Wire processing cooperative control method and system for magnetic ring winding machine

Abstract

The invention relates to the technical field of magnetic ring winding machine control, and provides a wire processing cooperative control method and system for a magnetic ring winding machine, and the method comprises the steps: obtaining the physical positions of a winding part and an indexing part of the winding machine at an interruption moment when the winding motion and the indexing motion of the winding machine are interrupted on a function path; according to the physical position, a preset continuous function is used for reverse solving, and a logic interruption position is obtained; based on the logic interruption position and a preset continuous function, calculating to obtain a target continuous position for recovering the winding process; and based on the target splicing position, a winding part and an indexing part of the winding machine are controlled to cooperatively move to the target splicing position from the physical position. The winding device has the advantages that seamless recovery in the winding process and continuity of a winding path can be achieved, flaws are avoided, and the product quality is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of magnetic ring winding machine control, and particularly relates to a magnetic ring winding machine wire processing cooperative control method and system. BACKGROUND

[0002] In the manufacturing process of precision electronic components, magnetic ring winding machines are widely used to precisely wind wire on a ring-shaped magnetic core. Especially when manufacturing inductors with high performance and special electrical performance requirements, the distribution of the coil on the magnetic core often needs to follow a preset, nonlinear function relationship to achieve variable-pitch winding. This variable-pitch winding requires that the winding movement (usually driven by a winding component) of the winding machine and the indexing movement (usually driven by an indexing component) of the magnetic core maintain an accurate, functionally corresponding relationship that changes with the winding progress. The winding component is responsible for driving the wire to wrap around the cross-section of the magnetic core to form a coil, while the indexing component drives the magnetic core to rotate an accurate angle after each turn of the coil to determine the landing point for the next turn of the coil. In variable-pitch winding, the angle of rotation of the indexing component is not fixed, but is adjusted in real time according to the preset continuous function based on the current winding number or position, thereby achieving smooth changes in coil pitch.

[0003] Based on the recovery method of incremental encoder or step motor step count, only the relative position information since the last zero or power-on can be provided. Due to factors such as mechanical system clearance, elastic deformation, and impact during sudden stop, these relative position information is not enough to accurately reflect the true physical position of the winding component and the indexing component at the time of interruption, and it is also impossible to determine the logical correspondence of the physical position on the preset function path. Simply driving the machine to the stop position based on the relative count and continuing to execute the original program will cause the relative attitude between the winding component and the indexing component to deviate from the preset function relationship. This deviation makes the first turn of the coil after recovery unable to achieve smooth transition in pitch with the last turn of the coil before interruption, which may result in coil overlap, excessive gap, or pitch mutation, thereby forming a defect point in electrical performance on the product, seriously affecting product performance, and even causing expensive workpiece scrap.

[0004] In view of the above problems, the existing technology needs to be improved. SUMMARY

[0005] In order to solve the problems of the prior art, the present application provides a magnetic ring winding machine wire processing cooperative control method and system, which can realize seamless recovery of the winding process and continuity of the winding path, avoid the generation of defect points, and improve product quality.

[0006] The present application provides a magnetic ring winding machine wire processing cooperative control method, and the technical points are:

[0007] A kind of magnetic ring winding machine wire processing collaborative control method, applied to winding movement and index movement by the winding machine defined by preset continuous function, including:

[0008] When winding movement and index movement of winding machine occur interruption on function path, the physical position of winding component and index component of winding machine at interruption moment is acquired;

[0009] According to physical position, reverse solving is carried out using preset continuous function, and logical interruption position is obtained;

[0010] Based on logical interruption position and preset continuous function, target continuation position for restoring winding process is calculated;

[0011] Based on target continuation position, winding component and index component of winding machine are controlled to move from physical position to target continuation position collaboratively.

[0012] Through the above scheme, seamless recovery of winding process and continuity of winding path can be realized, and defect points are avoided, product quality is improved.

[0013] To further solve the problem, the present application also proposes that, according to physical position, reverse solving is carried out using preset continuous function, and logical interruption position is obtained, including:

[0014] Based on initial geometric dimension of workpiece, theoretical consumption length is determined;

[0015] In winding process, actual consumed wire length is acquired, and compared with theoretical consumption length, real-time geometric dimension of workpiece is determined;

[0016] Based on real-time geometric dimension of workpiece, preset continuous function is corrected, and instant continuous function is generated;

[0017] According to physical position, reverse solving is carried out using instant continuous function, and corresponding logical interruption position is obtained.

[0018] Through the above scheme, function can be corrected according to real-time geometric dimension of workpiece, and the accuracy of logical interruption position solving is improved.

[0019] To perfect the solution, the present application also proposes that, when winding movement and index movement of winding machine occur interruption on function path, the physical position of winding component and index component of winding machine at interruption moment is acquired, including:

[0020] Abnormal state in winding process is detected, and interruption operation is triggered when wire tension exceeds preset safety threshold;

[0021] In response to interruption operation, the movement of winding component and index component is stopped, and state freezing instruction is executed;

[0022] read the current value of the absolute position encoder arranged on the winding member and the indexing member as the physical positions of the winding member and the indexing member at the interruption moment.

[0023] Through the above scheme, the physical position at the interruption moment can be accurately obtained by detecting the abnormal state and freezing the state.

[0024] To perfect the solution, the application further proposes that during the winding process, the actual consumed wire length is obtained and compared with the theoretical consumed length to determine the real-time geometric size of the workpiece, comprising:

[0025] During the winding process, a preset transient disturbance is applied to the winding tension;

[0026] During the preset transient disturbance, the response change amount of the wire length is obtained;

[0027] Based on the response change amount, the elastic elongation characteristic of the current wire segment is determined;

[0028] According to the elastic elongation characteristic and the preset standard winding tension, the length component is determined;

[0029] The actual consumed wire length is obtained, and the length component is deducted from the actual consumed wire length to obtain a corrected length value;

[0030] The corrected length value is compared with the theoretical consumed length to determine the real-time geometric size of the workpiece.

[0031] Through the above scheme, the actual consumed wire length can be more accurately determined through transient disturbance and elastic elongation characteristic analysis, thereby improving the accuracy of the determination of the real-time geometric size of the workpiece.

[0032] To perfect the solution, the application further proposes that based on the response change amount, the elastic elongation characteristic of the current wire segment is determined, comprising:

[0033] During the preset transient disturbance, the movement displacement of the winding member of the winding machine is synchronously obtained;

[0034] Based on the movement displacement, a first length change amount due to the movement of the winding member is determined;

[0035] The first length change amount is deducted from the response change amount to obtain a second length change amount;

[0036] Based on the second length change amount, the elastic elongation characteristic of the current wire segment is determined.

[0037] Through the above scheme, the influence of the movement of the winding member on the length change amount of the wire can be excluded, and the elastic elongation characteristic of the wire itself can be more accurately determined.

[0038] To perfect the solution, the application also proposes that, based on the motion displacement, a step of determining the first length change amount attributed to the motion of the winding component includes:

[0039] Obtaining the index position of the workpiece during the instantaneous disturbance;

[0040] Based on the index position, establishing an instantaneous conversion relationship between the motion displacement of the winding component of the winding machine and the first length change amount;

[0041] According to the instantaneous conversion relationship, the corresponding first length change amount is calculated based on the motion displacement.

[0042] Through the above-mentioned scheme, the instantaneous conversion relationship can be established based on the index position, and the length change amount attributed to the motion of the winding component can be calculated more accurately.

