Take-up device for low-voltage wire harness production and method thereof

Abstract

The invention discloses a take-up device for low-voltage wire harness production and a method thereof, the take-up device comprises a base, a take-up reel, an XYZ three-axis driving mechanism and a wire inlet groove wheel are mounted on the base, a pressure sensor is mounted on a Z-direction transmission end of the XYZ three-axis driving mechanism, and a supporting groove wheel is mounted on the pressure sensor; a supporting plate synchronously moving with the supporting grooved wheel in the Y direction is further mounted on the XYZ three-axis driving mechanism; two distance monitoring assemblies are installed on the supporting plate. An angle monitoring assembly is installed between the wire inlet groove wheel and the supporting groove wheel. The take-up reel is driven by a take-up motor. The invention relates to the technical field of take-up equipment. The problems that in the prior art, a take-up device is generally insufficient in tension control precision, the levelness of an electric wire cannot be maintained in real time, and tension control and levelness maintenance are mutually coupled and interfered are solved.

Description

Technical Field

[0001] The present invention relates to the technical field of wire-taking equipment, and in particular to a wire-taking device and method for producing low-voltage wire harnesses. Background Art

[0002] Wire harnesses, as carriers of power and signal transmission, are widely used in various fields, including automotive, home appliances, communications, and aerospace. Low-voltage wire harnesses are the most in-demand product, and their production quality directly impacts the performance and reliability of end products. In the low-voltage wire harness production process, wire reeling is the last critical step, its core goal being to neatly and tightly wind the extruded or braided wires onto the reel.

[0003] At present, the common take-up tension control technologies in the industry usually adopt rocker / floating wheel and torque control structures.

[0004] The pendulum / floating wheel method is a traditional and common electronic control method. Tension changes are indirectly detected through the angular displacement of the pendulum or the displacement of the floating wheel, which serves as a feedback signal to adjust the torque or speed of the take-up motor. However, this method has inherent drawbacks: First, it detects position deviation rather than tension itself, making it an indirect measurement with limited accuracy. Second, the mass and inertia of the pendulum or floating wheel can cause system response lag, resulting in significant tension fluctuations at high speeds or during start-up and stop phases. Finally, its installation requires a large amount of space and is complex.

[0005] Torque control uses a servo motor or torque motor to directly drive the take-up reel, indirectly controlling tension by controlling the motor's output torque. While more advanced than the previous two methods, its control accuracy relies heavily on the efficiency of the system's transmission components, the precise calculation of the take-up reel's diameter, and the change in moment of inertia between an empty and full reel, requiring complex parameter tuning and compensation. More importantly, all of the aforementioned methods focus solely on tension control, completely ignoring the control of the wire's position between the guide wheel and the take-up reel.

[0006] In response to the above problems, we propose a wire take-up device and method for low-voltage wire harness production. Summary of the Invention

[0007] In order to solve the problems of insufficient tension control accuracy, inability to maintain the horizontality of wires in real time, and mutual coupling interference between tension control and horizontality maintenance commonly found in conventional wire take-up devices, the purpose of the present invention is to provide a wire take-up device and method for low-voltage wire harness production.

[0008] In order to achieve the above object, the application adopts the following technical scheme: a take-up device for low-voltage wire harness production, comprising a base, a take-up reel, an XYZ three-axis driving mechanism and an inlet slot wheel mounted on the base, a pressure sensor mounted on the Z-direction transmission end of the XYZ three-axis driving mechanism, and a support slot wheel mounted on the pressure sensor; a support plate that moves synchronously with the support slot wheel in the Y direction is further mounted on the XYZ three-axis driving mechanism, the wires of the low-voltage wire harness are introduced obliquely upward from the wheel groove below the inlet slot wheel into the wheel groove above the support slot wheel, and then guided to the take-up reel for winding; two distance monitoring components are mounted on the support plate for monitoring the vertical distance data between the two points of the wires between the support slot wheel and the take-up reel; an angle monitoring component is installed between the inlet slot wheel and the support slot wheel for monitoring the inclination angle of the wires between the inlet slot wheel and the support slot wheel; the take-up reel is driven by a take-up motor;

[0009] The take-up device further comprises a controller, the signal end of the controller is electrically connected with the pressure sensor, the two distance monitoring components and the angle monitoring component, and the control output end of the controller is electrically connected with the three axial driving mechanisms of the XYZ three-axis driving mechanism and the take-up motor of the take-up reel.

