A mechanical guide rail-based length control device and method for a brushless DC stranding machine

Abstract

This invention discloses a length control device for a brushless DC stranding machine based on a mechanical guide rail, comprising: a mechanical limiting guide rail assembly, including a guide rail body, a fixing base installed below the guide rail for fixing the guide rail body, a scale ruler set along the length direction of the guide rail, a slidable limiting block, and a detachable fixing component, wherein the limiting block is fixed to a preset position on the guide rail by the detachable fixing component; a cylinder clamping module including a cylinder, a gripper, and a triggering device, wherein the triggering device drives the cylinder to close the gripper to clamp the wire; the cylinder clamping module is positioned by the limiting block; and a turn count control and stop control module including a counter and a linkage signal circuit, wherein the counter is linked to the rotating shaft of the stranding machine, detects the number of strands, and triggers the motor to power off and stop when a preset value is reached, and synchronously controls the cylinder to reset and release the clamp. This achieves sub-millimeter-level positioning accuracy (error ≤ ±1mm) for the wire processing length and a time synchronization rate of all process actions (action synchronization error ≤ 0.3 seconds).

Description

Technical Field

[0001] This invention relates to the field of wire harness processing equipment technology, specifically to industrial equipment that achieves stranding length and stranding accuracy through guide rail limiting mechanism and electromechanical linkage control. Background Technology

[0002] Traditional stranding machines have the following technical defects:

[0003] 1. Insufficient clamping stability: One end of the wire is fixed manually rather than mechanically, which makes the wire prone to shifting during processing, resulting in uneven twisting;

[0004] 2. Length control is crude: It relies on manual visual inspection or experience, and one end of the wire is not mechanically fixed. The length is easy to change after twisting, with an error of more than ±5mm, which cannot meet the requirements of standardized production.

[0005] 3. Uneven tension control: Since one end of the wire is fixed by a clamp and the other end is fixed by manual pinching, the overall tension of the wire is easily uneven during the twisting process.

[0006] 4. Cumbersome operation process: A single operation requires multiple steps: measuring the wire length → clamping the wire → measuring the wire length again → manually pinching and straightening the wire → starting the equipment → visually stopping the machine → disassembling. The wire length needs to be measured and the limit adjusted multiple times, resulting in low production efficiency.

[0007] 5. Manual visual counting of revolutions causes a delay in machine shutdown (delay error approximately 0.5-3 seconds).

[0008] 6. Existing clamping devices are prone to damaging the wire surface (surface indentation rate > 15%).

[0009] 7. The clamping force and the stopping sequence lack precise coordination.

[0010] The above background information is provided only to aid in understanding the concept and technical solution of this invention. It does not necessarily belong to the prior art of this patent application. In the absence of clear evidence that the above information was disclosed on the filing date of this patent application, the above background information should not be used to evaluate the novelty and inventiveness of this application. Summary of the Invention

[0011] This invention proposes a length control device and method for a brushless DC stranding machine based on a mechanical guide rail, which achieves multi-parameter coordination of strand length positioning accuracy, strand start-up and clamping action timing error, and constant and controllable clamping force to meet the needs of standardized mass production.

[0012] To achieve the above objectives, the present invention adopts the following technical solution:

[0013] A length control device for a brushless DC stranding machine based on a mechanical guide rail includes: a mechanical limiting guide rail assembly, comprising: a guide rail body, a fixed base installed below the guide rail for fixing the guide rail body, a scale ruler set along the length direction of the guide rail, a slidable limiting block, and a detachable fixing component, wherein the limiting block is fixed to a preset position on the guide rail by the detachable fixing component; a cylinder clamping module, comprising: a cylinder, a gripper, and a triggering device, wherein the triggering device drives the cylinder to close the gripper to clamp the wire; the cylinder clamping module is positioned by the limiting block; and a turn count control and stop control module, comprising: a counter and a linkage signal circuit, wherein the counter is linked to the rotating shaft of the stranding machine, detects the number of strands, and triggers the motor to power off and stop when a preset value is reached, and synchronously controls the cylinder to reset and release the clamp.

