High-precision winding machine based on intelligent tension control

Abstract

The application discloses a high-precision winding machine based on intelligent tension control and belongs to the technical field of mechanical equipment manufacturing, which comprises a rack stand column, a support cantilever is slidably connected to the rack stand column, a support machine head is rotatably connected to the support cantilever, a wire harness distributor is fixedly connected to the support machine head, a first distance is arranged between the wire harness distributor and the support cantilever, so that the wire harness distributor and the support cantilever cooperate to form a containing space of a to-be-wound part when the support machine head rotates relative to the support cantilever, a plurality of material shafts are arranged on the support machine head, the material shafts are used for mounting wire harness rolls, wire harness on the wire harness rolls is connected with the to-be-wound part after passing through the wire harness distributor, and a tension control device is arranged on each material shaft, the tension control device controls the tension of the wire harness by adjusting the torque of the material shaft. The application solves the problems of large tension fluctuation, poor product tightness and consistency of an existing winding machine in a high-speed and high-precision winding process.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of mechanical equipment manufacturing, and particularly relates to a high-precision winding machine based on intelligent tension control. BACKGROUND

[0002] The winding machine is a device for winding a linear object onto a specific workpiece. In the power industry, for example, the performance of materials and the precision of processes are strictly required for precise electronic components, aerospace cables, etc. The existing winding machine adjusts the tension by inputting numerical values through electronic instruments during high-speed and high-precision winding, resulting in large deviation of tightness and tension during winding, which affects product quality and consistency.

[0003] Therefore, it is urgent to design a high-precision winding machine based on intelligent tension control to solve the above-mentioned problem of large deviation of tightness and tension during winding. SUMMARY

[0004] To solve the technical problem of large deviation of tightness and tension during winding mentioned in the background, a high-precision winding machine based on intelligent tension control is provided to solve the above-mentioned problems.

[0005] To achieve the above-mentioned purpose, the specific technical scheme of the high-precision winding machine based on intelligent tension control is as follows:

[0006] A high-precision winding machine based on intelligent tension control, comprising a rack stand column, a support cantilever is slidably connected to the rack stand column, a support head is rotatably connected to the support cantilever, a wire harness distributor is fixedly connected to the support head, a first distance is provided between the wire harness distributor and the support cantilever, so that when the support head rotates relative to the support cantilever, the wire harness distributor and the support cantilever cooperate to form a containing space for a winding piece, a plurality of material shafts are provided on the support head, the material shafts are used to install wire harness rolls, the wire harness on the wire harness roll is connected to the winding piece after passing through the wire harness distributor, and a tension control device is provided on each material shaft, the tension control device controls the tension of the wire harness by adjusting the torque of the material shaft.

[0007] Further, the tension control device comprises a magnetic powder brake and a tension sensor, the shaft hole on the magnetic powder brake is fixedly connected with the material shaft, so that the tension of the wire harness is controlled by the magnetic powder brake, and the tension sensor is arranged at the output end of the wire harness distributor, so that the tension data of the wire harness after passing through the wire harness distributor is monitored by the tension sensor.

[0008] Further, the plurality of magnetic powder brakes are electrically connected with the PLC, and the plurality of tension sensors are electrically connected with the PLC, the PLC controls the torque of the magnetic powder brake through the tension data of each tension sensor, so that the tension of the wire harness on each wire harness roll is the same.

[0009] Further, the PLC controls the output torque of the magnetic powder brake by controlling the current of each magnetic powder brake, so as to realize the balanced tension control of multi-axis cooperation.

[0010] Further, the first infrared sensor is installed on the support head, and is used to collect the radius of the wire harness roll on the material shaft and send data to the PLC.

[0011] ;

[0012] Wherein, is the feedforward term at time t, is the feedback term based on PID at time t; is the output torque of the magnetic powder brake at time t; is the tension of the wire harness set by the operator; is the radius of the roll on the material shaft measured by the first infrared sensor at time t; t is the instantaneous time.

[0013] Further, the feedback term of the PID includes:

[0014] ;

[0015] Wherein, is the proportional adjustment term of the PID; is the integral adjustment term of the PID; is the differential adjustment term of the PID; is the deviation between the set tension of the wire harness and the real-time measured tension of the wire harness at time t; is the cumulative value of the deviation between the set tension of the wire harness and the real-time measured tension of the wire harness in the range from 0 to t, is the integral variable of time; is the proportional adjustment coefficient of the PID; is the integral adjustment coefficient of the PID; is the differential adjustment coefficient of the PID;

[0016] ;

[0017] Wherein, is the tension of the wire harness measured by the tension sensor at time t.

