Self-adaptive winding method and system of intelligent winding machine based on CODESYS and medium

Abstract

The invention provides a self-adaptive winding method and system of an intelligent winding machine based on CODESYS and a medium, and the method comprises the steps: firstly, analyzing a graphic file according to a preset extraction function to obtain a geometric path, dynamically compensating the geometric path through a winding deviation model, and achieving the intelligent reconstruction of the geometric path; secondly, dynamically calculating arc parameters with deformation compensation and a layered speed regulation strategy in combination with the attributes of the wire rod and the coordinates of the key section of the geometric path, and eliminating the jump risk of the process parameters; then, the current of a dragging motor is adjusted in real time based on tension feedback, the deformation trend is predicted based on the wire length and speed, the spatial position of a guide wheel is dynamically adjusted, and self-adaptive speed adjustment is conducted based on the number of winding layers; finally, the theoretical winding track and the actual winding track are mapped through a visual platform in a 3D mode, and track deviation and key operation parameters are displayed. Therefore, the automation degree of operation of the winding machine is improved, and the stability and efficiency of the winding process are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of winding machines, more particularly, to an adaptive winding method, system and medium of an intelligent winding machine based on CODESYS. BACKGROUND

[0002] In the field of industrial automation, the winding process is widely used in the manufacturing of devices such as motors, transformers, etc. The current mainstream solution uses the CODESYS platform based on the IEC 61131-3 standard. CODESYS is a development and programming system in the field of industrial automation, supporting multiple programming languages such as ladder diagram (LD), structured text (ST), function block diagram (FB), sequential function chart (SFC), etc., and has good portability and compatibility. In addition, CODESYS also provides rich development tools and libraries to facilitate programming and debugging.

[0003] However, the existing technology based on CODESYS winding machine parses DXF graphic files through CNC function blocks and generates code paths. However, after importing the DXF graphic file, the winding machine system cannot accurately restore the design path, resulting in frequent problems such as misalignment of line segments, sudden changes in curvature of arcs, etc., which need to be manually checked and corrected, seriously increasing the debugging time cost. Moreover, the traditional CNC architecture requires a large amount of manual judgment, relies on the experience of operators, and the parameter debugging process is tedious and prone to jump risk. In addition, there is a lack of collaborative control mechanism, and a single winding speed is difficult to balance winding quality and winding efficiency.

[0004] The existing technology cannot meet the high-precision winding requirements, especially in the face of precise manufacturing scenarios such as automobile motors, the problems of high manual intervention cost and poor product consistency are increasingly prominent. Therefore, there is an urgent need for an intelligent winding machine technology that can automatically parse, adaptively generate parameters, and collaboratively control multiple processes. SUMMARY

[0005] In view of the above problems, the purpose of the present application is to provide an adaptive winding method, system and medium of an intelligent winding machine based on CODESYS, which assists path analysis based on machine learning algorithms, automatically corrects DXF graphic analysis deviation, and reconstructs the winding path; based on an adaptive parameter generation system, dynamically calculates the parameters of the arc, combines the material property to compensate for the trajectory error, and eliminates the risk of process parameter jump; and through the locking force closed-loop control, the wire deformation prediction and the multi-segment speed adaptive strategy, the yield of the winding process is improved and the winding efficiency is ensured.

[0006] The first aspect of the present application provides an adaptive winding method of an intelligent winding machine based on CODESYS, the method comprising: obtaining first geometric path information based on a preset extraction function in response to an imported graphic file; According to the first geometric path information, path compensation information is dynamically generated based on a preset winding deviation model, and the first geometric path information is updated; In response to the imported wire attribute, the updated first geometric path information is combined, and motion parameter information is obtained based on a preset planning function; When performing the winding operation; Tension information is obtained, and if the tension information is lower than a preset tension threshold, the drag motor current is increased; Length information and speed information are obtained, a deformation index is obtained according to a preset deformation calculation relationship, and the guide wheel position is dynamically adjusted; The number of winding layers is obtained, and the winding motor speed is adjusted according to a preset speed mapping curve; The winding trajectory is mapped by a preset visualization platform 3D, and the motion parameter information is displayed.

[0007] In the scheme, the path compensation information is dynamically generated based on the first geometric path information and the preset winding deviation model, and the first geometric path information is updated, which specifically includes: The historical winding path database is searched, the difference between the second geometric path information corresponding to the same named graphic file and the first geometric path information is calculated, and the first path deviation information is obtained; The historical winding path database is searched, the deviation between the analysis path and the ideal path corresponding to a preset number of historical graphic files is extracted, and the second path deviation information is obtained; It is judged whether the first path deviation information is lower than a preset first path deviation threshold; If yes, a correction coefficient is generated according to the first path deviation information; If not, a compensation coefficient is generated according to the second path deviation information; The correction coefficient or the compensation coefficient is input into the extraction function, and the reconstructed path information is obtained, which is used to update the first geometric path information.

[0008] In the scheme, in response to the imported wire attribute, the updated first geometric path information is combined, and motion parameter information is obtained based on a preset planning function, which specifically includes: According to the first geometric path information, three-point coordinates of a key sub-path are obtained based on a preset key path matching strategy, including start point coordinates, intermediate point coordinates and end point coordinates; According to the material type of the wire attribute, the three-point coordinates are combined to obtain a start angle and a transition angle; According to the tension coefficient and diameter of the wire attribute, the three-point coordinates are combined to obtain a deformation compensation offset of the circular arc path; Input the first geometric path information, the start angle, the transition angle and the deformation compensation offset into a preset planning function to obtain a motion parameter set with deformation compensation.

[0009] In the scheme, the tension information is acquired, and if the tension information is lower than a preset tension threshold, the dragging motor current is increased, and specifically includes: The tension information is measured based on a preset tension sensor. A first tension value is obtained based on a preset analog-digital conversion and tension value mapping relationship according to the tension information. The tension threshold is determined according to a tension coefficient of the wire property. If the tension value is lower than the tension threshold, the dragging motor current is increased according to a preset current step.

