A winding control system and method for an alloy steel wire production line

Abstract

The application discloses a winding control system and method of alloy steel wire production line, and relates to the technical field of alloy steel wire production, which comprises the following steps: carrying out winding test, acquiring tension test points and winding length for speed tension correlation test, and acquiring the speed tension test curve of each tension test point; carrying out winding simulation and acquiring length-speed correlation curve; and based on the length-speed correlation curve, the rotational speed output by the driving motor to the winding disc is adjusted in real time; the application is used for solving the problem that in the existing winding control method of alloy steel wire production line, the winding speed during winding is effectively controlled based on the length of the winding steel wire in terms of winding speed, which can accurately control the tension during winding, but can only ensure smooth entry and exit of the steel wire, and still causes the problem of winding shape defects after winding.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of alloy steel wire production, in particular to a winding control system and method of an alloy steel wire production line. BACKGROUND

[0002] The alloy steel wire production line is an industrial production line for producing steel wires through a drawing process with alloy steel wire rods as raw materials, and mainly produces products such as galvanized steel wires and electroplated brass steel wires; the winding control of the alloy steel wire production line mainly involves tension control and roll diameter management, for example, closed-loop vector control technology is adopted, the roll diameter change is fed back in real time through an encoder, the motor output torque is dynamically adjusted, or the roll diameter is calculated in real time through the encoder, recursive operation and hollow roll diameter activation technology are adopted to ensure the accuracy of the roll diameter calculation.

[0003] The existing winding control method for the alloy steel wire production line usually aims to reduce the friction between the steel wire and the rubber wheel during the winding process, thereby improving the accuracy of tension control during the winding control process, for example, positioning components and winding components are added to position the winding discs of different sizes and wind the steel wire; although this improved method can improve the stability of tension control, it cannot effectively control the winding speed during the winding process based on the length of the wound steel wire, resulting in that although the tension during winding can be accurately controlled, the smoothness of the steel wire in and out can only be ensured, and the problem of roll shape defects after winding still exists, affecting the actual steel wire output; for example, in the patent application with the publication number CN119797057A, a winding device for alloy steel wire processing is disclosed, which reduces the friction between the steel wire and the rubber wheel during the guiding and winding process to zero, thereby improving the accuracy of tension control, and controls the in and out angle of the steel wire and the rubber wheel during the guiding process to ensure the smoothness of the in and out of the steel wire and the stability of the tension control; other improvements for the winding control of the alloy steel wire production line are usually improvements in the optimization of the winding unit, and cannot effectively control the winding speed during the winding process based on the length of the wound steel wire, resulting in that although the tension during winding can be accurately controlled, the smoothness of the steel wire in and out can only be ensured, and the problem of roll shape defects after winding still exists; therefore, it is necessary to improve the existing winding control method of the alloy steel wire production line. SUMMARY

[0004] The application aims to at least solve one of the technical problems in the prior art, and provides a winding control system and method of an alloy steel wire production line to solve the problem that in the existing winding control method of the alloy steel wire production line, the winding speed during the winding process cannot be effectively controlled based on the length of the wound steel wire, resulting in that although the tension during winding can be accurately controlled, the smoothness of the steel wire in and out can only be ensured, and the problem of roll shape defects after winding still exists.

[0005] To achieve the above object, in a first aspect, the application provides a winding control system of an alloy wire production line, comprising a rotating speed and tension analysis module, a winding simulation module and a winding real-time control module;

[0006] The rotating speed and tension analysis module comprises a winding test unit and a speed-tension correlation analysis unit; the winding test unit is configured to perform winding test based on the alloy wire production line, and obtain a plurality of tension test points and winding length of each tension test point based on the test result;

[0007] The speed-tension correlation analysis unit is configured to perform speed-tension correlation test on each tension test point respectively, and obtain a speed-tension test curve of each tension test point based on the result of the speed-tension correlation test;

[0008] The winding simulation module is configured to perform winding simulation in the alloy wire production line based on the winding length and the speed-tension test curve of each tension test point, and obtain a length-speed correlation curve based on the result of the winding simulation;

[0009] The winding real-time control module is configured to perform real-time adjustment on the rotating speed of the driving motor to the winding disc in the alloy wire production line based on the length-speed correlation curve.

[0010] Further, the winding test comprises:

[0011] Obtaining a plurality of default gears corresponding to the rotating speed of the driving motor to the winding disc in the alloy wire production line, and recording them as preset gears YD1 to YD c ; recording the length of the wire that can be wound into the winding disc as L;

[0012] For any one preset gear YD v , when there is no wire in the winding disc, winding the wire into the winding disc at the preset gear YD v , and obtaining the thickness of the wire in the winding disc in real time, until the length of the wire wound into the winding disc is L, recording the data corresponding to the time of winding the wire and the thickness of the wire as wire winding data, wherein v is a positive integer less than or equal to c and greater than or equal to 1.

