An intelligent control method and system for a fully automatic winding machine for flipping and unloading

Abstract

The present invention relates to the field of automatic control technology for winders, and in particular to an intelligent control method and system for a fully automatic winder for flipping and unloading. The present invention determines the unloading offset anomaly based on the position information change of the finished material roll in the second unloading action sub-cycle to determine whether the current operating state of the winder needs to be regulated; determines a number of dynamic offset characterization vectors by obtaining the position information change of the finished material roll in the first unloading action sub-cycle; determines the setting of flipping pause points for the flipping mechanism based on the collaborative analysis results of the component vectors of the dynamic offset characterization vector in a preset spatial dimension, and determines the number of flipping pause points to be set. The present invention realizes the effective quantification and analysis of the dynamic offset of the material roll during the unloading process, and carries out targeted regulation of the production process according to the offset degree and trend, thereby improving the unloading stability of the winder and the reliability of large-scale continuous production.

Description

Technical Field

[0001] The present invention relates to the technical field of automatic control of winding machines, and in particular to an intelligent control method and system for a full-automatic winding machine for flipping and unloading materials. Background Art

[0002] In modern industrial production, the fully automatic winder is a key equipment for processing flexible materials such as film, paper, and metal strips. The stability and accuracy of its unloading and flipping process directly affect production efficiency and product quality. During operation, the flipping winder may cause problems such as deviation in the flipping angle control of the roll tray and position offset when unloading the roll, resulting in collision and damage to the finished roll during the unloading process, affecting the quality of continuous production products. With the increasing demand for automation and intelligent production in the flexible material processing industry, the key to improving the stability of equipment operation is to accurately detect and compensate for the roll offset during the unloading process of the winder through dynamic position monitoring and intelligent control methods. This method is urgently needed to perform offset analysis based on multi-dimensional information to improve the unloading stability of the fully automatic winder and the reliability of continuous production.

[0003] For example, Chinese patent publication number CN119797037A discloses a fully automatic rewinding device and operating method with a high-precision visual recognition and detection system, including an automatic feeding system, a tension control system, an automatic cutting system, a visual inspection system, an automatic packaging system, and an intelligent control system. By introducing high-precision visual recognition and detection technology, surface defects, geometric dimension deviations, and color differences in materials are detected in real time, and the detection results are fed back to the intelligent control system, dynamically adjusting the tension control and cutting path during the rewinding process. Combined with the PLC and HMI human-machine interface, production parameters are automatically optimized based on real-time data. The automatic packaging system can automatically adjust the packaging method according to the material specifications, achieving efficient packaging operations.

[0004] The following problems also exist in the prior art:

[0005] The existing technology does not take into account the local collision damage caused by the uneven contact between the finished material roll and the feeding mechanism during the unloading process caused by the continuous shaking of the flipping mechanism. The existing technology cannot effectively quantify and analyze the dynamic deviation of the material roll during the unloading process, and cannot carry out targeted regulation of the production process according to the deviation degree and trend, which affects the unloading stability of the fully automatic winder and the reliability of large-scale continuous production. Summary of the Invention

[0006] To this end, the present invention provides an intelligent control method and system for a fully automatic winding machine for flipping and unloading, so as to overcome the problem that the existing technology cannot effectively quantify and analyze the dynamic deviation of the material roll during the unloading process, and cannot carry out targeted regulation of the production process according to the deviation degree and trend.

[0007] To achieve the above object, the present invention provides an intelligent control method for a fully automatic winding machine for flipping and blanking, comprising:

[0008] Continuously acquiring position information of a plurality of finished coils unloaded from a coil support tray within a preset feature extraction cycle, the feature extraction cycle comprising a first unloading action sub-cycle and a second unloading action sub-cycle;

[0009] Determining a blanking offset variation of the finished coil based on a change in position information of the finished coil within the second blanking action sub-cycle, and determining whether it is necessary to regulate the current operating state of the winder according to a determination result between the blanking offset variation and a preset blanking offset variation threshold;

[0010] In response to a result that the current operating state of the winder needs to be regulated, position information changes of the finished coil within a first unloading action sub-cycle are obtained, and a plurality of dynamic offset characterization vectors of the finished coil are determined based on the position information changes in a time sequence relationship;

[0011] Determine the component vectors of the dynamic offset characterization vector in the preset spatial dimension, determine the flipping stop points for the flipping mechanism that drives the material roll tray to flip based on the collaborative analysis results of the component vectors, and determine the number of flipping stop points to be set according to the collaborative analysis results.

[0012] Furthermore, the starting time of the feature extraction cycle and the first unloading action sub-cycle are both the triggering time corresponding to the flipping completion signal of the flipping mechanism, and the starting time of the second unloading action sub-cycle is the triggering time corresponding to the material monitoring signal of the feeding mechanism.

[0013] Furthermore, the process of obtaining the location information includes:

[0014] Establishing a plane rectangular coordinate system with the feeding direction of the feeding mechanism as the longitudinal axis and the direction perpendicular to the feeding direction as the transverse axis;

[0015] The coordinate points of the finished material roll in the rectangular coordinate system are acquired during the feature extraction period, and the coordinate points corresponding to each moment are determined as position information of the finished material roll in the feature extraction period.

