Adaptive winding method, system, and medium for a CODESYS-based intelligent winding machine

Abstract

The application provides a CODESYS-based self-adaptive winding method and system for an intelligent winding machine and a medium. First, a geometric path is obtained by analyzing a graphic file according to a preset extraction function, and the geometric path is dynamically compensated through a winding deviation model to realize intelligent reconstruction of the geometric path. Second, the coordinates of a key section of the geometric path and the properties of a wire are combined to dynamically calculate arc parameters with deformation compensation and a layered speed regulation strategy to eliminate process parameter jump risks. Then, the current of a dragging motor is adjusted in real time based on tension feedback, the deformation trend is predicted based on the length and speed of the wire, the spatial position of a 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 through a 3D mapping theory of a visualization platform, and the trajectory deviation and key operating 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.

Description

Technical Field

[0001] This invention relates to the field of winding machines, and more specifically, to an adaptive winding method, system, and medium for an intelligent winding machine based on CODESYS. Background Technology

[0002] In the field of industrial automation, winding technology is widely used in the manufacturing of equipment such as motors and transformers. Current mainstream solutions utilize the CODESYS platform based on the IEC 61131-3 standard. CODESYS is a development and programming system for industrial automation that supports multiple programming languages, such as ladder diagrams (LD), structured text diagrams (ST), function block diagrams (FB), and sequential function diagrams (SFC), and boasts excellent portability and compatibility. Furthermore, CODESYS provides a wealth of development tools and libraries for convenient programming and debugging.

[0003] However, existing CODESYS-based winding machines parse DXF graphic files and generate code paths using CNC function blocks. However, after importing the DXF graphic file, the winding machine system cannot accurately reproduce the design path, leading to frequent problems such as misaligned line segments and abrupt changes in arc curvature. These issues require manual verification and correction segment by segment, significantly increasing debugging time and costs. Furthermore, traditional CNC architectures require extensive manual judgment, relying on operator experience, making parameter debugging cumbersome and prone to errors. In addition, the lack of a coordinated control mechanism makes it difficult to balance winding quality and efficiency at a single winding speed.

[0004] Existing technologies are insufficient to meet the demands of high-precision winding, especially in precision manufacturing scenarios such as automotive motors, where the high cost of manual intervention and poor product consistency are becoming increasingly prominent. Therefore, there is an urgent need for an intelligent winding machine technology that can achieve automatic analysis, adaptive parameter generation, and multi-process collaborative control. Summary of the Invention

[0005] In view of the above problems, the purpose of this invention is to provide an adaptive winding method, system and medium for an intelligent winding machine based on CODESYS. It utilizes machine learning algorithms to assist path analysis and automatically corrects DXF graphic analysis deviations to reconstruct the winding path. Based on an adaptive parameter generation system, it dynamically calculates arc parameters and compensates for trajectory errors using material properties, eliminating the risk of process parameter jumps. Furthermore, it improves the yield of the winding process and ensures winding efficiency through closed-loop control of the locking force, conductor deformation prediction, and a multi-segment speed adaptive strategy.

[0006] The first aspect of this invention provides an adaptive winding method for an intelligent winding machine based on CODESYS, the method comprising:

[0007] In response to the imported graphics file, the first geometric path information is obtained based on a preset extraction function;

[0008] Based on the preset winding deviation model, path compensation information is dynamically generated according to the first geometric path information to update the first geometric path information;

[0009] In response to the imported wire properties, combined with the updated first geometric path information, motion parameter information is obtained based on a preset planning function;

[0010] When performing a winding operation;

[0011] Acquire tension information; if the tension information is lower than a preset tension threshold, increase the current of the drag motor.

[0012] The system acquires line length and speed information, and obtains the deformation index based on a preset deformation calculation formula, which is used to dynamically adjust the position of the guide wheel.

[0013] Obtain information on the number of winding layers and adjust the speed of the winding motor according to the preset speed mapping curve;

[0014] The system uses a pre-set visualization platform to 3D map the winding trajectory and display motion parameter information.

[0015] In this scheme, the step of dynamically generating path compensation information based on a preset winding deviation model and the first geometric path information to update the first geometric path information specifically includes:

[0016] Search the historical winding path database, calculate the difference between the second geometric path information corresponding to the same name as the graphic file and the first geometric path information, and obtain the first path deviation information;

[0017] Search the historical winding path database, extract the deviation between the parsed path and the ideal path corresponding to a preset number of historical graphic files, and obtain the second path deviation information;

[0018] Determine whether the first path deviation information is lower than a preset first path deviation threshold;

[0019] If so, then a correction coefficient is generated based on the first path deviation information;

[0020] If not, then a compensation coefficient is generated based on the second path deviation information;

[0021] The correction coefficient or the compensation coefficient is input into the extraction function to obtain the reconstructed path information, which is used to update the first geometric path information.

[0022] In this solution, the motion parameter information is obtained based on a preset planning function in response to the imported wire properties and the updated first geometric path information, specifically including:

[0023] Based on the preset critical path matching strategy, the coordinates of three points of the critical sub-path are obtained according to the first geometric path information, including the coordinates of the starting point, the coordinates of the intermediate point, and the coordinates of the ending point.

[0024] Based on the material type of the wire and the coordinates of the three points, the starting angle and the transition angle are obtained;

[0025] Based on the tension coefficient and diameter of the wire, combined with the coordinates of the three points, the deformation compensation offset of the arc path is obtained.

[0026] 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 set of motion parameters with deformation compensation.