[0014] In some embodiments, the following technical features are also included:

[0015] The minimum division of the scale is ≤1mm, and the limiting block is provided with an indicator mark aligned with the scale.

[0016] In some embodiments, the following technical features are also included:

[0017] The linkage signal circuit includes a relay module, which controls the cylinder solenoid valve to switch the air path to synchronize the clamping action with the stop signal.

[0018] In some embodiments, the following technical features are also included:

[0019] The detachable fastener includes a gripper module and a hand-tightening bolt; the triggering device includes a foot pedal and a pneumatic pressure regulating valve, the foot pedal triggers the cylinder to close the gripper, and the clamping force is preset to 50-100N by the pneumatic pressure regulating valve.

[0020] In some embodiments, the following technical features are also included:

[0021] The counter is mounted coaxially with the rotating shaft and triggers a counting signal every 360° of rotation.

[0022] In some embodiments, the following technical features are also included:

[0023] The inner side of the gripper is provided with an anti-slip layer to prevent the wire from slipping off.

[0024] In some embodiments, the following technical features are also included:

[0025] The contact surface of the cylinder clamping module is provided with a flexible buffer layer.

[0026] In some embodiments, the following technical features are also included:

[0027] It includes a time delay control unit that gives the motor a preset delay time relative to the clamping action.

[0028] In some embodiments, the following technical features are also included:

[0029] The guide rail assembly is made of highly wear-resistant metal, and the moving parts are made of lightweight alloy material; the inner side of the gripper is provided with an anti-slip rubber pad to prevent damage to the wire surface when clamping.

[0030] The present invention also adopts the following technical solutions:

[0031] A method for controlling the length of a stranding machine includes the following steps: S1, setting a predetermined processing length on a guide rail with a graduated scale using a sliding limit block; S2, triggering a cylinder clamping module to fix the wire with a preset pressure; S3, driving a rotating shaft after a preset delay after completing the clamping action; S4, detecting the rotational motion status in real time using a counter and linkage signal circuit; S5, synchronously triggering the motor to stop and the cylinder to reset and release the clamp when the detected value reaches a set threshold.

[0032] In some embodiments, the following technical features are also included:

[0033] The preset delay for step S3 is adjustable within a range of 0.5-2 seconds.

[0034] In some embodiments, the following technical features are also included:

[0035] After step S5 is executed, the counter is automatically reset and enters the standby loop state.

[0036] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0037] This invention employs a brushless DC stranding machine with a mechanical guide rail and a basic length control system. Stable control of strand length and path is achieved through mechanical limiting. The linkage between the cylinder clamping module and the foot pedal reduces manual intervention and improves production efficiency. By using the scale and sliding limit block of the mechanical limit guide rail assembly, combined with the pressure adjustment control of the cylinder clamping module and the synchronous stop design of the number of turns control, sub-millimeter-level positioning accuracy (error ≤ ±1mm) for wire processing length and a high synchronization rate of all process actions (action synchronization error ≤ 0.3 seconds) is achieved. This is achieved by utilizing the mechanical principle of spatial precision locking, the electrical principle of time relay delaying the stranding start and clamping action synchronization, and the mechanical principle of pneumatic pressure regulating valve preset to de-reliance on manual experience in clamping force.

[0038] 1. Improved length control accuracy: The positioning error of the manual limit block meets general industrial requirements (≤±1mm in the example);

[0039] 2. Enhanced ease of operation: The scale clearly displays the length, and the adjustment time for the limit block is reduced by 60% in the embodiment;

[0040] 3. Optimized clamping efficiency: Clamping and starting are completed with one click using a foot pedal, and the cylinder-assisted clamping module reduces the intensity of manual operation. In this example, the production cycle time is increased by 40%.

[0041] 4. Automated clamp release: The release of the clamps is synchronized with the stop signal, reducing manual intervention;

[0042] In some embodiments, the present invention also has the following beneficial effects:

[0043] Enhanced stability: High wear-resistant metal guide rails and lightweight moving parts (such as aluminum alloy limit blocks) are used to ensure that the product does not deform during long-term use.

