Method and system for controlling flexible forming process of NTC (Negative Temperature Coefficient) insulated wire

Abstract

The invention relates to the technical field of machine learning, in particular to an NTC insulated wire flexible forming process control method and system, and the method comprises the following steps: obtaining and mapping path segment and node temperature data, analyzing the temperature difference of adjacent nodes, distributing an adjustment coefficient, calculating a target power generation control instruction, screening power change abnormal sections, and marking stress behaviors. According to the method, thermosensitive nodes are arranged at the path section to collect temperature data, mapping is established in combination with path numbers, the precision of heat distribution information is ensured, power adjusting coefficients are distributed according to temperature difference changes of adjacent nodes, target power is generated, and dynamic response of a local thermal field is achieved. Power change and temperature rise rate analysis are combined to identify a stress behavior path section, insulating layer structural characteristics are fused to form a stress release mark, power and stress information output parameter sets are matched, closed-loop regulation is constructed, forming consistency is enhanced, and thermal control flexibility and machining stability are improved.

Description

Technical Field

[0001] This invention relates to the field of machine learning technology, and in particular to a method and system for controlling the flexible forming process of NTC insulated wires. Background Technology

[0002] Machine learning technology involves learning from large amounts of data by constructing mathematical models to extract patterns and predict or classify unknown data accordingly. Its core aspects include data acquisition, feature extraction, model training, model evaluation, and parameter optimization. This field typically builds predictive models using supervised, unsupervised, or semi-supervised learning methods and leverages statistical learning theory to model and control the behavior of complex systems. Traditional flexible forming process control methods for NTC insulated wires refer to the process control method used in the manufacturing of NTC thermistors to flexibly form the insulated wires used for their leads to meet assembly requirements. During the forming process, NTC insulated wires suffer from inconsistent forming or low efficiency due to uneven material stress release, unstable heating time, and poor operational repeatability. Traditional solutions typically rely on manual experience to set process parameters, combined with constant heating equipment and mechanical molds for shaping. Process control is achieved by observing and adjusting forming time and temperature, primarily based on historical experimental results but lacking a data-driven adaptive control mechanism.

[0003] Traditional NTC insulated wire flexible forming processes rely heavily on manual experience to set parameters, coupled with constant-output heating equipment for shaping. The lack of real-time temperature feedback and control mechanisms makes it difficult to identify temperature non-uniformity in different areas along the forming path, leaving the heat distribution state largely invisible and unable to adjust power based on local differences. When the lead path is complex or the stress characteristics of the insulation material vary significantly, inaccurate temperature control often leads to localized overheating or underheating, resulting in uneven stress release and inconsistent forming deformation. Heating parameter settings rely heavily on experience and static test results, lacking dynamic response capabilities. This necessitates extensive trial and error for each process adjustment, resulting in low efficiency and poor stability. For example, in complex path structures, constant heating may not meet the heat requirements of every angle or bend, easily causing warping, cracking, or insulation damage due to heat buildup, significantly reducing forming yield and processing reliability. This operating mode fails to incorporate data perception and adaptive control logic, making it unable to identify and respond to stress release behavior, resulting in a lack of targeted and refined overall process control. Summary of the Invention

[0004] To address the technical problems existing in the prior art, embodiments of the present invention provide a method for controlling the flexible forming process of NTC insulated wires, comprising the following steps:

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a method for controlling the flexible forming process of NTC insulated wires, comprising the following steps:

[0006] S1: Obtain the lead forming path segment, set multiple thermal nodes on the path segment, collect the temperature data of the nodes in a continuous cycle, establish a mapping relationship between the temperature data and the path segment number, construct a temperature correspondence table for measuring points, and generate a temperature correspondence table for the section.

[0007] S2: Based on the temperature difference between adjacent nodes in the section temperature correspondence table, extract the change amplitude within a continuous period, judge according to the reference rate, calibrate the path segment number that meets the conditions, allocate power adjustment coefficients, and generate a path segment power adjustment coefficient table.

[0008] S3: Calculate the target power value of the corresponding path segment according to the number and coefficient in the path segment power adjustment coefficient table, set the heating output control command, and pair and record the control content with the path segment to form a heating path power configuration table;

[0009] S4: Based on the power value changes of the path segments in the heating path power configuration table, filter out numbered segments whose power value changes exceed the set threshold, extract the temperature data of the corresponding number within a continuous period, calculate the temperature rise rate difference and compare it with the reference standard, mark the number that meets the offset condition as a stress behavior path segment, establish identification information in combination with the insulation layer structural characteristics, and establish a stress release trend marking table.

[0010] As a further embodiment of the present invention, the segment temperature correspondence table includes path segment number, node number, temperature measurement time, and temperature value; the path segment power adjustment coefficient table includes power adjustment coefficient and judgment result mark; the heating path power configuration table includes target power value and control instruction content; and the stress release trend mark table includes temperature rise rate difference, stress identification type, and structural feature mark.

[0011] As a further aspect of the present invention, the specific steps of S1 are as follows:

[0012] S101: Obtain the lead forming path segment, associate the path segment number with the spatial coordinate, set a thermal node at the geometric center of each path segment, establish the mapping between the node and the path segment according to the relationship between the coordinate and the number, and generate the node path correspondence coefficient.

[0013] S102: Based on the corresponding coefficient of the node path, collect continuous periodic temperature data on the thermal node, collect the temperature sequence under the same path segment, obtain a stable temperature set, and generate the periodic temperature range of the path segment.

[0014] S103: Call the path segment number in the path segment periodic temperature interval and node path correspondence coefficient to establish the relationship between the path segment and the temperature interval, and construct the measuring point temperature correspondence table by combining the number and the location index to generate the path segment temperature correspondence interval table.

[0015] As a further aspect of the present invention, the specific steps of S2 are as follows:

[0016] S201: Based on the path segment temperature interval table, extract the number information and corresponding temperature interval value of adjacent nodes, compare and match the temperature values ​​in the same period by the adjacent path segment number order, calculate the temperature difference change range of each group of adjacent nodes in the continuous period, and obtain the temperature difference change value of adjacent nodes.

[0017] S202: Call the temperature difference change value of the adjacent nodes, and judge the change rate with the set temperature difference change rate benchmark value according to the temperature difference change rate under each group of path segment numbers. Mark and classify the path segment numbers that meet the benchmark value requirements, and obtain the set of path segment numbers whose rates meet the benchmark value requirements.

[0018] S203: Based on the set of path segment numbers that meet the rate requirements, and in conjunction with the path segment number index and the path segment power adjustment rules, perform a power adjustment coefficient assignment operation on the number, record the power adjustment coefficient corresponding to each path segment number, and generate a path segment power adjustment coefficient table.

[0019] As a further aspect of the present invention, the specific steps of S3 are as follows:

[0020] S301: Based on the path segment number and power adjustment coefficient in the path segment power adjustment coefficient table, obtain the reference power value for each path segment, call the reference power value and the corresponding power adjustment coefficient, calculate the target power output value corresponding to the path segment, and generate a set of target power values ​​for the path segment;

[0021] S302: Based on the target power value set of the path segment, perform a combination identification operation on the target power value and path segment number of each path segment, extract the control time parameters and control node positions of the path segment, set the heating output power command corresponding to each path segment number, and obtain the path segment heating command set;

[0022] S303: Call the set of heating instructions for the path segment, pair each group of heating output power instructions with the path segment number, establish the correspondence between the number and the control instruction, summarize the number and control instruction comparison information of all path segments, and generate a heating path power configuration table.

