A high speed operation control method and system for a core wire insulation extruder

Abstract

The application relates to the technical field of data processing anomaly detection, in particular to a high-speed operation control method and system of a core wire insulation extruder, which comprises the following steps: acquiring stress data and vibration signals of the core wire; obtaining a high-frequency vibration superposition degree according to the consistency degree of high-frequency changes of the stress data and the vibration signals on the core wire, the average level of the amplitude of the vibration signals in the frequency domain, the amplitude difference of the stress data and the vibration signals in the frequency domain; analyzing the change trend and random change characteristics of the high-frequency vibration superposition degree to obtain a high-frequency vibration anomaly degree; and performing anomaly detection on the high-frequency vibration anomaly degree to determine whether the tension of the core wire in the current collection cycle needs to be adjusted and compensated. The application can improve the operation control efficiency of the extruder and improve the core wire tension adjustment precision.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of data processing anomaly detection, and particularly relates to a high-speed running control method and system of a core wire insulation extruder. BACKGROUND

[0002] The extruder is a cable manufacturing device for extruding core wires, and mainly functions to wrap and extrude the core wires and external sheaths, then draw the core wires through a drawing machine, and finally wind the core wires on a winding machine to complete the production and processing of the core wires.

[0003] In the production and processing of the core wires through the extruder, the tension of the core wires usually needs to be adjusted and compensated to avoid the problem that the core wires cannot be accurately wound on the outside of the winding roller due to unsuitable tension during winding, thereby improving the uniformity of the core wires after winding. SUMMARY

[0004] To solve the above technical problems, the purpose of the present application is to provide a high-speed running control method and system of a core wire insulation extruder, and the technical solution is as follows:

[0005] The present application provides a high-speed running control method of a core wire insulation extruder, which comprises the following steps:

[0006] Obtaining stress data and vibration signals of the core wire during the processing of the core wire by the extruder;

[0007] According to the consistency degree of the high-frequency changes of the stress data and the vibration signals on the core wire in the frequency domain and the average level of the amplitude of the vibration signals in the frequency domain, and in combination with the difference between the amplitudes of the stress data and the vibration signals in the frequency domain, the high-frequency vibration superposition degree of each collection period is obtained;

[0008] By analyzing the change trend and random change characteristics of the high-frequency vibration superposition degree, the high-frequency vibration abnormality degree of each collection period is obtained;

[0009] The high-frequency vibration abnormality degree is subjected to anomaly detection to determine whether the tension of the core wire of the current collection period needs to be adjusted and compensated.

[0010] Preferably, the stress data and the vibration signal of the core wire after normalization in each collection cycle are respectively arranged in time sequence to obtain a stress sequence and a vibration sequence of each collection cycle, and a frequency domain transformation is performed on the stress sequence and the vibration sequence to obtain an amplitude spectrum of a positive frequency part in the frequency domain data of the stress sequence and the vibration sequence.

[0011] Preferably, all frequencies corresponding to the amplitudes not equal to 0 in the amplitude spectrum of the positive frequency part in the frequency domain data of the stress sequence and the vibration sequence are respectively composed into a stress change frequency set and a vibration change frequency set of each collection cycle, and an intersection of the two sets is counted, and a sum value of all frequencies in the intersection is taken as a first sum value of each collection cycle.

[0012] Preferably, the obtaining of the high-frequency vibration superposition degree of each collection cycle is further:

[0013] ; in the formula, is the high-frequency vibration superposition degree of the tth collection cycle, is the first sum value of the tth collection cycle, is a constant to avoid a denominator of 0, is a mean value of elements in the vibration amplitude sequence of the tth collection cycle, is a difference distance between the stress amplitude sequence and the vibration amplitude sequence of the tth collection cycle, wherein the amplitudes of all frequencies in the intersection are extracted from the amplitude spectrum of the positive frequency part in the frequency domain data of the stress sequence and the vibration sequence respectively, and arranged in descending order of frequency to obtain the stress amplitude sequence and the vibration amplitude sequence of each collection cycle.

[0014] Preferably, K collection cycles closest in time interval to each collection cycle are recorded as neighbor collection cycles of each collection cycle, and the high-frequency vibration superposition degrees of each collection cycle and its K neighbor collection cycles are arranged in time sequence to form a local superposition degree sequence of each collection cycle.