[0044] Anti-slip rubber pads prevent damage to the wires.

[0045] Delayed start control prevents the motor from starting before clamping is complete.

[0046] The combined adjustment of cylinder clamping force and counter improves the yield rate. Attached Figure Description

[0047] Figure 1 : Schematic diagram of mechanical guide rail assembly (including scale, fixed base, and sliding limit block);

[0048] Figure 2 : Structure diagram of cylinder clamping module and linkage circuit;

[0049] Figure 3 : Control circuit diagram (including the linkage relationship between the time relay and the counter);

[0050] Figure 4 Overall structural diagram.

[0051] The reference numerals in the attached figures are explained as follows:

[0052] 1: Mechanical limit guide rail; 2: Cylinder clamping and limiting mechanism; 10: Scale; 11: Fixed base; 12: Guide rail; 20: Anti-slip rubber pad; 21: Gripper; 22: Double-acting cylinder; 23: Sliding limit block; 24: Hand-tightening bolt; FU: Fuse; FR: Thermal relay; SB2: Foot pedal switch; KC: Mechanical counter; KA: Intermediate relay; KT: Time relay; KM: Motor controller; Y1: Cylinder solenoid valve clamping end; Y2: Cylinder solenoid valve releasing end; QF: Circuit breaker. Detailed Implementation

[0053] The embodiments of the present invention will be described in detail below. It should be emphasized that the following description is merely exemplary and not intended to limit the scope and application of the present invention.

[0054] It should be noted that when a component is referred to as "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as "connected to" another component, it can be directly connected to or indirectly connected to that other component. Furthermore, a connection can be used for both fixing and circuit / signal connectivity.

[0055] It should be understood that the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention.

[0056] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of embodiments of the present invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0057] Traditional equipment suffers from the decoupling of its three major systems: mechanical positioning, electrical timing, and clamping force control, resulting in:

[0058] Length error > ±5mm (mechanical and electrical defects);

[0059] There are many manual intervention steps (leading to failure of time-series coordination);

[0060] Unable to meet standardized mass production requirements (system out of control);

[0061] Therefore, the core of the following embodiments of the present invention lies in the following design:

[0062] 1. Mechanical limit guide rail assembly:

[0063] Sliding limit block: The main body of the guide rail is made of stainless steel, and a scale is set along the length of the guide rail with a minimum division of 1mm;

[0064] Manual locking mechanism: The limit block is fixed to the preset position of the guide rail (such as 100mm, 150mm) by hand-tightening bolts, with a positioning accuracy of ±1mm;

[0065] 2. Cylinder clamping module:

[0066] Foot pedal triggered clamping: Hold the wire and straighten it so that it passes through the cylinder jaws. Press the foot pedal to drive the double-acting cylinder to close the jaws. The clamping force is preset by the pressure regulating valve (50-100N) to ensure that the wire is fixed during the twisting process without damaging it.

[0067] Clamping and releasing linkage design: The clamping force is preset by the pneumatic pressure regulating valve (50-100N). The clamping and releasing action is linked with the stop signal. After the stranding is completed, the cylinder resets and the clamps automatically release the wire.

[0068] 3. Based on the linkage logic (foot pedal triggers clamping → delayed motor start and counting → count reaches target, stops and releases clamp), the circuit is designed as follows:

[0069] Initial state (no pedal pressed):

[0070] When the foot pedal switch (SB2) is off, the time relay (KT) is not energized, the KT contacts are open, and the motor and rotating shaft remain stationary.

[0071] Cylinder solenoid valve (Y1) de-energized → cylinder is in the open position;

[0072] The normally closed contact of the mechanical counter (KC) is closed, but there is no signal input.

[0073] Depress the foot pedal to trigger clamping:

[0074] When the foot pedal switch (SB2) is closed, the coil of the time relay (KT) is energized, and the timing begins (1 second delay).

[0075] When the intermediate relay (KA) coil is energized, its contacts close, the cylinder solenoid valve (Y1) is energized, the double-acting cylinder takes in air, and the clamps close to clamp the wire (the clamping force is preset by the pressure regulating valve).

