Steel wire diameter on-line monitoring system and method thereof

Abstract

The invention relates to a steel wire diameter on-line monitoring system and method, and belongs to the technical field of precision on-line measurement and process control in the industrial automation field, and the method comprises the following steps: S1, amplifying the transverse swing of a smooth wire through a lever mechanism to generate amplified displacement; the transverse swing is caused by the diameter change of the smooth silk; s2, detecting the amplified displacement by adopting a capacitive displacement sensor to generate real-time diameter data; the real-time diameter data is obtained through conversion according to a preset lever amplification factor; s3, filtering the real-time diameter data to generate a diameter monitoring value; s4, judging whether the diameter monitoring value exceeds a preset tolerance range or not; s5, if the judgment result is yes, triggering an alarm or sending a control signal; and if the judgment result is no, the steps from S1 to S4 are continued to be executed, and the surface integrity of the smooth silk product is effectively guaranteed.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of precision online measurement and process control in the field of industrial automation, in particular to a steel wire diameter online monitoring system and method thereof. BACKGROUND

[0002] In the high-speed production process of steel wire, especially steel cord smooth wire, the traditional diameter online monitoring method mainly relies on contact measurement or optical measurement; however, these methods have significant limitations, the contact measurement method is easy to scratch or damage the smooth surface of the steel wire, affecting the product quality; and the optical measurement method is easily disturbed by the light reflection characteristics of the smooth metal surface, resulting in unstable and low-precision measurement data; this situation makes it difficult to realize real-time, accurate and non-damaging monitoring of the diameter of the steel wire in the production process.

[0003] The above shortcomings mainly result from the limitations of the principle of traditional detection technology; when the contact probe physically contacts the steel wire moving at a speed of thousands of meters per minute, friction and wear are inevitably generated, thereby damaging the surface of the steel wire; and the optical method relies on the interaction of light and the measured object, for the metal wire with high surface finish and strong reflectivity, the reflection will change dramatically with slight vibration and angle change, causing serious interference to the measurement signal, reducing the reliability and stability of the detection.

[0004] As a result, stable and reliable real-time diameter data cannot be obtained, making it difficult for production managers to perform closed-loop control and automatic adjustment of the drawing process in a timely manner; when the diameter of the steel wire fluctuates beyond the tolerance range, the system cannot quickly discover and intervene, which not only increases the scrap rate, reduces the production efficiency and yield, but also limits the improvement of the overall production automation level, and cannot effectively guarantee the stringent quality requirements of high-end steel wire products on diameter consistency. SUMMARY

[0005] The purpose of the present application is to provide a steel wire diameter online monitoring system and method to solve the problems raised in the background.

[0006] The technical solution of the present application is as follows: S1, amplifying the transverse swing of the smooth wire through a lever mechanism to generate an amplified displacement; The transverse swing is caused by the diameter change of the smooth wire; S2, detecting the amplified displacement by using a capacitive displacement sensor to generate real-time diameter data; The real-time diameter data is obtained by conversion according to a preset lever amplification factor; S3, filtering the real-time diameter data to generate a diameter monitoring value; S4, determining whether the diameter monitoring value is beyond the preset tolerance range; S5, if the determination result is yes, triggering an alarm or sending a control signal; if the determination result is no, continuing to execute steps S1 to S4.

[0007] Preferably, the lever amplification factor of the lever mechanism is set to 5 to 10.

[0008] Preferably, the smooth wire and the guide wheel achieve rolling contact; the guide wheel is made of polytetrafluoroethylene composite material to achieve rolling contact with the smooth wire.

[0009] Preferably, the real-time diameter data D is generated in the following way: first, calculate the diameter change , equal to the displacement change detected by the sensor times 2 and then divided by the lever amplification factor K; then add the diameter change to the initial reference diameter .

[0010] Preferably, the filtering process adopts a sliding window mean algorithm; before calculating the mean value through the sliding window mean algorithm, first eliminate the abnormal data points beyond 3 times the standard deviation from the real-time diameter data.

