderly manner, and guiding them into the subsequent single-head center taping machine 4. This process ensures the neatness of the wire materials during transmission, avoids wire entanglement and chaos, and provides stable wire material input conditions for the subsequent taping and stranding processes. The single-head center taping machine 4 performs a taping operation on the wire materials that have been converged and preliminarily processed by the wire collecting base 3 during the stranding process. It winds taping materials (such as insulating tapes, shielding tapes, etc.) around the wire materials, providing additional protection and functional characteristics for the wire materials, such as insulation, shielding electromagnetic interference, etc., to meet the usage requirements of different stranding products. The tape storage rack 5 can store a certain amount of taping materials. When the single-head center taping machine 4 performs the taping operation, it can ensure the stable supply of taping materials. When the equipment operation speed fluctuates or there are short pauses, etc., the taping materials in the tape storage rack 5 can play a buffering role, avoiding the interruption of taping supply and maintaining the continuity of the taping process. The main function of the take-up machine 6 is to stably convey the wire materials after processes such as stranding and taping at a set speed and tension. It ensures the continuous transmission of the wire materials in the entire production process, avoids situations such as wire jams and slackness, and maintains the continuity and stability of production. The shaft row type wire drawing machine 7 is used to collect and store the finished wire materials after a series of processes such as stranding and taping. It winds the wire materials neatly around the shaft through the rotation of the wire drawing shaft, completing the winding work of the finished product, facilitating subsequent transportation, storage, and use.The tension sensor groups are respectively installed at the wire outlet end of the passive pay-off stand 1, the wire stranding wheel group of the main machine 2, and the wire inlet end of the shaft-type take-up machine 7. They can monitor the wire tension conditions at each working station in real time. By accurately measuring the tensions at different positions, real-time data of the wire tensions at each link are obtained. The collected tension data is transmitted to the controller in the main machine 2, providing accurate input information for the tension intelligent control module. Based on these data, the controller uses the built-in tension control algorithm for analysis and calculation, and then generates corresponding adjustment instructions to ensure that the tensions at each working station meet the requirements during the entire wire stranding process. By monitoring and feedback the tension data in real time, the system can promptly detect abnormal tension situations and make corresponding adjustments, avoiding problems such as wire breakage caused by excessive tension or wire stranding looseness caused by too small tension, thereby improving the quality and stability of wire stranding; The controller can receive the wire tension data of each working station collected by the tension sensor groups, perform processing such as filtering and noise reduction, normalization on these data, removing interference information to make the data more accurate and reliable. At the same time, combined with the built-in tension control algorithm, such as the fuzzy PID control model, it analyzes and calculates suitable tension adjustment parameters. According to the adjustment parameters obtained from the processing and analysis, it generates speed and torque control instructions for the pay-off driving motor of the passive pay-off stand 1, the stranding wheel driving motor of the main machine 2, and the take-up driving motor of the shaft-type take-up machine 7, and sends these instructions to the actuator to precisely regulate the operating states of each motor. Through data interaction with each component, it coordinates the collaborative work of devices such as the passive pay-off stand 1, the main machine 2, and the shaft-type take-up machine 7, dynamically adjusts the working parameters of each device according to the requirements in different stages of the wire stranding process, ensures the stable operation of the entire system, realizes high-precision tension intelligent control, and guarantees the quality of wire stranding; The actuator includes the pay-off driving motor of the passive pay-off stand 1, the stranding wheel driving motor of the main machine 2, and the take-up driving motor of the shaft-type take-up machine 7. These motors operate under the instructions of the controller, respectively providing pay-off power for the passive pay-off stand 1, driving the wire stranding wheel group of the main machine 2 for wire stranding operation, and driving the shaft-type take-up machine 7 to take up wire. They are the power sources for realizing the mechanical movements at each link of the wire stranding process. According to the speed and torque control instructions sent by the controller, the actuator precisely adjusts the operating states of each driving motor. By changing the motor speed and torque, it adjusts the pay-off speed of the passive pay-off stand 1, the rotation speed of the wire stranding wheel group of the main machine 2, and the take-up speed of the shaft-type take-up machine 7, and then realizes the adjustment of the wire tension at each working station, ensuring stable tension during the wire stranding process. The actuator strictly acts according to the instructions of the controller to ensure that each component works according to the preset parameters and rhythm. In the tape storage rack 5, the servo motor in the actuator drives the screw-nut mechanism to adjust the roller spacing of the tension buffer roller group to adapt to different tension adjustment requirements, improving the precise control ability of the system for the wire stranding process and guaranteeing the quality of wire stranding.;

[0039] Please refer to the appendix Figure 1 - Appendix Figure 3, the tension sensor group includes six non-contact tension sensors, and the six non-contact tension sensors respectively correspond to each wire path of the six-strand wire. The sampling frequency of each group of sensors is ≥100Hz.