[0043] To perfect the solution, the application also proposes that, based on the index position, a step of establishing an instantaneous conversion relationship between the motion displacement of the winding component of the winding machine and the first length change amount includes:

[0044] Calling a data structure pre-stored and recording a plurality of discrete index positions and conversion relationships corresponding to each discrete index position;

[0045] Based on the index position, at least one discrete index position adjacent to the index position and its corresponding conversion relationship are determined in the data structure;

[0046] Based on at least one adjacent discrete index position and its corresponding conversion relationship, the instantaneous conversion relationship corresponding to the index position is calculated.

[0047] Through the above-mentioned scheme, the pre-stored data structure and interpolation calculation can be used to quickly and accurately obtain the instantaneous conversion relationship corresponding to any index position.

[0048] To perfect the solution, the application also proposes that, based on at least one adjacent discrete index position and its corresponding conversion relationship, a step of calculating the instantaneous conversion relationship corresponding to the index position includes:

[0049] In the data structure, two adjacent discrete index positions surrounded by the index position are determined;

[0050] Based on the two adjacent discrete index positions and the conversion relationships corresponding to the two adjacent discrete index positions recorded in the data structure, linear interpolation calculation is performed to obtain the instantaneous conversion relationship corresponding to the index position.

[0051] Through the above-mentioned scheme, the accuracy of the instantaneous conversion relationship calculation can be improved through linear interpolation.

[0052] To perfect the solution, the application further provides a step of calling a pre-stored data structure recording a plurality of discrete indexing positions and conversion relationships corresponding to each discrete indexing position, comprising:

[0053] calling a data structure recording a plurality of discrete indexing positions and basic conversion relationships corresponding to each discrete indexing position;

[0054] reading preset calibration parameters from an internal memory of the winding machine controller;

[0055] using the calibration parameters to correct the basic conversion relationship in the data structure to obtain the conversion relationship corresponding to each discrete indexing position.

[0056] Through the above scheme, the basic conversion relationship can be corrected by the calibration parameters, and the accuracy and adaptability of the conversion relationship are improved.

[0057] A wire processing collaborative control system of a magnetic ring winding machine is used to perform wire processing collaborative control of the magnetic ring winding machine, comprising:

[0058] A logistics position acquisition module is configured to acquire physical positions of winding components and indexing components of the winding machine at the moment of interruption when winding movement and indexing movement of the winding machine are interrupted on a function path.

[0059] A logical position solving module is configured to solve the logical interruption position by using a preset continuous function in reverse according to the physical positions.

[0060] A continuation position acquisition module is configured to calculate a target continuation position for resuming the winding process based on the logical interruption position and the preset continuous function.

[0061] A collaborative motion control module is configured to control the winding components and the indexing components of the winding machine to move from the physical positions to the target continuation position based on the target continuation position.

[0062] Through the above scheme, a system for implementing the above method is provided, which is convenient for engineering application.

[0063] In summary, the magnetic ring winding machine wire processing collaborative control method and system provided by the application effectively solves the problem of inaccurate resumption after random interruption of the winding process by acquiring the physical positions at the moment of interruption, solving the logical positions in reverse based on the preset function, and then calculating the target continuation position and resuming the collaborative motion, thereby realizing seamless resumption of the winding process and continuity of the winding path, avoiding the generation of defective points, and improving product quality. BRIEF DESCRIPTION OF DRAWINGS

[0064] Figure 1A method flow chart of a wire processing collaborative control method of a magnetic ring winding machine in one embodiment of the present application;

[0065] Figure 2 A method flow chart of a wire processing collaborative control method of a magnetic ring winding machine in one embodiment of the present application;

[0066] Figure 3 A method flow chart of a wire processing collaborative control method of a magnetic ring winding machine in one embodiment of the present application;

[0067] Figure 4 A method flow chart of a wire processing collaborative control method of a magnetic ring winding machine in one embodiment of the present application;

[0068] Figure 5 A method flow chart of a wire processing collaborative control method of a magnetic ring winding machine in one embodiment of the present application;

[0069] Figure 6 A method flow chart of a wire processing collaborative control method of a magnetic ring winding machine in one embodiment of the present application;

[0070] Figure 7 A method flow chart of a wire processing collaborative control method of a magnetic ring winding machine in one embodiment of the present application;

[0071] Figure 8 A method flow chart of a wire processing collaborative control method of a magnetic ring winding machine in one embodiment of the present application;

[0072] Figure 9 A method flow chart of a wire processing collaborative control method of a magnetic ring winding machine in one embodiment of the present application;

[0073] Figure 10 A system block diagram of a wire processing collaborative control system of a magnetic ring winding machine in one embodiment of the present application;

[0074] BRIEF DESCRIPTION OF THE DRAWINGS

[0075] 1. A wire processing collaborative control system of a magnetic ring winding machine; 11. A logistics position acquisition module; 12. A logical position solving module; 13. A continuation position acquisition module; 14. A collaborative motion control module. DETAILED DESCRIPTION

[0076] The technical solutions in the present application will be clearly and completely described below with reference to the drawings in the present application. Obviously, the described embodiments are only some of the embodiments of the present application, rather than all the embodiments. The components of the present application described and shown in the drawings can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present application provided in the drawings is not intended to limit the scope of the claimed present application, but only represents selected embodiments of the present application. Based on the embodiments of the present application, all other embodiments obtained by those skilled in the art without creative work fall within the scope of the present application.

[0077] It should be noted that similar reference numbers and letters represent similar items in the following drawings, so once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings. Meanwhile, in the description of the present application, the terms "first", "second", etc. are only used to distinguish the description, and cannot be understood as indicating or implying relative importance.

[0078] When the winding process is interrupted on the function path, for example, the emergency stop is triggered due to abnormal wire tension, causing the winding component and the indexing component to stop at any non-predefined point on the function path, the traditional recovery program based on incremental encoder or step motor step count cannot accurately determine the logical position of the interruption point, nor can it plan a recovery path that ensures the continuity of the coil pitch after recovery. This inaccurate recovery method may cause the first coil after recovery to have a sudden change in pitch from the last coil before interruption.

[0079] For example, assume that a magnetic ring winding machine is winding a high-performance magnetic ring inductor according to a complex nonlinear function curve, which defines the correspondence between the rotation phase of the winding component and the rotation angle of the indexing component to achieve varying coil pitches. During the winding process, the system triggers an emergency stop due to an instantaneous increase in wire tension beyond the safety threshold caused by external factors. At this time, the winding component and the indexing component will immediately stop, and their physical positions may fall at any point on the function path, rather than at any program-controlled point or index point. The traditional recovery method can only record the number of pulses or steps of the motor since the last zero reset, but due to the mechanical system's clearance, elastic deformation, and dynamic response during emergency stop, these relative position information is not sufficient to accurately reflect the actual spatial posture of the winding component relative to the indexing component at the interruption moment, nor can it determine the exact logical progress of the physical position on the preset function curve.

[0080] To this end, the present application proposes a magnetic ring winding machine wire handling collaborative control method applied to a winding machine whose winding motion and indexing motion are defined by a preset continuous function, combiningFigure 1 illustrated, comprising:

[0081] S1, when the winding movement of the winding machine and the indexing movement occur interruption on the function path, obtaining the physical positions of the winding part and the indexing part of the winding machine at the interruption moment;

[0082] S2, according to the physical position, using a preset continuous function to solve reversely, obtaining the logical interruption position;

[0083] S3, based on the logical interruption position and the preset continuous function, calculating to obtain the target continuation position for restoring the winding process;

[0084] S4, based on the target continuation position, controlling the winding part and the indexing part of the winding machine to move from the physical position to the target continuation position.