[0011] Preferably, it further includes a mechanical damping step; the mechanical damping step includes: using an elastic hinge structure at the fulcrum of the lever mechanism, and setting a rubber damping pad on the equipment installation base.

[0012] Preferably, it further includes a temperature compensation step; the temperature compensation step includes: setting a temperature sensor, and correcting the lever amplification factor in real time according to the temperature data collected by the sensor and the preset temperature-deformation coefficient.

[0013] Preferably, it further includes the following auxiliary optical verification step: using a near-infrared LED light source to irradiate the contact area of the smooth wire and the guide wheel; using an industrial camera to take a contact state image; detecting the fit degree of the smooth wire and the main groove of the guide wheel through an image recognition algorithm; if the fit degree is lower than the preset threshold, triggering an adjustment signal; if the fit degree is not lower than the preset threshold, maintaining the current mechanical state.

[0014] Preferably, when the determination result is yes, the alarm is triggered or the control signal is sent within 50ms.

[0015] A steel wire diameter online monitoring system, comprising: a lever mechanism for amplifying the lateral swing of the smooth wire due to diameter change to generate an amplified displacement; A capacitive displacement sensor is used to detect the amplified displacement to generate real-time diameter data; A data processing unit is used to filter the real-time diameter data to generate diameter monitoring values; A system control unit is used to determine whether the diameter monitoring values exceed a preset tolerance range, and trigger an alarm or send a control signal when the determination result is yes.

[0016] The present application provides an online steel wire diameter monitoring system and method, which has the following improvements and advantages compared with the prior art: 1. The lever mechanism is used to mechanically amplify the lateral swing of the smooth wire caused by the change in its own diameter, and then the capacitive displacement sensor is used to non-contact detect the amplified displacement. This structural combination converts the micron-level diameter variation into a macro and easily measured displacement signal, solving the technical problems of traditional contact measurement which easily damages the smooth surface of the steel wire, and optical measurement which is easily disturbed by the reflection of the metal surface. This non-invasive measurement method ensures the monitoring accuracy while effectively protecting the product surface integrity of the smooth wire; 2. The technical solution is optimized from multiple dimensions. The amplification factor of the lever mechanism is limited in a range that takes into account signal gain and system stability, ensuring that the weak diameter change signal can be effectively amplified to the optimal detection range of the sensor, while avoiding excessive amplification factor which leads to structural redundancy and excessive sensitivity to environmental vibrations. On a physical level, a passive vibration isolation system is constructed by using an elastic hinge structure at the fulcrum of the lever mechanism and setting a rubber shock pad on the equipment base, which can effectively suppress high and low frequency vibration interference from the production site, ensuring the purity of the displacement signal source. On a data level, the filtering process uses an algorithm that first removes statistical outliers and then performs sliding window mean calculation. This processing method can effectively avoid extreme data pollution caused by instantaneous electrical interference or mechanical jitter, ensuring that the final diameter monitoring values truly reflect the smooth change trend of the diameter; 3. By introducing a series of compensation and verification mechanisms, the environmental adaptability and data reliability of the system are significantly improved. The temperature compensation step actively eliminates systematic measurement errors caused by material thermal expansion and contraction effects by monitoring the ambient temperature in real time and dynamically correcting the lever amplification factor, ensuring long-term measurement consistency of the device in different temperature environments. The auxiliary optical verification step adds an independent verification link to the reliability of the measurement reference, changing the ideal state of mechanical contact from a default premise to a variable that can be monitored in real time, which can timely alert poor contact caused by abnormality such as guide wheel wear or steel wire jumping, avoiding the generation of invalid data under the wrong measurement reference, and greatly improving the overall robustness of the monitoring solution; 4. Ensures the practicality of the measurement and the close integration with the production process; the smooth wire realizes rolling contact through a guide wheel made of polytetrafluoroethylene composite material, which stabilizes the transmission of lateral swing while ensuring that the surface quality of the smooth wire is not affected due to its extremely low friction coefficient; the generation mode of real-time diameter data establishes an accurate mathematical model from sensor displacement readings to absolute diameter values, enabling the monitoring results to output quantitative values with physical meaning, in line with industrial measurement standards; when the monitoring value exceeds the tolerance range, the system can trigger an alarm or send a control signal in a very short time, and this high-speed response capability plays a key role in reducing waste product output and achieving real-time closed-loop control of the production process, effectively minimizing the impact of quality problems and thus improving the yield and production efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0017] The present application will be further explained in conjunction with the accompanying drawings and embodiments: Figure 1 is a method step diagram of a steel wire diameter online monitoring method of the present application. DETAILED DESCRIPTION