[0010] Preferably, a vertical plate is fixedly installed on the base, and the take-up motor is fixedly installed on the vertical plate, and the output end of the take-up motor is connected with the take-up reel shaft.

[0011] Preferably, the XYZ three-axis driving mechanism comprises an X-direction linear module, a Y-direction linear module and a Z-direction linear module, the Y-direction linear module is fixedly installed on the base, the top of the Y-direction linear module transmission table is fixedly connected with the bottom of the X-direction linear module, the top of the X-direction linear module transmission table is fixedly connected with the bottom of the Z-direction linear module, the bottom of the X-direction linear module is fixedly connected with a rectangular block, a guide rod is slidably connected with the side wall of the rectangular block, and the end of the guide rod is fixedly connected with a rectangular plate fixedly connected with the top surface of the base; the control output end of the controller is electrically connected with the X-direction linear module, the Y-direction linear module and the Z-direction linear module.

[0012] Preferably, the top of the Z-direction linear module transmission end is fixedly connected with the bottom of the pressure sensor, the monitoring end of the top of the pressure sensor is fixedly connected with a mounting plate, and the support slot wheel is rotatably installed on the side wall of the mounting plate through a connecting shaft.

[0013] Preferably, one end of the support plate is fixedly connected with the side wall of the X-direction linear module, the distance monitoring assembly comprises a first square tube vertically fixedly installed on the top surface of the support plate, the inner wall of the first square tube is slidably sleeved with a first square rod, the top of the first square rod is fixedly connected with a first connecting plate, the side of the first connecting plate is rotatably connected with a first movable block through a connecting shaft, the side wall of the first movable block is fixedly installed with a first column, and the first column is coaxial with the connecting shaft of the first connecting plate and the first movable block; the side wall of the first square tube is fixedly installed with a distance sensor, the monitoring end of the distance sensor is vertically upward, and faces the outer wall of the first column; the wire of the low-voltage wire harness is slidably connected to the side wall of the first movable block, and the controller is signal-connected with the distance sensor.

[0014] Preferably, the angle monitoring assembly comprises a second square tube vertically fixedly installed on the base, the inner wall of the second square tube is slidably sleeved with a second square rod, the top of the second square rod is fixedly connected with a second connecting plate, the side wall of the second connecting plate is rotatably connected with a rotating shaft, one end of the rotating shaft is fixedly installed with a second movable block, and the other end of the rotating shaft is fixedly installed with an angle sensor; the controller is signal-connected with the angle sensor; the wire between the wire inlet groove wheel and the support groove wheel is slidably connected to the side wall of the second movable block.

[0015] A take-up control method for low-voltage wire harness production, a take-up reel is provided with a take-up reel encoder for real-time detection of the roll diameter data;

[0016] S1, controller system parameter initialization: set the target horizontal tension of the wire between the support groove wheel and the take-up reel , take-up speed , wire spacing , and wire linear density , elastic modulus material parameters;

[0017] S2, real-time data acquisition: synchronously read the pressure sensor value , the first distance value , the second distance value , the angle monitoring value , and calculate the real-time roll diameter through the take-up reel encoder ;

[0018] S3, calculation of sag and Z-axis horizontal adjustment:

[0019] a) definition and calculation: define the wire segment between the support groove wheel and the take-up reel as the object, and the horizontal distance between the installation points of the two distance monitoring assemblies is a fixed value . Calculate the real-time average height of the wire segment and the real-time height difference ;

[0020] b) Overhang modeling: Overhang , consider the wire as a horizontal tension The acting suspension cable;

[0021] c) Overhang control: the absolute horizontal state corresponds to the overhang , then the sag deviation ;

[0022] d) Z-axis adjustment: To eliminate the overhang deviation, the controller generates a Z-axis control instruction: drives the Z-axis to move to the transmission end of the drive mechanism :

[0023] ,in is the proportional coefficient of the controller, is the integration coefficient, is the differential coefficient, The sag deviation Derivative, The sag deviation Perform integral operations;

[0024] By adjusting the height of the supporting sheave, the average height of the wires can be changed and tension to make the sag Tends to zero, thus achieving precise horizontal adjustment; by controlling the physical quantity sag, it can effectively avoid the interference caused by the synchronous change of the absolute height of the two distance monitoring points;