[0085] Wherein, the winding machine with the winding motion and the indexing motion defined by the preset continuous function refers to that there is a continuous change corresponding relationship between the rotation motion of the winding component and the rotation motion of the indexing component, which is described by a mathematical function, can be realized by real-time calculation and output of instructions by the motion controller according to the preset function curve, and is mainly used to realize the function definition change of the coil pitch. Wherein, the interruption occurring on the function path refers to that the winding component and the indexing component are cooperatively moved according to the preset continuous function, and the motion is accidentally stopped due to external factors or system abnormalities, which can be triggered by reasons such as wire tension abnormality, power fluctuation, sensor failure, etc., and is mainly used to protect the equipment or workpiece in abnormal conditions. Wherein, the physical positions of the winding component and the indexing component of the winding machine at the interruption moment are obtained, which refers to reading the actual space position information of the winding component and the indexing component at the motion stopping moment, which can be realized by the position encoder or sensor configured on the motion component, and is mainly used to obtain the real state at the interruption moment as the input for subsequent calculation. Wherein, the preset continuous function is reversely solved, which refers to calculating the logical parameter value of the physical position on the function curve by using the preset continuous function describing the corresponding relationship between the winding motion and the indexing motion according to the physical positions of the winding component and the indexing component, which can be realized by numerical iteration algorithm or table lookup interpolation mathematical method, and is mainly used to map the physical space position to the logical progress defined by the function. Wherein, the logical interruption position refers to the logical progress or parameter value of the interruption point on the winding path represented by the preset continuous function, which is obtained by reverse solving, and is mainly used to represent the position of the winding process on the preset function curve at the interruption moment. Wherein, the target continuation position refers to the physical position calculated based on the logical interruption position and the preset continuous function, which is used to start the next winding period of the winding process, and is mainly used to determine the starting point of the winding component and the indexing component when they resume motion, and ensure the continuity with the winding path before the interruption. Wherein, the winding component and the indexing component of the winding machine are cooperatively moved from the physical position to the target continuation position, which refers to driving the winding component and the indexing component to move synchronously and coordinately from their physical positions at the interruption moment to the calculated target continuation position, which can be realized by trajectory planning and synchronous control of the multi-axis motion controller, and is mainly used to realize the continuous recovery of the winding process and avoid position mutation.

[0086] To achieve the above object, the scheme of the present application works in the following way. First, when the winding movement and the indexing movement of the winding machine are interrupted on the function path, the system obtains the physical positions of the winding components and the indexing components of the winding machine at the moment of interruption. This physical position is the actual spatial coordinates of the equipment movement components at the time of interruption, and is the basis for all subsequent calculations. Since the corresponding relationship between the winding movement and the indexing movement is defined by a preset continuous function, in order to determine the logical progress of the interruption point on the preset winding path, the system uses the obtained physical position to perform reverse solving using the preset continuous function, and obtains the logical interruption position. This logical interruption position represents the parameter value of the interruption point on the function curve, mapping the physical space position to the logical space defined by the function. Based on this logical interruption position and in combination with the preset continuous function, the system calculates a target continuation position for resuming the winding process. This target continuation position is the physical coordinates that the next winding period should start following the logical interruption position according to the preset function curve. Finally, the system controls the winding components and the indexing components of the winding machine to move from their physical positions at the time of interruption to the target continuation position in coordination. This coordinated movement ensures that the relative positional relationship between the winding components and the indexing components during the resumption process follows the requirements of the preset continuous function, thereby achieving continuous connection of the winding process and avoiding discontinuous pitch caused by sudden changes in position.

[0087] As a specific embodiment, the present application is implemented as follows. It is assumed that a preset continuous function describes the relationship between the indexing angle (θ) and the rotation angle of the winding component (φ) as θ = f(φ), where f is a function. When the winding process is interrupted due to abnormal wire tension, the system reads the values of the position encoders arranged on the rotation shaft of the winding component and the rotation shaft of the indexing component, which are the physical positions (φ physical, θ physical) of the winding component and the indexing component at the moment of interruption. In order to find the logical position of the interruption point on the function curve, the system uses numerical iterative algorithms such as Newton's method or the bisection method to solve the function θ = f(φ) inversely to find a logical parameter value φ logic, so that f(φ logic) matches θ physical, and φ logic matches φ physical. The obtained φ logic is the logical interruption position. Based on this logical interruption position φ logic, the system calculates the corresponding position of the next winding period (for example, the winding component rotates 360 degrees) on the function curve. If a winding period corresponds to an increase of Δφ in the rotation angle of the winding component, the starting logical position of the next period corresponds to φ logic + Δφ. Substituting φ logic + Δφ into the preset continuous function θ = f(φ) to calculate the corresponding indexing angle θ target = f(φ logic + Δφ). Then the target continuation position is (φ logic + Δφ, θ target). Finally, the motion controller generates a continuous and coordinated motion trajectory according to the physical position at the time of interruption (φ physical, θ physical) and the calculated target continuation position (φ logic + Δφ, θ target), controls the winding component and the indexing component to move synchronously to the target continuation position, thereby accurately resuming the winding process.

[0088] Through the above technical solution, the present application can solve the problem of how to accurately resume the winding process when the winding motion and the indexing motion of the winding machine are interrupted on the function path. This method maps the physical position at the time of interruption to the logical path defined by the preset continuous function by obtaining the physical position at the time of interruption and inversely solving the preset continuous function, thereby determining the logical position of the interruption point. Based on this logical position, the target continuation position for resuming the winding process is calculated, and the motion components are controlled to move cooperatively to this position. This ensures that the first coil after resuming can be continuous in pitch with the last coil before interruption, avoiding electrical performance defects caused by sudden changes in position. This scheme does not require manual positioning by the operator, nor does it need to return the workpiece to the original position, improving production efficiency and reducing scrap rate, and being suitable for production of components with high winding quality requirements.

[0089] Optionally, in combination with Figure 2As shown, S2 uses the preset continuous function to inversely solve according to the physical position, and the steps of obtaining the logical interrupt position include:

[0090] S21, based on the initial geometric size of the workpiece, determine the theoretical consumption length;

[0091] S22, in the winding process, the actual length of the wire consumed is obtained, and compared with the theoretical consumption length, to determine the real-time geometric size of the workpiece;

[0092] S23, based on the real-time geometric size of the workpiece, correct the preset continuous function to generate an instant continuous function;

[0093] S24, according to the physical position, use the instant continuous function to inversely solve to obtain the corresponding logical interrupt position.

[0094] Wherein, the preset continuous function refers to a mathematical model describing the corresponding relationship between the winding motion and the indexing motion, which can be implemented by using a polynomial function, a piecewise function or a function generated based on a lookup table interpolation; The preset continuous function is corrected, which means that the parameters or forms of the preset continuous function are adjusted according to the real-time geometric size of the workpiece, which can be realized by using proportional scaling, parameter offset or function reconstruction; The instant continuous function refers to the continuous function after correction, which can reflect the actual geometric size state of the current workpiece, and the purpose is to provide a mathematical model that is more in line with the actual situation for inverse solving; The inverse solving refers to the process of deriving the input value (logical position) according to the function output value (physical position), which can be realized by using numerical iteration method, lookup table reverse lookup or analytical inverse function calculation; The logical interrupt position refers to the theoretical progress or state point corresponding to the moment when the winding motion and the indexing motion are interrupted on the function path, which can be represented as the number of winding turns, the indexing angle or the numerical value of the function argument.