[0010] In the scheme, the wire length information and the speed information are acquired, a deformation index is obtained based on a preset deformation calculation relationship, and the guide wheel position is dynamically adjusted, and specifically includes: The deformation prediction model and the target deformation index are determined according to the material type of the wire property. The wire length information and the speed information are input into the deformation prediction model to obtain the deformation index. The position adjustment amount is obtained based on a preset PID control algorithm according to the deviation between the deformation index and the target deformation index. The guide wheel spatial coordinates are adjusted according to the current position of the guide wheel and the position adjustment amount.

[0011] In the scheme, the winding layer number information is acquired, and the winding motor speed is adjusted based on a preset speed mapping curve, and specifically includes: The winding layer number information is detected by a preset photoelectric sensor or encoder. The target speed information is obtained by calling a preset speed mapping curve according to the layer number information. The current speed information is acquired. If the difference between the target speed information and the current speed information exceeds a preset speed change threshold, a smoothing filtering algorithm is triggered to adjust the target speed. The winding motor speed is adjusted according to the adjusted target speed.

[0012] The second aspect of the present application provides an adaptive winding system of a CODESYS-based intelligent winding machine, which comprises an adaptive winding method program of a CODESYS-based intelligent winding machine. The first geometric path information is obtained based on a preset extraction function in response to the imported graphic file. based on the first geometric path information, dynamically generating path compensation information for updating the first geometric path information; in response to the imported wire attribute, combining the updated first geometric path information, and based on a preset planning function, obtaining motion parameter information; when performing the winding operation; obtaining tension information, and if the tension information is lower than a preset tension threshold, increasing the drag motor current; obtaining wire length information and speed information, and based on a preset deformation calculation relationship, obtaining a deformation index for dynamically adjusting the guide wheel position; obtaining winding layer information, and based on a preset speed mapping curve, adjusting the winding motor speed; mapping the winding trajectory and displaying the motion parameter information through a preset visualization platform.

[0013] In the scheme, based on the first geometric path information, the path compensation information is dynamically generated for updating the first geometric path information, and specifically includes: searching a historical winding path database, calculating the difference between the second geometric path information corresponding to the same naming as the graphic file and the first geometric path information, and obtaining first path deviation information; searching the historical winding path database, extracting the deviation between the analysis path and the ideal path corresponding to a preset number of historical graphic files, and obtaining second path deviation information; determining whether the first path deviation information is lower than a preset first path deviation threshold; if yes, generating a correction coefficient according to the first path deviation information; if no, generating a compensation coefficient according to the second path deviation information; inputting the correction coefficient or the compensation coefficient into the extraction function to obtain reconstructed path information for updating the first geometric path information.

[0014] In the scheme, in response to the imported wire attribute, combining the updated first geometric path information, and based on a preset planning function, obtaining motion parameter information, specifically includes: based on a preset key path matching strategy, according to the first geometric path information, obtaining three-point coordinates of a key sub-path, including a starting point coordinate, an intermediate point coordinate and an end point coordinate; according to the material type of the wire attribute, combining the three-point coordinates, obtaining a starting angle and a transition angle; based on the tension coefficient and the diameter of the wire attribute, combining the three-point coordinates, obtaining a deformation compensation offset of the arc path; The first geometric path information, the start angle, the transition angle and the deformation compensation offset are input into a preset planning function to obtain a motion parameter set with deformation compensation.

[0015] The third aspect of the present application provides a computer readable storage medium, wherein the computer readable storage medium comprises a CODESYS-based adaptive winding method program of an intelligent winding machine, and the CODESYS-based adaptive winding method program of the intelligent winding machine is executed by a processor to implement the steps of the adaptive winding method of the CODESYS-based intelligent winding machine according to any one of the above aspects.

[0016] The present application provides a CODESYS-based adaptive winding method, system and medium of an intelligent winding machine, first, a geometric path is obtained by analyzing a graphic file according to a preset extraction function, and the geometric path is dynamically compensated by a winding deviation model to realize intelligent reconstruction of the geometric path; second, the circular arc parameters with deformation compensation and the layered speed regulation strategy are dynamically calculated by combining the wire properties with the coordinates of the key segments of the geometric path to eliminate the process parameter jump risk; third, the current of the dragging motor is adjusted in real time based on the tension feedback, the deformation trend is predicted based on the wire length and speed, the spatial position of the guide wheel is dynamically adjusted, and the speed is adaptively adjusted based on the winding layer number; and finally, the winding trajectory and the actual winding trajectory are mapped by the 3D mapping theory of the visualization platform, the trajectory deviation and the key operation parameters are displayed, so that the automation degree of the winding machine operation is improved and the stability and efficiency of the winding process are improved. BRIEF DESCRIPTION OF DRAWINGS

[0017] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following will briefly introduce the drawings needed to be used in the embodiments. It should be understood that the following drawings only show some embodiments of the present application, and therefore should not be regarded as a limitation on the scope.

[0018] Figure 1 A flowchart of the adaptive winding method of the CODESYS-based intelligent winding machine is shown; Figure 2 A compensation operation flowchart of the geometric path information provided by the embodiment of the present application is shown; Figure 3 A flowchart of generating motion parameter information provided by the embodiment of the present application is shown; Figure 4 A block diagram of the adaptive winding system of the CODESYS-based intelligent winding machine is shown. DETAILED DESCRIPTION

[0019] With reference to the accompanying drawings, the technical solutions in the embodiments of the present application will be clearly and completely described below, obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. 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 protection of the present application.

[0020] Unless otherwise defined, all terms (including technical and scientific terms) used in the embodiments of the present application have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined in the embodiments of the present application.

[0021] The terms "first", "second", and similar terms used in the embodiments of the present application do not denote any order, quantity, or importance, but are only used to distinguish different constituent parts. The terms "one", "a", or "the" and similar terms do not denote a quantity restriction, but mean that at least one exists. Similarly, the terms "include" or "contain" and similar terms mean that the elements or objects before the terms encompass the elements or objects listed after the terms and their equivalents, and do not exclude other elements or objects. The terms "connect" or "connected" and similar terms are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. The steps before or after the method of the embodiments of the present application do not necessarily proceed in order. On the contrary, various steps can be processed in reverse order or simultaneously. Meanwhile, other operations can be added to these processes, or a step or several steps can be removed from these processes.