[0018] Further, the first rotating shaft and a driving motor are arranged on the support cantilever, the support head comprises a truss, one end of the first rotating shaft is in transmission connection with the driving motor, the other end of the first rotating shaft is fixedly connected with the truss, the wire harness distributor is fixedly connected on the truss, a first distance is arranged between the wire harness distributor and the first rotating shaft, and the magnetic powder brake is fixedly connected with the material shaft and symmetrically arranged on the two sides of the truss.

[0019] Further, the downstream of each material shaft is provided with a wire guide shaft for guiding the wire harness.

[0020] Further, the wire guide shafts are arranged on the same horizontal plane, so that the height of the wire harness is kept consistent.

[0021] Further, the second infrared sensor is arranged at the center position of the bottom surface of the first rotating shaft, for positioning the shaft center of the wire winding piece, so that the shaft center line of the wire winding piece is collinear with the shaft center line of the first rotating shaft.

[0022] The high-precision wire winding machine based on intelligent tension control has the following advantages:

[0023] The high-precision wire winding machine based on intelligent tension control has the following advantages:

[0024] By constructing an automatic closed-loop tension control system based on real-time feedback, the problem of large tension fluctuation, poor tightness and consistency of products in the high-speed and high-precision winding process of the existing wire winding machine is solved, and strong technical support is provided for producing wire harness products with high quality and high reliability. BRIEF DESCRIPTION OF DRAWINGS

[0025] Figure 1 It is a structural schematic view of the high-precision wire winding machine based on intelligent tension control;

[0026] Figure 2 It is a schematic view of the connection position of the support cantilever and the support head;

[0027] Figure 3 It is a schematic view of the arrangement of the magnetic powder brake;

[0028] Figure 4 It is a physical principle diagram;

[0029] Figure 5 It is a schematic view of the first infrared sensor;

[0030] Figure 6 It is a schematic view of the second infrared sensor.

[0031] Marked description in the figure: 1, rack stand column; 2, support cantilever; 201, first rotating shaft; 202, driving motor; 3, support machine head; 301, truss; 302, wire shaft; 4, wire harness distributor; 5, material shaft; 6, magnetic powder brake; 7, tension sensor; 8, first infrared sensor; 9, second infrared sensor. DETAILED DESCRIPTION

[0032] To make the purposes, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are some of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the scope of protection of the present application.

[0033] Those skilled in the art can understand that although some embodiments herein include certain features included in other embodiments rather than other features, the combination of features of different embodiments means to be within the scope of the present application and form different embodiments. For example, in the claims, any one of the claimed embodiments can be used in any combination.

[0034] The embodiments of the present application will be described below with reference to the accompanying drawings. Figure 1 to the accompanying drawings Figure 6 The present application describes a high-precision winding machine based on intelligent tension control.

[0035] The existing automatic winding machine in the power industry can rotate around the to-be-wound part on the base disc, and can uniformly distribute the wire harness with a certain tension on the axis of the to-be-wound part, but the traditional winding machine adjusts the tension by inputting numerical values from electronic instruments during high-speed and high-precision winding, which leads to large deviation of tightness and tension during winding, affecting product quality and consistency.

[0036] Therefore, the present application provides a high-precision winding machine based on intelligent tension control, as shown in the figure, which comprises a rack stand column 1, a support cantilever 2 is slidably connected to the rack stand column 1, a support machine head 3 is rotatably connected to the support cantilever 2, a wire harness distributor 4 is fixedly connected to the support machine head 3, a first distance D is provided between the wire harness distributor 4 and the support cantilever 2, so that when the support machine head 3 rotates relative to the support cantilever 2, the wire harness distributor 4 cooperates with the support cantilever 2 to form a containing space for the to-be-wound part, a plurality of material shafts 5 are provided on the support machine head 3, the material shafts 5 are used to install wire harness rolls (not shown in the figure), the wire harness on the wire harness roll is connected to the to-be-wound part (not shown in the figure) after passing through the wire harness distributor 4, and a tension control device is provided on each material shaft 5, the tension control device controls the tension of the wire harness by adjusting the torque of the material shaft 5, and in a specific embodiment, the torque of the material shaft 5 is adjusted by a magnetic powder brake 6, and the torque of the magnetic powder brake 6 is adjusted by a driving motor 202. Figures 1-6 ​Figure 1 For example, the support cantilever 2 can slide vertically on the rack column 1. During the operation of the winding machine, the winding object is placed in the accommodation space below the support cantilever 2, the wire harness distributor 4 rotates around the winding object to wind the wire harness on the winding object, and at the same time, the support cantilever 2 moves vertically on the rack column 1 to drive the wire harness distributor 4 to move vertically, so that the wire harness of each layer can be uniformly distributed on the winding object during the winding process, and the tension control device is used to make the tension of each wire harness consistent, avoid the uneven tension between the wire harnesses or the inaccurate overall tension control, and solve the problem of large deviation of tightness and tension in the existing winding process.

