A segmented tension control method, device, electronic equipment, and storage medium

Abstract

This application provides a segmented tension control method, apparatus, electronic device, and storage medium, applied in the field of strapping tape winding technology. It obtains the motor speed of the winding motor and the production line speed, and calculates the real-time winding diameter accordingly. Then, based on the real-time winding diameter and a preset segmented tension process curve, the target torque of the swing arm servo motor is determined. Next, the swing arm servo motor is controlled to output the target torque to drive the swing arm to rotate, and the real-time rotation angle of the swing arm is obtained. Finally, the deviation between the real-time rotation angle and the set rotation angle is calculated, and the motor speed of the winding motor is adjusted according to the deviation, so that the real-time rotation angle of the swing arm is dynamically stabilized at the set rotation angle. This achieves stable tension winding of the strapping tape, realizing stable and high-quality winding that meets process requirements, and effectively dealing with abnormal working conditions.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of packing tape winding, and in particular to a segmented tension control method and device, an electronic device, and a storage medium. BACKGROUND

[0002] In industrial production, the winding process of packing tape into large rolls is of great importance. The quality of the final packing tape roll largely depends on whether the tension applied to the packing tape during the entire winding operation is consistent and accurate.

[0003] Traditionally, achieving such perfect winding has always been a challenge. For example, some existing methods may simply apply a constant torque to the winding motor. However, due to the constant tension, the inner circle of the packing tape is stretched with a large force, and the winding is relatively tight. While the outer circle of the packing tape is relatively loose. During transportation, the loose outer circle of the roll is prone to unraveling, especially when subjected to vibration or impact. Moreover, when extracting the packing tape from the roll during subsequent use, the loose roll may cause the packing tape to jam or be difficult to extract.

[0004] Another common method is to use a spring pendulum arm. This is a mechanical arm with a spring designed to absorb sudden changes in tension. When the packing tape tension increases, the pendulum arm moves, stretching the spring, which then pulls back. Although it provides some buffering effect, the mechanical properties of the spring are fixed, with a constant spring constant. This means that the spring pendulum arm can only react passively and cannot actively adjust the tension according to specific process requirements. In addition, the spring may also experience mechanical fatigue and creep over time, resulting in a decrease in the consistency of tension control and the need for regular replacement. The response speed of the spring pendulum arm may also be slow, which can cause large fluctuations in tension when the production line speed changes rapidly. Other methods, such as magnetic powder clutches, can adjust torque but are generally slow to respond, generate a lot of heat, and are prone to wear. Torque sensors can directly and accurately measure tension, but they are usually expensive, delicate, and prone to damage, and lack the mechanical buffering function provided by the pendulum arm.

[0005] In summary, existing technologies have difficulty in accurately and adaptively adjusting the tension of the packing tape according to the dynamic changes in roll diameter and fluctuations in production line speed during the winding process of the packing tape, thereby ensuring that the outer layer of the finished roll is tight and not loose, achieving stable and high-quality winding that meets process requirements, and effectively dealing with abnormal working conditions.

[0006] In view of the above problems, there is an urgent need to improve the existing technology. SUMMARY

[0007] In view of the shortcomings of the prior art, this application provides a segmented tension control method, device, electronic device and storage medium, which aims to solve the problem that the prior art is difficult to achieve precise and adaptive adjustment of the tension of the packing tape according to the dynamic changes of the roll diameter and the fluctuations of the production line speed during the packing tape winding process, so as to ensure that the outer layer of the finished roll is tight and not loose, achieve stable and high-quality winding that meets the process requirements, and effectively deal with abnormal working conditions.

[0008] Firstly, a segmented tension control method is applied to the swing arm in a strapping tension control system to control the rotation of the swing arm, thereby achieving stable tension winding of the strapping. The method includes the following steps:

[0009] S1: Obtain the motor speed of the winding motor and the production line speed of the production line;

[0010] S2: Calculate the real-time winding diameter based on the motor speed and the production line speed;

[0011] S3: Determine the target set torque of the swing arm servo motor based on the real-time winding diameter and the preset segmented tension process curve.

[0012] S4: Control the swing arm servo motor to output the target set torque to drive the swing arm to rotate, and obtain the real-time rotation angle of the swing arm;

[0013] S5: Calculate the deviation between the real-time rotation angle and the set rotation angle, and adjust the motor speed of the winding motor according to the deviation, so that the real-time rotation angle of the swing arm is dynamically stabilized at the set rotation angle, thereby achieving stable tension winding of the packing strap.

[0014] This technical solution enables the application to dynamically adjust the target torque of the swing arm servo motor based on the real-time winding roll diameter and the preset segmented tension process curve, and adjust the winding motor speed through the real-time rotation angle feedback of the swing arm, thereby achieving stable tension winding of the packing tape. This effectively solves the problems of inaccurate tension control and poor winding quality in traditional methods, and can adapt to the tension control requirements under different roll diameters and production line speeds.

[0015] Furthermore, step S3 includes:

[0016] S31: Determine the current roll diameter range based on the real-time roll diameter;

[0017] S32: When the current roll diameter belongs to the inner circle, set the first winding tension according to the preset segmented tension process curve;

[0018] S33: When the current roll diameter belongs to the middle loop, set the second winding tension according to the preset segmented tension process curve;

[0019] S34: When the current roll diameter belongs to the outer ring, set the third winding tension according to the preset segmented tension process curve;

[0020] S35: Determine the target set torque of the swing arm servo motor based on the first winding tension, the second winding tension, or the third winding tension.

[0021] This technical solution allows for setting different winding tensions based on the different ranges (inner, middle, or outer rings) of the winding diameter, thereby achieving an ideal winding effect and effectively avoiding the problem of the packing tape easily unwinding during winding.

[0022] Furthermore, step S35 includes:

[0023] S351: Obtain the effective lever arm length of the swing arm;

[0024] S352: Calculate the product of the first winding tension, the second winding tension, or the third winding tension and the effective lever arm length based on the first winding tension, the second winding tension, or the third winding tension and the effective lever arm length;

[0025] S353: Use the product as the target set torque for the swing arm servo motor.

[0026] Through this technical solution, this application can determine the target set torque of the swing arm servo motor by accurately calculating the product of the first winding tension, the second winding tension, or the third winding tension and the effective lever arm length, thereby converting the theoretical tension requirement into an actual controllable motor torque, ensuring the accuracy and responsiveness of tension control, and further optimizing the accuracy of tension control.

[0027] Furthermore, in step S5, calculating the deviation between the real-time rotation angle and the set rotation angle includes the following steps:

[0028] S51: Determine whether the real-time rotation angle has reached the preset limit swing angle threshold;

[0029] S52: If the real-time rotation angle reaches the preset limit swing angle threshold, the target set torque of the swing arm servo motor is set to the limit torque value, and a deceleration command is sent to the spindle device.

[0030] S53: If the real-time rotation angle does not reach the preset limit swing angle threshold, then calculate the deviation between the real-time rotation angle and the set rotation angle.