[0022] In addition, the functional modules in each embodiment of the present application can be integrated together to form an independent part, or each module can exist independently, or two or more modules can be integrated to form an independent part.

[0023] Figure 1 A flowchart of an adaptive winding method of an intelligent winding machine based on CODESYS is shown.

[0024] As Figure 1 shown, the first aspect of the present application discloses an adaptive winding method of an intelligent winding machine based on CODESYS, the method comprising: S102, in response to the imported graphical file, obtaining first geometric path information based on a preset extraction function; S104, based on the preset winding deviation model, dynamically generating path compensation information according to the first geometric path information, for updating the first geometric path information; S106, in response to the imported wire attribute, combining the updated first geometric path information, based on the preset planning function, obtaining motion parameter information; S108, when performing the winding operation; S110, obtaining tension information, if the tension information is lower than a preset tension threshold, increasing the drag motor current; S112, obtaining wire length information and speed information, obtaining a deformation index based on a preset deformation calculation relationship, for dynamically adjusting the guide wheel position; S114, obtaining winding layer information, adjusting the winding motor speed based on a preset speed mapping curve; S116, mapping the winding trajectory and displaying the motion parameter information through a preset visualization platform 3D.

[0025] It should be noted that the first geometric path information is a winding running path derived from a graphic file; the path compensation information is a path correction value for improving the continuity and running stability of the first geometric path information; the motion parameter information is used to configure the running logic of the winding controller. The tension information is the tension received by the wire during winding; the wire length information is the length of the winding; the speed information is the speed of the winding; the winding layer number is the number of winding layers. The extraction function is a path extraction interface of the CODESYS platform; the planning function is a wire trajectory planning interface of the CODESYS platform.

[0026] In the embodiment, after receiving the DXF graphic file uploaded by the user, the winding path is parsed by calling the geometry extraction function of the CODESYS package, the typical path deviation mode in the historical winding database is compared in real time through the deviation model, including but not limited to U-shaped bending rate mutation, breakpoint repair and the like, the position compensation parameter is generated to reconstruct the geometric path. Subsequently, combined with the material type, wire diameter and tension coefficient and the like, the motion parameters are dynamically calculated through the planning function, including the circular arc angle of the injection deformation compensation and the layering speed strategy, so that the parameters for running the winding controller are obtained. Then, in the winding execution stage, the adaptive running parameter adjustment logic is run. The tension sensor is used to monitor the tension value of the wire in real time, and if it is lower than the material safety threshold, it indicates that the wire grabbing is unstable, and there is a risk of wire sliding down, so the current of the dragging motor is gradually increased to the stable interval. Through real-time calculation of the released wire length and real-time speed prediction of the deformation trend, based on the deviation of the deformation index and the target deformation index, the guide wheel position offset is dynamically adjusted based on the PID feedback control algorithm to offset the deformation risk. The number of winding layers is detected by the photoelectric sensor or the encoder, and the winding speed is automatically switched based on the speed mapping curve, wherein the inner layer adopts low speed to prevent pressure injury, and the outer layer adopts high speed to improve efficiency. The whole winding process is displayed by the visualization platform in a 3D mapping mode, and the actual trajectory and the superimposed theoretical trajectory are displayed synchronously. The real-time motion parameters of the winding controller are displayed synchronously. The embodiment realizes automatic parsing and path correction of the DXF graphic file, eliminates the manual correction link, solves the problem of improving the yield rate through the adaptive closed-loop control mechanism, and improves the automation degree of the winding machine and the stability and efficiency of the winding process.

[0027] Figure 2 A compensation operation flowchart of geometric path information provided by the embodiment of the application is shown.

[0028] According to the embodiment of the application, as Figure 2 shown, the path compensation information is dynamically generated based on the preset winding deviation model and the first geometric path information, and is used to update the first geometric path information, and specifically includes: S202, searching the historical winding path database, calculating the difference between the second geometric path information corresponding to the graphic file with the same name and the first geometric path information, and obtaining the first path deviation information; S204, searching the historical winding path database, extracting the deviation between the parsed path and the ideal path corresponding to a preset number of historical graphic files, and obtaining the second path deviation information; S206, judging whether the first path deviation information is lower than a preset first path deviation threshold; S208, if yes, generating a correction coefficient according to the first path deviation information; S210, if no, generating a compensation coefficient according to the second path deviation information; S212, input the correction coefficient or the compensation coefficient into the extraction function to obtain reconstructed path information, which is used to update the first geometric path information.

[0029] It should be noted that the second geometric path information is the compensation corrected running path of the same named graphic file in the historical record. In the embodiment, by searching the DXF file with the same name as the graphic file imported by the user in the historical database, the compensation corrected running path of the DXF file in the wire winding process, that is, the second geometric path information, is extracted. The coordinate displacement deviation of the first geometric path information and the second geometric path information is calculated and recorded as the first path deviation information. The deviation between the path parsed from the DXF graphic file of the historical database and the theoretical path is recorded as the second path deviation information, which is used to represent the deviation of the device itself. If the first path deviation information is lower than the preset first path deviation threshold, it indicates that the same DXF file is used as the reference, and the correction coefficient is determined based on the first path deviation information to locally optimize the coordinates of the line segment connection points. If the first path deviation information is not lower than the preset first path deviation threshold, it indicates that the reference of the second geometric path information is low, and the compensation coefficient is generated based on the second path deviation information as a global compensation parameter. The correction parameter or the compensation parameter is injected into the SMC_GEOINFO function to reconstruct the continuous path, which is used to update the first geometric path information. The compensation mechanism driven by the historical data in the embodiment improves the accuracy of path parsing, and in addition, the same file priority matching strategy also shortens the time consumption of path parsing.

[0030] Figure 3 A flowchart of generating motion parameter information is shown.