[0018] In order to make the purpose, technical solutions and advantages of the present application clearer and more apparent, the present application will be further described in detail below in conjunction with specific embodiments.

[0019] Example 1 Please refer to Figure 1 The present application provides a steel wire diameter online monitoring method, comprising the following steps: S1, amplifying the lateral swing of the smooth wire through a lever mechanism to generate an amplified displacement; The lateral swing is caused by the diameter change of the smooth wire; S2, detecting the amplified displacement using a capacitive displacement sensor to generate real-time diameter data; The real-time diameter data is obtained by conversion according to a preset lever amplification factor; S3, filtering the real-time diameter data to generate a diameter monitoring value; S4, determining whether the diameter monitoring value exceeds a preset tolerance range; S5, if the determination result is yes, triggering an alarm or sending a control signal; if the determination result is no, continuing to perform steps S1 to S4; The conversion is based on an initial reference diameter, and the change in the amplified displacement measured by the sensor is scaled back by the lever ratio, thereby calculating the real-time absolute diameter, and the core mathematical relationship can be expressed as:

[0020] Among them, is the real-time diameter data calculated, an initial reference diameter for pre-production calibration, a displacement variation detected by the capacitive displacement sensor relative to the calibrated initial position, and a preset lever amplification factor; The embodiment of the present application provides a steel wire diameter online monitoring method. The method amplifies the transverse swing of the smooth wire through a lever mechanism to generate an amplified displacement. The smooth wire refers to a steel cord after a large-drawing process, which has a smooth surface and will be used as raw material for a subsequent twisting process. The transverse swing refers to a radial position deviation of the smooth wire in a direction perpendicular to its movement direction due to a slight change in its own diameter when it moves at a high speed along its axis. The purpose of this step is to convert the micron-level change in the diameter of the smooth wire into a macro displacement signal that can be accurately detected by a sensor. In this embodiment, the smooth wire is guided to pass around a guide wheel connected to the lever mechanism. The change in the diameter of the smooth wire causes the center line position to deviate, and in turn causes the guide wheel to swing by an equivalent amplitude. The swing is received and amplified by the lever mechanism. Based on the amplified displacement, a capacitive displacement sensor detects it to generate real-time diameter data. The internal logic of this step is to non-contactly convert a mechanical displacement signal into a high-frequency electrical signal. In this embodiment, the sensor works at a sampling frequency of 1 kHz, and the detection end and the end of the lever mechanism maintain a non-contact distance of 0.5-1 mm to avoid mechanical interference. The generation of real-time diameter data is obtained by conversion according to a preset lever amplification factor. The lever amplification factor is a preset fixed ratio to represent the amplification capability of the lever mechanism to the input displacement. To improve the data signal-to-noise ratio, a data processing unit performs filtering processing on the collected real-time diameter data to generate a diameter monitoring value. The purpose of this step is to eliminate noise data introduced by mechanical vibration or transient jump of the electrical signal, and to extract the true trend that stably reflects the diameter change. According to the diameter monitoring value, a system control unit determines whether it exceeds a preset tolerance range. The preset tolerance range refers to the upper and lower threshold values of the allowable fluctuation of the diameter of the smooth wire according to the product specifications and process standards. The control unit also includes abnormal working condition processing logic. For example, when the displacement variation The change rate or absolute value of the displacement variation exceeds a preset physical limit threshold, the system will determine an emergency failure such as wire breakage and trigger the highest level of alarm. In the initial stage of device startup or roll change, the system can be set to a shielding mode, and then enter a normal monitoring state after the production is stable. If the determination result is yes, i.e., the diameter monitoring value is out of the range, the system immediately triggers an alarm or sends a control signal; if the determination result is no, the process continues online monitoring; the triggered alarm is embodied as an audible and light alarm in this embodiment; the sent control signal is embodied as sending a linkage signal to the control system of the drawing equipment to automatically adjust the process, for example, fine-tuning the pulling speed of the drawing host or adjusting the flow of the lubrication system; Through the synergistic effect of the above steps, this embodiment can convert the slight diameter change of the smooth wire into a reliable digital signal through non-damage mechanical amplification and high-precision sensing detection, and after filtering and determination, realize real-time and closed-loop monitoring of the diameter of the steel wire in the production process; compared with the contact measurement of the easily damaged surface or the optical measurement easily disturbed by the reflection, this method provides a high-precision, high-stability online monitoring solution for the smooth metal wire running at high speed, effectively guarantees the product quality and improves the production automation level.