[0095] In some preferred embodiments, the specific implementation is as follows. Based on the initial geometric size of the workpiece, the theoretical consumption length can be determined by reading the workpiece design parameters stored in the controller, such as the inner and outer diameters of the magnetic ring, the height, the wire diameter, and the mathematical expression of the preset continuous function, and then by numerical integration or analytical calculation to obtain the total length of the wire required to complete the entire winding process as the theoretical consumption length. In the winding process, the actual consumption length of the wire can be measured in real time by the encoder or length sensor installed on the wire pay-off path. The actual consumption length obtained is compared with the theoretical consumption length, for example, the ratio of the actual consumption length to the theoretical consumption length is calculated, or the difference between the two is calculated, and based on this, the real-time geometric size of the workpiece is determined, for example, the equivalent diameter or the change of the circumference of the workpiece is estimated. Based on the real-time geometric size of the workpiece, the preset continuous function is corrected to generate an instant continuous function, which can be achieved by adjusting the relevant parameters in the preset continuous function (such as the coefficient affecting the relationship between the indexing angle and the number of winding turns) by taking the change of the real-time geometric size as a correction factor, or by looking up the function correction table established in advance based on different geometric size deviations to obtain the corrected function parameters. According to the physical position, the corresponding logical interruption position is obtained by using the instant continuous function to solve inversely, which can be achieved by substituting the physical positions of the winding component and the indexing component at the interruption time (such as the rotation angle of the winding component and the rotation angle of the indexing component) into the inverse function of the corrected instant continuous function or solving the equation by numerical methods (such as bisection method, Newton method), thereby obtaining the number of winding turns or the function argument value corresponding to the interruption time, i.e. the logical interruption position.

[0096] Through the above technical solution, since the change of the geometric size of the workpiece in the actual winding process is considered and the preset continuous function is corrected in real time based on this, when solving inversely according to the physical position, the instant continuous function more consistent with the actual situation can be used, thereby improving the calculation accuracy of the logical interruption position. This provides an accurate starting point for subsequent calculation of the target continuation position and control of the winding machine to accurately resume the winding process, effectively avoids the sudden change of the coil pitch caused by the deviation of the recovery point position, and ensures the winding quality and product performance.

[0097] Optionally, as shown in Figure 3 S1 when the winding motion and the indexing motion of the winding machine are interrupted on the function path, the step of obtaining the physical positions of the winding component and the indexing component of the winding machine at the interruption time includes:

[0098] S11, detecting an abnormal state in the winding process, and triggering an interruption operation when the wire tension exceeds a preset safety threshold;

[0099] S12, in response to the interruption operation, stopping the motion of the winding component and the indexing component, and executing a state freezing instruction;

[0100] S13, reading the current value of the absolute position encoder configured on the winding component and the indexing component as the physical position of the winding component and the indexing component at the moment of interruption.

[0101] wherein detecting abnormal states during winding process refers to monitoring unexpected situations that may affect the normal progress of winding process, such as wire breakage, excessive tension, equipment failure, etc. Detecting that the wire tension exceeds the preset safety threshold is one of the specific abnormal detection methods, which aims to take timely measures before potential risks occur. In response to the interruption operation, the movement of the winding component and the indexing component is stopped, and a state freezing instruction is executed, wherein the state freezing instruction refers to a control instruction for locking or recording the current state information of the key moving parts, such as position, speed, etc., after the equipment stops moving, to ensure that these information will not change when read, which aims to ensure the accuracy of the state data at the moment of interruption. Reading the current value of the absolute position encoder configured on the winding component and the indexing component as the physical position of the winding component and the indexing component at the moment of interruption, wherein the absolute position encoder refers to a sensor that can directly output the absolute value of its current position, unlike incremental encoders, it does not need reference points or historical counts, and can provide unique and accurate position information every time it is powered on or read, which aims to provide high-precision and high-reliability position data, avoiding cumulative errors.

[0102] In some preferred embodiments, abnormal states during winding process are detected, and interruption operation is triggered when it is detected that the wire tension exceeds the preset safety threshold, which can be specifically achieved by configuring a tension sensor on the winding path to monitor the wire tension in real time, and inputting the tension signal to the winding machine controller. The controller has a preset safety tension threshold value, when the real-time monitored tension value exceeds the threshold value continuously or instantaneously, the controller judges that it is an abnormal state, and immediately sends an interruption instruction to the motion control system. In response to the interruption instruction, the motion control system immediately stops the motor power supply of the winding component and the indexing component, and performs brake or braking operation, at the same time, the controller executes the state freezing instruction, for example, by locking the value of the current shaft position register through software, or sending an instruction to the driver to maintain the current state. Reading the current value of the absolute position encoder configured on the winding component and the indexing component as the physical position of the winding component and the indexing component at the moment of interruption, which can be specifically achieved by reading the current absolute angle or position value from the multi-turn absolute position encoder installed on the winding component, such as the wire storage ring drive shaft, and the indexing component, such as the magnetic core clamp drive shaft, through industrial Ethernet or special encoder interface. These values are received and stored by the controller as accurate physical position information at the moment of interruption.

[0103] By the technical solution, the present application can provide a safer and more reliable way to obtain the physical positions of the winding component and the indexing component at the interrupting moment. By actively detecting the abnormality and triggering the interrupting, the damage of the equipment and the breakage of the wire can be effectively avoided. By freezing the state and using the absolute position encoder, the obtained position data can be ensured to be accurate and reliable, and a solid data foundation can be provided for the subsequent winding recovery process.

[0104] Optionally, in combination with Figure 4 As shown, S22 obtains the actual consumed wire length during the winding process, and compares the actual consumed wire length with the theoretical consumed length to determine the real-time geometric size of the workpiece.

[0105] S221, during the winding process, a preset transient disturbance is applied to the winding tension;

[0106] S222, during the preset transient disturbance, the response change amount of the wire length is obtained;

[0107] S223, based on the response change amount, the elastic elongation characteristic of the current wire segment is determined;

[0108] S224, according to the elastic elongation characteristic and the preset standard winding tension, the length component is determined;

[0109] S225, the actual consumed wire length is obtained, and the length component is deducted from the actual consumed wire length to obtain a corrected length value;

[0110] S226, the corrected length value is compared with the theoretical consumed length to determine the real-time geometric size of the workpiece.

[0111] The preset instantaneous disturbance refers to a short-term, known amplitude and duration tension change signal superimposed on the winding tension, which can be realized by using the fast response capability of the tension controller, and the purpose is to artificially introduce a controllable tension change in order to observe the length response of the wire; the response change amount refers to the change of the wire length relative to the length before the disturbance during the application of the preset instantaneous disturbance, which can be obtained by a high-precision length measuring device, and the purpose is to capture the elastic deformation information of the wire due to the change in tension; the elastic elongation characteristic refers to the physical property of the elastic deformation of the wire under the action of the tensile force, such as the elastic modulus or the tension-elongation curve of the wire, which can be determined by analyzing the relationship between the tension disturbance and the response change amount, and the purpose is to quantify the elastic behavior of the current wire section; the length component refers to the additional length of the current wire section due to elastic elongation under the preset standard winding tension, which can be calculated according to the determined elastic elongation characteristic and the standard winding tension through an elastic mechanics model, and the purpose is to calculate the elastic elongation part that needs to be compensated from the actual consumed length; the standard winding tension refers to the wire tension value expected or set by the system in the normal and stable winding process, and the purpose is to provide a reference tension value for calculating the elastic elongation amount of the wire under this tension; the corrected length value refers to the value obtained by deducting the length component caused by the elastic elongation of the wire from the actual consumed wire length, and the purpose is to obtain the true consumed length of the wire in the tension-free state.