[0031] Through this technical solution, this application can introduce a limit swing angle threshold judgment mechanism to take timely measures when the swing arm rotation angle is abnormal, such as setting a limit torque and sending a deceleration command, thereby effectively dealing with abnormal working conditions, preventing the packing strap from breaking or the winding quality from being severely reduced, and improving the robustness and safety of the system.

[0032] Furthermore, step S5 includes:

[0033] S54: Calculate the deviation between the real-time rotation angle and the set rotation angle, and use the deviation as input to apply the proportional-integral-derivative PID control algorithm to generate a winding motor speed adjustment command to compensate for the deviation.

[0034] S55: According to the speed adjustment command of the winding motor, the speed of the motor is adjusted so that the real-time rotation angle of the swing arm is dynamically stabilized at the set rotation angle, thereby achieving stable tension winding of the packing strap.

[0035] Furthermore, step S54 includes:

[0036] S541: Store multiple proportional-integral-derivative parameter sets, each parameter set corresponding to a preset winding diameter range and production line speed range;

[0037] S542: Based on the real-time winding diameter and production line speed, determine the winding diameter range and production line speed range to which the current working condition belongs, and obtain the judgment result;

[0038] S543: Based on the judgment result, select the proportional-integral-derivative parameter group that matches the current working condition from the plurality of proportional-integral-derivative parameter groups;

[0039] S544: Calculate the deviation between the real-time rotation angle and the set rotation angle, take the deviation as input, and use the selected proportional-integral-derivative parameter group to apply the proportional-integral-derivative PID control algorithm to generate a winding motor speed adjustment command to compensate for the deviation.

[0040] Furthermore, step S5 includes the following:

[0041] S6: After obtaining and adjusting the motor speed, the real-time rotation angle of the swing arm is dynamically stabilized at the set rotation angle for a duration.

[0042] S7: If the duration exceeds the preset time, the actual operating line speed of the spindle equipment is obtained, and the actual operating line speed is used as the production line speed.

[0043] Secondly, a segmented tension control device for implementing any of the methods described above, the device comprising:

[0044] First acquisition module: Acquires the motor speed of the winding motor and the production line speed of the production line;

[0045] First calculation module: Calculates the real-time winding diameter based on the motor speed and the production line speed;

[0046] Determining module: Based on the real-time winding diameter and the preset segmented tension process curve, determine the target set torque of the swing arm servo motor;

[0047] The second acquisition module controls the swing arm servo motor to output the target set torque to drive the swing arm to rotate, and acquires the real-time rotation angle of the swing arm;

[0048] The second calculation module calculates the deviation between the real-time rotation angle and the set rotation angle, and adjusts the motor speed of the winding motor according to the deviation, so that the real-time rotation angle of the swing arm is dynamically stabilized at the set rotation angle, thereby achieving stable tension winding of the packing strap.

[0049] Thirdly, an electronic device includes a processor and a memory storing computer-readable instructions that, when executed by the processor, perform the steps of any of the methods described above.

[0050] Fourthly, a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, performs the steps of any of the methods described above.

[0051] Beneficial Effects: This application proposes a segmented tension control method, device, electronic equipment, and storage medium, which, when applied to a swing arm in a strapping tension control system, controls the swing arm's rotation to achieve stable tension winding of the strapping. The method first obtains the motor speed of the winding motor and the production line speed, and calculates the real-time winding roll diameter accordingly. Then, based on the real-time winding roll diameter and a preset segmented tension process curve, the target set torque of the swing arm servo motor is determined. Next, the swing arm servo motor is controlled to output the target set torque to drive the swing arm's rotation, and the real-time rotation angle of the swing arm is obtained. Finally, the deviation between the real-time rotation angle and the set rotation angle is calculated, and the motor speed of the winding motor is adjusted according to the deviation, so that the real-time rotation angle of the swing arm is dynamically stabilized at the set rotation angle, thereby achieving stable tension winding of the strapping. Therefore, this application achieves the beneficial effects of accurately and adaptively adjusting the strapping tension according to the dynamic changes in roll diameter and fluctuations in production line speed, thereby ensuring that the outer layer of the finished roll is tight and not loose, achieving stable, high-quality winding that meets process requirements, and effectively coping with abnormal working conditions. Attached Figure Description

[0052] Figure 1This is a flowchart of a segmented tension control method proposed in this application.

[0053] Figure 2 This is a structural diagram of a segmented tension control device proposed in this application.

[0054] Figure 3 This is a schematic diagram of the structure of an electronic device proposed in this application.

[0055] Figure 4 This is a flowchart of a segmented tension control method proposed in this application.

[0056] Figure 5 This is a pre-defined segmented tension process curve diagram proposed in this application.

[0057] Labeling explanations: 201, First acquisition module; 202, First calculation module; 203, Determination module; 204, Second acquisition module; 205, Second calculation module; 301, Processor; 302, Memory; 303, Communication bus; 3, Electronic device. Detailed Implementation

[0058] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. The components of the embodiments of this application described and marked in the accompanying drawings can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0059] It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. Furthermore, in the description of this application, terms such as "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0060] Traditional strapping winding methods suffer from inaccurate and unstable tension control during the winding process. For example, some existing methods may simply apply a constant torque to the winding motor, resulting in the inner layer of the strapping roll being too tight while the outer layer becomes too loose, severely impacting product quality. Other methods use spring swing arms, but their fixed mechanical characteristics prevent them from actively adjusting tension and lead to mechanical fatigue and slow response. These problems make it difficult for existing technologies to accurately and adaptively adjust the strapping tension based on dynamic changes in roll diameter and fluctuations in production line speed, thereby ensuring a tight, non-loose outer layer of the finished roll, achieving stable, high-quality winding that meets process requirements, and effectively handling abnormal operating conditions.

[0061] For this, please refer to Figure 1 , Figure 4 This application proposes a segmented tension control method, applied to the swing arm in a strapping tension control system, to control the rotation of the swing arm to achieve stable tension winding of the strapping; the method includes the following steps:

[0062] S1: Obtain the motor speed of the winding motor and the production line speed of the production line;

[0063] S2: Calculate the real-time winding diameter based on motor speed and production line speed;

[0064] S3: Determine the target torque setting of the swing arm servo motor based on the real-time winding diameter and the preset segmented tension process curve.

[0065] S4: Control the swing arm servo motor to output the target set torque to drive the swing arm to rotate, and obtain the real-time rotation angle of the swing arm;

[0066] S5: Calculate the deviation between the real-time rotation angle and the set rotation angle, and adjust the motor speed of the winding motor according to the deviation, so that the real-time rotation angle of the swing arm is dynamically stabilized at the set rotation angle, thereby achieving stable tension winding of the strapping.

[0067] The segmented tension control method proposed in this application aims to solve the problems of inaccurate and unstable tension control during the winding process of strapping. The strapping tension control system typically includes components such as a winding motor, a swing arm, a swing arm servo motor, sensors, and a controller, used to monitor and adjust the tension of the strapping during the winding process.

[0068] The swing arm is a key mechanical component in the system. One end is fixed, and the other end is connected via a bearing and contacts the strapping. It is used to sense changes in the tension of the strapping and transmit them to the sensor.

[0069] The swing arm servo motor is a type of motor capable of precisely controlling angle, speed, and torque. In this application, it is used to drive the swing arm to rotate in order to actively adjust the tension of the packing strap.