[0027] In this solution, the acquisition of tension information, and if the tension information is lower than a preset tension threshold, the increase of the drag motor current, specifically includes:

[0028] Tension information is measured based on a preset tension sensor;

[0029] Based on the preset analog-to-digital conversion and tension value mapping relationship, the first tension value is obtained according to the tension information;

[0030] The tension threshold is determined based on the tension coefficient of the wire properties;

[0031] If the tension value is lower than the tension threshold, the drag motor current is increased according to the preset current step.

[0032] In this solution, the acquisition of line length and speed information, and the determination of the deformation index based on a preset deformation calculation formula for dynamically adjusting the guide wheel position, specifically includes:

[0033] Based on the material type of the wire, determine the deformation prediction model and the target deformation index;

[0034] The line length information and the velocity information are input into the deformation prediction model to obtain the deformation index;

[0035] Based on the deviation between the deformation index and the target deformation index, the position adjustment amount is obtained using a preset PID control algorithm.

[0036] Adjust the spatial coordinates of the guide wheel based on its current position and the position adjustment amount.

[0037] In this solution, obtaining the winding layer information and adjusting the winding motor speed based on a preset speed mapping curve specifically includes:

[0038] The number of winding layers is detected by a preset photoelectric sensor or encoder;

[0039] Based on the layer number information, a preset speed mapping curve is invoked to obtain the target rotational speed information;

[0040] Obtain current rotational speed information;

[0041] If the difference between the target speed information and the current speed information exceeds the preset speed change threshold, a smoothing filtering algorithm is triggered to adjust the target speed.

[0042] Adjust the wound motor speed according to the adjusted target speed.

[0043] A second aspect of the present invention provides an adaptive winding system for a CODESYS-based intelligent winding machine, comprising an adaptive winding method program for a CODESYS-based intelligent winding machine, wherein the adaptive winding method program for the CODESYS-based intelligent winding machine, when executed by the processor, implements the following steps:

[0044] In response to the imported graphics file, the first geometric path information is obtained based on a preset extraction function;

[0045] Based on the preset winding deviation model, path compensation information is dynamically generated according to the first geometric path information to update the first geometric path information;

[0046] In response to the imported wire properties, combined with the updated first geometric path information, motion parameter information is obtained based on a preset planning function;

[0047] When performing a winding operation;

[0048] Acquire tension information; if the tension information is lower than a preset tension threshold, increase the current of the drag motor.

[0049] The system acquires line length and speed information, and obtains the deformation index based on a preset deformation calculation formula, which is used to dynamically adjust the position of the guide wheel.

[0050] Obtain information on the number of winding layers and adjust the speed of the winding motor according to the preset speed mapping curve;

[0051] The system uses a pre-set visualization platform to 3D map the winding trajectory and display motion parameter information.

[0052] In this scheme, the step of dynamically generating path compensation information based on a preset winding deviation model and the first geometric path information to update the first geometric path information specifically includes:

[0053] Search the historical winding path database, calculate the difference between the second geometric path information corresponding to the same name as the graphic file and the first geometric path information, and obtain the first path deviation information;

[0054] Search the historical winding path database, extract the deviation between the parsed path and the ideal path corresponding to a preset number of historical graphic files, and obtain the second path deviation information;

[0055] Determine whether the first path deviation information is lower than a preset first path deviation threshold;

[0056] If so, then a correction coefficient is generated based on the first path deviation information;

[0057] If not, then a compensation coefficient is generated based on the second path deviation information;

[0058] The correction coefficient or the compensation coefficient is input into the extraction function to obtain the reconstructed path information, which is used to update the first geometric path information.

[0059] In this solution, the motion parameter information is obtained based on a preset planning function in response to the imported wire properties and the updated first geometric path information, specifically including:

[0060] Based on the preset critical path matching strategy, the coordinates of three points of the critical sub-path are obtained according to the first geometric path information, including the coordinates of the starting point, the coordinates of the intermediate point, and the coordinates of the ending point.

[0061] Based on the material type of the wire and the coordinates of the three points, the starting angle and the transition angle are obtained;

[0062] Based on the tension coefficient and diameter of the wire, combined with the coordinates of the three points, the deformation compensation offset of the arc path is obtained.

[0063] 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 set of motion parameters with deformation compensation.

[0064] A third aspect of the present invention provides a computer-readable storage medium comprising an adaptive winding method program for a CODESYS-based intelligent winding machine, wherein when the CODESYS-based intelligent winding machine adaptive winding method program is executed by a processor, it implements the steps of the adaptive winding method for a CODESYS-based intelligent winding machine as described in any of the preceding claims.

[0065] This invention provides an adaptive winding method, system, and medium for an intelligent winding machine based on CODESYS. First, the geometric path is obtained by parsing a graphic file using a preset extraction function. The geometric path is then dynamically compensated using a winding deviation model, achieving intelligent reconstruction. Second, by combining wire properties with the coordinates of key segments of the geometric path, arc parameters with deformation compensation and a layered speed control strategy are dynamically calculated to eliminate the risk of process parameter jumps. Then, the current of the traction motor is adjusted in real time based on tension feedback, and the spatial position of the guide wheel is dynamically adjusted based on the deformation trend predicted by wire length and speed. Adaptive speed control is achieved based on the number of winding layers. Finally, the theoretical winding trajectory and the actual winding trajectory are mapped in 3D through a visualization platform, displaying trajectory deviations and key operating parameters. This improves the automation level of the winding machine and enhances the stability and efficiency of the winding process. Attached Figure Description

[0066] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly described below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope.

[0067] Figure 1 A flowchart of an adaptive winding method for an intelligent winding machine based on CODESYS according to the present invention is shown;

[0068] Figure 2 This invention provides a flowchart of a geometric path information compensation operation according to an embodiment of the invention.