[0040] Specifically, the six non-contact tension sensors respectively correspond to each wire path of the six-strand wire, and can independently and accurately measure the tension of each wire. Compared with the single sensor for measuring multiple wires or the contact measurement method, this one-to-one non-contact measurement can avoid the mutual interference between wires and the damage that the contact measurement may cause to the wire surface, ensuring that the obtained tension data accurately reflects the actual stress of each wire; the sampling frequency of each group of sensors is ≥100Hz, and at least 100 data are collected per second, which can realize high-frequency real-time monitoring of the wire tension. During the wire stranding process, once there is a slight change in the wire tension, the sensor can quickly capture it and transmit the data to the controller, which enables the system to promptly detect the tension fluctuation and provide data support for subsequent rapid adjustment, ensuring the stability of the tension during the wire stranding process; precise and real-time tension monitoring helps the controller accurately adjust the operating parameters of components such as the passive pay-off reel 1, the main machine 2, and the shaft-type take-up machine 7 according to the tension changes of each wire, ensuring that during the entire wire stranding process of the six-strand wire, the tension on each wire is always within an appropriate range and remains consistent, effectively avoiding quality problems such as uneven wire thickness and looseness caused by uneven tension, and improving the overall quality and consistency of the stranded wire products.

[0041] The tension control algorithm of the controller includes a fuzzy PID control model, and the fuzzy PID control model is used to adjust parameters according to the wire diameter change and the stranding speed fluctuation.

[0042] Specifically, during the wire stranding process, it is inevitable that the wire diameter changes and the stranding speed fluctuates. The fuzzy PID control model can automatically adjust the control parameters according to these real-time changes. For example, when the wire diameter becomes thicker, the required tension will change, and the model can quickly sense and adjust the parameters to ensure that appropriate tension control can be provided under different wire specifications and stranding speeds, maintaining the stable operation of the system; the traditional control method is difficult to accurately handle complex changes, while the fuzzy PID control model combines the advantages of fuzzy logic and PID control. Through the fuzzy processing of a large amount of working condition data, it can more accurately calculate the control quantity that meets the actual requirements. When the stranding speed fluctuates, it can quickly respond and adjust the motor speed and torque, control the tension fluctuation range within a very small range, and improve the accuracy of tension control to ensure the quality of the stranded wire; this model continuously monitors and adjusts the parameters, and can timely compensate for the tension deviation caused by various factors. During the long-term operation of the wire stranding machine, even in the face of external interference or internal component performance changes, it can ensure the stable tension of the wires at each station, effectively avoiding problems such as wire breakage and uneven stranding caused by abnormal tension, enhancing the stability and reliability of the entire system, and reducing equipment failures and product defect rates.

[0043] A tension buffer roller group is arranged in the tape storage rack 5. The tension buffer roller group includes at least two groups of guide rollers arranged in parallel, and the roller spacing between the guide rollers is adjusted by a lead screw nut mechanism driven by a servo motor in the actuator.

[0044] Specifically, during the stranding process, the tension of the tape will change due to factors such as the fluctuation of the equipment operation speed and the characteristics of the tape material. The guide rollers of the tension buffer roller group can provide a certain buffer space for the tape by changing the winding path of the tape. When the tension suddenly increases or decreases, the tape can be adjusted adaptively between the guide rollers to avoid damage to the tape and the equipment caused by sudden tension changes; the roller spacing between the guide rollers can be adjusted by a lead screw nut mechanism driven by a servo motor in the actuator. The controller can accurately control the rotation of the servo motor according to the tape tension data fed back by the tension sensor, and then drive the lead screw nut mechanism to change the guide roller spacing. By adjusting the roller spacing, the stretching degree of the tape between the guide rollers can be directly changed, so as to accurately adjust the tape tension and keep it within a suitable range; a stable and appropriate tape tension is crucial for the tape quality. Through the above buffer and adjustment functions, it can ensure that the tape is wound evenly and tightly on the wire, avoiding problems such as tape slack, wrinkles or fractures, improving the tape quality. At the same time, it also ensures the continuity of the tape supply and enables the stranding operation to proceed continuously and stably.