[0070] The take-up motor is responsible for driving the take-up shaft to achieve the take-up of the packing strap.

[0071] Production line speed refers to the speed at which the packing strap runs on the production line, while motor speed is the actual rotational speed of the winding motor.

[0072] Real-time take-up diameter refers to the current diameter of the roll formed by the packing strap on the take-up shaft, which is a dynamically changing parameter.

[0073] A segmented tension process curve is a pre-defined curve describing the required tension or torque relationship under different roll diameters. It is typically derived from experience or experimental data to achieve precise adjustment of the packing strap's winding effect in different ranges. Specifically, to obtain the segmented tension process curve based on experimental data, the roll diameter of the packing strap is gradually increased during the experiment, and sensors are used at each roll diameter point to measure the tension of the packing strap and the torque of the swing arm servo motor. By recording this data, mathematical tools (commonly used ones such as MATLAB and Excel) are used to fit the data, resulting in the segmented tension process curve describing the required tension or torque relationship under different roll diameters.

[0074] In one implementation, the segmented tension process curve can be stored as a two-dimensional lookup table, where the horizontal axis represents the real-time winding diameter and the vertical axis represents the corresponding target tension value. For example, the lookup table can be defined as follows: the inner ring interval is [0.05m, 0.1m], with a corresponding target tension value of [5N, 10N]; the middle ring interval is (0.1m, 0.2m], with a corresponding target tension value of (10N, 15N); and the outer ring interval is (0.2m, 0.3m], with a corresponding target tension value of (15N, 25N). In actual operation, when the first calculation module calculates the real-time winding diameter to be 0.1m, the determination module will consult the lookup table to identify that 0.1m is located at the upper boundary of the 0.05m to 0.1m interval, thus determining the target tension to be 10N. Subsequently, this target tension value will be further used to calculate the target set torque of the swing arm servo motor. The segmented tension process curve provides tension or torque set values ​​for different winding diameters, enabling the system to dynamically determine the target set torque of the swing arm servo motor based on the real-time winding diameter. This solves the problem of the traditional method having a single tension setting that cannot adapt to changes in winding diameter.

[0075] In another implementation, the lookup table can also be defined as follows: the inner circle range is [0.05m, 0.1m], corresponding to a target tension value of 25N; the middle circle range is (0.1m, 0.2m], corresponding to a target tension value of 15N; and the outer circle range is (0.2m, 0.3m], corresponding to a target tension value of 20N.

[0076] In both embodiments described above, the tension gradually increases from the inner to the outer ring, resulting in a finished product with a looser inner ring and a gradually tighter outer ring. This type of winding is generally softer and suitable for products with lower requirements for tightness. Conversely, the tension first decreases and then increases from the inner to the outer ring, resulting in a finished product with a tighter inner and outer ring and a looser middle ring. This type of winding has better overall tightness and superior deformation control, making it suitable for scenarios with strict requirements on the finished product's shape. In practical applications, different modes can be adaptively selected according to specific requirements to ensure that the packing strap is wound with ideal tension throughout the entire winding process.

[0077] The target set torque is the torque that the swing arm servo motor needs to output to maintain the desired tension of the packing strap.

[0078] The real-time rotation angle is the angle of the swing arm during actual operation, while the set rotation angle is the angle that the swing arm should maintain under ideal tension.

[0079] The segmented tension control method of this application achieves precise control of the tension of the packing strap through the following steps:

[0080] Before step S1, the winding machine needs to be started. During the initial tape change or the winding machine's first tape pull, the production line continuously outputs tape, leaving a residue between the winding machine and the production line. The winding machine needs to catch up with this residue. Therefore, when the winding machine is started, the spindle (i.e., the winding shaft) rapidly winds the tape at an initial speed, at which point the winding speed is greater than the production line speed. During catching up, the servo tension value of the swing arm is the set tension for the winding, which is the target tension value that needs to be maintained during the catching up process. By controlling the servo tension value of the swing arm to match the set tension, tension stability during the catching up process can be ensured, thereby achieving a high-quality winding effect. This set tension causes the swing arm to generate a force that deflects towards a rotation angle of 0 degrees. However, if the rotation angle of the swing arm reaches 0 degrees, it will trigger a corresponding stop or other processing, and then the winding preparation may be restarted or the problem investigated. If the rotation angle is not 0 degrees, after catching up, the process proceeds to step S1.

[0081] In step S1, it is necessary to obtain the motor speed of the take-up motor and the production line speed. For example, the motor speed can be obtained in real time by installing an incremental encoder on the take-up motor, and the production line speed can be obtained by installing a laser speed sensor on the production line. The laser speed sensor is installed 500mm from the feed side of the swing arm, with a sampling frequency of not less than 100Hz to ensure the real-time acquisition of the production line speed. These data are the basis for subsequent calculations of the real-time take-up roll diameter.

[0082] In step S2, the real-time take-up diameter is calculated based on the obtained motor speed and production line speed. For example, it can be calculated using the following formula: Real-time take-up diameter = [Production line speed / (π * motor speed)] * ​​Reduction ratio. Here, the reduction ratio is the transmission ratio between the take-up motor and the take-up shaft. The real-time take-up diameter is updated every 50ms and stored in a buffer to form a diameter change curve for subsequent interval determination.

[0083] The derivation of this calculation formula is as follows:

[0084] In order to prevent the packing tape from piling up and breaking, the surface tangential speed V1 of the take-up reel must be equal to the production line speed V2.

[0085] The surface tangential velocity V1 of the take-up shaft is equal to its circumference (π×d) multiplied by its rotational speed N2, therefore V1=(π×d)×N2, where d is the real-time take-up diameter;

[0086] According to the definition of reduction ratio, the transmission ratio between the winding motor and the winding shaft is usually defined in mechanical engineering as i = n / N2; i is the reduction ratio, n is the speed of the winding motor, and N2 is the speed of the winding shaft.

[0087] From this reasoning, we can deduce that N2 = n / i, and further, V2 = π × d × (n / i).

[0088] Algebraically transforming the formula, we get: d=[V2 / (π×n)]×i, that is, real-time winding diameter = [production line speed / (π*motor speed)]*reduction ratio.

[0089] In step S3, the target torque setting of the swing arm servo motor is determined based on the real-time winding diameter and the preset segmented tension process curve. For example, a lookup table can be stored in the controller beforehand, which records the target torque setting values ​​corresponding to different winding diameter ranges. After calculating the real-time winding diameter, the system will query the lookup table to find the winding diameter range closest to the current winding diameter and obtain the corresponding target torque setting.

[0090] In one specific implementation, under the mode of gradually increasing tension from the inner to the outer ring, the segmented tension process curve can be divided into three roll diameter intervals: inner ring, middle ring, and outer ring. Taking a 300mm diameter take-up shaft as an example, the inner ring interval is [0.05m, 0.1m] (from the mandrel to 10 layers of packing tape), the middle ring interval is (0.1m, 0.2m] (10-40 layers), and the outer ring interval is (0.2m, 0.3m] (40 layers to full roll). The system determines the current take-up stage by comparing the real-time take-up roll diameter with the inner and outer ring thresholds.