[0037] As preferred, as shown in Figure 2 and Figure 3 , the tension control device includes a magnetic powder brake 6 and a tension sensor 7. The shaft hole of the magnetic powder brake 6 is fixedly connected with the material shaft 5, so that the tension of the wire harness is controlled through the magnetic powder brake 6. The tension sensor 7 is arranged at the output end of the wire harness distributor 4, so that the tension data of the wire harness after passing through the wire harness distributor 4 is monitored through the tension sensor 7. Specifically, the response speed of the magnetic powder brake 6 is fast, and the tension sensor 7 can provide high-frequency tension data, which provides a hardware basis for fast and accurate tension adjustment.

[0038] As preferred, the plurality of magnetic powder brakes 6 are electrically connected with a PLC (not shown in the figure), and the plurality of tension sensors 7 are electrically connected with the PLC. The PLC controls the torque of the magnetic powder brake 6 through the tension data of each tension sensor 7, so that the tension of the wire harness on each wire harness roll is the same. Specifically, the PLC automatically adjusts the torque of the corresponding magnetic powder brake 6 according to the real-time data fed back by the tension sensor 7, forming a closed-loop control system. This automatic closed-loop control can dynamically compensate the influence of running disturbance on the tension, thereby significantly reducing the problem of large deviation of tightness and tension, ensuring the stability and accuracy of the tension. At the same time, through the independent closed-loop control of the PLC to each material shaft 5 and taking the consistency of the tension as the goal, the consistency of the winding product can be significantly improved, and the defective products caused by the tension problem are reduced.

[0039] As preferred, the PLC controls the output torque of the magnetic powder brake 6 by controlling the current of each magnetic powder brake 6, so as to realize the balanced tension control of multiple axes in cooperation. Specifically, the current control has a fast response speed, and the PLC can quickly adjust the output current, so that the magnetic powder brake 6 can quickly respond to the demand of tension change, which further enhances the dynamic performance of the closed-loop control system, helps to control the tension more finely, further reduces the tightness and tension deviation, ensures the winding quality, and makes the response speed ≤0.1s.

[0040] The tension of the wire bundle wound on the winding part during the winding process of the wire bundle roll on the spool 5 is generated by the moment difference between the spool 5 and the winding part, so the tension of the wire bundle during the winding process is constant, assuming that the direction of the tension is from the spool 5 to the winding part, as shown in Figure 4 The formula principle is:

[0041] ;

[0042] Wherein, is the wire bundle tension, is the stretching force of the winding part, is the resistance provided by the magnetic powder brake 6 on the spool 5, is the torque provided by the winding part, is the torque provided by the magnetic powder brake 6, is the real-time radius of the winding part, is the real-time radius of the spool 5.

[0043] During the winding process, and are dynamically changing, decrease with the release of the wire bundle, increase with the increase of the number of layers of the wire bundle.

[0044] Therefore, based on the above physical principle, in some embodiments, in order to break through the limitation of the traditional fixed roll diameter model and realize more accurate wire bundle tension control, the radius of the spool 5 is measured in real time by a sensor, as shown in Figure 5 The first infrared sensor 8 is installed on the support head 3, used to collect the roll radius of the wire bundle roll on the spool 5, and send the data to the PLC, and the PLC obtains the roll radius in real time based on the first infrared sensor 8 data, and realizes the closed-loop control of the tension in the whole cycle through the feedforward and feedback compound control algorithm, including:

[0045] ;

[0046] Wherein, is the feedforward term at time t, is the feedback term based on PID at time t; is the output torque of the magnetic powder brake 6 at time t; is the tension of the wire bundle set by the operator; is the radius of the roll on the spool measured by the first infrared sensor 8 at time t; t is the instantaneous time.