[0112] In some preferred embodiments, specifically, a preset transient disturbance can be applied during the winding process by the tension control system of the winding machine, based on the normal winding tension, by temporarily increasing or decreasing a preset tension value, for example, for tens of milliseconds, with an amplitude of 10% of the standard tension. During the application of the transient disturbance, a laser ranging sensor installed near the workpiece can be used to continuously monitor the position change of the wire passing through a certain point, or a high-resolution encoder can be used in combination with a precision guide wheel to measure the length change by integrating the speed of the wire passing through, so as to obtain the response change amount of the wire length. Assuming that the wire meets Hooke's law, i.e., the elongation is proportional to the change amount of the tension, by recording the amplitude of the tension disturbance and the corresponding length response change amount, the equivalent elastic coefficient of the current wire segment can be calculated. According to the calculated elastic coefficient and the preset standard winding tension, the elastic elongation under the standard tension is calculated to determine the length component. The total length of the wire actually discharged from the start of winding to the current time is accurately measured by the encoder on the wire discharge mechanism of the winding machine, so as to obtain the actual consumed wire length. The actual consumed length obtained is subtracted from the calculated length component to obtain a corrected length value. By comparing the corrected length value with the theoretical consumed length calculated based on the theoretical size of the workpiece, for example, by comparing the proportion of the corrected length value and the theoretical consumed length, in combination with the number of turns and other information, the equivalent diameter or circumference of the workpiece at the current time can be calculated to determine the real-time geometric size of the workpiece. Further, when obtaining the response change amount, the motion displacement of the winding component can be synchronously obtained. Based on the current indexing position of the workpiece, the length change amount corresponding to the motion displacement of the winding component is calculated by table lookup or interpolation. The length change amount caused purely by the change in tension is obtained by subtracting the length change amount from the total response change amount. Based on the length change amount and the amplitude of the tension disturbance, the elastic elongation characteristic is more accurately determined.

[0113] By the above technical solutions, when determining the real-time geometric size of the workpiece, the elastic elongation of the wire under the winding tension is considered and compensated. This makes the actual consumed wire length used for comparison more accurate, thereby improving the calculation accuracy of the real-time geometric size of the workpiece. The improvement of the calculation accuracy of the real-time geometric size of the workpiece further improves the correction accuracy of the instant continuous function, and finally ensures the accuracy of the connection position when the winding is resumed after interruption, ensuring that the coil pitch after resumption remains continuous with that before interruption.

[0114] Optionally, in combination with Figure 5 As shown in FIG. 7, S223 includes the following steps:

[0115] S2231, synchronously obtaining the motion displacement of the winding component of the winding machine during the preset transient disturbance;

[0116] S2232, determining a first length change amount attributed to the motion of the winding component based on the motion displacement;

[0117] S2233, obtaining a second length change amount by deducting the first length change amount from the response change amount;

[0118] S2234, determining the elastic elongation characteristic of the current wire segment based on the second length change amount.

[0119] wherein the preset transient disturbance period refers to a time window for applying a short-term tension fluctuation for measuring the elastic characteristic of the wire, which can be implemented in a time length of milliseconds or microseconds, and the purpose is to minimize the overall interruption time of the winding process while the wire is elastically deformed; the synchronous acquisition of the motion displacement of the winding component of the winding machine refers to the parallel acquisition of the position data of the winding component of the winding machine within the time window of the applied transient tension disturbance, which can use a high-speed position sensor such as an absolute position encoder or a laser tracker to read the position of the winding component and calculate its displacement during the disturbance, and the purpose is to quantify the influence of the motion of the winding component itself on the length of the wire; the motion displacement refers to the spatial position change amount of the winding component of the winding machine during the preset transient disturbance period, which can be represented by linear displacement or angular displacement, and the purpose is to provide the basis data for calculating the length change of the wire caused by the winding component; the first length change amount attributed to the motion of the winding component refers to the change of the effective length of the wire on the winding path directly caused by the movement of the winding component of the winding machine in space, which can be determined by geometric calculation or table lookup, and the purpose is to separate the influence of the motion of the winding component on the total length change of the wire; the response change amount refers to the instantaneous change of the total length of the wire detected by the wire length measuring device after the application of the preset transient disturbance, which can be measured by a high-precision length sensor, and the purpose is to obtain the overall length response of the wire under tension disturbance; the second length change amount refers to the remaining length change obtained by subtracting the first length change amount attributed to the motion of the winding component from the response change amount of the total length of the wire, which can be obtained by numerical subtraction operation, and the purpose is to obtain a length change that more purely reflects the elastic deformation of the wire; the elastic elongation characteristic of the current wire segment refers to the elastic deformation law exhibited by the wire segment being wound under a specific tension, which can be represented by the elastic modulus, stress-strain curve or elastic coefficient, and the purpose is to accurately describe the elastic behavior of the wire for length correction.

[0120] In some preferred embodiments, specifically at certain time points during the winding process, such as after winding a certain number of turns, the control system can trigger a short tension disturbance, such as by quickly adjusting the braking force of the pay-off mechanism. Within the extremely short duration of the tension disturbance, the system synchronously reads the absolute position encoder data of the winding component (such as the storage ring) drive motor, calculates the movement displacement of the storage ring within this time period. At the same time, through a high-precision length sensor installed on the wire path, such as a measuring wheel with an encoder, the total length of the wire in the same time period is obtained. According to the current indexing position of the magnetic core, the system consults the pre-established conversion table or through real-time geometric calculation model, converts the movement displacement of the storage ring into the corresponding length change of the wire, i.e. the first length change due to the movement of the winding component. Then, the control system performs calculation, subtracts the first length change from the total response change, and obtains the second length change. Finally, based on the second length change and the size of the instantaneous tension disturbance applied (such as obtained through the tension sensor), the system calculates the elastic modulus or stress-strain coefficient of the current wire segment as its elastic elongation characteristic. This elastic characteristic data can be stored or used for subsequent real-time wire length correction calculation.

[0121] By the above technical solution, the wire length change caused by the movement of the winding component is separated from the total response change, making the calculated wire elastic elongation characteristic more accurate. Based on the more accurate elastic elongation characteristic, the wire length is corrected, improving the accuracy of the real-time geometric size determination of the workpiece, thereby providing basic data for accurate continuation after the winding process is interrupted, ensuring the winding quality.

[0122] Optionally, in combination with Figure 6 As shown in S2232, the step of determining the first length change due to the movement of the winding component based on the movement displacement includes:

[0123] A1, obtaining the indexing position of the workpiece during the instantaneous disturbance;

[0124] A2, based on the indexing position, establishing an instantaneous conversion relationship between the movement displacement of the winding component of the winding machine and the first length change;

[0125] A3, according to the instantaneous conversion relationship, calculating the corresponding first length change based on the movement displacement.

[0126] The index position of the workpiece refers to the rotational angular position of the magnetic ring workpiece relative to the index shaft of the winding machine, which can be obtained by using an absolute position encoder installed on the index motor. The first length variation refers to the variation in the effective path length of the wire caused by the movement of the winding component itself during the instantaneous disturbance, and the purpose is to separate this part of the length variation caused by mechanical movement rather than wire elasticity from the total response. The instantaneous conversion relationship refers to the proportion or functional relationship between the unit movement displacement of the winding component and the length variation of the wire caused thereby at a certain index position of the workpiece, which can be established in advance by geometric modeling or experimental calibration and stored as a data structure.