[0021] Embodiment 2 A steel wire diameter online monitoring system comprises: A lever mechanism is used to amplify the lateral swing of the smooth wire caused by the diameter change to generate an amplified displacement; A capacitive displacement sensor is used to detect the amplified displacement to generate real-time diameter data; A data processing unit is used to filter the real-time diameter data to generate a diameter monitoring value; A system control unit is used to determine whether the diameter monitoring value is out of a preset tolerance range, and trigger an alarm or send a control signal when the determination result is yes; The embodiment of the present application also provides a steel wire diameter online monitoring system, which is used to execute the foregoing method; The system comprises a lever mechanism, which is used to amplify the lateral swing of the smooth wire caused by the diameter change to generate an amplified displacement; in this embodiment, the lever mechanism is made of 6061 aluminum alloy material and adopts an equal strength beam structure design, which ensures that the deformation of the lever mechanism itself is controlled to a minimum limit while amplifying the displacement; The system further comprises a capacitive displacement sensor, which is used to detect the amplified displacement output by the lever mechanism and convert the displacement into an electrical signal to generate real-time diameter data; the sensor has a measurement resolution of 0.0001 mm and can accurately capture the amplified micro displacement; The system further comprises a data processing unit, which is used to filter the real-time diameter data generated by the sensor to generate a diameter monitoring value; in this embodiment, the unit is realized by an STM32H743 microprocessor with a main frequency of 480 MHz, which ensures the real-time processing capability of 1 kHz sampling frequency data; The system includes a system control unit, which is responsible for determining whether the diameter monitoring value generated by the data processing unit exceeds a preset tolerance range and triggering an alarm or sending a control signal if the determination result is yes. The control unit and the data processing unit are integrated into the aforementioned microprocessor and perform the determination and response through a built-in real-time comparison algorithm. The various components of this system are integrated into a compact measuring unit with a protection level of IP65. By working together, they realize a complete online monitoring closed loop of smooth wire diameter, from mechanical signal capture, electrical signal conversion, data optimization to logical judgment. The system has a simple structure and is easy to maintain. It effectively avoids the surface scratches and optical interference problems existing in the existing technology through the principle of mechanical amplification, providing a reliable and economical quality monitoring tool for steel cord production.