[0031] According to the embodiment of the present application, as Figure 3 shown, the motion parameter information is obtained based on a preset planning function in combination with the updated first geometric path information in response to the imported wire attribute, and specifically includes: S302, based on a preset key path matching strategy, three-point coordinates of a key sub-path are obtained according to the first geometric path information, including a starting point coordinate, an intermediate point coordinate and a terminal point coordinate; S304, a starting angle and a transition angle are obtained in combination with the three-point coordinates according to the material type of the wire attribute; S306, a deformation compensation offset of a circular arc path is obtained in combination with the three-point coordinates according to the tension coefficient and the diameter of the wire attribute; S308, the first geometric path information, the starting angle, the transition angle and the deformation compensation offset are input into a preset planning function to obtain a motion parameter set with deformation compensation.

[0032] It should be noted that in the present embodiment, based on the preset key path matching strategy, the key three-point coordinates of the key sub-paths are obtained, including the starting point coordinates, the intermediate point coordinates and the end point coordinates. In actual application, the key path is usually a U-shaped bending path. According to the elastic modulus selection angle calculation model of the wire material, the starting angle and the transition angle of the circular arc are dynamically output; as an implementation, the linear interpolation is used for hard materials, and the nonlinear fitting is used for soft materials. In combination with the wire diameter and the tension coefficient, the deformation variable is predicted, and the reverse compensation offset is injected at the path interpolation point to offset the insufficient or excessive winding caused by deformation. The motion planning function is called to integrate the path coordinates, the compensation angle and the offset, and a speed control curve with buffer acceleration is generated. The speed control curve, the path coordinates and other winding control data are combined into a motion parameter set and input to the winding controller. The present embodiment solves the forming difference between hard wire and soft wire based on the material adaptive angle calculation, and the deformation compensation mechanism improves the winding accuracy of the circular arc segment.

[0033] According to the embodiment of the present application, the tension information is obtained, and if the tension information is lower than a preset tension threshold, the drag motor current is increased, specifically including: The tension information is measured based on a preset tension sensor; Based on a preset analog-digital conversion and tension value mapping relationship, a first tension value is obtained according to the tension information; The tension threshold is determined according to the tension coefficient of the wire property; If the tension value is lower than the tension threshold, the drag motor current is increased according to a preset current step.

[0034] It should be noted that the present embodiment provides an adaptive tension adjustment mechanism. The tension sensor collects wire tension analog signals in real time, which are converted into digital quantities by a signal conditioning module; then based on the current tension value and the material preset safety threshold. If the sampling value is lower than the threshold for 3 consecutive times, a current increasing instruction is generated. The drag motor current is increased by a basic step for the first time, and the tension response curve is monitored. If it does not reach the safety interval within the preset time, the current is continuously increased with an incremental step. At the same time, the current-tension mapping relationship is recorded after each adjustment, the current value is locked when the tension is stable in the target interval, and the mapping relationship is stored in the material characteristic library for subsequent calling of similar wires. The tension change trend chart is drawn in real time during the adjustment process, and if the fluctuation is out of limit, an emergency pause is triggered. The present embodiment uses step-by-step current adjustment to avoid overshoot and wire breakage.

[0035] According to the embodiment of the present application, the wire length information and the speed information are obtained, and a deformation index is obtained based on a preset deformation calculation relationship, which is used to dynamically adjust the guide wheel position, specifically including: The deformation prediction model and the target deformation index are determined according to the material type of the wire property; input the wire length information and the speed information into the deformation prediction model to obtain a deformation index; obtain a position adjustment amount based on a preset PID control algorithm according to a deviation between the deformation index and the target deformation index; adjust a guide wheel spatial coordinate according to a current position of the guide wheel and the position adjustment amount.

[0036] It should be noted that the embodiment provides a self-adaptive guide wheel feedback adjustment mechanism. The encoder feeds back the wire release length in real time, and the wire winding length is calculated in unit time through the wire winding speed information. According to the material elastic characteristics, the prediction model is automatically matched, and the deformation index is calculated based on the ratio of the wire release length and the wire winding length. Then, according to the deviation between the deformation index and the target deformation index, the position adjustment amount of the guide wheel is calculated based on the PID controller to drive the spatial position of the guide wheel. The embodiment determines the wire deformation index calculation model and the target deformation index based on the wire material, and dynamically adjusts the consistency of the wire deformation index in the winding process through the PID.

[0037] According to the embodiment of the application, the winding layer number information is obtained, and the winding motor speed is adjusted based on a preset speed mapping curve, specifically including: The winding layer number information is detected through a preset photoelectric sensor or encoder; According to the layer number information, the target speed information is obtained by calling a preset speed mapping curve; The current speed information is obtained; If the difference between the target speed information and the current speed information exceeds a preset speed change threshold, a smoothing filter algorithm is triggered to adjust the target speed; The winding motor speed is adjusted according to the adjusted target speed.

[0038] It should be noted that the winding layer number change is detected based on a preset sensor, and as an implementation manner, the photoelectric sensor emits a grating to detect a group of pulse signals after completing a layer of winding, so as to determine the winding layer number. Based on the preset speed mapping curve, the winding speed is matched according to the winding layer number, wherein the anti-pressure injury low-speed curve is called in the low layer interval, the uniform speed stable curve is switched in the middle layer interval, and the high-efficiency speed-up curve is enabled in the high layer interval. In addition, before the speed adjustment, the speed change rate is calculated in real time, and if it exceeds the motor stable running threshold, the S-shaped smoothing algorithm is activated to re-plan the acceleration and deceleration slope. The embodiment ensures the winding quality through the layer-number-speed linkage strategy, and improves the efficiency; the smoothing acceleration and deceleration algorithm is adopted to eliminate the layer change jitter.

[0039] It is worth mentioning that it also includes: The coordinate feedback data of the motion controller is collected in real time; The theoretical path is drawn according to the motion parameter information; drawing an actual path according to the coordinate feedback data; performing a segmented comparison between the actual path and the theoretical path, and if the obtained path deviation exceeds a preset second path deviation threshold, displaying the segment of the actual path by a highlight color.