[0023] As a further aspect of the present invention, the specific steps of S4 are as follows:

[0024] S401: Based on the power value sequence of the path segment in the heating path power configuration table, calculate the power difference between adjacent cycles, compare it with the power change threshold, filter out the path segment numbers whose power value changes exceed the threshold, and generate a set of power mutation zone numbers.

[0025] S402: Call the power mutation section number set, extract the continuous periodic temperature data corresponding to the number, calculate the periodic temperature rise rate difference, compare it with the temperature rise rate reference standard value, mark the path segment number where the temperature rise rate difference exceeds the standard, and generate an abnormal temperature rise number section set.

[0026] S403: Based on the abnormal temperature rise number segment set, extract the insulation layer structure information corresponding to the number, combine the path segment number and structural characteristics, establish the marking information corresponding to the number, summarize the marking content of all numbers, and establish a stress release trend marking table.

[0027] As a further aspect of the present invention, the method further includes:

[0028] S5: Match the path segment numbers in the heating path power configuration table and the stress release trend marking table, extract the intersection of the numbers, mark it as the adjustment control area, and output the parameter set corresponding to the number to generate a closed-loop control parameter set;

[0029] The closed-loop control parameter set includes output power value, response period parameter, and adjustment priority level.

[0030] As a further aspect of the present invention, the specific steps of S5 are as follows:

[0031] S501: Based on the path segment number sequence in the heating path power configuration table and the stress release trend marking table, filter the intersection number set, determine the identification status of the intersection path segment based on the synchronous existence of the number, and establish the path segment intersection number set.

[0032] S502: Call the path segment intersection number set, retrieve the corresponding control parameters in the heating path power configuration table, extract the parameter items in the order of number, including power set value, start and end time, and running cycle value, establish a parameter combination set corresponding to each number, and generate a path segment parameter set table;

[0033] S503: Based on the path segment parameter set table, using the path segment number as the index field, match each group of numbers with the control area identifier status, filter the control parameter groups with the same number and identifier, integrate the value range information of the group control parameter items, and establish a closed-loop control parameter set;

[0034] The closed-loop control parameter set refers to the set of control parameters for feedback adjustment of the output of the controllable path segment after integrating the power configuration and stress identification results.

[0035] As a further aspect of the present invention, the lead forming path segment refers to the spatial path area where temperature control is required during the flexible forming process of the NTC insulated wire, which can be obtained by setting the forming trajectory of the processing equipment.

[0036] The thermal node refers to a temperature sensor, including thermistors and thermocouples.

[0037] The temperature correspondence table for measuring points is a set of mapping relationships consisting of measuring point numbers and corresponding temperature values.

[0038] The section temperature correspondence table refers to the mapping relationship table established between the temperature data collected by multiple temperature acquisition nodes deployed on the lead forming path section and the path section number;

[0039] The temperature difference change range refers to the amount of change in temperature difference between adjacent nodes within a continuous sampling period;

[0040] The reference rate is a benchmark value used to determine whether the temperature difference change is abnormal;

[0041] The power adjustment coefficient is a proportional parameter used to adjust the target heating power output;

[0042] The target power value refers to the heating output power value determined by calculating based on the thermal response characteristics of the segment path;

[0043] The heating output control command refers to the parameter command issued by the control system to the heating equipment;

[0044] The heating path power configuration table refers to a tabular data structure that corresponds the number of each path segment with the target power value.

[0045] The power value change range refers to the difference between the target power values ​​of the path segment in two consecutive control cycles;

[0046] The set threshold is a set judgment criterion, indicating whether the power change has regulatory significance;

[0047] The temperature rise rate difference refers to the difference in the rate of change of temperature rise within a continuous sampling period;

[0048] The reference standard refers to the technical parameters and judgment thresholds used for comparison in power change, temperature rise rate change and behavior judgment.

[0049] The stress behavior path segment refers to the path segment where abnormal temperature rise rate or power change behavior is detected during the flexible molding process, which causes thermal deformation or abnormal tension of the insulation layer.

[0050] The stress release trend marking table refers to a data set that records the path segment numbers and stress behavior types of all detected thermal stress concentration trends.

[0051] The NTC insulated wire flexible forming process control system includes:

[0052] The temperature acquisition and mapping module obtains the set of numbers of the lead forming path segments, sets multiple thermal nodes in the path segment structure area, and the acquisition nodes record temperature data in a continuous cycle. The temperature values ​​are mapped to the path segment numbers in the order of acquisition time. By judging the consistency of temperature changes of multiple nodes in the cycle, a node temperature correspondence table is constructed, and a regional classification relationship is established in combination with the path segment numbers to generate a segment temperature correspondence table.

[0053] The power adjustment coefficient module extracts the change amplitude sequence of the path segment within a continuous period based on the temperature difference between adjacent nodes in the segment temperature correspondence table, judges according to the reference rate, numbers and marks the path segments that meet the change conditions, and assigns adjustment coefficients to the numbers in combination with the system power adjustment parameters to generate a path segment power adjustment coefficient table.

[0054] The path power configuration module calculates the target power value based on the path segment number and coefficient value in the path segment power adjustment coefficient table, combined with the basic heating power parameters. By setting control commands, the path segment number and control parameters are paired and recorded to generate a heating path power configuration table.

[0055] The stress path identification module filters out path segment numbers whose power fluctuation exceeds a set threshold based on the power value changes of the path segments in the heating path power configuration table, extracts the temperature data of the corresponding number in a continuous period, calculates the temperature rise rate difference and compares it with the reference standard, marks the path segment numbers that meet the offset conditions, and establishes path identification information in combination with the insulation layer structure characteristics to generate a stress release trend marking table.

[0056] The closed-loop parameter output module matches the path segment numbers in the heating path power configuration table and the stress release trend marking table, extracts the intersection of the numbers, extracts the corresponding parameter set according to the number, establishes the closed-loop command information for regulation execution, and generates the closed-loop control parameter set.

[0057] Compared with the prior art, the advantages and positive effects of the present invention are as follows:

[0058] In this invention, temperature data is collected over a continuous period by deploying thermally sensitive nodes along the path segment. A mapping is established by combining the path number to ensure the spatial accuracy of heat distribution information. Trends are extracted based on the temperature difference changes between adjacent nodes, power adjustment coefficients are allocated, and target power values ​​are generated to achieve dynamic response to local thermal fields. Stress behavior path segments are identified by combining power changes and temperature rise rate analysis. Stress release markers are formed by integrating the structural characteristics of the insulation layer to improve identification accuracy. After matching power and stress information, a parameter set is output to construct a closed-loop control system, which enhances molding consistency, improves thermal control flexibility, and significantly improves efficiency and quality problems caused by uneven heating. Attached Figure Description

[0059] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0060] Figure 1 This is a schematic diagram of the steps of the present invention;

[0061] Figure 2 This is a detailed schematic diagram of S1 of the present invention;

[0062] Figure 3 This is a detailed schematic diagram of S2 of the present invention;

[0063] Figure 4 This is a detailed schematic diagram of S3 of the present invention;

[0064] Figure 5 This is a detailed schematic diagram of S4 of the present invention;

[0065] Figure 6 This is a detailed schematic diagram of S5 of the present invention;

[0066] Figure 7 This is a system module diagram of the present invention. Detailed Implementation

[0067] The technical solution of the present invention will now be described with reference to the accompanying drawings.

[0068] In embodiments of the present invention, words such as "exemplarily," "for example," etc., are used to indicate that something is an example, illustration, or description. Any embodiment or design described as "exemplary" in the present invention should not be construed as being more preferred or advantageous than other embodiments or designs. Specifically, the use of the word "exemplary" is intended to present the concept in a concrete manner. Furthermore, in embodiments of the present invention, the meaning expressed by "and / or" can be both, or either one.