[0025] S4: Horizontal tension calculation and X-axis constant tension adjustment:

[0026] a) Tension calculation model: Based on the force balance of the support sheave, the angle monitoring component monitors the inclination angle of the wire between the incoming sheave and the support sheave. :

[0027] The horizontal tension of the wire between the supporting sheave and the take-up drum ;

[0028] b) Real-time calculation :The real-time collection and , and obtain the real-time horizontal tension ;

[0029] c) Tension closed-loop control: calculation of tension deviation ;

[0030] Use the controller to generate X-axis control instructions:

[0031] ;

[0032] in, is the tension deviation of this time, For the The tension deviation at the sampling moment, For the Tension deviation at the sampling moment; is the proportionality coefficient, is the integration coefficient, is the differential coefficient, Indicates the serial number of the sampling time;

[0033] Drive the transmission platform of the X-axis drive mechanism to move , by slightly changing the guide angle, finely adjust the tension to the target value;

[0034] S5: Collaborative cable arrangement and coil diameter compensation:

[0035] a) Y-axis cable arrangement: according to the actual coil diameter and wiring pitch , generate the Y-axis drive mechanism control command, drive the Y-axis drive mechanism to drive the supporting groove wheel to perform reciprocating motion, and realize precise cable arrangement;

[0036] b) Z-axis feedforward compensation: real-time roll diameter change rate , generate Z-axis feedforward compensation , and superimposed on step S3 In the output, it is used to actively compensate for the slow change in the height of the take-up point caused by the increase in the take-up reel diameter, so that the distance monitoring value Keep within the sensor's optimal range; is the feedforward compensation coefficient, is a small change in the coil diameter, For small time intervals;

[0037] S6: Loop control: Return to step S2 and continue looping until the line-reeling process is completed.

[0038] Compared with the prior art, the present invention achieves the following beneficial effects:

[0039] 1. The present invention directly measures and integrates the real-time tension through pressure sensors and angle sensors, and combines the rapid fine-tuning of the X-axis with the coordination of the main power of the take-up reel. It can control the fluctuation of wire tension within an extremely small range, completely avoiding the problems of wire insulation deformation and conductor damage caused by excessive tension, or loose wires, tangled wires, and collapse caused by too little tension, fundamentally ensuring the internal quality of the take-up reel.

[0040] 2. The present invention directly monitors the horizontality of the take-up section through two distance sensors or one inclination sensor, and makes real-time corrections through closed-loop control of the Z-axis, ensuring that the wire is always in an ideal horizontal state before entering the take-up reel. This provides a stable and reliable reference for subsequent cable arrangement and is a prerequisite for forming neat reels. This control loop is independent of the tension ring and can automatically offset the overall height changes caused by changes in the take-up reel's reel diameter, solving the control problem caused by reference floating in traditional methods.

[0041] 3. The present invention decomposes the complex take-up process into two relatively independent control loops, with the X-axis mainly responsible for tension and the Z-axis mainly responsible for levelness, and eliminates coupling interference through a feedforward compensation mechanism.

[0042] 4. The present invention ensures that the tension of the inner and outer coils of the wound wire drum is consistent, the layers are tightly stacked, and the wire drum is neat and uniform through the coordination of constant tension, absolute levelness, and precise wire arrangement.

[0043] 5. The present invention comprehensively utilizes various sensor information such as pressure, angle, distance and inclination to form a full range of digital perception of the line-winding process.

[0044] Through multi-sensor fusion, decoupling control architecture and intelligent algorithms based on physical models, the present invention successfully and simultaneously solves the two core problems of constant tension and horizontal guidance in the wire-winding process, which are mutually coupled. Ultimately, it achieves significant beneficial effects in multiple dimensions such as improving product quality, enhancing equipment versatility, and improving production efficiency, and has high industrial application value. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments:

[0046] Figure 1 It is a schematic diagram of the overall side structure of the present invention;

[0047] Figure 2 Schematic diagram of the structure of the XYZ three-axis drive machine of the present invention;

[0048] Figure 3 It is a structural schematic diagram of the distance monitoring component of the present invention;

[0049] Figure 4 It is a structural schematic diagram of the angle monitoring component of the present invention.