[0015] Preferably, a time sequence decomposition is performed on the local superposition degree sequence of each collection cycle to obtain a trend sequence and a residual sequence, and a fitting slope is obtained by fitting the trend sequence.

[0016] Preferably, the obtaining of the high-frequency vibration abnormality degree of each collection cycle is further:

[0017] ; in the formula, is the high-frequency vibration abnormality degree of the tth collection cycle, is a sigmoid function, is a fitting slope of the trend sequence corresponding to the tth collection cycle, is a complexity of the residual sequence corresponding to the tth collection cycle, and the complexity is measured by permutation entropy.

[0018] Preferably, the 3Sigma interval range is extracted by the high-frequency vibration abnormality degree of the current collection cycle and all collection cycles before it, if the high-frequency vibration abnormality degree of the current collection cycle is in the 3Sigma interval range, the core wire tension is normal, and the core wire tension is not adjusted and compensated; otherwise, the core wire tension is abnormal, and the core wire tension needs to be adjusted and compensated.

[0019] Preferably, if the high-frequency vibration abnormality degree of the current collection cycle is greater than the maximum value of the 3Sigma interval range, the tension of the core wire is increased by 1-5%; if the high-frequency vibration abnormality degree of the current collection cycle is less than the minimum value of the 3Sigma interval range, the tension of the core wire is reduced by 1-5%.

[0020] The embodiment of the present application also provides a high-speed running control system of a core wire insulation extruder, which comprises a memory, a processor and a computer program stored in the memory and running on the processor, and the processor implements the steps of the high-speed running control method of the core wire insulation extruder according to any one of the above embodiments when executing the computer program.

[0021] As can be seen from the above, the high-speed running control method and system of the core wire insulation extruder provided by the present application at least have the following beneficial effects:

[0022] The present application extracts the intersection between the stress change frequency set and the vibration change frequency set, more clearly illustrates the consistency of the change frequency between the stress characteristics and the vibration characteristics on the core wire, and thus combines the consistent change frequency characteristics and amplitude characteristics between the stress data and the vibration signal on the core wire within a unit time, more accurately measures the high-frequency superposition characteristics between the stress amplitude and the vibration amplitude on the core wire, and is beneficial to subsequent avoidance of the problem that the core wire cannot be accurately taken up and wound outside the take-up roller due to unsuitable tension on the core wire;

[0023] Meanwhile, the present application accurately measures the high-frequency abnormal vibration characteristics generated due to unsuitable tension on the core wire by considering the severity deepening and complex random fluctuation phenomenon of the high-frequency superposition characteristics between the stress amplitude and the vibration amplitude on the core wire, more clearly shows the abnormal effect of the unsuitable tension on the core wire, and is beneficial to subsequent timely and effective adjustment and compensation of the tension of the core wire;

[0024] In the present application, the 3Sigma interval range of the high-frequency vibration abnormality degree is extracted by the 3Sigma abnormality detection method, and whether the tension of the core wire needs to be adjusted and compensated in the current collection cycle is judged by the 3Sigma interval range and the high-frequency vibration abnormality degree of the current collection cycle, so as to avoid invalid adjustment and compensation of the tension of the core wire, meanwhile, avoid the problems of too large or too small tension of the core wire, and improve the uniformity of the core wire after taking up and winding. Attached Figure Description

[0025] To more clearly illustrate the technical solutions and advantages in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 A flowchart illustrating the steps of a high-speed operation control method for a core wire insulation extruder provided in this application;

[0027] Figure 2 A block diagram of a high-speed operation control system for a core wire insulation extruder provided in an embodiment of this application. Detailed Implementation

[0028] To further illustrate the technical means and effects adopted by this application to achieve the intended purpose of the invention, the following, in conjunction with the accompanying drawings and preferred embodiments, details the specific implementation, structure, features, and effects of a high-speed operation control method and system for a core wire insulation extruder proposed in this application. In the following description, different "one embodiment" or "another embodiment" do not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics in one or more embodiments can be combined in any suitable form.