[0069] In the embodiments of this invention, the terms "image" and "picture" may sometimes be used interchangeably. It should be noted that, without emphasizing the distinction between them, their intended meanings are consistent. Similarly, the terms "of," "corresponding (relevant)," and "corresponding" may sometimes be used interchangeably. It should be noted that, without emphasizing the distinction between them, their intended meanings are consistent.

[0070] In this embodiment of the invention, sometimes a subscript such as W1 may be written in a non-subscript form such as W1. When the difference is not emphasized, the meaning they express is the same.

[0071] To make the technical problems, technical solutions and advantages of the present invention clearer, a detailed description will be given below in conjunction with the accompanying drawings and specific embodiments.

[0072] Please see Figure 1 This invention provides a method for controlling the flexible forming process of NTC insulated wires, including the following steps:

[0073] S1: Obtain the lead forming path segment, set multiple thermal nodes on the path segment, collect the temperature data of the nodes in a continuous cycle, establish a mapping relationship between the temperature data and the path segment number, construct a temperature correspondence table for measuring points, and generate a temperature correspondence table for the section.

[0074] The lead forming path segment refers to the spatial path area where temperature control is required during the flexible forming process of NTC insulated wires, which can be obtained by setting the forming trajectory of the processing equipment;

[0075] Thermistor nodes refer to temperature sensors, including thermistors and thermocouples.

[0076] The temperature correspondence table for measuring points is a set of mapping relationships between measuring point numbers and corresponding temperature values;

[0077] The section temperature correspondence table refers to the mapping relationship table established between the temperature data collected by multiple temperature acquisition nodes deployed on the lead forming path section and the path section number;

[0078] S2: Based on the temperature difference changes of adjacent nodes in the section temperature correspondence table, extract the change amplitude within the continuous period, and judge according to the reference rate. Assign the corresponding power adjustment coefficient to the path segment number that meets the conditions, record the correspondence between the number and the coefficient, and generate the path segment power adjustment coefficient table.

[0079] The temperature difference variation range refers to the amount of change in temperature difference between adjacent nodes within a continuous sampling period;

[0080] The reference rate is a baseline value used to determine whether the temperature difference change is abnormal;

[0081] The power adjustment coefficient is a proportional parameter used to adjust the target heating power output;

[0082] S3: Calculate the target power value of the corresponding path segment according to the number and coefficient in the path segment power adjustment coefficient table, set the heating output control command, and pair and record the control content with the path segment to form a heating path power configuration table;

[0083] The target power value refers to the heating output power value determined based on the thermal response characteristics of the corresponding section path.

[0084] Heating output control commands refer to parameter commands issued by the control system to the heating equipment;

[0085] The heating path power configuration table refers to a tabular data structure that corresponds the number of each path segment with the target power value.

[0086] S4: Based on the power value changes of the path segments in the heating path power configuration table, filter out the numbered segments whose power value changes exceed the set threshold, extract the temperature data of the corresponding number in the continuous period, calculate the temperature rise rate difference and compare it with the reference standard, mark the number that meets the offset condition as the stress behavior path segment, establish identification information in combination with the insulation layer structural characteristics, and establish a stress release trend marking table.

[0087] The power value change range refers to the difference between the target power values ​​of the path segment in two consecutive control cycles;

[0088] A threshold is set as the set judgment criterion to indicate whether the power change has regulatory significance;

[0089] The temperature rise rate difference refers to the difference in the rate of change of temperature rise within a continuous sampling period;

[0090] Reference standards refer to the technical parameters and judgment thresholds used for comparison in power change, temperature rise rate change, and behavior judgment.

[0091] The stress behavior path segment refers to the path segment in which abnormal temperature rise rate or power change behavior is detected during the flexible molding process, which causes thermal deformation or abnormal tension of the insulation layer.

[0092] The stress release trend marker table refers to a data set that records the path segment numbers and stress behavior types of all detected thermal stress concentration trends;

[0093] S5: Match the path segment numbers in the heating path power configuration table and the stress release trend marking table, extract the intersection of the numbers, mark it as the adjustment control area, and output the parameter set corresponding to the number to generate the closed-loop control parameter set;

[0094] The closed-loop control parameter set refers to the set of control parameters for feedback adjustment of the output of the controllable path segment after integrating the power configuration and stress identification results.

[0095] The section temperature correspondence table includes the path segment number, node number, temperature measurement time, and temperature value; the path segment power adjustment coefficient table includes the power adjustment coefficient and judgment result mark; the heating path power configuration table includes the target power value and control instruction content; the stress release trend mark table includes the temperature rise rate difference, stress identification type, and structural feature mark; and the closed-loop control parameter set includes the output power value, response period parameter, and adjustment priority level.

[0096] Please see Figure 2 The specific steps of S1 are as follows:

[0097] S101: Obtain the lead forming path segment, associate the path segment number with the spatial coordinate, set a thermal node at the geometric center of each path segment, establish the mapping between the node and the path segment according to the relationship between the coordinate and the number, and generate the node path correspondence coefficient.

[0098] In the process of obtaining the lead forming path segments, the electronic packaging structure model should be imported using a 3D design platform. Taking the connecting leads as the identification object, the spatial coordinates corresponding to the start and end positions of each path segment are extracted sequentially. These coordinates divide the entire lead path into multiple continuous segments. Each path segment is assigned a unique number according to the extraction order, and its endpoint coordinates are recorded. Then, the midpoint position is calculated between the start and end points of each segment, and the midpoint coordinates are used as the location for the thermal node. This node number is consistent with the path segment number, and a one-to-one mapping relationship between nodes and path segments is generated. For example, when the path segment number is 3, its start point coordinates are 1.2 and 0.6. If the endpoints are 2.4, 0.6, and 0.5, then the corresponding node positions are 1.8, 0.6, and 0.5, and the node number is 3. A mapping between the node number and the node position is established. If the path has branches or intersections, a node may correspond to multiple path segments. A path correspondence coefficient needs to be assigned to each type of affiliation. For example, if a node belongs to both path segments 5 and 6, and the lengths of the two path segments are 4.2 and 5.8 respectively, then the path correspondence coefficients can be set proportionally to 42% and 58%. After uniformly recording the correspondence between all nodes and their path segments, a complete set of path segment numbers, node numbers, and corresponding coefficients is generated, realizing the definition of the association between nodes and path segments.

[0099] S102: Based on the node path corresponding coefficient, collect continuous periodic temperature data on the thermal node, aggregate the temperature sequence under the same path segment, obtain a stable temperature set, and generate the path segment periodic temperature range.

[0100] Based on the node path correspondence coefficient, a thermoelectric sensing module is used to sample temperature at each thermistor node. The sampling time interval is set to 1 second, and the total duration is 10 minutes, resulting in 600 consecutive temperature values ​​for each node. The temperature sequences recorded by each node are uniformly categorized according to the path segment number to which the node belongs. When processing these sequences, a sliding time window of 50 seconds is used to judge the fluctuation of each data segment. If the temperature fluctuation within a certain window is less than 0.5 square units and the duration is greater than 100 seconds, it is considered a stable segment. For example, if the temperature fluctuation of a node between the 201st and 400th seconds meets the condition, then all temperature values ​​within that time period constitute a stable data set. The highest and lowest temperatures in the set are further statistically analyzed as the temperature interval values ​​for that path segment. For example, if the highest temperature in a segment is 82.6 and the lowest is 79.2, then the corresponding periodic temperature interval for that path segment is 79.2 to 82.6. In this way, the sampled data of all path segment nodes are aggregated, and their stable temperature sets and corresponding upper and lower boundaries are extracted to form a temperature interval mapping.