[0076] The intermediate relay (KA) contacts remain closed to ensure that the cylinder remains clamped after the foot pedal is released (to prevent accidental release).

[0077] Delayed start motor and counting:

[0078] After the time relay (KT) counts for 1 second, the KT delayed closing contact closes → the motor controller (KM) receives the start signal, and the brushless DC motor starts to rotate;

[0079] Every time the stranding machine clamp rotates 360°, the internal gears of the mechanical counter (KC) count the rotations (the number of rotations is displayed on the screen).

[0080] The machine will stop and release clamps once the count is reached.

[0081] When the mechanical counter accumulates to the preset number of revolutions, the internal mechanical structure activates → the normally closed contact opens the mechanical counter contact (KC);

[0082] When the time relay (KT) coil is de-energized, the motor controller (KM) receives no signal input, and the stranding machine clamp stops rotating.

[0083] Mechanical counter contact (KC) opens → intermediate relay (KA) coil de-energized → its contacts switch, cylinder solenoid valve release end (Y2) energized → double-acting cylinder exhausts, jaws release wire;

[0084] The operator removes the finished product, the mechanical counter automatically resets (KC contacts close again), and the next cycle begins.

[0085] Example 1

[0086] This embodiment is a length control device for a brushless DC stranding machine based on a mechanical guide rail, including:

[0087] Mechanical limiting guide rail assembly: includes a guide rail body, a fixing base installed below the guide rail for fixing the guide rail body, a scale ruler set along the length of the guide rail, a sliding limiting block and a detachable fixing component. The limiting block is fixed to a preset position on the guide rail by the detachable fixing component to achieve the positioning of the wire clamping end.

[0088] Cylinder clamping module: includes a cylinder, grippers and a triggering device. The triggering device drives the cylinder to close the grippers to clamp the wire. The clamping force is preset by the pressure regulating device.

[0089] The coil count control and shutdown control module includes a counter and a linkage signal circuit. The counter is linked to the rotating shaft of the stranding machine, detects the number of strands, and triggers the motor to power off and stop when the preset value is reached, and synchronously controls the cylinder to reset and loosen the clamp.

[0090] The minimum division of the scale is ≤1mm, and the limiting block is provided with an indicator mark aligned with the scale.

[0091] The linkage signal circuit includes a relay module, which controls the cylinder solenoid valve to switch the air path to synchronize the clamping action with the stop signal.

[0092] The detachable fastener includes a gripper module and a hand-tightening bolt; the triggering device includes a foot pedal and a pneumatic pressure regulating valve, the foot pedal triggers the cylinder to close the gripper, and the clamping force is preset to 50-100N by the pneumatic pressure regulating valve.

[0093] The counter is mounted coaxially with the rotating shaft and triggers a counting signal every 360° of rotation.

[0094] The inner side of the gripper is provided with an anti-slip layer to prevent the wire from slipping off.

[0095] The contact surface of the cylinder clamping module is provided with a flexible buffer layer.

[0096] It includes a time delay control unit that gives the motor a preset delay time relative to the clamping action.

[0097] The guide rail assembly is made of highly wear-resistant metal, and the moving parts are made of lightweight alloy material; the inner side of the gripper is provided with an anti-slip rubber pad to prevent damage to the wire surface when clamping.

[0098] The stranding machine length control method of this embodiment includes the following steps: S1, setting a predetermined processing length on a guide rail with a scale by means of a sliding limit block; S2, triggering the cylinder clamping module to fix the wire with a preset pressure; S3, after completing the clamping action and after a preset delay, driving the rotating shaft; S4, detecting the rotational motion status in real time through a counter and linkage signal circuit; S5, when the detected value reaches the set threshold, synchronously triggering the motor to stop and the cylinder to reset and release the clamp.

[0099] The preset delay for step S3 is adjustable within a range of 0.5-2 seconds.

[0100] After step S5 is executed, the counter is automatically reset and enters the standby loop state.