[0050] In the figure: 1. base; 2. wire take-up reel; 3. XYZ three-axis drive mechanism; 31. X-axis linear module; 32. Y-axis linear module; 33. Z-axis linear module; 34. rectangular block; 35. guide rod; 36. rectangular plate; 4. wire feed groove pulley; 5. support groove pulley; 51. mounting plate; 6. distance monitoring assembly; 61. first square tube; 62. first square rod; 63. first connecting plate; 64. first movable block; 65. first column; 66. distance sensor; 7. support plate; 8. pressure sensor; 9. angle monitoring assembly; 91. second square tube; 92. second square rod; 93. second connecting plate; 94. rotating shaft; 95. second movable block; 96. angle sensor; 21. vertical plate; 10. wire. DETAILED DESCRIPTION

[0051] The following describes the implementation of the present invention through specific embodiments. People skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification.

[0052] See also Figures 1 to 4 It should be noted that the structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification for understanding and reading by those familiar with this technology, and are not used to limit the conditions for implementation of the present invention. Therefore, they have no substantial technical significance. Any modification of the structure, change in the proportional relationship, or adjustment of the size should still fall within the scope of the technical content disclosed by the present invention without affecting the efficacy and purpose that can be achieved by the present invention. At the same time, the terms such as "upper", "lower", "left", "right", "middle" and "one" quoted in this specification are only for the convenience of description and are not used to limit the scope of implementation of the present invention. Changes or adjustments in their relative relationships should also be regarded as the scope of implementation of the present invention without substantially changing the technical content.

[0053] The present invention provides a technical solution: a take-up device for low-voltage wire harness production. The device utilizes a base 1 as its mounting foundation, with all functional components directly or indirectly mounted on the base 1, forming an integrated take-up system. The core of the system lies in adjusting the position of a support sheave 5 via an XYZ three-axis drive mechanism 3. In conjunction with monitoring data from a pressure sensor 8, a distance monitoring component 6, and an angle monitoring component 9, a controller precisely controls the take-up process. Ultimately, the take-up reel 2 achieves stable winding of the low-voltage wire harness. The wire inlet sheave 4 serves as a guide for wire introduction.

[0054] To ensure stable drive of the take-up reel 2, a vertical plate 21 is fixed to the top surface of the base 1. Vertical plate 21 must be perpendicular to the top surface of the base 1 and have sufficient structural strength to withstand the load during the take-up process. The take-up motor is directly fixed to the side wall of vertical plate 21. The output end of the take-up motor is connected to the central axis of the take-up reel 2 using a shaft connection. This ensures that the torque of the take-up motor can be stably transmitted to the take-up reel 2, driving the take-up reel 2 to rotate around its own axis, thereby completing the wire winding action.

[0055] The XYZ three-axis drive mechanism 3 is the core component for adjusting the spatial position of the support sheave 5. Its specific composition and installation method are as follows:

[0056] The Y-axis linear module 32 serves as the basis for the three-axis drive and is directly fixed on the top surface of the base 1. Its transmission direction is set along the length direction of the base 1 to provide Y-axis movement power for the supporting sheave 5;

[0057] The bottom of the X-direction linear module 31 is fixedly connected to the top surface of the transmission platform of the Y-direction linear module 32, and moves in the Y direction synchronously with the transmission platform of the Y-direction linear module 32. The transmission direction of the X-direction linear module 31 is perpendicular to that of the Y-direction linear module 32 and is arranged along the width direction of the base 1;

[0058] To enhance the stability of the movement of the X-axis linear module 31, a rectangular block 34 is fixedly connected to the bottom of the X-axis linear module 31. A sliding hole is provided in the side wall of the rectangular block 34. A guide rod 35 slides through the sliding hole. The two ends of the guide rod 35 are respectively connected to a rectangular plate 36 fixed to the top surface of the base 1, forming a guide support for the X-axis linear module 31 to prevent it from deflecting during movement.

[0059] The bottom of the Z-direction linear module 33 is fixedly connected to the top surface of the transmission platform of the X-direction linear module 31, and moves in the X-direction synchronously with the transmission platform of the X-direction linear module 31. The transmission direction of the Z-direction linear module 33 is perpendicular to the top surface of the base 1 and is arranged in the vertical direction to provide Z-direction position adjustment power for the support sheave 5.