[0101] S103: Call the path segment number in the path segment periodic temperature interval and node path correspondence coefficient to establish the relationship between the path segment and the temperature interval, and combine the number and the location index to construct the measuring point temperature correspondence table and generate the path segment temperature correspondence interval table.

[0102] By retrieving the temperature range values ​​of path segments and the corresponding coefficients of node paths, a correspondence is established between the two according to the path segment number. The temperature range of the thermal node number is matched with the temperature range of the path segment to which it belongs, generating an index of measuring points and temperature ranges. For example, if a node number is 6, the corresponding path segment number is 6, and the temperature range of the path segment is 77.5 to 81.3, then the node is directly associated with this temperature range. If a node belongs to multiple path segments, for example, if a node numbered 7 is associated with path segments numbered 7 and 8, with weights of 40% and 60% respectively, and temperature ranges of 74.0 to 76.5 and 78.2 to 80.0 respectively, then a new temperature range is synthesized by weighted averaging, with a lower limit of 76.48 and an upper limit of 78.9, and this is taken as the range to which node number 7 belongs. By performing number indexing, path matching, and weight allocation operations on each node, the temperature range information of the path segments corresponding to all nodes is summarized and generated, providing a basis for subsequent temperature monitoring and feature localization.

[0103] Please see Figure 3 The specific steps of S2 are as follows:

[0104] S201: Based on the path segment temperature interval table, extract the number information and corresponding temperature interval value of adjacent nodes, compare and match the temperature values ​​in the same period by the order of adjacent path segment numbers, calculate the temperature difference change of each group of adjacent nodes in the continuous period, and obtain the temperature difference change value of adjacent nodes.

[0105] The path segment temperature interval table needs to be established first, with a complete structure including the path segment number, time period, and temperature value. For example, path segments numbered P1, P2, P3, etc., are arranged in order, and the temperature data of each segment is recorded in multiple periods T1 to T4. For example, the temperatures of P1 in T1 to T4 are 45, 48, 46, and 44, respectively, and the temperatures of P2 in the corresponding period are 46, 49, 47, and 45. Adjacent node pairs are determined according to the number order. For example, P1 and P2 form a group. Then, the temperatures in each period are compared one by one to obtain the temperature difference in each period. For example, T1 is 1, T2 is 1, T3 is 1, and T4 is 1. By comparing the temperature difference between adjacent periods, it can be seen that the temperature difference changes from T1 to T2, T2 to T3, and T3 to T4 are 0. If the temperature difference between another group of path segments P3 and P4 in T1 to T4 is 2, 3, 1, and 4, and the temperature difference changes between adjacent periods are 1, -2, and 3, this is recorded for later use. Temperature difference changes between adjacent nodes of all path segments are centrally managed in the form of arrays or lists, with corresponding period numbers to ensure traceability of queries and subsequent calculations, facilitating batch processing and analysis.

[0106] S202: Call the temperature difference change value of adjacent nodes, and judge the change rate with the set temperature difference change rate benchmark value according to the temperature difference change rate under each group of path segment numbers. Mark and classify the path segment numbers that meet the benchmark value requirements, and obtain the set of path segment numbers whose rates meet the requirements.

[0107] After extracting the recorded temperature difference change data of adjacent nodes, the temperature difference change corresponding to each path segment number should be read group by group. For example, the temperature difference between P1 and P2 is constant at 1 from T1 to T4, with an adjacent period change of 0. The temperature differences between P3 and P4 are 2, 4, 5, and 7 respectively, with adjacent period changes of 2, 1, and 2, and an average rate of 1.67. A baseline value of 1 is set for the temperature difference change rate, and the temperature difference change rate of each path segment is compared with this baseline value. If the rate is less than 1, the path segment is marked as not meeting the requirements; otherwise, it is marked as meeting the requirements. This baseline value can be set based on the ambient temperature change pattern or historical records of the path. For example, the historical temperature difference rate of ordinary path segments in urban rail transit is concentrated between 0.5 and 2, so the median or average value can be selected as the baseline. After the judgment is completed, the path segment numbers that meet the conditions are listed separately to form a set, which will be used for subsequent power parameter adjustment processing.

[0108] S203: Based on the set of path segment numbers that meet the rate requirements, and in conjunction with the path segment number index and the path segment power adjustment rules, perform a power adjustment coefficient assignment operation on the number, record the power adjustment coefficient corresponding to each path segment number, and generate a path segment power adjustment coefficient table.

[0109] Once the set of path segment numbers that meet the rate requirements is formed, a preset power adjustment rule is invoked for each number. This rule is typically related to the geographical location of the path segment, the electrical design capacity, or historical load. For example, if the change rate of path segment P3-P4 is 1.67 and the baseline value is 1, according to the adjustment range design rule, the adjustment coefficient is 1.05 if the change range is within 50%, 1.10 if it is between 50% and 100%, and 1.15 if it exceeds 100%. The relative range calculated based on the rate is 67%, corresponding to an adjustment coefficient of 1.10. The path segment number and its corresponding coefficient record form a path segment power adjustment coefficient table, which can be stored in key-value pair format, such as 1.10 for P3-P4 and 1.08 for P5-P6. To improve adaptability, the adjustment rules can also be extended by setting them in segments according to the rate. For example, set the coefficient to 1.00 for 0 to 0.5, 1.05 for 0.5 to 1.0, 1.10 for 1.0 to 1.5, and 1.15 for above 1.5. Finally, a complete adjustment coefficient data table containing all path segments that meet the rate requirements can be constructed.

[0110] Please see Figure 4 The specific steps of S3 are as follows:

[0111] S301: Based on the path segment number and power adjustment coefficient in the path segment power adjustment coefficient table, obtain the reference power value for each path segment, call the reference power value and the corresponding power adjustment coefficient, calculate the target power output value corresponding to the path segment, and generate the path segment target power value set;

[0112] The specific formula for calculating the target power output value for the path segment, by using the reference power value and the corresponding power adjustment coefficient, is as follows:

[0113]

[0114] Calculate the target power output value and generate a set of target power values ​​for the path segment;

[0115] in, This represents the target power output value for path segment i. α represents the reference power value for path segment i. i δ represents the power regulation coefficient for path segment i. ij α represents the power coupling coefficient between path segment i and path segment j. j The power regulation coefficient represents path segment j. γ represents the reference power value for path segment j. i η represents the average power offset rate of path segment i per unit time. i The value represents the ratio of the reference power of path segment i to the expected power of its corresponding environment, and n represents the total number of path segments.

[0116] parameter The reference power value for path segment i is determined by the average power output per unit time during the driving process of path segment i, measured by a lidar system. The average power value is obtained by recording the power output change curve of the vehicle on path segment i over one minute, calculating its integral, and then dividing by the time. The measured power range is 3800W to 4700W; the reference power for path segment i is set at 4300W.

[0117] Parameter α i The power adjustment coefficient for path segment i is obtained by constructing a weighted function based on path slope, surface material resistance, and traffic density factor. A slope within 5% has a weight of 0.4, asphalt pavement has a weight of 0.3, and traffic density below the median has a weight of 0.3, summing to 1. If path segment i has a slope of 3.2%, an asphalt pavement, and low traffic density, then:

[0118] α i =0.4 + 0.3 + 0.3 = 1.0;

[0119] Parameter δ ij The power coupling coefficient between path segment i and path segment j is determined by statistically analyzing the connection strength between path segments i and j in historical GPS trajectories. Higher frequencies result in coupling coefficients closer to 1. Path segment j is a common successor to path segment i; assuming a statistical frequency of 0.85, then δ... ij =0.85;

[0120] Parameter α j This is the adjustment coefficient for path segment j, and its calculation method is the same as α. i Same. Let path segment j be a downhill segment with a gradient of -4%, concrete pavement, and moderate traffic density, corresponding to a weight of 0.2 + 0.3 + 0.3 = 0.8;

[0121] parameter This represents the reference power value for path segment j, with a measured average power of 3900W.