[0029] Unless otherwise specified and limited, terms such as “comprising,” “including,” or any other variations thereof are intended to cover a non-exclusive inclusion, such that a circuit structure, article, or device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such an article or device. Without further limitation, an element defined by the phrase “comprising one…” does not exclude the presence of other identical elements in the article or device that includes said element. Furthermore, the term “and / or” as used herein includes any and all combinations of one or more of the associated listed items. All technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0030] The following description, in conjunction with the accompanying drawings, details the specific scheme of the high-speed operation control method and system for a core wire insulation extruder provided in this application.

[0031] Please see Figure 1 The diagram illustrates a flowchart of a high-speed operation control method for a core wire insulation extruder according to an embodiment of this application, including the following steps:

[0032] Step 1: Obtain the stress data and vibration signal of the core wire in the core wire processing process of the extruder.

[0033] In order to improve the uniformity of the core wire after winding, it is necessary to fully tap the abnormal vibration characteristics generated on the core wire, and effectively adjust and compensate the tension of the core wire through the abnormal vibration characteristics generated on the core wire, so as to avoid the problem that the core wire cannot be accurately wound outside the winding roller due to improper tension during winding, thereby improving the uniformity of the core wire after winding.

[0034] The core wire is produced and processed by the extruder of the core wire insulation, the core wire is wrapped and extruded with the external skin cover by using the extruder, then is pulled by the pulling machine, and finally is wound on the winding machine. The extruder in this embodiment includes a pay-off roller, a take-up roller, a tension frame, an extruder main body, a driven wheel, a threaded rod and a driving motor, wherein the tension frame is used to adjust and compensate the tension of the core wire. In the process of using the extruder to produce and process the core wire, the stress data and vibration signal on the core wire are collected in real time by the fiber grating stress sensor and the acceleration sensor, and the data collection frequency of the sensor is set to 100Hz.

[0035] Further, the stress data and vibration signal on the core wire are preprocessed, and 1min is taken as the time length of each collection period. The normalized stress data and vibration signal in each collection period are arranged in time sequence respectively, and are recorded as the stress sequence and vibration sequence of each collection period respectively. In this embodiment, maximum normalization processing is used to eliminate the dimensional problems between different parameters, and the maximum normalization processing is a known technology, and the specific process is not described again.

[0036] Step 2: According to the consistency degree of high frequency change of the stress data and vibration signal on the core wire in the frequency domain and the average level of the amplitude of the vibration signal in the frequency domain, and combining the difference between the amplitudes of the stress data and vibration signal in the frequency domain, the high frequency vibration superposition degree of each collection period is obtained.

[0037] In order to fully tap the abnormal vibration characteristics generated on the core wire, first, the frequency domain feature extraction of the stress data and vibration signal on the core wire is performed. The stress sequence and vibration sequence of each collection period are respectively taken as the input of the Fourier transform. The Fourier transform can be fast Fourier transform or discrete Fourier transform. In this embodiment, the discrete Fourier transform is used to obtain the amplitude spectrum of the positive frequency part in the frequency domain data of the stress sequence and vibration sequence. The horizontal axis of the amplitude spectrum represents the frequency, and the vertical axis represents the amplitude. The Fourier transform is a known technology, and the specific process is not described again.

[0038] Further, the set composed of the frequencies corresponding to all the amplitudes not equal to 0 in the amplitude spectrum of the positive frequency part in the frequency domain data of the stress sequence and the vibration sequence is respectively taken as the stress change frequency set and the vibration change frequency set of each collection period, and the intersection between the stress change frequency set and the vibration change frequency set is calculated, wherein the intersection calculation is a known technology and the specific process is not described herein.

[0039] Generally, the more the number of elements in the intersection and the higher the average level of the elements in the intersection, the more consistent the change frequencies between the stress characteristics and the vibration characteristics on the core wire, and the more frequent the changes of the stress data and the vibration signal on the core wire per unit time, which clearly indicates that the tension on the core wire is not suitable at this time and cannot effectively avoid the phenomenon of high-frequency jitter on the core wire, and the tension of the core wire needs to be effectively adjusted and compensated in time.

