Automatic production control method and system for rubber cable

Abstract

The invention relates to the technical field of rubber cable automatic production, and provides a rubber cable automatic production control method and system, and the method comprises the steps: generating an extrusion path track according to a cable structure parameter and a conductor diameter, and extending to form an insulation layer extrusion model; generating a vulcanization control curve based on the vulcanization temperature parameters, and determining a time sequence matching relationship between the vulcanization control curve and the extrusion model; generating cooling section parameters according to the position and duration of the vulcanization section, and expanding into a cooling control model; generating a traction rate distribution diagram by combining the traction speed parameters, and superposing the traction rate distribution diagram to a cooling model to form a forming control model; and finally, performing time sequence synchronization on the extrusion model, the vulcanization curve and the forming model, and outputting a production control instruction. According to the invention, the insulation layer uniformity and vulcanization efficiency of the rubber cable can be improved, and the energy consumption and defect rate are reduced.

Description

Technical Field

[0001] This invention relates to the field of automated production technology for rubber cables, and more specifically, to an automated production control method and system for rubber cables. Background Art

[0002] In the production process of rubber cables, traditional production control methods mainly rely on manual operation and experience-based judgment, making it difficult to achieve precise automated control. For example, during the extrusion of the insulation layer, workers typically need to manually adjust the extrusion path based on the cable structure parameters and conductor diameter. This method is not only inefficient but also prone to product quality instability due to human factors. In the vulcanization stage, the precision of vulcanization temperature and time control directly affects cable performance. However, existing technologies often lack precise parameter matching in generating vulcanization control curves, resulting in unsatisfactory vulcanization effects. The cooling process faces similar problems. The setting of cooling cross-section parameters is not scientific enough, and the establishment of cooling control models is not perfect, making the cable prone to defects during cooling. In addition, the control of traction speed also has many shortcomings. Existing methods for generating traction rate distribution maps fail to fully consider factors such as temperature stratification, speed gradient, and traction compensation, resulting in large fluctuations in cable tension and speed during production, affecting product quality and production efficiency.

[0003] The existing technology has at least the following problems or defects: the automation level of the existing rubber cable production control method is low, and the reliance on manual operation leads to low production efficiency and unstable product quality; the control precision of the vulcanization and cooling process is insufficient, and there is a lack of scientific parameter matching and model establishment, which affects the cable performance; the traction speed control method is not perfect and fails to fully consider a variety of influencing factors, resulting in large fluctuations in tension and speed during the cable production process, which affects production efficiency and product quality. Summary of the Invention

[0004] This invention provides an automated production control method and system for rubber cables.

[0005] In a first aspect of the present invention, an automated production control method for rubber cables is provided, comprising:

[0006] An extrusion path trajectory is generated based on cable structure parameters and conductor diameter, wherein the cable structure parameters include insulation layer thickness;

[0007] Based on the conductor diameter, the extrusion path is extended along the cable axis to form an insulation extrusion model;

[0008] A vulcanization control curve is generated based on vulcanization temperature parameters, including the duration of the vulcanization stage.

[0009] Based on the location parameters of the vulcanization zone, the time-series matching relationship between the vulcanization control curve and the insulation layer extrusion model is determined;

[0010] Cooling section parameters are generated based on the relative position of the vulcanization section and the extrusion path, and the duration of the vulcanization stage. The cooling section parameters are then expanded along the conveying direction of the production line to obtain a cooling control model.

[0011] A traction rate distribution map is generated based on the traction speed parameters; the traction rate distribution map is then superimposed on the cooling control model to obtain the forming control model.

[0012] The insulation extrusion model, vulcanization control curve, and molding control model are synchronized in time to obtain cable production control commands.

[0013] Furthermore, the traction speed parameters include the number of temperature stratifications, the number of speed gradients, and the traction compensation amount;

[0014] A traction rate distribution map is generated based on the traction speed parameters, including:

[0015] Based on the stated number of temperature stratifications n, n temperature ranges are generated within the vulcanization control curve;

[0016] The conveyor belt in the highest temperature range is divided into m speed segments based on the speed gradient number m.

[0017] The speed is adjusted layer by layer from high temperature to low temperature for each temperature range, wherein the speed gradient number of the outer temperature range between two adjacent temperature ranges is an integer multiple of the speed gradient number of the inner temperature range.

[0018] The adjustment nodes of each speed segment are connected sequentially from the high-temperature zone to the low-temperature zone to form a stepped speed curve;

[0019] The traction rate distribution map is obtained by extending the traction compensation amount along the lateral direction perpendicular to each speed segment in the stepped speed curve.

[0020] Furthermore, the traction speed parameters also include a speed smoothing coefficient;

[0021] After obtaining the traction rate distribution map by laterally expanding the traction compensation amount along each speed segment of the stepped speed curve, the following steps are also included:

[0022] The adjustment node of the highest temperature range of the traction rate distribution map is moved forward in the conveying direction with the midpoint of the production line as the center by the speed smoothing coefficient to obtain the smoothed traction rate distribution map.

[0023] Furthermore, the traction speed parameters include tension offset angle, speed fluctuation range, and traction buffer amount;

[0024] A traction rate distribution map is generated based on the traction speed parameters, including:

[0025] Take the baseline speed line of the vulcanization control curve;

[0026] Using the intersection of the baseline velocity line and the cooling control model as the reference point, the velocity line is undulated upward and downward by the tension offset angle to obtain a wave-shaped velocity curve;

[0027] Multiple fluctuating velocity lines are obtained by adjusting the amplitude of the wave-shaped velocity curve according to the velocity fluctuation range.

[0028] By extending the traction buffer amount along the longitudinal direction of the peak segment in each fluctuation velocity line, a traction rate distribution map is obtained.

[0029] Furthermore, after overlaying the traction rate distribution map onto the cooling control model to obtain the forming control model, the model further includes:

[0030] Detection points are set within the cooling section based on the defect detection density parameters;

[0031] A temperature monitoring grid is generated within the cooling section based on the detection points;

[0032] Based on the safety threshold parameters, each monitoring grid within the cooling section is scaled down proportionally to generate optimized cooling parameters;

[0033] The optimized cooling parameters are expanded along the production line direction to obtain the optimized cooling model;

[0034] The molding control model and the optimized cooling model are fused to obtain the optimized molding control model.

[0035] Furthermore, cooling section parameters are generated based on the relative position of the vulcanization section and the extrusion path, and the duration of the vulcanization stage, including:

[0036] The starting end face of the vulcanization zone is taken as the first reference surface, and the intersection of the axis connecting the first reference surface and the center of the conductor with the extrusion path model is taken as the transition surface. The transition surface is extended outward along the direction perpendicular to the production line to the outer surface of the insulation layer to obtain the first termination surface.

[0037] Take the intersection line between the first termination surface and the plane containing the production line axis and the extrusion path model, and extend the first termination surface outward along the intersection line to the edge of the cooling water tank to obtain the second termination surface;

[0038] The first reference plane, the first termination plane, and the second termination plane are connected in sequence to form the cooling inner layer curve;

[0039] Calculate the distance between the first termination surface and the second termination surface in the production line direction, and take the smaller value between the distance and the vulcanization stage duration as the cooling delay amount;

[0040] The first reference plane is offset backward by the cooling delay amount along the production line direction to obtain the second reference plane;

[0041] Connect the second reference plane and the second termination plane to form a cooling outer layer curve;

[0042] The cooling inner layer curve and the cooling outer layer curve constitute the cooling cross-sectional parameters.