[0091] Different target tension values ​​can be set for each of these three winding stages. Please refer to [reference needed]. Figure 5 The preset segmented tension process curve is used to set tension values ​​according to the gradient principle of "low tension in the inner ring and high tension in the outer ring":

[0092] Inner ring: First winding tension F1∈[5N,10N] (adapts to the easy stretching characteristics of the initial layer, avoiding excessive deformation);

[0093] Middle loop: Second winding tension F2∈(10N, 15N] (balancing interlayer compactness and elongation);

[0094] Outer ring: Third winding tension F3∈(15N,20N] (overcoming the inertia of large roll diameter and ensuring winding tightness);

[0095] Among them, F3>F2>F. These tension values ​​can be further converted into the target set torque of the swing arm servo motor by the effective lever arm length of the swing arm.

[0096] The preset segmented tension process curve can be stored in the controller's non-volatile memory. The horizontal axis represents the real-time winding diameter, and the vertical axis represents the corresponding target tension value. During system operation, the processor performs a query based on the real-time winding diameter to obtain the corresponding tension, and thus the corresponding target torque.

[0097] For example, within the inner band range of [0.05m, 0.1m], the tension process curve might be set to smoothly increase the tension from 5N (corresponding to a 0.05m roll diameter) to 10N (corresponding to a 0.1m roll diameter). When the system calculates a real-time roll diameter of 0.08m, it will query this curve to obtain a specific value (e.g., 7.5N) between 5N and 10N.

[0098] In step S4, the target set torque is output by the control arm servo motor to drive the swing arm to rotate, and the real-time rotation angle of the swing arm is obtained. For example, the swing arm servo motor can receive a torque command from the controller and output the corresponding torque according to the command, thereby driving the swing arm to rotate. At the same time, a displacement encoder can be installed on the rotation shaft of the swing arm to monitor the rotation angle of the swing arm in real time.

[0099] In step S5, the deviation between the real-time rotation angle and the set rotation angle is calculated, and the motor speed of the take-up motor is adjusted according to this deviation to dynamically stabilize the real-time rotation angle of the swing arm at the set rotation angle, thereby achieving stable tension winding of the strapping. For example, the controller can continuously compare the real-time rotation angle with the set rotation angle. If the real-time rotation angle deviates from the set rotation angle, the controller will generate a speed adjustment command based on the magnitude and direction of the deviation and send it to the take-up motor driver to adjust the speed of the take-up motor. When the strapping tension is too high, causing the swing arm rotation angle to decrease, the take-up motor speed will be appropriately reduced; when the strapping tension is too low, causing the swing arm rotation angle to increase, the take-up motor speed will be appropriately increased. Through this closed-loop control, the real-time rotation angle of the swing arm can be dynamically stabilized at the set rotation angle, thereby ensuring that the tension of the strapping is always kept within the desired range.

[0100] The segmented tension control method of this application achieves precise and dynamic control of the strapping tension through the steps described above. First, by acquiring the motor speed and production line speed in real time, the real-time winding diameter can be accurately calculated, providing fundamental data for subsequent tension adjustment. Second, based on the real-time winding diameter and the preset segmented tension process curve, the target torque of the swing arm servo motor is determined, enabling tension control to adapt to changes in winding diameter and avoiding the problem of loose outer rings and easy unwinding of the strapping caused by traditional constant torque control. The active drive of the swing arm servo motor allows the swing arm to actively adjust the tension according to the target torque, rather than passively responding, thereby improving the response speed and accuracy of tension control. Finally, by monitoring the rotation angle of the swing arm in real time and adjusting the speed of the winding motor according to its deviation from the set angle, a closed-loop control system is formed. This system can dynamically compensate for tension fluctuations, keeping the strapping tension stable at the set value, thus ensuring stable strapping winding.

[0101] The segmented tension control method proposed in this application has significant advantages and innovations compared to existing technologies. Traditional methods often struggle to accurately and adaptively adjust the tension of the strapping tape based on dynamic changes in roll diameter and fluctuations in production line speed. For example, traditional constant torque control cannot solve the tension attenuation problem caused by changes in roll diameter, resulting in poor winding quality; while spring swing arms provide some buffering, their passive response and fixed mechanical characteristics limit their ability to actively adjust tension, and they are also susceptible to mechanical fatigue.

[0102] The core innovation of this application lies in the introduction of a segmented tension process curve and active control of the swing arm servo motor, combined with real-time roll diameter calculation and a closed-loop adjustment mechanism for the swing arm angle. By calculating the winding roll diameter in real time and determining the target torque based on the preset segmented tension process curve, this application can achieve refined management of tension changes with roll diameter, effectively solving the problem of easy unwinding of packing tape in traditional methods. The active drive of the swing arm servo motor means that the swing arm is no longer passively responding to tension changes, but can actively apply or reduce torque according to system commands, thereby achieving faster and more precise tension adjustment. In addition, by monitoring the real-time rotation angle of the swing arm and comparing it with the set angle, a closed-loop control loop is formed to dynamically adjust the speed of the winding motor, further ensuring the stability of the packing tape tension and the winding quality. This active, adaptive, and closed-loop control strategy enables this application to effectively cope with production line speed fluctuations and abnormal working conditions, significantly improving the quality and efficiency of packing tape winding, and achieving a stable and high-quality winding effect that is difficult to achieve with traditional technologies.

[0103] Furthermore, step S3 includes:

[0104] S31: Determine the current roll diameter range based on the real-time roll diameter;

[0105] S32: When the current roll diameter belongs to the inner circle, set the first winding tension according to the preset segmented tension process curve;

[0106] S33: When the current roll diameter belongs to the middle loop, set the second winding tension according to the preset segmented tension process curve;

[0107] S34: When the current roll diameter range is the outer ring, set the third winding tension according to the preset segmented tension process curve;

[0108] S35: Determine the target set torque of the swing arm servo motor based on the first winding tension, the second winding tension, or the third winding tension.

[0109] In step S31, the diameter range of the entire winding process can be divided into at least three intervals, typically including an inner circle, a middle circle, and an outer circle. This division can be based on a preset diameter threshold. When the real-time winding diameter is less than the inner circle threshold, it is determined to be the inner circle; when the real-time winding diameter is greater than or equal to the inner circle threshold but less than or equal to the outer circle threshold, it is determined to be the middle circle; and when the real-time winding diameter is greater than the outer circle threshold, it is determined to be the outer circle.

[0110] When the system determines that the current roll diameter belongs to the inner loop, it sets the first winding tension according to the preset segmented tension process curve. Similarly, when the system determines that the current roll diameter belongs to the middle loop, it sets the second winding tension according to the preset segmented tension process curve. When the system determines that the current roll diameter belongs to the outer loop, it sets the third winding tension according to the preset segmented tension process curve.

[0111] The system allows for the selection of different preset segmented tension process curves to set the first, second, and third winding tensions, based on varying process requirements. Specifically, when the product has lower requirements for tightness, the inner ring can be set to a range of [0.05m, 0.1m] with a target tension value of [5N, 10N], the middle ring to a range of (0.1m, 0.2m) with a target tension value of (10N, 15N), and the outer ring to a range of (0.2m, 0.3m) with a target tension value of (15N, 25N).