[0127] In some preferred embodiments, as a specific implementation, when the winding process is disturbed instantaneously, the control system can immediately read the absolute position encoder installed on the indexing component to obtain the index position of the current magnetic ring workpiece. For example, if the encoder reading is a position corresponding to a 45-degree rotation of the magnetic ring, the system will call the pre-stored conversion relationship data. This data structure can be a lookup table that records the length variation of the wire corresponding to the unit movement displacement of the winding component at multiple discrete angular positions of the magnetic ring. The system will look up the discrete angles adjacent to the current 45-degree position, such as 40 degrees and 50 degrees, and obtain their respective conversion relationship values. Then, the system can use a linear interpolation algorithm to calculate the instantaneous conversion relationship at the 45-degree position based on the 40-degree, 50-degree and their corresponding conversion relationships. Assuming that the calculated instantaneous conversion relationship is 0.1 mm / mm. At the same time, the system records the movement displacement of the winding component during the instantaneous disturbance, such as an axial movement of 5 mm. Based on this, the system multiplies the movement displacement of 5 mm by the instantaneous conversion relationship of 0.1 mm / mm to calculate the first length variation of 0.5 mm due to the movement of the winding component. This calculated 0.5 mm will be used to subsequently deduct from the total response variation.

[0128] Through the above technical solution, the length variation of the wire due to the movement of the winding component during the instantaneous disturbance can be calculated. This makes it possible to accurately separate this part of the change caused by mechanical movement from the total length response variation of the wire, thereby obtaining length variation data reflecting the elastic properties of the wire. Thus, the elastic elongation properties of the current wire segment can be determined, improving the accuracy of subsequent real-time geometric dimension calculation of the workpiece and providing a data basis for recovery after the winding process is interrupted.

[0129] Optionally, in combination with Figure 7 As shown, the step of A2 of establishing the instantaneous conversion relationship between the movement displacement of the winding component of the winding machine and the first length variation based on the index position includes:

[0130] A21, calling a pre-stored data structure recording a plurality of discrete indexing positions and corresponding conversion relationships of each discrete indexing position;

[0131] A22, determining at least one adjacent discrete indexing position and corresponding conversion relationship of the adjacent discrete indexing position based on the indexing position in the data structure;

[0132] A23, calculating the instantaneous conversion relationship corresponding to the indexing position based on the at least one adjacent discrete indexing position and corresponding conversion relationship.

[0133] Wherein, the pre-stored data structure recording a plurality of discrete indexing positions and corresponding conversion relationships of each discrete indexing position refers to a pre-prepared data set, which records a plurality of preset, non-continuous angle positions on the indexing circumference of the magnetic ring, and the corresponding proportion or function relationship between the movement displacement of the winding component of the winding machine and the first length change of the wire at these specific angle positions, which can be realized in the form of lookup table, array, database or file, etc., and its purpose is to store limited key data points as the basis for subsequent calculation of conversion relationship at any position; the discrete indexing position refers to a series of non-continuous angle points selected on the indexing circumference of the magnetic ring, which represents the specific state of the magnetic core rotation in the winding process, and its selection can be based on the characteristics of the winding function curve, the accuracy requirement or the calculation efficiency, and its purpose is to represent the continuous changing physical process with limited data points; the conversion relationship refers to the change amount of the wire length caused by the movement of the winding component (such as the wire storage ring) along its movement trajectory by one unit distance at a specific indexing position, which is affected by the geometry of the magnetic core, the winding path, the indexing position and other factors, and its purpose is to quantify the contribution of the winding component movement to the wire length; the adjacent discrete indexing position refers to one or more discrete indexing positions closest to the current actual indexing position in angle in the pre-stored data structure, and its determination can be realized by searching the data structure, and its purpose is to estimate the value of the unknown data point by using the information of the known data point; the instantaneous conversion relationship corresponding to the indexing position refers to the conversion relationship between the movement displacement of the winding component and the first length change at the actual indexing position, which is estimated by mathematical methods (such as interpolation, fitting, etc.) according to the actual indexing position and its adjacent discrete indexing position and corresponding conversion relationship, and its purpose is to obtain the conversion relationship at any position without storing all continuous position data.

[0134] In some preferred embodiments, specifically, the conversion relationship at key angular positions on the circumference of the magnetic core, for example, every 5 degrees, 10 degrees, or determined according to the rate of change of the winding function curve, can be pre-calculated or measured, and these discrete indexing positions and their corresponding conversion relationships are stored in a two-dimensional array or lookup table. When a transient disturbance occurs during the winding process, the system obtains the current indexing position, for example, 37 degrees. The system looks up in the pre-stored data structure to determine the discrete indexing positions adjacent to 37 degrees, for example, 35 degrees and 40 degrees, and reads their corresponding conversion relationship values. Then, the system can use a linear interpolation method to calculate the instantaneous conversion relationship at the 37-degree position according to the 35-degree, 40-degree, and their corresponding conversion relationships. For example, if the conversion relationship corresponding to 35 degrees is K35, and the conversion relationship corresponding to 40 degrees is K40, then the instantaneous conversion relationship K37 corresponding to 37 degrees can be calculated by the formula K37 = K35 + (K40 - K35) * (37 - 35) / (40 - 35). The calculated K37 is used to calculate the first length change amount based on the movement displacement of the winding component.

[0135] Through the above technical solutions, by storing the conversion relationships of discrete indexing positions and using adjacent positions for approximate calculation, the data storage amount is reduced, the real-time calculation complexity is reduced, the efficiency of obtaining the instantaneous conversion relationship by the winding machine is improved while ensuring the conversion accuracy, thereby improving the control performance of the winding process and the reliability of the interruption recovery.

[0136] Optionally, in combination with Figure 8 As shown in the figure, the step of A23 of calculating the instantaneous conversion relationship corresponding to the indexing position based on at least one adjacent discrete indexing position and its corresponding conversion relationship comprises:

[0137] A231, in the data structure, two adjacent discrete indexing positions surrounded by the indexing position are determined;

[0138] A232, based on the two adjacent discrete indexing positions and the conversion relationships corresponding to the two adjacent discrete indexing positions recorded in the data structure, a linear interpolation calculation is performed to obtain the instantaneous conversion relationship corresponding to the indexing position.

[0139] The data structure is a data organization form pre-stored and recording a plurality of discrete indexing positions and conversion relationships corresponding to each discrete indexing position, which can be realized in the form of a table, an array, a lookup table, etc., and the purpose thereof is to store basic data for calculating the instantaneous conversion relationship. The indexing position refers to the angular position of the workpiece in the indexing motion, and the purpose thereof is to represent the current rotation state of the workpiece. The discrete indexing position refers to a pre-recorded, non-continuous indexing angle point in the data structure, and the purpose thereof is to provide a known data point for interpolation calculation. The conversion relationship refers to the proportion or function relationship between the movement displacement of the winding machine winding component and the first length change, and the purpose thereof is to establish the corresponding relationship between the winding component movement and the wire length change. The adjacent discrete indexing positions refer to one or more discrete indexing positions in the data structure that are close in value to the current indexing position, and the purpose thereof is to provide data points for approximating the conversion relationship of the current indexing position. The two adjacent discrete indexing positions surrounded by the indexing position refer to a discrete indexing position that is smaller in value than the current indexing position and closest to the current indexing position, and a discrete indexing position that is larger in value than the current indexing position and closest to the current indexing position in the data structure, and the purpose thereof is to provide two boundary data points required for linear interpolation calculation. The linear interpolation calculation refers to a numerical approximation method that estimates the value of an unknown point between two known points, assuming a linear relationship between the two points, which can be realized by the formula y = y1 + (x-x1)*(y2-y1) / (x2-x1), where x is the indexing position to be interpolated, x1 and x2 are the two adjacent discrete indexing positions surrounding x, y1 and y2 are the conversion relationships corresponding to x1 and x2, and y is the instantaneous conversion relationship obtained by interpolation, and the purpose thereof is to estimate the conversion relationship of any indexing position according to the conversion relationship of the known discrete points. The instantaneous conversion relationship refers to the real-time corresponding relationship between the movement displacement of the winding machine winding component and the first length change at a certain specific indexing position, and the purpose thereof is to accurately reflect the proportional relationship between the movement displacement and the length change at the current indexing position.