[0043] Further, the cooling inner layer curve is formed by sequentially connecting the first reference plane, the first termination plane, and the second termination plane, including:

[0044] Multiple temperature measuring points are set on the transition section connecting the first reference surface and the first termination surface. The positions of the multiple temperature measuring points are adjusted by piecewise linear interpolation according to the thermal conductivity coefficient to obtain the cooling gradient curve from the reference surface to the termination surface.

[0045] The cooling gradient curve from the reference surface to the termination surface and the heat dissipation curve from the termination surface to the second termination surface together form the cooling inner layer curve.

[0046] Furthermore, the cooling outer layer curve is formed by connecting the second reference plane and the second termination plane, including:

[0047] Multiple pressure monitoring points are set on the transition section connecting the second reference surface and the second termination surface. The positions of the multiple monitoring points are adjusted by piecewise linear interpolation according to the fluid dynamics parameters to obtain the cooling outer layer curve.

[0048] Furthermore, the traction rate distribution map is superimposed on the cooling control model to obtain the forming control model, including:

[0049] The traction rate distribution map is extended along the production line direction by time compensation to obtain a three-dimensional control surface. The three-dimensional control surface is then superimposed with the cooling control model to obtain the molding control model.

[0050] In a second aspect of the present invention, an automated production control system for rubber cables is provided, comprising:

[0051] An extrusion control module is used to generate an extrusion path trajectory based on cable structural parameters and conductor diameter, including insulation layer thickness; and to extend the extrusion path trajectory along the cable axis direction according to the conductor diameter to form an insulation layer extrusion model.

[0052] The vulcanization control module is used to generate a vulcanization control curve based on vulcanization temperature parameters, including the vulcanization stage duration; and to determine the timing matching relationship between the vulcanization control curve and the insulation layer extrusion model based on the vulcanization section location parameters.

[0053] The cooling modeling module is used to generate cooling section parameters based on the relative position of the vulcanization section and the extrusion path and the duration of the vulcanization stage. The cooling section parameters are then expanded along the conveying direction of the production line to obtain a cooling control model.

[0054] The traction modeling module is used to generate a traction rate distribution map based on the traction speed parameters; the traction rate distribution map is then superimposed on the cooling control model to obtain the forming control model.

[0055] The production coordination module is used to synchronize the insulation extrusion model, vulcanization control curve, and molding control model in a timely manner to obtain cable production control instructions.

[0056] The above embodiments of the present invention have at least the following beneficial effects: The automated production control method and system for rubber cables of the present invention can achieve high-precision automated control of the cable production process. By generating an extrusion path trajectory based on cable structural parameters and conductor diameter, and extending it along the cable axis to form an insulation layer extrusion model, the uniformity and consistency of the insulation layer can be ensured. Simultaneously, by generating a vulcanization control curve based on vulcanization temperature parameters and accurately matching the vulcanization section position parameters, the vulcanization effect can be effectively improved, enhancing the mechanical and electrical properties of the cable. Furthermore, the scientific generation of cooling section parameters and the establishment of a cooling control model can optimize the cooling process, reduce cooling defects, and improve the overall quality of the cable. The method for generating the traction rate distribution map comprehensively considers multiple factors such as temperature stratification, speed gradient, and traction compensation, and through smoothing and optimization adjustments, precise control of the traction speed can be achieved, reducing tension fluctuations and improving production efficiency and product quality.

[0057] This invention can further improve the accuracy and stability of the cooling process by optimizing cooling parameters and fusing data from the molding control model, ensuring quality control of the cable during the cooling stage. Simultaneously, the systematic production control command generation method enables the synchronization of insulation extrusion, vulcanization control, and molding control, making the entire production process more coordinated and efficient. This highly automated and precisely controlled production method not only improves production efficiency and reduces production costs but also significantly enhances the product quality and consistency of rubber cables, meeting the high-performance and high-reliability requirements of modern industry. Attached Figure Description

[0058] The above and other objects, features, and advantages of exemplary embodiments of the present invention will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings. Several embodiments of the invention are illustrated in the drawings by way of example and not limitation, wherein:

[0059] Figure 1 A flowchart illustrating an embodiment of the automated production control method for rubber cables provided by the present invention;

[0060] Figure 2 This is a schematic diagram of the structure of an automated production control system for rubber cables provided in an embodiment of the present invention;

[0061] Figure 3 A schematic diagram of the structure of an electronic device according to an embodiment of the present invention is shown. DETAILED DESCRIPTION

[0062] The principles and spirit of the invention will now be described with reference to several exemplary embodiments. It should be understood that these embodiments are provided merely to enable those skilled in the art to better understand and implement the invention, and are not intended to limit the scope of the invention in any way. Rather, these embodiments are provided to make the invention more thorough and complete, and to fully convey the scope of the invention to those skilled in the art.

[0063] Those skilled in the art will recognize that embodiments of the present invention can be implemented as a system, apparatus, device, method, or computer program product. Therefore, the present invention can be specifically implemented in the following forms: entirely hardware, entirely software (including firmware, resident software, microcode, etc.), or a combination of hardware and software.

[0064] It should be noted that the number of any elements in the accompanying drawings is for illustrative purposes only and not as a limitation, and any naming is for distinction only and has no limiting meaning.

[0065] The following is for reference. Figure 1 , Figure 1 This is a flowchart illustrating an embodiment of the automated production control method for rubber cables provided by the present invention. Figure 1 As shown, an automated production control method for rubber cables includes:

[0066] S1 generates an extrusion path trajectory based on cable structure parameters and conductor diameter, wherein the cable structure parameters include insulation layer thickness;

[0067] S2 extends the extrusion path along the cable axis direction according to the conductor diameter to form an insulation extrusion model;

[0068] S3 generates a vulcanization control curve based on vulcanization temperature parameters, including the vulcanization stage duration;

[0069] S4 determines the timing matching relationship between the vulcanization control curve and the insulation layer extrusion model based on the vulcanization zone location parameters;

[0070] S5 generates cooling section parameters based on the relative position of the vulcanization section and the extrusion path, as well as the duration of the vulcanization stage. The cooling section parameters are then expanded along the conveying direction of the production line to obtain a cooling control model.

[0071] S6 generates a traction rate distribution map based on the traction speed parameters; the traction rate distribution map is then superimposed on the cooling control model to obtain the forming control model.

[0072] S7 synchronizes the insulation extrusion model, vulcanization control curve, and molding control model in a timely manner to obtain cable production control instructions.

[0073] It should be noted that the extrusion path trajectory generation step is based on cable structural parameters and conductor diameter. Cable structural parameters refer to various physical characteristics that need to be considered during cable design and production, such as insulation thickness. Insulation thickness refers to the radial dimension of the cable insulation layer, which directly affects the cable's electrical and mechanical properties. The extrusion path trajectory refers to the path along which the extruder head moves during extrusion to form the shape of the cable insulation layer. By generating the extrusion path trajectory based on cable structural parameters and conductor diameter, it is ensured that the extruded insulation layer meets design requirements, thereby guaranteeing cable quality. Simultaneously, extending the extrusion path trajectory along the cable axis to form an insulation extrusion model simulates the entire cable insulation extrusion process for subsequent production control. Vulcanization temperature parameters refer to temperature-related parameters that need to be controlled during vulcanization, including vulcanization stage duration. Vulcanization stage duration refers to the time required for each stage of the cable vulcanization process, which has a significant impact on the vulcanization effect. By generating a vulcanization control curve based on the vulcanization temperature parameters, the vulcanization process can be precisely controlled, improving cable performance.