[0101] Example 2

[0102] Specifically, the mechanical limit guide rail assembly in this embodiment includes: a guide rail body made of stainless steel (providing high strength and wear resistance), a fixing base installed below the guide rail for fixing the guide rail body, a scale ruler set along the length of the guide rail, a sliding limit block and a gripper module, and a hand-tightening bolt. The limit block is fixed to a preset position on the guide rail by the hand-tightening bolt, with a positioning accuracy of ±1mm.

[0103] The cylinder clamping module includes a double-acting cylinder, grippers, a foot pedal, and a pneumatic pressure regulating valve. The foot pedal triggers the cylinder to close the grippers, and the clamping force is preset to 50-100N by the pressure regulating valve.

[0104] The turn count control and stop control module is a preset turn count start and stop control module, including a mechanical counter and a linkage signal circuit. The mechanical counter is installed at the end of the stranding machine's rotating shaft (coaxial with the stranding machine clamp), and its counting trigger end is linked to the rotating shaft (triggers a count once every 360° rotation). The display screen is exposed on the stranding machine's operation panel (function: to display the number of strands in real time). After the preset number of turns is reached, the counter triggers the motor to power off and stop, and simultaneously sends a signal to the cylinder to reset and release the clamp.

[0105] The smallest division of the scale is 1mm. The limit block surface has an indicator mark aligned with the scale for visually setting the stranded wire length. The 0-degree mark on the guide rail scale is flush with the limit block surface, and the clamps are also flush with the limit block surface. At this point, the distance between the 0-degree mark and the limit block is the stranded wire length. By sliding the limit block, the indicator mark is aligned with the target scale (e.g., 150mm). The distance between the clamps and the stranding machine clamps at this point is the stranded wire length (150mm). One end of the wire is held by the stranding machine clamp (corresponding to the 0 point on the scale), and the other end is held by the limit block clamps (corresponding to the target scale point). After the wire is straightened, it is parallel to the length direction of the guide rail to ensure that the measured length is the actual stranded length.

[0106] The clamping action of the cylinder clamping module is linked to the stop signal, and the cylinder is reset after the machine stops.

[0107] The linkage signal circuit includes a relay module. After receiving a power failure signal, it controls the cylinder solenoid valve to switch the air path to complete the release.

[0108] The inside of the gripper is equipped with an anti-slip rubber pad to prevent damage to the wire surface when clamping.

[0109] A stranding clamp is installed at the end of the brushless DC motor's rotating shaft to hold one end of the wire. The motor control circuit is linked to the foot pedal signal of the cylinder clamping module, and a 1-second start delay is achieved through a time relay. Stranding begins only after the cylinder has fully clamped the wire.

[0110] The stranding machine clamp is installed at the end of the rotating shaft, clamping one end of the wire and rotating synchronously with the rotating shaft; the cylinder clamping module is combined with the sliding limit block and clamps the other end of the wire, fixing it in place; the motor provides rotational power, and the rotating shaft transmits torque to the stranding machine clamp;

[0111] The guide rails and slides retain the stainless steel material (for better wear resistance), while the limit blocks and cylinder housings are made of aluminum alloy to reduce the overall weight.

[0112] Taking an electronic wire with a stranding length of 150mm as an example, after setting the number of strands on the stranding machine, proceed with the following steps:

[0113] 1. Length setting: Slide the limit block along the scale to the 150mm position, and tighten the hand-tightening bolt to fix it;

[0114] 2. Cable fixing: Hold the cable through the cylinder gripper, and step on the foot pedal to trigger the cylinder to clamp it;

[0115] 3. Start the stranding: After the cylinder clamps the wire, after a delay of about 1 second, the brushless DC motor starts and drives the wire clamp to rotate and strand the wire.

[0116] 4. Automatic shutdown: When the stranding machine counter accumulates to the set number of turns, the electromagnetic clutch is de-energized and the machine stops, triggering the cylinder to release the clamp;

[0117] 5. Material handling cycle: The operator takes out the finished product and puts in the new wire to start the next cycle.