[0013] Further, the winding test further comprises:

[0014] Establish a plane rectangular coordinate system, recorded as the involvement analysis coordinate system, where the unit of the X-axis of the involvement analysis coordinate system is min and the unit of the Y-axis is m; use the time of wire involvement in the wire involvement data as the horizontal coordinate and the thickness of the wire as the vertical coordinate to draw the corresponding curve in the involvement analysis coordinate system, and record it as the gear involvement curve; except for the leftmost and rightmost points in the gear involvement curve, the point with the smallest slope is recorded as the tension influence point, and the point with the largest slope is recorded as the preferred speed point, and the vertical coordinate of the tension influence point is marked as Y1, and the vertical coordinate of the preferred speed point is marked as Y2;

[0015] Obtain a reel without steel wire, wind a steel wire with a thickness of Y1 into the reel, and record the position of any steel wire in the reel that is farthest from the center of the reel after winding as the tension test point, and record the length of the steel wire in the reel at this time as the reeling length of the tension test point.

[0016] Furthermore, the winding test also includes:

[0017] Get a reel without steel wire, roll a steel wire with a thickness of Y2 into the reel, and record the length of the steel wire in the reel at this time as the preset gear YD v The preferred winding length;

[0018] Obtain the tension test points of all preset gears, the winding length of the tension test points, and the preferred winding length.

[0019] Furthermore, the speed-tension correlation test includes:

[0020] For any tension test point: obtain the take-up reel without steel wire, and set the reel from the preset gear YD1 to the preset gear YD c The steel wire is wound into a reel where no steel wire is present, until the length of the wound steel wire reaches L;

[0021] For any one time with preset gear YD v When the steel wire in the reel reaches the tension test point, a tension sensor is placed at the tension test point and the detection data of the tension sensor is obtained in real time; when the steel wire in the reel finishes being wound in, the difference between the maximum and minimum tension values ​​in the detection data of the tension sensor is recorded as the winding tension difference.

[0022] Furthermore, the speed-tension correlation test also includes:

[0023] A difference in winding tension corresponding to the tension test point is obtained when the steel wire is wound into the winding disc without the steel wire in all preset gears; a plane rectangular coordinate system is established, which is denoted as a speed-tension analysis coordinate system, wherein the unit of the X axis of the speed-tension analysis coordinate system is r / min, and the unit of the Y axis is N; based on the speed corresponding to each preset gear and the winding pressure difference corresponding to the tension test point under each preset gear, a dot is marked in the speed-tension analysis coordinate system, and a curve obtained by fitting all the dots is denoted as a speed-tension test curve.

[0024] The speed-tension test curve corresponding to each tension test point is obtained.

[0025] Further, the winding simulation module comprises a winding simulation unit, and the winding simulation unit is configured with a winding simulation strategy, and the winding simulation strategy comprises:

[0026] The winding simulation comprises: for any one tension test point, a point with the lowest ordinate in the speed-tension test curve corresponding to the tension test point is denoted as a tension fluctuation valley point, and the abscissa of the tension fluctuation valley point is denoted as a stable winding speed;

[0027] A tension sensor is placed at a random tension test point in the winding disc without the steel wire after the steel wire with a length of L1 is wound into the winding disc at the stable winding speed, and the detection result of the tension sensor at this time is denoted as N1, wherein L1 is the winding length corresponding to the tension test point; the steel wire is continuously wound into the winding disc, and the detection result of the tension sensor is obtained in real time until the length of the steel wire in the winding disc is L, and the winding of the steel wire is stopped;

[0028] After the winding of the steel wire is completed, the time corresponding to the detection result with the smallest difference from N1 in the detection data of the tension sensor is denoted as a tension selectable time, and the length of the steel wire in the winding disc at the tension selectable time in the winding process of the steel wire is denoted as a tension preferred length corresponding to the stable winding speed, wherein the tension selectable time can be multiple.

[0029] Further, the winding simulation strategy further comprises:

[0030] All the tension test points are analyzed, and the tension preferred length corresponding to the stable winding speed of each tension analysis point is obtained based on the analysis result;

[0031] A plane rectangular coordinate system is established, which is denoted as a length-speed analysis coordinate system, wherein the unit of the X axis of the length-speed analysis coordinate system is m, and the unit of the Y axis is r / min; for the stable winding speed corresponding to any one tension analysis point, a dot is marked in the length-speed analysis coordinate with the stable winding speed as the ordinate and the tension preferred length corresponding to the stable winding speed as the abscissa, and a dot is marked in the length-speed analysis coordinate with each preset gear and the preferred winding length of the preset gear as the ordinate and the abscissa.

[0032] The curve obtained by fitting all the points is denoted as a length-speed correlation curve.