[0074] Specifically, when generating the insulation extrusion model, the conductor diameter refers to the diameter of the conductor in the cable, which is one of the important parameters affecting cable performance. The generation of the extrusion path trajectory needs to consider the conductor diameter to ensure that the insulation layer can be uniformly wrapped around the conductor. The generation of the vulcanization control curve involves vulcanization temperature parameters, where the vulcanization stage duration refers to the time required for each stage of the cable's vulcanization process. The vulcanization section location parameters refer to the location information of different stages during the vulcanization process. By determining the temporal matching relationship between the vulcanization control curve and the insulation extrusion model, the coordination between the vulcanization and extrusion processes can be ensured.

[0075] Cooling cross-section parameters refer to the relevant parameters of the cable cooling cross-section during the cooling process, including the inner cooling layer curve and the outer cooling layer curve. The inner cooling layer curve refers to the shape of the inner layer of the cooling cross-section. Its starting point is the initial end face of the vulcanization section, extending along the transition surface to the first termination surface. The transition surface is the plane formed by the intersection of the axis connecting the initial end face and the conductor center with the extrusion path model. The first termination surface is the plane obtained by extending the transition surface outwards along a direction perpendicular to the production line to the outer surface of the insulation layer. The inner cooling layer curve reflects the cooling path from the initial end face of the vulcanization section to the first termination surface. The outer cooling layer curve refers to the shape of the outer layer of the cooling cross-section. Its starting point is the second reference surface, and its ending point is the second termination surface. The second reference surface is the plane obtained by offsetting the first reference surface backwards along the production line direction by the cooling delay amount. The second termination surface is the plane obtained by extending the first termination surface outwards along the intersection of the plane containing the production line axis and the extrusion path model to the edge of the cooling water tank. The outer cooling layer curve reflects the cooling path from the second reference surface to the second termination surface.

[0076] The cooling outer layer curve refers to the shape of the outer layer of the cooling cross-section, which is related to the second reference plane and the second termination plane. By generating cooling cross-section parameters based on the relative position of the vulcanization section and the extrusion path, and the duration of the vulcanization stage, the cooling process can be optimized, improving cable quality. Traction speed parameters refer to speed-related parameters that need to be considered during traction, including the number of temperature stratification zones, the number of speed gradients, and the traction compensation amount. The number of temperature stratification zones refers to the number of temperature intervals divided within the vulcanization control curve; the number of speed gradients refers to the number of speed segments divided in the conveyor belt within the highest temperature interval; and the traction compensation amount refers to the amount of compensation applied to the speed segments in the traction rate distribution map. By generating a traction rate distribution map based on the traction speed parameters, precise control of the traction speed can be achieved, improving production efficiency and product quality.

[0077] Preferably, computer-aided design (CAD) software can be used to construct the insulation extrusion model. Input parameters include cable structure parameters and conductor diameter, and the software's modeling function can generate a precise extrusion path and insulation extrusion model. When generating the vulcanization control curve, the vulcanization process can be divided into different stages based on the vulcanization stage duration in the vulcanization temperature parameters, and corresponding temperature and time parameters can be set for each stage. For example, the vulcanization process can be divided into a preheating stage, a vulcanization stage, and a post-treatment stage, and the temperature and time for each stage can be adjusted according to the specific cable material and production process.

[0078] When generating cooling section parameters, the geometry of the cooling section is first determined by measuring the relative position of the vulcanization zone and the extrusion path, as well as the duration of the vulcanization stage. Specifically, the starting end face of the vulcanization zone is taken as the first reference plane, and the intersection of the first reference plane and the axis connecting the conductor center with the extrusion path model is taken as the transition plane. The transition plane is extended outward along the direction perpendicular to the production line to the outer surface of the insulation layer to obtain the first termination plane. The intersection line of the first termination plane and the plane containing the production line axis with the extrusion path model is taken, and the first termination plane is extended outward along this intersection line to the edge of the cooling water tank to obtain the second termination plane. The first reference plane, the first termination plane, and the second termination plane are connected in sequence to form the inner cooling layer curve. The distance between the first termination plane and the second termination plane in the production line direction is calculated, and the smaller value between this distance and the vulcanization stage duration is taken as the cooling delay amount. The first reference plane is offset backward along the production line direction by the cooling delay amount to obtain the second reference plane. The second reference plane and the second termination plane are connected to form the outer cooling layer curve. The inner cooling layer curve and the outer cooling layer curve together constitute the cooling section parameters. When generating the traction rate distribution map, a mathematical modeling method is used to generate the distribution map based on the number of temperature layers, the number of speed gradients, and the traction compensation amount in the traction speed parameters. Specifically, n temperature intervals are generated within the vulcanization control curve based on the number of temperature layers n; the conveyor belt in the highest temperature interval is divided into m speed segments based on the number of speed gradients m; the speed is adjusted layer by layer from high temperature to low temperature in each temperature interval, wherein the speed gradient number of the outer temperature interval is an integer multiple of the speed gradient number of the inner temperature interval between two adjacent temperature intervals; the adjustment nodes of each speed segment are connected sequentially from the high temperature zone to the low temperature zone to form a stepped speed curve; the traction compensation amount is extended along the lateral direction perpendicular to the segment in each speed segment of the stepped speed curve to obtain the traction rate distribution map. The number of temperature layers determines the number of temperature intervals within the vulcanization control curve, the number of speed gradients determines the number of speed segments within the highest temperature interval, and the traction compensation amount is used to laterally extend the speed segments to ensure a smooth transition of traction speed, thereby generating a traction rate distribution map that meets production requirements. In some embodiments, the traction speed parameters include the number of temperature layers, the number of speed gradients, and the traction compensation amount.

[0079] A traction rate distribution map is generated based on the traction speed parameters, including:

[0080] Based on the stated number of temperature stratifications n, n temperature ranges are generated within the vulcanization control curve;

[0081] The conveyor belt in the highest temperature range is divided into m speed segments based on the speed gradient number m.

[0082] The speed is adjusted layer by layer from high temperature to low temperature for each temperature range, wherein the speed gradient number of the outer temperature range between two adjacent temperature ranges is an integer multiple of the speed gradient number of the inner temperature range.

[0083] The adjustment nodes of each speed segment are connected sequentially from the high-temperature zone to the low-temperature zone to form a stepped speed curve;

[0084] The traction rate distribution map is obtained by extending the traction compensation amount along the lateral direction perpendicular to each speed segment in the stepped speed curve.

[0085] It is important to note that setting the traction speed parameters is a crucial step in the automated production control of rubber cables, directly impacting production efficiency and quality. Traction speed parameters include the number of temperature zones, the number of speed gradients, and the traction compensation amount. Properly setting these parameters ensures a stable traction speed during production, preventing quality defects caused by excessive speed variations. The number of temperature zones refers to the number of temperature intervals divided within the vulcanization control curve; the number of speed gradients refers to the number of speed segments divided on the conveyor belt within the highest temperature range; and the traction compensation amount refers to the amount of compensation applied to the speed segments in the traction rate distribution diagram. By setting these parameters, a traction rate distribution diagram can be generated, enabling precise control of the traction speed.