[0112] When product shape requirements are strict, the inner ring range can be selected as [0.05m, 0.1m], with a corresponding target tension value of 25N; the middle ring range can be (0.1m, 0.2m], with a corresponding target tension value of 15N; and the outer ring range can be (0.2m, 0.3m], with a corresponding target tension value of 20N, corresponding to the segmented tension process curve.

[0113] Then, based on the set first winding tension, second winding tension, or third winding tension, the target set torque of the swing arm servo motor is finally determined. This torque is the torque that the swing arm servo motor needs to output to counteract the torque generated by the strapping tension on the swing arm, thereby achieving precise control of the strapping tension.

[0114] The solution proposed in this application solves the problem of tension mismatch that may exist under different roll diameters by dividing the roll diameter of the winding process into different intervals and setting different winding tensions for each interval.

[0115] Furthermore, step S35 includes:

[0116] S351: Obtain the effective lever arm length of the swing arm;

[0117] S352: Calculate the product of the first winding tension, the second winding tension, or the third winding tension and the effective lever arm length based on the first winding tension, the second winding tension, or the third winding tension and the effective lever arm length.

[0118] S353: Use the product as the target set torque for the swing arm servo motor.

[0119] Specifically, the effective lever arm length of the swing arm refers to the vertical distance from the swing arm's rotation center to the line of action of the strapping tension (i.e., the direction of the strapping tension). This effective lever arm length changes dynamically with the swing arm's rotation angle. Therefore, in practical applications, a high-precision rotary encoder can be installed on the swing arm's rotation shaft. This rotary encoder can output the swing arm's rotation angle signal in real time, acquire the swing arm's rotation angle in real time, and calculate the current effective lever arm length according to a preset geometric relationship: effective lever arm length = L * sin(θ), where L is the fixed length of the swing arm and θ is the swing arm's rotation angle. Its purpose is to accurately reflect the torque effect of the strapping tension on the swing arm.

[0120] The first, second, and third winding tensions are determined based on the real-time winding roll diameter and a preset segmented tension process curve, corresponding to the target tension values ​​during the inner, inner, and outer windings, respectively. In practical applications, the product of the first and second winding tensions, or the second winding tension, with the effective lever arm length, represents the actual torque generated by the strapping tension on the swing arm. This product is used as the target torque setting for the swing arm servo motor, aiming to enable the swing arm servo motor to output a torque precisely matched to the strapping tension requirements, thereby achieving precise control of the strapping tension.

[0121] In some embodiments described above in this application, the deviation between the real-time rotation angle of the swing arm and the set rotation angle is calculated, and the motor speed of the winding motor is adjusted according to the deviation to achieve stable tension winding of the strapping. However, in actual operation, due to factors such as external interference, system response lag, or changes in strapping characteristics, the real-time rotation angle of the swing arm may fluctuate significantly, even reaching or exceeding its mechanical limit position. If such abnormalities are not addressed promptly and effectively, it may lead to damage to the swing arm mechanism, breakage of the strapping, or a severe decrease in winding quality, thereby affecting the stable operation of the entire production line and equipment safety.

[0122] Therefore, to solve this problem, further, in step S5, calculating the deviation between the real-time rotation angle and the set rotation angle includes the following steps:

[0123] S51: Determine whether the real-time rotation angle has reached the preset limit swing angle threshold;

[0124] S52: If the real-time rotation angle reaches the preset limit swing angle threshold, the target set torque of the swing arm servo motor is set to the limit torque value, and a deceleration command is sent to the spindle device.

[0125] S53: If the real-time rotation angle does not reach the preset limit swing angle threshold, calculate the deviation between the real-time rotation angle and the set rotation angle.

[0126] Specifically, the limit swing angle threshold refers to the critical rotation angle of the swing arm outside its normal operating range but before reaching the mechanical hard limit. This threshold can be preset based on the swing arm's mechanical structure, safety margin, and actual production experience; for example, it can be set to 90% or 95% of the swing arm's maximum allowable rotation angle. Its purpose is to trigger the protection mechanism in advance before the swing arm reaches a dangerous position. The limit torque value refers to the maximum or minimum torque that the swing arm servo motor is forced to output in an emergency to quickly pull the swing arm back to a safe area or limit its further deviation. For example, when the swing arm rotation angle is too large, a larger, reverse limit torque value can be set to provide rapid corrective force. When the swing arm rotation angle is too small, a larger, positive limit torque value can be set. Its purpose is to provide strong intervention to prevent the swing arm from exceeding the safe range. In practical applications, the deceleration command is a control signal sent to the spindle device to instruct it to reduce the production line speed. For example, the deceleration command can be sent to the spindle device's controller via industrial Ethernet, CAN bus, or digital I / O interface. The purpose is to reduce the tension fluctuation of the packing strap by lowering the production line speed, thereby providing a buffer time for the swing arm to recover and reducing the risk of system operation.

[0127] This application's solution introduces a judgment on whether the real-time rotation angle has reached a preset limit swing angle threshold before calculating the deviation between the real-time rotation angle and the set rotation angle. This allows for timely triggering of a protection mechanism when the swing arm is about to enter a dangerous area. When the real-time rotation angle reaches the limit swing angle threshold, the system no longer relies solely on conventional deviation adjustment but immediately sets the target torque of the swing arm servo motor to the limit torque value to provide a strong corrective effect and quickly pull the swing arm back to a safe working range. Simultaneously, a deceleration command is sent to the spindle equipment, instructing it to reduce the production line speed from the current value (e.g., 100 m / min) to a safer speed (e.g., 80 m / min). By reducing the production line speed, the tension fluctuation of the packing strap is reduced from the source, creating favorable conditions for the swing arm's recovery and preventing further deviation due to excessive or insufficient tension. It is precisely because of the synergistic effect of this multi-protection mechanism that the system can respond quickly and effectively control abnormal operating conditions, preventing potential equipment damage and production accidents.

[0128] In some embodiments described above, this application proposes calculating the deviation between the real-time rotation angle and the set rotation angle, and adjusting the motor speed of the winding motor based on the deviation to dynamically stabilize the real-time rotation angle of the swing arm at the set rotation angle. However, using only a simple deviation adjustment mechanism may be insufficient to handle complex dynamic changes in operating conditions, leading to system lag, insufficient control precision, and even oscillations under external disturbances, thus affecting the continuous stability of the strapping tension. Therefore, this application further proposes introducing a proportional-integral-derivative (PID) control algorithm into the above adjustment process to generate winding motor speed adjustment commands more accurately and efficiently, thereby achieving more stable and precise strapping tension control.

[0129] Furthermore, step S5 includes:

[0130] S54: Calculate the deviation between the real-time rotation angle and the set rotation angle, and use the deviation as input to apply the proportional-integral-derivative PID control algorithm to generate a speed adjustment command for the winding motor to compensate for the deviation.

[0131] S55: Adjust the motor speed according to the winding motor speed adjustment command, so that the real-time rotation angle of the swing arm is dynamically stabilized at the set rotation angle, thereby achieving stable tension winding of the strapping.