[0033] Further, the winding real-time control module comprises a winding real-time control unit, and the winding real-time control unit is configured with a winding real-time control strategy, and the winding real-time control strategy comprises:

[0034] When the steel wire is wound into the winding disc, the length of the steel wire in the winding disc after winding is obtained in real time and denoted as L2; the ordinate corresponding to the point with the abscissa L2 in the length-speed correlation curve is denoted as the adjusted rotating speed;

[0035] The driving motor is controlled, and the rotating speed output to the winding disc is adjusted to the adjusted rotating speed.

[0036] In the second aspect, the application further provides a winding control method of an alloy steel wire production line, comprising the following steps:

[0037] Winding tests are carried out based on the alloy steel wire production line, and a plurality of tension test points and winding lengths of each tension test point are obtained based on test results; speed-tension correlation tests are respectively carried out on each tension test point, and speed-tension test curves of each tension test point are obtained based on results of the speed-tension correlation tests;

[0038] Winding simulation is carried out based on the winding lengths of each tension test point and the speed-tension test curves in the alloy steel wire production line, and a length-speed correlation curve is obtained based on results of the winding simulation;

[0039] When winding is carried out in the alloy steel wire production line, the rotating speed output to the winding disc by the driving motor is adjusted in real time based on the length-speed correlation curve.

[0040] The application has the following beneficial effects: firstly, winding tests are carried out based on the alloy steel wire production line, and a plurality of tension test points and winding lengths of each tension test point are obtained based on test results; speed-tension correlation tests are respectively carried out on each tension test point, and speed-tension test curves of each tension test point are obtained based on results of the speed-tension correlation tests, which has the advantage that, by obtaining a plurality of tension test points, the positions at which the winding speed is slower when winding the steel wire under different gear positions allowed by the winding disc, i.e., the positions more affected by tension, can be obtained, which is beneficial to obtaining the speed-tension test curves based on the tension test points, so that the obtained speed-tension test curves can better conform to the relationship between the winding speed and the tension at the positions more affected by tension during actual winding, thereby providing data support for subsequent winding simulation, so as to effectively control the winding speed in the winding process based on the length of the wound steel wire, so that the stress of the wound steel wire in the overall winding process is more stable, and the problem of winding defects is prevented;

[0041] The application is also based on the winding length of each tension test point and the speed-tension test curve to perform winding simulation in the alloy steel wire production line, and based on the result of the winding simulation, the length-speed correlation curve is obtained; finally, based on the length-speed correlation curve, the rotational speed of the driving motor output to the winding disc is adjusted in real time when winding in the alloy steel wire production line, which has the advantage that the length-speed correlation curve can be obtained by performing winding simulation, and the relationship curve between the length of the wound steel wire and the winding speed under the condition that the wound steel wire is in a relatively stable tension state can be obtained, which is beneficial to effectively control the winding speed in the winding process based on the length of the wound steel wire. BRIEF DESCRIPTION OF DRAWINGS

[0042] Figure 1 A step flowchart of the method of the application;

[0043] Figure 2 A principle block diagram of the system of the application;

[0044] Figure 3 A schematic diagram of the thickness of the steel wire of the application;

[0045] Figure 4 A schematic diagram of the acquisition of the tension fluctuation valley point and the stable winding rotational speed of the application. DETAILED DESCRIPTION

[0046] The technical solutions in the embodiments of the application will be clearly and completely described below with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, rather than all the embodiments. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the application.

[0047] Embodiment 1, please refer to Figure 1 The application provides a winding control method of an alloy steel wire production line, which comprises the following steps:

[0048] Step S1, based on the winding test of the alloy steel wire production line, and based on the test result, a plurality of tension test points and the winding length of each tension test point are obtained; the speed-tension correlation test is performed on each tension test point respectively, and the speed-tension test curve of each tension test point is obtained based on the result of the speed-tension correlation test;

[0049] Step S101, the winding test comprises: step S1011, obtaining a plurality of default gears corresponding to the rotational speed of the driving motor output to the winding disc in the alloy steel wire production line, and respectively denoted as preset gears YD1 to preset gears YD c ; the length of the steel wire that can be wound in the winding disc is denoted as L;

[0050] In the specific implementation process, the preset gear can be customized according to the actual allowable rotating speed of the winding disc, to ensure that the preset gear is the gear that can be executed by the winding disc in actual application, so that the overall analysis of the embodiment is more in line with the actual situation.

[0051] In step S1012, for any one preset gear YD v When there is no steel wire in the winding disc, the preset gear YD v The steel wire is wound into the winding disc, and the thickness of the steel wire in the winding disc is obtained in real time. When the wound steel wire has a length of L, the data corresponding to the winding time of the steel wire and the thickness of the steel wire is recorded as the steel wire winding data, wherein v is a positive integer less than or equal to c and greater than or equal to 1.

[0052] In the specific implementation process, the thickness of the steel wire in the embodiment is the cross-sectional direction of the winding disc, and the width of the steel wire wound into the winding disc, as shown in Figure 3 , wherein ZZ1 is the cross-section of the winding disc, ZZ2 is the cross-section of the winding disc after the steel wire is wound, and the thickness of the steel wire is the length of d1.