[0060] The control output end of the controller is electrically connected to the X-axis linear module 31, the Y-axis linear module 32, and the Z-axis linear module 33 respectively, and can independently control the start and stop and transmission speed of the three linear modules according to the monitoring data, thereby adjusting the position of the support sheave 5 in the X, Y, and Z directions.

[0061] The support groove wheel 5 is connected to the Z-direction linear module 33 through the pressure sensor 8. The specific assembly method is: the top of the transmission end of the Z-direction linear module 33 is fixedly connected to the bottom of the pressure sensor 8 to ensure that the pressure sensor 8 can stably receive the pressure signal transmitted by the support groove wheel 5; the monitoring end at the top of the pressure sensor 8 is fixedly connected to the mounting plate 51, and the mounting plate 51 is made of metal and has a certain rigidity; a connecting shaft is passed through the center of the support groove wheel 5, and the two ends of the connecting shaft are rotatably mounted on the side walls of the mounting plate 51, so that the support groove wheel 5 can rotate freely around the connecting shaft. When the wire slides in the wheel groove of the support groove wheel 5, the support groove wheel 5 can rotate synchronously with the movement of the wire, reducing friction damage between the wire and the wheel groove.

[0062] The signal output end of the pressure sensor 8 is electrically connected to the signal end of the controller, which can monitor the wire pressure, i.e., the wire tension, exerted on the supporting sheave 5 in real time, and transmit the pressure data to the controller, providing a basis for the controller to adjust the Z-axis linear module 33.

[0063] The support plate 7 is used to mount the distance monitoring assembly 6. One end of the support plate is fixedly connected to the side wall of the X-axis linear module 31. It moves in the X-axis direction synchronously with the X-axis linear module 31 to ensure that the distance monitoring assembly 6 can always align with the wire between the support sheave 5 and the take-up reel 2. The specific structure and installation of each distance monitoring assembly 6 are as follows:

[0064] The first square tube 61 is vertically fixed on the top surface of the support plate 7. The inner wall of the first square tube 61 is slidably engaged with the outer wall of the first square rod 62. The first square rod 62 can slide vertically up and down along the inner wall of the first square tube 61.

[0065] The top of the first square rod 62 is fixedly connected to the first connecting plate 63, and the side of the first connecting plate 63 is rotatably connected to the first movable block 64 via a connecting shaft, so that the first movable block 64 can rotate freely around the connecting shaft;

[0066] A first column 65 is fixedly mounted on the side wall of the first movable block 64. The first column 65 is coaxial with the connecting axis of the first connecting plate 63 and the first movable block 64, ensuring that when the first movable block 64 rotates, the first column 65 can rotate synchronously with it around the same axis.

[0067] The distance sensor 66 is fixedly mounted on the side wall of the first square tube 61. The monitoring end of the distance sensor 66 is vertically upward and faces the outer wall of the first column 65, and is used to monitor the vertical distance between the distance sensor 66 and the outer wall of the first column 65.

[0068] The wires of the low-voltage wiring harness slide through the slots or holes provided on the side wall of the first movable block 64 . When the vertical position of the wires changes, the first movable block 64 is driven to rotate around the connecting axis, thereby changing the distance between the first column 65 and the distance sensor 66 .

[0069] The signal output end of the distance sensor 66 is electrically connected to the signal end of the controller, and the monitored distance data can be transmitted to the controller in real time. The controller determines whether the vertical direction of the wire between the supporting groove wheel 5 and the wire take-up drum 2 is stable through the distance data of the two distance monitoring components 6.

[0070] The angle monitoring assembly 9 is installed between the incoming sheave 4 and the supporting sheave 5 to monitor the tilt angle of the wires between the two. Its specific structure and installation are as follows:

[0071] The second square tube 91 is vertically fixed on the top surface of the base 1. The inner wall of the second square tube 91 is slidably engaged with the outer wall of the second square rod 92. The second square rod 92 can slide vertically up and down along the inner wall of the second square tube 91.

[0072] The top of the second square rod 92 is fixedly connected to the second connecting plate 93. The side wall of the second connecting plate 93 is provided with a through hole, and the rotating shaft 94 is rotatably connected to the through hole, so that the rotating shaft 94 can rotate freely around its own axis.