[0047] Further, the feedback term of the PID includes:

[0048] ;

[0049] wherein, is a proportional adjustment term of the PID; is an integral adjustment term of the PID; is a differential adjustment term of the PID; is a deviation between the set tension of the wire bundle at time t and the real-time measured tension of the wire bundle at time t; is an accumulated value of the deviation between the set tension of the wire bundle in the range from 0 to t and the real-time measured tension of the wire bundle, is an integral variable of time; is a proportional adjustment coefficient of the PID; is an integral adjustment coefficient of the PID; is a differential adjustment coefficient of the PID;

[0050] ;

[0051] wherein, is the tension of the wire bundle measured by the tension sensor 7 at time t.

[0052] Specifically, the essence of the tension control is that the magnetic powder brake 6 generates a resistance torque, so as to balance the wire tension through the resistance torque, and the PLC controls through the combination of the feedforward radius change and the PID dynamic adjustment of the tension error, so as to output the matched magnetic powder brake 6 torque in real time, solve the tension fluctuation problem caused by the reduction of the wire bundle winding radius, and realize the precise and rapid wire bundle tension control, with the response time shortened from the conventional 200 ms to 35 ms;

[0053] When the parameters of the PID are debugged,

[0054] Prior adjustment , so that = 0, = 0, gradually increase until the tension appears slight oscillation, at which moment is the maximum value of , take 0.6 times of the maximum value; Further adjust

[0055] , keep the adjusted unchanged, = 0, gradually increase until the static error is completely eliminated, the static error includes the tension deviation caused by the bearing friction or the wire elasticity, and the static error is completely eliminated when the tension is stable at ;

[0056] Finally adjust , keep the adjusted​ and Step by step increase , the process can be manually accelerated short time winding parts, observe the tension response, until the mutation is quickly suppressed, adjust the completion.

[0057] As preferred, as shown in Figure 1 , Figure 2 and Figure 3 , the bracket cantilever 2 is provided with a first rotating shaft 201 and a driving motor 202, the bracket head 3 includes a truss 301, one end of the first rotating shaft 201 is in transmission connection with the driving motor 202, the other end of the first rotating shaft 201 is in fixed connection with the truss 301, the wire harness distributor 4 is fixedly connected on the truss 301, a first distance D is provided between the wire harness distributor 4 and the first rotating shaft 201, the magnetic powder brake 6 is fixedly connected with the material shaft 5 and symmetrically installed on both sides of the truss 301, specifically, the first rotating shaft 201 is driven by the driving motor 202, and then the truss 301 is driven to rotate by the first rotating shaft 201, which provides a stable rotating platform for wire harness distribution and winding, maintains the stability of the equipment and reduces vibration at high speed, and the magnetic powder brake 6 is symmetrically installed on both sides of the truss 301, effectively balances the centrifugal force of the bracket head 3 during high-speed rotation, reduces vibration and shaking caused by equipment imbalance, thereby indirectly reducing the fluctuation of wire harness tension.

[0058] As preferred, a wire guide shaft 302 is arranged downstream of each material shaft 5 for guiding the wire harness, specifically, an independent wire guide shaft 302 is arranged after each material shaft 5, which can individually and accurately guide each wire harness, prevent the wire harness from winding and knotting, and ensure that the path between the wire harness roll output and the wire harness distributor 4 is smooth and obstacle-free, thereby minimizing the friction between the wire harness and the machine parts and reducing the tension fluctuation caused by uneven friction resistance.

[0059] As preferred, the wire guide shafts 302 are arranged on the same horizontal plane to keep the height of the wire harness consistent, the uniform wire harness height simplifies the work of the wire harness distributor 4, enables it to more accurately control the arrangement of each wire harness, further improves the winding accuracy, and also avoids additional distortion or stress of the wire harness before entering the wire harness distributor 4, further ensuring the stability of the wire harness tension.

[0060] As preferred, as shown in Figure 6 , a second infrared sensor 9 is arranged at the center position of the bottom surface of the first rotating shaft 201 for positioning the shaft center of the to-be-wound part, so that the shaft center line of the to-be-wound part is collinear with the shaft center line of the first rotating shaft 201, thereby eliminating the influence of eccentric winding, accurately centering to ensure the stability of the winding process and the uniformity of the wire harness tension.

[0061] The application solves the problems of large tension fluctuation, poor product tightness and consistency in the high-speed and high-precision winding process of the existing winding machine by constructing a set of automatic closed-loop tension control system based on real-time feedback, and provides strong technical support for producing high-quality and high-reliability wire harness products.

[0062] The application can overcome the uneven tension caused by the differences of materials, batches and reel states of different wire harnesses by setting independent and synchronous closed-loop tension control system, ensure the uniform stress of all wire harnesses in the final product, and significantly improve the product quality and reliability.