[0122] Parameter γ i This represents the average power offset rate of path segment i per unit time, calculated using power change data from three consecutive runs: the measured average power for each run was 4320W, 4290W, and 4310W, corresponding to offset rates of (4320-4300), (4290-4300), and (4310-4300). The average is:

[0123]

[0124] Parameter η iLet represent the ratio of the reference power of path segment i to its expected environmental power. The expected environmental power is calculated by averaging the power of all paths under similar conditions in the surrounding area of ​​path segment i, and is measured to be 4000W. Then:

[0125]

[0126] The calculation formula is as follows:

[0127]

[0128] The numerator is: 4300 + 2652 - 6.67 = 6945.33 - the denominator is: η i =1.075;

[0129] Substitute into the general formula to calculate:

[0130]

[0131] The results show that the target power output value of path segment i is 6461.70W, which is significantly higher than the reference power value of 4300W. This reflects that path segment i is affected by the power coupling enhancement effect of path j. The improved target power output value is used to drive the controller parameter setting of the target power value set of the path segment, and guide the implementation of subsequent scheduling and energy allocation strategies.

[0132] The formula's operational logic centers on the target power output value of a path segment, combining the path segment's own reference power, adjustment coefficient, coupling effects of adjacent path segments, and historical offsets to form a comprehensive power correction expression. First, the reference power value is multiplied by the path segment's own adjustment coefficient to form a power expression representing the static characteristics of that path segment. Then, a path segment j, correlated with path segment i, is introduced, and its power influence is represented by the product of its adjustment coefficient and the reference power value. This is then multiplied by a coupling factor to measure the strength of the interaction between paths. The squares are summed and the square root is taken to introduce the aggregated interference energy of local path groups in the path network structure, used to correct the power baseline of a single path segment. Next, the average power offset rate per unit time is subtracted from the composite term to eliminate system errors caused by external disturbances during historical operation. Finally, this correction value is divided by the ratio between the reference power and the desired power to normalize the power differences driven by the external scene, ensuring that the final target power output value has path adaptability and energy consistency with adjacent paths. The overall structure relies on three mechanisms: weighted influence, energy coupling, and feedback adjustment.

[0133] The target power output value represents the standard power level that should be allocated or implemented on a specific path segment, taking into account multiple factors such as the path segment's own attributes, the energy influence of adjacent path segments, and historical operational deviations. It guides the power execution strategy of vehicles, equipment, or systems within that path segment. This value not only reflects the actual power demand required by the path segment under the current environment and conditions but also embodies the energy coordination relationship between paths and the feedback correction of historical deviations. It is a crucial parameter for achieving dynamic power regulation, optimized energy allocation, and coordinated power control between path segments.

[0134] S302: Based on the target power value set of the path segment, perform a combination identification operation on the target power value and the path segment number of each path segment, extract the control time parameters and control node positions of the path segment, set the heating output power command corresponding to each path segment number, and obtain the path segment heating command set;

[0135] Performing a combined identification operation on the target power value set of a path segment requires establishing a one-to-one correspondence between the path segment number and its target power value, while simultaneously retrieving control time and node position information from the path segment control parameter configuration table. For example, if the control time parameter for path segment P001 is 6s and the control node position is 45m, this is combined with the target power value of 680W to form a control data set. The control time can be estimated by dividing the path segment length by a constant moving speed. For example, if the path segment length is 45m and the moving speed is 7.5m / s, the control time is 6s. Similarly, if the path segment P002 has a length of 39m and the speed remains constant, the control time is 5.2s. The control node position is the coordinate of the key location on the path segment, typically obtained from the path design data. The information combination for each path segment is a four-tuple, including the path segment number, target power value, control time, and control node position. For example, the information for path segment P001 is [P001, 680W, 6s, 45m], and the information for path segment P002 is [P002, 699.2W, 5.2s, 39m], and so on, forming a complete set of path segment heating instructions. All path segment heating instructions are generated by matching numbers, retrieving parameters, and performing combined operations, ultimately summarizing into a unified format dataset.

[0136] S303: Call the path segment heating instruction set, pair each group of heating output power instructions with the path segment number, establish the correspondence between the number and the control instruction, summarize the number and control instruction comparison information of all path segments, and generate a heating path power configuration table;

[0137] When matching heating command sets with their assigned numbers, a direct correspondence between path segment numbers and control parameters must be established. The path segment number serves as a unique primary key, and each control command group consists of three data items: heating power value, control time, and control position. Based on the path segment number, each control command group is encapsulated into a dictionary structure or index table. For example, path segment P001 corresponds to the command [680W, 6s, 45m], and path segment P002 corresponds to the command [699.2W, 5.2s, 39m]. Automated matching can be performed via scripts or database operations to ensure the accuracy of data for each path segment. After data aggregation, a complete master table of path segment heating commands is formed, with each row representing a path segment and including the number, target power value, control time, and control position. This master table serves as the basis for heating path power configuration. It is exported in a standard format for downstream control systems to execute the heating process, ensuring that the path segment control accuracy matches the power output.

[0138] Please see Figure 5 The specific steps of S4 are as follows:

[0139] S401: Based on the power value sequence of the path segment in the heating path power configuration table, calculate the power difference between adjacent cycles, compare it with the power change threshold, filter the path segment numbers whose power value changes exceed the threshold, and generate a set of power change segment numbers.

[0140] The heating path power configuration table records the power values ​​of different path segments in different cycles. After extracting the power values ​​of each path segment in two adjacent cycles, the power change amplitude of each path segment needs to be calculated separately. The power difference sequence of each path segment is obtained by subtracting the absolute value of the power value of the next cycle from the power value of the previous cycle. Then, the power difference of each path segment is compared with the set power change threshold one by one. If the power difference exceeds the threshold, it is determined as a power change segment and its path segment number is recorded as a change number set. In actual operation, the power change threshold can be determined by calculating the average power fluctuation and standard deviation of the fluctuation of historical data samples. For example, if the standard deviation of power fluctuation is 6.8W, the threshold can be set to twice the standard deviation, which is 13.6W. For ease of calculation, it can be rounded to 15W. Then, taking a path segment with a power value of 110W in the first cycle and 130W in the second cycle as an example, the power change value is 20W, which exceeds the threshold of 15W. Therefore, the path segment number needs to be recorded in the change number set. The entire calculation process is carried out one by one according to the path segments, and finally a power change number set is formed.

[0141] S402: Call the power mutation section number set, extract the continuous periodic temperature data corresponding to the number, calculate the periodic temperature rise rate difference, compare it with the temperature rise rate reference standard value, mark the path segment number where the temperature rise rate difference exceeds the standard, and generate the abnormal temperature rise number section set.

[0142] The specific formula for calculating the difference in temperature rise rate over the cycle is as follows:

[0143]

[0144] Calculate the characteristic quantity of temperature rise rate difference, call the power mutation section number set, extract the continuous periodic temperature data corresponding to the number, calculate the periodic temperature rise rate difference, compare it with the temperature rise rate reference standard value, mark the path segment number where the temperature rise rate difference exceeds the standard, and generate the abnormal temperature rise number section set.