[0140] In some preferred embodiments, a plurality of discrete indexing positions and their corresponding conversion relationships are pre-stored in the data structure, for example, the conversion relationship is 0.5 when the indexing position is 10 degrees, the conversion relationship is 0.6 when the indexing position is 20 degrees, the conversion relationship is 0.75 when the indexing position is 30 degrees, etc. When the current indexing position of the workpiece is 15 degrees, the system looks up in the data structure to determine that the two adjacent discrete indexing positions surrounding 15 degrees are 10 degrees and 20 degrees. Then, linear interpolation calculation is performed based on the two discrete indexing positions of 10 degrees and 20 degrees and their corresponding conversion relationships 0.5 and 0.6 recorded in the data structure. According to the linear interpolation formula, the instantaneous conversion relationship is

[0141] = 0.5 + (15 - 10) * (0.6 - 0.5) / (20 - 10) = 0.5 + 5 * 0.1 / 10 = 0.5 + 0.05 = 0.55. Thus, the instantaneous conversion relationship corresponding to the current index position 15 degrees is 0.55. This instantaneous conversion relationship can be used to convert the movement displacement of the winding component into the corresponding wire length change amount.

[0142] Through the above technical solution, by determining two adjacent discrete index positions surrounding the current index position, and performing linear interpolation calculation based on the two positions and their corresponding conversion relationships, a more accurate instantaneous conversion relationship can be obtained. This accurate instantaneous conversion relationship can more accurately reflect the corresponding relationship between the movement displacement of the winding component and the first length change amount, thereby improving the calculation accuracy of the first length change amount attributable to the movement of the winding component. The improvement of the calculation accuracy of the first length change amount helps to more accurately determine the elastic elongation characteristics of the wire segment, and ultimately improves the judgment accuracy of the real-time geometric size of the workpiece.

[0143] Optionally, in combination with the method shown in Figure 9 A21 calls the step of pre-storing a data structure recording a plurality of discrete index positions and the conversion relationship corresponding to each discrete index position includes:

[0144] A211, calling a data structure recording a plurality of discrete index positions and the basic conversion relationship corresponding to each discrete index position;

[0145] A212, reading the preset calibration parameters from the internal memory of the winding machine controller;

[0146] A213, using the calibration parameters to correct the basic conversion relationship in the data structure to obtain the conversion relationship corresponding to each discrete index position.

[0147] The data structure recording a plurality of discrete indexing positions and the basic conversion relationship corresponding to each discrete indexing position refers to a storage structure recording the corresponding relationship between the unit movement displacement of the winding component and the length variation of the wire at a plurality of predetermined, discontinuous indexing angle points, which can be implemented by a lookup table, an array or an association list. The internal memory of the winding machine controller refers to a non-volatile or volatile storage medium integrated in the main control unit of the winding machine, used to store program codes, configuration data and running parameters, which can be implemented by a Flash memory, an EEPROM or a RAM. The preset calibration parameter refers to a correction value or coefficient for adjusting the basic conversion relationship obtained according to the actual running state of the winding machine or through a calibration program, which can be implemented by an offset, a proportion factor or correction curve data. The basic conversion relationship in the correction data structure refers to the adjustment calculation of the original basic conversion relationship value stored in the data structure according to the read calibration parameter, so as to make it closer to the actual running characteristics of the device, which can be implemented by additive correction, multiplicative correction or lookup table correction.

[0148] In some preferred embodiments, the data structure recording a plurality of discrete indexing positions and the basic conversion relationship corresponding to each discrete indexing position can be a two-dimensional lookup table, in which one column stores the numerical value of the discrete indexing position, and the other column stores the basic conversion relationship value of the corresponding position. The internal memory of the winding machine controller can be a Flash memory chip on the winding machine main control unit. The preset calibration parameter can be a calibration coefficient array stored in the Flash chip, and the index of the array corresponds to the discrete indexing position in the lookup table. Using the calibration parameter to correct the basic conversion relationship in the data structure can be specifically implemented by reading the lookup table and the calibration coefficient array after system initialization or periodic calibration, traversing each basic conversion relationship value in the lookup table, multiplying it by the coefficient at the corresponding position in the calibration coefficient array, and updating the calculation result back to the lookup table to form a calibrated conversion relationship lookup table for subsequent runtime call.

[0149] Through the above technical solution, the pre-stored basic conversion relationship is corrected by introducing the calibration parameter, so that the conversion relationship can adapt to the change of the actual running state of the winding machine, and the accuracy and reliability of the instantaneous conversion relationship between the movement displacement of the winding component and the length variation of the wire are improved. The more accurate conversion relationship makes the subsequent wire length calculation, function correction and interruption and connection more accurate, thereby ensuring the continuity of the winding process and the uniformity of the pitch, avoiding the coil overlapping or excessive gap caused by inaccurate position calculation, and improving the product quality and production efficiency.

[0150] A wire processing cooperative control system of a magnetic ring winding machine is used to perform wire processing cooperative control of the magnetic ring winding machine, which combines Figure 10The magnetic ring winding machine wire processing collaborative control system 1 comprises:

[0151] The logistics position acquisition module 11 is configured to acquire the physical positions of the winding component and the indexing component of the winding machine at the time of interruption when the winding movement and the indexing movement of the winding machine are interrupted on the function path.

[0152] The logical position solving module 12 is configured to solve the logical interruption position by using a preset continuous function in reverse according to the physical positions.

[0153] The continuation position acquisition module 13 is configured to calculate the target continuation position for resuming the winding process based on the logical interruption position and the preset continuous function.

[0154] The collaborative movement control module 14 is configured to control the winding component and the indexing component of the winding machine to move collaboratively from the physical positions to the target continuation position based on the target continuation position.

[0155] The logistics position acquisition module refers to a functional unit for acquiring the physical positions of the winding machine components at the time of interruption, which can be implemented by using a position sensor, an encoder, or a visual recognition system. The logical position solving module refers to a functional unit for calculating the logical interruption position based on the physical positions and the preset continuous function, which can be implemented by using a computing unit with an internal processor or an externally connected computer. The continuation position acquisition module refers to a functional unit for calculating the target continuation position based on the logical interruption position and the preset continuous function, which can be implemented by using a computing unit with an internal processor or an externally connected computer. The collaborative movement control module refers to a functional unit for controlling the winding machine components to move collaboratively to the target continuation position, which can be implemented by using a motion controller, a servo driver, or a stepping driver.