[0040] It should be noted that the motion controller coordinate data stream is collected in real time through an industrial communication protocol and transmitted to the Unity3D rendering engine. As an implementation, on the visualization window, the theoretical path model is drawn using a white dashed line and the actual motion trajectory is drawn using a blue solid line, and the two sets of path lines are spatially superimposed. The Euclidean distance deviation value is calculated in segments, and the deviation exceeding limit segment is highlighted with a red translucent cube, and the deviation value is displayed in suspension. In addition, on the monitoring panel of the visualization window, the data stream is dynamically refreshed, including but not limited to the tension waveform diagram, the speed ladder diagram, and the circular arc parameter table. Through the visualization window, rapid fault location is assisted, and the diagnosis efficiency is improved.

[0041] It is worth mentioning that it also includes: recording the first geometric path, the wire attribute, the motion parameter information, and the running result index of a single winding, and the running result index includes the good product rate, the single time consumption, and the path correction times; obtaining a process score based on a preset scoring system according to the good product rate, the single time consumption, and the path correction times; if the process score exceeds a preset score threshold, generating an optimization suggestion rule library based on the first geometric path, the wire attribute, and the motion parameter information; when the same first geometric path and wire attribute are detected, using the corresponding motion parameter information as the running recommended value.

[0042] It should be noted that the system automatically archives four types of data of a single winding, including the geometric path, the wire attribute, the motion control instruction set, and the quality index, wherein the quality index includes the good product rate, the time consumption, and the correction times of the control instruction. The quality score engine calculates the process total score according to the preset weight, extracts the key feature combination of the case with an excellent score, for example, the U-shaped path of 1.0 mm enameled wire, and binds the feature combination with the optimal motion parameter to generate an optimization rule and store it in the cloud rule library. When the same path and wire combination are detected again, the recommended parameter identifier is automatically output. This embodiment adopts a historical optimal parameter reuse mechanism to reduce the debugging time consumption; in addition, the rule library self-iterates to improve the system adaptability.

[0043] Figure 4 A block diagram of an adaptive winding system of an intelligent winding machine based on CODESYS is shown.

[0044] As Figure 4As shown, the second aspect of the present application discloses an adaptive winding system 4 of a CODESYS-based intelligent winding machine, comprising a memory 41 and a processor 42, wherein the memory comprises an adaptive winding method program of a CODESYS-based intelligent winding machine, and the adaptive winding method program of the CODESYS-based intelligent winding machine is executed by the processor to implement the following steps: In response to the imported graphical file, first geometric path information is obtained based on a preset extraction function; Based on a preset winding deviation model, path compensation information is dynamically generated according to the first geometric path information, for updating the first geometric path information; In response to the imported wire attribute, combined with the updated first geometric path information, motion parameter information is obtained based on a preset planning function; When performing a winding operation; Tension information is obtained, and if the tension information is lower than a preset tension threshold, the drag motor current is increased; Length information and speed information of the wire are obtained, a deformation index is obtained based on a preset deformation calculation relationship, for dynamically adjusting the position of the guide wheel; Layer information of the winding is obtained, and the speed of the winding motor is adjusted based on a preset speed mapping curve; The winding trajectory is 3D mapped through a preset visualization platform, and the motion parameter information is displayed.

[0045] It should be noted that the first geometric path information is a winding running path derived from a graphical file; the path compensation information is a path correction value for improving the continuity and running stability of the first geometric path information; the motion parameter information is a running logic for configuring a winding controller. The tension information is the tension received by the wire during winding; the length information is the length of the winding; the speed information is the speed of the winding; the number of winding layers is the number of layers of the winding stack. The extraction function is a path extraction interface of the CODESYS platform; the planning function is a wire trajectory planning interface of the CODESYS platform.

[0046] In the embodiment, after receiving the DXF graphic file uploaded by the user, the winding path is parsed by calling the geometry extraction function of the CODESYS package, the typical path deviation mode in the historical winding database is compared in real time through the deviation model, including but not limited to U-shaped bending rate mutation, breakpoint repair, etc., and the position compensation parameter is used to reconstruct the geometric path. Subsequently, combined with the material type, wire diameter and tension coefficient and other wire properties, the motion parameters are dynamically calculated through the planning function, including the injection of deformation compensation arc angle and layering speed strategy, so as to obtain the parameters for configuring the winding controller to run. Then, in the winding execution stage, the adaptive running parameter adjustment logic is run. The tension sensor is used to monitor the tension value of the wire in real time, and if it is lower than the material safety threshold, it indicates that the wire grabbing is unstable, and there is a risk of wire sliding down, so the drag motor current is gradually increased to the stable interval. By real-time calculation of the released wire length and real-time speed prediction of the deformation trend, based on the deviation of the deformation index and the target deformation index, the guide wheel position offset is dynamically adjusted based on the PID feedback control algorithm to offset the deformation risk. The number of winding layers is detected by the photoelectric sensor or the encoder, and the winding speed is automatically switched based on the speed mapping curve, wherein the inner layer adopts low speed to prevent pressure injury, and the outer layer adopts high speed to improve efficiency. The whole winding process is displayed by the visualization platform in the form of 3D mapping, and the actual trajectory and the superimposed theoretical trajectory are displayed synchronously. The real-time motion parameters of the winding controller are displayed synchronously. The embodiment realizes automatic parsing and path correction of the DXF graphic file, eliminates the manual correction link, solves the problem of improving the yield rate through the adaptive closed-loop control mechanism, and improves the automation degree of the winding machine and the stability and efficiency of the winding process.

[0047] According to the embodiment of the application, the preset winding deviation model is used to dynamically generate path compensation information according to the first geometric path information, and the first geometric path information is updated, specifically including: The historical winding path database is searched, the difference between the second geometric path information corresponding to the graphic file with the same name and the first geometric path information is calculated, and the first path deviation information is obtained; The historical winding path database is searched, the deviation between the parsed path and the ideal path corresponding to a preset number of historical graphic files is extracted, and the second path deviation information is obtained; It is judged whether the first path deviation information is lower than a preset first path deviation threshold; If yes, a correction coefficient is generated according to the first path deviation information; If no, a compensation coefficient is generated according to the second path deviation information; The correction coefficient or the compensation coefficient is input into the extraction function, and the reconstructed path information is obtained, which is used to update the first geometric path information.