[0053] In step S1013, a plane rectangular coordinate system is established and is recorded as a winding analysis coordinate system, wherein the unit of the X-axis of the winding analysis coordinate system is min, and the unit of the Y-axis is m. The time of winding the steel wire in the steel wire winding data is taken as the abscissa, and the thickness of the steel wire is taken as the ordinate. A corresponding curve in the winding analysis coordinate system is drawn and is recorded as a gear winding curve. The point with the smallest slope in the gear winding curve, except the leftmost point and the rightmost point, is recorded as a tension influencing point, and the point with the largest slope is recorded as an optimal rotating speed point. The ordinate of the tension influencing point is recorded as Y1, and the ordinate of the optimal rotating speed point is recorded as Y2.

[0054] In the specific implementation process, because the actual friction force and the tension are considered, even under the preset gear, there is still a state of unstable speed of the wound steel wire. In the winding analysis coordinate system, the point with the largest slope is the point with the fastest winding speed of the steel wire, which indicates that under this preset gear, when the length of the wound steel wire is at the ordinate of the optimal rotating speed point, the winding speed of the steel wire is the fastest. Therefore, the ordinate of the optimal rotating speed point can be taken as the optimal winding length of this gear, to provide data support for the construction of the length-speed correlation curve. The point with the smallest slope is the point with the slowest winding speed of the steel wire, which indicates that under this preset gear, the length of the wound steel wire is affected by the friction force or the tension, resulting in slow winding speed. Therefore, it can be used as a target for subsequent analysis, to ensure that the winding of steel wires of different lengths can be executed at the most appropriate rotating speed, to prevent the wound steel wire from being greatly affected by the tension, resulting in unstable force of the steel wire and problems of winding defects.

[0055] Step S1014, obtaining a winding disc without steel wires, winding the steel wires with a thickness of Y1 in the winding disc, and recording the position of the steel wire farthest from the center of the winding disc in the winding disc after winding as a tension test point, and recording the length of the steel wire in the winding disc at this time as the winding length of the tension test point;

[0056] Step S1015, obtaining a winding disc without steel wires, winding the steel wires with a thickness of Y2 in the winding disc, and recording the length of the steel wire in the winding disc at this time as the preferred winding length of the preset gear YD v ;

[0057] Step S1016, obtaining the tension test point, the winding length of the tension test point, and the preferred winding length of all preset gears.

[0058] Step S102, speed-tension correlation test, including: step S1021, for any tension test point: obtaining a winding disc without steel wires, and winding the steel wires in the winding disc without steel wires with preset gears YD1 to YD c , until the length of the wound steel wire is L;

[0059] Step S1022, for any winding with preset gear YD v , when the steel wire in the winding disc reaches the tension test point, placing a tension sensor at the tension test point, and obtaining the detection data of the tension sensor in real time; when the winding of the steel wire in the winding disc is completed, recording the difference between the maximum value and the minimum value of the tension in the detection data of the tension sensor as the winding tension difference;

[0060] In the specific implementation process, by obtaining the winding tension difference, the tension change of the tension test point when winding the steel wire with the preset gear can be obtained. The greater the winding tension difference, the greater the amplitude of the tension change of the steel wire at the tension test point when winding the steel wire with the preset gear, and the more likely the problem of damage or winding defect of the steel wire;

[0061] Step S1023, obtaining the winding tension difference corresponding to the tension test point when winding the steel wire in the winding disc without steel wire with all preset gears; establishing a plane rectangular coordinate system, denoted as a speed-tension analysis coordinate system, wherein the unit of the X-axis of the speed-tension analysis coordinate system is r / min, and the unit of the Y-axis is N; based on the corresponding speed of each preset gear and the corresponding winding tension difference of the tension test point under each preset gear, marking points in the speed-tension analysis coordinate system, and recording the curve obtained by fitting all the points as a speed-tension test curve;

[0062] Step S1024, obtaining the speed-tension test curve corresponding to all tension test points.

[0063] Step S2, performing a winding simulation in the alloy steel wire production line based on the winding length of each tension test point and the speed tension test curve, and obtaining a length-speed correlation curve based on the results of the winding simulation;

[0064] Step S2 includes:

[0065] Step S201: performing a winding simulation in the alloy steel wire production line based on the winding length and speed-tension test curve of each tension test point. The winding simulation includes: for any tension test point, marking the point with the lowest vertical coordinate in the speed-tension test curve corresponding to the tension test point as the tension fluctuation valley point, and marking the horizontal coordinate of the tension fluctuation valley point as the stable winding speed;

[0066] In the specific implementation process, through the above analysis, it can be obtained that in the speed test curve, the smaller the vertical coordinate of a point is, the smaller the speed corresponding to the horizontal coordinate of the point is applied to the actual steel wire reeling, and the smaller the change amplitude of the steel wire tension at the tension test point is, the more it can ensure that the steel wire at the tension test point can be in a stable stress state when the entire steel wire is reeled in. Therefore, the point with the lowest vertical coordinate should be marked, that is, the tension fluctuation valley point is obtained; for example, in a data analysis, the speed test curve obtained is as follows Figure 4 As shown in the figure, through analysis, it can be obtained that the tension fluctuation valley point is ZG, and the stable winding speed is XX1. This means that for the tension test point, when the speed of winding the steel wire is XX1, the steel wire at the tension test point is subjected to the most stable force during the entire steel wire winding process.