[0045] The wire collecting base 3 is provided with a tension equalizer. The tension equalizer includes six elastic guide wheels arranged in a circumferential array, and each elastic guide wheel is connected to the mounting bracket of the wire collecting base 3 through a return spring.

[0046] Specifically, due to various factors affecting the wire during wire pay-off and transmission, there will be differences in tension. In the tension equalizer of the wire collecting base 3, the six elastic guide wheels arranged in a circumferential array can respectively contact the wires on different paths. When the wire tensions are different, under the action of the return spring, the elastic guide wheels can adaptively adjust the supporting force and friction force on the wires. The wire with a larger tension will compress the return spring of the elastic guide wheel, reducing the resistance to this wire; the wire with a smaller tension will, due to the action of the return spring, receive a greater acting force from the elastic guide wheel, thereby equalizing the tensions between the wires and ensuring that the wire tensions entering the subsequent process are consistent. Uniform wire tension is a key factor in ensuring the quality of the twisted wire. After being adjusted by the tension equalizer, each wire enters the single-head center tape wrapping machine 4 with a similar tension, avoiding problems such as loose twisted wires and uneven thickness caused by uneven tension. This helps to improve the tightness, stability, and overall quality of the twisted wire, making the produced twisted wire products more in line with the quality standards. The presence of the tension equalizer reduces the impact of wire tension fluctuations on the entire system. It can effectively buffer and regulate the tension changes, reduce the additional stress borne by the equipment components due to uneven tension, and extend the service life of the equipment. At the same time, stable wire tension is also conducive to the continuous and stable operation of the system, reducing equipment failures and downtime caused by tension problems and improving production efficiency.

[0047] Pressure sensors are arranged on the surface of the take-up wheel of the take-up machine 6, and the pressure sensors are evenly distributed along the circumferential direction of the take-up wheel. The pressure sensors are electrically connected to the controller.

[0048] Specifically, by evenly distributing the pressure sensors along the circumferential direction of the take-up wheel, the pressure conditions when the take-up wheel contacts the wire can be monitored in real time in all directions. During the wire twisting process, the pressure of the wire on the take-up wheel is not uniformly constant. Through the evenly distributed sensors, the pressure data at different positions can be obtained, more comprehensively and accurately reflecting the actual pressure state. The pressure sensors are electrically connected to the controller, and the collected pressure data is transmitted to the controller in real time. Since the wire pressure is closely related to the tension, based on these pressure data and combined with the control algorithm of the system, the controller can accurately judge the tension change situation of the wire. For example, when the pressure increases, it may mean that the wire tension increases, and the controller makes corresponding adjustment decisions accordingly to ensure stable tension. With the data feedback from the pressure sensors, the controller timely adjusts the operating parameters of the take-up machine 6, such as the rotation speed and torque of the take-up wheel, so that the wire maintains an appropriate tension during transmission. This not only avoids wire breakage caused by excessive tension but also prevents problems such as loose twisted wires caused by too small tension, ensuring the quality of the twisted wire. At the same time, stable tension helps to reduce the wear of equipment components, improve the stability and reliability of equipment operation, and extend the service life of the equipment.

[0049] The take-up shaft of the shaft arrangement type take-up machine 7 is provided with a torque sensor. The torque sensor is nested in the bearing seat of the take-up shaft and is electrically connected to the controller.

[0050] Specifically, the torque sensor is nested in the bearing seat of the take-up shaft, which can accurately monitor the torque change of the take-up shaft in real time during the take-up process. During take-up, as the wire is continuously wound around the take-up shaft, the load of the take-up shaft will change, and the torque will also change accordingly. The torque sensor can capture these change data in a timely manner; the take-up shaft torque is closely related to the wire tension. By monitoring the take-up torque, the wire tension information during take-up can be indirectly obtained. Because when the wire tension fluctuates, the torque of the take-up shaft will change accordingly to maintain the take-up operation. The torque sensor transmits the torque data to the controller, and the controller can judge whether the wire tension is stable and meets the requirements based on these data; the torque sensor is electrically connected to the controller and feeds back the collected torque data to the controller in real time. The controller, based on these data and combined with the preset tension standard, adjusts the speed and torque of the take-up drive motor by controlling the actuator. When abnormal torque is detected, it means that the tension may deviate. The controller adjusts the motor in a timely manner to achieve closed-loop control of the take-up tension, ensuring the stability of the wire tension during the take-up process and improving the quality of the stranded wire.

[0051] The pay-off reel of the passive pay-off stand 1 is provided with a damping adjustment device. The damping adjustment device includes a magnetic powder brake coaxially arranged with the pay-off reel, and the excitation current input end of the magnetic powder brake is electrically connected to the actuator.