[0086] Specifically, the number of temperature stratification zones refers to the number of intervals divided within the vulcanization control curve based on temperature changes. For example, the vulcanization control curve can be divided into three temperature intervals, each corresponding to a different temperature range. The number of speed gradients refers to the number of speed segments divided on the conveyor belt in the highest temperature interval. For example, the conveyor belt in the highest temperature interval can be divided into five speed segments, each corresponding to a different speed value. The traction compensation amount refers to the compensation amount used to expand the speed segments in the traction rate distribution map. For example, each speed segment can be expanded by 10 mm in the lateral direction to ensure a smooth transition in traction speed. When generating the traction rate distribution map, firstly, the corresponding temperature intervals are generated within the vulcanization control curve based on the number of temperature stratification zones. Then, the conveyor belt in the highest temperature interval is divided into multiple speed segments based on the number of speed gradients. Next, the speed is adjusted layer by layer from high temperature to low temperature in each temperature interval. The speed gradient number of the outer temperature interval is an integer multiple of the speed gradient number of the inner temperature interval. For example, if the speed gradient number of the inner temperature interval is 5, the speed gradient number of the outer temperature interval can be set to 10. Finally, the adjustment nodes of each speed segment are connected sequentially from the high temperature zone to the low temperature zone to form a stepped speed curve. The traction compensation amount is then extended along the lateral direction perpendicular to the segment in each speed segment of the stepped speed curve to obtain a traction rate distribution map.

[0087] When generating the traction rate distribution map, parameters can be optimized using computer simulation methods based on finite element analysis (FEA). Specifically, the temperature data from the vulcanization control curve and the initial speed parameters of the conveyor belt can be input into a thermo-structural coupling simulation model. Nonlinear optimization algorithms (such as genetic algorithms or particle swarm optimization algorithms) can be used to iteratively calculate the number of temperature stratifications and speed gradients to obtain the optimal combination. During speed adjustment, a temperature-speed coupling model can be established based on one-dimensional heat conduction equations (such as Fourier's law of heat conduction) to calculate the rate of speed change within each temperature range, thereby ensuring the rationality and stability of speed adjustment. For setting the traction compensation amount, a suitable compensation value can be determined through experimental data based on the cable's physical properties, such as the elastic modulus and coefficient of friction. For example, for a specific rubber cable, experiments have shown that when the traction compensation amount is set to 10 mm, the cable maintains optimal traction stability during production. Furthermore, when generating the stepped speed curve, a smoothing algorithm can be introduced to reduce the impact of speed changes and further improve the quality of cable production.

[0088] In some embodiments, the traction speed parameter further includes a speed smoothing coefficient;

[0089] After obtaining the traction rate distribution map by laterally expanding the traction compensation amount along each speed segment of the stepped speed curve, the following steps are also included:

[0090] The adjustment node of the highest temperature range of the traction rate distribution map is moved forward in the conveying direction with the midpoint of the production line as the center by the speed smoothing coefficient to obtain the smoothed traction rate distribution map.

[0091] It should be noted that the speed smoothing coefficient in the traction speed parameters is an important parameter used to optimize the traction rate distribution map. In the process of generating the traction rate distribution map, the speed smoothing coefficient reduces abrupt changes in the speed curve at the adjustment node in the highest temperature range, thereby reducing tension fluctuations during cable production caused by excessively rapid speed changes. By shifting the adjustment node in the highest temperature range forward by the distance of the speed smoothing coefficient from the midpoint of the production line in the conveying direction, a smoothed traction rate distribution map can be obtained, thus improving the stability of cable production and product quality.

[0092] Specifically, the speed smoothing coefficient is a parameter used to adjust the smoothness of the speed curve. It represents the distance at which smoothing processing needs to be performed at the adjustment node in the highest temperature range. For example, the speed smoothing coefficient can be set to 10 mm, meaning that at the adjustment node in the highest temperature range, the node needs to be moved forward by 10 mm to reduce abrupt changes in the speed curve. The production line midpoint refers to the geometric center of the production line and serves as a reference point for speed smoothing. By smoothing around the production line midpoint, a smooth transition of the speed curve throughout the entire production line can be ensured. In practical applications, the value of the speed smoothing coefficient can be adjusted according to the physical characteristics of the cable and the manufacturing process. For example, for stiffer cable materials, the speed smoothing coefficient can be set smaller, while for softer cable materials, it can be set larger to adapt to different production needs.

[0093] Preferably, when generating the smoothed traction rate distribution map, computer simulation can be used to optimize the speed smoothing coefficient setting. Specifically, finite element analysis can be used for computer simulation. First, the physical property parameters of the cable, such as the elastic modulus and coefficient of friction, and the production process parameters, such as the speed and temperature distribution of the production line, are input. Then, a mathematical model is established based on these parameters, and the impact of the traction rate distribution map under different speed smoothing coefficients on the cable production process is calculated through finite element analysis. For example, the tension changes and speed fluctuations of the cable during the production process under different speed smoothing coefficients are analyzed. By comparing and analyzing these results, the optimal speed smoothing coefficient is determined, thereby obtaining the smoothed traction rate distribution map to reduce the impact of speed changes and improve the stability of cable production and product quality.

[0094] In some embodiments, the traction speed parameters include tension offset angle, speed fluctuation range, and traction buffer amount;

[0095] A traction rate distribution map is generated based on the traction speed parameters, including:

[0096] Take the baseline speed line of the vulcanization control curve;

[0097] Using the intersection of the baseline velocity line and the cooling control model as the reference point, the velocity line is undulated upward and downward by the tension offset angle to obtain a wave-shaped velocity curve;

[0098] Multiple fluctuating velocity lines are obtained by adjusting the amplitude of the wave-shaped velocity curve according to the velocity fluctuation range.

[0099] By extending the traction buffer amount along the longitudinal direction of the peak segment in each fluctuation velocity line, a traction rate distribution map is obtained.

[0100] It should be noted that the tension offset angle, speed fluctuation range, and traction buffer amount in the traction speed parameters are key parameters for further optimizing the traction rate distribution map. Introducing these parameters can effectively solve the problem of uneven tension caused by traction speed fluctuations during cable production, thereby improving the stability of cable production and product quality. By introducing the tension offset angle onto the baseline speed line, a wavy speed curve can be generated. The amplitude can then be adjusted by controlling the speed fluctuation range, and finally, the peak segment can be extended by using the traction buffer amount, thus generating a traction rate distribution map that better suits production needs.

[0101] Specifically, the tension offset angle refers to the angle at which the speed line fluctuates upwards and downwards, using the intersection of the reference speed line and the cooling control model as the reference point. The magnitude of this angle directly affects the shape of the wavy speed curve, and consequently, the tension distribution of the cable during production. The speed fluctuation range refers to the adjustment range of the amplitude of the wavy speed curve, used to control the magnitude of speed fluctuations and ensure the stability of the cable tension during production. The traction buffer amount refers to the distance extended longitudinally along the crest of the wavy speed curve, used to further optimize the traction rate distribution diagram and reduce the impact of speed fluctuations. In practical applications, the tension offset angle can be adjusted according to the physical characteristics of the cable and the production process. For example, for stiffer cable materials, the tension offset angle can be set smaller, while for softer cable materials, it can be set larger. The speed fluctuation range and traction buffer amount can also be optimized according to actual production conditions to ensure the efficiency and stability of cable production.