[0069] Figure 3 This invention provides a flowchart for generating motion parameter information according to an embodiment of the invention.

[0070] Figure 4 A block diagram of an adaptive winding system for an intelligent winding machine based on CODESYS according to the present invention is shown. Detailed Implementation

[0071] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0072] Unless otherwise defined, all terms (including technical and scientific terms) used in embodiments of this invention shall have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. It should also be understood that terms such as those defined in a common dictionary shall be interpreted as having a meaning consistent with their meaning in the context of the relevant art, and not as being interpreted in an idealized or highly formalized sense, unless expressly defined in this embodiment of the invention.

[0073] The terms "first," "second," and similar words used in the embodiments of this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "an," "a," or "the" do not indicate a quantity limitation, but rather indicate the presence of at least one. Similarly, terms such as "including" or "comprising" mean that the element or object preceding the word encompasses the elements or objects listed after the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. The steps preceding or following the steps in the method of the embodiments of this invention are not necessarily performed precisely in sequence. Instead, various steps can be processed in reverse order or simultaneously. Furthermore, other operations can be added to these processes, or one or more steps can be removed from these processes.

[0074] In addition, the functional modules in the various embodiments of the present invention 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.

[0075] Figure 1 A flowchart of an adaptive winding method for a CODESYS-based intelligent winding machine according to the present invention is shown.

[0076] like Figure 1 As shown, the first aspect of this invention discloses an adaptive winding method for an intelligent winding machine based on CODESYS, the method comprising:

[0077] S102, in response to the imported graphic file, obtain the first geometric path information based on the preset extraction function;

[0078] S104, based on the preset winding deviation model, dynamically generate path compensation information according to the first geometric path information, which is used to update the first geometric path information;

[0079] S106, in response to the imported wire properties, combined with the updated first geometric path information, and based on the preset planning function, obtain motion parameter information;

[0080] S108, when performing a winding operation;

[0081] S110, Obtain tension information; if the tension information is lower than a preset tension threshold, increase the current of the drag motor.

[0082] S112: Obtain line length and speed information, and obtain the deformation index based on the preset deformation calculation formula, which is used to dynamically adjust the position of the guide wheel;

[0083] S114: Obtain the winding layer information and adjust the winding motor speed based on the preset speed mapping curve;

[0084] S116 uses a preset visualization platform to 3D map the winding trajectory and display motion parameter information.

[0085] It should be noted that the first geometric path information is the winding path exported from the graphic file; the path compensation information is a path correction value used to improve the continuity and operational stability of the first geometric path information; the motion parameter information is used to configure the operating logic of the winding controller. The tension information is the tension force on the conductor during winding; the wire length information is the length of the winding; the speed information is the winding speed; and the number of winding layers is the number of winding layers. The extraction function is the path extraction interface of the CODESYS platform; and the planning function is the conductor trajectory planning interface of the CODESYS platform.

[0086] In this embodiment, after receiving the DXF graphic file uploaded by the user, the winding path is parsed by calling the geometry extraction function encapsulated by CODESYS. A deviation model is used to compare the path with typical deviation patterns in the historical winding database in real time, including but not limited to sudden changes in U-shaped bending rate and breakpoint repair, to generate position compensation parameters and reconstruct the geometric path. Subsequently, combining wire properties such as material type, wire diameter, and tension coefficient, motion parameters are dynamically calculated using a planning function, including the arc angle for deformation compensation and the layered speed strategy, to obtain the parameters for configuring the winding controller's operation. Then, during the winding execution phase, adaptive operating parameter adjustment logic is run. The tension value of the conductor is monitored in real time by a tension sensor. If it is lower than the material safety threshold, it indicates unstable wire gripping and a risk of conductor slippage; therefore, the drag motor current is gradually increased to a stable range. The deformation trend is predicted by real-time calculation of the release wire length and real-time speed. Based on the deviation between the deformation index and the target deformation index, the guide wheel position offset is dynamically adjusted using a PID feedback control algorithm to offset the deformation risk. The number of winding layers is detected by photoelectric sensors or encoders, and the winding speed is automatically switched based on the speed mapping curve. The inner layer uses low speed to prevent damage, while the outer layer uses high speed to improve efficiency. The entire winding process is visualized through a platform, using 3D mapping to display the actual trajectory and the superimposed theoretical trajectory, simultaneously displaying the real-time motion parameters of the winding controller. This embodiment achieves automatic parsing and path correction of DXF graphic files, eliminating manual correction; an adaptive closed-loop control mechanism improves yield; thereby increasing the automation level of the winding machine and enhancing the stability and efficiency of the winding process.

[0087] Figure 2 A flowchart illustrating a geometric path information compensation operation provided by an embodiment of the present invention is shown.

[0088] According to embodiments of the present invention, such as Figure 2 As shown, the method of dynamically generating path compensation information based on the preset winding deviation model and the first geometric path information to update the first geometric path information specifically includes:

[0089] S202, Search the historical winding path database, calculate the difference between the second geometric path information corresponding to the same name as the graphic file and the first geometric path information, and obtain the first path deviation information;

[0090] S204, Search the historical winding path database, extract the deviation between the parsed path and the ideal path corresponding to a preset number of historical graphic files, and obtain the second path deviation information;

[0091] S206, determine whether the first path deviation information is lower than a preset first path deviation threshold;

[0092] S208, if so, then generate a correction coefficient based on the first path deviation information;

[0093] S210, if not, then generate a compensation coefficient based on the second path deviation information;

[0094] S212, the correction coefficient or the compensation coefficient is input into the extraction function to obtain the reconstructed path information, which is used to update the first geometric path information.