[0067] Step S202: Obtain a reel without steel wire, wind a steel wire of length L1 into the reel at a stable reeling speed, randomly obtain a tension test point in the reel, and place a tension sensor. The detection result of the tension sensor at this time is recorded as N1, where L1 is the reeling length corresponding to the tension test point. Continue to reel the steel wire into the reel and obtain the detection result of the tension sensor in real time until the length of the steel wire in the reel reaches L, at which time the reeling stops.

[0068] Step S203: After the wire is wound in, the time corresponding to the detection result of the tension sensor with the smallest difference from N1 is recorded as the tension selectable time, and the length of the wire in the winding drum during the tension selectable time during the wire winding process is recorded as the tension preferred length for a stable winding speed, wherein there can be multiple tension selectable times;

[0069] In the specific implementation process, the minimum value of the difference between the detection data of the tension sensor and N1 can be 0, and by obtaining the tension optional time, the length of the steel wire wound into the tension test point under the condition of maintaining the stable winding speed can be obtained, so as to facilitate subsequent acquisition of the length-speed correlation curve, that is, to ensure that the wound steel wire is in a relatively stable tension state, and the relationship curve between the length of the wound steel wire and the winding speed is beneficial to effectively control the winding speed in the winding process based on the length of the wound steel wire.

[0070] Step S204, analyze all tension test points, and obtain the tension optimal length of the stable winding speed corresponding to each tension analysis point based on the analysis result;

[0071] Step S205, establish a plane rectangular coordinate system, denoted as a length-speed analysis coordinate system, wherein the unit of the X-axis of the length-speed analysis coordinate system is m, and the unit of the Y-axis is r / min; for the stable winding speed corresponding to any tension analysis point, the stable winding speed is taken as the vertical coordinate, and the tension optimal length of the stable winding speed is taken as the horizontal coordinate to mark points in the length-speed analysis coordinate, and each preset gear and the optimal winding length of the preset gear are taken as the vertical coordinate and the horizontal coordinate to mark points in the length-speed analysis coordinate;

[0072] Step S206, the curve obtained by fitting all the marked points is denoted as a length-speed correlation curve.

[0073] Step S3, when winding in the alloy steel wire production line, the rotational speed output by the driving motor to the winding disc is adjusted in real time based on the length-speed correlation curve;

[0074] Step S3 includes: step S301, when winding the steel wire into the winding disc, the length of the steel wire in the winding disc after winding is obtained in real time and denoted as L2; the vertical coordinate corresponding to the point with the horizontal coordinate L2 in the length-speed correlation curve is denoted as the adjustment speed;

[0075] In the specific implementation process, the adjustment speed can be adjusted in real time according to the change of the length of the steel wire in the actual winding disc, so as to ensure that the steel wire in the winding disc is in a stable stress state when the steel wire winding is performed;

[0076] Step S302, control the driving motor to adjust the rotational speed output to the winding disc to the adjustment speed.

[0077] Embodiment 2, please refer to Figure 2 As shown in the figure, the application also provides a winding control system of an alloy steel wire production line, which comprises a rotational speed and tension analysis module, a winding simulation module, and a winding real-time control module;

[0078] The rotating speed-tension analysis module comprises a winding test unit and a rotating speed-tension correlation analysis unit; the winding test unit is configured to perform winding test based on the alloy wire production line, and obtain a plurality of tension test points and winding length of each tension test point based on the test result;

[0079] The winding test comprises: obtaining a plurality of default gears corresponding to the rotating speed of the driving motor output to the winding disc in the alloy wire production line, and denoted as preset gears YD1 to YD c ; the length of the steel wire that can be wound into the winding disc is denoted as L;

[0080] For any one preset gear YD v , when there is no steel wire in the winding disc, the winding disc is wound with the steel wire at the preset gear YD v , and the thickness of the steel wire in the winding disc is obtained in real time, until the length of the wound steel wire is L, the data corresponding to the time of winding the steel wire and the thickness of the steel wire is denoted as the steel wire winding data, wherein v is a positive integer less than or equal to c and greater than or equal to 1;

[0081] A plane rectangular coordinate system is established, denoted as a winding analysis coordinate system, wherein the unit of the X-axis of the winding analysis coordinate system is min, and the unit of the Y-axis is m; the time of winding the steel wire in the steel wire winding data is taken as the abscissa, and the thickness of the steel wire is taken as the ordinate to draw the corresponding curve in the winding analysis coordinate system, and denoted as a gear winding curve; the point with the smallest slope in the gear winding curve except the leftmost point and the rightmost point is denoted as a tension influencing point, the point with the largest slope is denoted as an optimal rotating speed point, the ordinate of the tension influencing point is denoted as Y1, and the ordinate of the optimal rotating speed point is denoted as Y2;

