Online control method and system for delay test equipment

Abstract

The invention relates to the technical field of an insulation process of data wire production, and discloses an online control method and system of delay test equipment, and the method comprises the steps: constructing a data collection module, a data analysis module, a parameter setting module, a real-time monitoring module and a feedback control module; real-time monitoring and intelligent control of key parameters in the wire production process are achieved, the data acquisition module acquires data and monitors the equipment operation state and environmental conditions, and the data analysis module processes the data through a delay calculation formula and conducts moving average and error correction so as to ensure the data accuracy. The parameter setting module prompts an operator to adjust unreasonable parameters, the real-time monitoring module displays production data and abnormal information, and the feedback control module automatically adjusts equipment parameters and continuously monitors until production returns to normal. The method has the advantages of online real-time monitoring, full-process coverage detection and accurate identification of the axial delay difference.

Description

Technical Field

[0001] The present invention relates to the technical field of insulation procedures for data cable production, and in particular to an online control method and system for delay test equipment. Background Art

[0002] In the production of data cables, delay variability control is a key technical indicator for ensuring signal transmission quality. However, current industry testing for data cables with delay variability requirements faces limitations. Traditionally, delay testing requires offline testing using time domain reflectometry (TdR) on finished products. This approach presents two significant challenges: First, because testing lags behind production, discovering delay defects during the finished product phase can lead to the scrapping of the entire batch, resulting in wasted resources and increased costs. Second, testing methods based on network analyzers (network analysis) can only perform spot tests on the head and tail sections of a single-axis cable and cannot effectively identify delay variations within the middle section of the cable, making it difficult to detect potential local defects. Furthermore, existing technologies have yet to implement online testing and control of delay variability during initial processes, such as single-wire processing or assembly. This is particularly true for the consistency of delay along the length (axial) of data cables, lacking efficient, real-time testing methods. Therefore, overcoming the limitations of traditional offline testing and enabling online monitoring and control of delay variability at the front end of production has become a pressing technical need to improve the yield rate and production efficiency of data cables. The present invention addresses this industry pain point and proposes an online control method and system for delay testing equipment, which solves the problem of real-time detection of long-direction delay differences. Summary of the Invention

[0003] (1) Technical problems solved

[0004] In response to the shortcomings of the existing technology, the present invention provides an online control method and system for delay testing equipment, which has the advantages of online real-time monitoring, full-process coverage detection, and accurate identification of axial delay differences. It solves the problems of batch scrapping caused by lag in traditional offline testing, missed detection of delay defects in the intermediate section, and lack of real-time control means in the initial process.

[0005] (2) Technical solution

[0006] To achieve the above object, the present invention provides the following technical solution: an online control method for a delay test device, comprising the following steps:

[0007] Step 1: Establish the system: Build the system and set up the data acquisition module, data analysis module, parameter setting module, real-time monitoring module and feedback control module within the system;

[0008] Step 2, data collection phase: The data collection module collects conductor outer diameter, insulation outer diameter and electrostatic capacitance data, as well as the fluctuation data of factors affecting Td in the longitudinal direction, and monitors and collects equipment operating status and environmental data in real time;

[0009] Step 2, Data Analysis Phase: The data analysis module receives the collected basic parameter data, calculates the Td value of each point using the delay calculation formula, and performs moving average processing on the factor data. It then combines the environmental and equipment status data to analyze the error and correct the original data. Finally, based on the set parameters and the corrected data, it determines whether Td is abnormal.

[0010] Step 3, parameter setting stage: The operator inputs the conductor diameter center value, ± tolerance, and sets Td related parameters and "discrimination length" in the parameter setting module according to production requirements. The system sets the parameters based on real-time monitoring and analysis results.

[0011] Step 4, adjustment stage: When it is found that the parameter setting is unreasonable or the production process changes, the system automatically prompts the operator to adjust the parameters;

[0012] Step 5: Real-time monitoring stage: The real-time monitoring module displays production data and abnormal information in real time, and operators can view it at any time;

[0013] Step 6: Feedback control stage: When Td anomalies occur, the feedback control module automatically adjusts the production equipment parameters, records the adjustment process, and continuously monitors subsequent production data until production returns to normal.