[0022] Example 3 The lever magnification of the lever mechanism is set to 5 to 10; In this embodiment, the lever magnification of the lever mechanism is limited; the lever magnification is set to 5 to 10; the lever magnification The calculation method is the lever arm With short arms The ratio of the lengths is:

[0023] in, is the magnification, is the long arm length, is the short arm length; in this embodiment, by , the length of the force arm is set to 20mm, and the long arm The length of the arm where the sensor detection point is located is set to the range of 100mm to 200mm, achieving a 5- to 10-fold amplification effect. For example, when the diameter of the smooth wire changes by 0.001mm, its center line will shift by 0.0005mm. After 5-fold amplification, the displacement generated by the end of the lever is 0.0025mm, which is much larger than the resolution of the capacitive displacement sensor of 0.0001mm, thus ensuring a sufficiently high signal-to-noise ratio for the detection signal. Limiting the amplification factor to 5 to 10 times achieves a technical balance between signal amplification and system stability. An amplification factor below 5 times may result in insufficient signal gain, while an amplification factor above 10 times would oversize the lever mechanism and dramatically increase sensitivity to environmental vibration, hindering stable application in industrial sites. The technical gain effect of this setting is that, while ensuring the system's compact structure and vibration resistance, it effectively amplifies the weak diameter change signal to the sensor's optimal detection range, significantly improving monitoring sensitivity and accuracy. The smooth wire and the guide wheel are in rolling contact; the guide wheel is made of polytetrafluoroethylene composite material to achieve rolling contact with the smooth wire; In this embodiment, the contact method between the smooth wire and the lever mechanism is optimized; the smooth wire contacts a guide wheel connected to the short arm end of the lever mechanism; the guide wheel is made of a polytetrafluoroethylene composite material, the purpose of which is to achieve rolling contact with the smooth wire; this composite material has an extremely low friction coefficient of ≤ 0.05 and a high surface finish of Ra ≤ 0.8 μm, ensuring that the smooth surface will not be scratched or damaged while guiding the smooth wire; the guide wheel adopts a double-groove structure, in which the main groove matches the diameter of the smooth wire, and the groove width is 0.05-0.1 mm larger than the maximum nominal diameter of the smooth wire, ensuring both reliable radial contact and avoiding jamming; The gain technical effect brought about by this specific contact method is that it solves the technical pain point that traditional contact probes may scratch the surface of the smooth wire; by converting sliding friction into rolling friction and selecting self-lubricating PTFE composite materials, this embodiment ensures the stable and precise transmission of the lateral swing of the smooth wire while ensuring the product quality of the smooth wire, which is crucial for subsequent surface treatment processes such as coating.

[0024] Real-time diameter data The generation method is: first calculate the diameter change , Equal to the displacement change detected by the sensor Multiply by 2 and divide by the lever magnification K; then calculate the diameter change With the initial reference diameter Addition; In this embodiment, the real-time diameter data The generation method of the diameter change is clarified; the generation method first calculates the diameter change , the change The value is equal to the displacement change detected by the sensor Divide by the leverage ratio The calculated diameter change With an initial reference diameter Add together to get the final real-time diameter data The calculation formula is as follows:

[0025] Where, is the real-time diameter, is the base diameter, is the displacement change, is the magnification; initial reference diameter is obtained through a static calibration step, and the acquisition method is as follows: before the measurement starts, a standard sample rod, for example, with a diameter of 0.2000 mm, is used for calibration, at which time the sensor records an initial displacement reading , and the diameter value of the standard sample rod is assigned to ; the displacement change amount refers to the difference between the displacement reading collected by the sensor in real time and the initial displacement reading , that is,

[0026] In the formula, : displacement change amount; : displacement reading collected by the sensor in real time; initial displacement reading recorded by the sensor during calibration; The technical effect brought by this calculation method is that an accurate and traceable mathematical model from the displacement reading of the sensor to the actual steel wire diameter is established; the reference diameter and the magnification are used for calculation, and this method not only can reflect the relative change of the diameter, but also can output an absolute diameter value with physical meaning, so that the monitoring result is intuitive and meets the measurement standard of industrial production, and high-precision quantitative measurement is realized.