[0016] Furthermore, the process of determining the offset variation of the finished coil includes:

[0017] Obtain the coordinate points corresponding to several moments of each finished product roll of the continuous unloading operation in the second unloading action sub-cycle;

[0018] Determine the maximum and minimum values ​​of the abscissas of a plurality of coordinate points;

[0019] The absolute value of the difference between the maximum value of the horizontal coordinate and the minimum value of the horizontal coordinate is determined as the blanking offset variable of each finished material roll.

[0020] Furthermore, the process of determining whether the current operating state of the winder needs to be regulated includes:

[0021] If the blanking offset anomaly corresponding to more than a preset proportion of the continuously blanked finished coils exceeds the blanking offset anomaly threshold, it is determined that the current operating state of the winder needs to be regulated.

[0022] Furthermore, the process of determining the dynamic offset characterization vector of the finished roll includes:

[0023] Obtain the coordinate points corresponding to several moments of each finished product roll of the continuous unloading operation in the first unloading action sub-cycle;

[0024] Constructing a number of dynamic offset representation vectors based on the coordinate points corresponding to adjacent moments in time sequence;

[0025] The vector starting point of the dynamic offset characterization vector is a coordinate point corresponding to a previous moment in adjacent moments, and the vector ending point is a coordinate point corresponding to a next moment in adjacent moments.

[0026] Furthermore, the process of determining the collaborative analysis results of the component vectors includes:

[0027] Determine the dynamic offset component vector along the horizontal axis direction of the plane rectangular coordinate system according to each dynamic offset characterization vector;

[0028] Adding the dynamic offset components of the plurality of dynamic offset characterization vectors to determine a cumulative vector;

[0029] The vector length of the accumulation vector is determined as a dynamic accumulation amount.

[0030] Furthermore, the process of determining the setting of the flipping stop point for the flipping mechanism includes:

[0031] According to the comparison result that the dynamic cumulative amount exceeds the preset dynamic cumulative amount threshold, determining to set a flipping stop point for the flipping mechanism that drives the material roll supporting tray to flip;

[0032] The number of the set flip pause points is related to the dynamic accumulation amount.

[0033] Furthermore, the present invention also provides an intelligent control method for a fully automatic winding machine for flipping and blanking, which is characterized by comprising:

[0034] frame;

[0035] A material roll supporting tray is provided on the frame and is used to support the material roll at a first position for lamination and to support the finished material roll after lamination to a second position;

[0036] a turning mechanism connected to the coil support tray, for driving the coil support tray to turn from a first position to a second position, so that the finished coil supported on the coil support tray can be unloaded under the action of gravity;

[0037] The axis direction of the material coil holding tray at the first position is parallel to the horizontal plane, and the axis direction of the material coil holding tray at the second position is perpendicular to the horizontal plane;

[0038] The turning mechanism includes a mounting plate connected to the coil support tray for driving the coil support tray to turn over, a turning shaft fixed to the frame for turning the mounting plate around an axis, and a turning cylinder for turning the mounting plate and the coil support tray connected to the mounting plate by telescoping.

[0039] One end of the tilting cylinder is fixed to the mounting plate, and the other end is fixed to the frame;

[0040] The feeding mechanism is arranged at the bottom of the frame and is used to transport the finished material coils unloaded from the material coil supporting tray.

[0041] Furthermore, it also includes a signal acquisition module, which is connected to the turning mechanism and the feeding mechanism, including an angle detection unit for detecting the turning angle of the turning mechanism and issuing a turning completion signal, a material monitoring unit provided at the unloading position of the finished material roll for detecting whether there is material on the feeding mechanism and issuing a material monitoring signal, and a timing unit for obtaining the triggering time corresponding to the turning completion signal and the material monitoring signal;

[0042] a position recording module connected to the signal acquisition module for continuously acquiring position information of a plurality of finished coils unloaded from the coil holding tray within a preset feature extraction period;

[0043] an offset analysis module connected to the position recording module, comprising a state analysis unit and an offset quantification unit, wherein the state analysis unit is configured to determine a blanking offset variation of the finished coil based on a change in position information of the finished coil within the second blanking action sub-cycle, and to determine whether the current operating state of the winder needs to be regulated based on the blanking offset variation;

[0044] The offset quantization unit is used to obtain the position information change of the finished material roll in the first material unloading action sub-cycle, and determine a plurality of dynamic offset characterization vectors based on the position information change in the time sequence relationship;

[0045] An intelligent control module is connected to the offset analysis module and the flipping mechanism respectively, and is used to determine the flipping stop points for the flipping mechanism that drives the material roll tray to flip based on the component vector of the dynamic offset characterization vector in the preset spatial dimension, and to determine the number of flipping stop points to be set.

[0046] Compared with the prior art, the beneficial effect of the present invention lies in that the present invention continuously obtains the position information of several finished coils unloaded from the coil support tray within a preset feature extraction cycle, determines the unloading offset anomaly based on the change in the position information of the finished coils in the second unloading action sub-cycle, so as to determine whether it is necessary to regulate the current operating state of the winder, and determines several dynamic offset characterization vectors by obtaining the change in the position information of the finished coils in the first unloading action sub-cycle. Finally, according to the collaborative analysis results of the components of the dynamic offset characterization vectors in the preset spatial dimensions, it is determined to set the flipping stop points for the flipping mechanism that drives the coil support tray to flip, and the number of flipping stop points to be set is determined according to the collaborative analysis results. The present invention realizes the effective quantification and analysis of the dynamic offset of the coil during the unloading process, and carries out targeted regulation of the production process according to the degree and trend of the offset, thereby improving the unloading stability of the winder and the reliability of large-scale continuous production.