[0132] Specifically, in step S54, the deviation between the real-time rotation angle and the set rotation angle reflects the difference between the actual position and the desired position of the swing arm. The set rotation angle is typically a pre-set ideal value, representing the position the swing arm should maintain under stable tension winding. Subsequently, the deviation is fed as input into a proportional-integral-derivative (PID) control algorithm for processing. The PID algorithm is a feedback control algorithm widely used in industrial control. It combines three control terms—proportional (P), integral (I), and derivative (D)—to comprehensively analyze the input deviation and generate a precise control output. Specifically, after receiving the deviation data, the algorithm calculates based on preset proportional coefficient Kp, integral coefficient Ki, and derivative coefficient Kd. For example, the proportional term immediately generates an output based on the current value of the deviation, the integral term accumulates historical deviations to eliminate long-term steady-state errors, and the derivative term makes predictive adjustments based on the rate of change of the deviation. These calculations are combined to generate a winding motor speed adjustment command. This command is a speed increment relative to the current motor speed; it can be a positive increase (acceleration) or a negative increase (deceleration). This command is then sent to the winding motor's inverter or servo drive via a digital or analog output interface to precisely adjust the winding motor's speed.

[0133] In step S55, the winding motor speed adjustment command is used to adjust the motor speed of the winding motor. This adjustment command aims to precisely change the operating state of the winding motor so that its speed can dynamically respond to the deviation between the real-time rotation angle of the swing arm and the set rotation angle. Through this precise speed adjustment, the deviation can be effectively offset, allowing the real-time rotation angle of the swing arm to be dynamically stabilized at the set rotation angle. Therefore, the tension of the strapping tape is kept stable, ensuring a smooth winding process.

[0134] In some preferred embodiments, the segmented tension control method is implemented as follows: During the winding process of the packing tape, the real-time rotation angle of the swing arm is first monitored by a sensor. Assuming the rotation angle is set to 90 degrees, and the real-time monitored rotation angle is 88 degrees, the deviation is calculated to be -2 degrees. This -2 degree deviation is input into a pre-configured PID controller. The PID controller performs real-time calculations on this deviation based on its internal proportional gain Kp, integral time Ti, and derivative time Td parameters. For example, the proportional term will immediately generate an adjustment based on the -2 degree deviation, the integral term will accumulate historical deviations to eliminate long-term steady-state errors, and the derivative term will make predictive adjustments based on the trend of deviation changes (e.g., the deviation is rapidly decreasing). Through these calculations, the PID controller outputs a precise speed adjustment command for the winding motor, for example, instructing the winding motor to reduce its speed by 20 rpm. If the current speed of the winding motor is 1000 rpm, the speed adjustment command requires its speed to be reduced by 20 rpm to reach 980 rpm. Upon receiving the command, the winding motor will fine-tune its speed accordingly, thereby changing the winding speed of the strapping and affecting the force on the swing arm, causing its real-time rotation angle to gradually approach 90 degrees. Through this closed-loop feedback control, the real-time rotation angle of the swing arm is dynamically stabilized around 90 degrees, ensuring the continuous stability of the strapping tension.

[0135] Furthermore, step S54 includes:

[0136] S541: Stores multiple proportional-integral-derivative parameter sets, each parameter set corresponding to a preset winding diameter range and production line speed range;

[0137] S542: Based on the real-time winding diameter and production line speed, determine the winding diameter range and production line speed range to which the current working condition belongs, and obtain the judgment result;

[0138] S543: Based on the judgment result, select the proportional-integral-derivative parameter set that matches the current working condition from multiple proportional-integral-derivative parameter sets;

[0139] S544: Calculate the deviation between the real-time rotation angle and the set rotation angle, take the deviation as input, and use the selected proportional-integral-derivative parameter group to apply the proportional-integral-derivative PID control algorithm to generate a winding motor speed adjustment command to compensate for the deviation.

[0140] Specifically, the proportional-integral-derivative (PID) parameter set refers to the set of proportional coefficients (Kp), integral coefficients (Ki), and derivative coefficients (Kd) used in the proportional-integral-derivative (PID) control algorithm. These parameter sets are pre-stored in the system's memory, and each parameter set is associated with a specific winding diameter range and production line speed range. For example, different operating ranges can be defined based on the winding diameter (e.g., inner, middle, outer) and the production line speed (e.g., low, medium, high), and an optimal set of PLD parameters is preset for each range. Determining the winding diameter range and production line speed range of the current operating condition can be understood as the system monitoring the winding diameter and production line speed in real time and comparing them with the preset ranges. For example, if the real-time winding diameter is in the "inner" range and the production line speed is in the "medium" range, then the current operating condition is determined to be in the "inner-medium speed" range. In practical applications, the PLD parameter set matching the current operating condition is selected based on the determination result, specifically through table lookup or logical judgment. Once the current operating range is determined, the system extracts the parameter set that precisely matches or is closest to that range from multiple stored proportional-integral-derivative (PI) parameter sets. Then, the deviation between the real-time rotation angle and the set rotation angle is used as input, and the selected PI parameter set is used to apply a proportional-integral-derivative (PID) control algorithm for calculation. The purpose is to accurately calculate and compensate for the deviation using the most suitable control parameters based on the current actual operating conditions, thereby generating more accurate speed adjustment commands for the winding motor.

[0141] This application's solution effectively addresses the performance limitations of traditional fixed-parameter proportional-integral-derivative (PID) control under dynamically changing operating conditions by introducing a condition-adaptive proportional-integral-derivative (PI-D) parameter selection mechanism. Specifically, changes in winding diameter and production line speed significantly affect the dynamic characteristics of the strapping tension control system. For example, a larger winding diameter results in greater system inertia, leading to different requirements for the controller's response speed and stability. By pre-identifying and tuning the system parameters for different winding diameter and production line speed ranges, the optimal PI-D parameter set can be configured for each specific operating condition. During system operation, the real-time acquired winding diameter and production line speed are used to dynamically determine the current operating condition range and select the most suitable PI-D parameter set accordingly. Because the PI-D parameters can be dynamically adjusted according to the actual operating conditions, the PID control algorithm always operates in the optimal state, ensuring that the real-time rotation angle of the swing arm is precisely and stably controlled within the set rotation angle throughout the entire winding process, regardless of changes in winding diameter or production line speed, thereby achieving stable tension winding of the strapping.

[0142] In some preferred embodiments, a specific example is given below. Assume the strapping rewinding system has three preset rewinding diameter ranges (inner, middle, and outer) and two production line speed ranges (low speed and high speed). The system stores six sets of corresponding proportional-integral-derivative (PID) parameters, corresponding to six operating conditions: "inner low speed, inner high speed, middle low speed, middle high speed, outer low speed, and outer high speed." The calculated deviation Δθ is input to the matched PID controller, which calculates and generates the rewinding motor speed adjustment Δn. Then, according to the formula: n' = n + Δn (n' is the adjusted rewinding motor speed, n is the rewinding motor speed, and Δn is the rewinding motor speed adjustment), the rewinding motor speed is adjusted so that the real-time rotation angle is dynamically stabilized within the set rotation angle ±0.5° range. Through this dynamic adjustment, the PID control algorithm can always maintain optimal control performance, ensuring stable rotation angle of the swing arm, thereby achieving stable tension rewinding of the strapping.