[0102] When generating the traction rate distribution map, parameters can be optimized using a combination of computer simulation and experimental verification. Specifically, the physical properties of the cable (such as elastic modulus and coefficient of friction) and production process parameters (such as production line speed and temperature distribution) can be input into a multiphysics simulation platform (such as COMSOL Multiphysics). A multi-objective optimization algorithm (such as NSGA-II) can then be used to calculate the optimal combination of tension offset angle, speed fluctuation range, and traction buffer. Simultaneously, the simulation can be verified on a pilot production line using Design of Experiments (DOE) methods, and the simulation results can be corrected using response surface methodology to ensure the accuracy and feasibility of the parameter settings. During the processing, piecewise linear interpolation can be used to generate a wavy velocity curve.

[0103] Furthermore, the baseline velocity line can be divided into multiple segments, and linear interpolation can be performed on each segment to generate a wavy velocity curve. In addition, the effectiveness of the optimized traction rate distribution map can be verified experimentally. For example, cable quality under different parameter settings can be tested in actual production, and the optimal parameter values ​​can be determined through comparative analysis, thereby further optimizing the cable production process.

[0104] In some embodiments, after overlaying the traction rate distribution map onto the cooling control model to obtain the forming control model, the method further includes:

[0105] Detection points are set within the cooling section based on the defect detection density parameters;

[0106] A temperature monitoring grid is generated within the cooling section based on the detection points;

[0107] Based on the safety threshold parameters, each monitoring grid within the cooling section is scaled down proportionally to generate optimized cooling parameters;

[0108] The optimized cooling parameters are expanded along the production line direction to obtain the optimized cooling model;

[0109] The molding control model and the optimized cooling model are fused to obtain the optimized molding control model.

[0110] Detection points are set within the cooling section based on defect detection density parameters. Specifically, based on the cable diameter and manufacturing process requirements, detection points are evenly distributed on the cooling section at certain intervals. The spacing is determined by the defect detection density parameters to ensure comprehensive detection of temperature changes within the cooling section.

[0111] A temperature monitoring grid is generated within the cooling cross-section based on the detection points. Specifically, the cooling cross-section is divided into multiple small grid regions, with each detection point as a node. The temperature within each grid region can be calculated by interpolating the temperature values ​​of adjacent detection points, thus forming a temperature monitoring grid covering the entire cooling cross-section for real-time monitoring of the temperature distribution during the cooling process.

[0112] Based on the safety threshold parameter, each monitoring grid within the cooling section is scaled down proportionally to generate optimized cooling parameters. Specifically, the safety threshold parameter refers to the highest allowable temperature range during the cooling process. The temperature value within each monitoring grid is compared with the safety threshold. If the temperature within a grid exceeds the safety threshold, the grid is scaled down proportionally, that is, the temperature value within that grid is reduced by a certain proportion, thereby generating optimized cooling parameters to ensure that the temperature distribution during the cooling process meets quality requirements.

[0113] The optimized cooling parameters are expanded along the production line direction to obtain an optimized cooling model. Specifically, the optimized cooling parameters are extended and expanded along the production line direction to form an optimized cooling model distributed along the production line direction, which is used to guide the control of the cooling process. The forming control model and the optimized cooling model are fused to obtain an optimized forming control model. Specifically, the traction rate distribution map in the forming control model and the cooling parameters in the optimized cooling model are comprehensively analyzed and processed. Through data fusion algorithms, such as the weighted average method, the data of the two are fused to obtain an optimized forming control model that comprehensively considers traction speed and cooling effect, which is used to guide the control of the entire cable production process to improve the overall quality and production efficiency of the cable.

[0114] Specifically, the cooling cross-section refers to the cross-section of the cable's cooling area during the cooling process, and it is a key area for cooling control. Setting up detection points on this cross-section allows for real-time monitoring of temperature changes during cooling. The number and location of these detection points can be adjusted according to the cable diameter and manufacturing process; for example, more detection points can be set on a larger cooling cross-section to ensure comprehensive temperature monitoring. The temperature monitoring grid is a grid structure formed by connecting these detection points, used for real-time monitoring of temperature distribution during cooling. The safety threshold parameter refers to the highest permissible temperature range during cooling; this parameter can be set according to the heat resistance of the cable material and the requirements of the manufacturing process. By proportionally scaling down each monitoring grid within the cooling cross-section, optimized cooling parameters can be generated. These parameters can be used to adjust the cooling water flow rate, temperature, etc., to ensure cable quality during cooling. The optimized cooling model is a model obtained by expanding the optimized cooling parameters along the production line direction, used to guide the control of the cooling process. The forming control model is the final control model obtained by fusing the optimized cooling model with the previous traction rate distribution map, used to guide the control of the entire cable production process.

[0115] Preferably, when generating the temperature monitoring grid, computer simulation methods can be used to optimize the layout of the detection points and the shape of the monitoring grid. For example, physical property parameters of the cable, such as diameter and thermal conductivity of the material, as well as production process parameters, such as cooling water temperature and flow rate, can be input, and the optimal layout of the detection points and the shape of the monitoring grid can be calculated by an algorithm. During processing, finite element analysis can be used to simulate the temperature distribution during the cooling process, thereby determining the optimal location of the detection points. In addition, the effectiveness of the optimized temperature monitoring grid can be verified experimentally. For example, the cable cooling effect under different detection point layouts and monitoring grid shapes can be tested in actual production, and the optimal parameter settings can be determined through comparative analysis, thereby further optimizing the cable cooling process.

[0116] In some embodiments, cooling section parameters are generated based on the relative position of the vulcanization section and the extrusion path, and the duration of the vulcanization stage, including:

[0117] The starting end face of the vulcanization zone is taken as the first reference surface, and the intersection of the axis connecting the first reference surface and the center of the conductor with the extrusion path model is taken as the transition surface. The transition surface is extended outward along the direction perpendicular to the production line to the outer surface of the insulation layer to obtain the first termination surface.

[0118] Take the intersection line between the first termination surface and the plane containing the production line axis and the extrusion path model, and extend the first termination surface outward along the intersection line to the edge of the cooling water tank to obtain the second termination surface;

[0119] The first reference plane, the first termination plane, and the second termination plane are connected in sequence to form the cooling inner layer curve;

[0120] Calculate the distance between the first termination surface and the second termination surface in the production line direction, and take the smaller value between the distance and the vulcanization stage duration as the cooling delay amount;

[0121] The first reference plane is offset backward by the cooling delay amount along the production line direction to obtain the second reference plane;

[0122] Connect the second reference plane and the second termination plane to form a cooling outer layer curve;

[0123] The cooling inner layer curve and the cooling outer layer curve constitute the cooling cross-sectional parameters.

[0124] It should be noted that generating cooling cross-section parameters is a crucial step in the automated production control method for rubber cables. Its purpose is to optimize the cooling process through precise geometric modeling, ensuring the quality and performance of the cable during the cooling phase. This step involves defining multiple geometric surfaces and parameters, including the first reference surface, transition surface, first termination surface, and second termination surface. The definition and connection methods of these geometric surfaces directly affect the shape of the cooling cross-section and the cooling effect. By calculating the cooling delay and generating the inner and outer cooling curves, complete cooling cross-section parameters can be formed, thus providing a foundation for establishing the cooling control model.