[0073] A second movable block 95 is fixedly installed on one end of the rotating shaft 94, and the wires between the incoming groove wheel 4 and the supporting groove wheel 5 are slidably connected to the side wall of the second movable block 95; an angle sensor 96 is fixedly installed on the other end of the rotating shaft 94, and the angle sensor 96 can accurately monitor the rotation angle of the rotating shaft 94.

[0074] When the inclination angle of the wire between the incoming groove wheel 4 and the supporting groove wheel 5 changes, the wire will drive the second movable block 95 to rotate, and then drive the rotating shaft 94 to rotate synchronously. The angle sensor 96 converts the monitored rotation angle into an electrical signal and transmits it to the signal end of the controller, providing a basis for the controller to adjust the position of the supporting groove wheel 5.

[0075] First, complete the connection of the wires of the low-voltage wiring harness: insert one end of the wire 10 into the groove below the inlet groove wheel 4, lead it out in an oblique upward direction and slide it through the side wall of the second movable block 95, and then insert it into the groove above the support groove wheel 5, and then pass through the side walls of the first movable block 64 of the two distance monitoring components 6 in turn, and finally fix it on the take-up reel of the take-up drum 2.

[0076] A wire take-up control method for low-voltage wire harness production, wherein a wire take-up reel encoder is installed on the wire take-up reel for real-time detection of winding diameter data;

[0077] S1, controller system parameter initialization: set the target horizontal tension of the wire between the supporting sheave 5 and the take-up drum 2 , take-up speed , wiring pitch , and wire density , elastic modulus Material parameters;

[0078] S2, real-time data acquisition: synchronously read the pressure sensor value , first distance value , second distance value , Angle monitoring value The real-time winding diameter is calculated by the take-up reel encoder ;

[0079] S3, sag calculation and Z-axis level adjustment:

[0080] a) Definition and calculation: Define the wire segment between the support sheave 5 and the take-up drum 2 as the object, and the horizontal distance between the installation points of the two distance monitoring components 6 as a fixed value Calculate the real-time average height of the wire section , and real-time height difference ;

[0081] b) Overhang modeling: Overhang , consider the wire as a horizontal tension The acting suspension cable;

[0082] c) Overhang control: the absolute horizontal state corresponds to the overhang , then the sag deviation ;

[0083] d) Z-axis adjustment: To eliminate the overhang deviation, the controller generates a Z-axis control instruction: drives the Z-axis to move to the transmission end of the drive mechanism :

[0084] ,in is the proportional coefficient of the controller, is the integration coefficient, is the differential coefficient, The sag deviation Derivative, The sag deviation Perform integral operations;

[0085] By adjusting the height of the supporting groove wheel 5, the average height of the wires can be changed and tension to make the sag Tends to zero, thus achieving precise horizontal adjustment; by controlling the physical quantity sag, it can effectively avoid the interference caused by the synchronous change of the absolute height of the two distance monitoring points;

[0086] S4: Horizontal tension calculation and X-axis constant tension adjustment:

[0087] a) Tension calculation model: Based on the force balance of the support sheave 5, the angle monitoring component 9 monitors the inclination angle of the wire between the incoming sheave 4 and the support sheave 5. :

[0088] The horizontal tension of the wire between the supporting sheave 5 and the take-up drum 2 is ;

[0089] b) Real-time calculation :The real-time collection and , and obtain the real-time horizontal tension ;

[0090] c) Tension closed-loop control: calculation of tension deviation ;

[0091] Use the controller to generate X-axis control instructions:

[0092] ;

[0093] in, is the tension deviation of this time, For the The tension deviation at the sampling moment, For the Tension deviation at the sampling moment; is the proportionality coefficient, is the integration coefficient, is the differential coefficient, Indicates the serial number of the sampling time;

[0094] Drive the transmission platform of the X-axis drive mechanism to move , by slightly changing the guide angle, finely adjust the tension to the target value;

[0095] S5: Collaborative cable arrangement and coil diameter compensation:

[0096] a) Y-axis cable arrangement: according to the actual coil diameter and wiring pitch , generate the Y-axis drive mechanism control instruction, drive the Y-axis drive mechanism to drive the supporting groove wheel 5 to reciprocate, and realize precise cable arrangement;

[0097] b) Z-axis feedforward compensation: real-time roll diameter change rate , generate Z-axis feedforward compensation , and superimposed on step S3 In the output, it is used to actively compensate for the slow change in the height of the take-up point caused by the increase in the take-up reel diameter, so that the distance monitoring value Keep within the sensor's optimal range; is the feedforward compensation coefficient, is a small change in the coil diameter, For small time intervals;

[0098] S6: Loop control: Return to step S2 and continue looping until the line-reeling process is completed.