[0143] Furthermore, step S5 includes the following:

[0144] S6: After obtaining the motor speed adjustment, the real-time rotation angle of the swing arm is dynamically stabilized at the set rotation angle for a certain duration.

[0145] S7: If the duration exceeds the preset time, obtain the actual operating line speed of the spindle equipment and use the actual operating line speed as the production line speed.

[0146] Specifically, after the speed of the winding motor is adjusted to dynamically stabilize the real-time rotation angle of the swing arm at the set rotation angle, the system continuously monitors and acquires the duration of this stable state. The duration refers to the length of time the real-time rotation angle of the swing arm remains stably fluctuating around the set rotation angle. Further, if this duration exceeds a preset time threshold (which can be set to 2 minutes in practical applications), it indicates that the system has entered a relatively stable operating phase. In this case, to further improve the accuracy of tension control, the system actively acquires the actual operating linear speed of the spindle equipment. The actual operating linear speed of the spindle equipment is the real speed of the current production line, which may have slight differences from the initially set production line speed. After acquiring this actual operating linear speed, it is input as the new production line speed into the control flow of the proportional-integral-derivative (PID) control algorithm to replace the original production line speed, achieving real-time dynamic adjustment during the production process.

[0147] Furthermore, if the real-time rotation angle of the swing arm stabilizes at the set rotation angle, but this stable state does not last for 2 minutes, and an anomaly occurs during the winding process with swing angle fluctuations, then it is determined whether the real-time rotation angle of the swing arm is 0 degrees. If it is 0 degrees, corresponding shutdown procedures will be triggered, such as an abnormal shutdown during winding, and then winding preparation or troubleshooting may be restarted. If it is not 0 degrees, the process proceeds to determine whether the real-time rotation angle has reached the preset limit swing angle threshold, in order to continue dynamic adjustment.

[0148] After adopting this method, the inner ring elongation of the packing tape is reduced from 3.2% to 1.5% in the traditional method, the interlayer gap of the outer ring is reduced from 0.8mm to 0.2mm, and the tension fluctuation range is controlled within ±2N, which improves the control accuracy by 40% compared with the existing technology.

[0149] Please refer to Figure 2 A segmented tension control device for implementing any of the above methods, the device comprising:

[0150] First acquisition module 201: Acquires the motor speed of the winding motor and the production line speed of the production line;

[0151] First calculation module 202: Calculates the real-time winding diameter based on motor speed and production line speed;

[0152] Determine module 203: Based on the real-time winding diameter and the preset segmented tension process curve, determine the target set torque of the swing arm servo motor;

[0153] The second acquisition module 204 controls the swing arm servo motor to output the target set torque to drive the swing arm to rotate, and acquires the real-time rotation angle of the swing arm.

[0154] The second calculation module 205 calculates the deviation between the real-time rotation angle and the set rotation angle, and adjusts the motor speed of the winding motor according to the deviation, so that the real-time rotation angle of the swing arm is dynamically stabilized at the set rotation angle, thereby achieving stable tension winding of the strapping.

[0155] Specifically, the first acquisition module 201 can be a data acquisition unit configured to receive signals from the take-up motor encoder and the production line speed sensor. For example, this module may include an analog-to-digital converter (ADC) and a communication interface for converting the analog signals output by the sensors into digital signals and transmitting them to a processor via a bus. In some embodiments, the first acquisition module 201 may also acquire the required data from other control systems via a network interface.

[0156] The first calculation module 202 can be a processor or microcontroller programmed to execute a roll diameter calculation algorithm. For example, this module can receive data provided by the first acquisition module 201 and calculate the real-time roll diameter according to a preset mathematical model, such as real-time roll diameter = [production line speed / (π * motor speed)] * ​​reduction ratio. The calculation result is then passed to the determination module.

[0157] The determining module 203 can be a memory storing segmented tension process curves and a processor. For example, this module can include a lookup table or a function model for querying or calculating the target set torque of the corresponding swing arm servo motor based on the real-time winding diameter provided by the first calculation module 202. This module can preset multiple process curves to adapt to different types of strapping or different winding requirements.

[0158] The second acquisition module 204 can be a servo driver and displacement encoder interface. For example, this module is configured to receive the target set torque command output by the determination module 203 and convert it into a control signal executable by the swing arm servo motor, thereby driving the swing arm to rotate. At the same time, this module is also connected to the displacement encoder of the swing arm to acquire the rotation angle of the swing arm in real time and feed the angle data back to the second calculation module 205.

[0159] The second calculation module 205 can be a closed-loop controller configured to receive the real-time rotation angle of the swing arm and a preset rotation angle. For example, this module can execute a control algorithm (such as a PID control algorithm) to calculate the deviation between the real-time rotation angle and the preset rotation angle, and generate a speed adjustment command for the winding motor based on the deviation. This command is then sent to the driver of the winding motor to adjust the speed of the winding motor, thereby dynamically stabilizing the real-time rotation angle of the swing arm and ultimately achieving stable tension winding of the strapping.

[0160] The segmented tension control device proposed in this application demonstrates significant progress in tension control during the winding of packing tape compared to existing technologies. Traditional devices often rely on constant torque control or passive spring swing arms, which struggle to cope with tension instability caused by dynamic changes in roll diameter and fluctuations in production line speed, resulting in poor winding quality.

[0161] The device described in this application achieves automated and precise execution of the segmented tension control method through a modular design. Its core innovation lies in the real-time acquisition and calculation of the winding roll diameter by the first acquisition module 201 and the first calculation module 202, providing an accurate basis for subsequent tension adjustment. The determination module 203 can actively determine the target torque of the swing arm servo motor based on the real-time roll diameter and the preset segmented tension process curve, thereby achieving refined management of tension changes with roll diameter and effectively solving the problem of coarse tension control in traditional methods. Furthermore, the closed-loop control system composed of the second acquisition module 204 and the second calculation module 205 can monitor the rotation angle of the swing arm in real time and dynamically adjust the speed of the winding motor according to the deviation, ensuring the stability of the strapping tension and the winding quality. This proactive, adaptive, and closed-loop device design enables this application to effectively cope with complex production conditions, significantly improve the quality and efficiency of strapping winding, and achieve stable, high-quality winding results that are difficult to achieve with traditional technologies.

[0162] Please refer to Figure 3 , Figure 3 This application provides a schematic diagram of the structure of an electronic device 3, comprising a processor 301 and a memory 302. The processor 301 and the memory 302 are interconnected and communicate with each other via a communication bus 303 and / or other forms of connection mechanism (not shown). The memory 302 stores computer-readable instructions executable by the processor 301. When the electronic device is running, the processor 301 executes the computer-readable instructions to perform the method in any optional implementation of the above embodiments, thereby achieving the following functions: obtaining the motor speed of the winding motor and the production line speed; calculating the real-time winding diameter based on the motor speed and the production line speed; determining the target set torque of the swing arm servo motor based on the real-time winding diameter and a preset segmented tension process curve; controlling the swing arm servo motor to output the target set torque to drive the swing arm to rotate, and obtaining the real-time rotation angle of the swing arm; calculating the deviation between the real-time rotation angle and the set rotation angle, and adjusting the motor speed of the winding motor according to the deviation, so that the real-time rotation angle of the swing arm is dynamically stabilized at the set rotation angle, thereby achieving stable tension winding of the packing tape.