[0014] An online control system for a time delay test device, comprising a data acquisition module, a data analysis module, a parameter setting module, a real-time monitoring module and a feedback control module;

[0015] The data acquisition module includes a basic parameter acquisition submodule, a fluctuation data acquisition submodule, and an environment and equipment status acquisition submodule. The basic parameter acquisition submodule continuously collects conductor outer diameter, insulation outer diameter, and electrostatic capacitance data according to the inherent sampling period of the equipment. The fluctuation data acquisition submodule synchronously samples the fluctuation data of the factors affecting Td in the longitudinal direction. The environment and equipment status acquisition submodule monitors and collects equipment operating status and environmental data in real time.

[0016] The data analysis module includes a delay calculation submodule, an error analysis and correction submodule, and an abnormality determination submodule. The delay calculation submodule calculates the delay value Td and the moving average value Ys of each point based on the collected basic parameter data, and the error analysis and correction submodule calculates the corrected data B j ,The abnormal judgment submodule determines whether Td is abnormal based on the set parameters and the corrected data;

[0017] The parameter setting module includes a conductor diameter parameter setting submodule, a Td parameter setting submodule, and a discrimination length setting submodule, and allows the operator to input the conductor diameter center value, ± tolerance, and set Td related parameters and "discrimination length" according to production requirements. The system sets parameters based on real-time monitoring and analysis results;

[0018] The real-time monitoring module displays production data and abnormal information in real time, allowing operators to check the production status at any time, including the delay value Td, equipment operating status and environmental data;

[0019] When the feedback control module finds that Td is abnormal, it automatically adjusts the production equipment parameters, records the adjustment process, and continuously monitors subsequent production data until production returns to normal.

[0020] Preferably, the delay calculation submodule calculates the delay value Td at each point using the delay calculation formula based on the collected conductor outer diameter, insulation outer diameter and electrostatic capacitance data. The calculation formula is:

[0021]

[0022] In the formula, Td represents the delay value at each point, ε represents the dielectric constant, C represents the electrostatic capacitance, d1 represents the insulation outer diameter, and d2 represents the conductor outer diameter.

[0023] Preferably, the delay calculation submodule performs moving average processing according to the data detected by each factor according to a set average number of times. For a certain parameter sequence x1, x2, x3, ... x4, the moving average value Ys is calculated as follows:

[0024]

[0025] In the formula, Ys represents the value after moving average, x i represents the i-th parameter sequence, k represents the set number of averaging times, and n represents the current data point number.

[0026] Preferably, the error analysis and correction submodule combines the data obtained by the environment and equipment status acquisition submodule to analyze the error value E in the detection data caused by the detector and external factors, and establishes an error model to balance the data while correcting the original data A. j Correction is performed to obtain the corrected data B j , and its error correction formula is:

[0027] B j =A j -E

[0028] In the formula, B j represents the corrected data, and E represents the error value.

[0029] Preferably, the abnormality judgment submodule judges the calculated Td value based on the set Td center value, ± tolerance and "judgment length". When Td exceeds the tolerance continuously within the "judgment length", it is judged as Td abnormality and the corresponding product is treated as an abnormal product.

[0030] Preferably, the conductor diameter parameter setting submodule is used to input the conductor center value, which is not only the benchmark for the management of the conductor diameter online detection deviation value, but also an important parameter for Td calculation. At the same time, the ± tolerance value is input to detect abnormal conductor diameter.

[0031] Preferably, the parameter setting submodule automatically calculates the Td center value, and performs online control based on this value, setting a ± tolerance to define the qualified range of Td online detection. When it exceeds this range, it is considered defective.

[0032] Preferably, the judgment length setting submodule sets a "judgment length" parameter to specify the detection range within which Td exceeds the tolerance continuously before it is judged as abnormal.

[0033] Preferably, the feedback control module further automatically adjusts an algorithm based on historical adjustment data and production feedback.