[0047] Furthermore, the present invention divides the feature extraction cycle into a first unloading action sub-cycle and a second unloading action sub-cycle. It can be understood that, with the flipping mechanism's flip completion signal as the trigger point, the roll carrier has reached the theoretical unloading position. However, due to mechanical inertia and structural elasticity, the flipping mechanism continues to oscillate slightly. The feeder mechanism's material monitoring signal serves as the demarcation point, at which the roll begins to contact the feeder. This timing precisely captures the dynamic evolution of the roll from free fall to contact with the feeder, enabling time-series analysis of the roll's dynamic excursion. This refined division of the time dimension enables the system to separately analyze the roll's excursion behavior at different time stages.

[0048] Furthermore, the present invention realizes the quantification of the material roll offset through time-series coordinate analysis: first, a monitoring dimension is established in the horizontal axis direction of the feeding mechanism, and the discrete coordinate points of the material roll in the second unloading action sub-cycle are obtained. It can be understood that these points reflect the real-time position changes of the material roll during the contact process with the feeding mechanism. By extracting the extreme value of the horizontal coordinate, the maximum swing range of the material roll in the horizontal direction is captured. This range directly reflects the offset amplitude caused by the shaking of the flipping mechanism. Since mechanical shaking usually manifests as periodic or random displacement fluctuations, the difference in the extreme value of the horizontal coordinate can effectively characterize the boundary of such fluctuations. The larger the difference, the more significant the position deviation change of the material roll when contacting the feeding mechanism, and the more likely it is to cause local collisions, thereby realizing effective quantification and analysis of the dynamic offset of the material roll during the unloading process.

[0049] Furthermore, the present invention quantitatively analyzes the dynamic displacement of the material roll by combining the time dimension and the space dimension. During the first unloading action sub-cycle, the system continuously collects the coordinate points of each finished material roll at different times, and connects the coordinate points of adjacent times in chronological order to construct a dynamic displacement characterization vector. The direction of the vector reflects the displacement trend of the material roll under mechanical shaking, and the modulus of the vector reflects the intensity of the shaking. The larger the modulus, the more obvious the shaking. Then, the continuous shaking process of the material roll in the first unloading stage is discretized into multiple analyzable vectors, which realizes the intuitive presentation of the displacement direction and displacement size of the material roll, and realizes the effective quantification and analysis of the dynamic displacement of the material roll during the unloading process.

[0050] Furthermore, the present invention realizes quantitative analysis of the material roll offset trend by decomposing and superimposing the dynamic offset characterization vectors. It can be understood that each dynamic offset characterization vector is decomposed along the horizontal axis of the plane rectangular coordinate system to obtain its dynamic offset component vector in the horizontal direction, focusing on the offset of the material roll in the direction perpendicular to the feeding direction. The offset in this direction directly affects the contact stability between the material roll and the feeding mechanism. Then the component vectors are added to form a cumulative vector. This process integrates the horizontal offset of the material roll in multiple time segments within the first unloading action sub-cycle through the vector synthesis rule, and finally obtains the overall offset trend.

[0051] Furthermore, in the first feeding stage of the present invention, the degree of deviation caused by the shaking of the flipping mechanism has reached a level that affects the stability of the feeding. At this time, it is necessary to set a flipping pause point for intervention. By pausing during the flipping process, the mechanical stress can be effectively released and the influence of the large inertia on the posture of the material roll can be eliminated. At the same time, the higher the degree of deviation, the more pause points are set, and the deviation trend of the material roll is gradually corrected through multiple pauses; when the degree of deviation is low, the number of pause points is reduced to balance the regulation effect and production efficiency. Furthermore, targeted regulation of the production process according to the degree and trend of deviation is achieved, thereby improving the feeding stability of the winder and the reliability of large-scale continuous production. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Figure 1 This is a step diagram of an intelligent control method for a fully automatic winding machine for flipping and blanking according to an embodiment of the present invention;

[0053] Figure 2 This is a schematic diagram of the partial structure of a fully automatic winding machine for flipping and blanking according to an embodiment of the present invention;

[0054] Figure 3 A diagram showing the steps for determining the offset variance of blanking according to an embodiment of the present invention;

[0055] Figure 4 A diagram showing the steps for determining collaborative analysis results of component vectors according to an embodiment of the present invention;

[0056] Figure 5 This is a simplified structural diagram of an angle detection unit according to an embodiment of the present invention;

[0057] Figure 6 This is a simplified structural diagram of a material monitoring unit according to an embodiment of the present invention;

[0058] In the figure, 1-frame, 2-material roll tray, 3-mounting plate, 4-turning axis, 5-turning cylinder, 6-feeding roller, 7-angle detection unit, 8-material monitoring unit. DETAILED DESCRIPTION

[0059] In order to make the objects and advantages of the present invention more clearly understood, the present invention is further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are merely used to explain the present invention and are not intended to limit the present invention.