[0163] This application provides a computer-readable storage medium storing a computer program. When the computer program is executed by a processor, it performs the method in any optional implementation of the above embodiments to achieve the following functions: acquiring the motor speed of the winding motor and the production line speed; calculating the real-time winding diameter based on the motor speed and production line speed; determining the target set torque of the swing arm servo motor based on the real-time winding diameter and a preset segmented tension process curve; controlling the swing arm servo motor to output the target set torque to drive the swing arm to rotate, and acquiring the real-time rotation angle of the swing arm; calculating the deviation between the real-time rotation angle and the set rotation angle, and adjusting the motor speed of the winding motor according to the deviation, so that the real-time rotation angle of the swing arm is dynamically stabilized at the set rotation angle, thereby achieving stable tension winding of the packing tape.

[0164] The computer-readable storage medium can be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as Static Random Access Memory (SRAM), Electrically Erasable Programmable Read-Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM), Programmable Red-Only Memory (PROM), Read-Only Memory (ROM), magnetic storage, flash memory, magnetic disk, or optical disk.

[0165] In the embodiments provided in this application, it should be understood that the disclosed apparatus and methods can be implemented in other ways. The apparatus embodiments described above are merely illustrative. For example, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. Furthermore, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Additionally, the displayed or discussed mutual couplings or direct couplings or communication connections may be through some communication interfaces; indirect couplings or communication connections between devices or units may be electrical, mechanical, or other forms.

[0166] Furthermore, the units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0167] Furthermore, the functional modules in the various embodiments of this 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.

[0168] In this document, relational terms such as first and second are used only to distinguish one entity or operation from another entity or operation, without necessarily requiring or implying any such actual relationship or order between these entities or operations.

[0169] The above description is merely an embodiment of this application and is not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A method of segmental tension control, characterized by, The application is applied to a swing arm in a packing belt tension control system, and is used for controlling the swing arm to rotate to realize stable tension winding of the packing belt; the method comprises the steps of: S1: acquiring a motor speed of a winding motor and a line speed of a production line; S2: calculating a real-time winding diameter according to the motor speed and the line speed; S3: determining a target setting torque of a swing arm servo motor according to the real-time winding diameter and a preset segmented tension process curve; S4: controlling the swing arm servo motor to output the target setting torque to drive the swing arm to rotate, and acquiring a real-time rotation angle of the swing arm; S5: calculating a deviation between the real-time rotation angle and a setting rotation angle, and adjusting the motor speed of the winding motor according to the deviation to dynamically stabilize the real-time rotation angle of the swing arm at the setting rotation angle, thereby realizing stable tension winding of the packing belt; Step S3 comprises: S31: judging an interval to which a current winding diameter belongs according to the real-time winding diameter; S32: when the interval to which the current winding diameter belongs is an inner circle, setting a first winding tension according to the preset segmented tension process curve; S33: when the interval to which the current winding diameter belongs is a middle circle, setting a second winding tension according to the preset segmented tension process curve; S34: when the interval to which the current winding diameter belongs is an outer circle, setting a third winding tension according to the preset segmented tension process curve; S35: determining the target setting torque of the swing arm servo motor according to the first winding tension, the second winding tension or the third winding tension; Step S5 comprises: S54: calculating a deviation between the real-time rotation angle and a setting rotation angle, and taking the deviation as an input to apply a proportional-integral-derivative (PID) control algorithm to generate a winding motor speed adjustment instruction for compensating the deviation; S55: adjusting the motor speed according to the winding motor speed adjustment instruction to dynamically stabilize the real-time rotation angle of the swing arm at the setting rotation angle, thereby realizing stable tension winding of the packing belt; Step S54 comprises: S541: storing a plurality of proportional-integral-derivative parameter groups, each of which corresponds to a preset winding diameter interval and a line speed interval; S542: judging a winding diameter interval and a line speed interval to which a current working condition belongs according to a real-time winding diameter and a line speed to obtain a judgment result; S543: selecting a proportional-integral-derivative parameter group matched with the current working condition from the plurality of proportional-integral-derivative parameter groups according to the judgment result; S544: calculating a deviation between the real-time rotation angle and a setting rotation angle, taking the deviation as an input, and using the selected proportional-integral-derivative parameter group to apply a proportional-integral-derivative (PID) control algorithm to generate a winding motor speed adjustment instruction for compensating the deviation.

2. The method of claim 1, wherein, Step S35 comprises: S351: acquiring an effective arm length of the swing arm; S352: calculating a product of the first winding tension, the second winding tension, or the third winding tension and the effective arm length according to the first winding tension, the second winding tension, or the third winding tension and the effective arm length; S353: taking the product as a target set torque of the swing arm servo motor.

3. The method of claim 1, wherein, In step S5, the calculating the deviation of the real-time rotation angle from the set rotation angle comprises steps of: S51: judging whether the real-time rotation angle reaches a preset limit swing angle threshold value; S52: if the real-time rotation angle reaches the preset limit swing angle threshold value, setting the target set torque of the swing arm servo motor as a limit torque value, and sending a speed reduction instruction to the main shaft device; S53: if the real-time rotation angle does not reach the preset limit swing angle threshold value, calculating the deviation of the real-time rotation angle from the set rotation angle.

4. The method of claim 1, wherein, After step S5, further comprising steps of: S6: obtaining a duration that the real-time rotation angle of the swing arm dynamically stabilizes at the set rotation angle after the adjustment of the motor speed; S7: if the duration exceeds a preset time, obtaining an actual running linear speed of the main shaft device, and taking the actual running linear speed as a production line speed.

5. A segmented tension control device characterized by, The device for implementing the method of any one of claims 1-4 comprises: a first obtaining module: obtaining a motor speed of a winding motor and a production line speed of a production line; a first calculating module: calculating a real-time winding diameter according to the motor speed and the production line speed; a determining module: determining a target set torque of a swing arm servo motor according to the real-time winding diameter and a preset segmented tension process curve; a second obtaining module: controlling the swing arm servo motor to output the target set torque to drive the swing arm to rotate, and obtaining a real-time rotation angle of the swing arm; a second calculating module: calculating a deviation of the real-time rotation angle from a set rotation angle, and adjusting the motor speed of the winding motor according to the deviation, so that the real-time rotation angle of the swing arm dynamically stabilizes at the set rotation angle, thereby realizing stable tension winding of the packaging belt.

6. An electronic device, comprising: The device comprises a processor and a memory, and the memory stores computer readable instructions, when the computer readable instructions are executed by the processor, the steps in the method of any one of claims 1-4 are executed.

7. A computer readable storage medium having stored thereon a computer program, characterized in that, The computer program is executed by the processor to execute the steps in the method of any one of claims 1-4.

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