[0082] The winding disc without the steel wire is obtained, the steel wire with a thickness of Y1 is wound in the winding disc, and the position of the steel wire farthest from the center of the winding disc in the winding disc after winding is denoted as a tension test point, and the length of the steel wire in the winding disc at this time is denoted as the winding length of the tension test point;

[0083] The winding disc without the steel wire is obtained, the steel wire with a thickness of Y2 is wound in the winding disc, and the length of the steel wire in the winding disc at this time is denoted as the optimal winding length of the preset gear YD v ;

[0084] The tension test points, the winding length of the tension test point and the optimal winding length of all the preset gears are obtained.

[0085] The rotating speed-tension correlation analysis unit is configured to perform rotating speed-tension correlation test on each tension test point respectively, and obtain the rotating speed-tension test curve of each tension test point based on the result of the rotating speed-tension correlation test;

[0086] The rapid-tension correlation test comprises: for any one tension test point: obtaining a winding disc without steel wire, and winding the steel wire into the winding disc at each preset gear YD1 to YD c until the length of the wound steel wire is L;

[0087] For any one winding at each preset gear YD v , when the steel wire in the winding disc reaches the tension test point, a tension sensor is placed at the tension test point, and the detection data of the tension sensor is obtained in real time; when the winding of the steel wire in the winding disc is completed, the difference between the maximum value and the minimum value of the tension in the detection data of the tension sensor is recorded as the winding tension difference;

[0088] The winding tension difference corresponding to the tension test point when the steel wire is wound into the winding disc without steel wire at all preset gears is obtained; a plane rectangular coordinate system is established, which is denoted as a rapid-tension analysis coordinate system, wherein the unit of the X-axis of the rapid-tension analysis coordinate system is r / min, and the unit of the Y-axis is N; based on the corresponding rotating speed of each preset gear and the winding tension difference corresponding to the tension test point at each preset gear, a dot is marked in the rapid-tension analysis coordinate system, and a curve obtained by fitting all the dots is denoted as a rapid-tension test curve;

[0089] The rapid-tension test curve corresponding to all tension test points is obtained.

[0090] The winding simulation module is configured to perform winding simulation in the alloy steel wire production line based on the winding length of each tension test point and the rapid-tension test curve, and obtain a length-speed correlation curve based on the result of the winding simulation;

[0091] The winding simulation module comprises a winding simulation unit, and the winding simulation unit is configured with a winding simulation strategy, and the winding simulation strategy comprises:

[0092] The winding simulation in the alloy steel wire production line is performed based on the winding length of each tension test point and the rapid-tension test curve, and the winding simulation comprises: for any one tension test point, the point with the lowest ordinate in the rapid-tension test curve corresponding to the tension test point is denoted as a tension fluctuation valley point, and the abscissa of the tension fluctuation valley point is denoted as a stable winding rotating speed;

[0093] The winding disc without steel wire is obtained, and after the steel wire with a length of L1 is wound into the winding disc at the stable winding rotating speed, a tension test point in the winding disc is randomly obtained, and a tension sensor is placed, and the detection result of the tension sensor at this time is denoted as N1, wherein L1 is the winding length corresponding to the tension test point; the steel wire is continuously wound into the winding disc, and the detection result of the tension sensor is obtained in real time, until the length of the steel wire in the winding disc is L, and the winding of the steel wire is stopped;

[0094] After the steel wire is wound in, the time corresponding to the detection result with the smallest difference from N1 in the detection data of the tension sensor is recorded as the tension optional time, and the length of the steel wire in the winding drum during the tension optional time during the steel wire winding process is recorded as the tension preferred length for a stable winding speed, wherein there can be multiple tension optional times.

[0095] The winding simulation strategy also includes: analyzing all tension test points and obtaining the optimal tension length for the stable winding speed corresponding to each tension analysis point based on the analysis results;

[0096] Establish a plane rectangular coordinate system, recorded as the long-speed analysis coordinate system, where the unit of the X-axis of the long-speed analysis coordinate system is m, and the unit of the Y-axis is r / min; for the stable winding speed corresponding to any tension analysis point, use the stable winding speed as the vertical coordinate and the preferred tension length of the stable winding speed as the horizontal coordinate to mark the points in the long-speed analysis coordinate system, and use each preset gear and the preferred winding length of the preset gear as the vertical coordinate and the horizontal coordinate to mark the points in the long-speed analysis coordinate system;

[0097] The curve obtained by fitting all punctuation points is recorded as the long-speed correlation curve.