[0060] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0061] It should be noted that, in the description of the present invention, terms such as "upper", "lower", "inside" and "outside" indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings. This is only for the convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it cannot be understood as a limitation on the present invention.

[0062] Furthermore, it should be noted that, in the description of the present invention, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed, detachable, or integral connections; mechanical or electrical connections; direct or indirect connections through an intermediary; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0063] See also Figure 1 and Figure 2 As shown, Figure 1 This is a step diagram of an intelligent control method for a fully automatic winding machine for flipping and blanking according to an embodiment of the present invention. Figure 2 This is a schematic diagram of the partial structure of a fully automatic winding machine for flipping and blanking according to an embodiment of the present invention. An intelligent control method for a fully automatic winding machine for flipping and blanking according to the present invention includes:

[0064] Step S100, continuously acquiring position information of a plurality of finished coils unloaded from the coil holding tray 2 within a preset feature extraction cycle, wherein the feature extraction cycle includes a first unloading action sub-cycle and a second unloading action sub-cycle;

[0065] Step S200: determining a blanking offset variation of the finished coil based on a change in position information of the finished coil within the second blanking action sub-cycle, and determining whether it is necessary to regulate the current operating state of the winder based on a comparison between the blanking offset variation and a preset blanking offset variation threshold;

[0066] Step S300, in response to a result that the current operating state of the winder needs to be regulated, obtaining position information change of the finished coil within a first unloading action sub-cycle, and determining a plurality of dynamic offset characterization vectors of the finished coil based on the position information change in a time sequence relationship;

[0067] Step S400, determine the component vectors of the dynamic offset characterization vector in the preset spatial dimension, determine the setting of flipping stop points for the flipping mechanism that drives the material roll tray 2 to flip based on the collaborative analysis results of the component vectors, and determine the number of setting of the flipping stop points according to the collaborative analysis results.

[0068] Specifically, the starting time of the feature extraction cycle and the first unloading action sub-cycle are both the triggering time corresponding to the flipping completion signal of the flipping mechanism, and the starting time of the second unloading action sub-cycle is the triggering time corresponding to the material monitoring signal of the feeding mechanism.

[0069] In the implementation of the present invention, the first unloading action sub-cycle is a period of preset time after the flipping mechanism drives the material roll supporting tray 2 to complete the flipping, and the second unloading action sub-cycle is a period of preset time after the presence of material is detected at the unloading position of the feeding mechanism. The duration of the feature extraction cycle, the duration of the first unloading action sub-cycle and the duration of the second unloading action sub-cycle can all be set by technical personnel in this field according to monitoring requirements to ensure that sufficient data is obtained for analysis. Preferably, the duration of the feature extraction cycle can be 3s, the duration of the first unloading action sub-cycle can be 1s, and the duration of the second unloading action sub-cycle can be 2s.

[0070] Specifically, the present invention divides the feature extraction cycle into a first unloading action sub-cycle and a second unloading action sub-cycle. It can be understood that, with the flipping mechanism's flip completion signal as the trigger point, the roll tray 2 has reached the theoretical unloading position. However, due to mechanical inertia and structural elasticity, the flipping mechanism continues to oscillate slightly. The feeder mechanism's material monitoring signal serves as the demarcation point, at which point the roll begins to contact the feeder mechanism. This selection of moments accurately captures the dynamic change of the roll from free fall to contact with the feeder mechanism, enabling a time-series analysis of the roll's dynamic excursion. This refined division of the time dimension enables the system to separately analyze the roll's excursion behavior at different time stages.

[0071] Specifically, the process of obtaining the location information includes:

[0072] Establishing a plane rectangular coordinate system with the feeding direction of the feeding mechanism as the longitudinal axis and the direction perpendicular to the feeding direction as the transverse axis;

[0073] The coordinate points of the finished material roll in the rectangular coordinate system are acquired during the feature extraction period, and the coordinate points corresponding to each moment are determined as position information of the finished material roll in the feature extraction period.

[0074] It can be understood that the conveying direction of the conveying mechanism is the forward direction of the conveying roller 6 on the conveying mechanism.

[0075] Specifically, see Figure 3 As shown in FIG. 1 , which is a step diagram for determining the offset variation of blanking according to an embodiment of the present invention, the process of determining the offset variation of blanking of the finished coil includes:

[0076] Step S201, obtaining coordinate points corresponding to several moments of each finished roll of continuously unloaded material in the second unloading action sub-cycle;

[0077] Step S202, determining the maximum value and the minimum value of the horizontal coordinates of the plurality of coordinate points;

[0078] Step S203 , determining the absolute value of the difference between the maximum value of the horizontal coordinate and the minimum value of the horizontal coordinate as the blanking offset anomaly of each finished coil.

[0079] Specifically, the present invention realizes the quantification of the offset of the material roll through time-series coordinate analysis: first, a monitoring dimension is established in the horizontal axis direction of the feeding mechanism, and the discrete coordinate points of the material roll in the second unloading action sub-period are obtained. It can be understood that these points reflect the real-time position changes of the material roll during the contact process with the feeding mechanism. By extracting the extreme value of the horizontal coordinate, the maximum swing range of the material roll in the horizontal direction is captured. This range directly reflects the offset amplitude caused by the shaking of the flipping mechanism. Since mechanical shaking usually manifests as periodic or random displacement fluctuations, the difference in the extreme value of the horizontal coordinate can effectively characterize the boundary of such fluctuations. The larger the difference, the more significant the position deviation change of the material roll when contacting the feeding mechanism, and the more likely it is to cause local collisions, thereby realizing effective quantification and analysis of the dynamic offset of the material roll during the unloading process.