[0095] It should be noted that the second geometric path information is the winding path after compensation and correction from the same-named graphic file in the historical records. In this embodiment, by searching the historical database for DXF files with the same name as the user-imported graphic files, the winding path after compensation and correction during the winding process is extracted from the DXF file, which is the second geometric path information. The coordinate displacement deviation between the first and 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 in the historical database and the theoretical path is recorded as the second path deviation information, which is used to represent the device's own deviation. If the first path deviation information is lower than the preset first path deviation threshold, it indicates that the same DXF file exists, and a correction coefficient can be 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 value of the second geometric path information is low, and a compensation coefficient is generated based on the second path deviation information as a global compensation parameter. The correction parameter or compensation parameter is injected into the SMC_GEOINFO function to reconstruct the continuous path to update the first geometric path information. This embodiment improves the accuracy of path resolution through a historical data-driven compensation mechanism; in addition, the strategy of prioritizing matching files with the same name also shortens the path resolution time.

[0096] Figure 3 A flowchart illustrating a method for generating motion parameter information according to an embodiment of the present invention is shown.

[0097] According to embodiments of the present invention, such as Figure 3 As shown, the process of responding to the imported wire properties, combining the updated first geometric path information, and obtaining motion parameter information based on a preset planning function specifically includes:

[0098] S302, based on the preset critical path matching strategy, obtain the coordinates of three points of the critical sub-path according to the first geometric path information, including the coordinates of the starting point, the coordinates of the intermediate point and the coordinates of the ending point;

[0099] S304. Based on the material type of the wire and the coordinates of the three points, the starting angle and the transition angle are obtained.

[0100] S306. Based on the tension coefficient and diameter of the wire properties, combined with the coordinates of the three points, the deformation compensation offset of the arc path is obtained.

[0101] S308, input the first geometric path information, the starting angle, the transition angle and the deformation compensation offset into a preset planning function to obtain a set of motion parameters with deformation compensation.

[0102] It should be noted that in this embodiment, based on a preset critical path matching strategy, the coordinates of the three key points of several critical sub-paths are obtained, including the coordinates of the starting point, the intermediate point, and the ending point. In practical applications, the critical path is usually a U-shaped bend. An angle calculation model is selected based on the elastic modulus of the wire material, dynamically outputting the arc start angle and transition angle. As one implementation method, linear interpolation is used for rigid materials, and nonlinear fitting is used for soft materials. The deformation is predicted by combining the wire diameter and tension coefficient, and a reverse compensation offset is injected at the path interpolation point to counteract under-winding or over-winding caused by deformation. The motion planning function is called to integrate the path coordinates, compensation angle, and offset to generate a speed control curve with buffered acceleration. The speed control curve, path coordinates, and other winding control data are combined into a motion parameter set and input to the winding controller. This embodiment solves the forming difference between rigid and soft wires based on material-adaptive angle calculation, and the deformation compensation mechanism improves the winding accuracy of the arc segment.

[0103] According to an embodiment of the present invention, the step of acquiring tension information, wherein if the tension information is lower than a preset tension threshold, then increasing the current of the drag motor specifically includes:

[0104] Tension information is measured based on a preset tension sensor;

[0105] Based on the preset analog-to-digital conversion and tension value mapping relationship, the first tension value is obtained according to the tension information;

[0106] The tension threshold is determined based on the tension coefficient of the wire properties;

[0107] If the tension value is lower than the tension threshold, the drag motor current is increased according to the preset current step.

[0108] It should be noted that this embodiment provides an adaptive tension adjustment mechanism. A tension sensor collects simulated wire tension signals in real time, which are then converted into digital signals by a signal conditioning module. Based on the current tension value and a preset safety threshold for the material, if three consecutive sampled values ​​are below the threshold, a current increase command is generated. Initially, the drag motor current is increased by a basic step size, and the tension response curve is monitored. If the safety range is not reached within a preset time, the current is increased by incremental steps. Simultaneously, the current-tension mapping relationship is recorded after each adjustment. When the tension stabilizes within the target range, the current value is locked, and this mapping relationship is stored in the material property library for subsequent use with similar wires. A tension change trend graph is plotted in real time during the adjustment process; if fluctuations exceed limits, an emergency pause is triggered. This embodiment uses step-by-step current adjustment to avoid overshoot and wire breakage.

[0109] According to an embodiment of the present invention, the step of acquiring line length information and speed information, and obtaining a deformation index based on a preset deformation calculation formula for dynamically adjusting the position of the guide wheel specifically includes:

[0110] Based on the material type of the wire, determine the deformation prediction model and the target deformation index;

[0111] The line length information and the velocity information are input into the deformation prediction model to obtain the deformation index;

[0112] Based on the deviation between the deformation index and the target deformation index, the position adjustment amount is obtained using a preset PID control algorithm.

[0113] Adjust the spatial coordinates of the guide wheel based on its current position and the position adjustment amount.

[0114] It should be noted that this embodiment provides an adaptive guide wheel feedback adjustment mechanism. The encoder provides real-time feedback on the wire release length and calculates the winding length per unit time using winding speed information. A prediction model is automatically matched based on the material's elastic characteristics, and the deformation index is calculated based on the ratio of the wire release length to the winding length. Then, based on the deviation between the deformation index and the target deformation index, the position adjustment amount of the guide wheel is calculated using a PID controller to drive the guide wheel's spatial position. This embodiment determines the wire deformation index calculation model and the target deformation index based on the wire material, and uses PID dynamic adjustment to control the consistency of the wire deformation index during the winding process.