[0125] Specifically, the first reference plane is the plane originating from the starting end face of the vulcanization zone; it serves as the initial reference plane for the cooling cross-section parameters. The transition plane is the plane formed by the intersection of the axis connecting the first reference plane and the conductor center with the extrusion path model, used to smoothly transition the geometry from the vulcanization zone to the cooling zone. The first termination plane is the plane obtained by extending the transition plane outwards along a direction perpendicular to the production line to the outer surface of the insulation layer; it defines the inner boundary of the cooling cross-section. The second termination plane is the plane obtained by extending the first termination plane outwards along the intersection of the plane containing the production line axis and the extrusion path model to the edge of the cooling water tank; it defines the outer boundary of the cooling cross-section. The cooling delay amount refers to the smaller value between the distance between the first and second termination planes and the vulcanization stage duration in the production line direction; it is used to control the delay time of the cooling process, ensuring that the cable reaches a suitable degree of vulcanization before entering the cooling stage. The inner cooling curve and the outer cooling curve are formed by connecting the first reference plane, the first termination plane, and the second termination plane, respectively; together, they constitute the geometry of the cooling cross-section, used to guide precise control of the cooling process.

[0126] Preferably, when constructing the cooling cross-section parameters, precise geometric modeling can be achieved using computer-aided design (CAD) software. Input parameters include the starting position of the vulcanization zone, the axial coordinates of the conductor center, the geometric parameters of the extrusion path model, and the edge position of the cooling water tank. Using these input parameters, the software can automatically calculate the specific positions of the transition surface, the first termination surface, and the second termination surface, and generate the inner cooling layer curve and the outer cooling layer curve. For example, the geometric modeling tool in the CAD software can be used to generate the transition surface based on the input starting face of the vulcanization zone and the conductor center axis, and the first and second termination surfaces can be obtained through an extension operation. When calculating the cooling delay, a smaller value can be selected as the cooling delay based on the vulcanization stage duration and the distance between the first and second termination surfaces, thereby ensuring precise control of the cooling process. Furthermore, the generated cooling cross-section parameters can be optimized using simulation analysis tools to further improve cooling efficiency and cable quality.

[0127] In some embodiments, a cooling inner layer curve is formed by sequentially connecting a first reference surface, a first termination surface, and a second termination surface, including:

[0128] Multiple temperature measuring points are set on the transition section connecting the first reference surface and the first termination surface. The positions of the multiple temperature measuring points are adjusted by piecewise linear interpolation according to the thermal conductivity coefficient to obtain the cooling gradient curve from the reference surface to the termination surface.

[0129] The cooling gradient curve from the reference surface to the termination surface and the heat dissipation curve from the termination surface to the second termination surface together form the cooling inner layer curve.

[0130] It should be noted that in the automated production control methods for rubber cables, further optimization of the cooling inner layer curve is a crucial step in ensuring precise control of the cooling process. By setting multiple temperature measurement points on the transition section of the cooling cross-section and adjusting the positions of these points using piecewise linear interpolation, a cooling gradient curve can be generated. This method can more accurately simulate temperature changes during the cooling process, ensuring that the cooling inner layer curve reflects the actual cooling effect. The cooling gradient curve from the reference plane to the termination plane and the heat dissipation curve from the termination plane to the second termination plane together form the cooling inner layer curve. This design can better adapt to temperature changes in different cooling stages and improve the accuracy of cooling control.

[0131] Specifically, the reference plane refers to the starting plane of the cooling cross-section, usually corresponding to the starting end face of the vulcanization zone, and serves as the starting reference point for the cooling process. The termination plane refers to the ending plane of the cooling cross-section, usually connecting to the edge of the cooling water tank, and marks the end point of the cooling process. The transition section refers to the area connecting the reference plane and the termination plane, where multiple temperature measuring points are set to monitor temperature changes during the cooling process. The number and location of the temperature measuring points can be adjusted according to the cable diameter and the design of the cooling water tank. The thermal conductivity coefficient is an indicator of a material's ability to transfer heat, used to calculate the temperature distribution within the cooling cross-section. By adjusting the positions of the temperature measuring points through piecewise linear interpolation, a smooth cooling gradient curve can be generated, reflecting the temperature change trend from the reference plane to the termination plane. The heat dissipation curve refers to the temperature change curve from the termination plane to the second termination plane, describing the heat loss during the cooling process. Combining the cooling gradient curve and the heat dissipation curve forms a complete inner cooling curve, used to guide precise control of the cooling process.

[0132] Preferably, when generating the cooling inner layer curve, computer simulation methods can be used to optimize the layout of temperature measuring points and the shape of the cooling gradient curve. For example, the physical properties of the cable, such as the thermal conductivity and specific heat capacity of the material, and production process parameters, such as the temperature and flow rate of cooling water, can be input, and the optimal layout of temperature measuring points and cooling gradient curve can be calculated by an algorithm. During processing, finite element analysis can be used to simulate the temperature distribution during the cooling process, thereby determining the optimal location of the temperature measuring points. In addition, the effect of the optimized cooling inner layer curve can be verified experimentally. For example, the cable cooling effect under different temperature measuring point layouts and cooling gradient curves can be tested in actual production, and the optimal parameter settings can be determined through comparative analysis, thereby further optimizing the cable cooling process.

[0133] In some embodiments, connecting the second reference plane and the second termination plane to form a cooling outer layer curve includes:

[0134] Multiple pressure monitoring points are set on the transition section connecting the second reference surface and the second termination surface. The positions of the multiple monitoring points are adjusted by piecewise linear interpolation according to the fluid dynamics parameters to obtain the cooling outer layer curve.

[0135] It should be noted that the generation of the cooling outer layer curve mentioned in this embodiment is a crucial step in the automated production control method for rubber cables. By setting multiple pressure monitoring points on the transition section connecting the second reference surface and the second termination surface, and adjusting the positions of these monitoring points using piecewise linear interpolation based on fluid dynamic parameters, the cooling outer layer curve can be obtained. This curve accurately reflects the changes in pressure distribution within the cooling water tank during the cooling process, thus providing an important reference for cooling control and ensuring the quality and performance of the cable during the cooling stage.

[0136] Specifically, the second reference plane refers to the plane obtained by offsetting the first reference plane backward along the production line direction by the cooling delay during the generation of cooling section parameters. It is the starting reference plane for the outer cooling curve. The second termination plane refers to the outer boundary of the cooling section, usually connected to the edge of the cooling water tank, and is the endpoint of the outer cooling curve. The transition section refers to the area connecting the second reference plane and the second termination plane. Multiple pressure monitoring points are set in this area to monitor pressure changes in the cooling water tank during the cooling process. The number and location of the pressure monitoring points can be adjusted according to the size and shape of the cooling water tank. Fluid dynamic parameters refer to physical parameters related to the flow of cooling water, such as flow velocity and pressure gradient. These parameters are used to calculate the pressure distribution within the cooling section. By adjusting the position of the pressure monitoring points through piecewise linear interpolation, a smooth outer cooling curve can be generated, which reflects the pressure change trend from the second reference plane to the second termination plane.

[0137] Preferably, when generating the cooling outer layer curve, computer simulation can be used to optimize the layout of pressure monitoring points and the shape of the cooling outer layer curve. For example, parameters such as the size and shape of the cooling water tank and the flow rate of the cooling water can be input, and the optimal layout of pressure monitoring points and the cooling outer layer curve can be calculated by an algorithm. During the processing, computational fluid dynamics (CFD) simulation can be used to analyze the pressure distribution within the cooling water tank, thereby determining the optimal location of the pressure monitoring points.