[0048] It should be noted that the second geometric path information is the compensation and correction running path of the same named graphic file in the historical record. In the embodiment, by searching the DXF file with the same name as the imported graphic file in the historical database, the compensation and correction running path of the DXF file in the wire drawing process is extracted, that is, the second geometric path information. The coordinate displacement deviation of the first geometric path information and the second geometric path information is calculated, which is recorded as the first path deviation information. The deviation between the path parsed from the DXF graphic file of the historical database and the theoretical path is recorded as the second path deviation information, which is used to represent the deviation of the equipment itself. If the first path deviation information is lower than the preset first path deviation threshold, it indicates that the same DXF file is used as the reference, and the correction coefficient is determined based on the first path deviation information to locally optimize the coordinates of the line segment connection points. If the first path deviation information is not lower than the preset first path deviation threshold, it indicates that the reference of the second geometric path information is low, and the compensation coefficient is generated based on the second path deviation information as a global compensation parameter. The correction parameter or the compensation parameter is injected into the SMC_GEOINFO function to reconstruct the continuous path, so as to update the first geometric path information. The compensation mechanism driven by the historical data in the embodiment improves the accuracy of path parsing, and in addition, the same file priority matching strategy also shortens the path parsing time.

[0049] According to the embodiment of the application, the motion parameter information is obtained based on the preset planning function in response to the imported wire attribute and in combination with the updated first geometric path information, and specifically includes: Based on the preset key path matching strategy, three-point coordinates of a key sub-path are obtained according to the first geometric path information, including a starting point coordinate, an intermediate point coordinate and an end point coordinate; According to the material type of the wire attribute, the starting angle and the transition angle are obtained in combination with the three-point coordinates; According to the tension coefficient and the diameter of the wire attribute, the deformation compensation offset of the arc path is obtained in combination with the three-point coordinates; The first geometric path information, the starting angle, the transition angle and the deformation compensation offset are input into the preset planning function to obtain a motion parameter set with deformation compensation.

[0050] It should be noted that in the present embodiment, based on the preset key path matching strategy, the key three-point coordinates of the key sub-paths are obtained, including the starting point coordinates, the intermediate point coordinates and the end point coordinates. In actual application, the key path is usually a U-shaped bending path. According to the elastic modulus selection angle calculation model of the wire material, the starting angle and the transition angle of the circular arc are dynamically output; as an implementation, the linear interpolation is used for hard materials, and the nonlinear fitting is used for soft materials. In combination with the wire diameter and the tension coefficient, the deformation variable is predicted, and the reverse compensation offset is injected at the path interpolation point to offset the insufficient or excessive winding caused by deformation. The motion planning function is called to integrate the path coordinates, the compensation angle and the offset, and a speed control curve with buffer acceleration is generated. The speed control curve, the path coordinates and other winding control data are combined into a motion parameter set and input to the winding controller. The present embodiment solves the forming difference between hard wire and soft wire based on the material adaptive angle calculation, and the deformation compensation mechanism improves the winding accuracy of the circular arc segment.

[0051] According to the embodiment of the present application, the tension information is obtained, and if the tension information is lower than a preset tension threshold, the drag motor current is increased, specifically including: The tension information is measured based on a preset tension sensor; Based on a preset analog-digital conversion and tension value mapping relationship, a first tension value is obtained according to the tension information; The tension threshold is determined according to the tension coefficient of the wire property; If the tension value is lower than the tension threshold, the drag motor current is increased according to a preset current step.

[0052] It should be noted that the present embodiment provides an adaptive tension adjustment mechanism. The tension sensor collects the wire tension analog signal in real time, which is converted into digital quantity by the signal conditioning module; and then based on the current tension value and the material preset safety threshold. If the sampling value is lower than the threshold for three times in succession, a current increasing instruction is generated. The drag motor current is increased by a basic step for the first time, and the tension response curve is monitored. If the safety interval is not reached within the preset time, the current is continuously increased with an incremental step. At the same time, the current-tension mapping relationship is recorded after each adjustment, the current value is locked when the tension is stable in the target interval, and the mapping relationship is stored in the material characteristic library for subsequent calling of similar wires. The tension change trend graph is drawn in real time during the adjustment process, and if the fluctuation is out of limit, an emergency pause is triggered. The present embodiment adopts step-by-step current adjustment to avoid overshoot and wire breakage.

[0053] According to the embodiment of the present application, the wire length information and the speed information are obtained, and a deformation index is obtained based on a preset deformation calculation relationship, which is used to dynamically adjust the guide wheel position, specifically including: The deformation prediction model and the target deformation index are determined according to the material type of the wire property; input the wire length information and the speed information into the deformation prediction model to obtain a deformation index; obtain a position adjustment amount based on a preset PID control algorithm according to a deviation between the deformation index and the target deformation index; adjust a guide wheel spatial coordinate according to a current position of the guide wheel and the position adjustment amount.

[0054] It should be noted that the embodiment provides a self-adaptive guide wheel feedback adjustment mechanism. The encoder feeds back the wire release length in real time, and the wire winding length is calculated in unit time through the wire winding speed information. The deformation index is calculated based on the ratio of the wire release length and the wire winding length according to the automatic matching of the prediction model based on the material elastic characteristics. Then, the position adjustment amount of the guide wheel is calculated based on the PID controller according to the deviation between the deformation index and the target deformation index, so as to drive the spatial position of the guide wheel. The embodiment determines the wire deformation index calculation model and the target deformation index based on the wire material, and dynamically adjusts the consistency of the wire deformation index in the winding process through the PID.

[0055] According to the embodiment of the application, the winding layer number information is obtained, and the winding motor speed is adjusted based on a preset speed mapping curve, specifically including: The winding layer number information is detected through a preset photoelectric sensor or encoder; The target speed information is obtained by calling a preset speed mapping curve according to the layer number information; The current speed information is obtained; If the difference between the target speed information and the current speed information exceeds a preset speed change threshold, a smoothing filter algorithm is triggered to adjust the target speed; The winding motor speed is adjusted according to the adjusted target speed.