[0034] Compared with the prior art, the present invention provides an online control method and system for delay test equipment, which has the following beneficial effects:

[0035] 1. The present invention achieves the beneficial effect of improving the stability of the production process and product quality by real-time monitoring and analysis of key parameters in the production process, such as conductor outer diameter, insulation outer diameter and electrostatic capacitance, and performing moving average processing and error correction on these parameters. This method can promptly detect and correct deviations in the production process, avoid misjudgments caused by accidental interference, and thus ensure the consistency and reliability of product quality.

[0036] 2. The present invention achieves the beneficial effects of optimizing production efficiency and reducing resource waste by automatically adjusting production equipment parameters and closed-loop control. When an abnormality occurs, the system can automatically adjust the production equipment parameters, record the adjustment process, and continuously monitor subsequent production data until production returns to normal. This automated feedback control mechanism will reduce the need for manual intervention and improve production efficiency. At the same time, it can also reduce resource waste caused by unreasonable parameter settings or changes in the production process.

[0037] 3. The present invention achieves the beneficial effect of enhancing the adaptability and flexibility of the system by setting an appropriate average number of times and establishing an error model. The system can set parameters according to different production conditions and requirements to adapt to different production environments. In addition, by establishing an error model to correct the original data, the accuracy of the data is ensured, so that the system can flexibly respond to various production changes and improve the adaptability of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 Flow chart of the method of the present invention;

[0039] Figure 2 This is a working diagram of the system of the present invention. DETAILED DESCRIPTION

[0040] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. 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 making creative efforts are within the scope of protection of the present invention.

[0041] See also Figure 1-Figure 2 , an online control method for a delay test device, comprising the following steps:

[0042] Step 1: Establish the system: Build the system and set up the data acquisition module, data analysis module, parameter setting module, real-time monitoring module and feedback control module within the system;

[0043] Step 2, data collection phase: The data collection module collects conductor outer diameter, insulation outer diameter and electrostatic capacitance data, as well as the fluctuation data of factors affecting Td in the longitudinal direction, and monitors and collects equipment operating status and environmental data in real time;

[0044] Step 2, Data Analysis Phase: The data analysis module receives the collected basic parameter data, calculates the Td value of each point using the delay calculation formula, and performs moving average processing on the factor data. It then combines the environmental and equipment status data to analyze the error and correct the original data. Finally, based on the set parameters and the corrected data, it determines whether Td is abnormal.

[0045] Step 3, parameter setting stage: The operator inputs the conductor diameter center value, ± tolerance, and sets Td related parameters and "discrimination length" in the parameter setting module according to production requirements. The system sets the parameters based on real-time monitoring and analysis results.

[0046] Step 4, adjustment stage: When it is found that the parameter setting is unreasonable or the production process changes, the system automatically prompts the operator to adjust the parameters;

[0047] Step 5: Real-time monitoring stage: The real-time monitoring module displays production data and abnormal information in real time, and operators can view it at any time;

[0048] Step 6: Feedback control stage: When Td anomalies occur, the feedback control module automatically adjusts the production equipment parameters, records the adjustment process, and continuously monitors subsequent production data until production returns to normal.

[0049] An online control system for a time delay test device, comprising a data acquisition module, a data analysis module, a parameter setting module, a real-time monitoring module and a feedback control module;

[0050] The data acquisition module includes a basic parameter acquisition submodule, a fluctuation data acquisition submodule, and an environment and equipment status acquisition submodule. The basic parameter acquisition submodule continuously collects conductor outer diameter, insulation outer diameter, and electrostatic capacitance data according to the device's inherent sampling cycle (128 moving averages for conductor diameter and insulation diameter, and 0.2s / per cycle for electrostatic capacitance). The fluctuation data acquisition submodule synchronously samples the longitudinal fluctuation data of factors affecting Td. The environment and equipment status acquisition submodule monitors and collects equipment operating status and environmental data in real time.

[0051] The advantages are: by real-time monitoring and analysis of key parameters in the production process, such as conductor outer diameter, insulation outer diameter and electrostatic capacitance, and performing moving average processing and error correction on these parameters, the beneficial effect of improving the stability of the production process and product quality is achieved. This method can promptly detect and correct deviations in the production process, avoid misjudgments caused by accidental interference, and thus ensure the consistency and reliability of product quality.