[0115] According to an embodiment of the present invention, the step of obtaining the number of winding layers and adjusting the speed of the winding motor based on a preset speed mapping curve specifically includes:

[0116] The number of winding layers is detected by a preset photoelectric sensor or encoder;

[0117] Based on the layer number information, a preset speed mapping curve is invoked to obtain the target rotational speed information;

[0118] Obtain current rotational speed information;

[0119] If the difference between the target speed information and the current speed information exceeds the preset speed change threshold, a smoothing filtering algorithm is triggered to adjust the target speed.

[0120] Adjust the wound motor speed according to the adjusted target speed.

[0121] It should be noted that, based on preset sensor detection of changes in the number of winding layers, one implementation method involves a photoelectric sensor emitting a grating for detection. A set of pulse signals is received after each winding layer is completed, thereby determining the number of winding layers. Based on a preset speed mapping curve, the winding speed is matched according to the number of winding layers. Specifically, a low-speed curve to prevent pressure damage is used in the lower layer range, a uniform and stable curve is switched in the middle layer range, and a high-efficiency acceleration curve is used in the upper layer range. Furthermore, before speed adjustment, the rate of speed change is calculated in real time. If it exceeds the threshold for smooth motor operation, an S-shaped smoothing algorithm is activated to replan the acceleration and deceleration ramps. This embodiment ensures winding quality and improves efficiency through a layer-speed linkage strategy; a smooth acceleration and deceleration algorithm is used to eliminate layer-changing jitter.

[0122] It is worth mentioning that it also includes:

[0123] Real-time acquisition of coordinate feedback data from the motion controller;

[0124] The theoretical path is drawn based on the motion parameter information;

[0125] Draw the actual path based on the coordinate feedback data;

[0126] The actual path is compared with the theoretical path in segments. If the obtained path deviation exceeds the preset second path deviation threshold, the actual path segment is highlighted.

[0127] It should be noted that the motion controller coordinate data stream is acquired in real time via an industrial communication protocol and transmitted to the Unity3D rendering engine. As one implementation method, the theoretical path model is drawn using white dashed lines and the actual motion trajectory is drawn using blue solid lines on the visualization window, and the two sets of path lines are spatially superimposed. Segmented calculation of Euclidean distance deviation values ​​is used, with sections exceeding the deviation limit highlighted by red semi-transparent cubes, and the deviation values ​​are displayed in a floating manner. Furthermore, the data stream is dynamically refreshed on the monitoring panel of the visualization window, including but not limited to tension waveform graphs, velocity step graphs, and arc parameter tables. This visualization window assists in rapid fault location and improves diagnostic efficiency.

[0128] It is worth mentioning that it also includes:

[0129] Record the first geometric path, wire properties, motion parameter information and operation result indicators of a single winding, including yield rate, single winding time and number of path corrections;

[0130] Based on the yield rate, single-process time, and number of path corrections, a process score is obtained using a preset scoring system.

[0131] If the process score exceeds the preset score threshold, an optimization suggestion rule base is generated based on the first geometric path, wire properties and motion parameter information;

[0132] When the same first geometric path and wire properties are detected, the corresponding motion parameter information is used as the recommended running value.

[0133] It should be noted that the system automatically archives four types of data for a single winding operation: geometric path, wire properties, motion control command set, and quality indicators. The quality indicators include yield rate, time consumption, and the number of control command corrections. The quality scoring engine calculates the total process score according to preset weights and extracts key feature combinations from cases with excellent scores, such as the U-shaped path of 1.0mm enameled wire. These feature combinations are bound to optimal motion parameters to generate optimization rules, which are stored in a cloud rule base. When the same path and wire combination are detected again, a recommended parameter identifier is automatically output. This embodiment employs a historical optimal parameter reuse mechanism to reduce debugging time; furthermore, the rule base iterates to improve system adaptability.

[0134] Figure 4 A block diagram of an adaptive winding system for an intelligent winding machine based on CODESYS according to the present invention is shown.

[0135] like Figure 4 As shown, the second aspect of the present invention discloses an adaptive winding system 4 for a CODESYS-based intelligent winding machine, including a memory 41 and a processor 42. The memory includes an adaptive winding method program for the CODESYS-based intelligent winding machine. When the processor executes the adaptive winding method program for the CODESYS-based intelligent winding machine, it performs the following steps:

[0136] In response to the imported graphics file, the first geometric path information is obtained based on a preset extraction function;

[0137] Based on the preset winding deviation model, path compensation information is dynamically generated according to the first geometric path information to update the first geometric path information;

[0138] In response to the imported wire properties, combined with the updated first geometric path information, motion parameter information is obtained based on a preset planning function;

[0139] When performing a winding operation;

[0140] Acquire tension information; if the tension information is lower than a preset tension threshold, increase the current of the drag motor.

[0141] The line length and speed information are obtained, and the deformation index is obtained based on the preset deformation calculation formula, which is used to dynamically adjust the position of the guide wheel;

[0142] Obtain information on the number of winding layers and adjust the speed of the winding motor based on a preset speed mapping curve;

[0143] The system uses a pre-set visualization platform to 3D map the winding trajectory and display motion parameter information.

[0144] It should be noted that the first geometric path information is the winding path exported from the graphic file; the path compensation information is a path correction value used to improve the continuity and operational stability of the first geometric path information; the motion parameter information is used to configure the operating logic of the winding controller. The tension information is the tension force on the conductor during winding; the wire length information is the length of the winding; the speed information is the winding speed; and the number of winding layers is the number of winding layers. The extraction function is the path extraction interface of the CODESYS platform; and the planning function is the conductor trajectory planning interface of the CODESYS platform.