[0056] It should be noted that the winding layer number change is detected based on a preset sensor, and as an implementation manner, the photoelectric sensor emits a grating to detect, and a group of pulse signals is received after each layer of winding is completed, so that the winding layer number is determined. The winding speed is matched according to the winding layer number based on a preset speed mapping curve, wherein a low-speed curve for preventing pressure injury is called in a low layer interval, a uniform speed stable curve is switched in a middle layer interval, and a high-efficiency speed-up curve is enabled in a high layer interval. In addition, before the speed adjustment, the speed change rate is calculated in real time, and if the speed change rate exceeds a motor stable running threshold, an S-shaped smoothing algorithm is activated to re-plan the acceleration and deceleration slope. The embodiment ensures the winding quality through the layer number-speed linkage strategy, and improves the efficiency; and the smoothing acceleration and deceleration algorithm is adopted to eliminate the layer change jitter.

[0057] It is worth mentioning that it also includes: The coordinate feedback data of the motion controller is collected in real time; The theoretical path is drawn according to the motion parameter information; drawing an actual path according to the coordinate feedback data; performing a segmented comparison between the actual path and the theoretical path, and if a path deviation obtained exceeds a preset second path deviation threshold, displaying the segment of the actual path by a highlight color.

[0058] It should be noted that the motion controller coordinate data stream is collected in real time through an industrial communication protocol and transmitted to a Unity3D rendering engine. As an implementation, on the visualization window, a theoretical path model is drawn using a white dashed line and an actual motion trajectory is drawn using a blue solid line, and the two sets of path lines are spatially superimposed. The Euclidean distance deviation value is calculated in segments, and the deviation exceeding limit segment is highlighted by a red translucent cube, and the deviation value is displayed in suspension. In addition, on the monitoring panel of the visualization window, the data stream is dynamically refreshed, including but not limited to a tension waveform diagram, a speed ladder diagram, and a circular arc parameter table. Through the visualization window, rapid fault location is assisted, and diagnostic efficiency is improved.

[0059] It is worth mentioning that it also includes: recording a first geometric path, wire properties, motion parameter information, and running result indicators of a single winding, the running result indicators including a good product rate, a single time consumption, and a path correction number; obtaining a process score based on a preset scoring system according to the good product rate, the single time consumption, and the path correction number; if the process score exceeds a preset score threshold, generating an optimization suggestion rule library based on the first geometric path, the wire properties, and the motion parameter information; when the same first geometric path and wire properties are detected, using corresponding motion parameter information as a running recommended value.

[0060] It should be noted that the system automatically archives four types of data of a single winding, including a geometric path, wire properties, a motion control instruction set, and a quality indicator, wherein the quality indicator includes a good product rate, a time consumption, and a correction number of control instructions. A quality score engine calculates a process total score according to a preset weight, extracts key feature combinations of cases with excellent scores, for example, a U-shaped path of 1.0 mm enameled wire, and binds the feature combinations with optimal motion parameters to generate optimization rules and store them in a cloud rule library. When the same path and wire combination are detected again, a recommended parameter identifier is automatically output. This embodiment uses a historical optimal parameter reuse mechanism to reduce debugging time consumption; in addition, the rule library is self-iteratively improved to improve system adaptability.

[0061] The third aspect of the present application provides a computer readable storage medium, the computer readable storage medium comprises a CODESYS-based adaptive winding method program of an intelligent winding machine, and the CODESYS-based adaptive winding method program of the intelligent winding machine is executed by a processor to implement the steps of the adaptive winding method of the CODESYS-based intelligent winding machine according to any one of the preceding aspects.

[0062] To sum up, the present application provides a CODESYS-based adaptive winding method, system and medium of an intelligent winding machine, first, the geometric path is obtained by analyzing the graphic file according to the preset extraction function, and the geometric path is dynamically compensated by a winding deviation model to realize intelligent reconstruction of the geometric path; second, the circular arc parameters with deformation compensation and the layered speed regulation strategy are dynamically calculated by combining the wire properties with the coordinates of the key sections of the geometric path, so as to eliminate the process parameter jump risk; third, the current of the dragging motor is adjusted in real time based on the tension feedback, the deformation trend is predicted based on the wire length and speed, the spatial position of the guide wheel is dynamically adjusted, and the speed is adaptively regulated based on the winding layer number; finally, the winding trajectory and the actual winding trajectory are mapped by the 3D mapping theory of the visualization platform, and the trajectory deviation and the key operating parameters are displayed; thereby improving the automation degree of the winding machine operation and improving the stability and efficiency of the winding process.

[0063] If the functions are realized in the form of software function modules and sold or used as independent products, they can be stored in a computer readable storage medium. Based on this understanding, the technical solutions of the present application or parts of the present application that essentially contribute to the prior art or parts of the technical solutions can be embodied in the form of software products, which are stored in a storage medium and include a plurality of instructions for causing a computer device (which can be a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present application. The aforementioned storage medium includes a U disk, a mobile hard disk, a read-only memory (ROM, Read-Only Memory), a random access memory (RAM, Random Access Memory), a magnetic disk or an optical disk, and various program code storage media.

[0064] The above only describes the preferred embodiments of the present application and is not intended to limit the present application. For those skilled in the art, the present application can have various modifications and changes. Any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. An adaptive winding method of a CODESYS-based intelligent winding machine, characterized in that, The method comprises: in response to the imported graphical file, obtaining first geometric path information based on a preset extraction function; based on a preset winding deviation model, dynamically generating path compensation information according to the first geometric path information, for updating the first geometric path information; in response to the imported wire attribute, combining the updated first geometric path information, and based on a preset planning function, obtaining motion parameter information; when performing the winding operation; obtaining tension information, and if the tension information is lower than a preset tension threshold, increasing the drag motor current; obtaining wire length information and speed information, obtaining a deformation index according to a preset deformation calculation relationship, for dynamically adjusting the guide wheel position; obtaining winding layer information, and adjusting the winding motor speed according to a preset speed mapping curve; mapping the winding trajectory and displaying the motion parameter information through a preset visualization platform 3D.