[0080] Specifically, the process of determining whether the current operating state of the winder needs to be regulated includes:

[0081] If the number of finished coils discharged continuously that exceeds a preset ratio does not exceed the threshold value of the material discharge offset, it is determined that the current operating state of the winder does not need to be regulated;

[0082] If the blanking offset anomaly corresponding to more than a preset proportion of the continuously blanked finished coils exceeds the blanking offset anomaly threshold, it is determined that the current operating state of the winder needs to be regulated.

[0083] Exemplarily, in the implementation of the present invention, the material feeding offset anomaly threshold can be set by a person skilled in the art based on pre-tested data, and the coordinate points corresponding to several moments in the second material feeding action sub-cycle of the finished material roll of the same specification are obtained in advance, the horizontal coordinate difference between any two coordinate points is calculated, and the average value of the horizontal coordinate difference is calculated. The material feeding offset anomaly threshold = the average value of the horizontal coordinate difference × the first threshold value factor. The value range of the first threshold value factor is [1.2, 1.5]. Preferably, the value of the first threshold value factor is 1.3 to ensure that the screened finished material roll has a significant position deviation when it contacts the feeding mechanism. The preset ratio can be set by a person skilled in the art based on the monitoring sensitivity. The lower the preset ratio, the lower the threshold for regulating the current operating state of the winder. Preferably, the preset ratio is 25%.

[0084] Specifically, the process of determining the dynamic offset characterization vector of the finished roll includes:

[0085] Obtain the coordinate points corresponding to several moments of each finished product roll of the continuous unloading operation in the first unloading action sub-cycle;

[0086] Constructing a number of dynamic offset representation vectors based on the coordinate points corresponding to adjacent moments in time sequence;

[0087] The vector starting point of the dynamic offset characterization vector is a coordinate point corresponding to a previous moment in adjacent moments, and the vector ending point is a coordinate point corresponding to a next moment in adjacent moments.

[0088] Specifically, the present invention quantifies and analyzes the dynamic offset of the material roll by combining the time dimension and the space dimension. During the first unloading action sub-cycle, the system continuously collects the coordinate points of each finished material roll at different times, and connects the coordinate points of adjacent times in chronological order to construct a dynamic offset characterization vector. The direction of the vector reflects the offset trend of the material roll under mechanical shaking, and the modulus of the vector reflects the intensity of the shaking. The larger the modulus, the more obvious the shaking. Furthermore, the continuous shaking process of the material roll in the first unloading stage is discretized into multiple analyzable vectors, which realizes the intuitive presentation of the offset direction and offset size of the material roll, and realizes the effective quantification and analysis of the dynamic offset of the material roll during the unloading process.

[0089] Specifically, see Figure 4 As shown in FIG. , it is a diagram showing the steps of determining the collaborative analysis results of component vectors according to an embodiment of the present invention. The process of determining the collaborative analysis results of component vectors includes:

[0090] Step S401, determining a dynamic offset component vector along the horizontal axis of a plane rectangular coordinate system according to each dynamic offset characterization vector;

[0091] In implementation, the vector starting point of each dynamic offset component vector is the vector starting point of the corresponding dynamic offset representation vector.

[0092] Step S402, adding the dynamic offset components of a plurality of dynamic offset characterization vectors to determine a cumulative vector;

[0093] In the implementation of the present invention, the specific method of adding the dynamic offset component vectors may be to directly accumulate the dynamic offset component vectors. This is a prior art and will not be described in detail here.

[0094] Step S403: Determine the vector length of the accumulated vector as a dynamic accumulation amount.

[0095] Specifically, the present invention realizes the quantitative analysis of the material roll offset trend by decomposing and superimposing the dynamic offset characterization vectors. It can be understood that each dynamic offset characterization vector is decomposed along the horizontal axis of the plane rectangular coordinate system to obtain its dynamic offset component vector in the horizontal direction, focusing on the offset of the material roll in the direction perpendicular to the feeding direction. The offset in this direction directly affects the contact stability between the material roll and the feeding mechanism. Then the component vectors are added to form a cumulative vector. This process integrates the horizontal offset of the material roll in multiple time segments within the first unloading action sub-cycle through the vector synthesis rule, and finally obtains the overall offset trend.

[0096] It can be understood that the length of the cumulative vector is used as the dynamic cumulative amount, and its numerical value directly reflects the overall degree of horizontal deviation of the material roll in the first material unloading stage. The larger the dynamic cumulative amount, the more obvious the impact of the shaking of the flipping mechanism on the position of the material roll.

[0097] Specifically, the process of determining the turning stop point for the turning mechanism includes:

[0098] According to the comparison result that the dynamic cumulative amount does not exceed the preset dynamic cumulative amount threshold, determining not to adjust the flip mechanism;

[0099] According to the comparison result that the dynamic cumulative amount exceeds the preset dynamic cumulative amount threshold, determining to set a flipping pause point for the flipping mechanism that drives the material roll supporting tray 2 to flip;

[0100] The number of the set flip pause points is related to the dynamic accumulation amount.