[0118] Example 3

[0119] More specifically, such as Figure 1 , 2 As shown, the mechanical limiting guide rail assembly in this embodiment includes a guide rail body 1, a fixing base 11 installed below the guide rail for fixing the guide rail body, a scale 10 set along the length of the guide rail, a sliding limiting block 23, and a detachable fixing component. The limiting block is fixed to a preset position on the guide rail by the detachable fixing component to achieve the positioning of the wire clamping end. The cylinder clamping module includes a cylinder, a gripper, and a triggering device. The triggering device drives the cylinder to close the gripper to clamp the wire. The clamping force is preset by the pressure regulating device. The number of turns control and stop control module includes a counter and a linkage signal circuit. The counter is linked with the twisting machine's rotating shaft, detects the number of twisted turns, and triggers the motor to power off and stop when the preset value is reached, and synchronously controls the cylinder to reset and release the clamp.

[0120] The main body of the guide rail 1 is made of SUS304 stainless steel (supplier: Baosteel, size 1200×50×30mm, tolerance ±0.1mm, hardness HRC58-60); the detachable fastener is an M8 hand-tightening bolt (model: FH-M8-316); the clamping force is preset to 80±5N by the SMC pneumatic pressure regulating valve (model: AR20-03BG), and the limit block is made of 6061-T6 aluminum alloy.

[0121] The circuit in this embodiment is as follows: Figure 3 As shown. The fuse FU1 and thermal relay FR provide dual overload / short circuit protection to ensure safe operation of the equipment. The start button SB2 controls the cylinder clamping end Y1 via intermediate relay KA, closing the cylinder gripper. The start button SB2 also controls the motor KM via time relay KT. When the preset number of revolutions is reached, KC disconnects, time relay KT is de-energized, and motor KM stops. KC disconnects, de-energizing intermediate relay KA, energizing the cylinder opening end Y2, and opening the gripper. The linkage signal circuit uses an Omron relay (model: MY4NJ, control voltage 24VDC).

[0122] This embodiment is as follows: Figure 4 As shown. Its working principle:

[0123] After receiving the counter signal, the relay switches the solenoid valve's air path (intake → exhaust).

[0124] The steps for using the brushless DC stranding machine length control device based on a mechanical guide rail in this embodiment are as follows:

[0125] 1. Slide the limit block to the target position on the scale (e.g., 150mm) and tighten the hand-tightening bolt;

[0126] 2. Pressing the foot pedal triggers the gripper to close, straightening the wire and starting the motor;

[0127] 3. After the counter detects that the number of revolutions has reached the target, it synchronously triggers the motor to stop and the cylinder to release.

[0128] Technical verification:

[0129] Test Project Example 3 Comparative example (without guide rails) Improvement rate Length error (mm) ±1.0 ±5.2 80％↑ Single operation time (s) 15 25 40％↓

[0130] Wear resistance test: After 10,000 sliding tests, the wear of the guide rail is ≤0.05mm.

[0131] Example 4

[0132] Based on Example 3, this example adopts the following variation:

[0133] • Guide rail assembly: SUS316L stainless steel guide rails (purchased from Shanghai Baosteel, dimensions: length 1200±0.5mm × width 50±0.2mm)

[0134] Clamping module: SMC CDU32-40D double-acting cylinder (clamping force adjustable from 50±5N to 100±5N)

[0135] • Rotation control: Omron H7EC-NB mechanical counter (detection accuracy: ±0.5 revolutions)

[0136] Effect verification:

[0137] Test Project Comparative example (without guide rails) Example 4 Improvement rate Length deviation (mm) ±5.8 ±0.9 84.5％ Single operation time (s) 18.7 11.2 40.1％

[0138] The background section of this invention may include background information about the problems or circumstances surrounding the invention, rather than a description of prior art by others. Therefore, the content included in the background section is not an admission of prior art by the applicant.

[0139] The above description provides a further detailed explanation of the present invention in conjunction with specific / preferred embodiments, and it should not be construed that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, various substitutions or modifications can be made to these described embodiments without departing from the concept of the present invention, and all such substitutions or modifications should be considered within the scope of protection of the present invention. In the description of this specification, the reference to terms such as "an embodiment," "some embodiments," "preferred embodiment," "example," "specific example," or "some examples," etc., indicates that the specific features, structures, materials, or characteristics described in connection with that embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in any suitable manner in one or more embodiments or examples. Furthermore, those skilled in the art can combine and integrate different embodiments or examples and features of different embodiments or examples described in this specification without contradiction. Although the embodiments of the present invention and their advantages have been described in detail, it should be understood that various changes, substitutions, and modifications can be made herein without departing from the scope defined by the appended claims.