[0052] The data analysis module includes a delay calculation submodule, an error analysis and correction submodule, and an anomaly determination submodule. The delay calculation submodule calculates the delay value Td and the moving average value Ys of each point based on the collected basic parameter data. The error analysis and correction submodule calculates the corrected data B j ,The abnormal judgment submodule determines whether Td is abnormal based on the set parameters and the corrected data;

[0053] The parameter setting module includes the conductor diameter parameter setting submodule, the Td parameter setting submodule, and the discrimination length setting submodule. It allows the operator to input the conductor diameter center value, ± tolerance, and set Td related parameters and the "discrimination length" according to production requirements. The system sets parameters based on real-time monitoring and analysis results to adapt to different production conditions and requirements.

[0054] The real-time monitoring module displays production data and abnormal information in real time, allowing operators to check the production status at any time, including the delay value Td, equipment operating status and environmental data, ensuring the transparency and controllability of the production process;

[0055] When the feedback control module detects an abnormal Td, it automatically adjusts the production equipment parameters, records the adjustment process, and continuously monitors subsequent production data until production returns to normal, thereby achieving closed-loop control and improving production efficiency and product quality.

[0056] The advantages are: by automatically adjusting production equipment parameters and closed-loop control, the beneficial effects of optimizing production efficiency and reducing resource waste are achieved. When an abnormality occurs, the system can automatically adjust the production equipment parameters, record the adjustment process, and continuously monitor subsequent production data until production returns to normal. This automated feedback control mechanism will reduce the need for manual intervention and improve production efficiency. At the same time, it can also reduce resource waste caused by unreasonable parameter settings or changes in the production process.

[0057] To monitor Td fluctuations online, data is also sampled for longitudinal fluctuations of factors influencing Td. Therefore, the collected data may contain test errors caused by the detector and external factors. If these errors are used, excessive data collection and overly stringent requirements may result in biased final cable evaluation (for example, a cable that is judged NG by online Td value may actually pass electrical test). Therefore, a moving average is applied to the data measured by each factor before output to achieve a certain degree of balance. However, if the data is over-averaged, there is a risk that some of the data that was originally NG will be omitted. Therefore, it is necessary to set an appropriate number of averaging cycles. The average number of cycles for the data in the table below is the most appropriate value verified to date and cannot be changed.

[0058] Table 1

[0059] Data Project Conductor diameter Control outer diameter electrostatic capacitance Average number of times 99 30 30

[0060] The inherent sampling period of the equipment is shown in Table 2 below:

[0061] Table 2

[0062]

[0063] The delay calculation submodule uses the delay calculation formula to calculate the delay value Td at each point based on the collected conductor outer diameter, insulation outer diameter and electrostatic capacitance data. The calculation formula is:

[0064]

[0065] In the formula, Td represents the delay value at each point, ε represents the dielectric constant, C represents the electrostatic capacitance, d1 represents the insulation outer diameter, and d2 represents the conductor outer diameter.

[0066] The advantage is that the delay value Td of each point can be obtained by calculating the dielectric constant ε, which can accurately reflect the influence of the dielectric properties of the material on the delay value, thereby providing accurate delay measurement for the production process.

[0067] The delay calculation submodule performs moving average processing based on the data detected by each factor according to the set number of averages (99 times for conductor diameter, 30 times for control outer diameter, 30 times for electrostatic capacitance, and 40 times for Td). For a parameter sequence x1, x2, x3, ... x4, the moving average value Ys is calculated as follows:

[0068]

[0069] In the formula, Ys represents the value after moving average, xi represents the i-th parameter sequence, k represents the set number of average times (such as the average number of conductor diameters is 99), and n represents the sequence number of the current data point. This formula is used to smooth the collected data and reduce the impact of errors.

[0070] The advantages are: by calculating the moving average value Ys, this value can smooth data fluctuations, reduce the impact of random errors, and improve the accuracy of delay calculation. By smoothing the collected data, misjudgment caused by excessive data fluctuations can be avoided.