[0098] The real-time winding control module is used to adjust the speed of the winding reel output by the drive motor in real time based on the long-speed correlation curve when winding in the alloy steel wire production line;

[0099] The real-time winding control module includes a real-time winding control unit. The real-time winding control unit is configured with a real-time winding control strategy. The real-time winding control strategy includes:

[0100] When the steel wire is wound into the reel, the length of the steel wire in the reel after winding is obtained in real time and recorded as L2; ​​the vertical coordinate corresponding to the point with the horizontal coordinate L2 in the length-speed correlation curve is marked as the adjusted speed;

[0101] Control the drive motor to adjust the output speed of the winding reel to the adjusted speed.

[0102] Working principle: First, a winding test is performed based on the alloy steel wire production line, and multiple tension test points and the winding length of each tension test point are obtained based on the test results; a speed-tension correlation test is performed on each tension test point respectively, and the speed-tension test curve of each tension test point is obtained based on the results of the speed-tension correlation test; then, a winding simulation is performed in the alloy steel wire production line based on the winding length of each tension test point and the speed-tension test curve, and a long-speed correlation curve is obtained based on the results of the winding simulation; finally, when winding in the alloy steel wire production line, the speed of the winding reel output by the drive motor is adjusted in real time based on the long-speed correlation curve.

[0103] Through the description of the above embodiments, the embodiments of the present application can be provided as a method, a system or a computer program product. Based on such understanding, the above technical solutions can be embodied in the form of a software product, which can be stored in a computer readable storage medium, such as a ROM / RAM, a magnetic disk, an optical disk, etc., and includes a plurality of instructions to make a computer device (which can be a personal computer, a server, or a network device, etc.) execute the methods described in various embodiments or some parts of the embodiments.

[0104] In the embodiments provided by the present application, it should be understood that the disclosed system or method can be implemented in other manners. The embodiments described above are merely schematic, and should not be construed as limiting. For example, the division of the modules or the units is merely logical function division, and there can be other division manners in actual implementation. For example, a plurality of modules or units can be combined or integrated into another system, or some features can be ignored or not executed. In addition, the displayed or discussed mutual couplings or direct couplings or communication connections between different modules can be indirect couplings or communication connections through some interfaces, and there can be electric, mechanical or other forms.

[0105] Finally, it should be noted that the above-mentioned embodiments are merely used to illustrate the technical solutions of the present application, rather than limit them; even if the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that they can still make modifications to the technical solutions recorded in the foregoing embodiments, or make equivalent replacements to some technical features; and these modifications or replacements do not cause the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A winding control system for an alloy steel wire production line, characterized in that: Including speed and tension analysis module, winding simulation module and winding real-time control module; The speed-tension analysis module includes a winding test unit and a speed-tension correlation analysis unit; the winding test unit is used to perform winding tests on the alloy steel wire production line and obtain multiple tension test points and the winding length of each tension test point based on the test results; The speed-tension correlation analysis unit is used to perform a speed-tension correlation test on each tension test point respectively, and obtain a speed-tension test curve of each tension test point based on the result of the speed-tension correlation test; The winding simulation module is used to simulate the winding in the alloy steel wire production line based on the winding length of each tension test point and the speed-tension test curve, and obtain the length-speed correlation curve based on the winding simulation results; The real-time winding control module is used to adjust the speed of the winding reel output by the drive motor in real time based on the long-speed correlation curve when winding in the alloy steel wire production line.

2. The winding control system of the alloy steel wire production line according to claim 1, characterized in that: The winding test includes: Get multiple default gears corresponding to the output speed of the drive motor to the winding reel in the alloy steel wire production line, and record them as preset gears YD1 to preset gears YD c ; The length of the steel wire that can be wound into the reel is recorded as L; For any preset gear YD v When there is no steel wire in the reel, the preset gear YD v The steel wire is wound into the reel, and the thickness of the steel wire in the reel is obtained in real time until the steel wire of length L is wound into the reel. The data corresponding to the time of winding the steel wire and the thickness of the steel wire are recorded as the steel wire winding data, where v is a positive integer less than or equal to c and greater than or equal to 1.

3. The winding control system of the alloy steel wire production line according to claim 2, characterized in that: The rewinding test also includes: Establish a plane rectangular coordinate system, recorded as the involvement analysis coordinate system, where the unit of the X-axis of the involvement analysis coordinate system is min and the unit of the Y-axis is m; use the time of wire involvement in the wire involvement data as the horizontal coordinate and the thickness of the wire as the vertical coordinate to draw the corresponding curve in the involvement analysis coordinate system, and record it as the gear involvement curve; except for the leftmost and rightmost points in the gear involvement curve, the point with the smallest slope is recorded as the tension influence point, and the point with the largest slope is recorded as the preferred speed point, and the vertical coordinate of the tension influence point is marked as Y1, and the vertical coordinate of the preferred speed point is marked as Y2; Obtain a reel without steel wire, wind a steel wire with a thickness of Y1 into the reel, and record the position of any steel wire in the reel that is farthest from the center of the reel after winding as the tension test point, and record the length of the steel wire in the reel at this time as the reeling length of the tension test point.