[0027] The filtering processing adopts a sliding window mean algorithm; before the mean value is calculated through the sliding window mean algorithm, the abnormal data points exceeding 3 times the standard deviation are first removed from the real-time diameter data; In this embodiment, the implementation manner of the filtering processing is specified; the filtering processing adopts a sliding window mean algorithm; the sliding window mean algorithm is a digital signal processing technology, and the working principle is as follows: a fixed length time window, for example, 2 seconds, is set, the arithmetic mean value of all real-time diameter data in the window is continuously calculated, and the mean value is taken as the output at the current time; with the passage of time, the window slides forward on the data stream, and a new mean value is continuously generated; If the size of the sliding window, that is, the number of sampling points, is , at time , the data points in the window are the real-time diameter data sequence after the abnormal values are removed , then the calculation formula of the diameter monitoring value output at this time is as follows:

[0028] In the formula, : diameter monitoring value output at time t; N: size of the sliding window, that is, number of sampling points; t: represents the current time; i: index variable for summation; : a data point in the real-time diameter data sequence after removing outliers; This formula ensures that the output value is the arithmetic mean of the last effective data points, effectively smoothing short-term fluctuations; To further ensure the effectiveness of the data, a preprocessing step is added before calculating the mean value by the sliding window mean algorithm: remove the abnormal data points that exceed 3 times the standard deviation from the real-time diameter data in the current window; 3 times the standard deviation is based on the normal distribution theory, The principle of setting the threshold is to identify statistically small probability outliers caused by accidental interference; The technical effect of this filtering method is to greatly enhance the stability and reliability of the diameter monitoring value; by removing statistical outliers first, it effectively avoids the pollution of extreme error data caused by equipment instantaneous jitter, electromagnetic interference and other factors on the mean value calculation, ensuring the authenticity of the overall trend of the data in a statistical sense; the subsequent sliding window mean algorithm further smooths the high-frequency noise in the data, so that the final output diameter monitoring value can more truly reflect the average state and trend of the smooth wire diameter over a period of time, with the error effectively controlled within ±0.0005mm.

[0029] It also includes a mechanical damping step; the mechanical damping step includes using an elastic hinge structure at the fulcrum of the lever mechanism, and setting a rubber damping pad at the equipment installation base; In this embodiment, a mechanical damping step is added; the purpose of this step is to physically suppress the interference of external environmental vibration on the measurement accuracy; this mechanical damping step includes two aspects: Use an elastic hinge structure at the fulcrum of the lever mechanism; the elastic hinge structure is a flexible structure that uses material elastic deformation to achieve rotation, which has a stiffness coefficient of 500N / m in this embodiment, and can effectively absorb and dissipate high-frequency vibrations from the equipment itself or the production line, above 100Hz; Set a rubber damping pad at the equipment installation base; the damping coefficient of this damping pad is 0.3, which is specifically used to isolate low-frequency environmental vibrations from the ground or rack, below 10Hz; Through the combination of high and low frequency vibration suppression measures, the technical effect of this embodiment is to significantly improve the environmental adaptability and anti-interference ability of the monitoring system in complex industrial sites; the synergistic effect of the elastic hinge and the rubber damping pad creates a wideband vibration passive isolation system for the lever-sensor core measurement link, ensuring that even near the vibration source, the displacement signal captured by the sensor is mostly derived from the diameter change of the smooth wire itself, rather than external noise, thereby ensuring the purity and reliability of the measurement data.