[0071] The error analysis and correction submodule combines the data obtained by the environment and equipment status acquisition submodule to analyze the error value E in the detection data caused by the detector and external factors. By establishing an error model, while balancing the data, the original data A j Correction is performed to avoid the problem of excessive data collection, overly strict requirements and deviation in the final wire evaluation due to errors. In order to reduce the impact of errors on the results, according to the collected original data A j Perform error correction to obtain the corrected data B j , and its error correction formula is:

[0072] B j =A j -E

[0073] In the formula, B j Represents the corrected data, and E represents the error value, which is calculated through the established error model combined with the environment and equipment status data to ensure the accuracy of the data.

[0074] The advantage is that through the error correction formula, the error value can be calculated based on the established error model and combined with the environment and equipment status data, and the original data can be corrected. The advantage of this method is that it can ensure the accuracy of the data and avoid the problems of excessive data collection, overly strict requirements and deviations in the final wire evaluation due to errors.

[0075] The abnormality judgment submodule judges the calculated Td value based on the set Td center value, ± tolerance and "judgment length". When Td exceeds the tolerance continuously within the "judgment length" range, it is judged as Td abnormal and the corresponding product is treated as an abnormal product, effectively avoiding misjudgment due to accidental interference.

[0076] The conductor diameter parameter setting submodule is used to input the conductor center value, which is not only the benchmark for the management of the conductor diameter online detection deviation value, but also an important parameter for Td calculation. At the same time, the ± tolerance value is input to detect abnormal conductor diameter.

[0077] The parameter setting submodule automatically calculates the Td center value and performs online control based on this value, setting the ± tolerance to define the qualified range of Td online detection. When it exceeds this range, it is considered defective.

[0078] The judgment length setting submodule sets the "judgment length" parameter to clearly define the detection range within which Td exceeds the tolerance continuously before it is judged as abnormal, thereby improving the accuracy of abnormality judgment.

[0079] The feedback control module further automatically adjusts the algorithm based on historical adjustment data and production feedback. The optimized adjustment strategy can reduce adjustment time and improve adjustment accuracy to adapt to the rapidly changing production environment and improve the system's response speed.

[0080] The advantages are: by setting the appropriate average number of times and establishing an error model, the beneficial effect of enhancing the adaptability and flexibility of the system is achieved. The system can set parameters according to different production conditions and requirements to adapt to different production environments. In addition, by establishing an error model to correct the original data, the accuracy of the data is ensured, so that the system can flexibly respond to various production changes and improve the adaptability of the system.

[0081] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. An online control method for a delay test device, characterized in that: The following steps are involved: Step 1: Establish the system: Build the system and set up the data acquisition module, data analysis module, parameter setting module, real-time monitoring module and feedback control module within the system; Step 2, data collection phase: The data collection module collects conductor outer diameter, insulation outer diameter and electrostatic capacitance data, as well as the fluctuation data of factors affecting Td in the longitudinal direction, and monitors and collects equipment operating status and environmental data in real time; Step 2, Data Analysis Phase: The data analysis module receives the collected basic parameter data, calculates the Td value of each point using the delay calculation formula, and performs moving average processing on the factor data. It then combines the environmental and equipment status data to analyze the error and correct the original data. Finally, based on the set parameters and the corrected data, it determines whether Td is abnormal. Step 3, parameter setting stage: The operator enters the conductor diameter center value, ± tolerance, and sets Td related parameters and "discrimination length" in the parameter setting module according to production requirements. The system sets parameters based on real-time monitoring and analysis results. Step 4, adjustment stage: When it is found that the parameter setting is unreasonable or the production process changes, the system automatically prompts the operator to adjust the parameters; Step 5: Real-time monitoring stage: The real-time monitoring module displays production data and abnormal information in real time, and operators can view it at any time; Step 6: Feedback control stage: When Td anomalies occur, the feedback control module automatically adjusts the production equipment parameters, records the adjustment process, and continuously monitors subsequent production data until production returns to normal.