[0099] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the present invention. Anyone skilled in the art may modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by one of ordinary skill in the art without departing from the spirit and technical principles disclosed herein are intended to be covered by the claims of the present invention.

Claims

1. A take-up device for low-voltage wire harness production, comprising a base (1), characterized in that: The base (1) is equipped with a take-up reel (2), an XYZ three-axis drive mechanism (3) and a wire feed groove wheel (4); a pressure sensor (8) is installed on the Z-direction transmission end of the XYZ three-axis drive mechanism (3); and a support groove wheel (5) is installed on the pressure sensor (8); a support plate (7) is also installed on the XYZ three-axis drive mechanism (3) and moves synchronously with the support groove wheel (5) in the Y direction; the wires of the low-voltage wire harness are introduced obliquely upward from the wheel groove below the wire feed groove wheel (4) The wire is passed through the wheel groove above the wheel (5) and then led to the take-up reel (2) for winding; two distance monitoring components (6) are installed on the support plate (7) for monitoring the vertical distance data of two points of the wire between the support groove wheel (5) and the take-up reel (2); an angle monitoring component (9) is installed between the wire feed groove wheel (4) and the support groove wheel (5) for monitoring the inclination angle of the wire between the wire feed groove wheel (4) and the support groove wheel (5); the take-up reel (2) is driven by a take-up motor; The wire-taking device further comprises a controller, a signal end of the controller being electrically connected to a pressure sensor (8), two distance monitoring components (6) and an angle monitoring component (9), and a control output end of the controller being electrically connected to three axial drive mechanisms of an XYZ three-axis drive mechanism (3) and a wire-taking motor of a wire-taking reel (2).

2. A take-up device for low-voltage wire harness production according to claim 1, characterized in that: A vertical plate (21) is fixedly mounted on the base (1), the wire-taking motor is fixedly mounted on the vertical plate (21), and the output end of the wire-taking motor is axially connected to the wire-taking drum (2).

3. The low-voltage wire harness production take-up device according to claim 1, characterized in that: The XYZ three-axis driving mechanism (3) comprises an X-axis linear module (31), a Y-axis linear module (32) and a Z-axis linear module (33), wherein the Y-axis linear module (32) is fixedly mounted on the base (1), the top of the transmission platform of the Y-axis linear module (32) is fixedly connected to the bottom of the X-axis linear module (31), the top of the transmission platform of the X-axis linear module (31) is fixedly connected to the bottom of the Z-axis linear module (33), the bottom of the X-axis linear module (31) is fixedly connected to a rectangular block (34), the side wall of the rectangular block (34) is slidably connected to a guide rod (35), and the end of the guide rod (35) is fixedly connected to a rectangular plate (36) fixedly connected to the top surface of the base (1); the control output end of the controller is electrically connected to the X-axis linear module (31), the Y-axis linear module (32) and the Z-axis linear module (33) respectively.

4. A take-up device for low-voltage wire harness production according to claim 3, characterized in that: The top of the transmission end of the Z-axis linear module (33) is fixedly connected to the bottom of the pressure sensor (8), the monitoring end of the top of the pressure sensor (8) is fixedly connected to the mounting plate (51), and the supporting groove wheel (5) is rotatably mounted on the side wall of the mounting plate (51) via a connecting shaft.

5. The low-voltage wire harness production take-up device according to claim 3, characterized in that: One end of the support plate (7) is fixedly connected to the side wall of the X-axis linear module (31). The distance monitoring assembly (6) includes a first square tube (61) vertically fixedly mounted on the top surface of the support plate (7). The inner wall of the first square tube (61) is slidably sleeved with a first square rod (62). The top of the first square rod (62) is fixedly connected to a first connecting plate (63). The side of the first connecting plate (63) is rotatably connected to a first movable block (64) via a connecting shaft. A first column (65) is fixedly mounted on the side wall of the first movable block (64). The first column (65) is coaxial with the connecting shaft of the first connecting plate (63) and the first movable block (64). A distance sensor (66) is fixedly mounted on the side wall of the first square tube (61). The monitoring end of the distance sensor (66) is vertically upwardly arranged and faces the outer wall of the first column (65). The wires of the low-voltage wiring harness are slidably connected to the side wall of the first movable block (64). The controller and the distance sensor (66) are signal connected.