[0040] Therefore, the sum of all the frequencies in the intersection is recorded as the first sum value of each collection period, and the larger the first sum value, the more frequent the changes of the stress data and the vibration signal on the core wire per unit time, which is more likely to cause the problem that the tension on the core wire is not suitable and the core wire cannot be accurately wound on the outside of the take-up roller.

[0041] Meanwhile, the amplitudes of all the frequencies in the intersection are extracted from the amplitude spectrum of the positive frequency part in the frequency domain data of the stress sequence and the vibration sequence, respectively, and arranged in order from small to large to obtain the stress amplitude sequence and the vibration amplitude sequence of each collection period, and the higher the similarity between the stress amplitude sequence and the vibration amplitude sequence and the higher the average level of the vibration amplitudes in the vibration amplitude sequence, the more likely there is a superposition between the stress amplitude and the vibration amplitude on the core wire, which will more easily affect the suitability of the tension on the core wire, and the tension of the core wire needs to be adjusted and compensated in time.

[0042] Based on the above analysis, the high-frequency vibration superposition degree of each collection period is calculated as follows:

[0043] wherein, is the high-frequency vibration superposition degree of the tth collection period, is the first sum value of the tth collection period, is the average of the elements in the vibration amplitude sequence of the tth collection period, is the difference distance between the stress amplitude sequence and the vibration amplitude sequence of the tth collection period, is a constant to avoid the denominator being 0, and is taken in a small data range (0.01, 0.1) to have little effect on the calculation result, which can be ignored, and in this embodiment, the value is 0.05.

[0044] The difference distance can be measured by a dynamic time warping (DTW) distance, an Euclidean distance, or a Mahalanobis distance.

[0045] It can be understood that the high-frequency vibration superposition degree reflects the high-frequency superposition characteristics between the stress amplitude and the vibration amplitude on the core wire. The greater the high-frequency vibration superposition degree, the greater the high-frequency superposition characteristics between the stress amplitude and the vibration amplitude on the core wire, and thus the core wire is more likely to be unable to be accurately taken up and wound outside the take-up roller due to the inappropriate tension on the core wire, and the tension on the core wire needs to be adjusted and compensated in time.

[0046] Step 3: Obtain the high-frequency vibration abnormality degree of each collection period by analyzing the change trend and random change characteristics of the high-frequency vibration superposition degree.

[0047] In order to fully mine the abnormal vibration characteristics generated on the core wire, K nearest neighbor collection periods of each collection period are recorded, a local superposition degree sequence of each collection period is obtained by arranging the high-frequency vibration superposition degrees of each collection period and the K nearest neighbor collection periods thereof in time sequence, and the value of K is 30, so that the local superposition degree sequence can reflect the change of the high-frequency superposition characteristics within the last half hour.

[0048] Generally, the more significant the rising trend of the data change in the local superposition degree sequence and the higher the complexity of the irregular random fluctuations in the local superposition degree sequence, the more serious the high-frequency superposition characteristics between the stress amplitude and the vibration amplitude on the core wire due to the inappropriate tension on the core wire, and the more complex the random fluctuations, and thus the more significant the abnormal vibration characteristics on the core wire due to the inappropriate tension on the core wire, and the more likely to affect the uniformity of the core wire after taking up and winding.

[0049] Therefore, the local superposition degree sequence of each collection period is taken as an input of an STL decomposition model (Seasonal-Trend Decomposition using LOESS), a trend sequence and a residual sequence of the local superposition degree sequence are obtained by the STL decomposition model, the trend sequence is taken as an input of a least square linear fitting algorithm, and a fitting slope of the trend sequence is obtained by the least square linear fitting algorithm, where the STL decomposition model and the least square linear fitting algorithm are both known technologies, and the specific process is not described herein.

[0050] Based on the above analysis, the high-frequency vibration abnormality degree of each collection period is calculated as follows:

[0051] ; in the formula, the high-frequency vibration abnormality degree of the tth collection cycle, sigmoid function, the fitting slope of the trend sequence corresponding to the tth collection cycle, the complexity of the residual sequence corresponding to the tth collection cycle. The complexity can be measured by permutation entropy or sample entropy, and the permutation entropy is used in this embodiment to measure the complexity.