[0145] In this embodiment, after receiving the DXF graphic file uploaded by the user, the winding path is parsed by calling the geometry extraction function encapsulated by CODESYS. A deviation model is used to compare the path with typical deviation patterns in the historical winding database in real time, including but not limited to sudden changes in U-shaped bending rate and breakpoint repair, to generate position compensation parameters and reconstruct the geometric path. Subsequently, combining wire properties such as material type, wire diameter, and tension coefficient, motion parameters are dynamically calculated using a planning function, including the arc angle for deformation compensation and the layered speed strategy, to obtain the parameters for configuring the winding controller's operation. Then, during the winding execution phase, adaptive operating parameter adjustment logic is run. The tension value of the conductor is monitored in real time by a tension sensor. If it is lower than the material safety threshold, it indicates unstable wire gripping and a risk of conductor slippage; therefore, the drag motor current is gradually increased to a stable range. The deformation trend is predicted by real-time calculation of the release wire length and real-time speed. Based on the deviation between the deformation index and the target deformation index, the guide wheel position offset is dynamically adjusted using a PID feedback control algorithm to offset the deformation risk. The number of winding layers is detected by photoelectric sensors or encoders, and the winding speed is automatically switched based on the speed mapping curve. The inner layer uses low speed to prevent damage, while the outer layer uses high speed to improve efficiency. The entire winding process is visualized through a platform, using 3D mapping to display the actual trajectory and the superimposed theoretical trajectory, simultaneously displaying the real-time motion parameters of the winding controller. This embodiment achieves automatic parsing and path correction of DXF graphic files, eliminating manual correction; an adaptive closed-loop control mechanism improves yield; thereby increasing the automation level of the winding machine and enhancing the stability and efficiency of the winding process.

[0146] According to an embodiment of the present invention, the step of dynamically generating path compensation information based on a preset winding deviation model and according to the first geometric path information to update the first geometric path information specifically includes:

[0147] Search the historical winding path database, calculate the difference between the second geometric path information corresponding to the same name as the graphic file and the first geometric path information, and obtain the first path deviation information;

[0148] Search the historical winding path database, extract the deviation between the parsed path and the ideal path corresponding to a preset number of historical graphic files, and obtain the second path deviation information;

[0149] Determine whether the first path deviation information is lower than a preset first path deviation threshold;

[0150] If so, then a correction coefficient is generated based on the first path deviation information;

[0151] If not, then a compensation coefficient is generated based on the second path deviation information;

[0152] The correction coefficient or the compensation coefficient is input into the extraction function to obtain the reconstructed path information, which is used to update the first geometric path information.

[0153] It should be noted that the second geometric path information is the winding path after compensation and correction from the same-named graphic file in the historical records. In this embodiment, by searching the historical database for DXF files with the same name as the user-imported graphic files, the winding path after compensation and correction during the winding process is extracted from the DXF file, which is the second geometric path information. The coordinate displacement deviation between the first and 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 in the historical database and the theoretical path is recorded as the second path deviation information, which is used to represent the device's own deviation. If the first path deviation information is lower than the preset first path deviation threshold, it indicates that the same DXF file exists, and a correction coefficient can be 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 value of the second geometric path information is low, and a compensation coefficient is generated based on the second path deviation information as a global compensation parameter. The correction parameter or compensation parameter is injected into the SMC_GEOINFO function to reconstruct the continuous path to update the first geometric path information. This embodiment improves the accuracy of path resolution through a historical data-driven compensation mechanism; in addition, the strategy of prioritizing matching files with the same name also shortens the path resolution time.

[0154] According to an embodiment of the present invention, the step of obtaining motion parameter information based on a preset planning function in response to the imported wire properties and in combination with the updated first geometric path information specifically includes:

[0155] Based on the preset critical path matching strategy, the coordinates of three points of the critical sub-path are obtained according to the first geometric path information, including the coordinates of the starting point, the coordinates of the intermediate point, and the coordinates of the ending point.

[0156] Based on the material type of the wire and the coordinates of the three points, the starting angle and the transition angle are obtained;

[0157] Based on the tension coefficient and diameter of the wire, combined with the coordinates of the three points, the deformation compensation offset of the arc path is obtained.

[0158] 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 set of motion parameters with deformation compensation.

[0159] It should be noted that in this embodiment, based on a preset critical path matching strategy, the coordinates of the three key points of several critical sub-paths are obtained, including the coordinates of the starting point, the intermediate point, and the ending point. In practical applications, the critical path is usually a U-shaped bend. An angle calculation model is selected based on the elastic modulus of the wire material, dynamically outputting the arc start angle and transition angle. As one implementation method, linear interpolation is used for rigid materials, and nonlinear fitting is used for soft materials. The deformation is predicted by combining the wire diameter and tension coefficient, and a reverse compensation offset is injected at the path interpolation point to counteract under-winding or over-winding caused by deformation. The motion planning function is called to integrate the path coordinates, compensation angle, and offset to generate a speed control curve with buffered acceleration. The speed control curve, path coordinates, and other winding control data are combined into a motion parameter set and input to the winding controller. This embodiment solves the forming difference between rigid and soft wires based on material-adaptive angle calculation, and the deformation compensation mechanism improves the winding accuracy of the arc segment.

[0160] According to an embodiment of the present invention, the step of acquiring tension information, wherein if the tension information is lower than a preset tension threshold, then increasing the current of the drag motor specifically includes:

[0161] Tension information is measured based on a preset tension sensor;

[0162] Based on the preset analog-to-digital conversion and tension value mapping relationship, the first tension value is obtained according to the tension information;

[0163] The tension threshold is determined based on the tension coefficient of the wire properties;

[0164] If the tension value is lower than the tension threshold, the drag motor current is increased according to the preset current step.