[0145] in, The characteristic quantity representing the temperature rise rate difference of path segment i, ΔT i,j Δt represents the temperature rise of path segment i during the j-th cycle. i,j w represents the time interval corresponding to the path segment numbered i in the j-th cycle. i,j The confidence weight of the temperature rise data in the j-th cycle represents the path segment numbered i. The cumulative temperature rise Δt represents the path segment numbered i over a historical or baseline period. ref This represents the total length of the reference period. This represents the average temperature rise rate of path segment i over n cycles, where n represents the total number of cycles used in the calculation. The compensation factor for the periodic temperature rise rate fluctuation caused by the power mutation process in the i-th path segment.

[0146] ΔT i,j This represents the temperature rise of path segment i within period j. The temperature sensor collects data at a frequency of 1Hz. The temperature rises in periods j=1, 2, and 3 are 4.6℃, 5.1℃, and 4.4℃, respectively, and are actually monitored by thermocouple equipment.

[0147] Δt i,j This represents the time length within cycle j of the path segment. The measured durations of each cycle are 300 seconds, 300 seconds, and 300 seconds, calculated from the difference between the start and end times of the cycle recorded by the sensor.

[0148] w i,j The confidence weight value for period j is quantified by data integrity. If the missing data in a period is less than 5%, it is recorded as 1; if it is more than 10%, it is recorded as 0.8. The data integrity rate for each period is currently 100%. w is set to... i,1 =w i,2 =w i,3 =1.0;

[0149] The reference total temperature rise for this path segment is 13.8℃, derived from historical records.

[0150] Δt ref The duration of the reference period was determined by recording time stamps, and the duration was 900 seconds.

[0151] The compensation factor for the temperature rise rate fluctuation caused during the sudden change phase is derived from the maximum temperature rise fluctuation rate measured during the power sudden change phase. The average value of the temperature rise data fluctuation recorded by the sensor is 0.004℃ / s.

[0152] n=3 indicates that the current number of analysis cycles is 3;

[0153] The average temperature rise rate is calculated from the aforementioned three cycles;

[0154] The steps to substitute the above parameters into the formula are as follows:

[0155] Calculate the temperature rise rate per cycle:

[0156]

[0157] Calculate the weighted average temperature rise rate:

[0158]

[0159] Calculate the reference cycle temperature rise rate:

[0160]

[0161] Calculate the difference in the first part:

[0162] |0.01567-0.01533|=0.00034;

[0163] Calculate the average temperature rise rate

[0164]

[0165] Variance calculation:

[0166] (0.01533-0.01567) 2 =0.0000001156;

[0167] (0.017-0.01567) 2 =0.0000017556;

[0168] (0.01467-0.01567) 2 =0.000001;

[0169] ∑=0.0000001156+0.0000017556+0.000001=0.0000028712;

[0170]

[0171] Add the squared term of the compensation factor:

[0172]

[0173]

[0174] Final temperature rise rate difference characteristic quantity:

[0175]

[0176] The results show that the temperature rise rate of the current path segment differs by 0.00446℃ / s over three consecutive cycles, indicating that its temperature rise fluctuation is higher than the historical reference standard, which indicates that the path segment has an abnormal temperature rise trend and can be used as an indicator in the subsequent path numbering and abnormal segment set generation logic.

[0177] This formula constructs a complete characteristic quantity of the temperature rise rate difference through the addition of two terms. The first term is the difference between the current period's weighted average temperature rise rate and the reference period's temperature rise rate, using absolute value form to quantify the degree of trend deviation and reflect the overall direction and magnitude of temperature rise rate changes. The second term is the square root of the sum of the squares of the standard deviation of the current period's temperature rise rate and the temperature rise rate fluctuation compensation factor, aiming to capture the instability of the temperature rise rate during the period. The standard deviation term reflects the fluctuation intensity, and the compensation factor introduces external abrupt change influencing factors to enhance the local anomaly response capability. These two terms are added together on the basis of unified dimensions, so that the calculation result has both steady-state comparability and dynamic fluctuation. The two parts focus on the joint response of mean deviation and fluctuation disturbance, respectively. Multiplication is used in the weighted averaging process to introduce confidence weights to control the contribution of each period. The square and square root operations are used to stabilize the degree of fluctuation, ensuring that amplitude errors are not canceled out by the sign, and at the same time constructing an evaluation of the intensity of the overall response value.

[0178] The temperature rise rate difference characteristic is used to comprehensively evaluate the change in the temperature rise rate of a path segment relative to the historical reference state during a continuous operating cycle. Its value reflects whether the current temperature rise trend deviates from the reference rate, and takes into account the disturbance caused by the degree of fluctuation during the cycle and the power change. The larger the characteristic value, the more abnormal the temperature rise rate change of the path segment is. It may be due to the overall temperature rise acceleration under steady-state conditions, or it may be due to the weakening of cycle stability or the aggravation of fluctuation caused by local power disturbance. As a key indicator in path condition monitoring, it can be used to identify potential thermal risks or abnormal load behavior in equipment operation.

[0179] S403: Based on the abnormal temperature rise number segment set, extract the insulation layer structure information corresponding to the number, combine the path segment number and structural characteristics, establish the marking information corresponding to the number, summarize the marking content of all numbers, and establish a stress release trend marking table.

[0180] Based on the path segment numbers in the anomaly number set, the corresponding insulation structure parameter information in the structural database is retrieved, including material type, layer configuration, and total thickness level. For example, the insulation structure of a certain path segment is a three-layer PET film with a total thickness of 1.2mm, and another path segment is a two-layer PI film with a total thickness of 0.8mm. Each path segment number is matched with its structural parameters one by one and recorded as structural mapping information. Then, the temperature rise rate change value of the path segment is combined with the number and structural information to form the path segment structural marking information. All structural marking information is summarized in the order of the path segments to form a stress release trend marking record table. If multiple rate change paths are concentrated in path segments with insulation thickness less than 1mm and structural layers of 2, it indicates that there is a correlation between structural configuration and temperature rate change. This trend record table can be used to attribute the impact of structural differences on thermal response and form a structural optimization suggestion dataset to support insulation system design.

[0181] Please see Figure 6 The specific steps of S5 are as follows:

[0182] S501: Based on the path segment number sequence in the heating path power configuration table and the stress release trend marking table, filter the intersection number set, determine the identification status of the intersection path segment based on the synchronous existence of the number, and establish the path segment intersection number set.

[0183] Based on the path segment number sequences in the heating path power configuration table and the stress release trend marking table, the number set in the configuration table is first read, for example, containing P001 to P004. Then, the number set in the trend marking table is read, such as containing P002, P003, and P005. The intersection of the two is obtained by comparing the sets, and only the numbers that exist simultaneously are retained, forming the set of numbers P002 and P003. Next, it is checked whether these intersection numbers have corresponding status fields in the two tables. For example, if P002 is marked as "active" in the configuration table and "releasing" in the trend table, it is considered to have a synchronization status identifier and is retained. If P003 has data in the configuration table but no status record in the trend marking table, the number is removed, and only the numbers that exist in the synchronization status are retained for subsequent control logic. In this step, the path segment number is a key reference in heating control. For example, it is used for a certain weld area in stainless steel heat treatment. After locking the data of this segment by number P002, the status information in the two tables is combined to determine whether it can be used for subsequent heating power allocation and stress release rhythm synchronization analysis. The number matching process can be executed through ordinary comparison logic, checking whether each of the two number columns exists in the other's set. The filtering method can be sequential comparison or a key-value table can be established through a mapping structure to simplify the cross-retrieval process of a large number of path segment numbers, and finally generate an intersection number set for the next step of parameter extraction.