[0101] In practice, it can be understood that, under the condition that the dynamic cumulative amount does not exceed the preset dynamic cumulative amount threshold, it means that the generation of the material offset anomaly is weakly correlated with the dynamic cumulative amount, and the effect of adjusting the flipping mechanism on reducing the material offset anomaly is insufficient. The running speed of the feed roller 6 of the feed mechanism can be used to reduce the impact force between the finished material roll and the feed mechanism, so as to avoid local impact damage.

[0102] Exemplarily, the value of the dynamic accumulation threshold in the present invention can be determined according to the blanking offset anomaly threshold, dynamic accumulation threshold = blanking offset anomaly threshold × second threshold value factor, the value range of the second threshold value factor is [0.2, 0.35], preferably, the value of the second threshold value factor is 0.25 to ensure that the dynamic accumulation threshold is sufficiently small compared with the blanking offset anomaly threshold, that is, the correlation between the generation of blanking offset anomaly and the dynamic accumulation is weak.

[0103] The number of set flip pause points in the present invention can be determined based on the dynamic accumulation amount, for example,

[0104] When the dynamic accumulation exceeds the dynamic accumulation threshold and the dynamic accumulation does not exceed 1.2 times the dynamic accumulation threshold, the number of set flip pause points is 1;

[0105] When the dynamic accumulation exceeds 1.2 times the dynamic accumulation threshold, and the dynamic accumulation does not exceed 1.5 times the dynamic accumulation threshold, the number of rollover pause points is set to 2;

[0106] When the dynamic accumulation exceeds 1.5 times the dynamic accumulation threshold, the number of set flip pause points is 3.

[0107] The flipping pause points are distributed at flipping angles with equal spacing during the flipping process of the flipping mechanism.

[0108] In the implementation of the present invention, the specific setting of the flipping stop point can be: if the number of flipping stop points is 1, the setting position of the flipping stop point can be the middle position between the first position and the second position, that is, the axis of the material roll supporting tray 2 driven by the flipping mechanism at the flipping stop point is at a 45° angle to the axis of the material roll supporting tray at the first position and the second position; if the number of flipping stop points is 2, the angular interval between the axis of the material roll supporting tray 2 at the two flipping stop points driven by the flipping mechanism is 30°; if the number of flipping stop points is 3, the angular interval between the axis of the material roll supporting tray 2 at the two flipping stop points driven by the flipping mechanism is 22.5°.

[0109] In the implementation of the present invention, the method of pausing at the flipping pause point can be to control the opening and closing of the air inlet valve and the air outlet valve of the flipping cylinder 5 through the solenoid valve. When the angle detection unit 7 receives a signal that the flipping angle reaches the flipping pause point, the opening and closing of the air inlet valve and the air outlet valve of the flipping cylinder 5 are controlled by the solenoid valve to enable the flipping cylinder 5 to maintain the current action. For example, the pause time at each flipping pause point can be 3s to reduce the structural shaking caused by the inertia of the flipping mechanism in the process of flipping the material roll tray 2.

[0110] It can be understood that when the dynamic cumulative amount calculated by the system exceeds the preset threshold, it indicates that the degree of deviation of the material roll caused by the shaking of the flipping mechanism in the first unloading stage has reached a level that affects the stability of unloading. At this time, it is necessary to set a flipping pause point to intervene. By pausing during the flipping process, the mechanical stress can be effectively released and the influence of large inertia on the posture of the material roll can be eliminated. At the same time, the higher the degree of deviation, the more pause points are set, and the deviation trend of the material roll is gradually corrected through multiple pauses; when the degree of deviation is low, the number of pause points is reduced to balance the control effect and production efficiency. In addition, targeted control of the production process according to the degree and trend of deviation is achieved, thereby improving the unloading stability of the winder and the reliability of large-scale continuous production.

[0111] This embodiment also provides a computer-readable storage medium, which stores computer program code. When the computer program code runs on a computer, the computer executes the above-mentioned related method steps to implement the intelligent control method for the fully automatic winding machine for flipping and unloading provided in the above embodiment.

[0112] For more details, please refer to Figure 2 As shown, it is a partial structural diagram of a fully automatic winding machine for flipping and blanking according to an embodiment of the present invention, an intelligent control system for a fully automatic winding machine for flipping and blanking, and an intelligent control method for a fully automatic winding machine for flipping and blanking according to the present invention, characterized in that it includes:

[0113] Rack 1;

[0114] A material roll supporting tray 2 is provided on the frame 1 and is used to support the material roll at a first position for lamination and to support the finished material roll after lamination to a second position;

[0115] a turning mechanism connected to the coil support tray 2, for driving the coil support tray 2 to turn from a first position to a second position, so that the finished coil supported on the coil support tray 2 can be unloaded under the action of gravity;

[0116] The axis direction of the material roll tray 2 at the first position is parallel to the horizontal plane, and the axis direction of the material roll tray 2 at the second position is perpendicular to the horizontal plane;

[0117] The turning mechanism includes a mounting plate 3 connected to the material coil support tray 2 for driving the material coil support tray 2 to turn over, a turning shaft 4 fixed to the frame 1 for turning the mounting plate 3 around an axis, and a turning cylinder 5 for turning the mounting plate 3 and the material coil support tray 2 connected to the mounting plate 3 by telescoping.