[0138] Furthermore, the effectiveness of the optimized cooling outer layer curve can be verified through experiments. For example, the cable cooling effect under different pressure monitoring point layouts and cooling outer layer curves can be tested in actual production. By comparing and analyzing the results, the optimal parameter settings can be determined, thereby further optimizing the cable cooling process.

[0139] In some embodiments, the traction rate distribution map is superimposed on the cooling control model to obtain a forming control model, including:

[0140] The traction rate distribution map is extended along the production line direction by time compensation to obtain a three-dimensional control surface. The three-dimensional control surface is then superimposed with the cooling control model to obtain the molding control model.

[0141] It should be noted that in the automated production control method for rubber cables, overlaying the traction rate distribution map onto the cooling control model to generate the molding control model is a key step in achieving precise production control. This process constructs a three-dimensional control surface by expanding the time compensation amount of the traction rate distribution map and then overlays it with the cooling control model, thereby achieving synergistic optimization of the traction and cooling processes during cable production. This method ensures that the cable maintains a stable traction speed during production while optimizing the cooling effect, thus improving the overall quality and production efficiency of the cable.

[0142] Specifically, the traction rate distribution map is generated based on traction speed parameters and is used to describe the changes in traction speed during cable production. The time compensation parameter is an adjustment parameter introduced to reconcile the time differences between the traction rate distribution map and the cooling control model; it can be set according to the cable's production speed and cooling time. The three-dimensional control surface is obtained by extending the traction rate distribution map along the production line direction with the time compensation parameter; it more intuitively reflects the changes in traction speed in time and space. The cooling control model is generated based on cooling section parameters and is used to describe the temperature distribution and cooling effect of the cable during the cooling process. Data overlay refers to integrating the three-dimensional control surface with the cooling control model to generate a comprehensive forming control model, used to guide traction and cooling control during cable production.

[0143] Preferably, computer-aided design (CAD) software and computational fluid dynamics (CFD) simulation tools can be used to construct the three-dimensional control surface. Input parameters include the traction rate distribution map, time compensation, and relevant parameters of the cooling control model, such as the dimensions of the cooling water tank and the temperature of the cooling water. Through algorithmic calculations, an accurate three-dimensional control surface can be generated and superimposed onto the cooling control model. During processing, finite element analysis can be used to optimize the data superposition effect, ensuring that the forming control model accurately reflects the actual working conditions during cable production.

[0144] Furthermore, the effectiveness of the optimized molding control model can be verified through experiments. For example, cable quality can be tested under different parameter settings in actual production, and the optimal parameter configuration can be determined through comparative analysis, thereby further optimizing the cable production process.

[0145] The various embodiments of the present invention have the following beneficial effects: The present invention can dynamically coordinate the matching relationship between extrusion path, vulcanization temperature and traction speed. By establishing a three-dimensional collaborative control system of insulation extrusion model, vulcanization control curve and cooling control model, precise control of the entire cable production process can be achieved. The traction rate distribution map based on temperature stratification and speed gradient can optimize the heat conduction efficiency during vulcanization. Combined with the dynamic generation of cooling cross-section parameters, the cooling uniformity of the insulation layer can be improved, thereby significantly improving the product quality and production efficiency of rubber cables. The timing synchronization mechanism can ensure seamless connection of each process link, while the fusion of defect detection grid and optimized cooling model can provide early warning of production anomalies, ultimately forming a closed-loop control. The stepped speed curve and smoothing can reduce traction tension fluctuations, and the wavy speed curve combined with traction buffer can absorb mechanical vibrations. This composite control strategy can balance production stability and process accuracy. The application of cooling delay and piecewise linear interpolation algorithm can accurately match the heat dissipation requirements of different vulcanization stages. The data superposition of three-dimensional control surfaces can eliminate timing errors, enabling the entire production system to have adaptive adjustment capabilities.

[0146] like Figure 2 As shown in some embodiments, an automated production control system for rubber cables includes:

[0147] The extrusion control module 201 is used to generate an extrusion path trajectory based on cable structural parameters and conductor diameter, wherein the cable structural parameters include insulation layer thickness; and to extend the extrusion path trajectory along the cable axis direction according to the conductor diameter to form an insulation layer extrusion model.

[0148] The vulcanization control module 202 is used to generate a vulcanization control curve based on vulcanization temperature parameters, including the vulcanization stage duration; and to determine the timing matching relationship between the vulcanization control curve and the insulation layer extrusion model based on the vulcanization section location parameters.

[0149] The cooling modeling module 203 is used to generate cooling section parameters based on the relative position of the vulcanization section and the extrusion path and the duration of the vulcanization stage. The cooling section parameters are then expanded along the conveying direction of the production line to obtain a cooling control model.

[0150] The traction modeling module 204 is used to generate a traction rate distribution map based on the traction speed parameters; the traction rate distribution map is superimposed on the cooling control model to obtain the forming control model.

[0151] The production coordination module 205 is used to synchronize the insulation extrusion model, vulcanization control curve and molding control model in a timely manner to obtain cable production control instructions.

[0152] It is understandable that the modules described in this automated production control system for rubber cables are similar to those in the reference. Figure 1The steps described correspond to those in the automated production control method for rubber cables. Therefore, the operations, characteristics, and beneficial effects described above for the automated production control method for rubber cables also apply to the automated production control system for rubber cables and its constituent modules, and will not be repeated here.

[0153] The following is for reference. Figure 3 The diagram illustrates a structural schematic of an electronic device 300 suitable for implementing some embodiments of the present invention. The electronic devices in some embodiments of the present invention may include, but are not limited to, mobile terminals such as mobile phones, laptops, digital broadcast receivers, PDAs (personal digital assistants), PADs (tablet computers), PMPs (portable multimedia players), in-vehicle terminals (e.g., in-vehicle navigation terminals), and fixed terminals such as digital TVs and desktop computers. Figure 3 The terminal device shown is merely an example and should not be construed as limiting the functionality and scope of the embodiments of the present invention.

[0154] like Figure 3 As shown, the electronic device 300 may include a processing unit (e.g., a central processing unit, a graphics processing unit, etc.) 301, which can perform various appropriate actions and processes according to a program stored in a read-only memory (ROM) 302 or a program loaded from a storage device 308 into a random access memory (RAM) 303. The RAM 303 also stores various programs and data required for the operation of the electronic device 300. The processing unit 301, ROM 302, and RAM 303 are interconnected via a bus 304. An input / output (I / O) interface 305 is also connected to the bus 304.

[0155] Typically, the following devices can be connected to I / O interface 305: input devices 306 including, for example, touchscreens, touchpads, keyboards, mice, cameras, microphones, accelerometers, gyroscopes, etc.; output devices 307 including, for example, liquid crystal displays (LCDs), speakers, vibrators, etc.; storage devices 308 including, for example, magnetic tapes, hard disks, etc.; and communication devices 309. Communication device 309 allows electronic device 300 to communicate wirelessly or wiredly with other devices to exchange data. Although Figure 3 An electronic device 300 with various devices is shown; however, it should be understood that it is not required to implement or possess all of the devices shown. More or fewer devices may be implemented or possessed alternatively. Figure 3 Each box shown can represent a device or multiple devices as needed.

[0156] Furthermore, the storage medium in the embodiments of this application stores program instructions capable of implementing all the above methods. These program instructions can be stored in the storage medium in the form of a software product, including several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) or processor to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks, or terminal devices such as computers, servers, mobile phones, and tablets.