[0030] The temperature compensation step is further included, which comprises: setting a temperature sensor and correcting the lever amplification factor in real time according to the temperature data collected by the sensor and a preset temperature-deformation coefficient; In the embodiment, the temperature compensation step is added, which aims to eliminate the measurement error caused by thermal expansion and contraction of the lever mechanism material due to environmental temperature changes. The temperature compensation step comprises: setting a high-precision temperature sensor near the lever mechanism and the sensor, with an accuracy of ±0.1℃, for collecting temperature data of the environment in which the key components are located in real time; the system corrects the lever amplification factor in real time according to the temperature data collected by the sensor and a preset temperature-deformation coefficient; the correction logic is: calculating the change amount of the lever arm length caused by temperature changes in real time and dynamically updating the value of the amplification factor. The dynamically updated lever amplification factor can be calculated by the following correction model:

[0031] In the formula, is the lever amplification factor calibrated at a standard reference temperature , for example, 20℃, is the ambient temperature collected by the temperature sensor in real time, and is a temperature correction coefficient that characterizes the influence of the overall measurement system, including the lever mechanism and the sensor mounting seat, on the amplification factor caused by thermal deformation, which is calibrated in advance through experiments; the coefficient comprehensively considers the linear expansion coefficient of the material and the structural factors; The gain technical effect brought by this temperature compensation mechanism is to significantly improve the measurement consistency and accuracy of the monitoring method under different environmental temperatures; by actively monitoring temperature changes and dynamically correcting core parameters, the embodiment effectively eliminates the systematic error source introduced by thermal effects, ensuring that the device can maintain high precision in the calibrated state when running for a long time or experiencing seasonal temperature changes, and realizing stable monitoring all day round; The following auxiliary optical verification step is further included: A near-infrared LED light source is used to irradiate the contact area between the light surface wire and the guide wheel; An industrial camera is used to shoot the contact state image; An image recognition algorithm is used to detect the fit degree of the light surface wire and the main groove of the guide wheel; If the fit degree is lower than the preset threshold, an adjustment signal is triggered; if the fit degree is not lower than the preset threshold, the current mechanical state is maintained; ​In this embodiment, an auxiliary optical verification step is added; the purpose of this step is to confirm in real time whether the mechanical contact state as the measurement reference is stable and reliable; this step uses a near-infrared LED light source aimed at avoiding visible light glare interference, with a wavelength of 850 nm to irradiate the contact area of the smooth wire and the guide wheel; an industrial camera with a frame rate of 30 fps continuously captures images of the contact state; through the built-in image recognition algorithm, the collected images are analyzed to detect the fit of the smooth wire and the guide wheel main groove; for example: the algorithm identifies the guide wheel main groove profile and the smooth wire profile through the edge detection algorithm, and quantifies the fit by calculating the ratio of the overlapping pixel length of the two profiles in the contact area to the total pixel length of the smooth wire in that area; the fit is a quantitative indicator for evaluating whether the smooth wire is in close contact with the guide wheel groove without gaps; the threshold in this embodiment is determined by a correlation model related to measurement stability based on experimental data, and is determined to be good when the fit rate is not less than 95%; if the algorithm detects that the fit is lower than the preset threshold, for example 90%, the system will trigger an adjustment signal, prompting the need to check or adjust the mechanical structure; if the fit is maintained above the threshold, the current mechanical state is maintained; The technical effect brought by this auxiliary optical verification step is that an independent verification link is added to the reliability of the entire monitoring system; the ideal contact premise relied on by the main measurement method is changed from a default assumption to a variable that can be monitored in real time; when the smooth wire jumps or the guide wheel wears abnormally, the system can timely alarm, thereby avoiding invalid data under the wrong measurement reference, greatly improving the robustness and credibility of the entire monitoring scheme.

[0032] When the determination result is yes, an alarm or a control signal is triggered within 50 ms; In step S5 of the method in this embodiment, the response speed is specifically limited; when the determination result is yes, that is, the diameter monitoring value exceeds the tolerance range, the system is required to trigger an alarm or send a control signal within 50 ms; this fast response capability is achieved by selecting a high-speed data processing chip such as STM32H743 and optimizing the internal processing algorithm; the delay of the entire process from data collection from the sensor, through filtering calculation, to the final comparison with the threshold and output of the decision signal is strictly controlled within 50 ms; The technical effect brought by this limitation is to achieve nearly instantaneous feedback and intervention on production abnormalities; on a production line with a smooth wire running speed of up to 1200 m / min, a response time of 50 ms means that the abnormality has been discovered and an adjustment instruction has been issued before at most 1 meter of steel wire is produced; this high-speed response capability plays a key role in reducing waste production and achieving real-time closed-loop control of the production process, effectively minimizing the impact of quality problems, thereby improving the yield and production efficiency.