[0052] Specifically, the magnetic powder brake in the damping adjustment device is coaxially arranged with the pay-off reel. By changing the excitation current of the magnetic powder brake, the magnitude of the damping force generated by it can be adjusted. When the actuator changes the excitation current of the magnetic powder brake according to the controller's instruction, the magnetic powder brake generates different damping, thereby accurately controlling the rotation speed of the pay-off reel. This ensures that the pay-off reel can pay off wire at an appropriate speed under different working conditions, avoiding the impact on the quality of the stranded wire caused by too fast or too slow pay-off; during the stranding process, a stable pay-off tension is crucial. The damping generated by the magnetic powder brake can effectively suppress the speed fluctuation of the pay-off reel caused by factors such as inertia, thereby stabilizing the pay-off tension of the wire. If the pay-off tension fluctuates, the actuator will adjust the excitation current of the magnetic powder brake according to the controller's instruction to change the damping magnitude, so that the pay-off tension is maintained within an appropriate range, ensuring the stability of the quality of the stranded wire; the excitation current input end of the magnetic powder brake is electrically connected to the actuator, enabling the passive pay-off stand 1 to work in coordination with the entire tension intelligent control system. The controller, based on the data collected by the tension sensor group and combined with the stranding process requirements, controls the excitation current of the magnetic powder brake through the actuator, ensuring that the pay-off process of the passive pay-off stand 1 matches the stranding operation of the main machine 2 and the take-up action of the shaft arrangement type take-up machine 7, realizing the stable operation of the entire system.

[0053] The operation panel of the host 2 integrates a human-machine interaction interface. The human-machine interaction interface is communicatively connected to the controller via the RS485 bus. The human-machine interaction interface is provided with a tension setting input module, a real-time data display module, and a fault alarm module.

[0054] Specifically, for the tension setting input module set on the human-machine interaction interface, it allows the operator to directly input the target tension value according to the requirements of the stranding process. Through the RS485 bus, these set values are quickly transmitted to the controller. The controller adjusts the parameters of each device accordingly to achieve precise control of the tension during the stranding process and meet the production requirements of different products. The real-time data display module obtains the data of each working station collected by the controller, such as the wire tension at each position, the running speed of the equipment, etc., via the RS485 bus, and visually displays it to the operator. The operator can grasp the running state of the system in real time, discover abnormal situations in a timely manner, so as to take corresponding measures to ensure the smooth progress of the production process. The fault alarm module plays a key role when the system is abnormal. When the controller detects problems such as abnormal tension and equipment failure, it will send an alarm signal to the human-machine interaction interface via the RS485 bus. The fault alarm module prompts the operator in a prominent way, such as sound and light alarm, pop-up window prompt, etc., which is convenient for the operator to quickly locate and handle the fault, reduce equipment damage and production interruption time, and improve production efficiency and equipment reliability.

[0055] The control method of the intelligent tension control system for the high-precision six-head bow-type stranding machine includes the following steps:

[0056] S1. Data acquisition trigger: The controller sends acquisition instructions to the tension sensor groups at the outlet end of the passive pay-off stand 1, the stranding wheel group of the host 2, and the inlet end of the shaft-type take-up machine 7 to obtain the real-time tension data of the wire at each working station.

[0057] S2. Signal processing and algorithm operation: The controller performs filtering, noise reduction, and normalization processing on the collected tension data, and generates tension adjustment parameters based on the built-in fuzzy PID control model in combination with the wire diameter and stranding speed parameters.

[0058] S3. Execution instruction generation: The controller generates speed and torque control instructions for the pay-off drive motor of the passive pay-off stand 1, the stranding wheel drive motor of the host 2, and the take-up drive motor of the shaft-type take-up machine 7 according to the tension adjustment parameters, and sends them to the actuator.

[0059] S4. Closed-loop feedback adjustment: The controller receives the motor adjustment state feedback from the actuator, compares it with the preset tension threshold value. If there is a deviation, repeat steps S1 - S3 until the wire tension at each working station is stable.