[0165] It should be noted that this embodiment provides an adaptive tension adjustment mechanism. A tension sensor collects simulated wire tension signals in real time, which are then converted into digital signals by a signal conditioning module. Based on the current tension value and a preset safety threshold for the material, if three consecutive sampled values ​​are below the threshold, a current increase command is generated. Initially, the drag motor current is increased by a basic step size, and the tension response curve is monitored. If the safety range is not reached within a preset time, the current is increased by incremental steps. Simultaneously, the current-tension mapping relationship is recorded after each adjustment. When the tension stabilizes within the target range, the current value is locked, and this mapping relationship is stored in the material property library for subsequent use with similar wires. A tension change trend graph is plotted in real time during the adjustment process; if fluctuations exceed limits, an emergency pause is triggered. This embodiment uses step-by-step current adjustment to avoid overshoot and wire breakage.

[0166] According to an embodiment of the present invention, the step of acquiring line length information and speed information, and obtaining a deformation index based on a preset deformation calculation formula for dynamically adjusting the position of the guide wheel specifically includes:

[0167] Based on the material type of the wire, determine the deformation prediction model and the target deformation index;

[0168] The line length information and the velocity information are input into the deformation prediction model to obtain the deformation index;

[0169] Based on the deviation between the deformation index and the target deformation index, the position adjustment amount is obtained using a preset PID control algorithm.

[0170] Adjust the spatial coordinates of the guide wheel based on its current position and the position adjustment amount.

[0171] It should be noted that this embodiment provides an adaptive guide wheel feedback adjustment mechanism. The encoder provides real-time feedback on the wire release length and calculates the winding length per unit time using winding speed information. A prediction model is automatically matched based on the material's elastic characteristics, and the deformation index is calculated based on the ratio of the wire release length to the winding length. Then, based on the deviation between the deformation index and the target deformation index, the position adjustment amount of the guide wheel is calculated using a PID controller to drive the guide wheel's spatial position. This embodiment determines the wire deformation index calculation model and the target deformation index based on the wire material, and uses PID dynamic adjustment to control the consistency of the wire deformation index during the winding process.

[0172] According to an embodiment of the present invention, the step of obtaining the number of winding layers and adjusting the speed of the winding motor based on a preset speed mapping curve specifically includes:

[0173] The number of winding layers is detected by a preset photoelectric sensor or encoder;

[0174] Based on the layer number information, a preset speed mapping curve is invoked to obtain the target rotational speed information;

[0175] Obtain current rotational speed information;

[0176] If the difference between the target speed information and the current speed information exceeds the preset speed change threshold, a smoothing filtering algorithm is triggered to adjust the target speed.

[0177] Adjust the wound motor speed according to the adjusted target speed.

[0178] It should be noted that, based on preset sensor detection of changes in the number of winding layers, one implementation method involves a photoelectric sensor emitting a grating for detection. A set of pulse signals is received after each winding layer is completed, thereby determining the number of winding layers. Based on a preset speed mapping curve, the winding speed is matched according to the number of winding layers. Specifically, a low-speed curve to prevent pressure damage is used in the lower layer range, a uniform and stable curve is switched in the middle layer range, and a high-efficiency acceleration curve is used in the upper layer range. Furthermore, before speed adjustment, the rate of speed change is calculated in real time. If it exceeds the threshold for smooth motor operation, an S-shaped smoothing algorithm is activated to replan the acceleration and deceleration ramps. This embodiment ensures winding quality and improves efficiency through a layer-speed linkage strategy; a smooth acceleration and deceleration algorithm is used to eliminate layer-changing jitter.

[0179] It is worth mentioning that it also includes:

[0180] Real-time acquisition of coordinate feedback data from the motion controller;

[0181] The theoretical path is drawn based on the motion parameter information;

[0182] Draw the actual path based on the coordinate feedback data;

[0183] The actual path is compared with the theoretical path in segments. If the obtained path deviation exceeds the preset second path deviation threshold, the actual path segment is highlighted.

[0184] It should be noted that the motion controller coordinate data stream is acquired in real time via an industrial communication protocol and transmitted to the Unity3D rendering engine. As one implementation method, the theoretical path model is drawn using white dashed lines and the actual motion trajectory is drawn using blue solid lines on the visualization window, and the two sets of path lines are spatially superimposed. Segmented calculation of Euclidean distance deviation values ​​is used, with sections exceeding the deviation limit highlighted by red semi-transparent cubes, and the deviation values ​​are displayed in a floating manner. Furthermore, the data stream is dynamically refreshed on the monitoring panel of the visualization window, including but not limited to tension waveform graphs, velocity step graphs, and arc parameter tables. This visualization window assists in rapid fault location and improves diagnostic efficiency.

[0185] It is worth mentioning that it also includes:

[0186] Record the first geometric path, wire properties, motion parameter information and operation result indicators of a single winding, including yield rate, single winding time and number of path corrections;

[0187] Based on the yield rate, single-process time, and number of path corrections, a process score is obtained using a preset scoring system.

[0188] If the process score exceeds the preset score threshold, an optimization suggestion rule base is generated based on the first geometric path, wire properties and motion parameter information;

[0189] When the same first geometric path and wire properties are detected, the corresponding motion parameter information is used as the recommended running value.

[0190] It should be noted that the system automatically archives four types of data for a single winding operation: geometric path, wire properties, motion control command set, and quality indicators. The quality indicators include yield rate, time consumption, and the number of control command corrections. The quality scoring engine calculates the total process score according to preset weights and extracts key feature combinations from cases with excellent scores, such as the U-shaped path of 1.0mm enameled wire. These feature combinations are bound to optimal motion parameters to generate optimization rules, which are stored in a cloud rule base. When the same path and wire combination are detected again, a recommended parameter identifier is automatically output. This embodiment employs a historical optimal parameter reuse mechanism to reduce debugging time; furthermore, the rule base iterates to improve system adaptability.