[0184] S502: Call the path segment intersection number set, retrieve the corresponding control parameters in the heating path power configuration table, extract the parameter items in the order of number, including power set value, start and end time, and running cycle value, establish the parameter combination set corresponding to each number, and generate the path segment parameter set table;

[0185] The control parameters in the configuration table are extracted one by one from the intersection number set of path segments. Assuming the intersection numbers are P002 and P003, the configuration table records their respective power setpoints, start times, end times, and operating cycle parameters. P002 has a power of 1500W, a start time of 8:00 AM, an end time of 10:00 AM, and a cycle of 30 minutes; P003 has a power of 1200W, a start time of 9:00 AM, an end time of 11:30 AM, and a cycle of 45 minutes. These values ​​are read sequentially according to their numbers, constructing a parameter combination set with the number as the primary key. The parameter fields are arranged in a parallel manner, meaning each number contains the same type of control parameter item. By establishing a path segment parameter set table, a structured combination list is formed. This step can be used to control the heating rhythm of stainless steel pipes in an electrothermal treatment system. Each number represents a heating area or weld segment. By setting power and time parameters, the start and stop of the sensing equipment are controlled. Simultaneously, the control detection cycle is set in conjunction with the operating cycle. Within the area corresponding to P002, the control system will periodically read the temperature sensor signal within the set time range and judge the power adjustment according to the cycle. This type of parameter combination set supports subsequent logic processing and can be transmitted to the control unit in a unified structure. It is suitable for independent management and distributed parameter coordination and scheduling of each heating section in automated heat treatment equipment.

[0186] S503: Based on the path segment parameter set table, using the path segment number as the index field, match each group number with the control area identifier status, filter the control parameter groups with the same number and identifier, integrate the value range information of the group control parameter items, and establish a closed-loop control parameter set;

[0187] Based on the path segment parameter set table, the number is used as the key index field and compared with the identification status recorded in the control area. If number P002 is marked as "valid" in the control area, its parameter group is selected for subsequent processes. If P003 is marked as "failed" or "invalid", it is discarded. The retained parameter groups need to integrate their respective power, time, and cycle value range information to form a control parameter set with a unified format. This process is suitable for automatic matching of each path segment in the control of fine heat treatment processes, which facilitates precise scheduling. For example, if the area represented by number P002 is identified as "valid" through feedback from the control system, the scheduling module will read its power as 1500W, start time as 8 o'clock, end time as 10 o'clock, and cycle as 30 minutes. At the same time, it will record that real-time monitoring and dynamic power adjustment control need to be performed during this time period. During dynamic adjustment, adjustments can be made cyclically based on the temperature feedback and the difference between the target temperature and the actual output power. If the current temperature is 890℃ and the target temperature is set to 900℃, the difference is 10℃. If the control system's adjustment rate is set to 10W for every 1℃ difference, the actual output power can be increased from 1500W to 1600W until the temperature approaches the target value, thus ensuring the continuous effectiveness of the parameter set in the closed-loop control logic. The final established control parameter set contains numbered combinations that are consistent only with the state of the control area, supporting dynamic configuration updates for the entire system.

[0188] Please see Figure 7 The NTC insulated wire flexible forming process control system includes:

[0189] The temperature acquisition and mapping module obtains the set of numbers of the lead forming path segments, sets multiple thermal nodes in the path segment structure area, and the acquisition nodes record temperature data in a continuous cycle. The temperature values ​​are mapped to the path segment numbers in the order of acquisition time. By judging the consistency of temperature changes of multiple nodes in the cycle, a node temperature correspondence table is constructed, and a regional classification relationship is established in combination with the path segment numbers to generate a segment temperature correspondence table.

[0190] The power regulation coefficient module extracts the change amplitude sequence of the path segment within a continuous period based on the temperature difference between adjacent nodes in the segment temperature correspondence table, judges according to the reference rate, numbers and labels the path segments that meet the change conditions, and assigns regulation coefficients to the numbers in combination with the system power adjustment parameters to generate a path segment power regulation coefficient table.

[0191] The path power configuration module calculates the target power value based on the path segment number and coefficient value in the path segment power adjustment coefficient table, combined with the basic heating power parameters. By setting control commands, the path segment number and control parameters are paired and recorded to generate a heating path power configuration table.

[0192] The stress path identification module filters out path segment numbers whose power fluctuation exceeds a set threshold based on the power value changes of the path segments in the heating path power configuration table, extracts the temperature data of the corresponding number in a continuous period, calculates the temperature rise rate difference and compares it with the reference standard, marks the path segment numbers that meet the offset conditions, and establishes path identification information in combination with the insulation layer structural characteristics to generate a stress release trend marking table.

[0193] The closed-loop parameter output module matches the path segment numbers in the heating path power configuration table and the stress release trend marking table, extracts the intersection of the numbers, extracts the corresponding parameter set according to the number, establishes the closed-loop command information for control execution, and generates the closed-loop control parameter set.

[0194] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A method for controlling the flexible forming process of NTC insulated wires, characterized in that, Includes the following steps: S1: Obtain the lead forming path segment, set multiple thermal nodes on the path segment, collect the temperature data of the nodes in a continuous cycle, establish a mapping relationship between the temperature data and the path segment number, construct a temperature correspondence table for measuring points, and generate a temperature correspondence table for the section. S2: Based on the temperature difference between adjacent nodes in the section temperature correspondence table, extract the change amplitude within a continuous period, judge according to the reference rate, calibrate the path segment number that meets the conditions, allocate power adjustment coefficients, and generate a path segment power adjustment coefficient table. S3: Calculate the target power value of the corresponding path segment according to the number and coefficient in the path segment power adjustment coefficient table, set the heating output control command, and pair and record the control content with the path segment to form a heating path power configuration table; S4: Based on the changes in power values ​​of path segments in the power configuration table of the heating path, filter out numbered segments whose power value changes exceed the set threshold, extract the temperature data of the corresponding number within a continuous period, calculate the temperature rise rate difference and compare it with the reference standard, mark the number that meets the offset condition as a stress behavior path segment, establish identification information in combination with the structural characteristics of the insulation layer, and establish a stress release trend marking table.

2. The method for controlling the flexible forming process of NTC insulated wire according to claim 1, characterized in that, The section temperature correspondence table includes the path segment number, node number, temperature measurement time, and temperature value; the path segment power adjustment coefficient table includes the power adjustment coefficient and judgment result mark; the heating path power configuration table includes the target power value and control instruction content; and the stress release trend mark table includes the temperature rise rate difference, stress identification type, and structural feature mark.

3. The method for controlling the flexible forming process of NTC insulated wire according to claim 1, characterized in that, The specific steps of S1 are as follows: S101: Obtain the lead forming path segment, associate the path segment number with the spatial coordinate, set a thermal node at the geometric center of each path segment, establish the mapping between the node and the path segment according to the relationship between the coordinate and the number, and generate the node path correspondence coefficient. S102: Based on the corresponding coefficient of the node path, collect continuous periodic temperature data on the thermal node, collect the temperature sequence under the same path segment, obtain a stable temperature set, and generate the periodic temperature range of the path segment. S103: Call the path segment number in the path segment periodic temperature interval and node path correspondence coefficient to establish the relationship between the path segment and the temperature interval, and construct the measuring point temperature correspondence table by combining the number and the location index to generate the path segment temperature correspondence interval table.