[0060] Although embodiments of the present invention have been shown and described, it will be understood by those of ordinary skill in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. High-precision six-head bow-type stranding machine tension intelligent control system, including a passive pay-off stand (1), a main machine (2), a wire collecting base (3), a single-head center taping machine (4), a tape storage rack (5), a take-up machine (6) and an axle-row type wire winding machine (7), characterized in that: A tension intelligent control module is provided inside the host (2), and the tension intelligent control module includes: A set of tension sensors, which are respectively installed at the wire outlet end of the passive pay-off stand (1), the stranding wheel set of the host (2), and the wire inlet end of the shaft row type take-up machine (7); A controller, which is electrically connected to the set of tension sensors and has a built-in tension control algorithm; An actuator, which is electrically connected to the controller and includes a pay-off drive motor arranged on the passive pay-off stand (1), a stranding wheel drive motor of the host (2), and a take-up drive motor of the shaft row type take-up machine (7); The controller collects the wire tension data of each working station through the set of tension sensors, and adjusts the rotation speed and torque of each drive motor through the actuator.

2. The intelligent tension control system for the high-precision six-head bow-type stranding machine according to claim 1, characterized in that: The set of tension sensors includes six groups of non-contact tension sensors, and the six groups of non-contact tension sensors respectively correspond to each wire path of the six-strand wire. The sampling frequency of each group of sensors is ≥100Hz.

3. The intelligent tension control system for the high-precision six-head bow-type stranding machine according to claim 1, wherein: The tension control algorithm of the controller includes a fuzzy PID control model, and the fuzzy PID control model is used to adjust parameters according to the change of wire diameter and the fluctuation of stranding speed.

4. The intelligent tension control system for the high-precision six-head bow-type stranding machine according to claim 1, wherein: A tension buffer roller set is provided inside the tape storage rack (5), and the tension buffer roller set includes at least two groups of parallel guide rollers. The roller spacing between the guide rollers is adjusted by a servo motor-driven lead screw nut mechanism in the actuator.

5. The intelligent tension control system of the high-precision six-head bow-type stranding machine according to claim 1, characterized in that: The wire collecting base (3) is provided with a tension equalizer, and the tension equalizer includes six elastic guide wheels arranged in a circumferential array. Each elastic guide wheel is connected to the mounting rack of the wire collecting base (3) through a return spring.

6. The intelligent tension control system of the high-precision six-head bow-type stranding machine according to claim 1, characterized in that: A pressure sensor is arranged on the surface of the take-off wheel of the take-off machine (6), and the pressure sensors are evenly distributed along the circumferential direction of the take-off wheel. The pressure sensors are electrically connected to the controller.

7. The intelligent tension control system for a high-precision six-head bow-type stranding machine according to claim 1, characterized in that: A torque sensor is arranged on the take-up shaft of the shaft row type take-up machine (7), and the torque sensor is nested in the bearing seat of the take-up shaft. The torque sensor is electrically connected to the controller.

8. The intelligent tension control system for the high-precision six-head bow-type stranding machine according to claim 1, characterized in that: A damping adjustment device is arranged on the pay-off reel of the passive pay-off stand (1), and the damping adjustment device includes a magnetic powder brake coaxially arranged with the pay-off reel. The excitation current input end of the magnetic powder brake is electrically connected to the actuator.

9. The intelligent tension control system for the high-precision six-head bow-type stranding machine according to claim 1, wherein: The operation panel of the host (2) is integrated with a human-machine interaction interface. The human-machine interaction interface is communicatively connected to the controller through an RS485 bus. The human-machine interaction interface is provided with a tension setting input module, a real-time data display module, and a fault alarm module.

10. A control method for the intelligent tension control system of a high-precision six-head bow-type stranding machine, which is applied to the intelligent tension control system of the high-precision six-head bow-type stranding machine according to any one of claims 1-9, characterized in that, It includes the following steps: S1. Data acquisition trigger: The controller sends acquisition instructions to the set of tension sensors at the wire outlet end of the passive pay-off stand (1), the stranding wheel set of the host (2), and the wire inlet end of the shaft row type take-up machine (7) to obtain the real-time tension data of the wire at each working station; S2. Signal processing and algorithm operation: The controller performs filtering, noise reduction, and normalization processing on the collected tension data, and generates tension adjustment parameters based on the built-in fuzzy PID control model in combination with the wire diameter and stranding speed parameters; S3. Execution instruction generation: The controller generates speed and torque control instructions for the wire pay-off drive motor of the passive pay-off stand (1), the wire stranding wheel drive motor of the main machine (2), and the wire take-up drive motor of the shaft-type wire take-up machine (7) according to the tension adjustment parameters, and sends them to the actuator; S4. Closed-loop feedback adjustment: The controller receives the motor adjustment status feedback from the actuator, compares it with the preset tension threshold value. If there is a deviation, repeat steps S1 - S3 until the wire tension at each station is stable.

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