Claims

1. A length control device for a brushless DC stranding machine based on a mechanical guide rail, characterized in that, include: A mechanical limiting guide rail assembly includes: a guide rail body, a fixing base installed below the guide rail for fixing the guide rail body, a scale ruler set along the length of the guide rail, a sliding limiting block and a detachable fixing component, wherein the limiting block is fixed to a preset position on the guide rail by the detachable fixing component; The cylinder clamping module includes a cylinder, grippers, and a triggering device. The triggering device drives the cylinder to close the grippers to clamp the wire. The cylinder clamping module is positioned by the limiting block. The triggering device includes a foot pedal and a pneumatic pressure regulating valve. The foot pedal triggers the cylinder to close the grippers, and the clamping force is preset to 50-100N by the pneumatic pressure regulating valve to ensure that the wire is fixed during the stranding process without being damaged. The coil count control and shutdown control module includes: a counter and a linkage signal circuit. The counter is linked to the rotating shaft of the stranding machine, detects the number of strands, and triggers the motor to power off and stop when a preset value is reached, simultaneously controlling the cylinder to reset and release the clamp. The counter is coaxially mounted with the rotating shaft and triggers a counting signal every 360° of rotation. The linkage signal circuit includes a time relay and an intermediate relay. The time relay delays until the stranding start and clamping actions are synchronized. The intermediate relay ensures that the cylinder remains clamped after the foot pedal is released. Depressing the foot pedal simultaneously triggers the time relay and the intermediate relay to control the cylinder solenoid valve to switch the air path to synchronize the clamping action with the shutdown signal. The time relay has a preset delay range of 0.5-2 seconds, ensuring that stranding begins after the cylinder is fully clamped. When the counter accumulates to a preset number of revolutions, its internal mechanical structure disconnects the normally closed contact, causing the time relay coil to lose power and thus stopping the motor. At the same time, the intermediate relay coil loses power, causing the cylinder solenoid valve to switch the air path, and the gripper releases the wire, realizing the linkage between the release action and the stop signal.

2. The apparatus according to claim 1, characterized in that: The minimum division of the scale is ≤1mm, and the limiting block is provided with an indicator mark aligned with the scale.

3. The apparatus according to claim 1, characterized in that: The detachable fastener includes a gripper module and a hand-tightening bolt.

4. The apparatus according to claim 1, characterized in that: The inner side of the gripper is provided with an anti-slip layer to prevent the wire from slipping off; the contact surface of the cylinder clamping module is provided with a flexible buffer layer.

5. The apparatus according to claim 1, characterized in that: It includes a time delay control unit that gives the motor a preset delay time relative to the clamping action.

6. The apparatus according to claim 1, characterized in that: The guide rail assembly is made of highly wear-resistant metal, and the moving parts are made of lightweight alloy material; the inner side of the gripper is provided with an anti-slip rubber pad to prevent damage to the wire surface when clamping.

7. A method for controlling the length of a stranding machine, characterized in that, The device applied to any one of claims 1-6, the method comprising the following steps: S1, setting a predetermined processing length on a guide rail with a graduated scale by means of a sliding limit block; S2, triggering a cylinder clamping module to fix the wire with a preset pressure; S3, after completing the clamping action and after a preset delay, driving a rotating shaft; S4, detecting the rotational motion status in real time by means of a counter and a linkage signal circuit; S5, when the detected value reaches a set threshold, synchronously triggering the motor to stop and the cylinder to reset and release the clamp.

8. The method according to claim 7, characterized in that: The preset delay for step S3 is adjustable within a range of 0.5-2 seconds.

9. The method according to claim 7, characterized in that: After step S5 is executed, the counter is automatically reset and enters the standby loop state.

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