[0052] According to the above calculation process, it can be understood that the high-frequency vibration abnormality degree reflects the high-frequency abnormal vibration characteristics caused by the inappropriate tension on the core wire. The greater the high-frequency vibration abnormality degree, the more significant the high-frequency abnormal vibration caused by the inappropriate tension on the core wire, and thus the more necessary it is to adjust and compensate the tension of the core wire, thereby avoiding the problem that the core wire cannot be accurately wound on the outside of the take-up roller due to the inappropriate tension during winding.

[0053] Step 4: Abnormality detection is performed on the high-frequency vibration abnormality degree to determine whether the tension of the core wire in the current collection cycle needs to be adjusted and compensated.

[0054] In order to more effectively adjust and compensate the tension of the core wire, the high-frequency vibration abnormality degrees of the current collection cycle and all the previous collection cycles are taken as inputs of the 3Sigma abnormality detection method, and the 3Sigma interval range is obtained by the 3Sigma abnormality detection method. The tension of the core wire in the collection cycle corresponding to the high-frequency vibration abnormality degree not in the 3Sigma interval range is abnormal, wherein the 3Sigma abnormality detection method is a known technology, and the specific process is not described herein.

[0055] Specifically, if the high-frequency vibration abnormality degree of the current collection cycle is in the 3Sigma interval range, the tension on the core wire is in a normal state, which can ensure the uniformity of the core wire after winding, and thus the tension of the core wire does not need to be adjusted and compensated, which can avoid invalid adjustment and compensation of the tension of the core wire. If the high-frequency vibration abnormality degree of the current collection cycle is not in the 3Sigma interval range, the tension on the core wire is in an abnormal state and needs to be adjusted. Preferably, in this embodiment, the specific adjustment process is as follows:

[0056] In this embodiment, if the high-frequency vibration abnormality degree of the current collection cycle is greater than the maximum value in the 3Sigma interval range, it indicates that the high-frequency abnormal vibration characteristics caused by the too small tension on the core wire are large, and thus the tension of the core wire on the tension frame is increased by 1-5%, and in this embodiment, the tension is increased by 3%.

[0057] If the high-frequency vibration abnormality degree of the current collection cycle is less than the minimum value in the 3 Sigma interval range, it indicates that the high-frequency abnormal vibration feature generated on the core wire is small at this time, and there is a greater possibility that the tension on the core wire is too large, in order to avoid the tension on the core wire being too large and causing damage to the core wire, the tension of the core wire on the tension frame is reduced by 1-5% at this time, and in the embodiment, the tension is reduced by 3%.

[0058] Based on the same inventive concept as the above method, the embodiment of the present application also provides a high-speed running control system of a core wire insulation extruder, which comprises a memory, a processor and a computer program stored in the memory and running on the processor, and the processor implements the steps of the high-speed running control method of the core wire insulation extruder according to any one of the above methods when executing the computer program.

[0059] Preferably, in the embodiment, the high-speed running control system of the core wire insulation extruder comprises a data monitoring module, a superposition analysis module, an abnormality identification module and a running control module. Specifically, the block diagram of the high-speed running control system of the core wire insulation extruder is as shown in Figure 2

[0060] The data monitoring module is used to obtain the stress data and vibration signal of the core wire during the processing of the core wire by the extruder; the superposition analysis module is used to obtain the high-frequency vibration superposition degree of each collection cycle according to the consistency degree of the high-frequency variation of the stress data and the vibration signal on the core wire in the frequency domain and the average level of the amplitude of the vibration signal in the frequency domain, and combining the difference between the amplitudes of the stress data and the vibration signal in the frequency domain; the abnormality identification module is used to obtain the high-frequency vibration abnormality degree of each collection cycle by analyzing the variation trend and random variation characteristics of the high-frequency vibration superposition degree; and the running control module is used to perform abnormal detection on the high-frequency vibration abnormality degree to determine whether the tension of the core wire in the current collection cycle needs to be adjusted and compensated.

[0061] It can be understood that the above-mentioned sequence of the embodiments is only for description, and does not represent the advantages and disadvantages of the embodiments. Moreover, the above description is made for specific embodiments of the present application. In addition, the processes depicted in the drawings do not necessarily require the specific order or continuous order shown to achieve the desired results. In some embodiments, multi-task processing and parallel processing are possible or can be advantageous.