2. An online control system for a delay test device, characterized in that: It includes data acquisition module, data analysis module, parameter setting module, real-time monitoring module and feedback control module; The data acquisition module includes a basic parameter acquisition submodule, a fluctuation data acquisition submodule, and an environment and equipment status acquisition submodule. The basic parameter acquisition submodule continuously collects conductor outer diameter, insulation outer diameter, and electrostatic capacitance data according to the inherent sampling period of the equipment. The fluctuation data acquisition submodule synchronously samples the fluctuation data of the factors affecting Td in the longitudinal direction. The environment and equipment status acquisition submodule monitors and collects equipment operating status and environmental data in real time; The data analysis module includes a delay calculation submodule, an error analysis and correction submodule, and an abnormality determination submodule. The delay calculation submodule calculates the delay value Td and the moving average value Ys of each point based on the collected basic parameter data. The error analysis and correction submodule calculates the corrected data Bj. The abnormality determination submodule determines whether Td is abnormal based on the set parameters and the corrected data. The parameter setting module includes a conductor diameter parameter setting submodule, a Td parameter setting submodule, and a discrimination length setting submodule. It allows operators to input the conductor diameter center value, ± tolerance, and set Td-related parameters and the "discrimination length" according to production requirements. The system sets parameters based on real-time monitoring and analysis results. The real-time monitoring module displays production data and abnormal information in real time, allowing operators to check the production status at any time, including the delay value Td, equipment operating status and environmental data; When the feedback control module finds that Td is abnormal, it automatically adjusts the production equipment parameters, records the adjustment process, and continuously monitors subsequent production data until production returns to normal.

3. The online control system of a delay test device according to claim 2, characterized in that: The delay calculation submodule calculates the delay value Td at each point using the delay calculation formula based on the collected conductor outer diameter, insulation outer diameter and electrostatic capacitance data. The calculation formula is: In the formula, Td represents the delay value at each point, ε represents the dielectric constant, C represents the electrostatic capacitance, d1 represents the insulation outer diameter, and d2 represents the conductor outer diameter.

4. The online control system of a delay test device according to claim 2, characterized in that: The delay calculation submodule performs moving average processing based on the data detected by each factor according to the set average number of times. For a certain parameter sequence x1, x2, x3, ... x4, the moving average value Ys is calculated as follows: In the formula, Ys represents the value after moving average, x i represents the i-th parameter sequence, k represents the set number of averages, and n represents the current data point number.

5. The online control system of a delay test device according to claim 2, characterized in that: The error analysis and correction submodule combines the data obtained by the environment and equipment status acquisition submodule to analyze the error value E in the detection data caused by the detector and external factors. By establishing an error model, while balancing the data, the original data A j Correction is performed to obtain the corrected data B j , and its error correction formula is: B j =A j -E In the formula, B j represents the corrected data, and E represents the error value.

6. The online control system of a delay test device according to claim 2, characterized in that: The abnormality determination submodule determines the calculated Td value based on the set Td center value, ± tolerance, and "judgment length". If Td exceeds the tolerance continuously within the "judgment length", it is determined to be a Td abnormality and the corresponding product will be treated as an abnormal product.

7. The online control system of a delay test device according to claim 2, characterized in that: The conductor diameter parameter setting submodule is used to input the conductor center value, which is not only the benchmark for the management of the conductor diameter online detection deviation value, but also an important parameter for Td calculation. At the same time, the ± tolerance value is input to detect abnormal conductor diameter.

8. The online control system of a delay test device according to claim 2, characterized in that: The parameter setting submodule automatically calculates the Td center value and performs online control based on this value, setting a ± tolerance to define the qualified range of Td online detection. When it exceeds this range, it is considered defective.

9. The online control system of a delay test device according to claim 2, characterized in that: The judgment length setting submodule sets the "judgment length" parameter to specify the detection range within which Td exceeds the tolerance continuously before it is judged as abnormal.

10. The online control system of a delay test device according to claim 2, characterized in that: The feedback control module further automatically adjusts the algorithm based on historical adjustment data and production feedback.

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