4. The winding control system of the alloy steel wire production line according to claim 3, characterized in that: The rewinding test also includes: Get a reel without steel wire, roll a steel wire with a thickness of Y2 into the reel, and record the length of the steel wire in the reel at this time as the preset gear YD v The preferred winding length; Obtain the tension test points of all preset gears, the winding length of the tension test points, and the preferred winding length.

5. The winding control system of the alloy steel wire production line according to claim 4, characterized in that: The tachycardia-tension correlation tests include: For any tension test point: obtain the take-up reel without steel wire, and set the reel from the preset gear YD1 to the preset gear YD c The steel wire is wound into a reel where no steel wire is present, until the length of the wound steel wire reaches L; For any one time with preset gear YD v When the steel wire in the reel reaches the tension test point, a tension sensor is placed at the tension test point and the detection data of the tension sensor is obtained in real time; when the steel wire in the reel finishes being wound in, the difference between the maximum and minimum tension values ​​in the detection data of the tension sensor is recorded as the winding tension difference.

6. The winding control system of the alloy steel wire production line according to claim 5, characterized in that: The tachycardia-tension correlation test also includes: Obtain the winding tension difference corresponding to the tension test point when winding the steel wire into the winding reel without steel wire at all preset gears; establish a plane rectangular coordinate system, recorded as the speed tension analysis coordinate system, where the unit of the X axis of the speed tension analysis coordinate system is r / min and the unit of the Y axis is N; based on the rotation speed corresponding to each preset gear and the winding pressure difference corresponding to the tension test point at each preset gear, mark the points in the speed tension analysis coordinate system, and record the curve obtained by fitting all the points as the speed tension test curve; Obtain the speed tension test curves corresponding to all tension test points.

7. The winding control system of the alloy steel wire production line according to claim 6, characterized in that: The winding simulation module includes a winding simulation unit, which is equipped with a winding simulation strategy. The winding simulation strategy includes: For any tension test point, the point with the lowest vertical coordinate in the speed test curve corresponding to the tension test point is recorded as the tension fluctuation valley point, and the horizontal coordinate of the tension fluctuation valley point is marked as the stable winding speed; Obtain a reel without steel wire. After winding a steel wire of length L1 into the reel at a stable winding speed, randomly obtain a tension test point in the reel and place a tension sensor. The detection result of the tension sensor at this time is recorded as N1, where L1 is the winding length corresponding to the tension test point. Continue to reel the steel wire into the reel and obtain the detection result of the tension sensor in real time until the steel wire length in the reel reaches L, at which time stop reeling. After the steel wire is wound in, the time corresponding to the detection result with the smallest difference from N1 in the detection data of the tension sensor is recorded as the tension optional time, and the length of the steel wire in the winding drum during the tension optional time during the steel wire winding process is recorded as the tension preferred length for a stable winding speed, wherein there are multiple tension optional times.

8. The winding control system of the alloy steel wire production line according to claim 7, characterized in that: The winding simulation strategy also includes: Analyze all tension test points and obtain the optimal tension length for the stable winding speed corresponding to each tension analysis point based on the analysis results; Establish a plane rectangular coordinate system, recorded as the long-speed analysis coordinate system, where the unit of the X-axis of the long-speed analysis coordinate system is m, and the unit of the Y-axis is r / min; for the stable winding speed corresponding to any tension analysis point, use the stable winding speed as the vertical coordinate and the optimal tension length of the stable winding speed as the horizontal coordinate to mark the point in the long-speed analysis coordinate system; The curve obtained by fitting all punctuation points is recorded as the long-speed correlation curve.

9. The winding control system of the alloy steel wire production line according to claim 8, characterized in that: The real-time winding control module includes a real-time winding control unit. The real-time winding control unit is configured with a real-time winding control strategy. The real-time winding control strategy includes: When the steel wire is wound into the reel, the length of the steel wire in the reel after winding is obtained in real time and recorded as L2; ​​the vertical coordinate corresponding to the point with the horizontal coordinate L2 in the length-speed correlation curve is marked as the adjusted speed; Control the drive motor to adjust the output speed of the winding reel to the adjusted speed.

10. A winding control method for an alloy steel wire production line, applicable to the winding control system of an alloy steel wire production line according to any one of claims 1 to 9, characterized in that: The steps include: Conduct a winding test on the alloy steel wire production line, and obtain multiple tension test points and the winding length of each tension test point based on the test results; conduct a speed-tension correlation test on each tension test point, and obtain a speed-tension test curve for each tension test point based on the results of the speed-tension correlation test; Based on the winding length of each tension test point and the speed test curve, a winding simulation is performed in the alloy steel wire production line, and a length-speed correlation curve is obtained based on the results of the winding simulation; When winding in an alloy steel wire production line, the speed of the winding reel output by the drive motor is adjusted in real time based on the long-speed correlation curve.

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