[0062] Each embodiment in the present application is described in a progressive manner, and the same or similar parts between each embodiment can be referred to each other, and each embodiment mainly describes the differences from other embodiments.

[0063] ​The above merely illustrates the embodiments of the present application, and is not intended to limit the scope of the present application, and any equivalent structure or equivalent process transformation, or direct or indirect application in other related technical fields, which are made by using the content of the present application specification and drawings, are also included in the protection scope of the present application.

Claims

1. A method of controlling the high speed running of a core wire insulating extruder, characterized by, The method comprises the following steps: obtaining stress data and vibration signals of the core wire during the processing of the core wire in the extruder; obtaining a high-frequency vibration abnormality degree of each collection period by analyzing the change trend and random change characteristics of the high-frequency vibration superposition degree; performing abnormality detection on the high-frequency vibration abnormality degree to determine whether the tension of the core wire in the current collection period needs to be adjusted and compensated; arranging the normalized stress data and vibration signals of the core wire in each collection period in time sequence to obtain stress sequences and vibration sequences of each collection period, performing frequency domain transformation on the stress sequences and vibration sequences, and obtaining amplitude spectra of positive frequency parts in the frequency domain data of the stress sequences and vibration sequences; the high-frequency vibration superposition degree of each collection period is further obtained as follows: the K collection periods closest in time to each collection period are recorded as neighbor collection periods of each collection period, and the high-frequency vibration superposition degrees of each collection period and its K neighbor collection periods are arranged in time sequence to form a local superposition sequence of each collection period.

2. A method of controlling the high speed running of a core insulation extruder as defined in claim 1, characterized in that performing time sequence decomposition on the local superposition sequence of each collection period to obtain a trend sequence and a residual sequence, and fitting the trend sequence to obtain a corresponding fitting slope. ; wherein, is the high frequency vibration superimposition degree of the tth acquisition cycle, is the first sum of the tth acquisition cycle, is a constant to avoid the denominator being 0, is the element mean of the vibration amplitude sequence of the tth acquisition cycle, is the difference distance between the stress amplitude sequence and the vibration amplitude sequence of the tth acquisition cycle, wherein the amplitudes of all frequencies in the intersection are extracted from the amplitude spectrum of the positive frequency part of the frequency domain data of the stress sequence and the vibration sequence respectively, and arranged in descending order of frequency, to obtain the stress amplitude sequence and the vibration amplitude sequence of each acquisition cycle.

3. A method of controlling the high speed running of a core insulation extruder as defined in claim 1, wherein the high-frequency vibration abnormality degree of each collection period is further obtained as follows:

4. A method of controlling the high speed running of a core insulation extruder as defined in claim 3, wherein the high-frequency vibration abnormality degrees of the current collection period and all previous collection periods are used to extract a 3Sigma interval range, if the high-frequency vibration abnormality degree of the current collection period is within the 3Sigma interval range, the core wire tension is normal, and the core wire tension is not adjusted and compensated; otherwise, the core wire tension is abnormal, and the core wire tension needs to be adjusted and compensated.

5. A method of controlling the high speed running of a core insulation extruder as defined in claim 4, wherein if the high-frequency vibration abnormality degree of the current collection period is greater than the maximum value of the 3Sigma interval range, the tension of the core wire is increased by 1-5%; if the high-frequency vibration abnormality degree of the current collection period is less than the minimum value of the 3Sigma interval range, the tension of the core wire is decreased by 1-5%. wherein, is the high-frequency vibration anomaly degree of the tth acquisition cycle, is a sigmoid function, is the fitting slope of the trend sequence corresponding to the tth acquisition cycle, is the complexity of the residual sequence corresponding to the tth acquisition cycle, and the complexity is measured by permutation entropy.

6. A method of controlling the high speed running of a core insulation extruder as defined in claim 1, wherein the processor executes the computer program to realize the steps of the high-speed running control method of the core wire insulation extruder according to any one of claims 1-7.

7. A method of controlling the high speed running of a core insulation extruder as defined in claim 6, wherein ​ 8. A high speed run control system for a core insulation extruder comprising a memory, a processor, and a computer program stored in the memory and running on the processor, characterized in that, ​

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