[0118] One end of the tilting cylinder 5 is fixed on the mounting plate 3, and the other end is fixed on the frame 1;

[0119] The feeding mechanism is arranged at the bottom of the frame and is used to transport the finished material coils unloaded from the material coil supporting tray.

[0120] Specifically, it also includes a signal acquisition module, which is connected to the flipping mechanism and the feeding mechanism, including an angle detection unit 7 for detecting the flipping angle of the flipping mechanism and issuing a flipping completion signal, a material monitoring unit 8 provided at the unloading position of the finished material roll for detecting whether there is material on the feeding mechanism and issuing a material monitoring signal, and a timing unit for obtaining the triggering time corresponding to the flipping completion signal and the material monitoring signal;

[0121] Specifically, the angle detection unit 7 in the present invention can be a photoelectric coded angle sensor, which is used to obtain the flipping angle of the flipping mechanism in real time. The photoelectric coded angle sensor is widely used in the field of industrial monitoring, which will not be repeated here. The flipping angle is the angle between the axis of the material roll tray and the horizontal plane.

[0122] Specifically, the material monitoring unit 8 in the present invention can be a photoelectric sensor, and the transmitter and receiver of the photoelectric sensor are respectively installed on both sides of the unloading position. The axis of the light beam is perpendicular to the material roll conveying direction and passes through the unloading center point of the material roll supporting tray 2 at the second position. The vertical distance H=3cm±1cm between the transmitter and receiver of the photoelectric sensor and the plane where the feed roller 6 of the feed mechanism is located is located, so as to ensure that the photoelectric sensor can capture the unloading of the finished material roll to the finished material roll unloading position; wherein, the finished material roll unloading position is the area on the plane where the feed roller 6 of the feed mechanism corresponding to the unloading of the material roll supporting tray 2 at the second position is located.

[0123] Specifically, the timing unit in the present invention can be a timing register in a microprocessor, which triggers timing when a signal is input and stores a timestamp in a data register. This is a prior art and will not be described in detail here.

[0124] a position recording module connected to the signal acquisition module for continuously acquiring position information of a plurality of finished coils unloaded from the coil holding tray 2 within a preset feature extraction cycle;

[0125] Specifically, the present invention does not limit the position recording module, which can be an industrial camera installed on a rack and image processing software connected to the industrial camera. The video image information of the finished material roll is obtained through the industrial camera, and the position information of the finished material roll in the set plane rectangular coordinate system is determined according to the image information of the finished material roll through the image processing software. This is a commonly used technical means in the field of industrial visual positioning and will not be repeated here.

[0126] an offset analysis module connected to the position recording module, comprising a state analysis unit and an offset quantification unit, wherein the state analysis unit is configured to determine a blanking offset variation of the finished coil based on a change in position information of the finished coil within the second blanking action sub-cycle, and to determine whether the current operating state of the winder needs to be regulated based on the blanking offset variation;

[0127] The offset quantization unit is used to obtain the position information change of the finished material roll in the first material unloading action sub-cycle, and determine a plurality of dynamic offset characterization vectors based on the position information change in the time sequence relationship;

[0128] An intelligent control module is connected to the offset analysis module and the flipping mechanism respectively, and is used to determine the flipping stop point for the flipping mechanism that drives the material roll tray 2 to flip based on the component vector of the dynamic offset characterization vector in the preset spatial dimension, and to determine the number of flipping stop points to be set.

[0129] Specifically, the present invention does not limit the offset analysis module and the intelligent control module. The module itself or each unit therein can be constructed using logic components. The logic components can be field programmable logic components, microprocessors, processors used in computers, etc., which will not be repeated here.

[0130] Thus far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art may make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will fall within the scope of protection of the present invention.

[0131] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that the present invention is susceptible to various modifications and variations. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. An intelligent control method for a fully automatic winding machine for flipping and blanking, characterized in that: include: Continuously acquiring position information of a plurality of finished coils unloaded from a coil holding tray within a preset feature extraction cycle, the feature extraction cycle comprising a first unloading action sub-cycle and a second unloading action sub-cycle; wherein the start time of the feature extraction cycle and the first unloading action sub-cycle are both triggered by a flipping completion signal of a flipping mechanism, and the start time of the second unloading action sub-cycle is triggered by a material monitoring signal of a feeding mechanism; Based on the change of the position information of the finished material roll in the second unloading action sub-cycle, the unloading offset anomaly of the finished material roll is determined, and according to the judgment result of the unloading offset anomaly and the preset unloading offset anomaly threshold, it is determined whether the current operating state of the winder needs to be regulated; wherein, the process of determining the unloading offset anomaly of the finished material roll includes: obtaining the coordinate points corresponding to several moments of each finished material roll unloaded continuously in the second unloading action sub-cycle; determining the maximum value and the minimum value of the horizontal coordinate in the horizontal coordinates of the several coordinate points; and determining the absolute value of the difference between the maximum value and the minimum value of the horizontal coordinate as the unloading offset anomaly of each finished material roll; In response to the result that the current operating state of the winder needs to be regulated, the position information change of the finished material roll in the first unloading action sub-cycle is obtained, and a number of dynamic offset characterization vectors of the finished material roll are determined based on the position information change in a time sequence relationship; wherein the process of determining the dynamic offset characterization vector of the finished material roll includes: obtaining the coordinate points corresponding to a number of moments in the first unloading action sub-cycle of each continuously unloaded finished material roll; constructing a number of dynamic offset characterization vectors according to the coordinate points corresponding to adjacent moments in time sequence; the vector starting point of the dynamic offset characterization vector is the coordinate point corresponding to the previous moment in the adjacent moments, and the vector end point is the coordinate point corresponding to the next moment in the adjacent moments; Determine the component vectors of the dynamic offset characterization vector in the preset spatial dimension, determine the flipping stop points for the flipping mechanism that drives the material roll tray to flip based on the collaborative analysis results of the component vectors, and determine the number of flipping stop points to be set according to the collaborative analysis results.