[0156] As a specific embodiment, the magnetic ring winding machine wire processing collaborative control system can include an industrial controller, such as a programmable logic controller (PLC) or an industrial computer. The logistics position acquisition module can be composed of absolute position encoders connected to the winding component and the indexing component, and an input interface in communication with the industrial controller, for reading the current position values of the encoders when interruption occurs. The functions of the logical position solving module and the continuation position acquisition module can be implemented by the central processor inside the industrial controller executing a preset software program, which receives physical position data, calls a stored preset continuous function model, and performs reverse solving and continuation position calculation. The collaborative movement control module can be composed of a motion control output interface of the industrial controller connected to the servo drivers of the winding motor and the indexing motor, and the industrial controller generates motion instructions according to the calculated target continuation position, accurately controls the movement of the motor through the servo driver, and moves the winding component and the indexing component collaboratively to the target position.

[0157] Through the technical solution, the application provides a wire processing cooperative control system of a magnetic ring winding machine. The system converts the method steps of interrupting and resuming the winding process into specific system function units through modular design, and provides the required execution mechanism for the implementation method. This enables the system to quickly and accurately obtain the physical position at the interrupting time when the winding movement and the indexing movement are interrupted on the function path, and accurately calculate the logical interrupting position and the target resuming position based on the physical position. Further, the system can accurately control the cooperative movement of the winding component and the indexing component to the target resuming position, thereby realizing seamless resumption of the winding process. The system solves the problem of lacking specific execution mechanism in actual application by simply relying on the method, improves the efficiency and reliability of interrupting and resuming, avoids workpiece scrap caused by interruption, ensures the winding quality, and is especially suitable for variable-pitch winding tasks that require accurate control of coil pitch.

[0158] The above only describes the embodiments of the application and is not used to limit the protection scope of the application. For those skilled in the art, the application can have various changes and modifications. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the application shall be included in the protection scope of the application.

Claims

1. A method for coordinated control of wire processing in a magnetic winding machine, applied to a winding machine where the winding motion and indexing motion are defined by a preset continuous function, characterized in that... include: When the winding motion and indexing motion of the winding machine are interrupted on the function path, obtain the physical position of the winding component and the indexing component of the winding machine at the moment of interruption. Based on the physical location, the logical interruption location is obtained by inverse calculation using a preset continuous function. Based on the logical interruption position and the preset continuity function, the target continuation position for resuming the winding process is calculated; Based on the target continuation position, the winding component and indexing component of the control winding machine are moved together from their physical positions to the target continuation position.

2. The method for coordinated control of wire processing in a magnetic winding machine according to claim 1, characterized in that, The step of obtaining the logical interruption location by performing a reverse calculation using a preset continuous function based on the physical location includes: Determine the theoretical consumption length based on the initial geometric dimensions of the workpiece; During the winding process, the actual length of wire consumed is obtained and compared with the theoretical length consumed to determine the real-time geometric dimensions of the workpiece. Based on the real-time geometric dimensions of the workpiece, the preset continuous function is corrected to generate an instantaneous continuous function; Based on the physical location, the corresponding logical interruption location is obtained by inverse calculation using the instantaneous continuous function.

3. The method for coordinated control of wire processing in a magnetic winding machine according to claim 1, characterized in that, The step of obtaining the physical positions of the winding component and the indexing component of the winding machine at the moment of interruption when the winding motion and indexing motion of the winding machine are interrupted on the function path includes: Detect abnormal conditions during the winding process and trigger an interrupt operation when the wire tension exceeds a preset safety threshold; In response to an interrupt operation, the movement of the winding component and the indexing component is stopped, and a state freeze command is executed; Read the current value of the absolute position encoder configured on the winding component and the indexing component, and use it as the physical position of the winding component and the indexing component at the moment of interruption.

4. The method for coordinated control of wire processing in a magnetic winding machine according to claim 2, characterized in that, The step of obtaining the actual wire length consumed during the winding process and comparing it with the theoretical consumption length to determine the real-time geometric dimensions of the workpiece includes: During the winding process, a preset instantaneous disturbance is applied to the winding tension; During a preset instantaneous disturbance period, the change in wire length is obtained. Based on the change in response, the elastic elongation characteristics of the current wire segment are determined; The length component is determined based on the elastic elongation characteristics and the preset standard winding tension; Obtain the actual length of wire consumed, and subtract the length component from the actual length of wire consumed to obtain the corrected length value; The corrected length value is compared with the theoretical consumption length to determine the real-time geometric dimensions of the workpiece.

5. The method for coordinated control of wire processing in a magnetic winding machine according to claim 4, characterized in that, The step of determining the elastic elongation characteristics of the current wire segment based on the response change includes: During the preset instantaneous disturbance period, the motion displacement of the winding component of the winding machine is acquired synchronously; Based on the displacement, a first length change attributable to the movement of the winding component is determined; Subtract the first length change from the response change to obtain the second length change; Based on the second length change, the elastic elongation characteristics of the current wire segment are determined.

6. The method for coordinated control of wire processing in a magnetic winding machine according to claim 5, characterized in that, The step of determining the first length change attributable to the motion of the winding component based on the motion displacement includes: Obtain the indexing position of the workpiece during the instantaneous disturbance; Based on the indexing position, an instantaneous conversion relationship is established between the motion displacement of the winding component of the winding machine and the first length change. Based on the instantaneous conversion relationship, the corresponding first length change is calculated based on the motion displacement.

7. The method for coordinated control of wire processing in a magnetic winding machine according to claim 6, characterized in that, The step of establishing the instantaneous conversion relationship between the motion displacement of the winding component of the winding machine and the first length change based on the indexing position includes: The data structure that calls the pre-stored record has several discrete scale positions and the corresponding conversion relationship between each discrete scale position; Based on the division position, at least one discrete division position adjacent to the division position and its corresponding conversion relationship are determined in the data structure; Based on at least one neighboring discrete graduation position and its corresponding conversion relationship, the instantaneous conversion relationship corresponding to the graduation position is calculated.

8. The method for coordinated control of wire processing in a magnetic winding machine according to claim 7, characterized in that, The step of calculating the instantaneous conversion relationship corresponding to the division position based on at least one neighboring discrete division position and its corresponding conversion relationship includes: In the data structure, determine the two adjacent discrete graduation positions enclosed by the graduation position; Based on two adjacent discrete division positions and the conversion relationship recorded in the data structure corresponding to the two adjacent discrete division positions, linear interpolation is performed to obtain the instantaneous conversion relationship corresponding to the division position.

9. The method for coordinated control of wire processing in a magnetic winding machine according to claim 7, characterized in that, The step of calling a pre-stored data structure containing several discrete scale positions and corresponding conversion relationships between each discrete scale position includes: The call record contains a data structure with several discrete scale positions and the basic conversion relationship corresponding to each discrete scale position; Read the preset calibration parameters from the internal memory of the winding machine controller; Using the calibration parameters, the basic conversion relationships in the data structure are corrected to obtain the conversion relationships corresponding to each discrete division position.

10. A collaborative control system for wire processing of a magnetic winding machine, used to perform collaborative control of wire processing in a magnetic winding machine, characterized in that, include: The logistics location acquisition module is used to acquire the physical position of the winding component and the indexing component of the winding machine at the moment of interruption when the winding motion and indexing motion of the winding machine are interrupted on the function path. The logic location solving module is used to perform reverse solving based on the physical location using a preset continuous function to obtain the logic interruption location; The continuation position acquisition module is used to calculate the target continuation position for resuming the winding process based on the logical interruption position and the preset continuity function. The coordinated motion control module is used to control the winding component and the indexing component of the winding machine to move collaboratively from their physical positions to the target continuation position based on the target continuation position.

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