[0063] Obviously, the above embodiments of the application are only examples for clearly illustrating the application, and are not intended to limit the implementation modes of the application. Based on the above description, other different forms of changes or variations can be made by those skilled in the art. Here, all the implementation modes are not required or can not be exhausted. Any modification, equivalent replacement and improvement made within the spirit and principle of the application shall be included in the protection scope of the claims of the application.

Claims

1. A high-precision winding machine based on intelligent tension control, characterized in that, The rack post is provided with a bracket cantilever connected thereto in a sliding manner, the bracket cantilever is provided with a bracket head connected thereto in a rotating manner, the bracket head is provided with a wire harness distributor fixedly connected thereto, a first distance is provided between the wire harness distributor and the bracket cantilever, so that the wire harness distributor and the bracket cantilever form a containing space for the wire winding part when the bracket head rotates relative to the bracket cantilever, a plurality of material shafts are provided on the bracket head, the material shafts are used for mounting wire harness reels, the wire harness on the wire harness reels is connected to the wire winding part after passing through the wire harness distributor, a tension control device is provided on each material shaft, and the tension control device controls the tension of the wire harness by adjusting the torque of the material shaft; The tension control device comprises a magnetic powder brake and a tension sensor, the shaft hole of the magnetic powder brake is fixedly connected with the material shaft, so that the tension of the wire harness is controlled through the magnetic powder brake, and the tension sensor is arranged at the output end of the wire harness distributor, so that the tension data of the wire harness after passing through the wire harness distributor is monitored through the tension sensor; The plurality of magnetic powder brakes are electrically connected with the PLC, the plurality of tension sensors are electrically connected with the PLC, the PLC controls the torque of the magnetic powder brake through the tension data of each tension sensor, so that the tension of the wire harness on each wire harness reel is the same; The PLC controls the output torque of the magnetic powder brake by controlling the current of each magnetic powder brake, so as to realize balanced tension control of multi-axis cooperation; The first infrared sensor is installed on the bracket head and is used for collecting the winding diameter radius of the wire harness reel on the material shaft and sending data to the PLC, the PLC obtains the winding diameter radius in real time based on the first infrared sensor data, and realizes tension closed-loop control in the whole cycle through a feedforward and feedback compound control algorithm.

2. The high precision winding machine based on intelligent tension control according to claim 1, characterized in that, The feedforward and feedback compound control algorithm comprises: ； wherein, is a feed forward term at time t, is a feedback term at time t based on PID; is an output torque of the magnetic powder brake at time t; is a tension force of the wire harness set by the operator; is a radius of the rolled diameter of the material shaft measured by the first infrared sensor at time t; t is the instantaneous time.

3. The high precision winding machine based on intelligent tension control according to claim 2, characterized in that, The feedback term of the PID comprises: ； wherein, is a proportional adjustment term of the PID; is an integral adjustment term of the PID; is a differential adjustment term of the PID; is a deviation of the set tension of the wire harness from the real-time measured tension of the wire harness at time t; is an accumulated value of the deviation of the set tension of the wire harness from the real-time measured tension of the wire harness in the range from 0 to time t, is an integral variable of time; is a proportional adjustment coefficient of the PID; is an integral adjustment coefficient of the PID; is a differential adjustment coefficient of the PID; ； wherein, is the tension force of the wire harness measured by the tension sensor at time t.

4. The high precision winding machine based on intelligent tension control as claimed in claim 1, wherein, The bracket cantilever is provided with a first rotating shaft and a driving motor, the bracket head comprises a truss, one end of the first rotating shaft is in transmission connection with the driving motor, the other end of the first rotating shaft is fixedly connected with the truss, the wire harness distributor is fixedly connected with the truss, a first distance is provided between the wire harness distributor and the first rotating shaft, and the magnetic powder brakes are fixedly connected with the material shafts and symmetrically installed on both sides of the truss.

5. The high precision winding machine based on intelligent tension control as claimed in claim 4, wherein, A wire guide shaft is arranged downstream of each material shaft and is used for guiding the wire harness.

6. The high precision winding machine based on intelligent tension control according to claim 5, characterized in that, The wire guide shafts are arranged on the same horizontal plane, so that the height of the wire harness remains consistent.

7. The high precision winding machine based on intelligent tension control as claimed in claim 4, wherein, A second infrared sensor is arranged at the center position of the bottom surface of the first rotating shaft and is used for positioning the shaft center of the wire winding part, so that the shaft center line of the wire winding part is collinear with the shaft center line of the first rotating shaft.

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