[0191] A third aspect of the present invention provides a computer-readable storage medium comprising an adaptive winding method program for a CODESYS-based intelligent winding machine, wherein when the CODESYS-based intelligent winding machine adaptive winding method program is executed by a processor, it implements the steps of the adaptive winding method for a CODESYS-based intelligent winding machine as described in any of the preceding claims.

[0192] In summary, this invention provides an adaptive winding method, system, and medium for an intelligent winding machine based on CODESYS. First, the geometric path is obtained by parsing a graphic file using a preset extraction function. The geometric path is then dynamically compensated using a winding deviation model, achieving intelligent reconstruction. Second, by combining wire properties with the coordinates of key segments of the geometric path, arc parameters with deformation compensation and a layered speed control strategy are dynamically calculated to eliminate the risk of process parameter jumps. Then, the current of the traction motor is adjusted in real-time based on tension feedback, and the deformation trend is predicted based on wire length and speed. The spatial position of the guide wheel is dynamically adjusted, and adaptive speed control is achieved based on the number of winding layers. Finally, the theoretical winding trajectory and the actual winding trajectory are mapped in 3D through a visualization platform, displaying trajectory deviations and key operating parameters. This improves the automation level of the winding machine and enhances the stability and efficiency of the winding process.

[0193] If the aforementioned functions are implemented as software functional modules and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0194] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An adaptive winding method of a CODESYS-based intelligent winding machine, characterized in that, The method comprises: in response to the imported graphic 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, specifically comprising: 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 start point coordinates, intermediate point coordinates and end point coordinates; according to the material type of the wire attribute, combining the three-point coordinates to obtain the start angle and the transition angle; according to the tension coefficient and diameter of the wire attribute, combining the three-point coordinates to obtain the deformation compensation offset of the arc path; inputting the first geometric path information, the start angle, the transition angle and the deformation compensation offset into the preset planning function to obtain the motion parameter set with deformation compensation; when performing the winding operation, acquiring tension information, and if the tension information is lower than a preset tension threshold, increasing the drag motor current; acquiring wire length information and speed information, and obtaining a deformation index according to a preset deformation calculation relationship for dynamically adjusting the guide wheel position, specifically comprising: determining a deformation prediction model and a target deformation index according to the material type of the wire attribute; inputting the wire length information and the speed information into the deformation prediction model to obtain the deformation index; based on a preset PID control algorithm, obtaining a position adjustment amount according to the deviation between the deformation index and the target deformation index; adjusting the guide wheel spatial coordinates according to the current position of the guide wheel and the position adjustment amount; acquiring 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 graphic 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 graphic 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 tension sensor, measuring 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 a tension coefficient of the wire attribute; if the tension value is lower than the tension threshold, increasing the current of the dragging motor according to a preset current step.

4. The self-adaptive winding method of the CODESYS-based intelligent winding machine according to claim 1, wherein, The method comprises the following steps: detecting the winding layer information through a preset photoelectric sensor or encoder; obtaining target speed information according to the winding layer information by calling a preset speed mapping curve; obtaining current speed information; if the difference between the target speed information and the current speed information exceeds a preset speed change threshold, triggering a smoothing filtering algorithm to adjust the target speed; adjusting the winding motor speed according to the adjusted target speed.

5. An adaptive winding system of a CODESYS-based intelligent winding machine, characterized in that, The system comprises a memory and a processor, the memory 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 implemented by the processor to realize the following steps: obtaining first geometric path information based on a preset extraction function in response to an imported graphical file; dynamically generating path compensation information based on a preset winding deviation model according to the first geometric path information, and updating the first geometric path information; obtaining motion parameter information based on a preset planning function in combination with the updated first geometric path information in response to imported wire attributes, specifically comprising: obtaining three-point coordinates of a key sub-path including a starting point coordinate, an intermediate point coordinate and a terminal point coordinate based on a preset key path matching strategy according to the first geometric path information; obtaining a starting angle and a transition angle in combination with the three-point coordinates according to a material type of the wire attribute; obtaining a deformation compensation offset of an arc path in combination with the three-point coordinates according to a tension coefficient and a diameter of the wire attribute; 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; obtaining tension information when performing a winding operation, and increasing the current of the dragging motor if the tension information is lower than a preset tension threshold; obtaining wire length information and speed information, obtaining a deformation index according to a preset deformation calculation relationship for dynamically adjusting the position of the guide wheel, specifically comprising: determining a deformation prediction model and a target deformation index according to a material type of the wire attribute; inputting the wire length information and the speed information into the deformation prediction model to obtain the deformation index; obtaining a position adjustment amount based on a preset PID control algorithm according to the deviation between the deformation index and the target deformation index; adjusting the spatial coordinates of the guide wheel according to the current position of the guide wheel and the position adjustment amount; obtaining winding layer information and adjusting the winding motor speed according to a preset speed mapping curve; mapping the winding track and displaying the motion parameter information through a preset visualization platform.

6. The self-adaptive winding system of an intelligent winding machine based on CODESYS according to claim 5, wherein, The method comprises the following steps: searching a historical winding path database, calculating a difference between second geometric path information corresponding to a same name as the graphic file and the first geometric path information, to obtain first path deviation information; searching the historical winding path database, extracting a deviation between an analysis path and an ideal path corresponding to a preset number of historical graphic 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, which is used to update the first geometric path information.

7. 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. 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 4 are implemented.

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