2. The intelligent control method for a fully automatic winding machine for flipping and blanking according to claim 1 is characterized in that: The process of obtaining the location information includes: Establishing a plane rectangular coordinate system with the feeding direction of the feeding mechanism as the longitudinal axis and the direction perpendicular to the feeding direction as the transverse axis; The coordinate points of the finished material roll in the rectangular coordinate system are acquired during the feature extraction period, and the coordinate points corresponding to each moment are determined as position information of the finished material roll in the feature extraction period.

3. The intelligent control method for a fully automatic winding machine for flipping and blanking according to claim 2 is characterized in that: The process of determining whether the current operating status of the winder needs to be regulated includes: If the blanking offset anomaly corresponding to more than a preset proportion of the continuously blanked finished coils exceeds the blanking offset anomaly threshold, it is determined that the current operating state of the winder needs to be regulated.

4. The intelligent control method for a fully automatic winding machine for flipping and blanking according to claim 3 is characterized in that: The process of determining the collaborative analysis results of the component vectors includes: Determine the dynamic offset component vector along the horizontal axis direction of the plane rectangular coordinate system according to each dynamic offset characterization vector; Adding the dynamic offset components of the plurality of dynamic offset characterization vectors to determine a cumulative vector; The vector length of the accumulation vector is determined as a dynamic accumulation amount.

5. The intelligent control method for a fully automatic winding machine for flipping and blanking according to claim 4 is characterized in that: The process of determining the turning stop point for the turning mechanism includes: According to the comparison result that the dynamic cumulative amount exceeds the preset dynamic cumulative amount threshold, determining to set a flipping stop point for the flipping mechanism that drives the material roll supporting tray to flip; The number of the set flip pause points is related to the dynamic accumulation amount.

6. An intelligent control system for a fully automatic winding machine for turning over and blanking, used to execute the intelligent control method for a fully automatic winding machine for turning over and blanking according to any one of claims 1 to 5, characterized in that: include: frame; A material roll supporting tray is provided on the frame and is used to support the material roll at a first position for lamination and to support the finished material roll after lamination to a second position; a turning mechanism connected to the coil support tray, for driving the coil support tray to turn from a first position to a second position, so that the finished coil supported on the coil support tray can be unloaded under the action of gravity; The axis direction of the material coil holding tray at the first position is parallel to the horizontal plane, and the axis direction of the material coil holding tray at the second position is perpendicular to the horizontal plane; The turning mechanism includes a mounting plate connected to the coil support tray for driving the coil support tray to turn over, a turning shaft fixed to the frame for turning the mounting plate around an axis, and a turning cylinder for turning the mounting plate and the coil support tray connected to the mounting plate by telescoping. One end of the tilting cylinder is fixed to the mounting plate, and the other end is fixed to the frame; The feeding mechanism is arranged at the bottom of the frame and is used to transport the finished material coils unloaded from the material coil supporting tray.

7. The intelligent control system for the full-automatic winding machine for flipping and blanking according to claim 6 is characterized in that: The system also includes a signal acquisition module connected to the flipping mechanism and the feeding mechanism, including an angle detection unit for detecting the flipping angle of the flipping mechanism and issuing a flipping completion signal, a material monitoring unit provided at the unloading position of the finished material roll for detecting whether there is material on the feeding mechanism and issuing a material monitoring signal, and a timing unit for obtaining the triggering time corresponding to the flipping completion signal and the material monitoring signal; a position recording module connected to the signal acquisition module for continuously acquiring position information of a plurality of finished coils unloaded from the coil holding tray within a preset feature extraction period; an offset analysis module connected to the position recording module, comprising a state analysis unit and an offset quantification unit, wherein the state analysis unit is configured to determine a blanking offset variation of the finished coil based on a change in position information of the finished coil within the second blanking action sub-cycle, and to determine whether the current operating state of the winder needs to be regulated based on the blanking offset variation; The offset quantization unit is used to obtain the position information change of the finished material roll in the first material unloading action sub-cycle, and determine a plurality of dynamic offset characterization vectors based on the position information change in the time sequence relationship; An intelligent control module is connected to the offset analysis module and the flipping mechanism respectively, and is used to determine the flipping stop points for the flipping mechanism that drives the material roll tray to flip based on the component vector of the dynamic offset characterization vector in the preset spatial dimension, and to determine the number of flipping stop points to be set.

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