[0033] It should be noted that the above examples are only used to illustrate the technical solutions of the present application but not to limit the present application. Although the present application has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present application can be modified or equivalent replaced without departing from the spirit and scope of the technical solutions of the present application.

Claims

1. A method for online monitoring of steel wire diameter, characterized in that: The steps include: S1, amplifying the lateral swing of the smooth wire through a lever mechanism to generate an amplified displacement; The lateral oscillation is caused by the diameter variation of the smooth wire; S2, using a capacitive displacement sensor to detect the amplified displacement to generate real-time diameter data; Real-time diameter data is converted according to the preset lever magnification; S3. Filtering the real-time diameter data to generate a diameter monitoring value; S4, determining whether the diameter monitoring value exceeds the preset tolerance range; S5. If the determination result is yes, trigger an alarm or send a control signal; If the determination result is no, then continue to execute steps S1 to S4.

2. The method for online monitoring of steel wire diameter according to claim 1, characterized in that: The lever magnification of the lever mechanism is set to 5 to 10 times.

3. The method for online monitoring of steel wire diameter according to claim 1, characterized in that: The smooth wire is in rolling contact with the guide wheel; the guide wheel is made of polytetrafluoroethylene composite material to achieve rolling contact with the smooth wire.

4. The method for online monitoring of steel wire diameter according to claim 1, characterized in that: The real-time diameter data D is generated as follows: First, calculate the diameter change , Equal to the displacement change detected by the sensor Multiply by 2 and divide by the lever magnification K; then calculate the diameter change With the initial reference diameter Add.

5. The method for online monitoring of steel wire diameter according to claim 1, characterized in that: The filtering process uses a sliding window mean algorithm; before calculating the mean using the sliding window mean algorithm, abnormal data points exceeding three times the standard deviation are first removed from the real-time diameter data.

6. The method for online monitoring of steel wire diameter according to claim 1, characterized in that: The method also includes a mechanical shock absorption step; the mechanical shock absorption step includes: adopting an elastic hinge structure at the fulcrum of the lever mechanism, and arranging a rubber shock absorption pad on the equipment installation base.

7. The method for online monitoring of steel wire diameter according to claim 1, characterized in that: It also includes a temperature compensation step; the temperature compensation step includes: setting a temperature sensor, and correcting the lever magnification in real time based on the temperature data collected by the sensor and a preset temperature-deformation coefficient.

8. The method for online monitoring of steel wire diameter according to claim 1, characterized in that: The following auxiliary optical verification steps are also included: Use near-infrared LED light source to illuminate the contact area between the smooth wire and the guide wheel; Use industrial cameras to capture contact status images; The fit between the smooth wire and the main groove of the guide wheel is detected by image recognition algorithm; If the fit is lower than the preset threshold, an adjustment signal is triggered; if the fit is not lower than the preset threshold, the current mechanical state is maintained.

9. The method for online monitoring of steel wire diameter according to claim 1, characterized in that: When the judgment result is yes, an alarm is triggered or a control signal is sent within 50ms.

10. A steel wire diameter online monitoring system, based on the steel wire diameter online monitoring method according to any one of claims 1 to 9, characterized in that: include: A lever mechanism for amplifying the lateral swing of the smooth wire due to the change in diameter to generate an amplified displacement; Capacitive displacement sensors to detect amplified displacement to generate real-time diameter data; A data processing unit, configured to filter the real-time diameter data to generate a diameter monitoring value; The system control unit is used to determine whether the diameter monitoring value exceeds the preset tolerance range, and trigger an alarm or send a control signal when the determination result is yes.

Images