[0157] The above description is merely a selection of preferred embodiments of the present invention and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of the invention as described in the embodiments is not limited to technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the inventive concept. For example, technical solutions formed by substituting the above-described features with (but not limited to) technical features with similar functions disclosed in the embodiments of the present invention.

Claims

1. A method for automated production control of rubber cables, characterized in that, The following steps are involved: An extrusion path trajectory is generated based on cable structure parameters and conductor diameter, wherein the cable structure parameters include insulation layer thickness; Based on the conductor diameter, the extrusion path is extended along the cable axis to form an insulation extrusion model; A vulcanization control curve is generated based on vulcanization temperature parameters, including the duration of the vulcanization stage. Based on the location parameters of the vulcanization zone, the time-series matching relationship between the vulcanization control curve and the insulation layer extrusion model is determined; Cooling section parameters are generated based on the relative position of the vulcanization section and the extrusion path, and the duration of the vulcanization stage. The cooling section parameters are then expanded along the conveying direction of the production line to obtain a cooling control model. A traction rate distribution map is generated based on the traction speed parameters; the traction rate distribution map is then superimposed on the cooling control model to obtain the forming control model. The insulation extrusion model, vulcanization control curve, and molding control model are synchronized in time to obtain cable production control commands.

2. The automated production control method for rubber cables according to claim 1, characterized in that, Traction speed parameters include the number of temperature stratifications, the number of speed gradients, and the traction compensation amount; A traction rate distribution map is generated based on the traction speed parameters, including: Based on the stated number of temperature stratifications n, n temperature ranges are generated within the vulcanization control curve; The conveyor belt in the highest temperature range is divided into m speed segments based on the speed gradient number m. The speed is adjusted layer by layer from high temperature to low temperature for each temperature range, wherein the speed gradient number of the outer temperature range between two adjacent temperature ranges is an integer multiple of the speed gradient number of the inner temperature range. The adjustment nodes of each speed segment are connected sequentially from the high-temperature zone to the low-temperature zone to form a stepped speed curve; The traction rate distribution map is obtained by extending the traction compensation amount along the lateral direction perpendicular to each speed segment in the stepped speed curve.

3. The automated production control method for rubber cables according to claim 2, characterized in that, Traction speed parameters also include speed smoothing coefficients; After obtaining the traction rate distribution map by laterally expanding the traction compensation amount along each speed segment of the stepped speed curve, the following steps are also included: The adjustment node of the highest temperature range of the traction rate distribution map is moved forward in the conveying direction with the midpoint of the production line as the center by the speed smoothing coefficient to obtain the smoothed traction rate distribution map.

4. The automated production control method for rubber cables according to claim 1, characterized in that, Traction speed parameters include tension offset angle, speed fluctuation range, and traction buffer amount; A traction rate distribution map is generated based on the traction speed parameters, including: Take the baseline speed line of the vulcanization control curve; Using the intersection of the baseline velocity line and the cooling control model as the reference point, the velocity line is undulated upward and downward by the tension offset angle to obtain a wave-shaped velocity curve; Multiple fluctuating velocity lines are obtained by adjusting the amplitude of the wave-shaped velocity curve according to the velocity fluctuation range. By extending the traction buffer amount along the longitudinal direction of the peak segment in each fluctuation velocity line, a traction rate distribution map is obtained.

5. The automated production control method for rubber cables according to claim 1, characterized in that, After overlaying the traction rate distribution map onto the cooling control model to obtain the forming control model, it also includes: Detection points are set within the cooling section based on the defect detection density parameters; A temperature monitoring grid is generated within the cooling section based on the detection points; Based on the safety threshold parameters, each monitoring grid within the cooling section is scaled down proportionally to generate optimized cooling parameters; The optimized cooling parameters are expanded along the production line direction to obtain the optimized cooling model; The molding control model and the optimized cooling model are fused to obtain the optimized molding control model.

6. The automated production control method for rubber cables according to claim 1, characterized in that, Cooling section parameters are generated based on the relative position of the vulcanization section and the extrusion path, and the duration of the vulcanization stage, including: The starting end face of the vulcanization zone is taken as the first reference surface, and the intersection of the axis connecting the first reference surface and the center of the conductor with the extrusion path model is taken as the transition surface. The transition surface is extended outward along the direction perpendicular to the production line to the outer surface of the insulation layer to obtain the first termination surface. Take the intersection line between the first termination surface and the plane containing the production line axis and the extrusion path model, and extend the first termination surface outward along the intersection line to the edge of the cooling water tank to obtain the second termination surface; The first reference plane, the first termination plane, and the second termination plane are connected in sequence to form the cooling inner layer curve; Calculate the distance between the first termination surface and the second termination surface in the production line direction, and take the smaller value between the distance and the vulcanization stage duration as the cooling delay amount; The first reference plane is offset backward by the cooling delay amount along the production line direction to obtain the second reference plane; Connect the second reference plane and the second termination plane to form a cooling outer layer curve; The cooling inner layer curve and the cooling outer layer curve constitute the cooling cross-sectional parameters.

7. The automated production control method for rubber cables according to claim 6, characterized in that, A cooling inner layer curve is formed by sequentially connecting the first reference plane, the first termination plane, and the second termination plane, including: Multiple temperature measuring points are set on the transition section connecting the first reference surface and the first termination surface. The positions of the multiple temperature measuring points are adjusted by piecewise linear interpolation according to the thermal conductivity coefficient to obtain the cooling gradient curve from the reference surface to the termination surface. The cooling gradient curve from the reference surface to the termination surface and the heat dissipation curve from the termination surface to the second termination surface together form the cooling inner layer curve.

8. The automated production control method for rubber cables according to claim 6, characterized in that, Connecting the second reference plane and the second termination plane to form a cooling outer layer curve includes: Multiple pressure monitoring points are set on the transition section connecting the second reference surface and the second termination surface. The positions of the multiple monitoring points are adjusted by piecewise linear interpolation according to the fluid dynamics parameters to obtain the cooling outer layer curve.

9. The automated production control method for rubber cables according to claim 1, characterized in that, The forming control model is obtained by overlaying the traction rate distribution map onto the cooling control model, including: The traction rate distribution map is extended along the production line direction by time compensation to obtain a three-dimensional control surface. The three-dimensional control surface is then superimposed with the cooling control model to obtain the molding control model.

10. An automated production control system for rubber cables, characterized in that, The system includes: An extrusion control module is used to generate an extrusion path trajectory based on cable structural parameters and conductor diameter, including insulation layer thickness; and to extend the extrusion path trajectory along the cable axis direction according to the conductor diameter to form an insulation layer extrusion model. The vulcanization control module is used to generate a vulcanization control curve based on vulcanization temperature parameters, including the vulcanization stage duration; and to determine the timing matching relationship between the vulcanization control curve and the insulation layer extrusion model based on the vulcanization section location parameters. The cooling modeling module is used to generate cooling section parameters based on the relative position of the vulcanization section and the extrusion path and the duration of the vulcanization stage. The cooling section parameters are then expanded along the conveying direction of the production line to obtain a cooling control model. The traction modeling module is used to generate a traction rate distribution map based on the traction speed parameters; the traction rate distribution map is then superimposed on the cooling control model to obtain the forming control model. The production coordination module is used to synchronize the insulation extrusion model, vulcanization control curve, and molding control model in a timely manner to obtain cable production control instructions.

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