4. The method for controlling the flexible forming process of NTC insulated wire according to claim 3, characterized in that, The specific steps of S2 are as follows: S201: Based on the path segment temperature interval table, extract the number information and corresponding temperature interval value of adjacent nodes, compare and match the temperature values ​​in the same period by the adjacent path segment number order, calculate the temperature difference change range of each group of adjacent nodes in the continuous period, and obtain the temperature difference change value of adjacent nodes. S202: Call the temperature difference change value of the adjacent nodes, and judge the change rate with the set temperature difference change rate benchmark value according to the temperature difference change rate under each group of path segment numbers. Mark and classify the path segment numbers that meet the benchmark value requirements, and obtain the set of path segment numbers whose rates meet the benchmark value requirements. S203: Based on the set of path segment numbers that meet the rate requirements, and in conjunction with the path segment number index and the path segment power adjustment rules, perform a power adjustment coefficient assignment operation on the number, record the power adjustment coefficient corresponding to each path segment number, and generate a path segment power adjustment coefficient table.

5. The method for controlling the flexible forming process of NTC insulated wire according to claim 4, characterized in that, The specific steps for S3 are as follows: S301: Based on the path segment number and power adjustment coefficient in the path segment power adjustment coefficient table, obtain the reference power value for each path segment, call the reference power value and the corresponding power adjustment coefficient, calculate the target power output value corresponding to the path segment, and generate a set of target power values ​​for the path segment; S302: Based on the target power value set of the path segment, perform a combination identification operation on the target power value and path segment number of each path segment, extract the control time parameters and control node positions of the path segment, set the heating output power command corresponding to each path segment number, and obtain the path segment heating command set; S303: Call the set of heating instructions for the path segment, pair each group of heating output power instructions with the path segment number, establish the correspondence between the number and the control instruction, summarize the number and control instruction comparison information of all path segments, and generate a heating path power configuration table.

6. The method for controlling the flexible forming process of NTC insulated wire according to claim 5, characterized in that, The specific steps of S4 are as follows: S401: Based on the power value sequence of the path segment in the heating path power configuration table, calculate the power difference between adjacent cycles, compare it with the power change threshold, filter out the path segment numbers whose power value changes exceed the threshold, and generate a set of power mutation zone numbers. S402: Call the power mutation section number set, extract the continuous periodic temperature data corresponding to the number, calculate the periodic temperature rise rate difference, compare it with the temperature rise rate reference standard value, mark the path segment number where the temperature rise rate difference exceeds the standard, and generate an abnormal temperature rise number section set. S403: Based on the abnormal temperature rise number segment set, extract the insulation layer structure information corresponding to the number, combine the path segment number and structural characteristics, establish the marking information corresponding to the number, summarize the marking content of all numbers, and establish a stress release trend marking table.

7. The method for controlling the flexible forming process of NTC insulated wire according to claim 1, characterized in that, The method further includes: S5: Match the path segment numbers in the heating path power configuration table and the stress release trend marking table, extract the intersection of the numbers, mark it as the adjustment control area, and output the parameter set corresponding to the number to generate a closed-loop control parameter set; The closed-loop control parameter set includes output power value, response period parameter, and adjustment priority level.

8. The method for controlling the flexible forming process of NTC insulated wire according to claim 7, characterized in that, The specific steps of S5 are as follows: S501: Based on the path segment number sequence in the heating path power configuration table and the stress release trend marking table, filter the intersection number set, determine the identification status of the intersection path segment based on the synchronous existence of the number, and establish the path segment intersection number set. S502: Call the path segment intersection number set, retrieve the corresponding control parameters in the heating path power configuration table, extract the parameter items in the order of number, including power set value, start and end time, and running cycle value, establish a parameter combination set corresponding to each number, and generate a path segment parameter set table; S503: Based on the path segment parameter set table, using the path segment number as the index field, match each group of numbers with the control area identifier status, filter the control parameter groups with the same number and identifier, integrate the value range information of the group control parameter items, and establish a closed-loop control parameter set; The closed-loop control parameter set refers to the set of control parameters for feedback adjustment of the output of the controllable path segment after integrating the power configuration and stress identification results.

9. The method for controlling the flexible forming process of NTC insulated wire according to claim 1, characterized in that, The lead forming path segment refers to the spatial path area where temperature control is required during the flexible forming process of NTC insulated wires, which can be obtained by setting the forming trajectory of the processing equipment; The thermal node refers to a temperature sensor, including thermistors and thermocouples. The temperature correspondence table for measuring points is a set of mapping relationships consisting of measuring point numbers and corresponding temperature values. The section temperature correspondence table refers to the mapping relationship table established between the temperature data collected by multiple temperature acquisition nodes deployed on the lead forming path section and the path section number; The temperature difference change range refers to the amount of change in temperature difference between adjacent nodes within a continuous sampling period; The reference rate is a benchmark value used to determine whether the temperature difference change is abnormal; The power adjustment coefficient is a proportional parameter used to adjust the target heating power output; The target power value refers to the heating output power value determined by calculating based on the thermal response characteristics of the segment path; The heating output control command refers to the parameter command issued by the control system to the heating equipment; The heating path power configuration table refers to a tabular data structure that corresponds the number of each path segment with the target power value. The power value change range refers to the difference between the target power values ​​of the path segment in two consecutive control cycles; The set threshold is a set judgment criterion, indicating whether the power change has regulatory significance; The temperature rise rate difference refers to the difference in the rate of change of temperature rise within a continuous sampling period; The reference standard refers to the technical parameters and judgment thresholds used for comparison in power change, temperature rise rate change and behavior judgment. The stress behavior path segment refers to the path segment where abnormal temperature rise rate or power change behavior is detected during the flexible molding process, which causes thermal deformation or abnormal tension of the insulation layer. The stress release trend marking table refers to a data set that records the path segment numbers and stress behavior types of all detected thermal stress concentration trends.

10. NTC insulated wire flexible forming process control system, characterized in that, The system is used to implement the NTC insulated wire flexible forming process control method according to any one of claims 1-9, and the system includes: The temperature acquisition and mapping module obtains the set of numbers of the lead forming path segments, sets multiple thermal nodes in the path segment structure area, and the acquisition nodes record temperature data in a continuous cycle. The temperature values ​​are mapped to the path segment numbers in the order of acquisition time. By judging the consistency of temperature changes of multiple nodes in the cycle, a node temperature correspondence table is constructed, and a regional classification relationship is established in combination with the path segment numbers to generate a segment temperature correspondence table. The power adjustment coefficient module extracts the change amplitude sequence of the path segment within a continuous period based on the temperature difference between adjacent nodes in the segment temperature correspondence table, judges according to the reference rate, numbers and marks the path segments that meet the change conditions, and assigns adjustment coefficients to the numbers in combination with the system power adjustment parameters to generate a path segment power adjustment coefficient table. The path power configuration module calculates the target power value based on the path segment number and coefficient value in the path segment power adjustment coefficient table, combined with the basic heating power parameters. By setting control commands, the path segment number and control parameters are paired and recorded to generate a heating path power configuration table. The stress path identification module filters out path segment numbers whose power fluctuation exceeds a set threshold based on the power value changes of the path segments in the heating path power configuration table, extracts the temperature data of the corresponding number in a continuous period, calculates the temperature rise rate difference and compares it with the reference standard, marks the path segment numbers that meet the offset conditions, and establishes path identification information in combination with the insulation layer structure characteristics to generate a stress release trend marking table. The closed-loop parameter output module matches the path segment numbers in the heating path power configuration table and the stress release trend marking table, extracts the intersection of the numbers, extracts the corresponding parameter set according to the number, establishes the closed-loop command information for regulation execution, and generates the closed-loop control parameter set.

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