6. The low-voltage wire harness production take-up device according to claim 1, characterized in that: The angle monitoring assembly (9) comprises a second square tube (91) vertically fixedly mounted on the base (1); a second square rod (92) is slidably sleeved on the inner wall of the second square tube (91); a second connecting plate (93) is fixedly connected to the top of the second square rod (92); a rotating shaft (94) is rotatably connected to the side wall of the second connecting plate (93); a second movable block (95) is fixedly mounted on one end of the rotating shaft (94), and an angle sensor (96) is fixedly mounted on the other end thereof; the controller and the angle sensor (96) are signal-connected; and the wires between the inlet groove wheel (4) and the support groove wheel (5) are slidably connected to the side wall of the second movable block (95).

7. A wire take-up control method for low-voltage wire harness production, characterized in that: A take-up device for low-voltage wire harness production according to any one of claims 1 to 6 is adopted, wherein a take-up reel encoder is installed on the take-up reel for real-time detection of winding diameter data; S1, controller system parameter initialization: set the target horizontal tension of the wire between the support sheave (5) and the take-up drum (2) , take-up speed , wiring pitch , and wire density , elastic modulus Material parameters; S2, real-time data acquisition: synchronously read the pressure sensor value , first distance value , second distance value , Angle monitoring value The real-time winding diameter is calculated by the take-up reel encoder ; S3, sag calculation and Z-axis level adjustment: a) Definition and calculation: Define the wire segment between the support sheave (5) and the take-up reel (2) as the object, and the horizontal distance between the installation points of the two distance monitoring components (6) as a fixed value , calculate the real-time average height of the wire section , and real-time height difference ; b) Overhang modeling: Overhang , consider the wire as a horizontal tension The acting suspension cable; c) Overhang control: the absolute horizontal state corresponds to the overhang , then the sag deviation ; d) Z-axis adjustment: To eliminate the overhang deviation, the controller generates a Z-axis control instruction: drives the Z-axis to move to the transmission end of the drive mechanism : ,in is the proportional coefficient of the controller, is the integration coefficient, is the differential coefficient, The sag deviation Derivative, The sag deviation Perform integral operations; By adjusting the height of the supporting groove wheel (5), the average height of the wires can be changed. and tension to make the sag Tends to zero, thus achieving precise horizontal adjustment; by controlling the physical quantity sag, it can effectively avoid the interference caused by the synchronous change of the absolute height of the two distance monitoring points; S4: Horizontal tension calculation and X-axis constant tension adjustment: a) Tension calculation model: Based on the force balance of the support groove wheel (5), the angle monitoring component (9) monitors the inclination angle of the wire between the incoming groove wheel (4) and the support groove wheel (5) as follows: : The horizontal tension of the wire between the supporting sheave (5) and the take-up reel (2) is ; b) Real-time calculation :The real-time collection and , and obtain the real-time horizontal tension ; c) Tension closed-loop control: calculation of tension deviation ; Use the controller to generate X-axis control instructions: ； in, is the tension deviation of this time, For the The tension deviation at the sampling moment, For the Tension deviation at the sampling moment; is the proportionality coefficient, is the integration coefficient, is the differential coefficient, Indicates the serial number of the sampling time; Drive the transmission platform of the X-axis drive mechanism to move , by slightly changing the guide angle, finely adjust the tension to the target value; S5: Collaborative cable arrangement and coil diameter compensation: a) Y-axis cable arrangement: according to the actual coil diameter and wiring pitch , generating a Y-axis drive mechanism control instruction, driving the Y-axis drive mechanism to drive the supporting groove wheel (5) to perform reciprocating motion, thereby achieving precise wiring; b) Z-axis feedforward compensation: real-time roll diameter change rate , generate Z-axis feedforward compensation , and superimposed on step S3 In the output, it is used to actively compensate for the slow change in the height of the take-up point caused by the increase in the take-up reel diameter, so that the distance monitoring value Keep within the sensor's optimal range; is the feedforward compensation coefficient, is a small change in the coil diameter. For small time intervals; S6: Loop control: Return to step S2 and continue looping until the line-reeling process is completed.

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