2. The self-adaptive winding method of the CODESYS-based intelligent winding machine according to claim 1, wherein, The method comprises: finding a historical winding path database, calculating the difference between the second geometric path information corresponding to the same naming as the graphical file and the first geometric path information, to obtain first path deviation information; finding a historical winding path database, extracting the deviation between the analysis path and the ideal path corresponding to a preset number of historical graphical files, to obtain second path deviation information; determining whether the first path deviation information is lower than a preset first path deviation threshold; if yes, generating a correction coefficient according to the first path deviation information; if no, generating a compensation coefficient according to the second path deviation information; inputting the correction coefficient or the compensation coefficient into the extraction function to obtain reconstructed path information for updating the first geometric path information.

3. The self-adaptive winding method of the CODESYS-based intelligent winding machine according to claim 1, wherein, The method comprises: based on a preset key path matching strategy, obtaining three-point coordinates of a key sub-path according to the first geometric path information, including a starting point coordinate, an intermediate point coordinate, and an end point coordinate; obtaining a starting angle and a transition angle according to the material type of the wire attribute and the three-point coordinates; obtaining a deformation compensation offset of the circular path according to the tension coefficient and the diameter of the wire attribute and the three-point coordinates; inputting the first geometric path information, the starting angle, the transition angle, and the deformation compensation offset into a preset planning function to obtain a motion parameter set with deformation compensation.

4. The self-adaptive winding method of the CODESYS-based intelligent winding machine according to claim 1, wherein, The method comprises: based on a preset tension sensor to measure the tension information; based on a preset analog-digital conversion and tension value mapping relationship, obtaining a first tension value according to the tension information; determining the tension threshold according to the tension coefficient of the wire attribute; if the tension value is lower than the tension threshold, increasing the drag motor current according to a preset current step.

5. The self-adaptive winding method of the CODESYS-based intelligent winding machine according to claim 1, wherein, The method comprises: According to the material type of the wire attribute, a deformation prediction model and a target deformation index are determined; The wire length information and the speed information are input into the deformation prediction model to obtain a deformation index; According to the deviation of the deformation index and the target deformation index, a position adjustment amount is obtained based on a preset PID control algorithm; According to the current position of the guide wheel and the position adjustment amount, the space coordinates of the guide wheel are adjusted.

6. The self-adaptive winding method of the CODESYS-based intelligent winding machine according to claim 1, wherein, The wire winding layer information is obtained, and the wire winding motor speed is adjusted based on a preset speed mapping curve, specifically including: The wire winding layer information is detected by a preset photoelectric sensor or encoder; According to the layer information, a target speed information is obtained by calling a preset speed mapping curve; Current speed information is obtained; If the difference between the target speed information and the current speed information exceeds a preset speed change threshold, a smoothing filtering algorithm is triggered to adjust the target speed; The wire winding motor speed is adjusted according to the adjusted target speed.

7. An adaptive winding system of a CODESYS-based intelligent winding machine, characterized in that, The system includes a memory and a processor, and the memory includes a CODESYS-based intelligent wire winding machine adaptive winding method program, which is executed by the processor to implement the following steps: In response to the imported graphical file, first geometric path information is obtained based on a preset extraction function; Based on a preset winding deviation model, path compensation information is dynamically generated according to the first geometric path information, which is used to update the first geometric path information; In response to the imported wire attribute, combined with the updated first geometric path information, motion parameter information is obtained based on a preset planning function; When performing the wire winding operation; Tension information is obtained, and if the tension information is lower than a preset tension threshold, the drag motor current is increased; Wire length information and speed information are obtained, and a deformation index is obtained according to a preset deformation calculation relationship, which is used to dynamically adjust the position of the guide wheel; The number of wire winding layers is obtained, and the wire winding motor speed is adjusted based on a preset speed mapping curve; The wire winding trajectory is mapped and the motion parameter information is displayed through a preset visualization platform 3D.

8. The adaptive winding system of an intelligent winding machine based on CODESYS according to claim 7, characterized in that, Based on the preset winding deviation model, path compensation information is dynamically generated according to the first geometric path information, which is used to update the first geometric path information, specifically including: The historical winding path database is searched, the difference between the second geometric path information corresponding to the same named graphical file and the first geometric path information is calculated, and the first path deviation information is obtained; The historical winding path database is searched, and the deviation between the analysis path and the ideal path corresponding to a preset number of historical graphical files is extracted to obtain second path deviation information; It is judged whether the first path deviation information is lower than a preset first path deviation threshold; If yes, a correction coefficient is generated according to the first path deviation information; If not, a compensation coefficient is generated according to the second path deviation information; The correction coefficient or the compensation coefficient is input into the extraction function to obtain reconstructed path information for updating the first geometric path information.

9. The self-adaptive winding system of an intelligent winding machine based on CODESYS according to claim 7, wherein, In response to the imported wire attribute, combined with the updated first geometric path information, motion parameter information is obtained based on a preset planning function, specifically including: According to the first geometric path information, three-point coordinates of a key sub-path are obtained, including a start point coordinate, an intermediate point coordinate, and an end point coordinate, based on a preset key path matching strategy; According to a material type of a wire attribute, a start angle and a transition angle are obtained in combination with the three-point coordinates; According to a tension coefficient and a diameter of the wire attribute, a deformation compensation offset of an arc path is obtained in combination with the three-point coordinates; The first geometric path information, the start angle, the transition angle, and the deformation compensation offset are input into a preset planning function to obtain a motion parameter set with deformation compensation.

10. A computer-readable storage medium having stored thereon a computer program, characterized in that, The computer readable storage medium comprises a CODESYS-based adaptive winding method program of an intelligent winding machine, and when the CODESYS-based adaptive winding method program of the intelligent winding machine is executed by a processor, the steps of the CODESYS-based adaptive winding method of the intelligent winding machine according to any one of claims 1 to 6 are implemented.

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